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GMPVB
Gas-Fired
Hot Water
Induced Draft Boiler
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Series II Models
GMPVB-42
GMPVB-75
GMPVB-112
An ISO 9001-2008 Certified Company
GMPVB-150
GMPVB-188
GMPVB-225
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com
PN 240009367 REV. D [06/15/2018]
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Summary of Contents for ECR International Green Mountain GMPVB II Series
- Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL Series II Models GMPVB-42 GMPVB-150 GMPVB-75 GMPVB-188 GMPVB-112 GMPVB-225 An ISO 9001-2008 Certified Company Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 240009367 REV. D [06/15/2018]...
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Page 2: Table Of Contents
TABLE OF CONTENTS Boiler Ratings & Capacities...... 3 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Dimensions ..........4 Safety Symbols & Warnings Installation Procedure ......5 The following defined symbols are used throughout this Ventilation & Combustion Air ....6 manual to notify the reader of potential hazards of varying risk levels. -
Page 3: Boiler Ratings & Capacities
BOILER RATINGS & CAPACITIES Table 1 - RATINGS NATURAL AND PROPANE GASES Vent Diameter (Inches) **Net Heating Model AFUE AHRI Rating Water Input Capacity To Chimney Horizontal Vent *Mbh *Mbh *Mbh (Category I) (Category III) GMPVB-42 42.5 84.4 GMPVB-75 75.0 83.4 GMPVB-112 112.5... -
Page 4: Dimensions
DIMENSIONS Model Width (A) GMPVB-42 GMPVB-75 14-1/4 GMPVB-112 17-1/2 GMPVB-150 20-3/4 GMPVB-187 GMPVB-225 27-1/4 PN 240009367, Rev. D [06/15/2018]... -
Page 5: Installation Procedure
INSTALLATION PROCEDURE WARNING NOTICE Follow local regulations with respect to installation Improper installation, adjustment, alteration, service of CO detectors. or maintenance could result in death or serious injury Installation must conform to requirements of authority Figure 1 - Minimum Clearances To Combustible having jurisdiction or, in absence of such requirements, Construction to the National Fuel Gas Code, ANSI Z223.1/NFPA 54. -
Page 6: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR • All Outdoor Air. Provide permanent opening(s) Provide combustion air and ventilation air in accordance communicating directly or by ducts with outdoors. with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections о... -
Page 7: Installation System Piping
INSTALLATION SYSTEM PIPING WARNING Figure 2 - Safety Relief Valve Discharge Piping Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. RELIEF VALVE Refer to local codes and appropriate ASME Boiler DISCHARGE and Pressure Vessel Code for additional installation PIPING... - Page 8 INSTALLATION SYSTEM PIPING Figure 3 - Forced Hot Water Typical Piping Figure 4 - Forced Hot Water Typical Piping With Zone Control Valve MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR PN 240009367, Rev.
- Page 9 INSTALLATION SYSTEM PIPING • Install radiation units (panels, radiators or cabinets) and Low Design Water Temperature Systems (Below supply and return mains first then make connections at 140°F) And Large Water Content Systems boiler. • Verify clean water supply is available when connecting Condensation is corrosive and can eventually cause severe cold water supply to water valve.
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Page 10: Vent Installation
VENT INSTALLATION Check Your Chimney Fasten sections of vent pipe with sheet metal screws to make piping rigid. Use stovepipe wires to support pipe Chimney must be clean, right size, properly constructed from above. and in GOOD CONDITION. Do not connect to fireplace flue. Installation must conform to requirements of the authority having jurisdiction or, in absence of such Do not install damper on this boiler. - Page 11 VENT INSTALLATION Figure 7 - Type B Gas Vent Vent pipe must be: At lease 2 ft. (610mm) higher than any part of the roof, but not less than 3 ft. Liner (915mm) tall, and within a 10 ft. within a 10 ft. (3m) radius of the apex.
