Dunkirk CCB-150 User Manual
Model
CCB-150
COMBI
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
cod. 3541F060
Manufacturedfor:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N# 240010632, Rev. B [07/17/2014]
Figure 1 - Overall Dimensions
DIMENSIONS
Top View
Side View Front View
Rear View
1 = 1“ MPT Supply Water to Heating
System (Out)
2 = 3/4” MPT Tap Water Outlet
3 = 3/4” FPT Gas Inlet
4 = 3/4” MPT Tap Water Inlet
5 = 1” MPT Return Water From
Heating System (IN)
Bottom View
2
TABLE OF CONTENTS
1 - Introduction ................................................................................................................... 4
2 - Important Safety Information ........................................................................................... 5
3 - General view and main components .................................................................................. 6
4 - Locating Boiler ............................................................................................................... 9
5 - Hydronic Piping ............................................................................................................11
6 - Combustion Air And Vent Piping - Category I (Chimney Vent) ............................................ 15
6 - Combustion Air And Vent Piping of direct vent and Category III .......................................... 17
6 - Combustion Air And Ventilation ....................................................................................... 19
7 - Gas Supply Piping ......................................................................................................... 22
8 - Electrical Connections ................................................................................................... 23
9 - Start Up Procedure ....................................................................................................... 24
10 - Operating Instructions ................................................................................................. 26
11 - General Maintenance And Cleaning ................................................................................ 33
12 - Ratings And Capacities ................................................................................................ 34
13 - Trouble Shooting......................................................................................................... 37
Wiring diagram ............................................................................................................... 38
Repair Parts List .............................................................................................................. 40
3
1 - INTRODUCTION
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Catagory I or III Venting.
• Direct vent boiler.
• For use with natural gas or liquefi ed petroleum gases
(LP/propane).
• Directly heat potable water. Indirect heating is
acceptable.
1.2 The unit MUST NOT:
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 185°F (85°C) system design temperature.
• Exceed MWAP 43.5 PSIG
1.3 Operational Features
• Modulating: 3-1 turn down.
• Integral Dual Limit.
Information and specifi cations outlined in this manual in effect at the
time of printing of this manual. ECR International, Inc. reserves the right to
discontinue, change specifi cations or system design at any time without
notice and without incurring any obligation, whatsoever.
4
2 - IMPORTANT SAFETY INFORMATION
!
2.1 General
Boiler installation shall be completed by qualifi ed agency.
See glossary for additional information.
WARNING
!
2.3 Installation shall conform to requirements of
authority having jurisdiction or in absence of such
requirements:
•
Fire, explosion, asphyxiation and electrical
shock hazard. Improper installation could
• Canada
result in death or serious injury. Read this
manual and understand all requirements
before beginning installation.
2.2 Become familiar with symbols identifying
potential hazards.
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.
!
DANGER
Indicates a hazardous situation which, if not
2.4 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 fi tter.
2.5
Where required by the authority having jurisdiction, the
installation must conform to the
Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD1.
avoided, WILL result in death or serious injury.
United States
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
• National Electrical Code, NFPA 70.
• Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
• Canadian Electrical Code, Part I, Safety Standard
for Electrical Installations, CSA C22.1
.
!
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
NOTICE
Used to address practices not related to
personal injury.
5
3 - GENERAL VIEW AND MAIN COMPONENTS
Figure 2 Component Listing
6
3 - GENERAL VIEW AND MAIN COMPONENTS
Item
Number
5 Sealed Chamber
7 Gas Inlet
8 Domestic Hot Water (DHW) Outlet
9 Domestic Cold Water (DHW) Inlet
10 Supply System
11 System Return
16 Modulating Fan
19 Combustion Chamber
20 Burner Assembly
22 Burner
26 Combustion Chamber Insulation
27 Copper Heat Exchanger
28 Exhaust Manifold
29 Exhaust Outlet Manifold
32 Heating circulating pump
36 Automatic Air Vent
39 DHW Flow Regulator
42 DHW Temperature Sensor
44 Gas Valve
81 Ignition and Detection Electrode
95 3 Way Diverter Valve
114 Water Pressure Switch
136 Flow Meter
194 DHW Flate Plate Heat Exchanger
278 Double Sensor - High Limit NTC
297 Air Pressure Switch
364 Condensate Union
Description
Unit Weight - 74 LBS (33.5 kg)
Shipping Weight - ~ 78 LBS (35.5 kg)
7
3 - GENERAL VIEW AND MAIN COMPONENTS
WARNING
!
Fire, explosion, asphyxiation and electrical
shock hazard. Disconnect electrical power
supply and turn off gas at shutoff valve before
attemting to remove boiler jacket. Failure to
follow these instructions could result in death
or serious injury.
Remove Boiler Jacket
1.
Unscrew screws (A).
2.
Pivot jacket upwards. See fi gure 3.
3.
Raise Jacket up and off boiler. See fi gure 4.
Figure 3 - Jacket Removal - Screw
Locations
Figure 4 - Pivot Jacket and Raise to Remove
3
2
A
A
1
8
4 - LOCATING BOILER
4.1 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
Figure 5 - Boiler Clearances
prevent freezing.
