ECR International 75, 100, 075 97gb, 100 97gb Installation, Operation & Maintenance Manual

CONDENSING

GAS BOILER

Models 075 & 100

INSTALLATION,

OPERATION &

MAINTENANCE

MANUAL

H

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

DIMENSIONS

FIGURE 1-1 Dimensions

(D)

Wall Hanging

Bracket

(D)

(B)

Vent Connection

Supply Water

Gas

Connection

(G)

(F)

Floor

(E)

Combustion Air

Return Water

(E)

User Interface

(A)

(B)

Size

075

/100

Width

(A)

22-1/16"

(560mm)

(H)

(I)

Condensate

Drain

Height

(B)

35-5/8"

(905mm)

Alternate Gas

Supply Water

Depth

(C)

16-3/16"

(411mm)

Connection

(F)

Alternate

(E)

Table 1 : Physical Data

Bracket

(D)

27-1/2"

(969mm)

Water Connections

Size

(E)

1-1/4"

NPT

Height

(F)

31-1/16"

(789mm)

(C)

Alternate

Return Water

(E)

Gas

Connection

(G)

1/2" NPT 7-1/2" 5"

Condensate Drain

(H) (I)

Weight

Shipping Unit

140 lb

(63.5 kg)

115 lb

(51.2 kg)

2

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..........................................................................................................18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3

1 - INTRODUCTION

1.1 Designated Use

Hot water heating boiler.•
Indoor installation.•
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 195°F (90.5°C) system design temperature.•

1.3 Operational Features

Modulating: 20-100%.•
Integral Dual Limit.•
Integral Low Water Cutoff (with test button).•
Outdoor Temperature Reset.•

Integral Multiple Boiler Control.•

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, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.

2.2

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.

2.3 Installation shall conform to requirements
of authority having jurisdiction or in absence of
such requirements:

United States

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

National Electrical Code, NFPA 70.•

Canada •

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

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

2.4 Where required by authority having

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

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of
Massachusetts:

Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not

limited to:

Installation by licensed plumber or gas fi tter.•

.

!

CAUTION

Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal
injury.

5

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

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 (with test button).

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.

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 information

(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 (with test button).

Safety Relief Valve

23.

Field installed. See 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) - Factory supplied,

(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)
1-1/4"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

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 (29)

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.

Pressure Switch

36.

(see page 7)

(see page 7)

(see page 9)

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

(not shown)

(see page 7) - Convenience

(see page 7)

(see page 9) - Gently pull

(see page 9)

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

Test Port

37.

Combustion Analysis Test Port

38.

- (see page 8)

6

- (see page 8)

FIGURE 3-1 Boiler Components

LOW VOLTAGE

TERMINAL

STRIP

SAFETY

RELIEF

VALVE

AIR VENT

RETURN WATER

FROM HEATING

SYSTEM (IN)

HIGH VOLTAGE
JUNCTION BOX

SUPPLY WATER TO

HEATING SYSTEM

(OUT)

GAS CONNECTION

SERVICE SWITCH

AUXILIARY POWER

OUTLET

CENTRAL HEATING

PUMP CIRCUIT BREAKER

BRACKET FOR

OPTIONAL WALL

MOUNT

LOW VOLTAGE

TERMINAL

STRIP

COMBUSTION

AIR INLET- 2" PVC

3 - COMPONENT LISTING

VENT

CONNECTOR - 2" PVC

HIGH VOLTAGE
JUNCTION BOX

SAFETY

RELIEF

VALVE

AIR VENT

RETURN WATER

FROM HEATING

SYSTEM (IN)

BRACKET FOR

OPTIONAL WALL

MOUNT

SUPPLY WATER TO

HEATING SYSTEM

(OUT)

GAS CONNECTION

SERVICE SWITCH

AUXILIARY POWER

OUTLET

CENTRAL HEATING

PUMP CIRCUIT BREAKER

NOTE:

See Section 5-3

For Safety Relief

Valve Piping
Instructions

7

3 - COMPONENT LISTING

LOW

VOLTAGE

TERMINAL

STRIP

HIGH VOLTAGE
JUNCTION BOX

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

IGNITER

SIGHT
GLASS

HEAT EXCHANGER

BALL VALVE

CONDENSATE

DRAIN 1/2" PVC

GAS SHUTOFF

VALVE

LOW WATER

CUTOFF

COMBUSTION

AIR

BLOWER

COMBUSTION

CHAMBER

GAS (CONTROL)

VALVE

USER INTERFACE

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

SUPPLY WATER TO

HEATING SYSTEM

(OUT) 1-1/4" NPT

HEAT EXCHANGER

PUMP

SAFETY RELIEF VALVE

COMBUSTION

ANALYSIS TEST

PORT

IN-LINE

PRESSURE

SWITCH

VAPOR

COLLECTOR

FIGURE 3-2 Boiler Components

HIGH VOLTAGE
JUNCTION BOX

SAFETY RELIEF VALVE

NOTE:

See Section 5

For Piping

Instructions

LOW WATER

CUTOFF

HIGH TEMPERATURE

SUPPLY SWITCH

GAS (CONTROL)

VALVE

COMBUSTION

AIR

BLOWER

VENT CONNECTOR

(2" PVC)

