Dunkirk CCB-150 User Manual

Model

CCB-150

COMBI

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

cod. 3541F060

Manufacturedfor:

ECRInternational,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

6 - COMBUSTION AIR AND VENT PIPING- CATEGORY I (CHIMNEY VENT)

6.2 Minimum Vent Pipe Clearance

• Use Type B vent pipe through crawl space. Where vent
pipe passes through combustible wall or partition, use
ventilated metal thimble. Thimble should be 4 inches
larger in diameter than vent pipe.

• Boiler installed with single wall vent, must have 6”
clearance between its surface and any combustible
material. New Type B gas vent or fl exible liner must be
installed in accordance with instructions furnished with
vent. Maintain clearances as specifi ed for vent pipe.

• Verify vent pipe is fi re-stopped where it goes through
fl oor or ceiling. It should have approved vent cap with
clearances from roof. If clearances are less than shown,
have vent checked by local authorities. Figure 12, Page

20.

• Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.

7.

8.

9.

6.3 Removing Existing Boiler From Common

Venting System

When an existing boiler is removed from a common
venting system, common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it.

1.

At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliance
remaining connected to the common venting system
are not in operation.

2.

Seal any unused openings in the common venting
system.

3.

Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.

4.

Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fi replace dampers.

5.

Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.

6.4 Modulating Fan

6.5 Venting Materials

Table 2 - Combustion Air and Vent Pipe Fittings
Category I (Chimney Vent)

After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fi replace dampers and
any other gas-burning appliance to their previous
conditions of use.

Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1. When re-sizing any portion of the
common venting system, the common venting system
should be re-sized to approach the minimum size
determined using the appropriate tables in Chapter 13
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1.

It is recommended that existing gas vents be checked
to be sure they meet local codes.

• Unit is equipped with an advanced combustion air, vent
fl ow control system, with modulating fan and pressure
sensor.

• Unit automatically adapts its operation to fl ue type
and length, without requiring adjustments during
installation or use of baffl es in combustion circuit.

• Unit consistantly and automatically regulates
combustion air and vent fl ow according to change in
thermal load. Combustion and heat exchange occur in
optimum conditions. Unit’s thermal effi ciency remains
high throughout its power range.

• See Table 2

Item Material Standards

Type B Vent UL 441, ULC S605

Vent Pipe & Fittings

Combustion Air

Masonry Chimney

- must conform to
proper sizing and

materials

Stainelss Steel,

PVC, CPVC, PP,

Aluminum

National Fuel Gas

Code, ANSI Z223.1/

NFPA 54

ANSI/ASTM D2564,

ANSI/ASTM F493,

UL 1738/ULC636-08

6.

Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use fl ame of a
match or candle, or smoke from a cigarette, cigar, or
pipe.

16

6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III

Induced Draft Boilers

Horizontal (Category III) venting systems installation
shall conform to the requirements of the authority having
jurisdiction or, in the 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

1.

Boilers may be vented horizontally. Vent pipe is pitched
down from boiler to vent termination. Do not connect
other appliances to this vent.

2.

Vent Pipe Material UL Listed - AL294C Stainless Steel
vent pipe and fi ttings.

3.

Clearance to Combustible Materials: For stainless steel
vent pipe maintain 6” minimum air space clearance to
combustible materials.

4.

Vent Pipe Size: 3” vent pipe connected directly to the
outlet of the induced draft blower.

5.

Vent Pipe Length:
A. For stainless steel vent pipe, the maximum

horizontal vent length is 65 equivalent feet.

B. Minimum horizontal vent length is 5 equivalent

feet.

C. For 3” 90° elbows = 5 equivalent feet of vent

length.

6.

Vent Termination Fitting: For all vent pipe materials,
you may use either:

A. 90° elbow pointing down, fi tted with a minimum

1/4” mesh screen to keep out rodents and birds.
The elbow shall be of the same material and size
as vent pipe. The elbow exit should be at least 6”
away from exterior wall.

-or­B. Concentric side wall vent hood.

7.

Vent Pipe Termination Location :
A. When venting through combustible walls,

combustible clearances must be considered. ECR
vent termination, 5612601, is a certifi ed direct vent
termination (for Catagory III venting) providing
both the outside vent termination and a double
wall pipe for passing through a combustible
wall up to 10” thick. Vent terminations by other
manufacturers may also be used as long as they
are certifi ed for catagory III venting.

B. If the 90° elbow is the termination fi tting of choice,

then the single wall pipe will be passing through the
side wall. For combustible walls, a UL listed thimble
shall be used where the single wall pipe passes
through the wall.

C. For single wall pipe through non-combustible

walls, the hole through the wall need only be large
enough to maintain the pitch of the vent pipe, and
provide proper sealing. A thimble is not required for
single wall pipe passing through non-combustible
walls.

8.

9.

