ECR International CH-80 Installation And Service Manual

High efficiency condensing gas boiler
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HIGH EFFICIENCY CONDENSING GAS BOILER
NSF/ANSI/CAN 372
INSTALLATION AND SERVICE MANUAL
QUICK CONTENTS
FULL TABLE OF CONTENTS ................................ 3
1.0 IMPORTANT WARNINGS................................7
2 0 SAFETY GUIDELINES .......................................... 9
3.0 INTRODUCTION. ................................................ 15
4.0 TECHNICAL DATA ........................................................ 17
5.0 BOILER DIMENSIONS .......................................... 27
6.0 UNPACKING AND ACCESSORIES ....................... 29
7.0 INSTALLATION LOCATION ................................... 30
8.0 CONNECTIONS ..................................................... 33
9.0 CIRCULATOR CHARACTERISTICS ...................... 47
10.0 FLUE GAS AND AIR SUPPLY SYSTEM ................ 52
11.0 ELECTRICAL INSTALLATION ............................... 77
12.0 DISPLAY AND PARAMETERS .................................. 89
13.0 TEMPERATURE PROTECTION......................... 117
14.0 ERROR INFORMATION ...................................... 117
15.0 CASCADING SYSTEM SETUP .......................... 123
16.0 SYSTEM TEST ................................................. 129
17.0 COMMISSIONING THE BOILER ........................ 130
18.0
ADJUSTING AND SETTING THE BOILER ......... 133
19.0 INSPECTION, MAINTENANCE AND SERVICE .. 140
20.0 USER INSTRUCTIONS ..................................... 153
21.0 INSTALLATION EXAMPLES .............................. 153
22.0 SPARE PARTS CH-xx .................................................. 157
23.0 SPARE PARTS CO-xx .................................................. 162
WARNING: If the information in
this manual is not followed
exactly, a fire or explosion may
result causing property damage,
personal injury or loss of life.
- Do not store or use gasoline or
other flammable vapors and
liquids in the vicinity of this or
any other appliance.
California Proposition 65 Warning: This product contains chemicals known to
the State of California to cause cancer, birth defects, or other reproductive harm.
Heating Contractor
Address
Phone Number
E93.1907.035.915.B
RESIDENTIAL BOILER MODELS
CH-80 / CH-100 / CH-120 / CH-150 / CH-180
CO-90 / CO-150 / CO-200
- 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.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
If you cannot reach your gas supplier, call the
fire department.
- Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
Boiler Model Number
Boiler Serial Number
Installation Date
This manual must be
left with owner and
must be hung on or
adjacent to the boiler
for reference.

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Summary of Contents for ECR International CH-80

  • Page 1 RESIDENTIAL BOILER MODELS CH-80 / CH-100 / CH-120 / CH-150 / CH-180 CO-90 / CO-150 / CO-200 HIGH EFFICIENCY CONDENSING GAS BOILER NSF/ANSI/CAN 372 INSTALLATION AND SERVICE MANUAL QUICK CONTENTS FULL TABLE OF CONTENTS ........
  • Page 3: Table Of Contents

    (AHRI) ................ 26 PECIFICATIONS INPUT OUTPUT EFFICIENCY BOILER DIMENSIONS ..........................27 CH-80 / CH-100 / CH-120 / CH-150 / CH-180 ................27 CO-90 / CO-150 / CO-200 ......................28 UNPACKING AND ACCESSORIES......................29 ......................29 UPPLIED WITH THE BOILER ........................29...
  • Page 4 Example of a multiple boiler heating circuit with low loss header ........46 CIRCULATOR CHARACTERISTICS ......................47 ....................47 RESSURE DROP AND FLOW GRAPHS Boiler resistance graph CH-80 / CO-90 ................47 Boiler resistance graph CH-100 ..................47 Boiler resistance graph CH-120 / CO-150 ................. 48 Boiler resistance graph CH-150 ..................48 Boiler resistance graph CH-180 / CO-200 .................
  • Page 5 ......................... 82 LECTRICAL SCHEMATICS Electrical schematic CH boilers ..................82 Electrical schematic CO boilers ..................84 ......................... 86 ADDER OGIC DIAGRAM ........................87 ENSOR AVAILABILITY Sensor availability CH boilers .................... 87 Sensor availability CO boilers .................... 87 ........................87 SENSOR CURVE ....................
  • Page 6 – B ......................126 ASCADE OILER ROTATION Next depending to start selection ..................127 ......................127 ASCADE RROR HANDLING Cascade Frost protection ....................127 Emergency mode ......................128 16 SYSTEM TEST............................129 17 COMMISSIONING THE BOILER......................130 ..................130 IRST FLUSHING THE BOILER WITH WATER &...
  • Page 7: Important Warnings

    1 IMPORTANT WARNINGS Definitions IMPORTANT READ ALL OF THE FOLLOWING WARNINGS AND STATEMENTS BEFORE READING THE INSTALLATION INSTRUCTIONS DANGER Danger Sign: indicates the presence of an imminently hazardous situation that will cause death, serious personal injury or substantial property damage. WARNING Warning Sign: indicates the presence of a hazardous situation which can cause death, serious personal injury or substantial property damage.
  • Page 8: General Warnings

    General warnings WARNING This Boiler must be installed by a licensed and trained Heating Technician, a qualified installer, service agency, or the gas supplier or the Warranty is void. Failure to properly install this unit could result in property damage, serious injury to occupants, or possibly death.
  • Page 9: Safety Guidelines

    2 SAFETY GUIDELINES English version Set the thermostat to the lowest setting Turn off all electric power to the appliance. Set the thermostat to the lowest setting Turn off all electric power to the appliance if service is to be performed Installation and Service Manual CH / CO...
  • Page 10: Version Français

    Version français Réglez le thermostat à la température la plus basse Coupez l’alimentation électrique de l’appareil Réglez le thermostat à la température la plus basse Coupez l’alimentation électrique de l’appareil s’il faut procéder à l’entretien Installation and Service Manual CH / CO...
  • Page 11: For Installations In The Commonwealth Of Massachusetts

    For installations in the Commonwealth of Massachusetts The following local requirements apply in addition to all other applicable NFPA requirements: For direct-vent boilers, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the intake is installed below four feet above grade, the following requirements must be met: 1) If not present on each floor level where there are bedrooms, a carbon monoxide detector and alarm must be placed in a living area outside the bedrooms.
  • Page 12 This boiler is equipped with a pressure switch. In the event of a blocked vent the boiler will lockout. No attempt by the user/owner should be made to put the boiler back into operation. A qualified service technician must be notified of the issue. The boiler should only be reset by a qualified service technician after they have diagnosed and corrected the issue that caused the CAUTION safety lockout of the boiler.
  • Page 13: Que Faire Si Vous Sentez Une Odeur De Gaz

    Avertissement (Pour installateurs francophones) AVERTISSEMENT. Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d'incendie ou d'explosion ou pour éviter tout dommage matériel, toute blessure ou la mort. — Ne pas entreposer ni utiliser d'essence ou ni d'autres vapeurs ou liquides inflammables à...
  • Page 14: Entretien Et Inspection

    « C. Ne tournez la manette d'admission du gaz qu'à la main ; ne jamais utiliser d'outil. Si la manette reste coincée, ne pas tenter de la réparer ; appelez un technicien qualifié. Le fait de forcer la manette ou de la réparer peut déclencher une explosion ou un incendie.
  • Page 15: Introduction

