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CONDENSING GAS FIRED

BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Model

DMG-240

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 253 7900

www.ecrinternational.com

PN 240011656 REV. E [07/30/2018]

Содержание DMG-240

Страница 1: ...S FIRED BOILER INSTALLATION OPERATION MAINTENANCE MANUAL Model DMG 240 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240011656 REV...

Страница 2: ...essential documents Drain Valve Gas Shutoff Valve TP Gauge and Safety Relief Valve Connections Document Package Used for measuring outside temperature Used for connecting condensate piping to boiler...

Страница 3: ...ensor 45 8 10 Central Heating Thermostat 45 8 11 DHW Indirect Water Heater 46 8 12 Frost Protection 46 9 Start Up Procedure 49 9 1 Fill Condensate Trap With Water 49 9 2 Commission Setup Water 49 9 3...

Страница 4: ...4 NPT Condensate Drain Connection Location J 2 57 2mm Size 3 4 NPT Weight Shipping 145 LBS 65 8 Unit 120 LBS 54 5kg Vent Connector 80 125 mm Electrical Cord Length 5 ft 1 5m Dimensions Vent Connector...

Страница 5: ...on FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can scald and cause permanent injury Children elder...

Страница 6: ...176 F 80 C system design temperature 2 7 Operational Features Modulating 6 7 1 ratio Integral Dual Limit Integral Low Water Pressure Cutoff Outdoor Temperature Reset Heat exchanger over heat protecti...

Страница 7: ...t 12 Thermal fuse 6 on wire diagram 13 Exchanger flange high limit 4 on wire diagram 14 Ignition Flame detection electrode 15 Spark generator 16 Automatic air vent 17 Auxiliary control board box 18 Ai...

Страница 8: ...f the boiler Boiler may be installed in any room or internal space special attention shall be given to the requirements of the current electrical provisions with respect to the installation of the boi...

Страница 9: ...Boiler Front View FIGURE 4 2c Service Clearances Closet Installation 17 3 4 450mm Minimum Service clearance to front of boiler Boiler Left Side View 17 3 4 450mm CLOSET INSTALLATION TOP VIEW 1 3 4 40...

Страница 10: ...This will give the position of the center of the hole for the flue Cut 5 5 16 135 00 mm diameter hole in the wall for concentric flue Lift boiler and hang it on wall Adjust the position of the boiler...

Страница 11: ...sed to freezing conditions Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system Do not use automotive or ethylene glycol Boiler installed a...

Страница 12: ...n rating plate Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping Install union if used close to safety relief valve outlet Install elbow s...

Страница 13: ...y and return on boiler A If soldering to boiler ensure unions are not connected to supply and return piping otherwise internal seals may be damaged B Verify appropriately sized isolating valve with fi...

Страница 14: ...ow system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction WARNING Burn Scald Hazard Water temperature over 125 F 51 C can cause seve...

Страница 15: ...Relief Valve 1 DHW Pump P N 240011656 Rev E 07 30 2018 1 12 305mm Maximum Separation Note Note Manufacturer requires all domestic hot water DHW installations use an anti scald valve Local codes may re...

Страница 16: ...equire additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements T P Relief Valve to Drain Cold Water Supply Optional Indirect DHW...

Страница 17: ...DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note...

Страница 18: ...ld valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Use external pump relay or Argo Zo...

Страница 19: ...er Support horizontal sections of vent pipe to prevent sags capable of accumulating condensation Unless otherwise specified support venting every 3 feet using steel strapping or equivalent Unless spec...

Страница 20: ...n venting system should be corrected so installation conforms with National Fuel Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 When re sizing any portion of...

Страница 21: ...ation when using fittings Separate vent terminal from air inlet terminal to prevent flue gas recirculation If T Terminal is used on flue pipe at sidewall air inlet terminal shall be at least 36 or mor...

Страница 22: ...ound Anticipated Snow Line Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof or ground Anticipated Snow Line 18 Vertical Clearance to ventilated s...

Страница 23: ...transition from Coaxial at the top of the boiler to Twin Pipe CPVC PVC a kit is available B Twin Pipe Polypropylene System Single wall polypropylene is used for both exhaust and air intake piping To t...

Страница 24: ...ical fastener with larger hole in it and place it onto male end of pipe Slide clamp all the way down the pipe with smaller opening of clamp towards female end of the pipe Bend clamp over the female en...