- Page 12 VENT INSTALLATION Removing Existing Boiler From Common Venting Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use flame of a match System or candle, or smoke from a cigarette, cigar, or pipe. When an existing boiler is removed from a common After it has been determined that each appliance venting system, the common venting system is likely to be...
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Page 13: Horizontal Venting Instructions
HORIZONTAL VENTING INSTRUCTIONS INDUCED DRAFT HIGH EFFICIENCY BOILERS Horizontal (Category III) venting systems must be installed CHOICE OF VENT PIPE MATERIAL in accordance with these instructions. • U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe. Maximum Horizontal Vent Length For Stainless Steel Vent •... - Page 14 HORIZONTAL VENTING INSTRUCTIONS Boilers may be vented horizontally as shown in Vent Termination Fitting: For all vent pipe materials, Figure 8, Page 13. Vent pipe is pitched down from you may use either: boiler to vent termination. Do not connect other A.
- Page 15 HORIZONTAL VENTING INSTRUCTIONS Figure 9 - Horizontal Venting Clearances D. The venting system shall terminate at least 3 feet A. The venting system shall terminate at least 4 feet (0.9m) above any forced air inlet located within below any eave, soffit, or roof overhang. 10 feet (3m).
- Page 16 HORIZONTAL VENTING INSTRUCTIONS B. For Heat-Fab Saf-T-Vent stainless steel vent pipe Joining and Sealing the Vent Pipe: use a high temperature silicone sealant rated for The vent pipe needs to be both watertight and gas 550°F The outside of the male end and inside tight.
- Page 17 HORIZONTAL VENTING INSTRUCTIONS D. For ProTech Systems FasNSeal stainless steel C. For Flex-L StaR-34 stainless steel vent pipe use vent pipe no cleaning fluid is required. For 3” a high temperature silicone sealant rated for vent pipe runs on 2, 3, 4 and 5 section boilers, 550°F.
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Page 18: Optional Horizontal Venting Instruction
HORIZONTAL VENTING INSTRUCTIONS Support Spacing: If horizontal vent must go through a crawl space or other unheated space, cool temperatures will cause Do not restrict thermal expansion movement of the flue gases to continuously condense inside the vent vent. Vent pipe must expand and contract freely with pipe. -
Page 19: Gas Supply Piping
GAS SUPPLY PIPING Connecting Gas Piping CAUTION Gas line enters boiler from right side. Flexible gas WHAT TO DO IF YOU SMELL GAS connectors must never breach any boiler openings. • Do not try to light any appliance. • Use piping materials and joining methods acceptable to authority having jurisdiction. - Page 20 GAS SUPPLY PIPING Table 5 - NATURAL GAS Table 6 - PROPANE GAS Pipe Capacity - BTU Per Hour Input Pipe Capacity - BTU Per Hour Input Length of Length Includes Fittings Includes Fittings Pipe - Ft. Copper Tubing* Iron Pipe ½"...
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Page 21: Electrical Wiring
ELECTRICAL WIRING LWCO kit 550002998 includes wiring instructions WARNING and diagrams. If using other LWCO, refer to specific Electrical shock hazard. Turn OFF electrical power manufacturer instructions supplied by appropriate supply at service panel before making electrical manufacturer. connections. Failure to do so could result in death Connect 115 volt power supply to terminals L1 (HOT) and or serious injury. -
Page 22: Sequence Of Operation
SEQUENCE OF OPERATION Sequence of Operation -See Figure 12, Page 23 Thermostat calls for heat, control relay contacts. Circulator pump is powered through terminals C1 and C2. Control holds off burner and attempts to satisfy thermostat with residual boiler heat. Induced draft blower and transformer primary are powered. -
Page 23: Wiring Diagrams
WIRING DIAGRAMS Figure 12 - Control Module Damper is not an option. PN 240009367, Rev. D [06/18/2018]... -
Page 24: Starting Your Boiler
STARTING YOUR BOILER NOTICE Do not add water into hot empty boiler. Filling System With Water • Close air vents on all radiation units. Open valves to these units. • Verify boiler and expansion tank drain valves are closed. Air bleed screw on tank drain fitting should be closed. •... - Page 25 STARTING YOUR BOILER Operating Instructions. WARNING STOP! Read Safety Information on previous page. If you do not follow these instructions Set the thermostat to lowest setting. exactly, a fire or explosion may result Turn off all electric power to the appliance. causing property damage, personal injury This appliance is equipped with an ignition device which or loss of life.
