ECR International 75 Installation, Operation & Maintenance Manual
  1. Manuals
  2. Brands
  3. ECR International Manuals
  4. Boiler
  5. 75
  6. Installation, operation & maintenance manual

ECR International 75 Installation, Operation & Maintenance Manual

Condensing gas boiler
Hide thumbs Also See for 75:
Table of Contents

Advertisement

Quick Links

CONDENSING
GAS BOILER
Models 075 & 100
INSTALLATION,
OPERATION &
MAINTENANCE
MANUAL
H
P/N # 240008282, REV D [10/2010]

Advertisement

Table of Contents
loading

Related Manuals for ECR International 75

Summary of Contents for ECR International 75

  • Page 1 CONDENSING GAS BOILER Models 075 & 100 INSTALLATION, OPERATION & MAINTENANCE MANUAL P/N # 240008282, REV D [10/2010]...
  • Page 2 DIMENSIONS FIGURE 1-1 Dimensions Vent Connection Combustion Air Supply Water Return Water Connection User Interface Floor Wall Hanging Bracket Condensate Drain Alternate Gas Connection Alternate Alternate Return Water Supply Water Table 1 : Physical Data Water Connections Condensate Drain Weight Width Height Depth...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 - Introduction ..........................4 2 - Important Safety Information ....................5 3 - Component Listing ........................6 4 - Locating Boiler ......................... 10 5 - Hydronic Piping ........................12 5.2 Special Conditions ........................12 5.3 Safety Relief Valve and Air Vent ....................12 5.4 Trim Piping ..........................

  • Page 4: Introduction

    1 - INTRODUCTION 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: •...

  • Page 5: Important Safety Information

    2 - IMPORTANT SAFETY INFORMATION 2.1 General 2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of Boiler installation shall be completed by qualifi ed agency. such requirements: See glossary for additional information. • United States WARNING •...

  • Page 6: Component Listing

    3 - COMPONENT LISTING 3.1 Component Listing Gas (Control) Valve Gas (Control) Valve (see page 8) - Delivers - Delivers proper quantity of fuel to Combustion Air Blower. proper quantity of fuel to Combustion Air Blower. See section 7. See section 7. User Interface (see Page 8) - Displays information regarding boiler condition.
  • Page 7 3 - COMPONENT LISTING FIGURE 3-1 Boiler Components LOW VOLTAGE LOW VOLTAGE COMBUSTION TERMINAL TERMINAL AIR INLET- 2" PVC STRIP STRIP VENT CONNECTOR - 2" PVC HIGH VOLTAGE HIGH VOLTAGE JUNCTION BOX JUNCTION BOX SAFETY SAFETY RELIEF RELIEF VALVE VALVE AIR VENT AIR VENT RETURN WATER...
  • Page 8 3 - COMPONENT LISTING FIGURE 3-2 Boiler Components COMBUSTION AIR INLET RETURN WATER RETURN WATER USER INTERFACE USER INTERFACE VENT CONNECTOR HIGH VOLTAGE HIGH VOLTAGE 2" PVC FROM HEATING FROM HEATING (2" PVC) JUNCTION BOX JUNCTION BOX SYSTEM (IN) SYSTEM (IN) 1-1/4"...
  • Page 9 3 - COMPONENT LISTING INTERNAL ACCESS PANEL - CLOSED Note: To open Lift panel up then pull forward Control Module Fuse and holder CONTROL MODULE INTERNAL ACCESS PANEL -OPEN TRANSFORMER CENTRAL HEATING PUMP RELAY...

  • Page 10: Locating Boiler

    4 - LOCATING BOILER Boiler Location Considerations • Ambient room temperature always above 32°F (0°C) to TABLE 2: BOILER CLEARANCES prevent freezing of liquid condensate. Combustible Dimension Service (1)(2) • Approved for installation in closets and on combustible Materials fl oors. Do not install boiler on carpeting. Top (A) 0"...
  • Page 11 4 - LOCATING BOILER 4.2 Wall Mounting Option Boiler can be wall mounted using wall mounting bracket FIGURE 4-2 Wall Mount Bracket Engaged with included with unit. Bracket on Boiler • Structure must be capable of supporting boiler weight plus 60 lbs (28 kg). See Table 1, page 2. •...

  • Page 12: Hydronic Piping

    5 - HYDRONIC PIPING 5.1 General • Install piping in accordance with authority having jurisdiction. WARNING NOTICE • Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol. Use two (2) wrenches when tightening and fi tting to pipe boiler's threaded fi ttings. Boiler's internal •...

