ECR International 75 Gebrauchsanweisung

INSTALLATION,

OPERATION &

MAINTENANCE

MANUAL

P/N # 240008282, REV D [10/2010]

CONDENSING

GAS BOILER

Models 075 & 100

DIMENSIONS

FIGURE 1-1 Dimensions

Wall Hanging

Bracket

(D)

Gas

Connection

(G)

Supply Water

(E) Return Water

(E)

User Interface

(B)

(A)

Alternate

Return Water

(E)

Alternate

Supply Water

(E)

Alternate Gas

Connection

(F) (C)

(B)

(F)

Table 1 : Physical Data

Size Width

(A) Height

(B) Depth

(D)

Water Connections Gas

Connection

(G)

Condensate Drain Weight

Shipping Unit

Size

(E) Height

(F) (H) (I)

075

/100 22-1/16"

(560mm) 35-5/8"

(905mm) 16-3/16"

(411mm) 27-1/2"

(969mm) 1-1/4"

NPT 31-1/16"

(789mm) 1/2" NPT 7-1/2" 5" 140 lb

(63.5 kg) 115 lb

(51.2 kg)

Vent Connection Combustion Air

Floor

(D)

(H)

(I)

Condensate

Drain

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............................................................................................................................. 13

5.5 System Piping......................................................................................................................... 13

6 - Combustion Air And Vent Piping .............................................................................................. 18

6.2 Removal of Existing Boiler..........................................................................................................18

6.3 Materials ............................................................................................................................... 18

6.4 Pipe Installation...................................................................................................................... 19

6.5 Termination............................................................................................................................ 19

6.6 Condensate Piping...................................................................................................................25

7 - Gas Supply Piping ....................................................................................................................26

8 - Electrical Connections..............................................................................................................28

8.2 Line Voltage Connections.......................................................................................................... 28

8.3 Low Voltage Connections.......................................................................................................... 28

9 - Start Up Procedure...................................................................................................................30

10 - Operating Instructions...........................................................................................................34

11 - General Maintenance And Cleaning ........................................................................................35

12 - Ratings And Capacities........................................................................................................... 38

13 - Trouble Shooting....................................................................................................................39

14 - Wiring Diagram......................................................................................................................56

15 - Glossary.................................................................................................................................58

Appendix A - Control Module .........................................................................................................60

1.1 Introduction ........................................................................................................................... 60

1.2 Operation............................................................................................................................... 60

1.3 Status Indication..................................................................................................................... 60

1.4 Sequence of Operation............................................................................................................. 61

1.5 Theory of Operation................................................................................................................. 63

TABLE OF CONTENTS

1.1 Designated Use

Hot water heating boiler.•

Indoor installation.•

Closet or alcove installation.•

Direct vent boiler.•

For use with natural gas or liqueﬁed petroleum gases• (LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals

present (example, swimming pool water).

Exceed 50 psig (344 kPa) system pressure.•

Exceed 195°F (90.5°C) system design temperature.•

1.3 Operational Features

Modulating: 20-100%.•

Integral Dual Limit.•

Integral Low Water Cutoff (with test button).•

Outdoor Temperature Reset.•

Integral Multiple Boiler Control.•

1 - INTRODUCTION

NOTICE

Used to address practices not related to personal

injury.

2.3 Installation shall conform to requirements

of authority having jurisdiction or in absence of

such requirements:

United States

•

National Fuel Gas Code, ANSI Z223.1/NFPA 54•

National Electrical Code, NFPA 70.•

Canada•

Natural Gas and Propane Installation Code,• CAN/CSA B149.1.

Canadian Electrical Code, Part I, Safety Standard• for Electrical Installations, CSA C22.1

2.4 Where required by authority having

jurisdiction, installation shall conform to

Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of

Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not

limited to:

Installation by licensed plumber or gas ﬁtter.•

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

This is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.

2.2

Become familiar with symbols identifying

potential hazards.

2.1 General

Boiler installation shall be completed by qualiﬁed agency.

See glossary for additional information.

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death

or serious injury. Read this manual and understand

all requirements before beginning installation.

2 - IMPORTANT SAFETY INFORMATION

3.1 Component Listing

User Interface

(see Page 8) - Displays information

regarding boiler condition. Allows adjustment of

boiler operating parameters. NOTE: Does not replace

thermostat used to control central heating space.

