ECR 97gb 075, 97gb 100 Installation, Operation And Maintanance Manual

DIMENSIONS

FIGURE 1-1 Dimensions

(D)

(D)

Floor

(B)

(F)

Wall Hanging

Vent Connection

Supply Water

(E)

Gas

Connection

(G)

Bracket

(D)

Combustion Air

Return Water

(E)

User Interface

(A)

(B)

Size

075

100

Width

(A)

22-1/16"

(560mm)

22-1/16"

(560mm)

Height

(B)

35-5/8"

(905mm)

35-5/8"

(905mm)

Alternate Gas

Connection

(F)

Alternate

Supply Water

(E)

Table 1 : Physical Data

Depth

(C)

16-3/16"

(411mm)

16-3/16"

(411mm)

Bracket

27-1/2"

(969mm)

27-1/2"

(969mm)

(D)

(C)

Return Water

Water Connections

Size (E) Height (F)

1-1/4"

NPT

1-1/4"

NPT

38"

(965mm)

38"

(965mm)

Alternate

(E)

Gas

Connection

(G)

1/2" NPT

1/2" NPT

Weight

Shipping Unit

140 lb

(63.5 kg)

140 lb

(63.5kg)

115 lb

(51.2 kg)

115 lb

(51.2 kg)

2

1 - TABLE OF CONTENTS

1 - Introduction ............................................................................................................................... 4

2 - Important safety Information ....................................................................................................5

3 - Component Listing .....................................................................................................................6

4 - Locating Boiler ......................................................................................................................... 10

5 - Hydronic Piping ........................................................................................................................12

5.2 Special Conditions ................................................................................................................... 12

5.3 Safety Relief Valve and Air Vent........................................................................................... 12

5.4 Trim Piping ............................................................................................................................. 13

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

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

6.2 Removal of Existing Boiler From Common Vent System.................................................................18

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

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

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

6.6 Condensate Piping ................................................................................................................... 24

7 - Gas Supply Piping ....................................................................................................................25

8 - Electrical Connections .............................................................................................................. 27

8.2 Line Voltage Connections .......................................................................................................... 27

8.3 Low Voltage Connections .......................................................................................................... 27

9 - Start Up Procedure ................................................................................................................... 29

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

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

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

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

15 - Wiring Diagram ......................................................................................................................56

16 - Glossary .................................................................................................................................58

Appendix A - Control Module .........................................................................................................59

1.1 Introduction ............................................................................................................................ 59

1.2 Operation ................................................................................................................................59

1.3 Status Indication ...................................................................................................................... 59

1.4 Sequence of Operation .............................................................................................................. 60

1.5 Theory of Operation ................................................................................................................. 62

3

1 - INTRODUCTION

1.1 Designated Use

Hot water heating boiler.•
Indoor installations.•
Closet or alcove installation.•
Direct vent boiler.•
For use with natural gas or liquefi ed petroleum gases •

(LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).

Exceed 50 psig (344 kPa) system pressure.•
Exceed 200°F (93°C) system design temperature.•

1.3 Operational Features

Modulating: 20-100%.•
Integral Dual Limit.•
Integral Low Water Cutoff.•
Outdoor Temperature Reset.•
Integral Multiple Boiler Control.•

Auto Low Voltage or Intermittent Power Reset.•

4

!

This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.

2.2

Become familiar with symbols identifying

potential hazards.

2 - Important safety Information

2.1 General

Boiler installation shall be completed by qualifi ed agency.
See glossary for additional information.

WARNING

!

Fire, explosion, asphyxiate and electrical shock
hazard. Improper installation could 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 avoided,
WILL result in death or serious injury

!

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.

Installation shall conform to requirements

2.3

of authority having jurisdiction or in absence of
such requirements:

United States

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

National Electrical Code, NFPA 70.•

Canada •

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

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

.

2.4 Where required by authority having

jurisdiction, installation shall conform to
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be re­quired.

2.5 Requirements for Commonwealth of
Massachusetts:

Boiler installation must conform to state code 248 CMR
which includes but is not limited to:

Installation by licensed plumber or gas fi tter.•
Carbon monoxide detectors with side wall horizontally •

vented gas-fuel equipment in residential dwelling,
building or structure.

NOTICE

Used to address practices not related to personal
injury.

5

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

(see pages 7 & 8)

-

Connections supplied to con-

nection top and/or bottom of boiler.

Low Voltage Terminal Strip

(see pages 7 & 8)

- Connection of all low voltage wiring, including
thermostat. See section

8.

Heat Exchanger Pump Pump

Gas Shutoff Valve

- Fuel supply isolation

during servicing. See section 7

Combustion Air Blower

- Delivers
proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
for combustion.

Gas (Control) Valve

- Delivers
proper quantity of fuel to Combustion Air Blower.
See section 7.

High Temperature Supply Switch

Low Water Cutoff

Senses inadequate
quantity of water. Turns off boiler before damage can
occur.

8

Gas Connection

- Gas supply may be
piped either through top or bottom of boiler. See
section 7.

Control Module

3 - COMPONENT LISTING

3.1 COMPONENT LISTING

User Interface

1.

tion regarding boiler condition. Allows adjustment of
boiler operating parameters. NOTE: Does not replace
thermostat used to control central heating space.

2.

Combustion Air Inlet (2" PVC)

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

3.

NPT

(see pages 7 & 8)

nection top and/or bottom of boiler.

Low Voltage Terminal Strip

4.

- Connection of all low voltage wiring, including
thermostat. See section

Igniter

5.

Flame Sensor

6.

Sight Glass

7.

burner fl ame.

Burner

8.

(see page 8)

(see page 8)

(see Page 8) - Displays informa-

(see page 7 & 8)

-

Connections supplied to con-

(see pages 7 & 8)

8.

(see page 8)

(see page 8) - Permits observation of

Gas (Control) Valve

20.

proper quantity of fuel to Combustion Air Blower.
See section 7.

High Temperature Supply Switch

21.

Low Water Cutoff

22.

quantity of water. Turns off boiler before damage can
occur.

Safety Relief Valve

23.

section 5.

High Voltage Junction Box

24.

connection of 120V components. See section

Vent Connector (2" PVC)

25.

section 6.

Gas Connection

26.

piped either through top or bottom of boiler. See
section 7.

Bracket for Optional Wall Mount

27.

Integral to boiler. Allows optional wall mounting when
used with supplied wall mounting bracket. See section 4.

(see page 8)

(see page 8) --

(see page 8) - Field installed. See

(see page 8) - For

(see pages 7 & 8) - See

(see page 7)

- Delivers

(see page 8)

Senses inadequate

8.

- Gas supply may be

(see page 7) -

Combustion Chamber

9.

Condensate Collector

10.

Return Temperature Sensor

11.

Drain Valve

12.

Heat Exchanger Ball Valve

13.

14.

Supply Water Outlet to Heating System (Out)
1-1/14"NPT (see pages 7 & 8) - Connections supplied

for connecting from either top or bottom of boiler. See
section 5.

Vent Temperature Sensor

15.

Condensate Drain

16.

a liquid (condensate) as a by-product of combustion.
Condensate must be piped to appropriate drain. See
section 6.

Heat Exchanger Pump Pump

17.

(see page 8)

(see page 8)

(see page 8)

(see page 8)

(see page 8)

(see page 8)

(see page 8) - Boiler produces

(see page 8)

Auxiliary Power Outlet

28.

outlet for condensate pump or service. Controlled by
Service Switch (28)

Service Switch

29.

Air Vent

30.

Central Heating Pump Circuit Breaker

31.

5 amp circuit breaker protects control module.

Control Module

32.

Internal Access Panel

33.

upward then forward to access control module.
Removable for access to internal components of boiler.

Central Heating Pump Relay

34.

Transformer

35.

water cutoff.

36.

Air Pressure Switch

(see page 7)

(see page 7)

(see page 9)

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

(see page 7) - Convenience

(see page 7)

(see page 9) - Gently pull

(see page 9)

(not shown) - see page 31

Gas Shutoff Valve

18.

during servicing. See section 7

Combustion Air Blower

19.

proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
for combustion.

(see page 8)

(see page 8)

- Fuel supply isolation

- Delivers

Flue Transition Test Port

37.

Combustion Air Analysis Test Port

38.

(see page 8)

(37) (see page 8)

6

(38)

FIGURE 3-1 Boiler Components

LOW VOLTAGE

TERMINAL

STRIP (4)

SAFETY

RELIEF

VALVE

(23)

AIR VENT

(30)

RETURN WATER

FROM HEATING

SYSTEM (IN) (3)

HIGH VOLTAGE
JUNCTION BOX

(24)

SUPPLY WATER TO

HEATING SYSTEM

(OUT) (14)

GAS CONNECTION

(26)

SERVICE SWITCH

(29)

AUXILIARY POWER

OUTLET (28)

CENTRAL HEATING

PUMP CIRCUIT BREAKER

(31)

BRACKET FOR

OPTIONAL WALL

MOUNT (27)

LOW VOLTAGE

TERMINAL

STRIP (4)

COMBUSTION

AIR INLET- 2" PVC

(2)

3 - COMPONENT LISTING

VENT

CONNECTOR - 2" PVC

(25)

HIGH VOLTAGE
JUNCTION BOX

(24)

SAFETY

RELIEF

VALVE

(23)

AIR VENT

(30)

RETURN WATER

FROM HEATING

SYSTEM (IN) (3)

BRACKET FOR

OPTIONAL WALL

MOUNT (27)

SUPPLY WATER TO

HEATING SYSTEM

(OUT) (14)

GAS CONNECTION

(26)

SERVICE SWITCH

(29)

AUXILIARY POWER

OUTLET (28)

PUMP CIRCUIT BREAKER

CENTRAL HEATING

(31)

7

3 - COMPONENT LISTING

LOW

VOLTAGE

TERMINAL

STRIP (4)

HIGH VOLTAGE
JUNCTION BOX

(24)

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT (3)

IGNITER

(5)

SIGHT
GLASS

(7)

HEAT EXCHANGER

BALL VALVE (13)

CONDENSATE

DRAIN 1/2" PVC

(16)

GAS SHUTOFF

VALVE (18)

LOW WATER

CUTOFF (22)

COMBUSTION

AIR

BLOWER (19)

COMBUSTION

CHAMBER

(9)

GAS (CONTROL)

VALVE (20)

USER INTERFACE (1)

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

(3)

SUPPLY WATER TO

HEATING SYSTEM

(OUT) 1-1/4" NPT

(14)

HEAT EXCHANGER

PUMP

(17)

SAFETY RELIEF

VALVE (23)

COMBUSTION

AIR ANALYSIS

TEST PORT (38)

FIGURE 3-2 Boiler Components

HIGH VOLTAGE
JUNCTION BOX

(24)

SAFETY RELIEF

VALVE (23)

LOW WATER

CUTOFF (22)

HIGH TEMPERATURE

SUPPLY SWITCH

(21)

GAS (CONTROL)

VALVE (20)

COMBUSTION

AIR

BLOWER (19)

GAS SHUTOFF

VALVE (18)

(SHOWN IN OPEN

POSITION)

COMBUSTION

AIR ANALYSIS

TEST PORT (38)

VENT

CONNECTOR

2" PVC (25)

USER INTERFACE (1)

COMBUSTION

AIR INLET

2" PVC (2)

perspective

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT (3)

VOLTAGE

TERMINAL

STRIP (4)

IGNITER

FLAME SENSOR

FLUE

TRANSITION

TEST PORT

(37)

BURNER

View has

different

than boiler

COMBUSTION

CHAMBER

LOW

(5)

(6)
SIGHT

GLASS

(7)

(8)

(9)

HEAT EXCHANGER

PUMP

(17)

CONDENSATE

DRAIN 1/2" PVC

(16)

VENT

TEMPERATURE

SENSOR (15)

SUPPLY WATER TO

HEATING SYSTEM

(OUT) 1-1/4" NPT

(14)

HEAT EXCHANGER

BALL VALVE (13)

DRAIN

VALVE (12)

8

RETURN TEMPERATURE

SENSOR (11)

CONDENSATE

COLLECTOR

(10)

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

(3)

INTERNAL ACCESS

PANEL - CLOSED

(33)

3 - COMPONENT LISTING

CONTROL

MODULE

(32)

INTERNAL ACCESS

PANEL -OPEN

(33)

CENTRAL HEATING

PUMP RELAY

(34)

Control Module
Fuse and holder

TRANSFORMER

(35)

9

4 - LOCATING BOILER

4.1 Boiler Location Considerations

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

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

Protection of gas ignition system components from •
water (dripping, spraying, rain, etc.) during operation
and service (circulator replacement, condensate trap,

control replacement, etc.).
Floor or wall mounting. •

Wall must be plumb and capable of supporting boiler •
weight plus 60 lbs (28 kg), see Table 12-1 (page 38)

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

Wall mounting - see section 4.2•

Access to outdoors to meet minimum and maximum •
pipe lengths for combustion air and vent piping. See
section 6.