17

D. The venting system shall terminate at least 3 feet

0.9m) above any forced air inlet located within
10 feet (3m). The venting system shall terminate
at least 4 feet (1.2m) below, 4 feet (1.2m)
horizontally from, or 1 foot (300 mm) above any
door, window, or gravity air inlet into any building.
The bottom of the vent shall be located at least 12
inches (300mm) above grade. Termination of the
vent shall be not less than 7 feet (2.13m) above
adjacent public walkway. The vent terminal shall
not be installed closer than 3 feet (0.9m) from the
inside corner of an L shaped structure. Termination
of the vent should be kept at least 3 feet (0.9m)
away from vegetation. The venting system shall
terminate at least 4 feet horizontally from, and in
no case above or below, unless a 4 foot horizontal
distance is maintained, from electric meters, gas
meters, regulators, and relief equipment.

• The venting system shall terminate at least 4 feet
below any eave, soffi t, or roof overhang.

• The venting system shall not terminate
underneath any deck, patio, or similar structure.

• Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to prevent
accidental contact with people or pets.

• Terminate the vent above normal snow-line. Avoid
locations where snow may drift and block the
vent. Ice or snow may cause the boiler to shut
down if the vent becomes obstructed.

• Under certain conditions, fl ue gas will condense,
forming moisture. In such cases, steps should be
taken to prevent building materials at the vent
terminal from being damaged by exhaust of fl ue
gas.

United States - Terminate vent system at least
4 feet (1.22m) horizontally from, and in no case
above or below, unless a 4 feet (1.22m) horizontal
distance is maintained, from electric meters, gas
meters, regulators and relief equipment.

Canada - Terminate vent system at least 6 feet
(1.83 m) horizontally from, and in no case above
or below, unless a 6 feet (1.83m) horizontal
distance is maintained, from electric meters, gas
meters, regulators and relief equipment.

Joining and Sealing the Vent Pipe: The vent pipe needs
to be both watertight and gas tight. Seal all joints and
seams following vent pipe manufacture’s installation
instructions.

Support Spacing: Do not restrict thermal expansion
movement of the vent. The vent pipe must expand
and contract freely with temperature change. Each run
of vent piping shall be supported following vent pipe
manufacture’s instructions.

6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III

10.

If the horizontal vent must go through a crawl space or
other unheated space, the cool temperatures will likely
cause the fl ue gases to continuously condense inside
the vent pipe. Do not insulate the vent pipe. It must be
visible for monthly inspection. Insure that the vent pipe
is properly pitched away from the boiler, with no low
spots, so that condensate in the vent will drain away
from the boiler. An insulated enclosure or chase, with
access for inspection and servicing of the vent, may
be required to prevent freezing of liquid condensate.
Consult the vent pipe manufacturer’s instructions for
specifi c guidelines.

11.

At beginning of each heating season and monthly
during the heating season, check all vent pipes and
vent terminal to make sure there are no obstructions.
Periodically clean the screen in the vent terminal.

Table 3 - Combustion Air and Vent Pipe Fittings

!

WARNING

Vent extending through exterior wall shall not
terminate adjacent to wall or below building
extensions such as eaves, balconies, parapets or
decks. Failure to comply could result in death or
serious injury.

Type Item Diameter Min Lenght Max Lenght Material Standards

Vent 3” 5 ft 65 ft

Direct vent

Air intake 3” 5 ft 65 ft

Category III Vent 3” 5 ft 65 ft

AL294C Stainless

Steel, Aluminum

Stainelss Steel,

PVC, CPVC, PP,

Aluminum

AL294C Stainless

Steel, Aluminum

UL1738,

ULC S636

ANSI/ASTM

D2564, ANSI/

ASTM F493, UL

1738/ULC636-08

UL1738,

ULC S636

Equivalent Length of Venting Components:

5 ft. equivalent for a 3” 90° elbow.
2 1/2 ft. equivalent for a 3” 45° elbow.

18

6 - COMBUSTION AIR AND VENTILATION

Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation
Code, CAN/CSA B149.1, or applicable provisions of local
building codes.

Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.

National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.

• Engineered Installations. Must be approved by
authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all
appliances in space. Use a different method if minimum
volume not available.

◊ Standard Method. Cannot be used if known air

infi ltration rate is less than 0.40 air changes per
hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

◊ Known Air Infi ltration Rate. See Table 3 for space

with boiler only. Use equation for multiple appliances.
Do not use an air infi ltration rate (ACH) greater than

0.60.

Volume ≥ 15 ft3/ACH x Total Input [Mbh]

◊ Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.

◊ Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second
opening commencing within 12 inches of bottom
enclosure.

 Direct communication with outdoors or

communicating through vertical ducts. Provide
minimum free area of 1 in 2 per 4 Mbh of total
input rating of all appliances in enclosure.

 Communicating through horizontal ducts. Provide

minimum free area of 1 in2 per 2 Mbh of total input
rating of all appliances in enclosure.

◊ One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides
and back and 6 inches on front of boiler (does not
supersede clearance to combustible materials).