    3 INTRODUCTION This manual is the installation and service manual for the high-efficiency heating systems from the CH (Central Heating boilers) series and CO (Combi boilers) series. This manual is specifically written for the installer. The distributor and manufacturer are not accountable for any damage caused by installers not correctly following these instructions.
  • Page 16: Codes, Standards And Regulations

    Cross-linked polyethylene Acidity degree Proportional Integral Derivative, a control concept used in automation Polypropylene, a thermoplastic Particles per million Pounds per square inch, a unit of pressure Pump Circulator Polyvinyl Chloride, a thermoplastic Pulse Width Modulation Refractory Ceramic Fibers Room Thermostat Total Dissolved Solids, a characteristic used in water quality Underwriters Laboratories, American testing and certification institute Volt Alternating Current...
  • Page 17: Technical Data Ch / Co Residential Boilers

    4 TECHNICAL DATA CH / CO RESIDENTIAL BOILERS UNCTIONAL INTRODUCTION The CH / CO boilers are central heating/combi boilers with a maximum high efficiency. Such a performance can be reached by, amongst other things, using a special heat exchanger made of stainless steel. This allows the flue gases to cool down below the condensation point, thus releasing extra heat.
  • Page 18: Location Of Burner Controller Version Numbers

    Location of burner controller version numbers ARDWARE ERSION Burner Controller Hardware Version Parameter Version – To be found on the second line of the white sticker - To be found on the small sticker on the side of located at the side of the burner controller. the burner controller.
  • Page 19: Technical Specifications Datasheets

    Technical specifications datasheets CH-80 / CO-90 / CH-100 ECHNICAL SPECIFICATIONS GENERAL Boiler category IV, direct vent Type boiler CH-80 CO-90 CH-100 Dimensions (h x w x d) inch (mm) 28.2" x 17.4" x 16.9" (717mm x 442mm x 429mm) gallon 0.37...
  • Page 20: Installation

    Type boiler CH-80 CO-90 CH-100 Low Fire % 4.0 – 4.2 Natural gas High Fire % 4.5 – 4.7 flue gas Low Fire % 5.9 – 6.1 Propane High Fire % 5.4 – 5.6 Low Fire % 9.4 – 9.6...
  • Page 21: Technical Specifications Ch-120 / Co-150 / Ch-150

    CH-120 / CO-150 / CH-150 ECHNICAL SPECIFICATIONS GENERAL Boiler category IV, direct vent Type boiler CH-120 CO-150 CH-150 Dimensions (h x w x d) Inch (mm) 28.2" x 17.4" x 16.9" (717mm x 442mm x 429mm) Gallon 0.55 0.55 0.85 Water content (liter) (2.1)
  • Page 22 Type boiler CH-120 CO-150 CH-150 Low Fire % 4.0 – 4.2 Natural gas High Fire % 4.5 – 4.7 flue gas Low Fire % 5.9 – 6.1 Propane High Fire % 5.4 – 5.6 Low Fire % 9.4 – 9.6 Natural gas High Fire % 9.1 –...
  • Page 23: Technical Specifications Ch-180 / Co-200

    CH-180 / CO-200 ECHNICAL SPECIFICATIONS GENERAL Boiler category IV, direct vent Type boiler CH-180 CO-200 Dimensions (h x w x d) Inch (mm) 28.2" x 17.4" x 16.9" (717mm x 442mm x 429mm) Gallon 0.85 0.85 Water content (liter) (3.2) (3.2) Weight (empty) Lbs (kg)
  • Page 24 Type boiler CH-180 CO-200 Low Fire % 4.0 – 4.2 Natural gas High Fire % 4.5 – 4.7 flue gas Low Fire % 5.9 – 6.1 Propane High Fire % 5.4 – 5.6 Low Fire % 9.4 – 9.6 Natural gas High Fire % 9.1 –...
  • Page 25: High Altitude Operation

    Max. Min. allowable allowable relieve water water valve Heat exch. Boiler model number pressure temperature* capacity surface CH-80 T4804.4CL 50 Psi 210 °F 91 MBH 7.99 SQFT CO-90 CH-100 T4804.4CL 50 Psi 210 °F 136 MBH 9.99 SQFT CH-120 T4806.4CL 50 Psi 210 °F...
  • Page 26: Specifications Input, Output, Efficiency (Ahri)

    Specifications input, output, efficiency (AHRI) CH Input, MBH Model Output AHRI AFUE number Net Ratings Water, MBH CH-80 95.2 CO-90 95.2 CH-100 95.2 CH-120 95.2 CO-150 95.2 CH-150 95.2 CH-180 95.2 CO-200 95.2 Listed Input and Output ratings are at minimum vent lengths at Sea Level. Numbers will be lower with longer venting and/or altitudes greater than 2000 feet [610 m].
  • Page 27: Boiler Dimensions

    5 BOILER DIMENSIONS CH-80 / CH-100 / CH-120 / CH-150 / CH-180 442 mm [17.4 in] 285 mm [11.22 in] 165 mm [6.5 in] DN80 mm (2x) [3 in] Vent connection Connections CH boilers Supply NPT ¾ “ (indirect) DHW Outlet NPT ¾...
  • Page 28 CO-90 / CO-150 / CO-200 442 mm [17.4 in] 285 mm [11.22 in] 165 mm [6.5 in] DN80mm (2x) Vent connection [3 in] Connections CO boilers Supply NPT ¾ “ DHW Outlet NPT ½ “ NPT ¾ “ DHW Inlet NPT ½...
  • Page 29: Unpacking And Accessories

    Contact your supplier for ordering. Item Part number Residential Boiler Yearly Maintenance and Service Kit S000.600.001.035 Propane conversion kit CH-80 and CO-90 S022.600.001.035 Propane conversion kit CH-100 S022.600.002.035 Propane conversion kit CH-120 and CO-150 S022.600.003.035...
  • Page 30: Installation Location Of The Boiler

    7 INSTALLATION LOCATION OF THE BOILER General The boiler must be positioned and installed by a qualified installer or the gas company in accordance with all applicable standards, local codes and regulations (see also paragraph 3.2). Commissioning of the boiler must be done by a qualified installer or technician, who has been trained for this type of boiler.
  • Page 31: Installation Clearances

    If the recommended clearances are not provided service or maintenance on the boiler might not be possible without removing the boiler from its space. Model No. Clearances to wall, ceiling and floor Distances – inches CH-80 CH-100 A: Front B: Top C: Sides...
  • Page 32: Mounting The Boiler

    Mounting the boiler Before mounting and installing the boiler the following connections must be considered:  Flue gas system and the flue gas pipe connections  Air supply system and connections  Supply and return pipe connections  Condensate and pressure relief valve drainage ...
  • Page 33: Connections

    8 CONNECTIONS Connections CH boilers Boiler connections CH boilers: A – CH Supply B – Indirect DHW Outlet C – Gas D – Indirect DHW Inlet E – CH Return F – Condensate trap clean out. G – Condensate drain H –...
  • Page 34: Gas Pipe Connection

