ECR 075 97gb Installation, Operation & Maintenance Manual
  1. Manuals
  2. Brands
  3. ECR Manuals
  4. Boiler
  5. 075 97gb
  6. Installation, operation & maintenance manual

ECR 075 97gb Installation, Operation & Maintenance Manual

Condensing gas boiler
Hide thumbs Also See for 075 97gb:
Table of Contents

Advertisement

Quick Links

See also: Installation, Operation & Maintenance Manual
CONDENSING
GAS BOILER
Models 075 & 100
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
ECR International, Inc.
2201 Dwyer Ave
Utica, NY 13501
P/N # 240008282, REV J [03/2014]

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 075 97gb and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ECR 075 97gb

Summary of Contents for ECR 075 97gb

  • Page 1 CONDENSING GAS BOILER Models 075 & 100 WALL MOUNTED GAS BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL An ISO 9001-2008 Certified Company ECR International, Inc. 2201 Dwyer Ave Utica, NY 13501 P/N # 240008282, REV J [03/2014]...

  • Page 2: Metal Wall Bracket

    VERIFY CONTENTS RECEIVED Description Illustration Item Fully Assembled Boiler Metal Wall Bracket Lag Bolt, 3/8" x 3" Hex (4 ea) *Safety Relief Valve 3/4" Elbow 90° 3/4" Close Nipple 3/4" F x 3/4" M NPT Tee 3/4" x 1/4" NPT 90° Elbow Air Vent **Temperature Pressure Gauge Bushing 3/4"...
  • Page 3 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 4: Table Of Contents

    TABLE OF CONTENTS 1 - Introduction ..........................5 2 - Important Safety Information ....................6 3 - Component Listing ........................7 4 - Locating Boiler ......................... 11 5 - Hydronic Piping ........................13 5.2 Special Conditions ........................13 5.3 Safety Relief Valve And Air Vent....................13 5.4 Trim Piping ..........................

  • Page 5: Introduction

    • Heat exchanger over heat protection. Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.

  • Page 6: 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 such Boiler installation shall be completed by qualified agency. requirements: See glossary for additional information. • United States WARNING •...

  • Page 7: Component Listing

    3 - COMPONENT LISTING 3.1 Component Listing Supply Water Temperature Sensor and High Limit Switch User Interface - Displays information regarding Low Water Cutoff Senses inadequate quantity of boiler condition. Allows adjustment of boiler operating water. Turns off boiler before damage can occur. parameters.
  • Page 8 3 - COMPONENT LISTING FIGURE 3-1 Boiler Components (4) LOW VOLTAGE (2) COMBUSTION TERMINAL AIR INLET- 2" PVC STRIP (25) VENT CONNECTOR - 2" PVC (24) HIGH VOLTAGE JUNCTION BOX (23) SAFETY RELIEF VALVE (30) AIR VENT (3) RETURN WATER FROM HEATING SYSTEM (IN) NOTE:...
  • Page 9 3 - COMPONENT LISTING FIGURE 3-2 Boiler Components (3) RETURN (1) USER INTERFACE (24) HIGH VOLTAGE (25) VENT CONNECTOR WATER FROM JUNCTION BOX (2" PVC) HEATING SYSTEM (IN) 1-1/4" NPT (23) SAFETY RELIEF VALVE (4) LOW VOLTAGE NOTE: TERMINAL See Section 5 STRIP For Piping Instructions...
  • Page 10 3 - COMPONENT LISTING (33) INTERNAL ACCESS PANEL - CLOSED Note: To open Lift panel up then pull forward Control Module Fuse and holder (32) CONTROL MODULE (33) INTERNAL ACCESS PANEL - OPEN (35)TRANSFORMER (34) CENTRAL HEATING PUMP RELAY...

  • Page 11: Locating Boiler

    4 - LOCATING BOILER 4.1 Boiler Location Considerations TABLE 2: BOILER CLEARANCES • Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate. Combustible Dimension Service (1)(2) Materials • Approved for installation in closets and on combustible Top (A) 0"...
  • Page 12 4 - LOCATING BOILER FIGURE 4-2 Wall Mount Bracket Engaged with Pre-pipe supply and return water connections Bracket on Boiler with factory fittings before wall mounting. 4.3 Wall Mounting Mount boiler on wall using wall mounting bracket included Center brackets. Avoid with unit.