Disposal of condensate. See section 6.•

TABLE 2: BOILER CLEARANCES

Dimension

Top (A)
Left Side (B)
Right Side (C)
Front (D)
Back (E)

Bottom (F)

Combustion
Air/Vent piping

Hot Water Piping

(1)

Required distances measured from boiler.

(2)

Service clearance recommendation.

Combustible

Materials

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

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

0" (0 cm) 1½" (4 cm)
0" (0 cm) 6" (16 cm)
0" (0 cm) 0" (0 cm)

0" (0 cm)

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

1/2" (1.3 cm) 6" (16 cm)

(1)

Service

0" (0 cm) Floor

12" (32 cm) for

Bottom Piped

(1)(2)

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 4-1.

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

FIGURE 4-1 Clearance to Combustible Materials

A

E

B

A

A

C

E

FLOOR

D

10

B

C

FLOOR

4 - LOCATING BOILER

!

!

WARNING

Do not install wall mount bracket directly on drywall.

FIGURE 4-2 Wall Mounting Bracket Engaged
with Bracket on Boiler

Center brackets. Avoid

overhang on sides of wall

mount bracket.

4 Slots for attaching Wall

Mount Bracket to Studs

4.2 WALL MOUNTING OPTION

Boiler can be wall mounted using wall mounting bracket
included with unit.

1.

Structure must be capable of supporting boiler
weight plus 60 lbs (28 kg). See Table 1, page 2.

Wall mount bracket has 4 slots allowing mounting

2.

on two (2) wall studs spaced at 11½" to 16½" on
center. See fi gure 4-2.

Boiler includes (4) 3/8" x 3" lag screws and (4)

3.

washers for attaching wall mount bracket to wood
studs. Field source appropriate fasteners for other
wall constructions (masonry, concrete).

Attach wall mount bracket level on wall.

4.

Boiler must engage with wall mount bracket.

5.

Avoid overhang on sides of wall mount bracket.

6.

Verify boiler bracket is centered on wall bracket.
See fi gure 4-2.

!

CAUTION

Boiler weigh's approximately 100 pounds (45.4 kg)
without jacket. Do not lift boiler onto wall without
assistance.

11

!

5 - HYDRONIC PIPING

5.1 General

Install piping in accordance with authority having jurisdiction.•

NOTICE

Use two (2) wrenches when tightening and fi tting
to pipe 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. Boiler pump
compensates for pressure drop through boiler internal
piping and heat exchanger.

Thoroughly clean and fl ush system before connecting to •
boiler.

5.2 Special Conditions

System piping exposed to freezing conditions: Use •
inhibited proplyene glycol solutions certifi ed by fl uid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.

Boiler installed above radiation level (or as required by •
authority having jurisdiction). Intergral low water cutoff
provided in boiler (see page 6).

!

CAUTION

Non-potable water only piped directly to boiler. DO
NOT connect drinking water to heating system.

!

WARNING

Poison hazard. Ethylene glycol is toxic. Do not •
use ethylene glycol.

Never use automotive or standard glycol antifreeze, •
even ethylene glycol made for hydronic systems.

Ethylene glycol can attack gaskets and seals used •
in hydronic systems.

Use only inhibited proplyene glycol solutions •
certifi ed by fl uid manufacturer as acceptable for
use with closed water heating system.

Thoroughly clean and fl ush any system that used •
glycol before installing new Boiler.

Provide user with Material Safety Data Sheet •
(MSDS) on fl uid used.

NOTICE

Do not expose boiler and condensate piping to
freezing temperatures.

Boiler used in connection with refrigeration system. •
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.

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.

5.3 Safety Relief Valve and Air Vent

NOTICE

Field source safety relief valve for system pres­sures greater than 30 psig (206 kPa). Temperature-
Pressure Gauge and Air Vent satisfactory for 30-50
psig (206-345 kPa) operation.

Install safety relief valve and air vent using pipe fi ttings •
provided with boiler. See fi gure 5-1

Install safety relief valve with spindle in vertical position.•
Do not install shutoff valve between boiler and safety •

relief valve.

FIGURE 5-1 Relief Valve & Air Vent

Safety Relief

Valve

Air Vent

3/4" NPT

90° Elbow

3/4" NPT

Close Nipple

3/4"F x 3/4"M

NPT Tee

3/4" x 1/4" NPT

90° Elbow

3/4 NPT

12

5 - HYDRONIC PIPING

FIGURE 5-2 Safety Relief Valve Discharge Piping

Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.

Check Local Codes

For Maximum

Distance To Floor

!

WARNING

Install discharge piping from safety relief valve. See •
fi gures 5-2 and 5-4.

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 loca-•
tion 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 5-3 Temperature Pressure Gauge
Installation

Temperature Pressure Gauge

Located at Optional Bottom

Supply Connection to Boiler

5.4 Trim Piping

Supply and Return Piping•

Supply. Select either top or bottom supply options.•
Return. Select either top, bottom, or both.•
Install brass plug(s) provided with boiler in unused •

tapping(s).

Temperature - Pressure Gauge. Install temperature •
pressure gauge using nipple and tee provided with
boiler. See fi gure 5-3.

5.5 System Piping

Single boiler system. See fi gures 5-4, 5-5, 5-6, 5-7 for •
general guidance. Additional considerations:

Control system designed for single central heating •
pump. Installer responsible for integration of
multiple central heating pumps.

Control system allows domestic hot water •
prioritization. Function could be lost if central
heating pump not directly connected to control
system.

Multiple boiler system. See fi gure 5-8 for general guid-•
ance. Additional considerations:

Control system requires equivalent water •
temperatures entering each boiler to properly se­quence and adjust system supply temperature.
Install multi boiler sensor kit. See parts list for part •
number.

13

5 - HYDRONIC PIPING

NOTICE

Illustrations are meant to show system piping con­cept only. Installer responsible for all equipment and
detailing required by authority having jurisdiction.

FIGURE 5-4 System Piping

System

Supply

System

Return

Piping Legend

Check Local Codes

For Maximum

Distance To Floor

14

5 - HYDRONIC PIPING

5-5 TWO-PIPE ZONED SYSTEM WITH VALVES

Circulating Ball

Valve Open

(as shipped)

5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS

3/8" Open End Wrench

Circulating Ball

Valve Open

(as shipped)

3/8" Open End Wrench

15

5 - HYDRONIC PIPING

5-7 SINGLE BOILER USING PRIMARY/SECONDAY PUMPING

12"/305mm Max. apart

12"/305mm
Max. apart

System

Pump

3/8" Open End Wrench

Heat Exchanger

valve open

Existing closely

spaced tees

in primary

system loop

Limit length to

5 feet water

pressure drop

Heat Exchanger

valves closed

3/8" Open End Wrench

16

5 - HYDRONIC PIPING

5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide)

System

Pump

12"/305mm Max. apart

System

T emperature

Sensor

Size common piping

according to max.

heat capacity of

entire system

Limit to

2 feet

Up to 16

boilers

All heat exchanger

valves closed

3/8" Open End Wrench

17

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

This boiler requires a dedicated direct vent system.
Install air and vent piping in accordance with these

instructions, authority having jurisdiction, and:

USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.•
Canada - Natural Gas and Propane Installation Code, •

CAN/CSA B149.1

Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft

systems operating under positive pressure.

6.2 Removal of Existing Boiler From Common
Vent System

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

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

Seal any unused openings in common venting system.•
Visually inspect venting system for proper size and •

horizontal pitch. Determine there is no blockage or
restrictions, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.

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

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

B149.1.

6.3 Materials

See Table 4•

Table 3 - Combustion Air and Vent Piping Length

Combustion Air and Vent Pipe Equivalent

Length

2” Pipe 3” Pipe

Minimum 6 ft (1.8 m) 6 ft (1.8 m)

Maximum 60 ft (18.3 m) 100 ft (30.4 m)

1 - 90° elbow = 5 ft (1.6 m)
1 - 45° elbow = 3.5 ft (1.1 m)
1- 2" x 3" adapter = 0 ft. (0 m)

For Example: Boiler can be installed on outside wall and
vented with 1-90° elbow and 2 feet of vent pipe.

Turn on appliance being inspected. Follow lighting •
instructions. Adjust thermostat so appliances will operate
continuously.

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

Determine each appliance remaining connected to •
common venting system properly vents when test­ed as outlined above. Then return doors, windows,
exhaust fans and any other gas-burning appliance to
their previous condition of use.

18

6 - COMBUSTION AIR AND VENT PIPING

Table 4 - Combustion air and vent pipe fi ttings

must conform with the following:

Item Material Standards

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC schedule 40

Vent Pipe

and Fittings

Pipe Ce-

ment/

Primer

IPEX is approved vent manufacturer in Canada listed •
to ULC-S636.

IPEX System 636 Cements and Primers are approved •
in Canada listed to ULC-S636.

SDR-21 & SDR-26 PVC ANSI/ASTM D2241

ABS-DWV ANSI/ASTM D2661

Schedule 40 ANSI/ASTM F628

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

DO NOT USE CELLULAR (FOAM) CORE PIPE

!

WARNING

ANSI/ASTM D1784/

F441

Use of cellular core PVC for venting fl ue gas could
result in death, serious injury.

!

WARNING

Exhaust 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.

6.4 Pipe Installation

Minimum and maximum combustion air and vent pipe •
lengths listed in Table (3). Pipe length counted from
combustion air connector to termination.

Install fi eld-sourced 2" to 3" transition, if used, in vertical •
section at combustion air inlet and vent connector.

90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows •
equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no
equivalent length.

Slope vent pipes minimum 1/4" per foot (21 mm/m) •
back toward boiler. Vent piping must be above boiler
vent connector. Provide condensate drain tee(s) in
piping below boiler. Avoid sags capable of accumulating
condensate.

Support piping in accordance with pipe manufacturer's •
instruction and authority having jurisdiction. In absence
of manufacturer's instruction use pipe hooks, pipe
straps, brackets, or hangers of adequate and strength
located at intervals of 4 ft (1.2 cm) or less. Allow for
expansion/contraction of pipe do not restrict.

Combustion air and vent piping must be air tight and •
water tight.

Certifi ed vent system components must NOT be inter-•
changed with other vent systems or unlisted pipe/fi ttings.

Canadian installations only. All plastic venting •
material,primer and glue must be listed to ULC S636.

Canadian installations only. First 3 ft (0.9 m) of plastic •
vent pipe from appliance fl ue outlet must be readily ac-

cessible for visual inspection.

6.5 Termination

Terminate combustion air and vent pipes with fi ttings or •
concentric vent kit.

See "Parts, Kits and Optional Accessory" manual •
for concentric vent kit part numbers. Follow
instructions provided with kit.

Use horizontal pipe for vent and 90° elbow for •
combustion air termination when using fi ttings.

Terminate combustion air and vent pipes in same •
atmospheric pressure zone through exterior sidewall or
roof.

Locate combustion air termination as far as possible •
from swimming pool, swimming pool pump house, and
other sources of airborne chlorine.

Locate combustion air and vent as required by authority •
having jurisdiction.

19

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1

12" (30 cm)

Minimum

8" (21 cm)

Minimum

Exhaust Combustion

12" (30 cm) 18" (46 cm)

Canada Minimum above

anticipated snow line

FIGURE 6-2

3" (8 cm)
Maximum

Air

15" (38 cm)

Maximum

Roof

Terminations

3" (8 cm) Maximum horizontal
separation between combustion air
intake and exhaust

 8" (21 cm) Minimum vertical
separation between combustion air
intake and exhaust.

15" (38 cm) Maximum horizontal
length of exhaust.



Properly support all piping.