Страница 25: ...6 11 Inside Air Single Pipe Figure 6 15 Table 5A Combustion Air Venting Locations Type Location Terminal Type Corresponding Figures Venting Flue Gas Side Wall S Terminal with 90 elbow Figure 6 9 6 10...

Страница 26: ...doned unused masonry chimney may be used as chaseway for combustion air and vent Both combustion air and vent pipe must exit above top of chimney with clearances as shown in figure 6 6 FIGURE 6 6 Two...

Страница 27: ...does not have a max separation requirement between flue gas and fresh air Fig 6 10 Flue on Roof Air Intake on Side Wall Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow l...

Страница 28: ...ICE Configurations of single pipe vent with flue on sidewall requires tee as vent terminal See figures 6 21 and 6 23 Vent Combustion Air Outer Ring Ground Level Snow line Maintain 12 305mm US 18 457mm...

Страница 29: ...be min 12 305mm from or below doors windows or gravity inlet If boiler uses inside air min 4 1219 mm 12 305mm Min Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termin...

Страница 30: ...or recirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkways Locate vent...

Страница 31: ...nce to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 305mm 3 ft 0 9m K Clearance to mechanical air supply inlet 3 ft 0 9m 6 ft 1 8m L Clearance abov...

Страница 32: ...0 0 mm from boiler Secure flue pipe to wall with supports 3 ft 0 92 meters from each other Secure supports along the joint of each pipe 6 10 Multiple Boiler Venting Mounting Procedure See Figures 6 20...

Страница 33: ...cascade vent system to flue connection on top of boilers 11 Secure flue adapters using approved clamps to wall Ensure clamps are connected minimum of 10 in from top of boiler See Figure 6 23 12 Secure...

Страница 34: ...th 45 5 ft 7 in 1 7m 12 ft 3 8 m 90 13 ft 1 in 4 0m 19 ft 5 8 m 6 in Cascade Vent System Example Elbow Equivalent Length 45 90 Number of Elbows 3 Equivalent Length 13 ft 1 in 4 0m Total Equivalent Len...

Страница 35: ...line each connected to common exhaust manifold 3 2 in per 3 ft 4 in 50 0 mm per 1 0 m B Back to Back System This system consists of boilers installed back to back connected to a common exhaust manifo...

Страница 36: ...3 ft 4 in 50 0 mm per 1 0 m 3 6 12 Multiple Boiler Venting Parameter Settings To set parameter P19 see section 9 PARAMETER P19 Revs min rpm at minimum Power Natural Gas LPG 30 30 Flue header size sha...

Страница 37: ...condensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by autho...

Страница 38: ...pound pipe dope suitable for liquefied petroleum gas Install external field sourced manual main gas shutoff valve ground joint union and sediment trap upstream of gas valve See figures 7 2 and 7 3 Lea...

Страница 39: ...tem by closing manual gas shutoff valve See figure 7 3 Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not...

Страница 40: ...vice panel before making electrical connections Failure to do so could result in death or serious injury FIGURE 8 1 Electric Knockouts Bottom Of Boiler 8 Wire Knockouts Front of Boiler Back of Boiler...

Страница 41: ...abinet by unfastening clip on front of control box Push lip back for latch 5 Run wire s through grommet s in control panel cabinet 6 Unscrew wire clamp to access connection block and bring wires throu...

Страница 42: ...IF 01 control PCB is built into auxiliary control box Refer to instructions supplied with product Do not connect freeze thermostat or room thermostat to boiler if using 0 10 V control PCB 1 Connectio...

Страница 43: ...Hysteresis 2 0 10 01 72 176 20 80 Temperature output required 1 Dependent on minimum modulation depth set speeds standard 20 5 Analog Heat Output Based Control 0 10V signal controls boiler output bet...

Страница 44: ...set using parameter P34 Three way valve is connected as follows N neutral C heating system D indirect tank If neutral position of three way valve is adjusted with parameter P34 connect the pump as fo...

Страница 45: ...ccupied room C Connect 2 wire dry contact room thermostat to ON OFF OT terminals of boiler s control board connection Note ON OFF OT terminals are NOT able to supply 24V to the thermostat D Use thermo...

Страница 46: ...with 1 K outdoor temperature sensor Radiator valve or zone must be open where there is a risk of freezing Connect 1 K outdoor temperature sensor to T out terminals of control board Frost protection ac...