    Gas pipe connection The gas supply piping must conform to all local codes and regulations and/or National Fuel Gas Code, ANSI Z223.1/NFPA 54 (USA) or CAN/CSA B149.1 Natural gas and propane installation code (Canada). Pipe size running to the appliance depends on the length of pipe, the number of fittings and the maximum input requirement of all gas appliances in the residence.
  • Page 35 Install a manual “Equipment Shut-Off Valve. The valve To equipment inlet must be listed by a nationally recognized testing lab. Should overheating occur or the gas supply fail to shut off, turn the manual gas shutoff valve to off (closed). The gas line piping can then safely be removed from the appliance for servicing.
  • Page 36: Condensate Drain Connection

    Condensate drain connection There must be an open connection of the condensate hose into the sewage system. A possible vacuum in the sewage system must never cause suction on the boiler’s condensate drain hose. The condensate drain is placed on the left at the back on the bottom of the boiler and has a ¾...
  • Page 37: Expansion Vessel

    Model Boiler connection CH Required piping Indirect tank Required diameter diameter piping diameter ¾” 1” 1” CH-80 / CH-100 / CH-120 ¾” 1 ¼” 1 ¼” CH-150 / CH-180 CO-90 ¾” 1” ¾” 1 ¼” CO-150 ¾” 1 ¼” CO-200 Table 8.2...
  • Page 38: Circulator Functionality

    Circulator functionality Delta T monitoring: A high temperature difference between supply and return of the boiler can indicate a clogged heat exchanger or filter, or a defective circulator. The burner load automatically decreases when the Return/Supply temperature differential increases too much. At maximum burner power ΔT is limited to 72°F and at low burner power a ΔT above 86°F is not allowed.
  • Page 39: Scalding Danger Protection

    Scalding danger protection  Water temperatures over 125 °F (52 °C) can cause severe burns instantly, or death from scalds.  Children, the disabled and the elderly are at the highest risk of being scalded.  Feel water before bathing or showering. ...
  • Page 40: Central Heating Water Quality

    Central Heating Water quality The pH value is reached with steady conditions. Maximum Contaminant Units These steady conditions will occur, when after filling allowable level the heating system (pH around 7) with fresh water, 7.5 to 9.5 the water loses its air because of the air bleeding 50 to 150 mg/l CaCo3 operation and heating up (dead water conditions).
  • Page 41: Use Of Glycol

    Use of glycol To protect the system from freezing the use of glycol-based products can be considered. All materials used in the boiler are resistant to glycol. Glycol in itself will acidify over time because of thermal degradation. This acidity will cause serious damage to most components in the heating system including the boiler.
  • Page 42: Plastic Piping In The Heating System

    Never mix treatment chemical from different brands or anti-freezes from different brands as there is no way to ensure they are compatible. The system cleaner must never be run through the boiler Corrosion-/ Scale inhibitors and recommended suppliers Producers -> Fernox Sentinel Sotin...
  • Page 43: Automatic Air Purging

    Automatic air purging The De-Air sequence is a safety function starting at every power ON and is used to remove the air from the heat- exchanger. This function must be used after the system has been filled with water during the commissioning procedure, see paragraph 17.2.
  • Page 44: Manual De-Airing The Heat Exchanger

    Manual de-airing the heat exchanger The heat exchanger of the boiler can be manually de-aired by means of the air-vent of the boiler. This air vent is situated at the top left of the boiler. To manually de-air the heat exchanger: ...
  • Page 45: Installation Examples

    Installation examples XAMPLES OF A NORMAL SINGLE BOILER HEATING CIRCUIT WITH LOW LOSS HEADER PREFERABLE Boiler circulator System circulator BOILER Flow/system BOILER temperature sensor HEATING ZONE HEATING ZONE Boiler circulator Check the following parameters: Central heating circulator Boiler parameter Name Change to Prog.
  • Page 46: Example Of A Multiple Boiler Heating Circuit With Low Loss Header

    XAMPLE OF A MULTIPLE BOILER HEATING CIRCUIT WITH LOW LOSS HEADER NON-RETURN VALVE (low BOILER BOILER resistance type) NOT SPRING LOADED HEATING ZONE Boiler circulator System circulator Flow/ system temperature sensor valve strainer (water filter) circulator air separator pressure relief valve automatic air vent dirt separator condensate trap...
  • Page 47: Circulator Characteristics

    9 CIRCULATOR CHARACTERISTICS Pressure drop and flow graphs CH-80 / CO-90 OILER RESISTANCE GRAPH flowrate [gallons/minute] heat exchanger circulator Figure 9.1 CH-100 OILER RESISTANCE GRAPH flowrate [gallons/minute] heat exchanger circulator Figure 9.2 Installation and Service Manual CH / CO...
  • Page 48: Boiler Resistance Graph Ch-120 / Co-150

    CH-120 / CO-150 OILER RESISTANCE GRAPH flowrate [gallons/minute] heat exchanger circulator Figure 9.3 CH-150 OILER RESISTANCE GRAPH flowrate [gallons/minute] heat exchanger circulator Figure 9.4 Installation and Service Manual CH / CO...
  • Page 49: Boiler Resistance Graph Ch-180 / Co-200

    CH-180 / CO-200 OILER RESISTANCE GRAPH flowrate [gallons/minute] heat exchanger circulator Figure 9.5 RAPH SHOWING THE VAILABLE IRCULATION PUMP HEAD Figure 9.6 Installation and Service Manual CH / CO...
  • Page 50: Minimum Required Circulator Head

    If a smaller delta T is desired than the built-in boiler circulator can provide an external circulator can be added in the field external to the boiler in line with the boiler circulator on the return. ΔT = 20 °F Minimum required flow gal/min CH-80 / CO-90 7.60 1.73 CH-100 9.50 2.16...
  • Page 51: Circulators: Maximum Electrical Power

    Circulators: maximum electrical power General  The inrush current of a conventional circulator is approximately 2½ x its nominal current.  The maximum switch current of the PCB is 4 A.  The total current of PCB and gas valve is approx. 0.5 A. All circulators and valves for the boiler loop, DHW, and the system that are connected to the boiler should not exceed 3.5 A.
  • Page 52: Flue Gas And Air Supply System

    ENT SIZING Boiler type Intake Air and Vent Connection CH-80 / CO-90 / CH-100 / CH-120 CO-150 / CH-150 / CH-180 / CO-200 3" Table 10.1 Only 2" and 3" venting listed in this manual is permitted for use with the boiler.
  • Page 53: Vent And Air Inlet Resistance Table (Twin Pipe)

    Reducer 3" - 2" (based on small diameter) Table 10.3 Terminals equivalent feet: for DuraVent PolyPro BOILER TERMINAL size Eq. feet vent Eq. feet air CH-80 / CO-90 CH-100 / concentric roof: 2" vent 18 ft 18 ft CH-120 CO-150 / CH-150 concentric wall: 2" vent...
  • Page 54: Vent And Air Intake Pipe Material

    Vent and air intake pipe material Items Materials Venting System Standards Warning United States Canada Flue piping and CPVC Schedule 40 ANSI/ASTM F441 All venting All Vent materials and Fittings material in Air-Inlet materials being PVC Schedule 40 ANSI/ASTM D1785 Canada must be installed on gas fired Stainless Steel SS...
  • Page 55: Pvc / Cpvc

    Approved PVC/ CPVC vent pipe and fittings: IPEX – System 636 Boiler Fitting Concentric Termination CPVC Low profile Termination CH-80 / CO-90 CH-100 / CH- FGV 45° Elbow CPVC 120 CO-150 / CH-150 CH-180 FGV 90° Elbow CPVC / CO-200 Termination Vent Screen FGV Tee CPVC Concentric termination is for use in vertical installations only.
  • Page 56: Instructions For Working With Cementing Pvc/ Cpvc Pipe Connections