USER INTERFACE

COMBUSTION

AIR INLET

2" PVC

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

LOW

VOLTAGE

TERMINAL

STRIP

IGNITER

FLAME

SENSOR

SIGHT
GLASS

TEST PORT

COMBUSTION

CHAMBER

GAS SHUTOFF

VALVE

(SHOWN IN OPEN

POSITION)

HEAT EXCHANGER

PUMP

CONDENSATE

DRAIN 1/2" PVC

VENT

TEMPERATURE

SENSOR

SUPPLY WATER TO

HEATING SYSTEM

(OUT) 1-1/4" NPT

HEAT EXCHANGER

BALL VALVE

DRAIN

VALVE

RETURN TEMPERATURE

SENSOR

IN-LINE

PRESSURE

SWITCH

VAPOR

COLLECTOR

COMBUSTION

ANALYSIS TEST

PORT

CONDENSATE

COLLECTOR

RETURN WATER

FROM HEATING

SYSTEM (IN)

1-1/4" NPT

8

Note: To open

Lift panel up

then pull forward

3 - COMPONENT LISTING

INTERNAL ACCESS

PANEL - CLOSED

CONTROL

MODULE

INTERNAL ACCESS

PANEL -OPEN

CENTRAL HEATING

PUMP RELAY

Control Module
Fuse and holder

TRANSFORMER

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 1.

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

Wall mounting. See section 4.2.•

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

Disposal of condensate. See section 6.•

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, proper operation 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)

½" (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 FLOOR

D

10

B

C

4 - LOCATING BOILER

!

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

Center brackets. Avoid

overhang on sides of wall

mount bracket.

4.2 Wall Mounting Option

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

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 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) 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.•
Boiler must engage with wall mount bracket. •
Avoid overhang on sides of wall mount bracket. Verify •

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

4 Slots for attaching Wall

Mount Bracket to Studs

!

CAUTION

Boiler weight exceeds 115 pounds (51.2 kg). 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. Heat exchanger
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.

!

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

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

Boiler rated at 50 psig (345 kPa) maximum
allowable working pressure. Boiler provided with
30 psig (206 kPa) safety relief valve. 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.

FIGURE 5-1 Safety Relief Valve & Air Vent

Safety Relief

Valve

3/4" NPT

Air Vent

3/4 NPT

90° Elbow

3/4" NPT

Close Nipple

3/4"F x 3/4"M

NPT Tee

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.

3/4" x 1/4" NPT

90° Elbow

12

5 - HYDRONIC PIPING

!

WARNING

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

FIGURE 5-2 Safety Relief Valve Discharge Piping

5.4 Trim Piping

Systems with automatic fi ll valves require back fl ow •
prevention device.

Install discharge piping from safety relief valve. See •
fi gure 5-2.

Use ¾" or larger pipe.•
Use pipe suitable for temperatures of 375°F (191°C) •

or greater.
Individual boiler discharge piping shall be independent •

of other discharge piping.
Size and arrange discharge piping to avoid reducing •

safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.

Run pipe as short and straight as possible to location •
protecting user from scalding and properly drain
piping.

Install union, if used, close to safety relief valve outlet.•
Install elbow(s), if used, close to safety relief valve •

outlet and downstream of union (if used).
Terminate pipe with plain end (not threaded).•

Supply and Return Piping•

Check Local Codes

For Maximum

Distance To Floor

FIGURE 5-3 Temperature Pressure Gauge
Installation

Temperature Pressure Gauge

shown at Optional Bottom

Supply Connection to Boiler

Supply - Select either top, bottom or both.•
Return - Select either top, bottom, or both.•
Use second temperature pressure gauge when piping •

top and bottom.
Install brass plug(s) provided with boiler in unused •

tapping(s). Use provided sealant.

Temperature - Pressure Gauge. Install temperature •
pressure gauge using nipple, bushing 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 •
guidance. 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, Kits & •
Optional Accessories" manual 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

FLOOR

Check Local Codes

For Maximum

Distance To Floor

14

5 - HYDRONIC PIPING

5-5 TWO-PIPE ZONED SYSTEM WITH VALVES

DHW
Pump

CH/System

Pump

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm

Open End

Wrench

5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS

DHW
Pump

Zone

Pump

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm

Open End

Wrench

15

5 - HYDRONIC PIPING

5-7 SINGLE BOILER USING PRIMARY/SECONDAY PUMPING

12"/305mm
Max. apart

CH/System

Pump

3/8"/10mm Open

End Wrench

12"/305mm Max. apart

Heat exchanger ball

valve open

Existing closely

spaced tees

in primary

system loop

Heat exchanger

ball valves closed

Limit length

to

5'/1.6 m

3/8"/10mm Open

End Wrench

16

5 - HYDRONIC PIPING

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

DHW
Pump

CH/

System

Pump

12"/305mm Max. apart

System

T emperature

Sensor

Size common piping

according to

maximum heat

capacity of

entire system

Up to 16

boilers

All heat exchanger

ball valves closed

3/8"/10mm Open

End Wrench

(See Multiple Boiler Guide)

17

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

This boiler requires a dedicated direct vent system.
Install combustion 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.

Install vent system in accordance with these instructions.

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.

After 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.

their previous condition of use.
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 approach
minimum size as determined using appropriate tables in
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)

Note: Concentric Vent Kit=5 ft (1.6m) equivalent
length

For Example: Boiler can be installed on outside wall and
vented with 1-90° elbow and 1 ft (0.30 m) 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

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

Cement/

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

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

!