  • Page 13: Hydronic Piping

    5 - HYDRONIC PIPING 5.1 General WARNING • Install piping in accordance with authority having jurisdiction. • Poison hazard. Ethylene glycol is toxic. Do not NOTICE use ethylene glycol. Use two (2) wrenches when tightening and fitting • Never use automotive or standard glycol antifreeze, to pipe boiler's threaded fittings.

  • Page 14: Trim Piping

    5 - HYDRONIC PIPING • Systems with automatic fill valves require back flow 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. figure 5-2.
  • Page 15 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 Supply Return F L O O R Pipe to condensate drain...
  • Page 16 5 - HYDRONIC PIPING FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves Pump CH/System Pump Heat exchanger ball valve open (as shipped) 3/8"/9.5 mm Open End Wrench FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps Pump Heat exchanger Zone ball valve open...
  • Page 17 5 - HYDRONIC PIPING FIGURE 5-7 Single Boiler Using Primary/Secondary Pumping With Closed External Primary Loop or Single Boiler Using Primary/Secondary Pumping With Open External Primary Loop 12"/305mm Max. apart Existing closely spaced tees 12"/305mm in primary Max. apart system loop CH/System Limit length Pump...
  • Page 18 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 All heat exchanger ball valves closed Up to 16 3/8"/9.5mm Open boilers...

  • Page 19: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING 6.1 General • Any improper operation of common venting system should be corrected so installation conforms with National This boiler requires a dedicated direct vent system. Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas Install combustion air and vent piping in accordance and Propane Installation Code, CAN/CSA B149.1.

  • Page 20: Pipe Installation

    6 - COMBUSTION AIR AND VENT PIPING 6.4 Pipe Installation 6.5 Termination • Minimum and maximum combustion air and vent pipe • Terminate combustion air and vent pipes with fittings or lengths listed in Table 5. Pipe length counted from concentric vent kit.

  • Page 21: Venting Configurations

    6.7 Venting Configurations NOTICE Various venting configurations can be applied to this boiler. Use of vent covers may cause freezing. If using For guidance see Venting Configuration Table 7 and vent covers overall vent length must be considered. corresponding figures. Failure to heed this information may compromise operation of this boiler.
  • Page 22 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 3" (80mm) Minimum  3" (8 cm) Minimum 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...
  • Page 23 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 Side Wall Concentric Terminal FIGURE 6-5 Side Wall Concentric Terminal Multiple Appliances Roof 1"(2.54cm) Overhang 1" (25mm) Maximum 1" (25.4mm) Maximum Maximum 12" (305mm) Minimum * See Note 36"(0.9m(457mm) Below (28m)) Minimum Vent Maintain 12"...
  • Page 24 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-7 Concentric Roof Terminal Vent  Glue inner vent pipe to prevent Maintain 12"(305mm) US recirculation. (18"(457mm) Canada) clearance above highest  Maintain 12" (305mm) US anticipated snow level 24" (18"(457mm) Canada) minimum Combustion Air (610mm) above roof clearance above highest...
  • Page 25 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-10 Flue on Sidewall, Combustion Air on Roof NOTICE Configurations of single pipe vent with flue on the sidewall, requires a tee as the vent terminal. See Maintain 12"(305mm) US figures 6-10 and 6-11. (18"(457mm) Canada) clearance above highest Combustion...

  • Page 26: Side Venting Terminal Requirements

    6 - COMBUSTION AIR AND VENT PIPING 6.8 Side Venting Terminal Requirements of • USA - National Fuel Gas Code, ANSI 223.1/NFPA 54. Venting terminal from doors and windows See figure 6-12 Venting terminal from forced air inlet of other appliances See figure 6-13 Venting terminal from snow level See figure 6-14...
  • Page 27 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-15 Keep vent termination 3’ minimum Vegetation, (0.9m) away from vegetation. Position Plants & termination where vent vapors will not Shrubs damage plants/shrubs or air conditioning equipment. Termination Vent termination US only - 4’ (1.2m), Meters, Canada - 6' (1.9m) horizontally from, Regulators,...