12" (30 cm)

Minimum from

overhang

See snow & ice

page 20

FIGURE 6-3

3" (8 cm)
Maximum

separation

12" (30 cm) Separation

between bottom of

combustion air intake

and bottom of exhaust

Exhaust

Combustion Air

12" (30cm)

Minimum

separation

Side Wall

Terminations

 3" (8 cm) Minimum horizontal
separation between combustion air
intake and vent terminations.

 8" (21 cm) Minimum vertical separ ation
between combustion air intake and
vent terminations.

12" (30 cm) Separation between



bottom of combustion air intake
and bottom of exhaust.

Multiple terminations as shown in
6-1, 6-2, and 6-3 must be a minimum
of 12” (300 mm) horizontally between
exhaust of one termination and air
intake of next termination.



Properly support all piping.

See snow & ice

page 20

Air Intake

Exhaust

20

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-4

Combustion

Air

FIGURE 6-5

1" Maximum

12" Minimum

1" Maximum

Exhaust

Roof overhang

12" Minimum

36" Minimum

Maintain 12" (18" for Canada)
minimum clearance above highest

Concentric

Vent Roof

Terminations

anticipated snow level. Maximum
of 24" above roof.

Support must be fi eld installed to
secure termination kit to structure.

Elbow, Roof Boot/Flashing fi eld
supplied.

FIGURE 6-6

Maintain 12" (30 cm)

18" (46 cm) Canada

Minimum clearance

above highest

anticipated snow

level maximum of 24"

above roof

Combustion Air

Roof boot/fl ashing
(fi eld supplied)

Exhaust

Support
(fi eld supplied)

Combustion

Air

FIGURE 6-7

Exhaust

Exhaust

Combustion Air

Elbow fi eld
supplied

Exhaust

Note: Support must

Maintain 12"

clearance above

Maintain 12" (18" Canada)

highest anticipated

clearance above highest

snow level or grade

anticipated snow level or
grade

be fi eld installed to
secure termination
kit to structure

Exhaust

Combustion Air

1-1/2"
(3.8 cm)

1" Maximum

1-3/16"
(4.0 cm)

31-7/8"
(0.8 m)

3" (7.6 cm) Diameter PVC intake/combustion air

46-3/4" (1.2 m)

Combustion Air

Exhaust

Note: Securing strap must
be fi eld installed to prevent
movement of termination
kit in side wall

21

6 - COMBUSTION AIR AND VENT PIPING

Forced Air

Inlet

12"'

(30.5cm m)

Minimum

Less than
10' (3 m)

Minimum

Termination must
be 12" (30.5 cm)

from or below doors,

windows or gravity

inlet.

Termination

Termination

3' (0.9 m)
[If located
within 10' (3 m)
of forced air
inlet]

Doors &

Windows

Condensate

Forced Air

Inlet

Combustion air and vent termination
must be 12" (30.5 cm) from or below
doors, windows or gravity inlet.

Vent gas may condense, forming
moisture, may be corrosive. Protect
building materials at vent from exhaust
of vent gas.

Terminate venting system 3’ (0.9 m)
above and 10' (3.0 m) from any forced
air inlet (except boiler’s combustion air
inlet).

3' (0.9 m)

Minimum

Grade,

Snow & Ice

"L"

Corner

Terminate vent bottom, min. 12"(300
mm) above highest anticipated snow
level.

Avoid locations where snow may drift and
block vent. Ice or snow may cause boiler
to shut down if vent becomes obstructed.

Vent termination shall NO T be installed
closer than 3' (0.9 m) from inside corner
of “L” shaped structure.

22

6 - COMBUSTION AIR AND VENT PIPING

Keep vent termination 3’min. (0.9

3' (0.9 cm)

Minimum

Vegetation,

Plants &

Shrubs

Termination

Meters,
Regulators,
deck, porch

Requirements for Commonwealth of Massachusetts

Boiler and venting installation must conform to state code
248 CMR which includes but is not limited to:

Installation by licensed plumber or gas fi tter.•

cm) away from vegetation. Position
termination where vent vapors will not
damage plants/shrubs or air conditioning
equipment.

Vent termination 4’ (1.2 m) horizontally
from, no case above or below, elec­tric meters, gas meters, regulators,
and relief equipment, or under deck or
porch.

Vapors

7' (2.1 m)

Minimum

Position termination where vent vapors are
not objectionable.

Carbon monoxide detectors with side wall horizontally •
vented gas-fuel equipment in residential dwelling,
building or structure.

Locate vent termination minimum 7'

Walkways

People or

Pets

Stones,

Balls,

Etc.

(2.1 m) above any public walkway, with
consideration to condensate.

Locate combustion air and vent termination
to prevent accidental contact with people
or pets.

Position combustion air and vent
termination where it will NOT be damaged
by foreign objects, such as stones, balls,
etc.

Position termination so it will not be effect-

Eddy,

Flue

Gases

ed by wind eddy, air born leaves, snow, or
recirculated vent gases. Give consideration
to excessive wind and locate away from
windward side of building.

Multiple

Family

Dwellings

23

Vent shall not terminate directly above
paved sidewalk or paved driveway located
between two single-family dwellings serving
both dwellings.

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1 Condensate Drain

6.6 Condensate Piping

Use materials acceptable to authority having jurisdiction. •
In absence of such authority:

USA - PVC or CPVC per ASTM D1785/D2845 Cement •
or primer per ASME D2564 or F493.

Canada - CSA or ULC certifi ed PVC/CPVC pipe, fi t-•
tings and cement.

Insert 1/2" (1.3 cm) PVC pipe through grommet in •
chassis.

Attach PVC tee provided with boiler and fi eld sourced •
piping to condensate drain stub on left side of boiler.
See fi gure 6-1.

Slope condensate drain pipe minimum 1/4" per foot •
(21mm/m) away from boiler.

Use condensate pump if boiler located below disposal •
point. 120 VAC auxiliary power outlet can be used to
power condensate pump.

Field source condensate neutralizing fi lter as required •
by authority having jurisdiction or for environmentally

friendly condensate disposal.

PVC Tee (fi eld installed)

on condensate drain

stub

24

!

7 - GAS SUPPLY PIPING

7-1 Gas Connection Knockout Plate at Bottom of
Boiler

Bottom knock out

for Optional Gas

Connection

7.1 General

7-2 Gas connection at Top of Boiler

Gas Connection Top

of Boiler

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.•
Do not touch any electrical switches; do not use •

any phones in your building.
Immediately call your gas supplier from a neigh-•

bor’s phone.
Follow the gas supplier’s instructions. •
If you cannot reach your gas supplier, call the fi re •

department

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.

7-3 Bottom Gas Connection

Optional Bottom Gas

Connection

SIZE

075 75,000

100 100,000

Note: See Piping Table 16-Glossary page 58

Maximum

Input (Btuh)

7.2 Near Boiler Gas Piping

Select top or bottom gas connection. To convert from

•
top connection to bottom connection:

Remove bottom knockout by removing two (2)

•
screws. See fi gure 7-1.

Disconnect gas connection by removing two (2)

•
screws. See fi gure 7-2.

Relocate gas connection to bottom opening.

•
Secure with two (2) screws. See fi gure 7-3.

Relocate knockout cover to top opening. Secure

•
with two (2) screws. See fi gure 7-4.

Install fi eld sourced manual main shutoff valve and

•
ground joint union. See fi gure 7-5.

TABLE 5: GAS SUPPLY PRESSURE

Natural Gas Propane

Min. Max. Min. Max.

3.0" w.c.

(0.7 kPa)

3.0" w.c.

(0.7 kPa)

13.5" w.c.
(3.3 kPa)

13.5" w.c.
(3.3 kPa)

5.0" w.c.

(1.2 kPa)

5.0" w.c.

(1.2 kPa)

13.5" w.c.
(3.4 kPa)

13.5" w.c.
(3.4 kPa)

25

7 - GAS SUPPLY PIPING

!

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 7-6.

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 providing ignition source.

Correct leaks immediately and retest.

•

7-4 Gas Connection Knockout Plate at Top of
Boiler

Top of Boiler knock out

for Gas Connection

7-5 Manual Main Gas Shutoff Valve Outside
Boiler Jacket

Manual Main Gas

Shutoff Valve

Option: Gas

Connection May be

Located

At Bottom of Boiler

7-6 Gas Shutoff Valve

Gas shutoff valve

(shown in closed

position)

26

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.

NOTICE

Wiring diagrams can be found in Section 15 of this
Manual.

8-1 LINE VOLTAGE CONNECTIONS

8-2 LOW VOLTAGE CONNECTIONS

8.1 General

Electrically bond boiler to ground in accordance with re­quirements of authority having jurisdiction. In absence of
such requirements:

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 (Figure 8-1)

Boiler•

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

Open High Voltage Junction Box (see Figures 3-1, B.
3-2) to access line voltage terminal strip.

Connect 120 VAC circuit to line voltage terminal C.
strip 120 VAC L,N,G.

Central Heating Pump, if used.•

Isolate pump from control module if pump FLA A.
exceeds 5 amps.

Connect pump to line voltage terminal strip CH B.
PUMP L,N,G.

Domestic Hot Water Pump, if used.•

Isolate pump from control module if pump FLA A.
exceeds 0.5 amps.

Connect pump to line voltage terminal strip DHW B.
PUMP L,N,G.

8.3 Low Voltage Connections (Figure 8-2)

User Interface Terminals •

Factory wired to low voltage terminal plug USER A.
INTERFACE terminals

Optional - Remote mount user interface for im-B.
proved access. See Controller Manual for additional
information.

Argus Link (Multiple boiler applications only)•
Outdoor Sensor, if used.•

Provided with boiler in accessory kit.A.
Locate outdoor sensor to protect against wind and B.

direct sunlight. Mounting instructions provided with
sensor.

Maximum wire length is 100 ft (30m) for 22 ga. C.
wire, or 150 ft (45m) for 18 ga. wire.

Connect wires to low voltage terminal plug OUT-D.
DOOR SENSOR terminals. Wires are interchangeable.

System Sensor •

When using system sensor with multiple boiler A.
applications, connect sensor wires to low voltage
terminal plug SYSTEM SENSOR terminals. Wires are
interchangeable.

27

8 - ELECTRICAL CONNECTIONS

Domestic Hot Water (DHW) Thermostat, if used.•

Use Temperature control with dry contacts rated at A.

0.5 amps @ 120 VAC. Boiler control does not pro­vide power to DHW temperature control

Maximum wire length is 330 ft (180 m) 22 gauge B.
wire.

Connect wires (interchangeable) to low voltage C.
terminal plug DHW T-T terminals. Wires are
interchangeable.

Use of isolation relay is required. Do not use control D.
with 24 VAC circuit typically found on zone t-stat

terminal.

Central Heating Thermostat•

Use thermostat or boiler system control with dry A.
contacts related 0.5 amps @ 120 VAC. Boiler
control does not provide 24 VAC power to central
heating thermostat.

Locate and install thermostat per manufacturer's B.
instructions and away from infl
hot or cold water pipes, light fi xtures, televisions,
sunlight, or fi replaces.

Maximum wire length isC. 330 ft (180 m) for 18 ga.
wire.

Connect wires to low voltage terminal plug CH T-T D.
terminals. Wires are interchangeable.

uences of drafts,

28

9 - START UP PROCEDURE

NOTICE

IMPORTANT: On initial start up condensate trap
must be manually fi lled with water.

9-1 Condensate Drain Assembly

9.1 Fill boiler with water and purge air

Consult local water treatment companies for hard water •
areas (above 7 grains hardness).

Do not fi ll boiler or operate with water containing chlorine •
in excess of 200ppm. Filling with chlorinated fresh tap
water should be acceptable.

Fill boiler and system piping with water (or antifreeze-

•
water solution, if used). See antifreeze information
page 12. Purge air from boiler using air vent. Purge
air from system piping.

Inspect system piping and boiler connections. Repair

•
any leaks immediately.

9.2 Fill Condensate Trap with Water

Disconnect collet clip from elbow. See fi gure 9-1.

•
Disconnect tubing below elbow.

•
Pour about 1 cup (237ml) of water into vent drain.

•

•

Reconnect tubing to elbow with collet clip. See Figure

•
9-1.

1. Disconnect collet clip from
hose barb and fi ll Condensate

trap with water.