    Terminations (example): Boiler Termination Twin Pipe Side Wall Single Pipe Side Wall Bird Screen CH-80 / CO-90 / CH-100 concentric roof / CH-120 / CO-150 / CH- Twin pipe roof 150 / CH-180 / CO-200 Single pipe roof concentric wall Termination tee Table 10.6...
  • Page 57: Reducer

    • Rigid polypropylene vent pipe must be installed with approved locking band clamps or connector rings and supports (wall strap or clamp, elbow or base, etc.). Consult vent manufacturer for complete list of required parts. • Maintain 1/4 in. [6 mm] per foot slope back toward appliance on all horizontal runs. •...
  • Page 58: Stainless Steel Vent

    Saf-T EZ Seal / EZ 316 Boiler Termination Termination Termination bird screen wall screen termination elbow termination CH-80 / CO-90 / CH-100 / termination tee termination tee tee termination with CH-120 / CO-150 / CH-150 rain cap roof rain cap roof screen...
  • Page 59: Sealed Combustion Air Supply

    Sealed Combustion Air supply When an air supply pipe is connected from the outside of the building to the boiler, the boiler will operate as a sealed combustion boiler. OMBUSTION AIR QUALITY Combustion air must be free of contaminants. Do not install the intake for the combustion air venting in an area which contains corrosive or other contaminants as outlined in section 10.8.1, especially Table 10.7 and Table 10.8.
  • Page 60: Room Air

    Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a wall or vertical rooftop Combustion Air Supply System: a) Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high-quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.
  • Page 61 1. If the boiler is installed in a room with a volume of more than 50 per 1,000 Btu/hr of the aggregate input rating of all combustion appliances in the room, the infiltration rate of the room will provide adequate combustion air. No additional measures have to be taken.
  • Page 62 If combustion air is provided from the outside by means of vertical ducts like above, the free size of each opening must be minimal 1 inch per 4,000 Btu/hr. of the aggregate input rating of all combustion appliances in the room. If the outside air is provided by means of horizontal ducts, the free size of each opening must be minimal 1 inch 2,000 Btu/hr.
  • Page 63: Air Contamination

    IR CONTAMINATION Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.
  • Page 64: Proper Vent Installation And Type Of Gas Vent Or Vent Connector

    Proper vent installation and type of gas vent or vent connector For boilers for connection to gas vents or chimneys, vent installations must be in accordance with “Venting of Equipment,” of the National Fuel Gas Code, ANSI Z223.1 / NFPA 54, or “Venting Systems and Air Supply for Appliances,”...
  • Page 65: Requirements For Installation In Canada

    Requirements for installation in Canada Installations must be made with a vent pipe system certified to ULC-S636. The first three (3) feet of plastic vent pipe from the appliance flue outlet must be readily accessible for visual inspection. The components of the certified vent system must not be interchanged with other vent systems or unlisted pipe/ fittings.
  • Page 66 Concentric wall - two pipe to boiler Concentric wall - concentric to boiler See paragraph 10.13 for more details. See paragraph 10.13 for more details. Note: Minimum short pipe lengths required. Air intake – 7” Exhaust outlet 12.5” Figure 10.12 Figure 10.11 Single pipe wall (room air) Single pipe roof (room air)
  • Page 67 Concentric vertical - two pipe to boiler Concentric vertical - concentric to boiler See paragraph 10.14 for more details. See paragraph 10.14 for more details. Note: Minimum short pipe lengths required. Air intake – 7” Exhaust outlet 12.5” Figure 10.15 Figure 10.16 Open, Air supply from room, See paragraph 10.14 for more details.
  • Page 68: Wall (Horizontal) Direct Venting

    Wall (Horizontal) direct venting AIR TERMINATION WALL  Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.  A gas vent extending through an exterior wall must not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks.
  • Page 69 5. Maintain clearances as stated in this manual. Also maintain the following: Figure 10.17 Clearance above grade, veranda, porch, deck, or 12" (30 cm) 12" (30 cm) balcony see note 3 see note 3 Clearance to window or door that may be opened Direct vent only: 12"...
  • Page 70 6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment. Alternate two pipe sidewall termination of air intake Two pipe sidewall termination of air intake and and exhaust vent exhaust vent.
  • Page 71 Multiple vent/air terminations 1. When terminating multiple boilers, terminate each vent/air connection as described in this manual. All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage. WARNING 2.
  • Page 72 Do not operate the appliance with the rain cap removed from the concentric terminations or else recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could WARNING result in product damage or improper operation, personal injury, or death.
  • Page 73: Roof (Vertical) Direct Venting

    Roof (vertical) direct venting – AIR TERMINATION VERTICAL Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. WARNING ETERMINE LOCATION Locate the vent/air terminations using the following guidelines: The total length of piping for vent or air must not exceed the limits given in the section 10.1 of this manual. Prepare the vent termination and the air intake termination elbow (see Figure 10.26) by inserting bird screens.
  • Page 74 Multiple vent/air terminations 1. When terminating multiple boilers, terminate each vent/air connection as described in this manual (Figure 10.27). Terminate all exhaust vent pipes at the same height and all air intake pipes at the same height to avoid recirculation of flue products and the possibility of severe personal injury, death, or WARNING substantial property damage.
  • Page 75 Concentric Vertical Termination. Minimum clearance above snow level (18” for Canada) Maximum 24” above roof or snow level Figure 10.29 Do not install U-Bend or elbow on concentric termination Figure 10.30 Do not operate the appliance with the rain cap removed from the concentric terminations or else recirculation of combustion products may occur.
  • Page 76: Common Venting

    Concentric vent and combustion air vertical termination multiple boilers. Figure 10.31 OMMON VENTING The boilers from the CH / CO series have no internal flue gas check valve and need to be calculated for an external flue gas check valve system or a separated flue system. If separated flue systems cannot be applied, ask a flue gas supplier to calculate a common vent system utilizing external flue gas check valves.
  • Page 77: Electrical Installation

    11 ELECTRICAL INSTALLATION General  For operation, the boiler needs a power supply of 120 VAC / 60Hz.  The boiler main supply connection is polarity sensitive: L-120 VAC, N-Neutral, PE-Earth ground (Figure 11.2). The wiring for the connections can be entered at the bottom of the boiler through the wiring knockouts. ...
  • Page 78: Explanation Of The Low Voltage Connections Ch Boilers, Figure 11.1

    11.1 XPLANATION OF THE LOW VOLTAGE CONNECTIONS BOILERS IGURE Low Voltage Terminals 1-2 OUTDOOR SENSOR If an outdoor temperature sensor is connected, the boiler will control the supply water temperature by using a calculated setting based on outdoor reset curve, which is related to the outdoor temperature. (CH modes 1 and 2).
  • Page 79: Mains Supply

    11.2 XPLANATION OF THE LINE VOLTAGE CONNECTIONS BOILERS IGURE Line Voltage Terminals 1-2-3-PE 3 WAY VALVE (TWV) This connection is internally connected to the 3-way valve in the appliance Line Voltage Terminals 4-5-PE SYSTEM PUMP / DHW CIRCULATOR / CH CIRCULATOR Connections for the power supply of a central heating system circulator P3, see paragraph 9.5.for detailed electrical specifications.
  • Page 80: Explanation Of The Low Voltage Connections Co Boilers, Figure 11.1