◊ Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements
for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer toNational
Fuel Gas Code for application information. National Gas
and Propane Installation Code Requires providing air
supply in accordance with:

• Section 8.2 and 8.3 when combination of applianceshas
a total input of up to and including 400 Mbh (120kW).

 Does not have draft control device.

• Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code
for specifi c air supply requirements for enclosure or
structure where boiler is installed, including air supply
openings and ducts.

Table 4 - Air Infi ltration

Input Mbh

150 7500 22,500 11,250 7,500 5,625 4,500 3,750

Standard

Method

Known Air Infi ltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 .05 0.6

19

6 - COMBUSTION AIR AND VENT PIPING

Figure 11 - Horizontal Venting Clearances

Figure 12 - Two Pipe Venting

( = Combustion Air / = Venting)

NOTICE

Maintain 12” (30cm) US, 18” (46cm) Canada
clearance above highest anticipated snow level
or grade.

20

6 - COMBUSTION AIR AND VENT PIPING

Figure 13 - Chimney Venting with Room Air

Single Wall

( = Combustion Air / = Venting)

NOTICE

Refer to section 6.1, numbers 3 through 12,
page 15 of this manual for proper installation.

Figure 14 - Chimney Venting with Outside Air

Single Wall

( = Combustion Air / = Venting)

DIRECT VENT BOILER - Boiler constructed and installed
so all combustion air is derived directly from outdoors and
all vent gases are discharged to outdoors. See Figure 14.

21

7 - GAS SUPPLY PIPING

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use
any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the fi re
department.

7.1 General

• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:

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

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

• Size and install gas piping system to provide suffi cient
gas supply to meet maximum input at not less than
minimum supply pressure. See Table 5.

• Support piping with hooks straps, bands, brackets,
hangers, or building structure components to prevent or
dampen excessive vibrations and prevent strain on gas
connection. Boiler will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for
liquefi ed petroleum gas.

• Provide sediment trap up stream of gas valve.

• Install manual main shutoff valve outside of jacket. See
fi gure 16.

Figure 15 Manual Main Gas Shutoff Valve

Outside Boiler Jacket

With Manufacturer Suggested Piping With Drip Leg

Gas

Connection

Nipple

¾” x 3” NPT

Tee ¾” NPT

¾” Gas
Shutoff

Valve in ON

Postion

Nipple ¾ x

3” NPT

¾” Pipe Cap

Nipple

¾ x 3”

NPT

7.2 Conversion To LP

Refer to Gas Conversion Kit Instructions.

DANGER

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.

7.3

Leak Check Gas Piping

Pressure test boiler and gas connection before placing
boiler in operation.

• Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas
supply system.

• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve. See fi gure 16.

• Locate leakage using gas detector, noncorrosive
detection fl uid, or other leak detection method
acceptable to authority having jurisdiction. Do not use
matches, candles, open fl ames, or other methods that
can provide ignition source.

• Correct leaks immediately and retest.

Manufacturer suggested gas piping with drip leg.

Table 5 - Gas Supply Pressure

Gas Supply Pressure

Natural Gas

Min. Max.

3.5" w.c.

(0.7 kPa)

14" w.c. (3.3

22

kPa)

8 - ELECTRICAL CONNECTIONS

!

WARNING

Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.

8.1 General

Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:

• USA- National Electrical Code, ANSI/NFPA 70.

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

8.2 Line Voltage Connections - Boiler

Provide individual 120V, 15 amp circuit (recommended)
with fused disconnect or service switch as required by
authority having jurisdiction.

8.3 Central Heating Thermostat

A. Use thermostat or boiler system control with

dry contacts rated 0.5 amps @ 120 VAC. Boiler
control does not provide 24 VAC power to central
heating thermostat. Do not use to power 24VAC
thermostat.

B. Locate and install thermostat per manufacturer's

instructions. Maximum wire length is 330 ft (100m)
for 22 ga. wire.

C. Connect wires to terminals 1 and 2 as shown in

fi gure 17. Wires are interchangeable.

Figure 16 - Terminal Block

2

1 - Thermostat or dry contacts

2 - 138 = Optional External Outdoor Reset Sensor

370 = Low Water Cutoff (LWCO) - fi eld source
Connections on 1 & 2 terminals are 120 Volts A/C.
Connections on 3 & 4 are dry contact only.

23

9 - START UP PROCEDURE

9.1 Fill Boiler With Water And Purge Air

NOTICE

To maintain boiler effi ciency and prevent boiling
inside the heat exchanger, fl ush entire heating
system until clean.

• Flush heating system, including all heating zones.

• Fill boiler with potable water.

• Fill boiler and system piping with water (or
antifreeze-water solution, if used). See antifreeze
information Section 5.3 page 11. Purge air from
boiler using air vent. Purge air from system piping.

• Inspect system piping and boiler connections.
Repair any leaks immediately.

