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- 075 97gb
- Installation, Operation And Maintanance Manual
ECR 075 97gb Installation, Operation And Maintanance Manual
Summary of 075 97gb
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2 dimensions figure 1-1 dimensions wall hanging bracket (d) gas connection (g) supply water (e) return water (e) user interface (b) (a) alternate return water (e) alternate supply water (e) alternate gas connection (f) (c) (d) (b) (f) table 1 : physical data size width (a) height (b) depth (c) brack...
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3 1 - introduction ............................................................................................................................... 4 2 - important safety information .................................................................................................... 5 3 - component l...
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4 1.1 designated use hot water heating boiler. • indoor installations. • closet or alcove installation. • direct vent boiler. • for use with natural gas or liquefi ed petroleum gases • (lp/propane). 1.2 the unit must not: • directly heat potable water. Indirect heating is acceptable. • heat water wi...
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5 notice used to address practices not related to personal injury. 2.3 installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: united states • national fuel gas code, ansi z223.1/nfpa 54 • . National electrical code, nfpa 70. • canada • natural...
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6 3.1 component listing user interface 1. (see page 8) - displays informa- tion regarding boiler condition. Allows adjustment of boiler operating parameters. Note: does not replace thermostat used to control central heating space. Combustion air inlet (2" pvc) 2. (see page 7 & 8) return water from h...
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7 3 - component listing figure 3-1 boiler components low voltage low voltage terminal terminal strip (4) strip (4) combustion air inlet- 2" pvc (2) vent connector - 2" pvc (25) safety safety relief relief valve valve (23) (23) air vent air vent (30) (30) return water return water from heating from h...
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8 3 - component listing figure 3-2 boiler components low low voltage voltage terminal terminal strip (4) strip (4) high voltage high voltage junction box junction box (24) (24) return water return water from heating from heating system (in) system (in) 1-1/4" npt (3) 1-1/4" npt (3) igniter igniter (...
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9 3 - component listing internal access panel - closed (33) internal access panel -open (33) control module (32) central heating pump relay (34) transformer (35) control module fuse and holder.
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10 table 2: boiler clearances dimension combustible materials (1) service (1)(2) top (a) 0" (0 cm) 14" (36 cm) left side (b) 6" (16 cm) 6" (16 cm) right side (c) 0" (0 cm) 1½" (4 cm) front (d) 0" (0 cm) 6" (16 cm) back (e) 0" (0 cm) 0" (0 cm) bottom (f) 0" (0 cm) 0" (0 cm) floor 12" (32 cm) for bott...
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11 4.2 wall mounting option boiler can be wall mounted using wall mounting bracket included with unit. Structure must be capable of supporting boiler 1. Weight plus 60 lbs (28 kg). See table 1, page 2. Wall mount bracket has 4 slots allowing mounting 2. On two (2) wall studs spaced at 11½" to 16½" o...
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12 5.1 general install piping in accordance with authority having jurisdiction. • notice use two (2) wrenches when tightening and fi tting to pipe boiler's threaded fi ttings. Boiler's internal piping can be damaged if subjected to excessive torque. Support system piping and safety relief valve disc...
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13 warning burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. ! Install discharge piping from safety relief valve. See • fi gures 5-2 and 5-4. Use ¾" or larger pipe. • use pipe suitable for temperatures of ...
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14 piping legend figure 5-4 system piping 5 - hydronic piping notice illustrations are meant to show system piping con- cept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. System return system supply check local codes for maximum distance to fl...
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15 5 - hydronic piping 5-5 two-pipe zoned system with valves 5-6 two-pipe zoned system with pumps circulating ball valve open (as shipped) 3/8" open end wrench circulating ball valve open (as shipped) 3/8" open end wrench.
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16 5 - hydronic piping 5-7 single boiler using primary/seconday pumping 12"/305mm max. Apart 12"/305mm max. Apart limit length to 5 feet water pressure drop existing closely spaced tees in primary system loop system pump heat exchanger valve open heat exchanger valves closed 3/8" open end wrench 3/8...
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17 5 - hydronic piping 5-8 typical multiple boiler piping - (see multiple boiler guide) system pump 12"/305mm max. Apart system temperature sensor size common piping according to max. Heat capacity of entire system limit to 2 feet up to 16 boilers all heat exchanger valves closed 3/8" open end wrenc...