WARNING

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

ANSI/ASTM D1784/

F441

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. Support horizontal sections to
prevent 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 (1.2m) or less. Allow for
expansion/contraction of pipe.

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 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 vent connector must be readily

accessible 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.

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

Vent Combustion

Air

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

Canada Minimum above

anticipated snow line

FIGURE 6-2

3" (8 cm)

Maximum

15" (38 cm)

Maximum

Roof Line

Roof

Terminations

y 3" (8 cm) Maximum horizontal
separation between combustion air
intake and vent of same appliance.

y 8" (21 cm) Minimum vertical
separation between combustion
air intake and vent of different
appliances.

y 15" (38 cm) Maximum horizontal
length of vent.

y Maximum vent/intake between
different appliances 12" (30cm).

y Maximum allowable total vertical
vent length with outside exposure
equals 10 ft.(3.05m).

y Abandoned unused masonry
chimney may be used as chase­way for combustion air and vent.
Both combustion air and vent pipe
must exit above top of chimney with
clearances as shown in fi gure 6-1.

12" (30 cm)

Minimum from

overhang

See snow & ice

page 23

FIGURE 6-3

3" (8 cm)
Maximum

separation

12" (30 cm) Separation

between bottom of

combustion air intake

and bottom of vent

Vent

Combustion Air

12" (30cm)

Minimum

separation

Side Wall

Terminations

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

y 8" (21 cm) Minimum vertical
separation between combustion air
intake and vent terminations.

y 12" (30 cm) Separation between
bottom of combustion air intake and
bottom of vent.

y Multiple terminations as shown in
6-1, 6-2, and 6-3 must be minimum
of 12” (30 cm) horizontally between
vent of one termination and air intake
of next appliance.

y Maximum allowable total outside
exposure vent length equals 10 ft.
(3.05m).

y Maintain a pitch of 1/2" per ft
(0.15m/m) back to boiler to ensure
proper condensate drainage for
horizontal runs.

See snow & ice

page 23

Combustion Air

Vent

20

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-4

1" (2.54cm)
Maximum

1"(2.54cm)
Maximum

Combustion

Vent

Air

NOTICE

Concentric termination kit reduces allowable intake/
vent piping length by 5' (1.5m) from that listed in
installation instructions.

FIGURE 6-7

FIGURE 6-5

1" (2.54cm)
Maximum

* See Note
Below

Combustion

Air

*Must be less than 4" or greater than 24" Horizontal dis­tance between end bells of each air intake to prevent fl ue
gas recirculation.

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

Roof overhang

12" (30cm) Minimum

36"(0.9m) Minimum

Maintain 12"(30cm) US

Vent

clearance above

(18"(46cm) Canada)

highest anticipated

clearance above highest

snow level or grade

anticipated snow level or

Maintain 12"

grade

OD 3½" (
OD 4½" (11.4cm) - 3" (7.6cm) kit

Combustion Air

Elbow fi eld
supplied

** Note Overall length may be modifi ed by cutting or
extending both combustion air and vent pipes. 12" is
minimum allowable length and 60" is maximum allowable
length for this dimension. SDR-26 PVC (D2241) only may
be used for extending pipes. Do not use Schedule 40 PVC
or use couplings to extend pipes. Dimension will change if
intake/vent pipes are lengthened or shortened.

8.9cm)

- 2" (

5.0cm)

kit

2 or 3" (5.0 or 7.6cm) Diameter

PVC intake/combustion air

2" (

5.0cm)

46-3/4" (1.2 m)

Diameter = 41" Length (1.0m)

3" (7.6cm) Diameter = 47" Length (1.2m)

**See

Note

Combustion Air

Vent

1"(2.54cm)
Maximum

21

6 - COMBUSTION AIR AND VENT PIPING

Concentric

Vent Roof

Termina-

tions

y Glue inner vent pipe to prevent
recirculation.

y Maintain 12" (30 cm) US (18"(46
cm) Canada) minimum clearance
above highest anticipated snow
level. Maximum of 24"(0.61m)
above roof.

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

y Elbow, roof boot/fl ashing fi eld
supplied.

y Allowed Wall/Roof thickness 1/2"-30"
(1.2 - 76cm).

y Vertical concentric vent system can be
installed in unused masonry chimney.

y Contact ECR Technical Support 800­325-5479, for questions regarding
installation or use.

FIGURE 6-6

Combustion Air

Roof boot/fl ashing
(fi eld supplied)

Note: Support must
be fi eld installed to
secure termination
kit to structure

Vent

Vent

Maintain 12"(30cm) US

(18"(46cm) Canada)

clearance above highest

anticipated snow level

24" above roof

Support
(fi eld supplied)

Combustion Air

22

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 system bottom,
minimum 12"(300 mm) above highest
anticipated snow level.

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

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

23

Vegetation,

Plants &

Shrubs

Meters,
Regulators,
deck, porch

Walkways

6 - COMBUSTION AIR AND VENT PIPING

Keep vent termination 3’ minimum
(0.9m) away from vegetation. Position
termination where vent vapors will not
damage plants/shrubs or air conditioning
equipment.

Termination

Vent termination US only - 4’ (1.2 m),
Canada - 6' (1.83m) horizontally from,
no case above or below, electric meters,
gas meters, regulators, and relief
equipment, or under deck or porch.

3' (0.9 cm)

Minimum

Locate vent termination minimum 7'
(2.1 m) above any public walkway, with
consideration to condensate.