Combustion Air Inlet (2" PVC)

(see page 7 & 8)

Return Water From Heating System (In) 1-1/4"

NPT

(see pages 7 & 8)

Connections supplied to con-

nection top and/or bottom of boiler.

Low Voltage Terminal Strip

(see pages 7 & 8)

- Connection of all low voltage wiring, including

thermostat. See section

Igniter

(see page 8)

Flame Sensor

(see page 8)

Sight Glass

(see page 8) - Permits observation of

burner ﬂame.

Burner

(see page 8)

Combustion Chamber

(see page 8)

Condensate Collector

10.

(see page 8)

Return Temperature Sensor

11.

(see page 8)

Drain Valve

12.

(see page 8)

Heat Exchanger Ball Valve

13.

(see page 8)

Supply Water Outlet to Heating System (Out)

14.

1-1/4"NPT (see pages 7 & 8) - Connections supplied

for connecting from either top or bottom of boiler. See

section 5.

Vent Temperature Sensor

15.

(see page 8)

Condensate Drain

16.

(see page 8) - Boiler produces

a liquid (condensate) as a by-product of combustion.

Condensate must be piped to appropriate drain. See

section 6.

Heat Exchanger Pump

17.

(see page 8)

Gas Shutoff Valve

18.

(see page 8)

- Fuel supply isolation

during servicing. See section 7

Combustion Air Blower

19.

(see page 8)

- Delivers

proper quantity of combustion air, receives fuel from

gas valve, mixes air and fuel sending mixture to burner

for combustion.

Gas (Control) Valve

20.

(see page 8)

- Delivers

proper quantity of fuel to Combustion Air Blower.

See section 7.

High Temperature Supply Switch

21.

(see page 8)

Low Water Cutoff

22.

(see page 8)

Senses inadequate

quantity of water. Turns off boiler before damage can

occur (with test button).

Safety Relief Valve

23.

(see page 8) - Factory supplied,

Field installed. See section 5.

High Voltage Junction Box

24.

(see page 8) - For

connection of 120V components. See section

Vent Connector (2" PVC)

25.

(see pages 7 & 8) - See

section 6.

Gas Connection

26.

(see page 7)

- Gas supply may be

piped either through top or bottom of boiler. See

section 7.

Bracket for Optional Wall Mount

27.

(see page 7) -

Integral to boiler. Allows optional wall mounting when

used with supplied wall mounting bracket. See section 4.

Auxiliary Power Outlet

28.

(see page 7) - Convenience

outlet for condensate pump or service. Controlled by

Service Switch (29)

Service Switch

29.

(see page 7)

Air Vent

30.

(see page 7)

Central Heating Pump Circuit Breaker

31.

(see page 7)

5 amp circuit breaker protects control module.

Control Module

32.

(see page 9)

Internal Access Panel

33.

(see page 9) - Gently pull

upward then forward to access control module.

Removable for access to internal components of boiler.

Central Heating Pump Relay

34.

(see page 9)

Transformer

35.

(see page 9) - Supplies 24V power to low

water cutoff.

Pressure Switch

36.

(not shown)

Test Port

37.

-(see page 8)

Combustion Analysis Test Port

38.

- (see page 8)

3 - COMPONENT LISTING

FIGURE 3-1 Boiler Components

LOW VOLTAGE

TERMINAL

STRIP

STRIP COMBUSTION

AIR INLET- 2" PVC VENT

CONNECTOR - 2" PVC

SAFETY

RELIEF

VALVE

AIR VENT

RETURN WATER

FROM HEATING

SYSTEM (IN)

HIGH VOLTAGE

JUNCTION BOX

SUPPLY WATER TO

HEATING SYSTEM

(OUT)

GAS CONNECTION

SERVICE SWITCH

AUXILIARY POWER

OUTLET

CENTRAL HEATING

PUMP CIRCUIT BREAKER

BRACKET FOR

OPTIONAL WALL

MOUNT

NOTE:

See Section 5-3

For Safety Relief

Valve Piping

Instructions

3 - COMPONENT LISTING

FIGURE 3-2 Boiler Components

LOW

VOLTAGE

TERMINAL

STRIP

HIGH VOLTAGE

JUNCTION BOX

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

IGNITER

SIGHT

GLASS

HEAT EXCHANGER

BALL VALVE

CONDENSATE

DRAIN 1/2" PVC

GAS SHUTOFF

VALVE

LOW WATER

CUTOFF

COMBUSTION

AIR

BLOWER

COMBUSTION

CHAMBER

GAS (CONTROL)