• Activate all heating zones and calls for heat,
including CH calls and DHW calls (if available).

• Close manual gas shut off valve. Let system run for
30 minutes. When boiler goes into lockout, reset
boiler by pressing “Reset” button until boiler resets.

• Do not open gas shutoff valve until all air is purged
from system.

9.2 Boiler Start-up and Operational Test

1.

Verify air is purged from hydronic piping

2.

System test pumps - verify each pump is
operational

3.

Verify gas piping

• Confi rm pressure test. See section 7.3 page 20.

• Visually inspect piping to determine there are no
open fi ttings or ends, and all valves at unused
outlets are closed and plugged/capped.

• Purge air from piping

• Check piping and connections for leaks immediately
after gas is turned on. Shut off gas supply and
make necessary repairs if leaks found.

4.

Follow OPERATING INSTRUCTIONS to initiate boiler
operation. See section 10.

5.

Inspect combustion air and vent piping. Verify pipe
is not leaking and terminations are unobstructed and
vent gas discharge is not a nuisance or hazard.

6.

Verify boiler operates.

7.

Check control module operation.

8.

Check fi eld sourced limits, low water cutoffs, etc. per
manufacturer's instructions.

WARNING

Asphyxiation hazard. Carbon monoxide is odorless,
tasteless, clear colorless gas, which is highly toxic.
Carbon monoxide production shall not exceed
400ppm. Failure to follow these instructions could
result in death or serious injury.

WARNING

Asphyxiation hazard. Verify cap is fi rmly placed on
combustion analyzer port to prevent CO emission.
Failure to do so could result in death or serious
injury.

9.3 Burner Pressure Adjustment

Unit has fl ame modulation, with two fi xed pressure values:
minimum and maximum. See Sec. 12, page 34.

Connect pressure gauge to pressure point “B” downstream
of the gas valve.

1.

Remove protection cap “D”.

2.

Operate boiler in TEST mode.

3.

Adjust maximum pressure by turning screw “G”
clockwise ↷ to increase pressure and counter clockwise

↶ to decrease.

4.

Disconnect one of two connectors “C” from modulation
regulator “F” on the gas valve.

5.

Adjust minimum pressure by turning screw “E” clockwise

↷

to increase the pressure and counter clockwise ↶ to

decrease it.

6.

Turn burner on and off, verify minimum pressure
remains stable.

7.

Reconnect connector “C” detached from modulation
regulator “F” on the gas valve.

8.

Verify maximum pressure has not changed.

9.

Replace protection cap “D”.

10.

To end TEST mode, repeat activation sequence or wait
15 minutes.

9.4 To Enter Test Mode/Adjust Heating Power

Press CH+/- buttons at the same time for 5 seconds.

• 3 way valve is in CH position and burner is forced at
100%. Boiler automatically exits test mode after 15
minutes or to exit test mode manually press CH +/­buttons together for 5 seconds.

• With Ch +/- buttons you can adjust Max power from (0
to 100%)

9.5 Ignition Adjustment

To adjust ignition, switch boiler to TEST mode (See Start
up Procedure). Press DHW buttons to increase or decrease
power (min.= 00, max. = 60). Press RESET button within
5 seconds and ignition remains set. Exit TEST mode.

24

9 - START UP PROCEDURE

9.6 Check Combustion

Natural Gas

1. Measure input. English unitsTurn off gas to all other

appliances.

•

Activate some heating zones to dissipate heat.

•

Set boiler on high fi re.

•

Use ½, 1 or 2 cu ft dial on gas meter. Measure
time required for one or more complete
revolutions. Measure time for 1-2 minutes.

•

Calculate input.

Input (MBH) =

Example: Gas fl ow from
Meter = 2 cu ft
Measured time = 72 seconds

Rate (MBH) =

3600 x cu ft

seconds

3600 x 2 cu ft

= 100 MBH

72 seconds

Figure 17 - Test Ports

Vent Gases
Test Port

Combustion Air Test

Port

Table 11 - Combustion Table

Figure 18 - Gas Valve

Two sampling points are available at top of the boiler, one
for venting and the other for combustion air. To sample:
Open the air/vent outlet plug.
Insert probes all the way in.
Turn on TEST mode, wait 10 minutes for boiler to stabilize;
Take measurement.

E

G

A Pressure point upstream
B Pressure point downstream
C Modureg electrical connection
D Protection cap
E Minimum pressure adjustment
F Modureg
G Maximum pressure adjustment
I Gas valve electrical connection
N Compensation tube

Combustion Minimum/Maximum

Natural Gas

High Fire - CO2 at 100 (%) 7.3 - 7.8

Low Fire - CO2 at 33 (%) 3.0 - 5.0

N

N

C

D

F

C

D

B

I

A

25

10 - OPERATING INSTRUCTIONS

WARNING

If you do not follow these instructions
exactly, a fi re or explosion may result
causing property damage, personal injury
or loss of life.