    11.1 XPLANATION OF THE LOW VOLTAGE CONNECTIONS BOILERS IGURE Low Voltage Terminals 1-2 OUTDOOR SENSOR If an outdoor temperature sensor is connected, the boiler will control the supply water temperature by using a calculated setting based on outdoor reset curve, which is related to the outdoor temperature. Low Voltage Terminals 3-4 SYSTEM SENSOR If a low loss header is used, this sensor measures the flow temperature at the system side.
  • Page 81: Explanation Of The Line Voltage Connections Co Boilers, Figure 11.2

    11.2 XPLANATION OF THE LINE VOLTAGE CONNECTIONS BOILERS IGURE Line Voltage Terminals 1-2-3-PE 3 WAY VALVE (TWV) This connection is internally connected to the 3-way valve in the appliance Line Voltage Terminals 4-5-PE SYSTEM PUMP / DHW CIRCULATOR / CH CIRCULATOR Connections for the power supply of a central heating system circulator P3, see paragraph 9.5.
  • Page 82: Electrical Schematics

    Electrical schematics LECTRICAL SCHEMATIC BOILERS Figure 11.4 Installation and Service Manual CH / CO...
  • Page 83 Figure 11.5 Installation and Service Manual CH / CO...
  • Page 84: Electrical Schematic Co Boilers

    LECTRICAL SCHEMATIC BOILERS Figure 11.6 Installation and Service Manual CH / CO...
  • Page 85 Figure 117 Installation and Service Manual CH / CO...
  • Page 86: Ladder / Logic Diagram

    Ladder / Logic diagram MAINS VOLTAGE VOLTAGE Figure 11.8 Installation and Service Manual CH / CO...
  • Page 87: Sensor Availability

    Sensor availability ENSOR AVAILABILITY BOILERS The following table shows the sensor availability for all CH and DHW control modes. Sensors not mentioned in the table are optionally available for other functions CH Mode T_Supply T_Return T_DHW T_Outdoor 0-10 Volt Water Flow DHW RT Switch M = Mandatory, O = Optional, --- = Disabled.
  • Page 88: Programmable In- And Outputs

    Programmable in- and outputs It is possible to re-program some in- and outputs to other functions. To do this use the list below and go to: Menu\settings\boiler settings\"1122" (installer password)\boiler parameters. Default Default Boiler parameter Name Description Terminal setting CH setting CO Prog.
  • Page 89: Display And Parameters

    12 DISPLAY AND PARAMETERS Display and buttons Each type of the CH / CO Boiler series is provided with a digital display.  PB-display – a pixel-based graphical user interface The PB-display will look like this: 100.0 °F 140.0 °F Figure 12.1 ON/OFF.
  • Page 90: Display Icons

    ISPLAY ICONS The following table gives a short description of the icons that can be visible on the main screen during operation: Icon Description Boiler Status CH control state RT_Input Central Heating demand (Central Heating controller ( Room thermostat open of state) closed) Domestic Hot Water demand...
  • Page 91: Control Panel Menu Structure

    Control panel menu structure  Press menu button    Press ENTER or RIGHT to select and Select ‘Central Heating (CH) and Select ‘CH setpoint’ and press press ENTER or RIGHT ENTER or RIGHT UP/ DOWN to change the value, and ENTER or RIGHT to confirm.
  • Page 92: Set Actual Setpoint/Dhw Setpoint Directly Via The Status Overview

    /DHW CTUAL SETPOINT SETPOINT DIRECTLY VIA THE TATUS OVERVIEW When CH is active, you can adjust the Actual setpoint directly on the bottom of the Status overview. When DHW is active, you can adjust the DHW setpoint directly on the bottom of the Status overview. This means that when CH is active, you cannot set the DHW setpoint directly via the Status overview.
  • Page 93: Protected Menu Items

    ROTECTED MENU ITEMS Some menu items are protected and only accessible via a password*. The following password screen will appear: Figure 12.12 * Installers have to use the password 1122 to change parameters protected by a password. Changing protected/safety parameters should only be conducted by experienced, licensed installers and service technicians or a service agency or the gas supplier.
  • Page 94: Boiler History

    Boiler history The boiler history found in the information menu displays several history counters that keep track of the boiler usage. The history cannot be erased and will continue for the entire burner controller life cycle. The following boiler history data are available: (Sub) Menu item Description Successful Ignitions...
  • Page 95: Service Reminder

    The second line will show the Error Description. The bottom line will show the Time Stamp (date and time) when the error was detected (in the format as configured in the Date Time Settings menu), and also the selected error index from the total number of errors in the (filtered) error log.
  • Page 96: General

    General The boiler controller is designed to function as a standalone control unit for intermittent operation on heating appliances with a premix (modulating) burner and a pneumatic air-gas system. Mains input 1 x 5AT, 120V 2 seconds Flame establishing period Safety time 5 seconds Ignition attempts...
  • Page 97: Ignition Cycle

    Ignition cycle During the ignition cycle multiple safety checks are active Figure 12.18 The table below shows the states of the burner ignition cycle, as shown in the diagram above Burner state Actions INIT  Controller initialization RESET  Software reset (and initialization) STANDBY Standby (waiting for demand) ...
  • Page 98: Flame Detection

    During the ignition cycle multiple safety checks are active, none of the initiation timing settings are adjustable: False flame detection If a flame is detected at the end of the pre-spark period (Pre_Ignit) a lockout error will occur. Re-ignition If at the end of the safety period no flame is detected the control will go to Post_Purge to remove any unburnt gas.
  • Page 99: Control Functions Central Heating

    Control functions Central Heating Depending on the required functions of the appliance and connected sensors and components, several operation modes for Central Heating (CH) can be selected. The following CH modes are available for both Heating Only (CH) and Combi (CO) boilers: ...
  • Page 100: Shutdown Temperature

    ; CH WITH AN OUTDOOR TEMPERATURE RESET AND THERMOSTAT MODE This mode is available to both Heating Only (CH) and Combi (CO) boilers. If the parameter CH Mode (parameter 1) is set to 1, the “Outdoor temperature reset with room thermostat” mode is selected.
  • Page 101 Setpoint adjustment It is possible to adjust the calculated setpoint with parameter CH_Setpoint_Diff. The calculated setpoint can be increased or decreased with a maximum of 50 °F (10 °C). The CH setpoint limits (Reset_Curve_Boiler_Minimum and Reset_Curve_Boiler_Maximum) are respected while adjusting the setpoint. Apart from the calculated setpoint the functionality is the same as described in paragraph 12.9.1.
  • Page 102: With Constant Circulation System Outdoor Reset; Ch Mode 2

    ; CH WITH CONSTANT CIRCULATION SYSTEM OUTDOOR RESET MODE This mode is available to both Heating Only (CH) and Combi (CO) boilers. When CH_Mode is set to 2, full weather compensator is chosen. For this mode an outdoor sensor has to be connected.
  • Page 103: Central Heating With Analog Input Control Of Setpoint; Ch Mode 4

    ; CH ENTRAL EATING WITH ANALOG INPUT CONTROL OF SETPOINT MODE This mode is available to both Heating Only (CH) and Combi (CO) boilers. In CH mode 4 of operation, the boiler CH setpoint is controlled by an analog input signal provided by a remote means such as a Building Management System or a system controller.
  • Page 104: With Analog Input Control Of Power Output; Ch Mode 5