  • Page 13: Trim Piping

    5 - HYDRONIC PIPING • Systems with automatic fi ll valves require back fl ow WARNING prevention device. Burn and scald hazard. Safety relief valve could • Install discharge piping from safety relief valve. See discharge steam or hot water during operation. fi...
  • Page 14 5 - HYDRONIC PIPING Piping Legend NOTICE Illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. FIGURE 5-4 System Piping System System Return Supply F L O O R Check Local Codes For Maximum Distance To Floor...
  • Page 15 5 - HYDRONIC PIPING 5-5 TWO-PIPE ZONED SYSTEM WITH VALVES Pump CH/System Pump Heat exchanger ball valve open (as shipped) 3/8"/10mm Open End Wrench 5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS Pump Heat exchanger Zone ball valve open Pump (as shipped) 3/8"/10mm Open End Wrench...
  • Page 16 5 - HYDRONIC PIPING 5-7 SINGLE BOILER USING PRIMARY/SECONDAY PUMPING 12"/305mm Max. apart Existing closely spaced tees 12"/305mm Max. apart in primary system loop CH/System Limit length Pump 5'/1.6 m Heat exchanger ball Heat exchanger 3/8"/10mm Open End Wrench valve open ball valves closed 3/8"/10mm Open End Wrench...
  • Page 17 5 - HYDRONIC PIPING 5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide) Pump System Pump 12"/305mm Max. apart System Temperature Size common piping Sensor according to maximum heat capacity of entire system Up to 16 boilers All heat exchanger ball valves closed 3/8"/10mm Open End Wrench...

  • Page 18: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING their previous condition of use. 6.1 General This boiler requires a dedicated direct vent system. • Any improper operation of common venting system Install combustion air and vent piping in accordance should be corrected so installation conforms with National with these instructions, authority having jurisdiction, Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and:...

  • Page 19: Pipe Installation

    6 - COMBUSTION AIR AND VENT PIPING Table 4 - Combustion air and vent pipe fi ttings must conform with the following: 6.4 Pipe Installation Item Material Standards • Minimum and maximum combustion air and vent pipe lengths listed in Table (3). Pipe length counted from PVC schedule 40 ANSI/ASTM D1785 combustion air connector to termination.
  • Page 20 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 3" (8 cm) Maximum 3" (8 cm) Maximum horizontal separation between combustion air intake and vent of same appliance. 12" (30 cm) 15" (38 cm) 8" (21 cm) Minimum vertical Minimum Maximum Roof Line separation between combustion...
  • Page 21 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 FIGURE 6-5 1" (2.54cm) 1" (2.54cm) Roof overhang Maximum Maximum 1"(2.54cm) Maximum 12" (30cm) Minimum * See Note 36"(0.9m) Minimum Below Maintain 12" Maintain 12"(30cm) US clearance above Vent Vent (18"(46cm) Canada) highest anticipated Combustion clearance above highest...
  • Page 22 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-6 Glue inner vent pipe to prevent Vent recirculation. Maintain 12"(30cm) US Maintain 12" (30 cm) US (18"(46 (18"(46cm) Canada) cm) Canada) minimum clearance clearance above highest above highest anticipated snow anticipated snow level Combustion Air level.
  • Page 23 6 - COMBUSTION AIR AND VENT PIPING Combustion air and vent termination Doors & must be 12" (30.5 cm) from or below Windows doors, windows or gravity inlet. Termination must Vent gas may condense, forming be 12" (30.5 cm) moisture, may be corrosive. Protect Condensate from or below doors, building materials at vent from exhaust...
  • Page 24 6 - COMBUSTION AIR AND VENT PIPING Keep vent termination 3’ minimum Vegetation, (0.9m) away from vegetation. Position Plants & termination where vent vapors will not damage plants/shrubs or air conditioning Shrubs equipment. Termination Vent termination US only - 4’ (1.2 m), Meters, Canada - 6' (1.83m) horizontally from, Regulators,...

  • Page 25: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 Condensate Drain 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. •...

  • Page 26: Gas Supply Piping

    TABLE 5: GAS SUPPLY PRESSURE Natural Gas Propane Maximum SIZE Input (Btuh) Min. Max. Min. Max. 3.0" w.c. 13.5" w.c. 5.0" w.c. 13.5" w.c. 075/100 75,000 (0.7 kPa) (3.3 kPa) (1.2 kPa) (3.4 kPa) Note: See Glossary - Piping Table 16...
  • Page 27 7 - GAS SUPPLY PIPING 7-4 Gas Connection Knockout Plate at Top of DANGER Boiler Fire Hazard. Do not use matches, candles, open fl ames, or other methods providing ignition source. Failure to comply will result in death or serious injury.