• This appliance is equipped with an ignition device
which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area
for gas. Be sure to smell next to fl oor because
some gas is heavier than air and will settle to the
fl oor.

• Use only your hand to turn the gas shutoff
valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualifi ed
service technician. Force or attempted repair may
result in fi re or explosion.

• Do not use this appliance if any part has
been under water. Immediately call a qualifi ed

service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use
any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the fi re
department.

10.2 TO TURN OFF GAS TO APPLIANCE

• Set thermostat to lowest setting.

• Turn "OFF" all electric power to appliance if service is
to be performed.

• Turn gas shutoff valve handle to closed position.
Handle should be perpendicular to gas pipe.

Figure 19 Gas Shutoff Valve - Open Position

10.1 OPERATING INSTRUCTIONS

Stop! Read Safety information above.

• Set thermostat to lowest setting.

• Turn "OFF" all electrical power to appliance.

• This appliance is equipped with an ignition device which
automatically lights the burner. Do not try to light

burner by hand!

• Turn gas shutoff valve to closed position. Handle
should be perpendicular to gas pipe.

• Wait 5 minutes for any gas to clear. Smell for gas,
including near fl oor. If you smell gas, STOP! Follow
instructions on this page: “What To Do If You Smell
Gas.” If you do not smell gas, go to next step.

• Turn gas shutoff valve to open position. Handle
should be parallel to gas pipe.

• Turn "ON" electrical power to appliance.

• Set thermostat to desired setting.

• If the appliance will not operate, follow instructions TO
TURN OFF GAS TO APPLIANCE and call your service
technician or gas supplier.

OPEN

Figure 20 Gas Shutoff Valve - Closed Position

26

CLOSED

10 - OPERATING INSTRUCTIONS

10.3 Checks During Operation

• Check for leaks in piping systems. Correct immediately
if found.

• Check the effi ciency of the fl ue gases and combustion
air ducts while the boiler is working.

• Check water is circulating between boiler and systems.

• Verify the gas valve modulates correctly in both
heating and hot water production phases.

• Check proper ignition of the boiler by turning it on and
off with the room thermostat.

• Verify with no call for heating burner correctly ignites
on opening hot water tap. Check that during heating
operation, on opening hot water tap, heating circulator
stops and there is regular production of hot water.

• Check parameters are programmed correctly and
perform any required customization (compensation
curve, power, temperatures, etc.)

10.4 Control Panel

6

14

43

10.5 Indicator During Operation

Heating

Call for heat (generated by Room Thermostat) is indicated
by hot air fl ashing above radiator symbol on the control.

Hot water

Call for hot water (generated by drawing off hot tap water) is
indicated by hot water fl ashing under the tap on the control.

64

13

15

10

11

12

5

8

9

217

Key

1 = DHW temperature setting decrease button
2 = DHW temperature setting increase button
3 = Heating system temperature setting decrease button - CH
4 = Heating system temperature setting increase button - CH
5 = Display
6 = Summer/Winter mode selection - Reset button
7 =

Unit On/Off - Economy/Comfort mode selection button

8 = DHW symbol
9 = DHW mode
10 = Summer mode
11 = Multifunction - Temperature
12 = Eco (Economy) mode
13 = Heating
14 = Heating symbol
15 = Burner On and actual power
64 = C.H. temperature pressure gauges

10.6 Turning on and off

NO electrical power to the boiler

The antifreeze system does not work when power and/or
gas to the unit are turned off. To avoid damage caused by
freezing during long idle periods in winter, it is advisable to
drain all water from the boiler, DHW circuit and system; or
drain just the DHW circuit and add a suitable antifreeze to
the heating system. See Section 5.2 page 11.

27

10 - OPERATING INSTRUCTIONS

Boiler Ignition

Supply unit with electricity.

Boiler ignition

For 120 seconds display will show FH which identifi es the
air venting cycle for the heating system.
During the fi rst 5 seconds the display will show the
software release of the card also.

Open the gas valve before the boiler.
When FH vanishes, boiler is ready to automatically work
whenever hot tap water is drawn or room thermostat
requests heating.

Summer/Winter Switchover

Press the button for 2 seconds.

Display will activate Summer symbol (see item 10 on the
control panel display). Boiler will deliver tap water only.
Antifreeze system stays on.
To turn off Summer mode, press button again for 2
seconds.

Heating temperature setting

Use heating buttons (see items 3 and 4 on the control
panel display) to change the temperature from minimum of
86°F (30C) to a maximum of 185°F (85C); it is advisable to
not operate boiler below 113°F (45C).

Turning the boiler off

Press the button below (see item 7 on the control panel
display) for 5 seconds.

When the boiler is turned off, the electronic board is still
powered.
Domestic hot water and heating operation are disabled. The
antifreeze system remains activated.
To re-light the boiler, press the button (see item 7 on the
control panel display) again for 5 seconds.