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Page 26: Checking And Adjusting
CHECKING AND ADJUSTING Gas Valve Safety Shutdown Test Figure 14 - Automatic Gas Valve WARNING Electrical shock hazard. Follow instructions to turn off electric power. Failure to do so could result in death or serious injury. Ignition system safety shutoff device must be tested after placing boiler in operation. - Page 27 CHECKING AND ADJUSTING Adjust Thermostat Heat Anticipator Figure 16 - Main Burner Flame Instruction for final adjustment of thermostat are packaged with thermostat. Set Heat anticipator at .2. Check thermostat operation. When set above temperature indicated on thermometer, boiler burners should ignite.
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Page 28: Maintaining Your Boiler
MAINTAINING YOUR BOILER Burners Cleaning Your Boiler And Burners Beginning of heating season visually check pilot end main Flue passages between sections should be examined yearly burner flames. See Figures 14, 15 & 16 Pages 26 & 27. and cleaned if necessary. To clean: Safety Relief Valve •... -
Page 29: Service Hints
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service: CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. -
Page 30: Equipment & Optional Accessories
EQUIPMENT & OPTIONAL ACCESSORIES AIR ELIMINATING FITTING (AIR PURGER) WARNING Air purger is used to remove excess air from system. It and scald hazard. Safety relief valve could Burn is installed in supply line. It will eliminate air from water discharge steam or hot water during operation. - Page 31 EQUIPMENT & OPTIONAL ACCESSORIES PRESSURE SWITCH Air pressure switch works on negative pressure. When blower comes on air pressure switch operates intermittent pilot and gas valve. Air pressure switch is factory set and will only work when blower operates properly. It will not allow boiler to come on if blower does not generate enough pressure or if venting system is blocked.
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Page 32: Appendix A - Control Module
APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations A.3 Adjusting Settings To discourage unauthorized changing of settings, procedure WARNING to enter adjustment mode is required. If you do not follow these instructions To enter adjustment mode, press UP, DOWN, and I buttons exactly, a fire or explosion may result (see Figure 1) simultaneously for three seconds. -
Page 33: Operation
APPENDIX A - CONTROL MODULE A.5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes list) Module continuously monitors boiler water temperature and and heats water in boiler until setpoint temperature is fires or shuts off burner based on this temperature data. achieved or thermostat is satisfied. -
Page 34: Boiler High Limit Temperature Controller
APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller A.7 Troubleshooting • When water temperature reaches setpoint, controller • Following service procedures are provided as general ends heating cycle. guide. • When water temperature drops below setpoint minus •... -
Page 35: Intermittent Pilot
APPENDIX A - CONTROL MODULE Table 8 - Troubleshooting Error Codes Error Code Definition Consequence Number Pressure switch failed to open (stuck closed). Wait for recovery Flame current too low. Check for flame. Non critical alarm Flame sensed out of normal sequence (before opening or after closing gas valve). Soft lockout Gas valve relays welded. - Page 36 APPENDIX A - CONTROL MODULE STEP 3: Check spark ignition circuit. • Recheck ignition sequence as follows. WARNING — Reconnect main valve wire. — Adjust thermostat above room temperature. Electrical shock hazard. Ignition circuit generates — Verify ignition sequence at burner. over 10,000 volts.
- Page 37 NOTES...
- Page 38 NOTES...
- Page 39 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/ maintenance person Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone...
- Page 40 Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
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