People or

Pets

Stones,

Balls,

Etc.

Vapors

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 where vent vapors are
not objectionable.

7' (2.1 m)

Minimum

Position termination so it will not be

Eddy,

Flue

Gases

effected 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

24

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 ttings and cement.

Insert 1/2" (1.3 cm) PVC pipe through grommet in •
chassis. See fi gure 6-1.

Attach PVC tee provided with boiler and fi eld sourced •
piping to condensate drain vertical tee 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 kit as required •
by authority having jurisdiction or for environmentally

friendly condensate disposal.

PVC Tee (fi eld installed)

on condensate drain

pipe

25

!

7 - GAS SUPPLY PIPING

7-1 Gas Connection Knockout Plate at Bottom of
Boiler

Bottom cover

for Optional Gas

Connection

7.1 General

7-2 Gas connection at Top of Boiler

Gas Connection Top

of Boiler

7-3 Bottom Gas Connection

!

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 neighbor’s phone. Follow 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.

Provide sediment trap up stream of gas valve.•

Optional Bottom Gas

Connection

TABLE 5: GAS SUPPLY PRESSURE

SIZE

075/100 75,000

Maximum

Input (Btuh)

Note: See Glossary - Piping Table 16

7.2 Conversion Kit Instructions

See Gas Conversion Kit Instructions included with Boiler.•

Natural Gas Propane

Min. Max. Min. Max.

3.0" w.c.

(0.7 kPa)

13.5" w.c.
(3.3 kPa)

5.0" w.c.
(1.2 kPa)

13.5" w.c.
(3.4 kPa)

26

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 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.

7-4 Gas Connection Knockout Plate at Top of
Boiler

Top of Boiler Cover for

Gas Connection

7-5 Manual Main Gas Shutoff Valve Outside
Boiler Jacket

Manual Main Gas

Shutoff Valve

7.4 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. Iso-

•
late 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.

•

Option: Gas

Connection May be

Located

At Bottom of Boiler

7-6 Gas Shutoff Valve

Gas shutoff valve

(shown in closed

position)

27

8 - ELECTRICAL CONNECTIONS

8.1 General

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

USA- National Electrical Code, ANSI/NFPA 70.•
Canada - Canadian Electrical Code, Part I, CSA C22.1: •
Safety Standard for Electrical Installations.

8.2 Line Voltage Connections (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 (Full A.
Load Amps) 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 1.0 amp.

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

!

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 14 of this
Manual.

8-1 LINE VOLTAGE CONNECTIONS

8-2 LOW VOLTAGE CONNECTIONS

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 B.
improved access.

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

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 (Multiple boiler applications only)•

28

8 - ELECTRICAL CONNECTIONS

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

Use temperature control with dry contacts rated A.
at 0.5 amps @ 120 VAC. Boiler control does not
provide power to DHW temperature control.

IMPORTANT: Do not apply power to DHW T-T
terminals. Dry contact only, use of isolation relay
may be necessary.

Maximum wire length is 330 ft (100 m) 22 gauge B.
wire.

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

interchangeable.

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

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

NOTICE

29

9 - START UP PROCEDURE

9.1 Fill boiler with water and purge air

Fill boiler with potable water.•
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 condensate

•
drain.

Reconnect tubing to elbow with collet clip. See Figure

•
9-1.

NOTICE

IMPORTANT: Condensate trap must be manually
fi lled with water at initial start up.

9-1 Condensate Drain Assembly

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

trap with water.

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

30

9 - START UP PROCEDURE

e

9 -2 User Interface

-2 User Interfac

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

Boiler is factory programmed with following factory de­fault settings, Figure 9-3.

Parameters can be adjusted to suit particular
application.

Detailed explanation of each can be found in Appendix
A - Control Module.

List parameters in event of Control Module Failure to
reprogram your settings.

Factory De-

9-3 Default Table

Control Parameter

Central Heating Setpoint

User

Menu

Installer

Menu

* List parameters in event of Control Module Failure to reprogram your settings.

Settings

Boiler

Confi guration

CH Settings

DHW Setpoint 180°F 82°C 104 - 195°F 40 - 91°C
Temperature Units °F °F/°C
Language English English/French
Boiler Address 0 0-15
Low Water Cutoff Enabled Enable/Disabled
Pump Mode 0 0 & 4
Service Reminder Status On ON/OFF
Service Reminder Days 365 Days 1- 999 Days

CH Mode 1 0-3
Warm Weather Shutdown 70°F 21°C 35-100°F 2-38°C
Reset Curve Design Temperature - Boiler 180°F 82°C 60-195°F 40-91°C
Reset Curve Design Temperature - Outdoor 25°F -4°C -60-32°F -51-25°C
Reset Curve Mild Weather Temperature - Boiler 70°F 21°C 35-120°F 2-49°C
Reset Curve Mild Weather Temperature - Outdoor 70°F 21°C 35-85°F 2-29°C

Reset Curve Boiler Minimum Temperature 70°F 21°C 40-180°F 4-82°C
Reset Curve Boiler Maximum Temperature 180° 82°C 80-195°F 27-91°C
Boost Function Temperature 18°F 10°C 0-36°F 0-20°C
Boost Function Time 20 Minutes 1-120
Maximum Power CH 100% 1-100%
DHW Mode 0 0/2
DHW Maximum Priority Time 30 Minutes 1-60 minutes

fault Setting

Stan-

dard

140°F 60°C 104 - 195°F 40 - 91°C

Setting Range

Metric Standard Metric

*Actual

Parameter

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 2.

operational
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

•
immediately 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 7.

condensate 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 Maximum

075 65 85
100 90.0 110

Adjust rate if needed using diagram 9-3 below.3.