Страница 47: ...Connect CH Central Heating pump on terminal N L Pump of control PCB SCU 02 see section 8 8 Connect DHW Domestic Hot Water pump on terminal N D 3wV of control PCB SCU 02 see section 8 8 FIGURE 8 15 Ex...

Страница 48: ...48 8 ELECTRICAL CONNECTIONS FIGURE 8 16 Wiring Diagram 13 P N 240011656 Rev E 07 30 2018...

Страница 49: ...n Check distribution system to ensure it is sized and installed correctly Before filling open all valves on the heating circuit in the installation Flush heating system including all heating zones Fil...

Страница 50: ...0 mbar B Purge gas supply pipe within boiler by unscrewing pressure outlet on gas valve C Tighten the port when pipe has been sufficiently purged 12 Check all gas connections in the boiler are tight 1...

Страница 51: ...el can be changed Energy saving mode Economic mode activated Fault Boiler fault indicated Can be seen from code and red display Frost protection Boiler running in frost protection mode Hour counter me...

Страница 52: ...See Figure 9 4 Boiler pump will run on and off for up to 10 minutes This will purge air from the system The burner will switch on for a few seconds to verify increasing temperature on flow return sen...

Страница 53: ...nction to set boiler to operate on full load and on part load in Heating mode 2 Adjust Fan Speed as indicated in table found in section Parameter Settings if required 3 Modify fan speeds using paramet...

Страница 54: ...n taking measurements Set boiler to low fire by pressing two buttons simultaneously If the boiler is already in combustion setup mode for high fire press the button several time until L3 is displayed...

Страница 55: ...nstaller To prevent unwanted settings some parameter settings can only be changed after special access code 0012 is entered Modification of factory settings may be detrimental to operation of the boil...

Страница 56: ...t run time CH 1 to 98 minutes 99 minutes continuous 3 P8 Display brightness when backlight is active 0 Low 1 High 1 P17 Max fan speed during CH mode Natural gas 1 x100 rpm 64 73 Propane x100 rpm 63 71...

Страница 57: ...CH enable 1 Blocking without frost protection 2 Blocking with frost protection 3 Lock out with frost protection 1 P37 Function of release input 0 DHW enable 1 Burner release 1 P38 Wait time for valid...

Страница 58: ...CPVC 90 C 194 F 2 PP SS 110 C 230 F 1 P52 Air pressure sensor 0 Off 1 On 0 P53 DHW time out mode 0 None 1 Absolute 1 P54 DHW time out 10 to 180 minutes 150 P55 CH prior time 10 to 180 minutes 120 P56...

Страница 59: ...is displayed alternating with the current sub status for example 4 Press the button is displayed alternating with the current flow temperature 1 5 7 F for example 5 Press the button successively to s...

Страница 60: ...protection gradient level 3 Blockage 36 Modulate up for flame control 37 Temperature stabilization time 38 Cold start 4 Burner on DHW mode 30 Temperature control 31 Limited temperature control T safet...

Страница 61: ...g Press button df x is displayed with x flashing This is the current value of X for dF Check this against the value of X on the type plate Enter the value of X shown on the type plate using the or but...

Страница 62: ...eeds central heating loop setpoint unit will shutdown and go through 3 minute time delay burner pause time before another call for heat During this time the pump will run for additional three minutes...

Страница 63: ...valve manufacturer s instructions packaged with relief valve Examine flue passages in heat exchanger burner condensate lines and cleaning if necessary by following instructions in Annual Examination a...

Страница 64: ...from factory and require no further lubrication Lubricate field sourced pumps and or motors according to pump and or motor manufacturer s instruction Check following components are operating properly...

Страница 65: ...tles this might damage the injector 4 Remove any fallen deposits from bottom of inner case 5 Clean burner with soft brush and check flame ports are clear Blockages may be removed with stiffer brush 6...

Страница 66: ...se central heating flow and return valves Connect suitable pipe to drain point Route it to suitable container Open drain tap 11 GENERAL MAINTENANCE AND CLEANING DANGER Before servicing turn off electr...

Страница 67: ...t AHRI Rating Water MBH 1 3 AFUE 2 Maximum Minimum 241 36 216 188 95 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Efficiency are based on DOE Depa...