VALVE

USER INTERFACE

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

SUPPLY WATER TO

HEATING SYSTEM

(OUT) 1-1/4" NPT

HEAT EXCHANGER

PUMP

CONDENSATE

COLLECTOR

DRAIN

VALVE

FLAME

SENSOR

(SHOWN IN OPEN

POSITION)

VENT

TEMPERATURE

SENSOR

SAFETY RELIEF VALVE

VENT CONNECTOR

(2" PVC)

COMBUSTION

AIR INLET

2" PVC

HIGH TEMPERATURE

SUPPLY SWITCH

RETURN TEMPERATURE

SENSOR

COMBUSTION

ANALYSIS TEST

PORT

TEST PORT

NOTE:

See Section 5

For Piping

Instructions

IN-LINE

PRESSURE

SWITCH

VAPOR

COLLECTOR

3 - COMPONENT LISTING

INTERNAL ACCESS

PANEL - CLOSED

INTERNAL ACCESS

PANEL -OPEN

CONTROL

MODULE

CENTRAL HEATING

PUMP RELAY TRANSFORMER

Control Module

Fuse and holder

Note: To open

Lift panel up

then pull forward

LOW

VOLTAGE

TERMINAL

STRIP

HIGH VOLTAGE

JUNCTION BOX

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

IGNITER

SIGHT

GLASS

HEAT EXCHANGER

BALL VALVE

CONDENSATE

DRAIN 1/2" PVC

GAS SHUTOFF

VALVE

LOW WATER

CUTOFF

COMBUSTION

AIR

BLOWER

COMBUSTION

CHAMBER

GAS (CONTROL)

VALVE

USER INTERFACE

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

SUPPLY WATER TO

HEATING SYSTEM

(OUT) 1-1/4" NPT

HEAT EXCHANGER

PUMP

SAFETY RELIEF VALVE

COMBUSTION

ANALYSIS TEST

PORT

IN-LINE

PRESSURE

SWITCH

VAPOR

COLLECTOR

TABLE 2: BOILER CLEARANCES

Dimension Combustible

Materials (1) Service(1)(2)

Top (A)

0" (0 cm) 14" (36 cm)

Left Side (B)

6" (16 cm) 6" (16 cm)

Right Side (C)

0" (0 cm) 1½" (4 cm)

Front (D)

0" (0 cm) 6" (16 cm)

Back (E)

0" (0 cm) 0" (0 cm)

Bottom (F)

0" (0 cm) 0" (0 cm) Floor

12" (32 cm) for

Bottom Piped

Combustion

Air/Vent piping

0" (0 cm) 6" (16 cm)

Hot Water Pip-

ing

½" (1.3 cm) 6" (16 cm)

(1) Required distances measured from boiler.

(2) Service, proper operation clearance recommendation.

4 - LOCATING BOILER

FIGURE 4-1 Clearance to Combustible Materials

4.1 Boiler Location Considerations

Ambient room temperature always above 32°F (0°C) to• prevent freezing of liquid condensate.

Approved for installation in closets and on combustible• ﬂoors. Do not install boiler on carpeting.

Protection of gas ignition system components from• water (dripping, spraying, rain, etc.) during operation

and service (circulator replacement, condensate trap,

control replacement, etc.).

Floor or wall mounting.•

Wall must be plumb and capable of supporting boiler• weight plus 60 lbs (28 kg). See Table 1.

Floor must be level. Leveling feet allow adjustment• up to 1/4" (6 mm).

Wall mounting. See section 4.2.•

Access to outdoors to meet minimum and maximum• pipe lengths for combustion air and vent piping. See

section 6.

Disposal of condensate. See section 6.•

Drainage of water (or water - antifreeze solution) during• boiler service or from safety relief valve discharge. See

section 5.

Access to system water piping, gas supply, and electrical• service. See sections 5, 7 and 8.

Clearances to combustible materials and service• clearances. See Table 2 and ﬁgure 4-1.

Multiple Boilers can be placed side by side, back to back• or wall mounted.

FLOOR FLOOR

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