ECR 97gb 075 Installation, Operation And Maintanance Manual
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ECR 97gb 075 Installation, Operation And Maintanance Manual

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Summary of Contents for ECR 97gb 075

  • Page 2 DIMENSIONS FIGURE 1-1 Dimensions Vent Connection Combustion Air Supply Water Return Water Connection Wall Hanging Bracket User Interface Floor Alternate Gas Connection Alternate Alternate Return Water Supply Water Table 1 : Physical Data Weight Water Connections Width Height Depth Bracket Size Connection Shipping...

  • Page 3: Table Of Contents

    1 - 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...................

  • Page 4: Introduction

    1 - INTRODUCTION 1.1 Designated Use • Hot water heating boiler. • Indoor installations. • 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. WARNING • United States Fire, explosion, asphyxiate and electrical shock •...

  • 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 informa- tion regarding boiler condition.
  • Page 7 3 - COMPONENT LISTING FIGURE 3-1 Boiler Components LOW VOLTAGE LOW VOLTAGE COMBUSTION TERMINAL TERMINAL AIR INLET- 2" PVC VENT STRIP (4) STRIP (4) CONNECTOR - 2" PVC HIGH VOLTAGE HIGH VOLTAGE (25) JUNCTION BOX JUNCTION BOX SAFETY SAFETY (24) (24) RELIEF RELIEF...
  • Page 8 3 - COMPONENT LISTING FIGURE 3-2 Boiler Components COMBUSTION VENT RETURN WATER RETURN WATER AIR INLET USER INTERFACE (1) USER INTERFACE (1) HIGH VOLTAGE HIGH VOLTAGE CONNECTOR FROM HEATING FROM HEATING 2" PVC (2) JUNCTION BOX JUNCTION BOX SYSTEM (IN) SYSTEM (IN) 2"...
  • Page 9 3 - COMPONENT LISTING INTERNAL ACCESS PANEL - CLOSED (33) Control Module Fuse and holder CONTROL MODULE (32) INTERNAL ACCESS PANEL -OPEN (33) TRANSFORMER CENTRAL HEATING (35) PUMP RELAY (34)

  • Page 10: Locating Boiler

    4 - LOCATING BOILER 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 11 4 - LOCATING BOILER 4.2 WALL MOUNTING OPTION WARNING Boiler can be wall mounted using wall mounting bracket Do not install wall mount bracket directly on drywall. included with unit. Structure must be capable of supporting boiler FIGURE 4-2 Wall Mounting Bracket Engaged weight plus 60 lbs (28 kg).

  • Page 12: Hydronic Piping

    5 - HYDRONIC PIPING 5.1 General CAUTION • Install piping in accordance with authority having jurisdiction. Non-potable water only piped directly to boiler. DO NOTICE NOT connect drinking water to heating system. Use two (2) wrenches when tightening and fi tting to pipe boiler's threaded fi...

  • Page 13: Trim Piping

    5 - HYDRONIC PIPING FIGURE 5-2 Safety Relief Valve Discharge Piping WARNING Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. • Install discharge piping from safety relief valve. See fi...
  • Page 14 5 - HYDRONIC PIPING Piping Legend NOTICE Illustrations are meant to show system piping con- cept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. FIGURE 5-4 System Piping System System Supply Return Check Local Codes For Maximum Distance To Floor...
  • Page 15 5 - HYDRONIC PIPING 5-5 TWO-PIPE ZONED SYSTEM WITH VALVES Circulating Ball Valve Open (as shipped) 3/8" Open End Wrench 5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS Circulating Ball Valve Open (as shipped) 3/8" Open End Wrench...
  • Page 16 5 - HYDRONIC PIPING 5-7 SINGLE BOILER USING PRIMARY/SECONDAY PUMPING 12"/305mm Max. apart Existing closely 12"/305mm spaced tees Max. apart in primary system loop System Limit length to Pump 5 feet water pressure drop Heat Exchanger Heat Exchanger valve open valves closed 3/8"...
  • Page 17 5 - HYDRONIC PIPING 5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide) System 12"/305mm Max. apart Pump System Temperature Size common piping Sensor according to max. heat capacity of entire system Limit to 2 feet Up to 16 boilers All heat exchanger valves closed...

  • Page 18: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING • Any improper operation of common venting system 6.1 General 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 air and vent piping in accordance with these and Propane Installation Code, CAN/CSA B149.1.

  • Page 19: Pipe Installation

    6 - COMBUSTION AIR AND VENT PIPING 6.4 Pipe Installation Table 4 - Combustion air and vent pipe fi ttings must conform with the following: • Minimum and maximum combustion air and vent pipe lengths listed in Table (3). Pipe length counted from Item Material Standards...
  • Page 20 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 3" (8 cm) Maximum 12" (30 cm) 15" (38 cm) Minimum Maximum 8" (21 cm) 3" (8 cm) Maximum horizontal Minimum separation between combustion air intake and exhaust  8" (21 cm) Minimum vertical Roof separation between combustion air Terminations...
  • Page 21 6 - COMBUSTION AIR AND VENT PIPING Maintain 12" (18" for Canada) FIGURE 6-4 minimum clearance above highest anticipated snow level. Maximum Concentric 1" Maximum of 24" above roof. Vent Roof Support must be fi eld installed to Terminations secure termination kit to structure. Elbow, Roof Boot/Flashing fi...
  • Page 22 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 23 6 - COMBUSTION AIR AND VENT PIPING Keep vent termination 3’min. (0.9 Vegetation, cm) away from vegetation. Position Plants & termination where vent vapors will not damage plants/shrubs or air conditioning Shrubs equipment. Termination Vent termination 4’ (1.2 m) horizontally Meters, from, no case above or below, elec- 3' (0.9 cm)

  • Page 24: 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 25: 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 knock out any phones in your building.
  • Page 26 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 27: Electrical Connections

    8 - ELECTRICAL CONNECTIONS 8.1 General WARNING Electrically bond boiler to ground in accordance with re- Electrical shock hazard. Turn OFF electrical power quirements of authority having jurisdiction. In absence of supply at service panel before making electrical such requirements: connections.
  • Page 28 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 pro- vide power to DHW temperature control Maximum wire length is 330 ft (180 m) 22 gauge wire.