• Approved for installation in closets.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, control replacement,
etc.).
• Wall mount only.
• Access to outdoors to meet minimum and maximum
pipe lengths for combustion air and vent piping. 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 fi gure 5.
• The boiler must not be installed on carpeting.
BC
F
Boiler
(Front View)
F
FLOOR
A
Boiler
D
(Side View)
Front
F
TABLE 1: BOILER CLEARANCES
Dimension
Top (A)
Left Side (B))
Right Side (C)
Front (D)
Back (E)
Bottom (F)
Combustion Air/piping
Vent piping
(1)
Required distances measured from boiler jacket.
(2)
Service, proper operation clearance recommendation.
Combustible
Materials
(1)
16” (41cm) 16" (41cm)
0" (0 cm) 1” (3 cm)
0" (0 cm) 1” (3 cm)
0" (0 cm) 1" 3 cm)
0" (0 cm) 0” (0 cm)
0" (0 cm) 12" (30 cm)
0" (0 cm) 3/8" (1 cm)
6" (15 cm) 6" (15 cm)
Service
(1)(2)
9
4 - LOCATING BOILER
!
4.2 Pre-pipe supply and return water connections
with factory fi ttings before wall mounting.
4.3 Wall Mounting
Mount boiler on wall using wall mounting bracket included
with unit.
• Structure must be capable of supporting boiler weight
plus 60 lbs (28 kg). See page 7.
• Wall mount bracket has 2 slots, spaced at
(23.5cm) on center
• Attach wall mount bracket level on wall.
• Boiler must engage with wall mount bracket. See fi gure 6.
Boiler weight exceeds 75 pounds (34 kg). Do not
lift boiler onto wall without assistance.
.
!
CAUTION
9¼”
NOTICE
Lift boiler using chassis. Using front jacket, vent
piping, water or gas fi ttings to lift boiler may cause
damage to the boiler.
Figure 6 - Wall Mounting Bracket
2⅜”
(2.4cm)
9¼” (23.5cm)
2⅜”
(2.4cm)
10
5 - HYDRONIC PIPING
5.1 General
• Install piping in accordance with authority having jurisdiction.
NOTICE
Use two (2) wrenches when tightening and fi tting
pipe to boiler's threaded fi ttings. Boiler's internal
piping can be damaged if subjected to excessive
torque.
• Support system piping and safety relief valve discharge
piping. Boiler's internal piping and wall mount bracket
can be damaged if subjected to excessive weight.
• Size central heating pump (and domestic hot water
pump, if used) for system requirements only. Internal
heat exchanger pump compensates for pressure drop
through boiler internal piping and heat exchanger.
• Thoroughly clean and fl ush system before connecting to boiler.
• If oil is present in system water, use approved detergent to
wash system.
• Flush system to remove any solid objects such as metal chips,
fi bers, or Tefl on tape, etc.
5.2 Water System Characteristics
• Water in the heating system must have protection of
metallic materials against corrosion.
• Filling water and subsequent replenishing, must be
clear, with hardness under 150 ppm CaCO3,
A. treated with approved conditioning chemicals
to ensure prevention of corrosion and attack on
metals and plastics, that gases do not form,
B. and bacterial or microbial masses do not proliferate
in low temperature systems.
• Hardness exceeding 150 ppm CaCO3, appropriate water
softening treatment and/or use of suitable anti-fouling
agents must be provided.
Water contained in the system must be checked at least
yearly and have:
A. pH above 7 and under 8.5 (under 8 with presence
of components in aluminum or light alloys),
B. iron content (Fe) less than 0.5 mg/l,
C. copper content (Cu) less than 0.1 mg/l,
D. total content of chlorides, nitrates and sulfates less
than 50mg/l,
E. must contain conditioning chemicals in
concentration suffi cient to protect system for a
year.
There must be no microbial or bacterial loads in low
temperature systems.
Conditioners, additives, inhibitors and anti-freeze fl uids can
be used only if manufacturer guarantees they are suitable
for use in heating systems and they do not cause damage
to heat exchanger or other components and/or materials of
boiler and system.
Use of generic chemicals not specifi cally suitable for use in
heating systems and/or incompatible with boiler materials
and system is forbidden.
Conditioning chemicals must ensure complete deoxygenation
of water and contain specifi c protective agents for yellow
metals (copper and its alloys), anti-fouling agents for
limescale at least up to 150 ppm CaCO3, pH neutral
stabilizers and, in low temperature systems, specifi c biocides
for use in heating systems.
In systems with continuous intake of oxygen (e.g. fl oor
systems without anti-diffusion pipes, open expansion
vessels), or intermittent (e.g. in case of frequent
replenishing), a separator must be provided. Regarding
domestic hot water (DHW), no type of treatment which
could prevent its possible food use can be provided for.
• Poison hazard. Ethylene glycol is toxic. Do not
• Never use automotive or standard glycol antifreeze,
• Ethylene glycol can attack gaskets and seals used
• Use only inhibited propylene glycol solutions
• Thoroughly clean and fl ush any system that used
• Provide user with Material Safety Data Sheet
Do not expose boiler to freezing temperatures.