NOTICE

Contact ECR Technical Support @ 800-325-5479 for
additional information or assistance.

Check CO4.
and 10.0%. See Figure 9-4 Combustion air analyzer
port.

If CO

•
9-3.

If CO

•

Propane Gas

Most propane systems do not have fl ow meters.

Check CO1.

11.0%.
If CO

•
9-3.

If CO

•
9-3.

. Natural gas should be between 8.5%

2

is low increase gas fl ow following fi gure

2

is high decrease gas following fi gure 9-3.

2

. Propane should be between 9.5% and

2

is low increase gas fl ow following fi gure

2

is high decrease gas fl ow following fi gure

2

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. Measure

•
time required for one or more complete
revolutions. Measure time for 1-2 minutes.

Calculate input.

•

Input (MBH) =

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

Rate (MBH) =

*Metric - See Glossary

3600 x cu ft
seconds

3600 x 2 cu ft
72 seconds

= 100 MBH

9-3 Gas Valve

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

•
clockwise .

To decrease gas fl ow turn 'throttle' right or

•
clockwise .

Limit adjustment to one turn and retest.

•

1/4" FLAT HEAD
SCREWDRIVER

MIN

OUT

32

9 - START UP PROCEDURE

NOTICE

Combustion analyzer port is provided. After use
replace cover.

9-4 Combustion Analyzer Port

In-line Pressure Switch

Vapor Collector

Combustion Analyzer Port

Verify Burner, Proper Operation

Inspect burner fl ame through Sight Glass. See 1.
fi gure 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
conspicuous location adjacent to boiler.

9-5 Burner Flame

Burner

Flame

Flame

Look for BLUE fl ame

with slight YELLOW tips

evenly spaced around

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 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 lowest setting.•
Turn "• OFF" all electrical power to appliance.
This appliance is equipped with an ignition device which •

automatically lights the burner. Do not try to light

burner by hand!

Remove 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.
Reassemble per instructions in section 6. Ensure proper
reassembly and resealing of system.

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

Visually inspect in-line pressure switch vapor trap for •
water build-up. Drain condensate collector by removing
bottom fi tting if water is detected. See Figure 9-4.

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

Components” in this section.

Sight Glass

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

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

required;
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 by pressing test button on low water •
cutoff.

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

Should get error message on User Interface •
(E36).

Every 5 years remove low water cutoff. Reinstall •
after cleaning.

Every 10 years replace low water cutoff.•

Check fl ame signal with user interface. Should be 8 micro •
amps at 100%.

35

11 - GENERAL MAINTENANCE AND CLEANING

Visual inspection of fl ame through sight glass. Burner •
should be fully illuminated. See fi gure 9-5.

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 •
heating system is to remain out of service during freezing
weather.

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

!

WARNING

Following service procedures must be performed
by qualifi ed service agent. Boiler owner shall not
attempt these steps.

!

WARNING

Use gloves when handling refractory to avoid
absorption of crystiline silica a potentially dangerous
compound.

11-2 Blower Inlet Assembly

A

B

C

D

E

11.3 Annual Examination and Cleaning of Boiler
Components

Obtain Burner Inspection Kit. See "Parts, Kits and •
Optional Accessories" manual.

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 verify no fl ame is •
present.

F

Burner Assembly

A Blower Inlet Housing

B Refractory
C Burner

D Flame Sensor

E Igniter
F Sight Glass
* Inlet Gasket

* Not Shown

36

11 - GENERAL MAINTENANCE AND CLEANING

11-2 Condensate Collector

Condensate Collector

A Combustion Chamber
B Condensate Collector
C Condensate Drain

Examine fl ue passages by removing blower/burner •
assembly from heat exchanger.

Confi rm manual gas valve is closed.•
Disconnect fl ame sensor and igniter wires.•
Remove 2 screws and carefully remove igniter.•

A

B

C

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

Loosen and remove four nuts connecting fuel mixer •
assembly to heat exchanger.

Entire gas train can be moved aside. Take precaution •
to not kink fl exible gas hose.

Remove gasket and burner. It may be necessary to •
unlatch both of the Heat Exchanger locking straps.

Clean burner using air hose directed into top of •
burner opening. This will dislodge any debris build up
in burner ports.

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 •
replace gasket (in that order). Position fuel mixer
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 igniter wires, and gas valve wires.•

Visually inspect condensate trap. Remove any foreign •
material visible in condensate lines as described below:

I• nspect for sediment or blockage.

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

With Water” section 9.1

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

9.4.

.

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 •
allowable working pressure of 50 psig (pounds per
square inch gauge) (345 kPa) in accordance with ASME
Boiler and Pressure Vessel Code, Section IV, Rules for

Construction of Heating Boilers.

Ratings are for sea level applications. •
US - Boiler derates input 4% for every 1000 feet (304 •

m) above an elevation of 2000 feet (610 m) above sea
level.

Heating Capacity

(1)(2)

(MBH)

Net I=B=R Rating,

Water (MBH)

(1)(3)

AFUE

(2)

Canada - Boiler certifi ed for altitudes of 0-4500 feet •
(1350 m) above sea level. Contact Provincial authority
having jurisdiction for installations above 4500 feet
(1350 m) above sea level.