  • Page 28: Electrical Connections

    8 - ELECTRICAL CONNECTIONS 8.1 General WARNING Electrically bond boiler to ground in accordance with Electrical shock hazard. Turn OFF electrical power requirements of authority having jurisdiction. Refer to: supply at service panel before making electrical • USA- National Electrical Code, ANSI/NFPA 70. connections.
  • Page 29 8 - ELECTRICAL CONNECTIONS • Domestic Hot Water (DHW) Thermostat, if used. Use temperature control with dry contacts rated 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.

  • Page 30: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Fill boiler with water and purge air NOTICE • Fill boiler with potable water. IMPORTANT: Condensate trap must be manually • Fill boiler and system piping with water (or antifreeze- fi lled with water at initial start up. water solution, if used).
  • Page 31 9 - START UP PROCEDURE 9 -2 User Interface -2 User Interface 9.3 Program Boiler Control 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...
  • Page 32 9 - START UP PROCEDURE 9.4 Boiler Start-up and Operational Test Compare to boiler rating Verify air is purged from hydronic piping Size Minimum Maximum System test pumps - verify each pump is operational 90.0 Verify gas piping Adjust rate if needed using diagram 9-3 below. •...
  • Page 33 9 - START UP PROCEDURE Verify Burner, Proper Operation NOTICE Inspect burner fl ame through Sight Glass. See Combustion analyzer port is provided. After use fi gure 9-5. replace cover. Operate boiler through several heating cycles, including domestic hot water, if used. Verify proper 9-4 Combustion Analyzer Port operation.

  • Page 34: Operating Instructions

    10 - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WARNING WHAT TO DO IF YOU SMELL GAS If you do not follow these instructions • Do not try to light any appliance. exactly, a fi re or explosion may result •...

  • Page 35: General Maintenance And Cleaning

    11 - GENERAL MAINTENANCE AND CLEANING 11.1 Beginning of Each Heating Season DANGER • Check boiler area is free from combustible materials, Before servicing, turn off electrical power to boiler gasoline, and other fl ammable vapors and liquids. at service switch. Close manual gas valve to turn •...
  • Page 36 11 - GENERAL MAINTENANCE AND CLEANING • Visual inspection of fl ame through sight glass. Burner 11-2 Blower Inlet Assembly 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.
  • Page 37 11 - GENERAL MAINTENANCE AND CLEANING 11-2 Condensate Collector • 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. •...

  • Page 38: Ratings And Capacities

    12 - RATINGS AND CAPACITIES TABLE 12-1: SEA LEVEL RATINGS NATURAL AND PROPANE GASES Net I=B=R Rating, Boiler Input Rate (MBH) Heating Capacity Size Water (MBH) AFUE (1)(3) (MBH) (1)(2) Maximum Minimum 97.0 97.0 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Effi...

  • Page 39: Trouble Shooting

    13 - TROUBLE SHOOTING GO TO NEXT PAGE...

  • Page 40: Trouble Shooting

    13 - TROUBLE SHOOTING _ _ _ _ _ _ F P _ _ _ _ A 0 0 Go to Page 48 Lockout Alarm Go to Page 41 Blocking Error E 3 5 Blocking Too Long Error False Flame Detect _ _ _ _ _ _ _ _ _ _ _ _ Go to Page 42...
  • Page 41 13 - TROUBLE SHOOTING...
  • Page 42 13 - TROUBLE SHOOTING...
  • Page 43 13 - TROUBLE SHOOTING...
  • Page 44 13 - TROUBLE SHOOTING...
  • Page 45 13 - TROUBLE SHOOTING 13-1 Differential Air Pressure Switch Differential Air Pressure Switch Vinyl Tubing Connect manometer to Air Pressure Switch tubing (see fi gure 13-2). Follow operating instructions to initiate boiler Silicone Tubing operation. Refer to Trouble Shooting Tree page 46. Test Port DANGER Vinyl Tubing...
  • Page 46 13 - TROUBLE SHOOTING...
  • Page 47 13 - TROUBLE SHOOTING...
  • Page 48 13 - TROUBLE SHOOTING...
  • Page 49 13 - TROUBLE SHOOTING...
  • Page 50 13 - TROUBLE SHOOTING...
  • Page 51 13 - TROUBLE SHOOTING...
  • Page 52 13 - TROUBLE SHOOTING...
  • Page 53 13 - TROUBLE SHOOTING...
  • Page 54 13 - TROUBLE SHOOTING...
  • Page 55 13 - TROUBLE SHOOTING...