Страница 68: ...g correctly Check sensor has been correctly fitted Replace sensor if necessary CHART 1 E04 E05 Temperature of heat exchanger too low Heat exchanger temperature too high Bad connection Sensor fault Sen...

Страница 69: ...eck that the air inlet and exhaust flue are not blocked Check the wiring on the gas valve Defective control SU PCB CHART 5 Presence of the flame but insufficient ionization 3 A Check that the gas valv...

Страница 70: ...nge during boiler operation burner on Bad connection Supply Return sensor damaged No water circulation Check the sensor connection Replace the sensor Check the pump connection CHART 11 E44 Difference...

Страница 71: ...Power supply incorrectly wired Floating or 2 phase network Line and neutral mixed up Set parameter p43 to 0 Su 10 Shutdown input is open External cause Parameter error Bad connection Correct the exte...

Страница 72: ...30 2 No tFG sensor connected shorted Boiler stop Flue high limit disconnected Sensor error Replace flue high limit Su 33 After 5 times tF tF Max controlled stop Non existent or insufficient circulati...

Страница 73: ...onfirm using button Er xx is displayed with xx flashing Last error which occurred for example 2 Use or buttons to scroll through faults Press button to display details of faults or shutdowns Press or...

Страница 74: ...9 84 2 858 28 4 3 131 86 0 827 30 2 2 990 87 8 796 32 0 2 857 89 6 767 33 8 2 730 91 4 740 35 6 2 610 93 2 713 37 4 2 496 95 0 687 39 2 2 387 96 8 663 41 0 2 284 98 6 640 42 8 2 186 100 4 617 44 6 2 0...

Страница 75: ...ons tight and wires undamaged NO YES Check continuity across sensor OK NO YES Repair wire and or fix connection Check sensor element is properly installed in pipe NO YES Replace Sensor Replace Control...

Страница 76: ...ass Is flame present NO YES Replace Flame Sense Adjust Gas Mixture See Section 9 Re check E 16 still present NO YES Replace Gas Valve Condition Corrected E16 False Flame Signal Initiate heat call Chec...

Страница 77: ...e Heat Exchanger E12 High Temperature Is external High Limit Switch off NO or N A YES 13 TROUBLE SHOOTING Troubleshooting Chart 3 Reset Switch Check Boiler Pump OK NO YES Water Circulation Adequate NO...

Страница 78: ...l board Check both sensors are properly inserted into pipe lines NO YES Repair sensor insertion into pipe lines E10 E11 Temperature Difference Between Supply and Return Too Great E35 Supply and Return...

Страница 79: ...as line Check gas inlet pressure at least equals rating plate requirements NO YES Press RESET for two 2 seconds and retry Is there a strong consistent spark NO YES Remove igniter and inspect Is there...

Страница 80: ...YES Provide proper ground Purge all air from gas line Check gas inlet pressure at least equals rating plate requirements NO YES Check gas line for obstructions Check venting Is exhaust gas recirculat...

Страница 81: ...L connection on control board terminal strip Is this function being utilized NO YES Secure wire connections Install jumper securely in place Repair Replace External Accessory Item As Required E39 Shut...

Страница 82: ...Is wiring connection to HRU terminal secure NO YES Is wiring connection from SCU board to main board secure NO YES Is Parameter P42 set to 1 NO YES Is P42 parameter set to 0 NO YES Done Set P42 to 0...

Страница 83: ...Check wire harness connections are secure NOT OK OK The error code is accurate Correct water pressure and or correct system leaks Replace Sensor NOT OK OK Note This error code refers to the onboard lo...

Страница 84: ...ence During Operation Check wire plugs are securely connected to temperature sensors NO YES Onboard pump operating properly NO YES Check both sensors are properly inserted into pipe lines NO YES Possi...

Страница 85: ...sors T C T F R Ohm 40 40 309396 30 22 171840 20 4 98932 10 14 58879 0 32 36129 10 50 22804 20 68 14773 25 77 12000 30 86 9804 40 104 6652 50 122 4607 60 140 3252 70 158 2337 80 176 1707 90 194 1266 10...

Страница 86: ...ough flame proofed fire retardant treated or plastered COMBUSTION AIR Air that is drawn into an appliance to mix with fuel and support combustion CONDENSATE Liquid separated from flue gas due to reduc...

Страница 87: ...to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner in event source of...

Страница 88: ...OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decre...

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