    ; CH WITH ANALOG INPUT CONTROL OF POWER OUTPUT MODE This mode is available to both Heating Only (CH) and Combi (CO) boilers. In CH mode 5 of operation, the boiler power (boiler input) is controlled by an analog input signal provided by a remote means such as a Building Management System or a system controller.
  • Page 105: Control Functions Domestic Hot Water

    DHW circulator is necessary. With the 180-CH there is always an additional DHW circulator necessary because the internal circulator has not enough capacity to maintain a delta T of 35⁰F. Boiler type maximum pressure drop coil @ delta T of 35⁰F unit CH-80 ft.head (w.c.) CH-100 ft.head (w.c.) CH-120 ft.head (w.c.)
  • Page 106: Dhw Storage With Thermostat; Dhw Mode 2

    DHW Priority Standard DHW demand has priority over CH demand but the priority period is limited up to DHW_Max_Priority_Time (parameter 43). The priority timer starts when both CH and DHW demand are present. After the DHW_Max_Priority_Time is achieved, the control will switch from DHW to CH operation. CH has priority now for a maximum period of DHW_Max_Priority_Time.
  • Page 107: Instantaneous Water Heating With Plate Heat Exchanger; Dhw Mode 5

    Relevant variables Specific Parameters Display Level (Default) Range parameter Value DHW Mode Installer 0, 1, 2,3, 4, 5, 6, 7, 8 DHW Store Setpoint User 122 ºF 104…185 ºF (40…85 ºC ) (50 ºC ) Sets the supply temperature from the boiler to prepare DHW in the indirect tank DHW Priority Installer...
  • Page 108: Anti-Legionella Protection

    LEGIONELLA PROTECTION This option is only available for Heating Only boilers (CH models). Anti-Legionella can be enabled for CH-boilers in DHW mode with an external tank with a sensor (DHW Mode 1). To prevent legionella a special function is implemented in the software. When DHW Mode 1 is selected the Anti-Legionella protection will be checked on the T_DHW_Out sensor.
  • Page 109: Menu Structure Display

    Menu structure display Menu structure Display: Access Description: level 1. Central Heating (CH) User Enter the Central Heating (CH) menu 2. Domestic Hot Water (DHW) User Enter the Domestic Hot Water (DHW) menu 3. Information User Enter the Information menu 4.
  • Page 110 3.2 Boiler status min. max. Default unit Access Description: level Flow Temperature °F (°C) User Actual supply flow temperature Flow 2 Temperature (Not used) °F (°C) User Actual supply 2 flow temperature Return Temperature °F (°C) User Actual return temperature DHW Temperature °F (°C) User...
  • Page 111 4 Settings min. max. Default unit Access Description: level 4.1 General Settings User Enter the General Settings menu 4.2 Boiler Settings User Enter the Boiler Settings menu 4.1 General settings min. max. Default unit Access Description: level 4.1.1 Language User Enter the Language menu 4.1.2 Unit Type User...
  • Page 112 4.1.4 Cascade mode min. max. Default unit Access Description: level Full Full Full Installer Select full cascade mode for more data for max 8 boilers Basic Installer Select basic cascade mode for 9 to 16 boilers 4.1.5 Other settings min. max.
  • Page 113 4.2.1 Boiler parameters min. max. Default unit Access Description: Dis- play level CH Hysteresis Down °F Installer Set the CH hysteresis down (20) (°C) Anti-Cycle Period sec. Installer Set the burner anti-cycling period Anti-Cycle Temp. Diff. 28.8 °F Installer Set the burner anti-cycling (20) (16) (°C)
  • Page 114 4.2.1 Boiler parameters min. max. Default unit Access Description: Dis- play level DHW Instant PID P 1275 Dep. Unit Installer Set the DHW instantaneous PID P factor DHW Instant PID I 1275 Dep. Unit Installer Set the DHW instantaneous PID I factor DHW On Off Period sec.
  • Page 115 4.2.2 Module Cascade min. max. Default unit Access Description: Dis- play Settings level Burner Address 0: Stand Installer Set the cascade burner address alone Permit Emergency Mode Installer Enable/disable the cascade emergency mode Emergency Setpoint °F Installer Set the emergency mode setpoint (20) (90) (70)
  • Page 116 Parameters for cascade operation are found in the Module cascade settings menu, located in the Boiler settings menu. Parameters in the below Boiler cascade settings menu must not be used. NOTICE 4.2.3 Boiler Cascade min. max. Default unit Access Description: Dis- play Settings...
  • Page 117: Temperature Protection

    13 TEMPERATURE PROTECTION The difference between Supply temperature and Return Temperature is continuously monitored. To large of a difference can indicate a defective pump or a clogged heat exchanger. To protect the boiler, the burner controller reduces the input when the temperature difference ΔT (Delta T) becomes too high: At maximum boiler input ΔT is limited to 63°F (35°C) - (Hx_Diff_DeltaT_Min ) In between 63°F (35°C) and 77°F (43°C) boiler input modulates between minimum and maximum.
  • Page 118: Lockout Codes

    Lockout codes Lock Error Description Cause Solving code EEPROM Read Internal software error wrongly programmed reset BCU or replace BCU Error BCU or PB and or display unit Ignition Error Five unsuccessful ignition no gas, wrongly check gas supply and ad- attempts in a row adjusted gas valve just gas valve, reset BCU...
  • Page 119 Lock Error Description Cause Solving code Flame Out Too Flame still present 10 sec. wrong earthing of check earthing of BCU and Late Error after closing the gas valve BCU and boiler boiler Flame Before Flame is detected before wrong earthing of check earthing of BCU and Ignition ignition...
  • Page 120: Blocking Codes

    Blocking codes Block- Error Description Cause Solving code WD Error Ram Internal software error wrongly programmed reset BCU or replace BCU BCU or PB and or display unit WD Error Rom Internal software error wrongly programmed reset BCU or replace BCU BCU or PB and or display unit High Temp Error...
  • Page 121 Block- Error Description Cause Solving code T Return Shorted Return sensor shorted malfunctioning return check connection to BCU sensor or short or check resistance NTC circuiting sensor T Supply Shorted Supply sensor shorted malfunctioning supply check connection to BCU sensor or short or check resistance NTC circuiting sensor...
  • Page 122: Warnings

    Warnings Warning Warning Description Cause Solving Comm. Lost with module Cascade System: connection check wiring Managing cascade between cascaded between boiler or control lost boilers is distance between communication with one interrupted or boilers is to big or of the depending. wiring is broken set par.
  • Page 123: Cascading

    15 CASCADING System setup For proper functioning of the system, certain settings have to be changed. See paragraph 15.2 NOTICE The boiler controller can control multiple boilers in a cascade setup. A system sensor input is available on the main board to measure the cascade system supply temperature. A circulator output is also available to run the system circulator, as well as an output for the DHW circulator.
  • Page 124: Setting The Boiler Address

    Changes in parameters must only be carried out by a skilled commissioning/service installer, who has had specific training for setting up the CH / CO boilers. The installer will be able to check whether the installation WARNING functions correctly after changing the parameters. Parameters for cascade operation are found in the Module cascade settings menu, located in the Boiler settings menu.
  • Page 125: Cascade - Heating Only (Ch) Managing Boiler