2. Reconnect collet clip to hose barb
before starting boiler.

29

9-2 User Interface

e

-2 User Interfac

9 - START UP PROCEDURE

9.3 Program Boiler Control

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Confi rm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Verify thermostat is off or in set to cooling mode.1.
Turn power switch to ON position.2.
Set language: default English3.

Press Menu [M]

•
Use arrow keys to scroll to • Settings; press OK

once
Use arrow keys to scroll to • Language
Press OK key once (choices start blinking)

•
Use arrow keys to scroll to desired Language

•
Press OK key once

•

4. Set Temperature Scale: default Fahrenheit

Use arrow keys to scroll to • Change

Temperature units

Press OK key once (units start blinking)

•
Use arrow keys to scroll to desired scale

•
Press OK key once

•
Press Menu once to return to main menu

•

Installer Menu5. - press both OK and Menu keys at

same time - hold down for 4 seconds.

Press arrow keys to scroll to • Boiler Confi g.
Press arrow keys to scroll to • Pump mode
Press OK key once

•
2 choices:

•

Pump Mode 0 : CH

A.

Pump Mode 1: CH & DHW

B.

Press OK key once

•

30

Use arrow keys to scroll to • SERVICE REMINDER

Press OK key once

A.

Use arrow keys to scroll to choice: ON or

B.

OFF
Press OK key once

C.

If ON use arrow keys to scroll to desired

D.

time for service reminder

9 - START UP PROCEDURE

Press OK key once

E.

Press Menu key once

F.

Press arrow keys to scroll to • CH (Central
Heating) SETTINGS

A.

Press OK key once

In CH Mode:

B.

Press OK key once

C.

4 modes to choose from, scroll to

D.

choice:
0 - No outdoor reset
1 - Outdoor reset (Default mode)

2 - Full outdoor reset - No thermostat

3 - CH with permanent demand

Press OK key once

•
Use arrow keys to scroll to • WARM WEATHER

SHUT DOWN TEMP. Down Temp. - default is
70°F (21°C)

Press OK key once

A.

Scroll to temperature choice

B.

Press OK key once

C.

Use arrow keys to scroll to • RESET CURVE design
temperatures. Default is 180°F (82°C) Boiler
temperature, 0°F (-18°C) Outdoor temperature.

Press OK key once

A.

Scroll to temperature choice

B.

Press OK key once

C.

Use arrow keys to scroll to • R.CURVE MILD
WEATH. Default is 70°F (21°C) Boiler, 70 °F
(21°) Outdoor. To change:

Press OK key once

A.

Scroll to temperature choice boiler

B.

Press OK key once

C.

Use arrow keys to scroll to • BOOST function,
default Temperature is 18°F, Time 20 minutes.
To change:

Press OK key once

A.

Scroll to temperature choice

B.

Press OK key once; scroll to select Time

C.

Scroll to time choice

D.

Press OK key once

E.

Use arrow keys to scroll to• MAXIMUM POWER
CH, default is 100%. To change:

Press OK key once

A.

Scroll to power choice

B.

Press OK key once

C.

Press Menu key once

•

In DHW mode • (DHW setting is for tank tem-

perature)

Press OK key once

A.

3modes to choose from

B.

0 - No DHW
1 - DHW store with sensor

2 - DHW setting is for tank temperature

Press OK key once

•
Use arrow keys to scroll to • DHW MAXIMUM

PRIORITY TIME, default is 30 minutes.

Press OK key once

A.

Scroll to Time choice

B.

Press OK key once

C.

Press Menu key twice will take you back to regu-

•
lar menu.

6.

System Test Mode

The installer menu also features a 'System Test' mode
which allows the contractor to test proper operation of

the combustion system and the pumps.

Combustion Check:

•

Use arrow keys scroll to System Test

A.

Menu

Press OK key once

B.

Use arrow keys scroll to 'System Test

C.

Power' menu

Press OK Key once

D.

3 selections to choose from

E.

0 - Low

2 - Ignition
3 - High
4 - Off

Press OK key once

F.

Note: In test mode boiler will stay at fi xed fi ring
rate until either 30 minutes elapses, user
switches to 'OFF' mode or boiler reaches
maximum temperature.

Pump Check:

•

Use arrow keys scroll to System Test

A.

Menu

Press OK key once

B.

Use arrow keys scroll to 'Pump' menu

C.

Press OK Key once

D.

Scroll to Boiler, CH/System or DHW to

E.

cycle Press OK key on choice

Pumps will shutoff after 6 minutes

F.

Cascade Settings 7. - See ECR Multiple Boiler Manual

Use arrow keys to scroll to • DHW Settings

31

9 - START UP PROCEDURE

9.4 Boiler Start-up and Operational Test

Verify air is purged from hydronic piping1.
System test pumps - verify each pump is opera-2.

tional
Verify gas piping3.

Confi rm pressure test. See section 7.3.

•
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 immedi-

•
ately after gas is turned on. Shut off gas supply
and make necessary repairs if leaks found.

Follow OPERATING INSTRUCTIONS to initiate boiler 4.
operation. See section 10.

Inspect combustion air and vent piping. Verify pipe 5.
is not leaking and terminations are unobstructed
and vent gas discharge is not a nuisance or hazard.

Verify boiler functions.6.
Inspect condensate disposal system. Verify con-7.

densate fl ows adequately and is disposed properly.
Check control module operation.8.
Check fi eld-sourced limits, low water cutoffs, etc. 9.

per manufacturer's instructions.

Compare to boiler rating2.

Size Minimum Nominal Maximum

075 68.0 75.0 77
100 90.0 100.0 103

Adjust rate if needed using diagram 9-3 below3.
Check CO4.

. Natural gas should be between 8.5%

2

and 10.0%.

If CO

•

is low increase gas fl ow following diagram

2

9-3 below.
If CO

•

is high decrease gas following diagram

2

9-3 below.

Propane Gas

Most propane systems do not have fl ow meters.

Check CO1.

. Propane should be between 9.5% and

2

11.0%.
If CO

•

is low increase gas fl ow following diagram

2

9-3 below.
If CO

•

is high decrease gas fl ow following dia-

2

gram 9-3.

9-3 Gas Valve

1/4" FLAT HEAD

SCREWDRIVER

9.5 Check Combustion

Natural Gas

Measure input. English units*1.

Turn off gas to all other appliances.

•
Use ½, 1 or 2 cu ft dial on gas meter. Mea-

•
sure 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
72 seconds

=

100

MBH

MIN

To increase gas fl ow turn 'throttle' left or counter

•

OUT

clockwise .
To decrease gas fl ow turn 'throttle' right or

•
clockwise .

Limit adjustment to one turn and retest.

•

*See Metric - Glossary page 58

32

9 - START UP PROCEDURE

NOTICE

Combustion analyzer port is provided. After use
replace cover.

9-4 Combustion Air Analyzer Port

Combustion Air Analyzer Port

Verify Burner, Proper Operation

Inspect burner fl ame through Sight Glass. See fi g-1.
ure 9-5.

Operate boiler through several heating cycles, 2.
including domestic hot water, if used. Verify proper
operation.

Reset control parameters to operating settings if

3.

adjusted to allow startup and operation test.
Follow instructions TO TURN OFF GAS TO APPLIANCE 4.

if boiler is not being placed into immediate operation.
Enter installer information on Warranty Registration 5.

Card.
Gather all instructions, manuals, wiring diagrams, 6.

warranty registration card and other supporting
information. Review with user and/or affi x in con-
spicuous location adjacent to boiler.

9-5 Burner Flame

Burner

Flame

Flame

Look for BLUE fl ame

with slight YELLOW tips

evenly spaced around

the burner

33

!

10 - OPERATING INSTRUCTIONS

FOR YOUR SAFETY READ BEFORE OPERATING

!

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 ser-
vice 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 quali-

fi 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 switches; do not use •

any phone in your building.
Immediately call your gas supplier from a neigh-•

bor’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.
Remove front jacket panel.•
Turn gas shutoff valve handle should be clockwise •

to closed position. Handle should be perpendicular to
gas pipe.

Replace front jacket panel.•

10-1 Gas Shutoff Valve

10.1 OPERATING INSTRUCTIONS

Stop! Read Safety information above.

Set thermostat to the 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

this burner by hand!

Remove the front jacket panel.•
Turn• gas shutoff valve clockwise 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 counter clockwise to the •
open position. Handle should be parallel to gas pipe.

Replace front jacket panel.•
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 POSITION

CLOSED POSITION

34

11 - GENERAL MAINTENANCE AND CLEANING

!

!

DANGER

Before servicing, turn off electrical power to boiler
at service switch. Close manual gas valve to turn
gas supply OFF to boiler.

!

CAUTION

Label all wires prior to disconnection when servic­ing controls. Wiring errors can cause improper and
dangerous operation.

NOTICE

Verify proper operation after servicing.

NOTICE

Perform regular service and maintenance by
qualifi ed service agency at least once every 12
months to assure safe, trouble free operation
and maximum effi ciency .

11-1 Sight Glass

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. Insure
proper reassembly and resealing of system.

Visually inspect condensate drain line for proper opera-•
tion. Checking for deteriorated or plugged condensate
drain line. Verify condensate trap drains freely.

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, con-•
densate lines, and cleaning (if necessary) by following
instructions in “Annual Examination and Cleaning of Boiler

Components” in this section.
Circulator pump and blower fan motor furnished with boil-•

er are permanently lubricated from factory and require
no further lubrication. Lubricate fi eld sourced pumps and/
or motors should be lubricated according to pump and/or
motor manufacturer’s instruction.

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

Sight Glass

air vent;•
check venturi air inlet for blockage and clean as re-•

quired;
check air hose is tight•

supply, return, and fl ue temperature sensor clips •
must be securely seated on pipes; Check boiler for
any sign of leaks.

Check low water cutoff using user interface.•

Check operation every year by pressing test button.•

"Low Water" LED should illuminate and burner •
should shut down.

Every 5 years remove Low water cutoff and clean •
all surfaces in contact with water. Reinstall after
cleaning.

Every 10 years replace low water cutoff.•

Check fl ame signal with user interface. Should be 8 micro •
amps at high fi re.

35

11 - GENERAL MAINTENANCE AND CLEANING

Visual inspection of fl ame through sight glass. Burner •
should be fully illuminated.

Check expansion tank.•

11.2 Annual shut down procedure

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

Drain system completely and add antifreeze when heat-•
ing system is to remain out of service during freezing
weather.

Drain condensate lines when boiler is to be exposed to •
freezing temperatures.

!

DANGER

Before servicing, turn off electrical power to boiler
at service switch. Close manual gas valve to turn
OFF gas supply to boiler.

11-2 Blower Inlet Assembly

A

B

C

D

E

F

G

!

WARNING

The following service procedures must be performed
by qualifi ed service agent. Boiler owner shall not at-
tempt these steps.

11.3 Annual Examination and Cleaning of Boiler
Components

Obtain Burner Inspection Kit. See parts list.•
Before servicing, turn off electrical power to boiler at •

service switch.
Follow instruction 'To Turn Off Gas to Appliance'. Close •

main gas valve.
Visually inspect through sight glass no fl ame is present.•
Examine fl ue passages by removing blower/burner as-•

sembly from heat exchanger.

Confi rm manual gas valve is closed. Disconnect gas •
line to gas valve at union. Disconnect air hoses to gas
valve and air inlet.

Disconnect wires to gas valve, fl ame rod sensor and •
igniter.

H

I

Burner Assembly

A Fuel Mixer
B Burner Gasket - Upper
C Burner Plate

D Refractory

E Burner
F Burner Gasket - Lower
G Flame Sensor

H Igniter

I Sight Glass

Remove 2 screws and carefully remove igniter.•
Remove 2 screws and carefully remove fl ame rod •

sensor.
Loosen and remove four nuts connecting blower inlet •

assembly to heat exchanger.

36

11 - GENERAL MAINTENANCE AND CLEANING

11-2 Condensate Collector

Condensate Collector

A Combustion Chamber
B Condensate Collector
C Condensate Drain

Remove inlet assembly with blower attached, remove •
gasket and burner.

Clean burner by inserting an air hose into blower •
opening of casting and blowing air through heat
exchanger side.

A

B

C

After cleaning burner, remove burner holder and •
refractory from top of combustion chamber. Remove
four nuts holding condensate collector from bottom of
heat exchanger assembly. Also remove gasket.