  • Page 56: Wiring Diagram

    14 - WIRING DIAGRAM 14.1 Connection Diagram...
  • Page 57 14 - WIRING DIAGRAM 14.2 Schematic Diagram of Ladder Form...

  • Page 58: Glossary

    15 - GLOSSARY • ANSI - American National Standards Institute, Inc. • GAS PIPE SIZES oversees creation and maintenance of voluntary consensus standards, including ANSI Z21.13/CSA 4.9: NATURAL GAS Gas-Fired Low Pressure Steam and Hot Water Boilers. Pipe Capacity - BTU Per Hour Input Includes Fittings Length of Pipe - Ft.
  • Page 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. •...

  • Page 60: Appendix A - Control Module

    APPENDIX A - CONTROL MODULE 1.1 Introduction Operation with LCD character display module Operation with LCD character display module Boiler is equipped with programmable electronic control and user interface module. 1.2 Operation • Display: 4x20 character LCD screen to show boiler status.

  • Page 61: Sequence Of Operation

    APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation Boiler operates in standby mode S t a n d b y : N o D e m a n d until demand for Central Heat (CH) or Heat Domestic Hot Water (DHW) is detected.
  • Page 62 APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation After 2 seconds If fl ame detected before Gas Valve opens during ignition boiler will lockout. Lockout Flame Error A21 Detected? Please refer to troubleshooting guide. Note: 5 Ignition trials,...

  • Page 63: Theory Of Operation

    APPENDIX A - CONTROL MODULE 1.5 Theory of Operation Explanation User Interface Display 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.
  • Page 64 APPENDIX A - CONTROL MODULE Explanation User Interface Display Adjust CH set point to hydronic system design while in Operating in CH Mode = 0 (CH with Thermostat) or 3 (Perma- nent Demand). In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2 (CH with Full Outdoor Reset).
  • Page 65 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu The Installer Menu structure includes: • ‘Boiler Status’ submenu – User monitors detailed boiler status parameters such as fl ame signal, fan speeds and stored error codes. • ‘Boiler Confi g’ submenu – Modifi es general boiler settings.
  • Page 66 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu Control module logs successful and failed ignition attempts. Information accessed in ‘Ignition Attempts’ Screen as shown. Ignition attempts are stored in non-volatile memory and are retained in event of power failure. Figure A-1 Typical Ignition Cycle S T A T U S ▲...
  • Page 67 APPENDIX A - CONTROL MODULE Explanation User Interface Display Boiler stores information regarding total CH and DHW run time S T A T U S ▲ in hours. B o i l e r R u n T i m e 3 2 0 H R Data stored in non-volatile memory and retained in event of power failure.
  • Page 68 APPENDIX A - CONTROL MODULE Explanation User Interface Display Two pump modes are available: Pump Mode = 0 ‘CH or CH&DHW’ • In this mode either the CH or DHW pump terminal is energized depending on the type of demand (CH or DHW). •...
  • Page 69 APPENDIX A - CONTROL MODULE Explanation User Interface Display 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 modulate its fi ring rate to maintain CH set point and match system heat load.
  • Page 70 APPENDIX A - CONTROL MODULE Explanation User Interface Display S E T T I N G S ▲ W a r m W e a t h e r If outdoor temperature is greater than Warm Weather Shutdown Temperature, demand for CH blocked and pumps stopped. S h u t d o w n T e m p 7 0 °...
  • Page 71 APPENDIX A - CONTROL MODULE Explanation User Interface Display 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 increase until set point reaches S E T T I N G S ▲...
  • Page 72 APPENDIX A - CONTROL MODULE Explanation User Interface Display Maximum time boiler operates in DHW mode limited by DHW Maximum Priority Time Setting. Priority timer starts when both CH and DHW demand is present. Boiler will switch from DHW back to CH operation after D H W S E T T I N G S ▲...
  • Page 76 CONDENSING GAS BOILER Models 075 & 100 ECR International, Inc. 2201 Dwyer Ave. Utica, NY 13501 www.ecrinternational.com...

This manual is also suitable for:

100075 97gb100 97gb

Table of Contents