  • Page 29: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Fill boiler with water and purge air NOTICE • Consult local water treatment companies for hard water IMPORTANT: On initial start up condensate trap areas (above 7 grains hardness). must be manually fi lled with water. •...
  • Page 30 9 - START UP PROCEDURE 9-2 User Interface 9-2 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 31 Press OK key on choice Scroll to power choice Pumps will shutoff after 6 minutes Press OK key once Cascade Settings - See ECR Multiple Boiler Manual • Press Menu key once • Use arrow keys to scroll to...
  • 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 Nominal Maximum System test pumps - verify each pump is opera- 68.0 75.0 tional 90.0 100.0 Verify gas piping Adjust rate if needed using diagram 9-3 below •...
  • Page 33 9 - START UP PROCEDURE NOTICE Verify Burner, Proper Operation Combustion analyzer port is provided. After use Inspect burner fl ame through Sight Glass. See fi g- replace cover. ure 9-5. Operate boiler through several heating cycles, 9-4 Combustion Air Analyzer Port including domestic hot water, if used.

  • 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 gas supply OFF to boiler.
  • 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. • 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 • Remove inlet assembly with blower attached, remove gasket and burner. • Clean burner by inserting an air hose into blower opening of casting and blowing air through heat exchanger side. •...

  • Page 38: Ratings And Capacities

    Heating Capacity and AFUE (Annual Fuel Utilization Effi ciency) are based on DOE (Department of Energy) test procedures. Net I=B=R Ratings based on piping and pickup allowance of 1.15. Contact ECR Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc..

  • Page 39: Trouble Shooting

    13 - TROUBLE SHOOTING...
  • Page 40 13 - TROUBLE SHOOTING _ _ _ _ _ _ F P _ _ _ _ Go to Page 48 Go to Page 41 A 0 0 Lockout Alarm 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 Differential Air Pressure Switch Vinyl Tubing Silicone Tubing Flue Transition Test Port Vinyl Tubing Combustion Air Analyzer Port Vinyl Cap (Typ. 2) Test Lines Inclined Manometer (Or Differential Pressure Gauge) DANGER Replace all test port caps. Failure to comply will result in death or serious injury.
  • 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...
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  • Page 53 13 - TROUBLE SHOOTING...
  • Page 54 13 - TROUBLE SHOOTING...
  • Page 55 13 - TROUBLE SHOOTING...

  • Page 56: Wiring Diagram

    15 - WIRING DIAGRAM 14.1 Connection Diagram...
  • Page 57 15 - WIRING DIAGRAM 14.2 Schematic Diagram of Ladder Form LIGHTED POWER SWITCH J22-6 ARGUS GROUND J22-5 CONTROL J22-4 J13-2 FLAME SENSOR J22-3 BURNER J16-1 LWCO IGNITION J16-4 J16-5 J9-1 J16-8 DC+/L J9-2 2 NO J9-6 J16-6 DATA/PWM J9-7 J16-7 HALL 120VAC J9-5...

  • Page 58: Glossary

    16 - GLOSSARY • ANSI - American National Standards Institute, Inc. over- • HIGH-VOLTAGE - Circuit involving potential of not more sees creation and maintenance of voluntary consen- than 600 volts and having circuit characteristics in excess sus standards, including ANSI Z21.13/CSA 4.9: Gas-Fired of those of low-voltage circuit.

  • Page 59: Appendix A - Control Module

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

  • Page 60: Sequence Of Operation

    APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation Boiler operates in standby mode until S t a n d b y : N o D e m a n d demand for Central Heat (CH) or Domes- Heat tic Hot Water (DHW) is detected.
  • Page 61 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 62: 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 63 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). Closed loop software control algorithm used to meet set point temperature boiler uses.
  • Page 64 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 65 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. Typical Ignition Cycle: Following control features are implemented to ensure safe and reliable operation of Combustion System:...
  • Page 66 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 67 APPENDIX A - CONTROL MODULE Explanation User Interface Display Two pump modes are available: Pump Mode = 0 ‘CH or CH&DHW’ • Mode either CH or DHW pump terminal energized dependant on demand (CH or DHW). • CH and DHW pumps not energized at same time. •...
  • Page 68 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 ther- mostat input is closed. • Boiler will modulate its fi ring rate to maintain CH set point and match system heat load.
  • Page 69 APPENDIX A - CONTROL MODULE Explanation User Interface Display ▲ S E T T I N G S Outdoor temperature greater than Warm Weather Shutdown W a r m W e a t h e r Temperature, demand for CH blocked and pumps stopped. S h u t d o w n T e m p 7 0 °...
  • Page 70 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 ▲...
  • Page 71 APPENDIX A - CONTROL MODULE Explanation User Interface Display DHW demand prioritized over CH demand when DHW Mode 2 is enabled. Maximum time boiler operates in DHW mode limited by DHW Maximum Priority Time Setting. ▲ Priority timer starts when CH and DHW demand is present. D H W S E T T I N G S Boiler will switch from DHW back to CH operation after Maxi-...
  • Page 72 ECR International, Inc. 2201 Dwyer Ave. Utica, NY 13501 www.ecrinternational.com...

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