38

13 - TROUBLE SHOOTING

GO TO NEXT

PAGE

NO YES

Is User Interface Lit?

YES

NO

Power Switch Lamp Lit?

104Vac?

Is voltage at Service

Receptacle more than

YESNO

Display function?

Does User Interface

harness plugs are

Make sure all wire

properly pushed in.

NO

company

NO YES

Repair wiring or call utility

finger, remove and

reconnect all 7 plugs .

Release plug lock with

Check wiring from User

checking continuity of

Terminal Strip including

Interface to Low Voltage

YES

YESNO

NO

the wires. Does User

Interface Display work?

Remove User Interface

from base. Using Digital

present?

to 30 Vdc. Is voltage

Voltmeter check for 25

Replace Control Module Replace User Interface

NO

Is Lamp Lit?

YES

Turn on Boiler Switch.

YES

Hi-Voltage Terminal Box

Check for 120 Vac Inside

Turn off Circuit Breaker.

Check Circuit Breaker or

or Repair External Wiring

Emergency Disconnect Switch

and 120 Vac Wiring to Boiler. Fix

NO

Partially pull back ¼”

wire. Turn on Circuit

connectors on Boiler Switch.

Jump 1 & 2. Do not use bare

YES

Breaker. Is Power Lamp lit?

39

LWCO lamps lit?

YES NO

User Interface Display or

Replace Switch

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

A 0 1

Go to Page 42

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 _ _ _ _ _ _ _ _ _ _

A 0 8

Lockout Alarm Blocking Error E 4 4

Go to Page 43

Fan Error Phase Error

_ _ _ _ _ _ _ _ _ _ _ _
Lockout Alarm Blocking Error E 4 5

A 0 9 to A 1 4

lace Control

Re
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

_ _ _ _ _ _ _ P _ _ _ _
Lockout Alarm Blocking Error E 5 9

Replace Gas

A 2 1

Valve

Flame Error 1 Supply Sens Shorted

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

A 2 2 A 2 3

lace Control

Re
Module

Various Text Messages Return Sens Shorted

_ _ _ _ _ _ _ P _ _ _ _

A 2 4

Lockout Alarm Blocking Error E 6 5

Go to Page 48

3 Flame Failures Flue Sens Shorted

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

A 2 7 to A 3 0

Re

lace Control

Module

Various Text Messages Reset Button Error

_ _ _ _ _ _ _ _ _ _ _ _
Blocking Error Blocking Error

E 3 1 to E 3 4

Replace Control
Module

Various Text Messages Various Fan Error Te

E73 to E79

E 81, 88, 89

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

Go to Page 54

Go to Page 55

Go to Page 55

Error clears in
1-2 minutes

Re

lace Control

Module

40

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

J13-4. Is resistance between

YES NO

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

flue way?

damage to burner

surface?

YES NO

YES NO

Tree

Valve

Refer to the Gas

Troubleshooting

section

Refer to the Heat

Exchanger cleaning

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,

consistent spark

Disconnect the gas

evident throught

Does the boiler

valve electrical

harness and close

the gas shutoff

valve.

YES NO

the sight glass?

YES NO

ignite and stay

running?

With the ignition

lead connected to

the igniter, hold the

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.

Is the flame signal

greater than

8.0uA?

Check vent

YES NO

termination for

of wind effects

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

Disconnect harness from

Control Module J9. Continuity

(yellow, red, white, black)?

in each wire of 4-wire harness

YES NO

Module

Replace Control

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

13 - TROUBLE SHOOTING

13-1 Differential Air Pressure Switch

Connect manometer to Air Pressure Switch tubing (see
fi gure 13-2). Follow operating instructions to initiate boiler
operation. Refer to Trouble Shooting Tree page 46.

!

DANGER

Test Port

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

Combustion

Analyzer Port

Differential Air
Pressure Switch

Vinyl Tubing

Silicone Tubing

Vinyl Tubing

Tee

Vinyl Cap
(Typ. 2)

Test Lines

-

+

Inclined Manometer

(Or Differential Pressure Gauge)

13-2 Test Port Locations

Test Port

In-line Pressure

Switch Vapor

Collector

Combustion

Analyzer
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

2K to 1K ohms

2K to 3K ohms

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

Resistance Chart

90 to 130

150 to 200

130 to 150

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

High Temperature Supply Switch

YES NO

Switch open (no continuity

Is High Temperature Supply

between terminals 1 and 3)?

Switch

Replace High

Temperature Supply

Replace High

Temperature Supply

YES NO

High Temperature Supply

Switch terminals 2 and 4?

Measure resistance across

Does resistance match supply

water temperature (see table)?

Module

32 to 54

Switch

54 to 66

66 to 94

47

Is High Temperature Supply

Switch open (no continuity

between terminals 1 and 3)?

Replace Control

YES NO

Switch

Replace High

Temperature Supply

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

boiler operation. Enter Installer

Menu, Boiler Status, Flame

Signal. Is flame signal greater

NO

than 3.7 uA?

YES

Replace Flame

Sensor and Burner

Module

Replace Control

Blocking Error E 3 5

False flame detect

_ P _ _ _

Module

NOYES

glass. Is flame present?

Inspect burner through sight

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

Harness?

YES

Is 120 Vac measured at

Harness from Transformer.

terminals 1 & 2?