    – H (CH) M ASCADE EATING ONLY ANAGING BOILER When a boiler is set as Managing (Address = 1), the controller of this boiler will drive the cascade. The CH mode of this managing boiler applies to all other boilers. It is only required to set the CH mode on the managing boiler. •...
  • Page 126: Cascade - Dhw Priority

    – DHW ASCADE PRIORITY The boiler cascade system has multiple options for priority and parallel DHW and heating. The following levels of priority are configurable (and possible): Priority level Description When both CH and DHW demand have to be served, the priority is given to the DHW demand for a given interval (indicated with parameter Minute_Switch_Priority).
  • Page 127: Next Depending To Start Selection

    With parameter First_Module_To_Start the current depending that is first to start in the sequence is selected. When the boilers are rotated the parameter First_Module_To_Start is automatically updated to the next boiler. When boiler rotation is disabled the parameter First_Module_To_Start is reset to 0. When the First_Module_To_Start is manually changed the control will clear all demand of the cascade control.
  • Page 128: Emergency Mode

    MERGENCY MODE Managing boiler error When the managing boiler is in error mode, the depending boilers can go into the "Emergency Mode", if enabled. In emergency mode the system setpoint is set to the temperature of the Emergency Setpoint and all cascaded boilers start burning on this setpoint.
  • Page 129: System Test

    16 SYSTEM TEST For testing the system at fixed power rates, a system test can be activated via the Installer menu. In the main menu of the display, select the option System Test. This option is password protected. Via the system test the boiler can be started without CH or DHW being present. The system test has priority. The following modes are available: System test mode Description...
  • Page 130: Commissioning The Boiler

    17 COMMISSIONING THE BOILER First: flushing the boiler with water After installation of the boiler and before commissioning, the first step is to flush the boiler and the whole heating installation with fresh water to remove pollution, debris and other material that might cause a blockage. This must also be done with heating installations, where only the boiler has been replaced.
  • Page 131: Mounting The Condensate Trap

    Mounting the Condensate Trap When mounting the bottom part of the condensate trap, before commissioning the boiler and/or after maintenance, it must ALWAYS be completely filled with water. When mounting the bottom part of the condensate trap, before commissioning the boiler and/or after maintenance, the condensate trap must ALWAYS be completely filled with water.
  • Page 132: Firing For The First Time

    Firing for the first time After the commissioning of the boiler and completing the previously described required actions, the display screen will show the following: Initializing Figure 17.2 This screen is active during power up and will remain active until communication with the main Control has been established.
  • Page 133: Adjusting And Setting The Boiler

    18 ADJUSTING AND SETTING THE BOILER Before carrying out any adjustments of the burner, carefully read this chapter entirely. The initial lighting of the appliance must be performed by a licensed Gas Technician. Failure to follow these instructions may result in property damage, serious injury or death. As soon as the appliance has been fully installed (with regard to hydraulics, filling and de- aeration of installation, gas, flue gas, air intake, wiring etc.) according to the preliminary WARNING...
  • Page 134: Setting Gas Valve Screws

    (to the left) counting the number of turns according the table below Number of turns anti clockwise Type of boiler CH-80 / CO-90 CH-120 / CH-100 CO-150 / CH-150 / CH-180 / CO-200 Table 18.2 If the boiler does not start, rotate the high fire screw an extra half turn clockwise Now proceed with the “O...
  • Page 135: O 2 / Co 2 Adjustment Procedures

    / CO Adjustment procedures The adjustment of the low fire screw is much more sensitive than the high fire screw. Only make small adjustments 1/8th of a turn at a time and then wait for the boiler to stabilize and give the combustion analyzer enough time to draw in a stable sample.
  • Page 136: Conversion From Natural Gas To Propane

    Conversion from natural gas to propane Adjustment of the boiler to a different gas type must be performed by a certified technician, qualified installer or gas company WARNING Use only parts/conversion kits obtained from the supplier and intended to be used with this particular boiler. Every conversion kit is provided with instructions how to assemble the kit to the boiler.
  • Page 137 Fan speed high fire Fan speed low fire Fan speed ignition Boiler model Parameter 92 Parameter 93 Parameter 94 Propane Natural gas Propane Natural gas Propane Natural gas CH-80 6850 7450 1400 1350 2000 6000 CH-100 6500 6750 1400 1300 2000...
  • Page 138: Start Up Checklist

    Start Up Checklist Installation/start-up checklist Site information Installer information Site name Company Site contact Engineer name (owner/ end-user) Address Address Postal code Postal code City City State/province State/province Tel. number Tel. number Boiler information Model Serial number Installation date New boiler or replacement Cascade installation (YES / NO) Number of boilers...
  • Page 139: Electronics & Power Supply

    Water circulation & temperature regulation (for DHW) Piping diameter Total length of straight pipe between boiler & tank Number of elbows Number of tees Temperature rise between inlet and outlet after 5 min. cold-start operating max. power °C / °F Water temperature setpoint Test of Water Flow Switch (DHW)? (YES / NO)
  • Page 140: Inspection, Maintenance And Service

    19 INSPECTION, MAINTENANCE AND SERVICE General For a good, safe and long-lasting operation of the boiler and to maintain warranty it is mandatory to carry out inspection, maintenance and service on the boiler at least once a year. Maintenance and inspection of the boiler must be carried out in the following situations: ...
  • Page 141 Potential Carcinogen - Use of Refractory Ceramic Fibers in high temperature applications (above 1805 °F) can result in the formation of Crystalline Silica (cristobalite), a respirable silica dust. Repeated airborne exposure to crystalline silica dust may result in chronic lung infections, acute respiratory illness, or death. Crystalline silica is listed as a (potential) occupational carcinogen by the following regulatory organizations: International Agency for Research on Cancer (IARC),...
  • Page 142: Inspection, Maintenance And Service Tasks

    Inspection, maintenance and service tasks Inspection, maintenance and service including the replacement of boiler parts must only be carried out by a licensed professional, service agency or the gas supplier. Apart from the maintenance proceedings it is required to maintain a service log for each boiler that includes all of the following information: ...
  • Page 143 After this, take out the complete burner unit by moving it forward out of the boiler housing. Watch out not to damage the burner plate insulation during this operation. CAUTION While removing the complete burner unplug both of the electrical and controlling cables of the fan. Next dismantle the venturi on the suction side of the fan and check the blade wheel of the fan.
  • Page 144  Cleaning the interior of the heat exchanger. Use nylon brush only. Do NOT use metallic brush. Vacuum the remaining residues Clean with a nylon brush Vacuum the combustion residues Wait about 3 to 5 minutes This step is necessary only in case of Rinse with water serious buildup of combustion Spray white vinegar or a...
  • Page 145  Condensate trap Disassemble the condensate trap and clean every part of it. Check the condensate trap connection of the heat exchanger for any blockage or pollution and clean it (if necessary). Check the functioning of the condensate trap by pouring clean tap water in the boiler combustion chamber (when the burner door is removed). This water will exit the heat exchanger by the condensate trap.
  • Page 146: Replacing Heat Exchanger Parts

    Replacing Heat exchanger parts. Warning Crystalline Silica – Read instructions in § 19.2 carefully EPLACEMENT OF THE BURNER DOOR GASKET If any part of a gasket has a discolored, changed texture, has been hardened, the rubber has cured and/or has damages, these gaskets must be replaced.
  • Page 147: Replacement Of The Burner Door Insulation