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18 table 3 - combustion air and vent piping length for example: boiler can be installed on outside wall and vented with 1-90° elbow and 2 feet of vent pipe. 6.1 general this boiler requires a dedicated direct vent system. Install air and vent piping in accordance with these instructions, authority h...
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19 warning use of cellular core pvc for venting fl ue gas could result in death, serious injury. ! Table 4 - combustion air and vent pipe fi ttings must conform with the following: item material standards vent pipe and fittings pvc schedule 40 ansi/astm d1785 pvc - dwv ansi/astm d2665 cpvc schedule ...
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20 6 - combustion air and vent piping side wall terminations 3" (8 cm) minimum horizontal separation between combustion air intake and vent terminations. 8" (21 cm) minimum vertical separation between combustion air intake and vent terminations. 12" (30 cm) separation between bottom of combusti...
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21 1" maximum combustion air exhaust 6 - combustion air and vent piping figure 6-4 figure 6-6 figure 6-7 exhaust exhaust combustion air 1" maximum 46-3/4" (1.2 m) 31-7/8" (0.8 m) 1-3/16" (4.0 cm) 3" (7.6 cm) diameter pvc intake/combustion air 1-1/2" (3.8 cm) elbow fi eld supplied combustion air exha...
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22 doors & windows combustion air and vent termination must be 12" (30.5 cm) from or below doors, windows or gravity inlet. Forced air inlet terminate venting system 3’ (0.9 m) above and 10' (3.0 m) from any forced air inlet (except boiler’s combustion air inlet). "l" corner vent termination shall n...
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23 stones, balls, etc. Position combustion air and vent termination where it will not be damaged by foreign objects, such as stones, balls, etc. Multiple family dwellings vent shall not terminate directly above paved sidewalk or paved driveway located between two single-family dwellings serving both...
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24 6 - combustion air and vent piping 6.6 condensate piping use materials acceptable to authority having jurisdiction. • in absence of such authority: usa - pvc or cpvc per astm d1785/d2845 cement • or primer per asme d2564 or f493. Canada - csa or ulc certifi ed pvc/cpvc pipe, fi t- • tings and cem...
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25 7.1 general use piping materials and joining methods acceptable • to authority having jurisdiction. In absence of such requirements: usa - national fuel gas code, ansi z223.1/nfpa 54 • canada - natural gas and propane installation code, • can/csa b149.1) size and install gas piping system to prov...
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26 7-5 manual main gas shutoff valve outside boiler jacket option: gas connection may be located at bottom of boiler manual main gas shutoff valve 7.3 leak check gas piping pressure test boiler and gas connection before placing boiler in operation. Pressure test over 1/2 psig (3.5 kpa). Disconnect •...
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27 8.1 general electrically bond boiler to ground in accordance with re- quirements of authority having jurisdiction. In absence of such requirements: usa- national electrical code, ansi/nfpa 70. • canada - canadian electrical code, part i, csa c22.1: • safety standard for electrical installations. ...
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28 8 - electrical connections domestic hot water (dhw) thermostat, if used. • use temperature control with dry contacts rated at a. 0.5 amps @ 120 vac. Boiler control does not pro- vide power to dhw temperature control maximum wire length is 330 ft (180 m) 22 gauge b. Wire. Connect wires (interchang...
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29 9.1 fill boiler with water and purge air consult local water treatment companies for hard water • areas (above 7 grains hardness). Do not fi ll boiler or operate with water containing chlorine • in excess of 200ppm. Filling with chlorinated fresh tap water should be acceptable. Fill boiler and sy...
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30 9-2 user interface 9 - start up procedure 9-2 user interface 9.3 program boiler control key description - manual lockout reset - enter/exit user menu - go to previous screen - select a menu item - confi rm new parameter value - scroll up to next menu item - increase value - scroll down to next me...
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31 press ok key once e. Press menu key once f. Press arrow keys to scroll to • ch (central heating) settings press ok key once a. In ch mode: b. Press ok key once c. 4 modes to choose from, scroll to d. Choice: 0 - no outdoor reset 1 - outdoor reset (default mode) 2 - full outdoor reset - no thermos...
