Dunkirk CHB-130 User Manual
Model
CHB-100
CHB-130
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION & MAINTENANCE MANUAL
cod. 3541F240
Manufacturedfor:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N# 240010633, Rev. B [07/17/2014]
Figure 1 - Overall Dimensions
DIMENSIONS
7 = Gas Inlet - 3/4” FPT
10 = System Delivery - 1” MPT
11 = System Return - 1” MPT
*209 = Hot Water Tank Delivery - 3/4” Capped
*210 = Hot Water Tank Return - 3/4” Capped
* BSPT To NPT Adapters Included
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
7 - Gas Supply Piping ......................................................................................................... 22
8 - Electrical Connections ................................................................................................... 23
9 - Start Up Procedure ....................................................................................................... 24
10 - Operating Instructions ................................................................................................. 26
11 - General Maintenance And Cleaning ................................................................................ 32
12 - Ratings And Capacities ................................................................................................ 33
13 - Trouble Shooting......................................................................................................... 36
Wiring diagram ............................................................................................................... 37
Repair Parts List - CHB-100 ............................................................................................. 38
Repair Parts List - CHB-130 ............................................................................................. 44
3
1 - INTRODUCTION
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Catagory I or III Venting.
• For use with natural gas or liquefi ed petroleum gases
(LP/propane). LP kit available.
• Indirect heating is acceptable.
• Boiler is arranged for connection to an external
storage tank for hot water production (optional).
All functions relevant to domestic hot water
production are only active with the optional water
tank sensor connected.
1.2 The unit MUST NOT:
•
Directly heat potable water.
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 185°F (85°C) system design temperature.
• Exceed 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
10 Supply System
11 System Return
16 Modulating Fan
19 Combustion Chamber
22 Burner
27 Copper Heat Exchanger
28 Exhaust Manifold
29 Exhaust Outlet Manifold
32 Heating circulating pump
36 Automatic Air Vent
44 Gas Valve
81 Ignition and Detection Electrode
95 3 Way Diverter Valve
114 Water Pressure Switch
209 Hot Water Tank Delivery
210 Hot Water Tank Return
278 Double Sensor - High Limit NTC
297 Air Pressure Switch
364 Condensation Coupling
Description
Unit Weight
Shipping Weight
LBS Kg
CHB 100 61 27.5
CHB 130 65 29.5
CHB 100 65 29.5
CHB 130 69 31.5
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 1 and fi gure 5.
• The boiler must not be installed on carpeting.
A
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.
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
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.
• 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.
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.
11
5 - HYDRONIC PIPING
• System piping connected to heating coils located in air
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
.
Figure 7 - Indirect Tank Performance Chart
5.4 Storage Tank Connection For Domestic Hot
Water Production
• Unit’s electronic board is arranged for managing an
external storage tank for domestic hot water production.
• See fi gure 10 for hydronic plumbing.
• Make electrical connections as shown on wiring diagram
page 36.
• Boiler’s control system recognizes presence of hot water
tank probe and automatically confi gures DHW function,
activating display and controls.
• Match Indirect tank heat exchanger and boiler capacity.
• Indirect tank requires dedicated pump. See fi gure 7 and
indirect tank specifi cation to determine pump.
• Incorrect tank size or insuffi cient fl ow may result in:
F. Unsatisfactory indirect tank performance.
G. Boiler short cycling
H. Extended DHW calls resulting in delayed response
to CH calls.
!
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.
5.5 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 8.
• 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 9.
• 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.
Figure 8 - Safety Relief Valve & Air Vent
(Viewed from front of boiler)
1” MPT
Coupling 1” NPT
Safety Relief
Valve
Nipple 1” x 5”
Tee 1” x 1” x ¾”
Street Elbow ¾”
12
5 - HYDRONIC 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).
• Terminate pipe with plain end (not threaded).
Figure 9 - Safety Relief Valve Discharge
Safety Relief
Valve
Piping
Check Local Codes
for Maximum
Distance to Floor
Gas Shutoff
Valve
in Open
position
13
Figure 10 - Hydronic Piping
5 - HYDRONIC PIPING
8 Domestic Hot Water Outlet
9 Domestic Cold Water Inlet
10 Heating System Supply
11 Heating System Return
95 Diverter Valve
209 Hot Water Tank Delivery
210 Hot Water Tank Return
14
6 - COMBUSTION AIR AND VENT PIPING - CATEGORY I (CHIMNEY VENT)
WARNING
!
Boiler and venting installations shall be performed
by a qualifi ed service agent 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.
7.
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.
8.
Boiler is only appliance connected to vent, Type B vent
pipe is recommended for vent connector.
9.
Slope pipe up from boiler to chimney not less than 1/4”
per foot (21mm/m).
10.
End of vent pipe must be fl ush with inside face of
chimney fl ue. Use sealed-in thimble for chimney
connection.
11.
Fasten sections of vent pipe with sheet metal screws to
make piping rigid. Use stovepipe wires to support pipe
from above.
12.
Do not connect to fi replace fl ue.
13.
Do not install damper on this boiler.
Figure 11 - Combustion Air Fitting
3
3
NOTICE
Boiler installation for chimney venting is not
complete unless increaser fi tting is located and
secured.
3.
These are Category I and Category III high effi ciency
boilers with lower stack or exhaust temperature.
4.
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.
5.
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
6.
Vent connector from boiler to chimney should run as
directly as possible with as few elbows as possible.
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 13, 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.
6.
7.
8.
6.3 Removing Existing Boiler From Common
Venting System
9.
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
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.
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 3
Table 3 - Combustion Air and Vent Pipe Fittings
Category I (Chimney Vent)
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
16
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