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- Installation, Operation & Maintenance Manual
ECR International 100 Installation, Operation & Maintenance Manual
Summary of 100
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H installation, operation & maintenance manual p/n # 240008282, rev d [10/2010] condensing gas boiler models 075 & 100
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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) (b) (f) table 1 : physical data size width (a) height (b) depth (c) bracket (...
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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 installation. • 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 wit...
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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 information 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 hea...
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7 3 - component listing figure 3-1 boiler components low voltage low voltage terminal terminal strip strip combustion air inlet- 2" pvc vent connector - 2" pvc safety safety relief relief valve valve air vent air vent return water return water from heating from heating system (in) system (in) high v...
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8 3 - component listing figure 3-2 boiler components low low voltage voltage terminal terminal strip strip high voltage high voltage junction box junction box return water return water from heating from heating system (in) system (in) 1-1/4" npt 1-1/4" npt igniter igniter sight sight glass glass hea...
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9 3 - component listing internal access panel - closed internal access panel -open control module central heating pump relay transformer control module fuse and holder note: to open lift panel up then pull forward low voltage terminal strip high voltage junction box return water from heating system ...
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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 weight • plus 60 lbs (28 kg). See table 1, page 2. Wall mount bracket has 4 slots allowing mounting on • two (2) wall studs spaced at 11½" to 16½" on ...
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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 systems with automatic fi ll valves require back fl ow • prevention device. Install discharge piping from safety relief valve. See • fi gure 5-2. Use ¾" or larger pipe. • use pipe suitable for temperatures of 375°f (191°c) • or greater. Individual boiler discharge piping shall be independent • of...
Page 14: F L O O R
14 piping legend figure 5-4 system piping 5 - hydronic piping notice illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. Check local codes for maximum distance to floor system return system suppl...
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15 5 - hydronic piping 5-5 two-pipe zoned system with valves 5-6 two-pipe zoned system with pumps heat exchanger ball valve open (as shipped) heat exchanger ball valve open (as shipped) dhw pump ch/system pump dhw pump zone pump 3/8"/10mm open end wrench 3/8"/10mm 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'/1.6 m existing closely spaced tees in primary system loop ch/system pump heat exchanger ball valve open heat exchanger ball valves closed 3/8"/10mm open end wrench 3/8...
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17 5 - hydronic piping 5-8 typical multiple boiler piping - (see multiple boiler guide) ch/ system pump 12"/305mm max. Apart system temperature sensor size common piping according to maximum heat capacity of entire system up to 16 boilers all heat exchanger ball valves closed 3/8"/10mm open end wren...
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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 1 ft (0.30 m) of vent pipe. 6.1 general this boiler requires a dedicated direct vent system. Install combustion air and vent piping in accordance with these instruc...
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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 y 3" (8 cm) minimum horizontal separation between combustion air intake and vent terminations. Y 8" (21 cm) minimum vertical separation between combustion air intake and vent terminations. Y 12" (30 cm) separation between bottom of combust...
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21 1"(2.54cm) maximum combustion air vent 6 - combustion air and vent piping figure 6-4 maintain 12" clearance above highest anticipated snow level or grade * see note below vent combustion air 1" (2.54cm) maximum roof overhang 36"(0.9m) minimum maintain 12"(30cm) us (18"(46cm) canada) clearance abo...
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22 6 - combustion air and vent piping figure 6-6 combustion air roof boot/fl ashing (fi eld supplied) support (fi eld supplied) combustion air vent note: support must be fi eld installed to secure termination kit to structure vent maintain 12"(30cm) us (18"(46cm) canada) clearance above highest anti...
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23 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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24 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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25 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 ttings and cemen...
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26 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 provi...
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27 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 near boiler gas piping select top or bottom gas connection. To convert from • top connection to bottom connection: remove bottom knockout by removing...
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28 8.1 general electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to: usa- national electrical code, ansi/nfpa 70. • canada - canadian electrical code, part i, csa c22.1: • safety standard for electrical installations. 8.2 line voltage connecti...
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29 8 - electrical connections domestic hot water (dhw) thermostat, if used. • use temperature control with dry contacts rated a. At 0.5 amps @ 120 vac. Boiler control does not provide power to dhw temperature control. Notice important: do not apply power to dhw t-t terminals. Dry contact only, use o...
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30 9.1 fill boiler with water and purge air fill boiler with potable water. • fill boiler and system piping with water (or antifreeze- • water solution, if used). See antifreeze information page 12. Purge air from boiler using air vent. Purge air from system piping. Inspect system piping and boiler ...
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31 9 -2 user interface 9 - start up procedure 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 menu item - decrease...