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32 9.4 boiler start-up and operational test verify air is purged from hydronic piping 1. System test pumps - verify each pump is opera- 2. Tional verify gas piping 3. Confi rm pressure test. See section 7.3. • visually inspect piping to determine there are no • open fi ttings or ends, and all valves...
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33 9-4 combustion air analyzer port combustion air analyzer port 9-5 burner flame flame flame burner 9 - start up procedure verify burner, proper operation inspect burner fl ame through sight glass. See fi g- 1. Ure 9-5. Operate boiler through several heating cycles, 2. Including domestic hot water,...
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34 for your safety read before operating caution what to do if you smell gas do not try to light any appliance. • do not touch any electrical switches; do not use • any phone in your building. Immediately call your gas supplier from a neigh- • bor’s phone. Follow the gas supplier’s instruc- tions. I...
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35 11.1 beginning of each heating season check boiler area is free from combustible materials, • gasoline, and other fl ammable vapors and liquids. Visually inspect combustion air and vent piping for proper • operation. Check for and remove any obstruction to fl ow of combustion air or vent gases. I...
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36 visual inspection of fl ame through sight glass. Burner • should be fully illuminated. Check expansion tank. • 11.2 annual shut down procedure follow instructions “to turn off gas to appliance” • unless boiler is also used to supply domestic hot water. See section 10. Drain system completely and ...
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37 remove inlet assembly with blower attached, remove • gasket and burner. Clean burner by inserting an air hose into blower • opening of casting and blowing air through heat exchanger side. After cleaning burner, remove burner holder and • refractory from top of combustion chamber. Remove four nuts...
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38 12.1 ratings and capacities constructed and hydrostatically tested for maximum • working pressure of 50 psig (pounds per square inch gauge) in accordance with asme boiler and pressure vessel code, section iv, rules for construction of heating boilers. Ratings are for sea level applications. Boile...
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39 13 - trouble shooting.
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40 13 - trouble shooting _ _ _ _ _ _ f p _ _ _ _ lockout alarm blocking error e 3 5 blocking too long error false flame detect _ _ _ _ _ _ _ _ _ _ _ _ lockout alarm blocking error e 3 6 ignit error low water cutoff _ _ _ _ _ _ _ _ _ _ _ _ lockout alarm blocking error e 4 0 gv relay error return temp...
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41 _ _ _ _ _ lockout alarm a 0 0 blocking too long e rror enter installer menu, boil er status. Scr o ll to most recent lockout alarm or blocking error. Di a g nose corrective action usi n g appropriate trou blesh ooting tree. Is harne ss co nne cted to ga s valve? Is ha rn ess conne cted to cont ro...
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42 13 - trouble shooting _ p _ _ _ lockout alarm a 0 1 ignit error open gas shutoff va lv es in sta ll propa ne or if ic e connect all wir e s and check for secure fit in spect v ent system for blockages. Is t h e ve n t s yst em cl ear? Ye s no check all wires, including ig niter an d flame se nsor...
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43 13 - trouble shooting disconn ect 4-wire ha rness from combustion air blower. Does combustion air blower sp eed increase? _ _ _ _ _ lockout alarm a 0 8 fan e rror is co mbustion air blower ope ra tin g ? Ye s no are 3 -wire a nd 4-wire harne sses co nnected to combustion air blower? Disconn ect h...
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44 13 - trouble shooting disconn ect ha rne s s from co ntrol mo dule j16. Con tin uity between j16 -2 an d j1 6-3? _ p _ _ _ lockout alarm a 1 5 air sw no t open is co mbustion air blower ope ra tin g ? No ye s no are ora nge wire s conn ecte d to air pressure switch no an d c terminals (interchang...
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45 danger replace all test port caps. Failure to comply will result in death or serious injury. ! Vinyl tubing silicone tubing vinyl tubing tee vinyl cap (typ. 2) inclined manometer (or differential pressure gauge) test lines combustion air analyzer port + - differential air pressure switch flue tra...