  • Page 28: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING 6.9 Condensate Piping FIGURE 6-17 Condensate Drain • 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 29: Gas Supply Piping

    7 - GAS SUPPLY PIPING 7-1 Gas Connection Knockout Plate at Bottom of CAUTION Boiler WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switches; do not use Bottom cover any phones in your building.
  • Page 30 7 - GAS SUPPLY PIPING 7-4 Gas Connection Knockout Plate at Top of Boiler DANGER Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Failure to comply will result in death or serious injury. Top of Boiler Cover for 7.3 Near Boiler Gas Piping Gas Connection...

  • Page 31: 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 32 8 - ELECTRICAL CONNECTIONS • Outdoor Sensor, if used. A. Provided with boiler in accessory kit. B. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor. C. Maximum wire length is 100 ft (30m) for 22 ga. wire, or 150 ft (45m) for 18 ga.

  • Page 33: Start Up Procedure

    9 - START UP PROCEDURE 9-1 Condensate Drain Assembly NOTICE Condensate trap must be manually filled with water at initial start up. 9�1 Fill Boiler With Water And Purge Air NOTICE To maintain boiler efficiency and prevent boiling inside the heat exchanger, flush entire heating system until clean.
  • Page 34 9 - START UP PROCEDURE 9.3 Program Boiler Control 9 -2 User Interface Description - Manual Lockout Reset - Enter/Exit user menu - Go to previous screen - Select a menu item - Confirm new parameter value - Scroll up to next menu item - Increase value - Scroll down to next menu item - Decrease value...
  • Page 35 9 - START UP PROCEDURE 9.4 Boiler Start-up and Operational Test 9�5 Check Combustion Natural Gas Verify air is purged from hydronic piping System test pumps - verify each pump is Measure input. English units* operational • Turn off gas to all other appliances. Verify gas piping •...
  • Page 36 9 - START UP PROCEDURE Verify Burner, Proper Operation Inspect burner flame through Sight Glass. See Min. Max. figure 9-5. Natural Gas <200ppm Operate boiler through several heating cycles, Propane 10.0 11.0 <200ppm including domestic hot water, if used. Verify proper operation.

  • Page 37: Perform Csd-1 Compliance Test

    9 - START UP PROCEDURE 9�6 Perform CSD-1 Compliance Test (see NOTICE paragraph 2�5 page 6) Combustion analyzer port is provided. After use Verify operation of boiler safety control operation with replace cover. regard to no flow conditions as follows: Turn off boiler using boiler service switch.

  • Page 38: Complete Start Up Procedure

    9 - START UP PROCEDURE FIGURE 9-6Control Module J7 Connector 9.7 Complete Start Up Procedure Reset control parameters to operating settings if adjusted to allow startup and operation test. Follow instructions TO TURN OFF GAS TO APPLIANCE (page 39) if boiler is not being placed into immediate operation.

  • Page 39: 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 fire or explosion may result •...

  • Page 40: 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 flammable vapors and liquids. at service switch. Close manual gas valve to turn •...
  • Page 41 11 - GENERAL MAINTENANCE AND CLEANING 11.2 Annual Shut Down Procedure 11-2 Blower Inlet Assembly • Follow instructions “To Turn Off Gas To Appliance” unless Blower boiler is also used to supply domestic hot water. See Inlet section 10 page 39. Housing •...
  • Page 42 11 - GENERAL MAINTENANCE AND CLEANING 11-3 Condensate Collector • Loosen upper hose clamp securing condensate collector to flue pipe using 3/8" socket with 6" extension. • Remove ¼-20 hex flange nuts securing condensate collector to heat exchanger using 7/16" deep well socket.

  • Page 43: Ratings And Capacities

    12 - RATINGS AND CAPACITIES SEA LEVEL RATINGS NATURAL AND PROPANE GASES Boiler Input Rate Net AHRI Heating (MBH) Rating, Water Size Capacity AFUE (MBH) (1)(3) Maximum Minimum (MBH) (1)(2) 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.