Domestic hot water temperature adjustment

Operate DHW buttons (see items 1 and 2 on the control
panel display) to vary the temperature from a minimum of
50°F (40C) to a maximum of 149°F (55C)

Boiler will be immediately ready to operate whenever
domestic hot water is drawn or room thermostat demand.

28

10 - OPERATING INSTRUCTIONS

ECO/COMFORT selection

The unit has a function that ensures a high domestic
hot water delivery speed and maximum comfort for the
user. When the device is activated (COMFORT mode), the
water contained in the boiler remains hot, ensuring faster
availability of domestic hot water.
The device can be deactivated by the user (ECO mode)
by pressing the eco/comfort button (see item 7 on the
control panel display). To activate the COMFORT mode,
press the eco/comfort button (see item 7 on the control
panel display) again.

Outdoor temperature

• When the optional external probe is installed, the boiler
control system operates with “Sliding Temperature”.
In this mode, the temperature of the heating system is
controlled according to the outside weather conditions,
in order to ensure high comfort and energy saving
throughout the year. As the outside temperature
increases the system delivery temperature decreases
according to a specifi c “compensation curve”.

• With Outdoor Temperature adjustment, the temperature
set with the heating buttons (see items 3 and 4 on
the control panel display) becomes the maximum
system delivery temperature. It is advisable to set the
maximum value to allow system adjustment throughout
its useful working range.

• The boiler must be adjusted at the time of installation
by qualifi ed personnel. Adjustments can in any case be
made by the user to improve comfort.

29

10 - OPERATING INSTRUCTIONS

Compensation curve and curve offset

Press the button (see item 6 on the control panel display)
for 5 seconds once to display the actual compensation
curve, which can be modifi ed with the DHW buttons (see
items 1 and 2 on the control panel display).
Adjust the required curve from 1 to 10 according to the
characteristic.
By setting the curve to 0, sliding temperature adjustment is
disabled.

Compensation curve

|

|

|

|

|

|

|

|

|

|

|

|

|

Press the heating buttons (see items 3 and 4 on the control
panel display) to access parallel curve offset modifi able
with the DHW buttons (see items 1 and 2 on the control
panel display).

|

|

|

|

|

|

|

|

|

|

|

|

|

Parallel curve shift

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

|

30

10 - OPERATING INSTRUCTIONS

Example of parallel compensation curve shift

Press the button (see item 6 on control panel display) for 5
seconds again to exit parallel curve adjustment mode.
If the room temperature is lower lower than the required
value, it is advisable to set a higher order curve and vice
versa. Proceed by increasing or decreasing in steps of one
and check the result in the room.

Compensation curves

31

10 - OPERATING INSTRUCTIONS

Water system pressure adjustment

The fi lling pressure with system cold, read on the boiler
water gauge, must be approximately 11 psi.
If the system pressure falls to values below minimum, the
boiler control will activate fault F37.

Low system pressure fault

Once the system pressure is restored, the boiler will
activate the 120-second air venting cycle indicated on the
display by FH.

TEST mode (heating power = 100%)

Press heating buttons simultaneously for 5 seconds to
turn on TEST mode. The boiler will ignite at the maximum
heating power set as described in the following paragraph.
On the display, the heating and tap water symbols will
blink; alongside, it will show the heating power and the
ignition power respectively.

To turn off TEST mode, repeat the sequence for turning it
on.

32

11 - GENERAL MAINTENANCE AND CLEANING

11.1 Beginning of Each Heating Season

• Check boiler area is free from combustible materials,
gasoline, and other fl ammable vapors and liquids.

• Visually inspect combustion air and vent piping for
proper operation. Check for and remove any obstruction
to fl ow of combustion air or vent gases. Immediately
repair or replace pipe showing deterioration or leakage.
Reassemble per instructions in section 6. Ensure proper
reassembly and resealing of system.

• Test safety relief valve for proper operation. Refer to
valve manufacturer's instructions packaged with relief
valve.

• Examine fl ue passages in heat exchanger, burner and
cleaning (if necessary) by following instructions in
“Annual Inspection and Cleaning of Boiler Components” in
this section.

• Circulator pump and combustion air blower motor
furnished with boiler are permanently lubricated from
factory and require no further lubrication. Lubricate fi eld
sourced pumps and/or motors according to pump and/or
motor manufacturer’s instruction.

• Check following components are operating properly and
are free of blockages or obstructions:

• air vent;

• check air inlet for blockage and clean as required;

• check boiler for any sign of leaks.

• Check heating system expansion tank.

• Check the Air pressure tubing

11.2 Annual Shut Down Procedure

• Follow instructions “To Turn Off Gas To Appliance” unless
boiler is also used to supply domestic hot water. See
section 10, page 26.

• Drain system completely if system does not have
antifreeze when heating system is to remain out of
service during freezing weather.

!

WARNING

Following service procedures must be performed
by qualifi ed service agent. Boiler owner shall not
attempt these steps. Failure to do so could result in
death or serious injury.