     Engage the high temp braided rope and place it in contact with the glue and press the braids. Figure 19.9 EPLACEMENT OF THE BURNER DOOR INSULATION The insulation burner door is fitted to the burner diameter and is fixed by 2 glue silicone dots. If the insulation is damaged and needs to be changed, it has to be replaced by a new insulation using the method described below.
  • Page 148 2 dots of silicone glue «Loctite 5366 or Ottoseal S17» Figure 19.13 Figure 19.14 3. Check the condition of the electrodes, if necessary replace them. Reassemble the electrodes equipping them with new gaskets and respecting the location of each electrode as well the tightening torque of the 4 screws of 2.5 Nm (22.1-inch Lbs).
  • Page 149: Replacement Of The Rear Wall Insulation Disk

    EPLACEMENT OF THE EAR WALL INSULATION DISK If the insulation disk is degraded or damaged, it must be replaced.  Ensure that the heat exchanger has cooled down; wait a few hours after burning. In this way the protective film of the new insulation disc will not stick to the back wall of the combustion chamber. ...
  • Page 150: Remounting The Burner Door

    Remounting the burner door Before mounting the burner door, make sure that its gaskets and insulation are in excellent shape. If any signs of damage or ageing are present, these parts must be replaced. The burner door must be mounted back on the heat exchanger as follows: •...
  • Page 151: Cleaning The Brazed Plate Heat Exchanger

    Cleaning the Brazed Plate Heat exchanger Cleaning the Brazed Plate Heat exchanger (Every 2-year maintenance or as needed based on water quality) The brazed plate heat exchanger should be cleaned at the service interval every 2 years. Failure to flush the brazed plate heat exchanger can cause damage to it.
  • Page 152: Maintenance Checklist

    Maintenance Checklist Allowing the boiler to operate with a dirty combustion chamber will be detrimental to its operation. Failure to clean the heat exchanger as required by the manual and dictated by the operating location could result in boiler failure, property damage, personal injury, or death. WARNING Such product failures ARE NOT covered under warranty Periodic maintenance must be performed once a year by a qualified service technician to guarantee that the...
  • Page 153: User Instructions

    20 USER INSTRUCTIONS After installing and commissioning of the boiler, the installer is obliged to do the following:  Demonstrate the operation of the entire heating system to the end-user;  Make the user familiar with all safety precautions of the boiler and the installation ...
  • Page 154 System Example 3 CH mode 1 Low Voltage Connections Wire Name terminal Room thermostat 12-13 Outdoor temperature sensor High Voltage Connections Boiler circulator 6-7-PE System heating circulator 4-5-PE Low Loss Header Check the following parameter: Change Boiler parameter Name Prog. Output 1. Figure 21.3 System Example 4 CH mode 1...
  • Page 155 System example 5 DHW mode 5 High Voltage Connections Boiler circulator 6-7-PE Plate heat exchanger (combi boiler only). Figure 21.5 System example 6 Figure 21.6 CH mode 1 DHW mode 5 Low Voltage Connections Wire Name terminal Room thermostat 12-13 Outdoor temperature sensor High Voltage Connections Boiler circulator...
  • Page 156 System example 7 Figure 21.7 CH mode 1 DHW mode 5 Low Voltage Connections Wire Name terminal Room thermostat 12-13 Flow temperature sensor Outdoor temperature sensor High Voltage Connections Boiler circulator 6-7-PE System circulator 4-5-PE Diverter valve (3-way-valve) 1-2-3-PE Low Loss Header Check the following parameters: Boiler parameter Name...
  • Page 157: Spare Parts Ch-Xx

    22 SPARE PARTS CH-xx Figure 22.1 Installation and Service Manual CH / CO...
  • Page 158 Remarks: Figure 22.2 All parts are supplied with glued/bonded parts, such as grounding lips, strips, isolation, stickers. Also bolts and nuts are supplied if necessary. Installation and Service Manual CH / CO...
  • Page 159: Spare Part List Ch-Xx

    CH-xx Type Description Part number Residential Yearly Maintenance Service Kit S000.600.001.035 Set. Electronics holder S000.600.002.035 Supply Pipe section one CH-80/CO-90/CH-100 S001.600.004 Supply Pipe section one CH-120/CO-150 S001.600.005 Supply Pipe section one CH-150/CH-180/CO-200 S001.600.006 Connection pipe between hydro block and supply S001.600.007...
  • Page 160 Clamp Boiler connector Ø80 mm S016.600.002 3 in 1 one exhaust connector gasket kit S016.600.003 80mm / 3" (contains all 3 gaskets) Intake air Silencer CH-80, CH-100, CH-120 S024.600.001 Intake air Silencer CH-150, CH-180 S024.600.002 Wiring harness ignition cable + earth cable S031.600.004...
  • Page 161 S036.600.018 Clip D10 S036.600.019 Adapter ¾" BSP to ¾" NPT S037.600.001 Gas Valve (120VAC) S037.600.002 Burner Control 900MN (120VAC) CH-80,100,120 S195010.035 Burner Control 900MN (120VAC) CH-150,180 S195040.035 Wiring harness Ionisation + Gas valve cable S031.600.003 Burner door nut 4 pcs.
  • Page 162: Spare Parts Co-Xx

    23 SPARE PARTS CO-xx Figure 23.1 Installation and Service Manual CH / CO...
  • Page 163 Remarks: Figure 23.2 All parts are supplied with glued/bonded parts, such as grounding lips, strips, isolation, stickers. Also bolts and nuts are supplied if necessary. Installation and Service Manual CH / CO...
  • Page 164: Spare Part List Co-Xx

    Pos. Description Part number Residential Yearly Maintenance Service Kit S000.600.001.035 Set Electronics holder S000.600.002.035 Supply Pipe section one CH-80/CO-90/CH-100 S001.600.004 Supply Pipe section one CH-120/CO-150 S001.600.005 Supply Pipe section one CH-150/CH-180/CO-200 S001.600.006 Connection pipe between hydro block and supply S001.600.007 section one Sensor NTC 10KOhm Ø18 mm...
  • Page 165 CO-xx Type Pos. Description Part number Power Supply Switch S006.500.005 Spring plunger 8 mm S006.500.006 EPDM sealing for EBM 957 S006.500.007 Mounting plate burner control S006.600.002.901.903 Bracket air intake damper S008.600.001 Combustion Blower NRG118/115W (120VAC) S008.600.003.035 Combustion Blower RG148/300W (120VAC) S008.600.009.035 Venturi (natural gas) CO-90 S008.600.010...
  • Page 166 CO-xx Type Pos. Description Part number Hose spring clamps Ø23.83 (DW15) S035.600.004 Hydro block plug S036.600.001 Hydro block Plug S036.600.007 3-way valve S036.600.009 Pressure sensor Eltek S036.600.010 Automatic air vent in hydro block S036.600.011 Circulator Motor UPS/R S036.600.013 Union 3/4" NPT Pump house S036.600.015 Union 3/4"...
  • Page 168 IN USA CONTACT: IN CANADA CONTACT: Granby Industries L.P. Industries Granby S.E.C. 98 des Industries, 2260 Dwyer Avenue, Utica, NY 13501 Cowansville, Qc. Tel. 800 325 5479 J2K 0A1. Canada. www.ecrinternational.com 450-378-2334 www.granbyindustries.com supporttechnique@granbyindustries.com...

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