  • Page 44: Trouble Shooting

    13 - TROUBLE SHOOTING...
  • Page 45 13 - TROUBLE SHOOTING Go to Page For Screen Display Explanation Troubleshooting Control has blocking error for more than 20 Go to Page 47 hours in a row. Three unsuccessful ignition attempts in a row Go to Page 48 Open gas valve power circuit. May involve high temperature switch, gas valve, or gas Go to Page 47 valve relay in control module.
  • Page 46 13 - TROUBLE SHOOTING Go to Page For Screen Display Explanation Troubleshooting Low water cutoff sees no water. Go to Page 53 Flue temperature sensor sees temperature Go to Page 54 higher than 200°F. B l o c k i n g E r r o r E 39 F l u e G a s E r r o r Return water temperature sensor sees...
  • 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 13 - TROUBLE SHOOTING...
  • Page 57 13 - TROUBLE SHOOTING...
  • Page 58 13 - TROUBLE SHOOTING...
  • Page 59 13 - TROUBLE SHOOTING...
  • Page 60 13 - TROUBLE SHOOTING...

  • Page 61: Wiring Diagram

    14 - WIRING DIAGRAM 14.1 Connection Diagram...
  • Page 62 14 - WIRING DIAGRAM 14.2 Schematic Diagram of Ladder Form...

  • Page 63: Glossary

    15 - GLOSSARY • ANSI - American National Standards Institute, Inc. • GAS PIPE SIZES - Table 14 oversees creation and maintenance of voluntary NATURAL GAS consensus standards, including ANSI Z21.13/CSA 4.9: Pipe Capacity - BTU Per Hour Input Includes Fittings Gas-Fired Low Pressure Steam and Hot Water Boilers.
  • Page 64 15 - GLOSSARY • QUALIFIED AGENCY - Any individual, firm, 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 65: Appendix A - Control Module

    APPENDIX A - CONTROL MODULE 1.1 Introduction Operation with LCD character display module The boiler is equipped with a programmable electronic control and user interface module. 1.2 Operation • Display: 4x20 character LCD screen to show boiler status. • Function Keys Description - Manual Lockout Reset - Enter/Exit user menu...

  • Page 66: 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 Domestic Hot Water (DHW) is detected.
  • Page 67 APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation After 2 seconds If flame 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 68: User Menu

    APPENDIX A - CONTROL MODULE 1.5 User Menu Explanation User Interface Display Boiler operates in standby mode until demand for Central Heat (CH) or Domestic Hot Water (DHW) is detected. User Menu (Press Menu button on user interface to access User Menu) User Menu structure includes: •...
  • Page 69 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 (Permanent Demand). In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2 (CH with Full Outdoor Reset).
  • Page 70 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu Installer Menu structure includes: • User 'Menu' can be accessed by pressing 'Menu' key on user interface. • Installer 'Menu' can be accessed by pressing and holding the 'Enter' key continue to hold and at the same time press and hold the 'Menu’...
  • Page 71 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 Following control features are implemented to ensure safe and reliable operation of Combustion System:...
  • Page 72 APPENDIX A - CONTROL MODULE Explanation User Interface Display Boiler stores information regarding total CH and DHW run time in hours. Data stored in non-volatile memory and retained in event of power failure. Boiler logs last 16 blocking errors and 16 lockout errors in non-volatile memory.
  • Page 73 APPENDIX A - CONTROL MODULE Explanation User Interface Display Two pump modes are available: Pump Mode = 0 ‘CH or CH&DHW’ • In this mode either CH or DHW pump terminal is energized depending on type of demand (CH or DHW). •...
  • Page 74 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 firing rate to maintain CH set point and match system heat load.
  • Page 75 Explanation User Interface Display If outdoor temperature is greater than Warm Weather Shutdown Temperature, demand for CH blocked and pumps stopped. Allowed Range: 35°F to 100°F (2°C to 38°C) Default Setting: 70°F (21°C) Boiler capable of operating in Outdoor Reset Mode when included Outdoor Sensor is connected and proper CH Mode selected.
  • Page 76 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 195°F / 91°C Allowable Temperature Increment: 0..36 °F (0..20 °C) Default Temperature increment:...
  • Page 77 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 Maximum Priority Time has elapsed.
  • Page 78 NOTES...
  • Page 80 CONDENSING GAS BOILER Models 075 & 100 ECR International, Inc. 2201 Dwyer Ave. Utica, NY 13501 www.ecrinternational.com...

This manual is also suitable for:

100 97gb

Table of Contents

Save PDF