11.3 Annual Inspection and Cleaning of Boiler

Components

• Burner and heat exchanger inspection and cleaning.

• Remove any remaining loosened sediment using shop
vacuum with snorkel attachment.

!

WARNING

“Caution: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.”
“Verify proper operation after servicing.”

33

12 - RATINGS AND CAPACITIES

34

Table 13 - Sea Level Ratings

12 - RATINGS AND CAPACITIES

SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Boiler Input Rate

Size

Maximum Minimum

CCB-150

(1)

1000 Btu/hr (British Thermal Units Per Hour)

(2)

Heating Capacity and AFUE (Annual Fuel Utilization Effi ciency) are based on DOE (Department of Energy) test

procedures.

(3)

Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for
installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems,
etc.

(MBH)

150 50 130 110 85.0

(1)

12.1 Ratings and Capacities

• Constructed and hydrostatically tested for maximum
allowable working pressure of 43.5 psig (pounds per

square inch gauge)
with ASME Boiler and Pressure Vessel Code, Section IV,
Rules for Construction of Heating Boilers.

• USA - Input rates are derated 4% for each 1000 ft (300m)
above sea level, beyond 2000 ft (600m).

• CANADA -

Ratings in table 13 used for elevations up to
2000 ft (600m) above sea level

- For elevations between 2000 ft (600m) and 4500
ft (1350m), derate 10% using high altitude kit.

- Contact Provincial authority having jurisdiction
for installations above 4500 feet (1350 m) above
sea level.

43.5 psig (.30MPa)

in accordance

Heating

Capacity

(MBH)

(1)(2)

Net AHRI

Rating, Water

(MBH)

(1)(3)

AFUE

(2)

35

Diagrams

Pressure - power diagrams

wc

6

12 - RATINGS AND CAPACITIES

5

4

3

2

1

0

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45

CCB 150

kW

A LPG
B NATURAL GAS

Losses of load / head of circulators

A Boiler losses of head
1 - 2 - 3 Circulator speed

20,00

18,00

16,00

14,00

12,00

10,00

8,00

6,00

Pump Head [feet w.c.]

4,00

2,00

0,00

0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0

Water Flow

3

2

1

[GPM]

36

13 - TROUBLE SHOOTING

Diagnostics

The boiler is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will fl ash indicating the
fault code.
There are faults that cause permanent shutdown (marked with the letter “A”): to restore operation just press the RESET
button (detail 6 - Section 10.4, Control, page 25) for 1 second or RESET on the optional remote timer control if installed;
if the boiler fails to start, it is necessary to fi rst eliminate the fault.
Other faults (marked with the letter “F”) cause temporary shutdowns that are automatically reset as soon as the value
returns within the boiler’s normal working range.

Table of faults

- List of faults

Fault

Fault Possible cause Cure

code

No gas

A01 No burner ignition

Flame present signal with burner

A02

off

Overtemperature protection

A03

activation

The air pressure transducer does

F05

not receive a suffi cient minimum
value within 25 seconds

A06 No fl ame after the ignition stage

F10 Delivery sensor 1 fault

F11 DHW sensor fault

F14 Delivery sensor 2 fault

A15 Air signal protection activation

F34 Supply voltage under 170V. Electric mains trouble Check the electrical system

F35 Faulty mains frequency Electric mains trouble Check the electrical system

F37 Incorrect system water pressure

F39 External probe fault

A41 Sensor positioning Delivery sensor detached from the pipe Check correct heating sensor positioning and operation

F42 Heating sensor fault Sensor damaged Replace the sensor

F43 Exchanger protection activation.

A44

DHW sensor disconnected Sensor disconnected

A48

Air signal protection activation Fault F05 for 150 seconds See Fault F05

F50 Modulation regulator fault Wiring disconnected Check the wiring

F51 Low water cutoff warning

Ignition/detection electrode fault

Faulty gas valve Check the gas valve and replace it is necessary

Ignition power too low Adjust the ignition power

Electrode fault Check the ionisation electrode wiring

Card fault Check the card

Heating sensor damaged Check correct heating sensor positioning and operation

No water circulation in the system Check the circulating pump

Air in the system Vent the system

Incorrect air pressure transducer wiring Check the wiring

Flue not correctly sized or obstructed Check the length of fl ue and that it is clean

Low pressure in the gas system Check the gas pressure
Burner minimum pressure setting Check the pressures

Sensor damaged

Wiring disconnected

Sensor damaged

Wiring disconnected

Sensor damaged

Wiring disconnected

Fault F05 generated 5 times in the last
15 minutes

Pressure too low Fill the system

Sensor damaged Check the sensor

Probe damaged or wiring short circuit Check the wiring or replace the sensor
Probe disconnected after activating the

sliding temperature

No system H

Air in the system Vent the system

Pressure too low Fill the system
Low water cutoff damaged Check the contact

O circulation Check the circulating pump

2

Check the regular gas fl ow to the boiler and that the air has
been eliminated from the pipes

Check the wiring of the electrode and that it is correctly
positioned and free of any deposits

Check the wiring or replace the sensorWiring shorted

Check the wiring or replace the sensorWiring shorted

Check the wiring or replace the sensorWiring shorted

See fault F05

Reconnect the external probe or disable the sliding
temperature

Check the correct positioning and operation of the DHW
sensor.