5.3 Special Conditions
• System piping exposed to freezing conditions: Use
• Boiler installed above radiation level (or as required by
• Boiler used in connection with refrigeration system.
• System piping connected to heating coils located in air
WARNING
!
use ethylene glycol.
even ethylene glycol made for hydronic systems.
in hydronic systems.
certifi ed by fl uid manufacturer as acceptable for
use with closed water heating system.
glycol before installing new Boiler.
(MSDS) on fl uid used.
NOTICE
inhibited propylene glycol solutions certifi ed by fl uid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
authority having jurisdiction) shall have low water cutoff
protection.
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
handling unit exposed to refrigerated air circulation. Install
fl ow control valves or other automatic means to prevent
gravity circulation of boiler water during cooling cycle
.
11
5 - HYDRONIC PIPING
!
WARNING
Burn and Scald Hazard. Safety relief vlave
could discharge steam or hot water during
operation. Install discharge piping per these
instructions. Failure to do so could result in
death or serious injury.
5.4 Safety Relief Valve
NOTICE
Boiler rated at 43.5 psig (.30MPa) maximum allowable
working pressure. Boiler provided with 30 psig
(.21MPa) safety relief valve.
• Install safety relief valve using pipe fi ttings provided with
boiler. See fi gure 7.
• Install safety relief valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety
relief valve.
• Install discharge piping from safety relief valve. See
fi gure 8.
• Use ¾” or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
Figure 7 - Safety Relief Valve & Air Vent
(Viewed from front of boiler)
1” MPT
Coupling 1” NPT
Safety Relief
Valve
Street Elbow ¾”
Nipple 1” x 5”
Tee 1” x 1” x ¾”
• Terminate pipe with plain end (not threaded).
12
5 - HYDRONIC PIPING
Figure 8 - Safety Relief Valve Discharge
Piping
Safety Relief
Valve
Check Local Codes
for Maximum
Distance to Floor
Gas Shutoff
Valve
in Open
position
13
Figure 9 - Hydronic Piping
278
27
95
5 - HYDRONIC PIPING
114
36
241
42
8 Domestic Hot Water Outlet
9 Domestic Cold Water Inlet
10 Heating System Supply
11 Heating System Return
27 Copper Exchanger For Heating And Hot Water
32 Heating Circulating Pump
36 Automatic Air Vent
42 DHW Temperature Sensor
95 Diverter Valve
114 Water Pressure Switch
136 Flow Meter
241 Automatic Bypass
278 Double Sensor (Safety + Heating)
9
- Plumbing circuit
32
136
1110 8
14
6 - COMBUSTION AIR AND VENT PIPING - CATEGORY I (CHIMNEY VENT)
WARNING
!
Boiler and venting installations shall be performed
by a qualifi ed expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to fi re or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
!
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
6.1 Check Your Chimney
Chimney must be clean, right size, properly constructed
and in GOOD CONDITION.
1.
Installation must conform to requirements of the
authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
2.
Increaser fi tting is required on this boiler for Category I
venting, and 4” is minimum permissible vent diameter.
This does not imply vent connector is intended to be 4”
diameter pipe. Vent connector shall be sized according
to appropriate venting tables in the National Fuel
Gas Code and may be required to be larger than 4”
diameter.
5.
Vent connector from boiler to chimney should run as
directly as possible with as few elbows as possible.
6.
Common venting shall not be allowed. Boiler and
other certifi ed appliances. appliances can share same
chimney vent. Consult appropriate Vent Sizing Tables
in National Fuel Gas Code for specifi c requirements of
multiple appliance venting.
7.
Boiler is only appliance connected to vent, Type B vent
pipe is recommended for vent connector.
8.
Slope pipe up from boiler to chimney not less than 1/4”
per foot (21mm/m).
9.
End of vent pipe must be fl ush with inside face of
chimney fl ue. Use sealed-in thimble for chimney
connection.
10.
Fasten sections of vent pipe with sheet metal screws to
make piping rigid. Use stovepipe wires to support pipe
from above.
11.
Do not connect to fi replace fl ue.
12.
Do not install damper on this boiler.
Figure 10 - Combustion Air Fitting
3
3
NOTICE
Boiler installation for chimney venting is not
complete unless increaser fi tting is located and
secured.
3.
Venting into masonry chimney without liner, line
chimney from top to bottom with either:
A. Listed Type B vent pipe
B. Listed fl exible vent liner
C. Poured ceramic liner.
4.
Outside chimneys should not be used unless they are
(choose one of the following):
A. Enclosed in a chase
B. Lined with Type B vent pipe
C. Use listed fl exible vent liner
D. Use certifi ed chimney lining system
Horizontal Venting requires fi eld supplied appliance adapter
for the boiler fl ue outlet.
Boiler is provided with a 3” vent connection, 3” x 4”
increaser must be fi eld sourced for chimney application.
This does not mean that the connection to the chimney will
always be 4”.
15
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