Cutoff. Is 24 Vac at

harness from Low Water

Transformer. Disconnect

YES

Replace Main Harness

Replace Transformer

NO

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

Replace circuit

loose or faulty?

YES

Is power supply circuit breaker

NO

YES

Is field wiring loose or faulty?

Module

Replace Control

Correct wiring

51

13 - TROUBLE SHOOTING

Blocking Error E 5 1

Supply Sens Open

_ P _ _ _

NOYES

Module J5?

Water Sensor?

Is harness plugged into Supply

Is harness plugged into Control

Insert Harness

Disconnect J5 from Control

Module. Using digital meter

measure check continuity of

and Sensor. Continuity?

brown wires between Control

YES NO

Replace Wires

Using digital meter measure

resistance between Supply

of Sensor with digital meter.

Water Sensor terminals J5-11

and J5-3. Measure resistance

Estimate Sensor temperature.

Does it fall in the range of the

Resistance Chart?

YES NO

Water Sensor

Replace Supply

Module

Blocking Error E 4 6

Faulty ground

_ P _ _ _

conductor

Connect ground

YES NO

connected to High Voltage

Is field grounding conductor

Terminal Strip 120 VAC (G)?

Disconnect field wiring. Is

continuity between field wiring

Replace Control

conductor

NOYES

Correct faulty ground

10 ohms?

neutral and ground less than

Module

Replace Control

°F°C Resistance

Resistance Chart

Supply Water Sensor

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

52

13 - TROUBLE SHOOTING

2K to 1K ohms

2K to 3K ohms

3K to 9K ohms

°F°C Resistance

50 to 9010 to 32 9K to 24K ohms

Resistance Chart

Return Temperature Sensor

90 to 130

32 to 54

150 to 200

130 to 150

54 to 66

66 to 94

Blocking Error E 5 2

Return Sens Open

_ P _ _ _

Module J5?

Temperature Sensor?

Is harness plugged into Return

Is harness plugged into Control

YES NO

Insert Harness

Continuity?

wires between Return

Temperature Sensor and

Check continuity of brown

Control Module J5-4 and J5-12

YES NO

Replace Wires

meter. Estimate Sensor

Measure Return Temperature

Sensor resistance with digital

temperature. Do temperature

ranges shown in chart?

and resistance fall within

Replace Return

Temperature Sensor

YES NO

Module

Replace Control

53

13 - TROUBLE SHOOTING

Replace wires

Switch 4?

High Temperature Supply

Blocking Error E 5 9

Supply Sensor Shorted

Disconnect wire harness from

_ P _ _ _

Switch. Measure resistance

across terminals 2 and 4. Do

NOYES

within ranges shown in chart?

temperature and resistance fall

Insert harness

J5-11 and Switch 2?

Disconnect J5 from Control

Module. Continuity between

Switch

Replace High

Temperature Supply

YES NO

Continuity between J5-3 and

Module

Replace Control

Resistance Chart

High Temperature Supply Switch

°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

Blocking Error E 5 7

Flue sens open

_ P _ _ _

Is harness plugged into Vent

Temperature Sensor? Is

harness plugged into Control

NOYES

Module J5?

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

Blocking Error E 6 5

Flue Sens Shorted

_ P _ _ _

13 - TROUBLE SHOOTING

NOYES

Does resistance match

Vent Temperature Sensor.

Measure Sensor resistance.

Disconnect wire harness from

estimated flue temperature?

Replace Vent

Temperature Sensor

in blue wires?

Disconnect harness from

Control Module J5. Continuity

YES NO

Replace wires

Module

°F°C Resistance

Resistance Chart

Vent Temperature Sensor

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

Disconnect harness from

Blocking Error E 6 0

Return sens shorted

_ P _ _ _

Disconnect harness from

Control Module J5. Measure

less than 50 ohms?

YES NO

Measure resistance across

Return Temperature Sensor.

sensor terminals. Is resistance

Sensor

resistance between brown

wires at terminals J5-4 and J5-

Replace Control

NOYES

ohms?

12. Is resistance less than 50

Module

Replace Control

Replace wires

Replace Return Water

55

14.1 Connection Diagram

14 - WIRING DIAGRAM

56

14 - WIRING DIAGRAM

14.2 Schematic Diagram of Ladder Form

57

15 - 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 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 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.

GAS PIPE SIZES•

NATURAL GAS

Length of Pipe

- Ft.

20 92,000 190,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000

Length of Pipe

- Ft.

20 131,000 216,000 189,000 393,000
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”

PROPANE GAS

Pipe Capacity - BTU Per Hour Input Includes Fittings

Copper Tubing

(Outside Diameter)

5/8” 3/4” 1/2” 3/4”

Iron Pipe

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 automatically

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.

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.
CONDENSATE• - Liquid separated from fl ue gas due to

reduction in temperature.

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

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.

FLA • - Full load amps.
FLUE GASES • - Products of combustion plus excess air in

appliance fl ues or heat exchanger.

METRIC GAS METERS•

127,116 x cu meters

MBH

MBH

=

Seconds

127,116 x 0.1

=

100

= 127 MBH

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
dissipation of any unburned gas or residual products of

combustion.

58

15 - GLOSSARY

QUALIFIED AGENCY• - Any individual, fi rm, corporation, or
company engaged in and responsible for:

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 requirements of authority having •

jurisdiction.

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.