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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 2. Operational 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 a...
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33 9-4 combustion analyzer port 9-5 burner flame flame flame burner 9 - start up procedure notice combustion analyzer port is provided. After use replace cover. Look for blue fl ame with slight yellow tips evenly spaced around burner verify burner, proper operation inspect burner fl ame through sigh...
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34 for your safety read before operating 10 - operating instructions 10-1 gas shutoff valve open position closed position warning if you do not follow these instructions exactly, a fi re or explosion may result causing property damage, personal injury or loss of life. This appliance is equipped with...
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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. See fi gure 9-5. 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 syste...
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37 examine fl ue passages by removing blower/burner • assembly from heat exchanger. Confi rm manual gas valve is closed. • disconnect fl ame sensor and igniter wires. • remove 2 screws and carefully remove igniter. • remove 2 screws and carefully remove fl ame rod • sensor. Loosen and remove four nu...
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38 12.1 ratings and capacities constructed and hydrostatically tested for maximum • allowable working pressure of 50 psig (pounds per square inch gauge) (345 kpa) in accordance with asme boiler and pressure vessel code, section iv, rules for construction of heating boilers. Ratings are for sea level...
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39 13 - trouble shooting check for 120 vac inside hi -volt ag e termi n al box power switch lamp lit? Ye s no turn on boiler switch. Is lamp lit? Yes yes no no does user interface displa y fu nction? Ch eck circuit break er or eme rgen cy dis conne ct switch and 12 0 va c wiring to boiler. Fix or re...
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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 c ted to cont r...
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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 vinyl tubing silicone tubing vinyl tubing tee vinyl cap (typ. 2) inclined manometer (or differential pressure gauge) test lines combustion analyzer port + - differential air pressure switch test port 13 - trouble shooting 13-1 differential air pressure switch danger replace all test port caps. Fa...
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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 p erature less than 185°f (91°c)? _ _ _ _ _ lockout alarm a 1 8 max temp error disconnect harness from high te...
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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 es in sp ect harne ss co nne ction fla m e 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 ai n 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 n d 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 er supply ra ted a t 60 hz +/- 2% re...
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52 13 - trouble shooting is harness plugged into supply wa te r sensor? Is harness plugged into control module j5? _ p _ _ _ blocking error e 5 1 supply sens open inser t ha rnes s re pla ce supply water sensor disconnect j5 from control mod u le. Using dig it al me te r measure check continuity of ...
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53 13 - trouble shooting is ha rne s s plug ged in to return te mpe rat ur e se ns or ? Is harness plugged into control module j5? _ p _ _ _ blocking error e 5 2 return sens open replac e re tur n t empera tur e se nsor replace control module check continuity of brown wires between return t e mperat...
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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 a rn 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 harn...
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55 13 - trouble shooting disconn ect ha rne s s from control m odule j5. M easure resistan ce b e twee 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 re tu rn te mperature sensor. Me...
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56 14 - wiring diagram 14.1 connection diagram.
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57 14 - wiring diagram 14.2 schematic diagram of ladder form.
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58 15 - 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 15 - glossary qualified agency • - any individual, fi rm, corporation, or company engaged in and responsible for: installation, testing, or replacement of gas piping, • or connection, installation, testing, repair or servicing of appliances and equipment. Experienced in such work. • familiar with...
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60 1.1 introduction boiler is equipped with programmable electronic control 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 be displ...
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61 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 domestic hot water (dhw) is detected. Ch or dhw pump is turned based on type of heating demand. (ch call is illustrated)...
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62 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. If fl ame undetected after 3 seconds boiler will ...
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63 appendix a - control module 1.5 theory of operation user interface display explanation standby 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 user interface. Installer menu can be acce...
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64 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 ▼ setting range: 104° f to 195° f (40° c to 91° c) default value: 140° f (60° c) adjust ch set point to hydronic system design while in operating in ch mode = 0 (ch with thermostat) or 3 (p...
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65 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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66 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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67 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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68 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. In this mode either the ch or dhw pump terminal is • energized depending on the type of demand (ch or...
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69 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 • thermostat input is closed. Boiler will modu...
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70 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°f to 100°f (2°c to 38°c) default setting: 70°f (21°c) if outdoor temperature is greater than warm weather shutdown temperature, demand for ch blocked and ...
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71 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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72 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 allowed range: 1 to 60 minutes default setting: 30 minutes maximum time boiler operates in dhw mode limited by dhw maximum priority time setting. Priority timer starts when both...
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Page 76: Condensing
Ecr international, inc. 2201 dwyer ave. Utica, ny 13501 www.Ecrinternational.Com condensing gas boiler models 075 & 100