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46 13 - trouble shooting disconn ect 3-wire ha rne s s from combustion air blower. Disconn ect ha rne s s from control module j9. Continuity in each wire? _ p _ _ _ lockout alarm a 1 7 air sw no t closed is co mbustion air blower ope ra tin g ? Ye s no ye s no is 3-wire harness connected to combusti...
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47 13 - trouble shooting measure resistance across h igh temper at ur e supply switch term inals 2 and 4? Do es resistan ce ma tch supp ly water temperature (see table)? Is supply water tem perature less than 185°f (91°c)? _ _ _ _ _ lockout alarm a 1 8 max temp error disconnect harness from high tem...
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48 13 - trouble shooting follow operat ing instructions to initiate bo iler op eration. Enter in staller me nu, bo iler status, flam e signa l. Is fla m e signal grea te r th an 3.7 ua? _ p _ _ _ lockout alarm a 2 4 3 flam e failur e s in sp ect harne ss co nne ction fla me sensor. Is conn ection cl...
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49 13 - trouble shooting check low water cutoff. I s am ber lamp lit? No yes _ _ _ _ _ bl ocking error e 3 6 low water cutoff c h e c k low wa te r cu to ff. Is g ree n power la mp lit? Yes no re place lo w wa te r c u to ff inser t ha rnes s repair system piping, re move a n y rem a in in g ai r in...
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50 13 - trouble shooting is co rrect ha rne s s co nne cted to re tu rn sensor (2 bro wn wire s)? No ye s _ _ _ _ _ blocking error e 4 0 return temp disconn ect ha rne s s from return water s e nsor. Measure re sistance using digital ohm met e r. Is re sistance be twee n 950 to 33 ,0 00 oh ms? Is he...
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51 13 - trouble shooting is field wiring loose or faulty? Is po we r supply between 5 9 a nd 61 hz? No ye s _ p _ _ _ blocking error e 4 5 net frequency error correct wiring is power supply circuit breaker loos e or faulty? Prov ide freq uenc y st abi liz ed pow e r supply ra ted a t 60 hz +/- 2 % r...
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52 is harness plugged into su pply wa te r sensor? Is harness plugged into cont rol module j5? No yes _ p _ _ _ blocking error e 5 1 supply sens open insert harness r e place sup p ly w a te r sens or re pla ce control m odule disconn ect j5 from contro l module. Using digital meter measure check co...
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53 is ha rne s s plug ged in to return wa te r sensor? Is ha rne s s plug ged in to control module j5? No ye s _ p _ _ _ blocking error e 5 2 return sens open insert harn ess replace return water se nsor replace con trol module check continuity of brown wires between ret u rn water se nsor a nd co n...
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54 13 - trouble shooting disconnect harness from vent t e mperature sensor and control module j5. Continuity for each blue wire? Is h arn ess plu gge d into ve nt temperatur e sens or ? Is harness p lugge d into co ntro l module j5? No ye s _ p _ _ _ blocking error e 5 7 flue sens open in sert harne...
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55 13 - trouble shooting disconn ect ha rne s s from control m odule j5. M easure resistan ce b etwee n brown wires a t terminals j5 -4 a nd j5 - 1 2. Is resistan ce le ss th an 50 ohms? _ p _ _ _ blocking error e 6 0 return sens shorted disconn ect ha rne s s from return water s e nsor. Measure res...
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56 15 - wiring diagram 14.1 connection diagram.
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57 15 - wiring diagram j22-6 j22-5 j22-4 j22-3 j5-2 j5-11 j5-3 j5-12 j5-4 j5-13 j5-5 j5-14 j5-6 j5-15 j5-7 j5-16 j5-8 s4 j18-1 j18-2 j16-1 j16-4 j16-8 j16-7 j16-3 j16-2 j12 t2 j13-2 j9-1 j9-2 j9-6 j9-7 j9-5 j9-4 j9-3 j13-5 j13-6 j13-3 j13-4 j7-1 j7-4 j7-3 j7-2 j6-1 j6-3 j6-2 j4-1 j4-2 j4-3 j4-4 j2-1...
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58 16 - glossary natural gas length of pipe - ft. Pipe capacity - btu per hour input includes fittings 1/2” 3/4” 1” 1 1/4” 20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000 60 50,000 105,000 195,000 365,000 propane gas length of pipe - ft. Pipe capacity - btu per hour input include...