37

WIRING DIAGRAM

95

278

M

370

138

370 - Field Source LWCO

138 - Optional Outdoor Sensor

120Vac

3

T

°

T

°

56412

AUX

1

X2

LN

60Hz

L

N

1 4

X7

GND
+ 15V

297

OUT

GND
OUT
+5V

47

72

42

114

136

Important: Before connecting the room thermostat, remove the jumper on terminal block.

Key

16 Modulating fan
32 Heating circulating pump
42 DHW temperature sensor
44 Gas valve
47 Modulation Regulator
72 Room thermostat (fi eld sourced)
81 Ignition/detection electrode
95 Diverter valve

DBM34

81

1k

114 Water pressure switch
136 Flow meter
138 External probe (fi eld sourced)
278 Double sensor (Safety + Heating)
297 Air pressure transducer
370 LWCO - fi eld sourced (fi eld sourced)

44

16

32

38

39

REPAIR PARTS LIST

KEY Part Number Description Qty

A01 FE3980B990 CASING "CTR" 1

40

REPAIR PARTS LIST

KEY Part Number Description Qty

B01 FE3980C200 KIT CONTROL BOX 1

B02 FE3980B850 KIT CONTROL BOARD DBM34 2

B03 FE3980C210 KIT FRONT COVER "CTR" 1

B04 FE3980B840 KIT PRESS.TEMP. GAUGE 1

B05 FE3980C330 KIT WIRING 1

B06 FE3980C220 KIT MONO CABLE EL. 1

41

REPAIR PARTS LIST

42

REPAIR PARTS LIST

KEY Part Number Description Qty

C01 FE3980C000 KIT GASKETS SET 10

C02 FE3980C010 KIT 20 GASKET ORING 1

C03 FE3980C020 KIT 10 CLIP 10

C04 FE3980C030 MONO HEAT EXCHANGER 2

C05 FE3980C040 SENOR TEMP DP 1

C06 FE3980C340 SENFOR TEMP 14 1

C07 FE3980C350 5 FLOW CONTROLLER 1

C08 FE3980C360 KIT FLOWMETER ELTEK 1

C09

FE3980C370 x5 H2O FILTERS 5

C10 FE3980C410 KIT NPT ADAPTERS 1

C11 FEF3980B890 KIT PUMP FX3-FP 1

C12 FE3980C380 3-WAY VALVE 1

C13 FE3980C060 MOTOR 3-WAY VALVE 1

C14 FE3980B900 AIR SEPARATOR 1

C15 FE3980C070 WATER PRESSURE SWITCH 1

C16 FE3980B910 3/4" SAFETY VALVE 1

C17 FE3980C400 DHW R. PLATE CONNECTION 1

C18 FE3980C390 PLATE EXCHANGER 20P. 1

C19 FE3980C080 BYPASS VALVE x 10 N/R 1

P01 FE34226290 CH FLOW PIPE 1

P02 FE34202290 CH RETURN PIPE 1

P03 FE3841L390 DHW OUTLET PIPE 1

P04 FE3840V700 FLOW METER PIPE 1

P05 FE3841E380 BYPASS PIPE 1

43

REPAIR PARTS LIST

44

REPAIR PARTS LIST

KEY Part Number Description Qty

D01 FE3980B930 KIT GASKETS SET 1

D02 FE3980C090 PRESSURE TEST POINT "VENTURI" 1

D03 FE3980C100 FAN GASKET 1

D04 FE3980B940 FAN 2

D05 FE3980C110 COMBUSTION CHAMBER INSULATION 1

D06 FE3980C120 IGNITION ELECTRODE 1

D07 FE3980C130 BURNER 17 R.m. 1

D08 FE3980B960 GAS VALVE VGU 54S 2

D09 FE3980C140 17 INJECTOR 1.35mm NG 17

D10 FE3980C150 17 INJECTOR 0.85mm LP 17

D11 FE3980C160 KIT FLUE GASES OUTLET BEND 1

D12 FE3980C170 PRESSURE TRANSDUCER 1

D13 FE3980C180 CASING PLUGS KIT 1

D14 FE3980C190 COUPLING CONDENSATION 1

D15 FE3980B970 WALL MOUNT BRACKET 1

D16 FE3980B980 KIT VENT. ADAPTERS FM 1

D17 FE3980D800 KIT AIR PRESSURE TEST POINT US (35101150) 1

P06 FE3841L410 GAS PIPE 1

45

NOTES

46

NOTES

47

ECRInternational,Inc

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com