Clean heat exchanger with low pressure water spray. •
If this does not clean fi ns adequately, use fl exible
handle nylon brush to loosen sediment and oxide on
all accessible heating surfaces of heat exchanger.
Take care not to get brush stuck in heat exchanger.

After brushing and rinsing, remove any remaining •
loosened sediment using shop vacuum with snor­kel attachment. Inspect burner for foreign matter in
fl ame ports or inside burner. Foreign matter should
be removed by blowing with compressed air or
vacuuming. If burner cannot be cleaned, it must be
replaced.

Reinstall refractory, burner holder, burner and re-•
place gasket (in that order). Position blower adapter
assembly over studs. Install four nuts and tighten.
Reinstall igniter and igniter gasket and fasten with
two screws. Replace gasket and condensate collector
to bottom of heat exchanger assembly. Replace and
tighten four nuts holding collector to heat exchanger
assembly.

Connect gas line to gas valve, pressure switch hose •
to gas valve and air inlet assembly, igniter wires, and

gas valve wires.

Visually inspect condensate trap. Any foreign material •
visible in condensate lines need to be cleaned out as

described below:

I• nspect for sediment or blockage.

Flush out with water or vacuum.•
Follow the instructions “Filling The Condensate Trap •

With Water”

Follow Boiler Start-up and Operational Test. See section •

9.4.

Page 29

.

37

12 - RATINGS AND CAPACITIES

TABLE 12-1: SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Size

075
100

(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 I=B=R Ratings based on piping and pickup allowance of 1.15. Contact ECR Technical Support before selecting boiler for
installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems,
etc..

Boiler Input Rate (MBH)

Maximum Minimum

75 15 69 60 97.0

100 20 91 79 97.0

(1)

12.1 Ratings and Capacities

Constructed and hydrostatically tested for maximum •
working pressure of 50 psig (pounds per square inch
gauge) in accordance with ASME Boiler and Pressure
Vessel Code, Section IV, Rules for Construction of

Heating Boilers.

Ratings are for sea level applications. Boiler •
derates input 2% for every 1000 feet above an elevation

of 2000 feet.

Heating Capacity

(MBH)

(1)(2)

Net I=B=R Rating,

Water (MBH)

(1)(3)

AFUE

(2)

38

13 - TROUBLE SHOOTING

39

13 - TROUBLE SHOOTING

x

p

p

p

p

p

p

_ _ _ _ _ _ F P _ _ _ _

Go to Page 41

Lockout Alarm Blocking Error E 3 5
Blocking Too Long Error False Flame Detect

_ _ _ _ _ _ _ _ _ _ _ _
Lockout Alarm Blocking Error E 3 6
Ignit Error Low Water Cutoff

_ _ _ _ _ _ _ _ _ _ _ _
Lockout Alarm Blocking Error E 4 0
GV Relay Error Return Temp

A 0 0

Go to Page 42

A 0 1

A 0 5

Go to Page 41

Go to Page 48

Go to Page 49

Go to Page 50

_ _ _ _ _ _ _ _ _ _ _ _
Lockout Alarm Blocking Error E 4 3

Replace Control
Module

A 0 6

Safety Relay Error Various Text Messages
_ P _ _ _ _ _ _ _ _ _ _

Go to Page 43

Lockout Alarm Blocking Error E 4 4

A 0 8

Fan Error Phase Error
_ _ _ _ _ _ _ _ _ _ _ _

Lockout Alarm Blocking Error E 4 5

A 0 9 to A 1 4

Re

lace Control

Module

Various Text Messages Net Freq Error
_ P _ _ _ _ _ _ _ _ _ _

A 1 5

Lockout Alarm Blocking Error E 4 6

Go to Page 44

Air SW Not Open Faulty Earth Error
_ _ _ _ _ _ _ _ _ _ _ _

Lockout Alarm Blocking Error E 4 7

Replace Control

A 1 6

Module

Varioius Text Various Text Messages
_ _ _ _ _ _ _ P _ _ _ _

A 1 7

Lockout Alarm Blocking Error E 5 1

Go to Page 46

Air SW Not Closed Supply Sens Open
_ _ _ _ _ _ _ P _ _ _ _

Go to Page 47

Lockout Alarm Blocking Error E 5 2

A 1 8

Max Temp Error Return Sens Open
_ _ _ _ _ _ _ P _ _ _ _

Lockout Alarm Blocking Error E 5 7

Replace Gas

A 2 0

Valve

Flame Out Too Late Flue Sens Shorted

Re

lace Control

Module

Go to Page 50

Go to Page 51

Go to Page 52

lace Control

Re
Module

Go to Page 52

Go to Page 53

Go to Page 54

_ _ _ _ _ _ _ P _ _ _ _
Lockout Alarm Blocking Error E 5 9
Flame Error 1 Supply Sens Shorted

_ _ _ _ _ _ _ P _ _ _ _
Lockout Alarm Blocking Error E 6 0

A 2 2 A 2 3

Various Text Messages Return Sens Shorted
_ _ _ _ _ _ _ P _ _ _ _

Lockout Alarm Blocking Error E 6 5
3 Flame Failures Flue Sens Shorted

_ _ _ _ _ _ _ P _ _ _ _
Lockout Alarm Blocking Error E 6 6

A 2 7 to A 3 0

Various Text Messages Reset Button Error
_ _ _ _ _ _ _ _ _ _ _ _

Blocking Error Blocking Error

E 3 1 to E 3 4

Various Text Messages Various Fan Error Te

Replace Gas

A 2 1

Valve

Re
Module

A 2 4

Go to Page 48

Re
Module

Replace Control
Module

lace Control

lace Control

40

E73 to E79

E 81, 88, 89

Go to Page 54

Go to Page 55

Go to Page 55

Error clears in
1-2 minutes

Re

lace Control

Module

13 - TROUBLE SHOOTING

Enter Installer Menu, Boiler

Status. Scroll to most recent

Diagnose corrective action using

Lockout Alarm A 0 0

Blocking too long error

Lockout Alarm or Blocking Error.

_ _ _ _ _

appropriate Troubleshooting Tree.

to Control Module J13?

Is harness connected to Gas

Lockout Alarm A 0 5

GV relay error

Valve? Is harness connected

_ P _ _ _

NOYES

Connect harness

YES NO

and Control Module?

Valve. Does each wire have

Disconnect harness from Gas

continuity between Gas Valve

Replace harness

Replace Gas Valve

1.0 and 1.2 kohms?

Disconnect harness from

resistance across J13-3 and

Control Module J13. Measure

YES NO

J13-4. Is resistance between

Module

Replace Control

41

Check all wires, including

Igniter and Flame Sensor

leads. Check for proper and

connected?

board. Are all wires

tight connections to control

YES NO

13 - TROUBLE SHOOTING

Inspect the flue

way along the

sides of the baffle

near the coil for

Clear vent blockage

check for secure fit

Connect all wires and

Remove the gas

train including the

flue transition.

Remove the

burner and

blockages.

Is there any

apparent debris or

inspect.

Any sign of

obstruction of the

damage to burner

surface?

Tree

Valve

Refer to the Gas

Troubleshooting

YES NO

flue way?

section

Refer to the Heat

Exchanger cleaning

YES NO

Is this a new boiler on first

startup?

NO

YES

Is the Gas Shutoff

Valve closed?

propane gas?

YES NO

Is this boiler to run with

YES NO

valves

Open gas shutoff

YESNO

Inspect Vent

System for

blockages.

YES NO

Is the vent system

clear?

Reset the boiler by

pressing the

‘Reset’ button.

When the boiler

tries to ignite, is

there a strong,

Disconnect the gas

valve electrical

harness and close

`

consistent spark

evident throught

the sight glass?

Does the boiler

ignite and stay

running?

the gas shutoff

valve.

With the ignition

lead connected to

the igniter, hold the

YES NO

YES NO

tip near the chassis

ground and attempt

ignition.

Remove the flame

rod and igniter rod

and inspect. Is

Is a spark observed

between the igniter

and ground?

there any

indication of

damage or debris

baked on?

Replace Burner

YES NO

Replace Control

YES NO

rod or igniter

Replace/clean flame

Is the propane gas orifice

Lockout Alarm A 0 1

Ignit error

_ P _ _ _

properly installed?

Install propane

Orifice

Enter the Installer

Menu and place

the boiler into test

mode in high fire.

Once the boiler

starts, go to the

boiler status

screen and

monitor the flame

signal.

YES NO

Is the flame signal

greater than

8.0uA?

Check vent

of wind effects

termination for

proper consideration

42

13 - TROUBLE SHOOTING

NO

operating?

YES

Is Combustion Air Blower

Lockout Alarm A 0 8

Fan error

_ _ _ _ _

NO

Are 3-wire and 4-wire

YES

harnesses connected to

Combustion Air Blower?

Connect harness

Disconnect harness from

NO

Is voltage 120 Vac ± 10%

Control Module J9. Measure

voltage between J9-2 and J9-3.

Air Blower

Replace Combustion

NO

YES

Module

Replace Control

NO

YES

Disconnect 3-wire harness

Measure continuity in each

from Combustion Air Blower.

wire. Continuity in each wire?

Replace harness

Air Blower

Replace Combustion

speed increase?

YES

Disconnect 4-wire harness

from Combustion Air Blower.

Does Combustion Air Blower

43

Replace harness

in each wire of 4-wire harness

YES NO

(yellow, red, white, black)?

Module

Replace Control

Disconnect harness from

Control Module J9. Continuity

13 - TROUBLE SHOOTING

Correct wiring

NO

Module

Replace Control

operating?

YES NO

Is Combustion Air Blower

Lockout Alarm A 1 5

Air SW not open

_ P _ _ _

YES NO

terminals (interchangeable)?

Air Pressure Switch NO and C

Are orange wires connected to

Air Pressure Switch.

Disconnect orange wires from

NO

YES

Combustion Air Blower?

Is 4-wire harness connected to

Connect harness

NO

terminals?

YES

Continuity across NO and C

NO

Disconnect harness from

between J16-2 and J16-3?

Control Module J16. Continuity

Switch

Replace Air Pressure

Replace wire(s)

YES

Replace harness

44

YES

and Control Module J9.

Disconnect 4-wire harness

Continuity in each wire?

from Combustion Air Blower

Air Blower

Replace Combustion

Silicone Tubing

Flue Transition

Test Port

Combustion Air

Analyzer Port

13 - TROUBLE SHOOTING

Differential Air
Pressure Switch

Vinyl Tubing

Vinyl Tubing

Tee

Vinyl Cap
(Typ. 2)

Test Lines

-

(Or Differential Pressure Gauge)

Inclined Manometer

+

!

DANGER

Replace all test port caps. Failure to comply will
result in death or serious injury.

Flue

Transition

Test Port

Combustion
Air Analysis

Test Port

45

13 - TROUBLE SHOOTING

Connect harness

operating?

YES NO

Is Combustion Air Blower

Lockout Alarm A 1 7

Air SW not closed

_ P _ _ _

YES NO

Combustion Air Blower?

Is 3-wire harness connected to

in each wire?

YES NO

Control Module J9. Continuity

Are orange wires connected to

NC and C?

Air Pressure Switch terminals

Disconnect harness from

Disconnect 3-wire harness

from Combustion Air Blower.

NOYES

Connect wires

Replace wires

and J9-3. Is voltage

approximately 120 VAC?

Measure voltage between J9-2

Replace wires

Module

NOYES

Replace Control

Air Blower

Replace Combustion

See page 45

is each wire?

YES NO

Disconnect wires from Air

Pressure Switch. Disconnect

harness from J16. Continuity

46

Remove obstructions

YES NO

Is combustion air and vent

piping free of obstructions?

Connect manometer to Air

Pressure Switch tubing (see

INSTRUCTIONS to initiate

boiler operation. Is pressure

figure). Follow OPERATING

greater than 0.14" wc (35 Pa)?

Air Blower

NOYES

Replace Combustion

Switch

Replace Air Pressure

13 - TROUBLE SHOOTING

Replace Control

Module

NTC Resistance Chart

°F°C Resistance

3K to 9K ohms

50 to 9010 to 32 9K to 24K ohms

90 to 130

32 to 54

2K to 1K ohms

2K to 3K ohms

150 to 200

130 to 150

54 to 66

66 to 94

and Control Module J13.