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59 1.1 introduction the boiler is equipped with a programmable electronic con- trol and user interface module. 1.2 operation display: 4x20 character lcd screen to show boiler • status. Function keys • operation with lcd character display module 1.3 status indication the following status screens can ...
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60 appendix a - control module 1.4 sequence of operation operational state user interface display explanation boiler operates in standby mode until demand for central heat (ch) or domes- tic hot water (dhw) is detected. Ch or dhw pump is turned based on type of heating demand. (ch call is illustrate...
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61 1.4 sequence of operation operational state user interface display explanation if fl ame detected before gas valve opens during ignition boiler will lockout. Please refer to troubleshooting guide. Gas valve energized to deliver air/fuel to burner. Flame undetected 3 seconds boiler will de-energiz...
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62 appendix a - control module 1.5 theory of operation user interface display explanation standby s t a n d b y : n o d e m a n d 7 5 ° f boiler operates in standby mode until demand for central heat (ch) or domestic hot water (dhw) is detected. User menu can be accessed by pressing ‘menu’ key on us...
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63 user interface display explanation settings s e t t i n g s c e n t r a l h e a t i n g s e t p o i n t ° f ▼ adjust ch set point to hydronic system design while in operating in ch mode = 0 (ch with thermostat) or 3 (perma- nent demand). Closed loop software control algorithm used to meet set poi...
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64 user interface display explanation installer menu installer menu i n s t a l l e r m e n u b o i l e r s t a t u s b o i l e r c o n f i g c h s e t t i n g s d h w s e t t i n g s c a s c a d e s e t t i n g s s y s t e m t e s t the installer menu structure includes: ‘boiler status’ submenu – u...
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65 appendix a - control module user interface display explanation installer menu boiler status s t a t u s ▲ i g n i t i o n a t t e m p t s s u c c e s f u l 4 2 6 7 f a i l e d 2 1 ▼ control module logs successful and failed ignition attempts. Information accessed in ‘ignition attempts’ screen as ...
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66 user interface display explanation boiler status s t a t u s ▲ b o i l e r r u n t i m e c h 3 2 0 h r d h w 1 4 5 h r ▼ boiler stores information regarding total ch and dhw run time in hours. Data stored in non-volatile memory and retained in event of power failure. S t a t u s # e 3 9 ▲ 2 h r s...
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67 user interface display explanation boiler con fi guration b o i l e r c o n f i g ▲ p u m p m o d e m o d e : 0 c h o r c h & d h w ▼ two pump modes are available: pump mode = 0 ‘ch or ch&dhw’ 1. Mode either ch or dhw pump terminal energized • dependant on demand (ch or dhw). Ch and dhw pumps not...
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68 user interface display explanation ch settings c h s e t t i n g s c h m o d e m o d e : 1 c h w i t h t h e r m o s t a t ▼ 4. Central heating (ch) modes available: ch mode = 0 ‘ch with thermostat’ • boiler will attempt to satisfy ch demand while ch ther- • mostat input is closed. Boiler will mo...
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69 user interface display explanation ch settings c h s e t t i n g s ▲ w a r m w e a t h e r s h u t d o w n t e m p 7 0 ° f ▼ allowed range: 35..100 °f (2..38 °c) default setting: 70 °f (21 °c) outdoor temperature greater than warm weather shutdown temperature, demand for ch blocked and pumps stop...
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70 user interface display explanation ch settings c h s e t t i n g s ▲ b o o s t f u n c t i o n t e m p 1 0 ° f t i m e 2 0 m i n ▼ outdoor reset boost function increases ch set point by increment (‘temp’) if ch demand continues beyond pre-set time limit (‘time’). Ch set point will continue to inc...
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71 user interface display explanation dhw settings d h w s e t t i n g s ▲ d h w m a x . P r i o r i t y t i m e 3 0 m i n dhw demand prioritized over ch demand when dhw mode 2 is enabled. Maximum time boiler operates in dhw mode limited by dhw maximum priority time setting. Priority timer starts wh...
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72 ecr international, inc. 2201 dwyer ave. Utica, ny 13501 www.Ecrinternational.Com.