Temperature Supply Switch

Lockout Alarm A 1 8

Max Temp Error

Disconnect harness from High

_ _ _ _ _

NO

Switch 3?

YES

1? Continuity from J13-6 to

Continuity from J13-5 to Switch

Replace wire(s)

NO

YES

less than 185°F (91°C)?

Is supply water temperature

YES NO

Switch open (no continuity

Is High Temperature Supply

between terminals 1 and 3)?

Switch

Replace High

Temperature Supply

Switch

Replace High

Temperature Supply

YES NO

High Temperature Supply

Switch terminals 2 and 4?

Measure resistance across

YES NO

Switch open (no continuity

Is High Temperature Supply

between terminals 1 and 3)?

Replace High

Does resistance match supply

water temperature (see table)?

Switch

Temperature Supply

Module

Replace Control

47

13 - TROUBLE SHOOTING

clean and secure?

Inspect harness connection

Lockout Alarm A 2 4

3 flame failures

Flame Sensor. Is connection

_ P _ _ _

NO

YES

Replace Flame

Sensor or harness

NO

YES

free of contamination?

Remove Flame Sensor. Is rod

Clean or replace

Follow OPERATING

Flame Sensor

INSTRUCTIONS to initiate

Menu, Boiler Status, Flame

boiler operation. Enter Installer

NO

than 3.7 uA?

YES

Signal. Is flame signal greater

Replace Flame

Sensor and Burner

Module

Replace Control

Blocking Error E 3 5

False flame detect

Inspect burner through sight

_ P _ _ _

Module

NOYES

glass. Is flame present?

Replace Control

Turn Gas Shutoff

Valve clockwise to

closed position.

Follow instructions

TO APPLIANCE.

TO TURN OFF GAS

Replace Gas Valve.

48

13 - TROUBLE SHOOTING

NO

amber lamp lit?

NO

YES

Check Low Water Cutoff.

NO

YES

Is Green Power Lamp lit?

NO

YES

Is Harness plugged into Low Water Cutoff?

Is Black/White Harness plugged into 24 volt harness?

Is Blue/Yellow Harness plugged into 24 Vac Transformer?

Insert Harness

Disconnect Black/White

NO

Disconnect Blue/Yellow

harness from Transformer.

YES

Vac. Is 24 to 30 Vac present?

Using digital meter check for 24

Connect harness to

Transformer. Disconnect

Harness?

YES

Is 120 Vac measured at

Harness from Transformer.

NO

terminals 1 & 2?

YES

Cutoff. Is 24 Vac at

harness from Low Water

Replace Main Harness

Replace Transformer

Blocking Error E 3 6

Low Water Cutoff

_ _ _ _ _

Check Low Water Cutoff. Is

NO

Replace Low Water Cutoff Replace Harness

Insert Harness

Replace Harness

YES

system and refill.

Repair System Piping,

remove any remaining air in

Control Module J16?

Is harness plugged into

Harness OK?

YES NO

continuity if harness.

Low Water Cutoff and

Disconnect harness from

Control Module J16. Check

Replace Low Water Cutoff

49

13 - TROUBLE SHOOTING

Blocking Error E 4 4

_ P _ _ _

Phase error

Measure incoming power with

NOYES

VAC? Is 120 VAC (N)

volt meter. Is terminal 120

approximately 0 VAC?

VAC (L) approximately 120

Module

Replace Control

Correct field wiring

Blocking Error E 4 0

Return Temp

_ _ _ _ _

Is correct harness connected to

return sensor (2 Brown Wires)?

NOYES

Correct wiring

oriented properly?

Is Heat Exchanger Pump

YES NO

(Pump Arrow pointing down?)

Install Heat

proper orientation

Exchanger Pump in

Return Water Sensor.

Disconnect harness from

Measure resistance using

digital ohm meter. Is

resistance between 950 to

Sensor

Replace Return Water

33,000 ohms?

YES NO

Module

Replace Control

50

13 - TROUBLE SHOOTING

+/- 2%

Blocking Error E 4 5

Net frequency error

_ P _ _ _

and 61 Hz?

Is power supply between 59

NO

YES

stabilized power

Provide frequency

supply rated at 60 Hz

breaker

NO

loose or faulty?

YES

Is power supply circuit breaker

Replace circuit

NO

YES

Is field wiring loose or faulty?

Module

Replace Control

Correct wiring

51

13 - TROUBLE SHOOTING

Insert Harness

NOYES

Replace Wires

Sensor

Blocking Error E 4 6

Faulty ground

_ P _ _ _

Control Module J5?

Supply Water Sensor?

Is harness plugged into

Is harness plugged into

Blocking Error E 5 1

Supply Sens Open

_ P _ _ _

conductor

Connect ground

YES NO

connected to High Voltage

Is field grounding conductor

Terminal Strip 120 VAC (G)?

Replace Supply Water

Continuity?

YES NO

Control and Sensor.

brown wires between

Disconnect J5 from Control

Module. Using digital meter

measure check continuity of

11 andJ5-3. Measure

digital meter. Estimate

resistance between Supply

Using digital meter measure

RTD Resistance Chart

conductor

NOYES

Correct faulty ground

resistance of Sensor with

Water Sensor terminals J5-

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

90 to 130

32 to 54

Sensor temperature. Does

2K to 3K ohms

130 to 150

54 to 66

it fall in the range of the

RTD Resistance Chart?

2K to 1K ohms

150 to 200

66 to 94

YES NO

Replace Control Module

10 ohms?

Disconnect field wiring. Is

neutral and ground less than

continuity between field wiring

Module

Replace Control

52

13 - TROUBLE SHOOTING

Insert Harness

Replace Wires

NOYES

Blocking Error E 5 2

Return Sens Open

_ P _ _ _

Return Water Sensor?

Is harness plugged into

Is harness plugged into

Control Module J5?

Check continuity of brown

wires between Return Water

YES NO

Sensor and Control Module

J5-4 and J5-12 Continuity?

Using digital meter measure

RTD Resistance Chart

Water Sensor terminals.

resistance between Return

°F°C Resistance

Estimate Sensor

Measure resistance of

Sensor with digital meter.

temperature. Does it fall in

2K to 3K ohms

3K to 9K ohms

50 to 9010 to 32 9K to 24K ohms

90 to 130

130 to 150

YES NO

Resistance Chart?

the range of the RTD

2K to 1K ohms

150 to 200

Sensor

Replace Return Water

Replace Control Module

53

54 to 66

32 to 54

66 to 94

13 - TROUBLE SHOOTING

Replace wires

Switch 4?

Supply Water Sensor.

Blocking Error E 5 9

Supply Sensor Shorted

Disconnect wire harness from

_ P _ _ _

NOYES

Switch terminals 2 and 4.

High Temperature Supply

Measure resistance across

Does resistance match supply

water temperature (see table)?

Insert harness

Disconnect J5 from Control

Module. Continuity between

Replace High

Temperature Supply

J5-11 and Switch 2?

Continuity between J5-3 and

Switch

YES NO

Module

Replace Control

NTC Resistance Chart

°F°C Resistance

3K to 9K ohms

50 to 9010 to 32 9K to 24K ohms

90 to 130

32 to 54

2K to 1K ohms

2K to 3K ohms

150 to 200

130 to 150

54 to 66

66 to 94

NOYES

Module J5?

Temperature Sensor? Is

Is harness plugged into Vent

Blocking Error E 5 7

Flue sens open

harness plugged into Control

_ P _ _ _

Replace wires

for each blue wire?

Temperature Sensor and

Disconnect harness from Vent

YES NO

Control Module J5. Continuity

Vent Temperature Sensor

Measure resistance across

54

match estimated flue

terminals. Does resistance

temperature (see table)?

YES NO

Replace Vent

Temperature Sensor

Module

Replace Control

13 - TROUBLE SHOOTING

Blocking Error E 6 5

Flue Sens Shorted

_ P _ _ _

NOYES

Does resistance match

Flue Temperature Sensor.

Measure Sensor resistance.

Disconnect wire harness from

estimated flue temperature?

Replace Flue

Temperature Sensor

in blue wires?

Disconnect harness from

Control Module J5. Continuity

YES NO

°F°C Resistance

Replace wires

Module

Replace Control

NTC Resistance Chart

50 to 9010 to 32 9K to 24K ohms

2K to 3K ohms

3K to 9K ohms

90 to 130

130 to 150

54 to 66

32 to 54

2K to 1K ohms

150 to 200

66 to 94

Disconnect harness from

Blocking Error E 6 0

Return sens shorted

_ P _ _ _

Disconnect harness from

Control Module J5. Measure

less than 50 ohms?

Return Water Sensor.

Measure resistance across

YES NO

sensor terminals. Is resistance

Sensor

Replace Return Water

55

resistance between brown

wires at terminals J5-4 and J5-

12. Is resistance less than 50

NOYES

ohms?

Module

Replace Control

Replace wires

14.1 Connection Diagram

15 - WIRING DIAGRAM

56

15 - WIRING DIAGRAM

14.2 Schematic Diagram of Ladder Form

L

LIGHTED
POWER
SWITCH

LWCO

AIR
PRESSURE
SWITCH

CH

THERMOSTAT

USER

INTERFACE

SUPPLY

SENSOR

RETURN

SENSOR

DHW

THERMOSTAT

FLUE

SENSOR

SYSTEM

SENSOR
(OPTIONAL)

OUTDOOR

SENSOR

ARGUS LINK
POWER

ARGUS LINK /
MULTI BOILER
(OPTIONAL)

43

2 NO

C

3 NC

DISPLAY

4

2

ON
OFF

J22-6
J22-5
J22-4
J22-3

J16-1
J16-4

J16-5
J16-8

J16-6
J16-7

J16-3
J16-2

J5-9
J5-1

J5-10
J5-2

J5-11
J5-3

J5-12
J5-4

J5-13
J5-5

J5-14
J5-6

J5-15
J5-7

J5-16
J5-8

S4

J18-1
J18-2

ARGUS

CONTROL

J12

J13-2

J9-1
J9-2
J9-6
J9-7
J9-5
J9-4
J9-3

J13-1

J13-5
J13-6

J13-3
J13-4

J7-1
J7-4
J7-3
J7-2

J6-1
J6-3
J6-2

J4-1
J4-2
J4-3
J4-4

J2-1
J2-2
J2-3
J2-4

NG

G

BURNER

T2

PE
DC+/L
+

DATA/PWM

HALL
GND
DC-/N

1

G
L

N

L
N
L

5

G
N
L

GROUND

FLAME SENSOR

IGNITION

FAN

120VAC

3

LIMIT

GAS VALVE

HEAT EXCHANGER
PUMP 120 VAC

DHW PUMP

120 VAC

FIELD SUPPLIED

1

CH PUMP
RELAY
120 VAC

43

5 A

BREAKER

CH PUMP
120 VAC
FIELD SUPPLIED

LM N

G

LWCO

24 VAC

1

RECEPTACLE
(REAR SHOWN)

120V / 24V, 15VA

TRANSFORMER

2

57

16 - GLOSSARY

ANSI• - American National Standards Institute, Inc. over­sees creation and maintenance of voluntary consen­sus standards, including ANSI Z21.13/CSA 4.9: Gas-Fired

Low Pressure Steam and Hot Water Boilers.
ASTM • - American Society for Testing and Materials. ASTM

International is one of largest voluntary standards devel­opment organizations in world trusted source for technical
standards for materials, products, systems, and services.
Known for their high technical quality and market relevan­cy, ASTM International standards have important role in
information infrastructure that guides design, manufactur­ing and trade in the global economy.

AUTHORITY HAVING JURISDICTION -• Individual or orga­nization adopting and enforcing codes, rules, and by-laws

HIGH-VOLTAGE• - Circuit involving potential of not more
than 600 volts and having circuit characteristics in excess

of those of low-voltage circuit.
IGNITER• - Device utilizing electrical energy to ignite gas
at main burner.
LEAK CHECK• - Operation performed on gas piping system
to verify system does not leak.
LOW WATER CUTOFF• - Device constructed to automati-

cally cut off fuel supply when surface of water in boiler
falls to lowest safe water level.
LOW-VOLTAGE• - Circuit involving potential of not more

than 30 volts.

METRIC GAS METERS•

governing various concerns of community. Commonly
referred to as "fi nal authority" for any matters relating
to LIFE SAFETY and BUILDING CONSTRUCTION within a

community.
Btu• - Abbreviation for British Thermal Unit. Quantity of

For example: Gas Meter measures 0.1 cubic Meters in 100
seconds

heat required to raise temperature of 1 pound of water1°F.
BURNER • - Device for fi nal conveyance of gas or mixture of
gas and air, to combustion zone.
COMBUSTION • - Rapid oxidation of fuel gases accompanied

by production of heat or heat and light. Complete combustion
of fuel is possible only in presence of adequate supply of

Oxygen.
COMBUSTIBLE MATERIAL• - Materials made of or surfaced

with wood, compressed paper, plant fi bers, or other
materials capable of being ignited and burned. Such ma­terial shall be considered combustible even though fl ame-

proofed, fi re-retardant treated, or plastered.

PRESSURE TEST• - Operation performed to verify gas
tight integrity of gas piping following its installation or
modifi cation.

PURGE • - To free gas conduit of air or gas, or mixture of
gas and air.
PURGE TIME• - Period of time intended to allow for dis-

sipation of any unburned gas or residual products of
combustion.
QUALIFIED AGENCY• - Any individual, fi rm, corporation, or

company engaged in and responsible for:

CONDENSATE• - Liquid separated from fl ue gas due to re-
duction in temperature.
DIRECT VENT BOILER• - Boiler constructed and installed so

all combustion air is derived directly from outdoors and all
vent gases are discharged to outdoors.
DRAFT• - Pressure difference causes gases or air to fl ow
through a chimney, vent , fl ue or appliance.
FLUE GASES • - Products of combustion plus excess air in

appliance fl ues or heat exchanger.

GAS PIPE SIZES•

NATURAL GAS

Length of Pipe

- Ft.

20 92,000 190,000 350,000 625,000
40
60 50,000 105,000 195,000 365,000

Length of Pipe

- Ft.

20
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000

Pipe Capacity - BTU Per Hour Input Includes Fittings

1/2” 3/4” 1” 1 1/4”

63,000 130,000 245,000 445,000

PROPANE GAS

Pipe Capacity - BTU Per Hour Input Includes Fittings

Copper Tubing

(Outside Diameter)

5/8” 3/4” 1/2” 3/4”

131,000 216,000 189,000 393,000

Iron Pipe

SAFETY RELIEF VALVE• - Valve designed to relieve
pressure, in hot water supply system, when pressure

exceeds pressure capability of equipment.
SAFETY SHUTOFF DEVICE• - Device that will shut off gas

supply to controlled burner in event source of ignition
fails.
SEDIMENT TRAP• - Gas piping arrangement designed to

collect any liquid or solid contaminant before reaching
gas valve.

VENT• - Passageway used to convey fl ue gases from
appliance vent connector to outdoors.
VENTING SYSTEM• - Continuous open passageway from

of appliance vent connector to outdoors for purpose of
removing fl ue or vent gases.

127,116 x cu meters

MBH

MBH

=

Seconds

127,116 x 0.1

=

100

= 127 MBH

Installation, testing, or replacement of gas piping, •
or connection, installation, testing, repair or
servicing of appliances and equipment.

Experienced in such work.•
Familiar with all precautions required.•
Complies with all requirement of authority having •

jurisdictions.

58

APPENDIX A - CONTROL MODULE

l

e

1.1 Introduction

The boiler is equipped with a programmable electronic con-
trol and user interface module.

n-

1.2 Operation

Display: 4x20 character LCD screen to show boiler •
status.

Function Keys•

Key Description

- Manual Lockout Reset

- Enter/Exit user menu

- Go to previous screen

- Select a menu item

- Confi rm new parameter value

- Scroll up to next menu item

- Increase value

- Scroll down to next menu item

- Decrease value

Operation with LCD character display module

eration with LCD character display modu

1.3 Status Indication

The following status screens can be displayed:

Boiler Status Indicator

F = Flame Detected

SERVICE Reminder

P = Boiler Pump On
B = Combustion Air Blower On
S = Safety Relay Check
G = Gas Valve Open
D = DHW Pump On

Combustion Air Blower
Speed Indicator

Service Reminder Indica
Boiler in Standby Mode

Boiler Supply Water
Temperature Indicator.

tor

Boiler Running in Central
Heat mode

Boiler Running in DHW
mode

Lockout Alarm Indicator

Error code and short text de­scription is displayed
Press 'Reset" key for manual
reset.

Boiler Running in DHW
mode

Error code and short text
description is displayed Boiler
automatically returns to Stand­by Mode when condition is
eliminated.

59

1.4 Sequence of Operation

Operational State User Interface Display Explanation

APPENDIX A - CONTROL MODULE

No

Heat

Demand?

Yes

DHW CH

Pump on

Supply

Temperature

<Setpoint?

Yes

Air Pressure

Switch Open?

No

No

Lockout

Error

A15

Standby: No Demand

Boiler operates in standby mode until
demand for Central Heat (CH) or Domes­tic Hot Water (DHW) is detected.

CH or DHW pump is turned based on
type of heating demand.

(CH call is illustrated)

Control Module compares supply
temperature to set point. Boiler proceeds
to ignition if supply temperature is less
than set point.

Air Pressure Switch is checked for open
circuit before energizing Combustion Air
Blower

Closed Air Pressure Switch during this
stage will result in Lockout Error.

Yes

Combustion

Air Blower

On

Air Pressure

Switch

Closed?

Yes

15 Second

Prepurge

Ignition

Sparking

After 2 seconds

No

After

3

Trials

Lockout

Error

A17

Combustion Air Blower is energized to
prove fl ow though Combustion and Vent
Systems.

Air Pressure Switch is checked for closed
circuit.

Open Air Pressure Switch during this
stage will result in Lockout Error after 3
trials.

Combustion Air Blower speed
modulates to prepurge setting for 15
seconds.

Initiates sparking

60

1.4 Sequence of Operation

Operational State User Interface Display Explanation

After 2 seconds

Flame

Detected?

No

Gas Valve
Energized

Yes

Lockout

Error A21

5 Ignition

Lockout A01

APPENDIX A - CONTROL MODULE

If fl ame detected before Gas Valve opens
during ignition boiler will lockout.

Please refer to troubleshooting guide.

Note:

trials,

then

Gas Valve energized to deliver air/fuel to
burner.

After 3 seconds

Flame

Detected?

Yes

Heat Demand

Met?

No

No

Simultaneous

DHW + CH

Demand?

Yes

DHW

Priority

Mode

No

See Max DHW

Priority Time

30 second

post purge

Yes

Setting

Flame undetected 3 seconds boiler will
de-energize Gas Valve and enter post
purge mode for 30 seconds.

Ignition attempted 5 times before lock­out.

Flame detected Boiler will run provided
all operational and safety devices devices
within limits

Refer to section 1.5 for more information.
Control module adjusts fi ring rate ac-

cording to heating demand. When Boiler
detects demand met, will enter post
purge mode and enter standby mode.

If simultaneous demand for Central Heat
and DHW, boiler will enter DHW Priority
Mode.

Mode limits amount of time boiler can
run in DHW mode to meet CH demand.

Max DHW Priority Time setting deter­mines maximum time allowed for DHW
heating mode.

Please refer to section 1.5 for more
information.

61

1.5 Theory of Operation

Standby: No Deman d

75° F

MENU



Bo i l e r St a t us
Set t i ngs
Cascade Sta tus

BO I LER STATUS ▲

Suppl y 140 °F
Return 120 °F
DHW S t a t Open

▼

BO I LER STATUS ▲

Syst em N.C.
Flue 132°F
Outdoor 36 °F

▼

BO I LER STATUS ▲

Bo i l e r Pump Of f
CH / Sys t em Pump O f f
DHW Pump O f f

BO I LER STATUS

Cur rent Suppl y
Setpoint 160°F

▼

APPENDIX A - CONTROL MODULE

STANDBY

User Menu

User Menu

User Interface Display

Explanation

Boiler operates in standby mode until demand for Central Heat
(CH) or Domestic Hot Water (DHW) is detected.

User Menu can be accessed by pressing ‘Menu’ key on user
interface.

Installer Menu can be accessed by simultaneously holding
‘Menu’ and ‘Enter’ keys for 5 seconds.

User Menu structure includes:

‘Boiler Status’ submenu– User can monitor general boiler •
status parameters such as sensor temperatures and
pump operation.

‘Settings’ submenu – User can view CH , adjust DHW •
supply water set points and also select control language.

‘Cascade Status’ submenu – Boiler set to function as •
part of multiple boiler installation; submenu used to view
runtime parameters. See Multiple Boiler Manual.

Boiler Status

Supply Temperature set point displayed.
If boiler running in CH mode, CH set point displayed.
Note:

While running in Outdoor Reset mode, this value may •
change in proportion with the outdoor temperature.

If the boiler is running in DHW mode, the DHW supply set •
point is displayed.

Several boiler runtime parameters can be viewed while in ‘Boiler
Status’ submenu.

Operational status of pump system also shown.
Information available during all states of boiler operation.

Sensor values with troubleshooting tree used to diagnose
typical problems.

62

SETT I NGS

Cen t ra l Hea t i ng
Setpoint

°F

▼

SETT I NGS ▲

DHW Se t po i n t

°F

▼

SETT I NGS ▲

Change
Temperature Uni ts

Fahrenhei t °F

▼

SETT I NGS ▲

Change
Language

Eng l i sh

▼

APPENDIX A - CONTROL MODULE

Settings

User Interface Display

Explanation

Adjust CH set point to hydronic system design while in
Operating in CH Mode = 0 (CH with Thermostat) or 3 (Perma­nent Demand).

Closed loop software control algorithm used to meet set point
temperature boiler uses. Algorithm calculates boiler modulation
rate based on several factors.

In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2
(CH with Full Outdoor Reset). Display will change to ‘OD Reset
Setpoint’ and cannot be changed. Controller is calculating set
point based on outdoor temperature.

Setting Range: 104..195 °F (40..91 °C)
Default Value: 140 °F (60 °C)

Note:

Explanation of available CH heating modes, refer to ‘CH •
Mode’ section located in ‘CH Settings’ submenu.

DHW set point determines supply water temperature set point
while operating in DHW mode.

Setting Range: 104..195 °F (40..91 °C)
Default Value: 180 °F (82 °C)

User interface temperature unit of measure is selected using
‘Change Temperature Units’ screen.

Fahrenheit and Celsius available.

Select user interface language using ‘Change Language’ screen.
English and French are available.

63

INSTALLER MENU



Bo i l e r St a t us
Bo i l e r Con f i g
CH Se t t i ngs
DHW Se t t i ngs
Cascade Set t ings
System Test

STAT US

Fa n Sp e ed

Ac t ua l 4000RPM
Low Power 1560RPM

▼

STAT US ▲

Fa n Sp e ed

I gn i t i on 3500RPM

H i Power 5725RPM

▼

STAT US ▲

Fl ame

Signal 07.2uA
Fai lures 2

▼

APPENDIX A - CONTROL MODULE

User Interface Display

Installer Menu

Installer Menu

Explanation

The Installer Menu structure includes:

‘Boiler Status’ submenu – User monitors detailed boiler •
status parameters such as fl ame signal, fan speeds and
stored error codes.

‘Boiler Confi g’ submenu – Modifi es general boiler •
settings.

‘CH Settings’ submenu – Modifi es advanced Central Heat-•
ing settings including outdoor reset curve parameters
and boost function.

‘DHW Settings’ – Modifi es Domestic hot Water control •
settings such as DHW priority time.

‘Cascade Settings’ - Refer to Multiple Boiler Manual.•

‘System Test’ – Tool aids setup of boiler installation or •
diagnosis of common problems.

Boiler Status

Pulse Width Modulated Combustion Air Blower provides airfl ow
through Combustion and Vent systems.

Fan speed is digital control and is determined by control
algorithm.

Fan speed status screen indicates actual fan speed in RPM, high,
low and ignition power speed settings.

Settings are for information only to aid in troubleshooting.

Boiler equipped with ionization rod to detect presence of
combustion using fl ame rectifi cation method. When fl ame is
present, fl ame ionization rod measures small DC offset current
across fl ame to ground (i.e. burner surface).

‘Flame’ screen in ‘Boiler Status’ submenu displays information
regarding fl ame ionization system; for information only and
used in diagnosing combustion problems. See troubleshooting
guide.

64

APPENDIX A - CONTROL MODULE

STAT US ▲

Ign i t i on Attempts

Suc c e s ful 4267
Fai led 21

▼

User Interface Display

Installer Menu

Explanation

Control module logs successful and failed ignition attempts.
Information accessed in ‘Ignition Attempts’ Screen as shown.

Ignition attempts are stored in non-volatile memory and are
retained in event of power failure.

Typical Ignition Cycle:

Following control features are implemented to ensure safe and
reliable operation of Combustion System:

Boiler Status

False Flame
Detection

Re-ignition

Intermittent
Operation

Flame out too
late

Safety relay test

UL3563 High
Limit Tempera­ture Device

If fl ame is detected at end of pre-spark
period (Ignit_0) than lockout will occur.

If at end of safety period no fl ame detected
control will go to post-purge removing
unburned gas. Re-ignition attempt started
following same cycle. Number of re-ignition
attempts limited to 4 after which lockout
occurs.

Boiler can be fi ring continuously for 24
hours. Burner switched off and restart
sequence follows.

If fl ame detected after post purge lockout
follows.

In Safety ON/OFF state correct operation
of safety relay is proved before ignition.

Boiler comes equipped with UL353
approved temperature high limit device.

Gas Valve energized when supply
temperature exceeds 195 °F lockout fol­lows.

65

STAT US ▲

Bo i l e r Run T ime

CH 320HR
DHW 145HR

▼

STAT US #E39 ▲

2H r s t o prev. Block

Low Water Cutoff

▼

STAT US #A01 ▲
13H r s t o prev. Lock

Ignition Error

BO I L E R C ONF I G
Add r e s s Se l e c t i on :

Bo i l e r Address: 0▼

BO I L E R C ONF I G ▲

LOW WA T ER CUTOFF

Disabled

▼

APPENDIX A - CONTROL MODULE

User Interface Display

Boiler Status

Explanation

Boiler stores information regarding total CH and DHW run time
in hours.

Data stored in non-volatile memory and retained in event of
power failure.

Boiler logs last 16 blocking errors and 16 locking errors in
non-volatile memory. Information retained in event of power
failure.

Most recent blocking error code and its text description
displayed with elapsed time in hours since logged.

Optional Computer interface Kit purchased separately to view
extended error code history

‘Address Selection” screen used to set boiler position in multiple
boiler cascade installation. Refer to Multiple Boiler Installation
Manual.

Default setting of ‘0’ indicates boiler is operating in single boiler
mode.

Boiler Confi guration

Boiler incorporates integrated Low Water Cutoff device (LWCO)
disables boiler when low water condition exists. LWCO device
located at high point of internal Heat Exchanger loop to detect
low water condition.

Detection of low water condition will result in blocking error,
boiler will automatically resume normal operation when proper
water level returns. Refer to Troubleshooting Guide.

LWCO device can be disabled for diagnostic purposes or where
applicable code permits.

66

BO I L E R C ONF I G ▲

Pump Mo de MODE: 0

CH o r C H&DHW

▼

BO I L E R C ONF I G ▲

SERV I C E REMI NDER

Status On
Rem i nder 365 days

APPENDIX A - CONTROL MODULE

User Interface Display

Explanation

Two pump modes are available:

Pump Mode = 0 ‘CH or CH&DHW’

1.

Mode either CH or DHW pump terminal energized •
dependant on demand (CH or DHW).

CH and DHW pumps not energized at same time.•

Simultaneous call for CH and DHW, energized pump •
dependant on boiler currently supplying CH or DHW

demand. Refer to DHW Priority settings below.

Typical hydronic system design with separate CH and DHW •
Pumps.

Pump Mode = 4 ‘System Pump’

2.

One external system pump installed in the hydronic system •
In mode only . Pump will energize independent of type of

demand (CH or DHW).

Connect pump to CH/System Pump electrical terminal •
block. See page ZZ for diagram

Boiler Confi guration

DHW pump terminal does not function.•

Typical hydronic system design utilizes zone valves for all •
CH zones and DHW indirect tank.

Note:

TPump Mode selection depends on electrical and hy-•
dronic system design. Refer to Installation, Maintenance
Manual for recommended hydronic piping and electrical
confi gurations.

Internal boiler pump energized anytime demand exists •
regardless of Pump Mode setting or type of demand (CH

or DHW).

‘Service Reminder’ allows installer to enable or disable service
reminder notifi cation on User Interface at predefi ned interval

Service reminder does not affect boiler operation i. It is
reminder to t End User that routine preventative maintenance
required by qualifi ed service technician.

Allowed Range: 1..999 days

67

CH SETT INGS

CH mod e MODE:1

CH w i t h thermostat

▼

APPENDIX A - CONTROL MODULE

User Interface Display

CH Settings

Explanation

4. Central Heating (CH) modes available:

CH Mode = 0 ‘CH with Thermostat’•

Boiler will attempt to satisfy CH demand while CH ther-•
mostat input is closed.

Boiler will modulate its fi ring rate to maintain CH set •
point and match system heat load.

CH set point adjusted in ‘Settings’ submenu under ‘User •
Menu’

CH Mode = 1 ‘CH with Thermostat and Outdoor Reset’•

Boiler will attempt to satisfy CH demand when CH ther-•
mostat input is closed.
Boiler will modulate its fi ring rate to maintain CH set •
point and match system heat load.
CH set point calculated as function of outdoor tem-•

perature using outdoor reset curve. See fi gure x.x

• CH Mode = 2 ‘CH with Full Outdoor Reset’

Boiler will permanently attempt to satisfy CH de-•
mand.

CH thermostat input is ignored.•
CH set point calculated as function of outdoor •
temperature using outdoor reset curve. See fi gure. x.x

CH Mode = 3 ‘CH with Permanent Demand’•

Boiler will permanently attempt to satisfy CH •
demand.

CH thermostat input is ignored.•
CH set point is adjusted in ‘Settings’ submenu under •
‘User Menu’

Note:

• Once CH demand is satisfi ed (i.e. CH thermostat opens or
boiler determines its minimum fi ring rate exceeds system
heating load):

Burner shuts off, boiler enters post purge.•
CH pump continues to run for 30 seconds.•
Control will wait until Anti-cycle time of 180 seconds •

elapses before boiler fi res again. Prevents short-
cycling.

• The internal boiler pump is energized anytime a demand
exists regardless of Pump Mode setting or type of demand (CH or
DHW).

68

CH SETT INGS ▲

Warm Weather

Shutdown Temp

70°F

▼

CH SETT INGS ▲

Reset Curve Design

Bo i l e r 180°F
Ou t do o r 25°F

▼

CH SETT INGS ▲

R.Curve Mild Weath.

Bo i l e r 70°F
Ou t do o r 70°F

▼

CH SETT INGS ▲

Reset Curve

Bo i l e r Min 070°F
Bo i l e r Max 180°F

▼

APPENDIX A - CONTROL MODULE

User Interface Display

Allowed Range: 35..100 °F (2..38 °C)
Default Setting: 70 °F (21 °C)

A

Allowed Boiler Range: 60..195 °F
(40..91 °C)
Default Boiler Setting: 180 °F ( 82

°C)

B

Explanation

Outdoor temperature greater than Warm Weather Shutdown
Temperature, demand for CH blocked and pumps stopped.

Boiler capable of operating in Outdoor Reset Mode when
included Outdoor Sensor connected and proper CH Mode
selected.

If CH Mode = 1, ‘Outdoor Temperature Reset with Thermo­stat’ or 2, ‘Full Outdoor Reset’ boiler will adjust CH set point
proportional to outdoor temperature as defi ned by Outdoor
Reset Curve below.

Outdoor reset curve adjusted by modifying Design and Mild
Weather reference temperatures. See points A & of Reset Curve
below.

Calculated CH set point always limited between ‘Reset Curve
Boiler Minimum/Maximum’ temperatures. See points C & of
Reset Curve below.

Outdoor Reset Curve

Allowed Boiler Range: 35..120 °F (2..49 °C)
Default Boiler Setting: 70 °F (21 °C)

Allowed Outdoor Range: 35..85 °F (2..29 °C)
Default Outdoor Setting: 70 °F (21 °C)

CH Settings

C

D

Allowed Min. Range: 40..180 °F (4..82 °C)
Default Min. Setting: 70 °F (21 °C)

Allowed Max. Range: 80..195 °F (27..91 °C)
Default Max. Setting: 180 °F (82 °C)

A

D

B

C

Note:

Modes only function when outdoor temperature sensor •
connected.

‘Open’ outdoor sensor detected CH set point equal to •
‘Boiler Reset Curve Design’ temperature.

Outdoor temperature used for CH set point calcula-•
tion measured once a minute and averaged with
previous measurement to address rapid outdoor
temperature variations.

69

CH SETT INGS ▲

Boos t Function

Temp 10°F
Time 20min

▼

CH SETT INGS ▲

Max imum Power CH

Max 100%

▼

DHW S E T T I NGS

DHW m o d e MODE : 1
DHW s t o r e w i t h
senso r

▼

APPENDIX A - CONTROL MODULE

User Interface Display

CH Settings

Explanation

Outdoor reset boost function increases CH set point by
increment (‘Temp’) if CH demand continues beyond pre-set
time limit (‘Time’).

CH set point will continue to increase until set point reaches
195°F / 90.5 °C

Allowable Temperature Increment: 0..36 °F (0..20 °C)
Default Temperature increment: 18 °F (10 °C)

Allowable Time Delay: 1..120 minutes
Default Time Delay: 20 minutes

Maximum boiler power in CH mode limited by adjusting
‘Maximum Power CH’ setting. Boiler will not exceed this value
while operating in CH Mode.

Allowable Range: 1..100%
Default Setting: 100%

Two DHW modes are available

DHW Mode = 0 ‘No DHW•

DHW Mode is disabled•
The DHW thermostat input is ignored and the DHW •

pump is not used.

DHW Settings

• DHW Mode = 2 ‘DHW Store with Thermostat’
Boiler reacts to DHW demand when DHW thermostat •

input closes.
Boiler modulates to meet DHW demand similar to CH •

Mode except DHW set point is used. DHW set point set
in Settings’ submenu found in 'User Menu’.

Simultaneous CH & DHW demands handled using DHW •
Priority Timing. See ‘DHW Maximum Priority Time’
below.

Note:

Outdoor reset function disabled while operating in DHW •
Mode
Hydronic system design which utilizes DHW indirect tank.•
After DHW demand satisfi ed, boiler enters post purge •

mode and DHW pump continues to run for 15 seconds.

70

DHW S E T T I NGS ▲

DH W m a x . p r i o r i t y

time

30min

SYSTEM TEST

Set t est power

Of f

SYSTEM TEST

Boi l e r Pump Off
CH\ Sys t em Pump Off
DHW Pump Off

APPENDIX A - CONTROL MODULE

User Interface Display

DHW Settings

Explanation

DHW demand prioritized over CH demand when DHW Mode 2 is
enabled.

Maximum time boiler operates in DHW mode limited by DHW
Maximum Priority Time Setting.

Priority timer starts when CH and DHW demand is present.
Boiler will switch from DHW back to CH operation after Maxi­mum Priority Time has elapsed.

CH demand has priority until Maximum Priority Time has
elapsed.

Process repeats until either CH or DHW demand satisfi ed.
Allowed Range: 1..60 Minutes

Default Setting: 30 Minutes

System test can be activated via installer menu, for testing sys­tem at fi xed power rates.

Boiler can be started without CH or DHW being present.
System Test has priority over any system demand while test
mode activated.

System test mode automatically ends after 30 minutes boiler
resumes normal operation.

System Test

The following modes are available:

Disabled•
Low power - Burner starts. After ignition period has •

fi nished the burner stays at low power
Ignition power - Burner starts. Stays at ignition power•
High power - Burner starts. After ignition period has •
fi nished burner stays at high power.

Note:

Before running system test modes, check if hydronic •
system capable of dissipating heat.

During system test only boiler and CH pump will be on.•
Boiler will run at fi xed power rates until supply water •

temperature is 93°C/200°F during System Test Mode.
All other safety functions remain active while in System •

Test Mode.

71

ECR International, Inc.
2201 Dwyer Ave.
Utica, NY 13501

www.ecrinternational.com

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