59

APPENDIX A - CONTROL MODULE

Op

l

e

1.1 Introduction

Boiler is equipped with programmable electronic control
and user interface module.

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 = Central Heating System 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.

Blocking Error in DHW

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

60

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.

Sparking initiated sequence.

61

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

If fl ame undetected after 3 seconds boiler
will de-energize Gas Valve and enter post
purge mode for 30 seconds.

Ignition attempted 5 times before
lockout.

Boiler will run provided all operational
and safety devices are within limits

Refer to for more information.
Control module adjusts fi ring rate

according to heating demand. When
Boiler detects demand met, will enter
post purge mode then standby mode.

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

Priority 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 Appendix A section

1.5 for more information.

62

1.5 Theory of Operation

MENU



Bo i l e r S t a t us

Se t t i ngs

Cascade St a tus

BO I L ER STAT US ▲

Supp l y 14 0 °F

Re t u r n 12 0 ° F

DHW S t a t Op e n

▼

BO I L ER STAT US ▲

Sys t em N.C .

Flue 132°F

Ou t doo r 36 ° F

▼

BO I L ER STAT US ▲

Bo i l e r Pump O f f

CH / Sy s t em P ump O f f

DHW P ump O f f

BO I L ER STAT US

Cur r en t Supp l y

Set point 160 ° F

▼

St andby : No Dema n d

75° 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.

63

SETT I NGS

Cen t r a l He a t i ng

Se t po i n t

°F

▼

SETT I NGS ▲

DHW S e t p o i n t

°F

▼

SETT I NGS ▲

Cha nge

Tempera t ure Un i t s

Fahrenhe i t ° F

▼

SETT I NGS ▲

Cha nge

Language

Eng l i sh

▼

APPENDIX A - CONTROL MODULE

User Interface Display

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

Settings

Explanation

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

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 calculates set point
based on outdoor temperature.

Note:

For 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° F to 195° F (40° C to 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.

64

INSTALLER MENU



Bo i l e r S t a t us

Bo i l e r Con f i g

CH Se t t i ng s

DHW S e t t i n g s

Cascade Set t i ngs

System Test

STA T U S

Fa n S p e ed

Ac t u a l 4000RPM

L ow P owe r 1560RPM

▼

STA T U S ▲

Fa n S p e ed

I g n i t i on 3500RPM

H i P ower 5725RPM

▼

STA T U S ▲

Fl ame

Signa l 07.2uA

Fa i l ures 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 •
Heating 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

Combustion air Blower provides airfl ow through Combustion and
Vent systems.

Fan speed status screen indicates actual and operational fan
speeds 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.

65

APPENDIX A - CONTROL MODULE

STA T U S ▲

Ign i t i on At tempts

Su c c e s ful 4267

Fa i 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.

Figure A-1 Typical Ignition Cycle

Boiler Status

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

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 de-energized when supply
temperature exceeds 203°F lockout
follows.

66

STA T U S ▲

Bo i l e r Run T ime

CH 320HR

DHW 145HR

▼

STA T U S # E3 9 ▲

2H r s t o prev . Block

Low Water Cutoff

▼

STA T U S #A01 ▲

13H r s t o prev . Lock

Igni t ion Error

BO I L E R C ONF I G

Add r e s s Se l e c t i o n :

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 lockout 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)
that 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.

67

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 ▲

SE R V I C E REMI NDER

Sta tus On

R em i n d er 365 days

APPENDIX A - CONTROL MODULE

User Interface Display

Explanation

Two pump modes are available:

Pump Mode = 0 ‘CH or CH&DHW’

1.

In this mode either the CH or DHW pump terminal is •
energized depending on the type of demand (CH or DHW).

CH and DHW pumps are never energized at the same time.•

In the case of a simultaneous call for both CH and DHW, •
the energized pump depends on whether the boiler is
currently supplying the CH or DHW demand. Refer to DHW
Priority settings below.

This is typical of a hydronic system design with separate CH •
and DHW Pumps.

Pump Mode = 4 ‘System Pump’

2.

In this mode only one external system pump is installed in •
the hydronic system. This pump will energize independent
of the type of demand (CH or DHW).

Boiler Confi guration

Connect this pump to the CH/System Pump electrical •
terminal block. See page 56 for diagram.

The DHW pump terminal does not function.•

This is typical of a hydronic system design which utilizes •
zone valves for all CH zones and an DHW indirect tank.

Note:

Pump Mode selection depends on electrical and •
hydronic system design. Please refer to sections 5
and 8 for recommended hydronic piping and electrical
confi gurations.

Internal heat exchanger pump is energized anytime •
demand exists regardless of Pump Mode setting or type
of demand (CH or DHW).

'Service Reminder’ feature allows the installer to enable or
disable a service reminder notifi cation on the User Interface at a
predefi ned interval .

Service reminder does not affect operation of boiler in any way.
It is only a reminder to End User that routine preventative
maintenance is required by qualifi ed service technician.

Allowed Range: 1 to 999 days

68

CH SETT I NGS

CH mo d e MODE:1

CH w i t h thermosta t

▼

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 •
thermostat 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 •
thermostat 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 •

temperature using outdoor reset curve. See Figure A-2

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

Boiler will permanently attempt to satisfy CH •
demand.

CH thermostat input is ignored.•
CH set point calculated as function of outdoor •
temperature using outdoor reset curve. See Figure A-2

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 heat exchanger pump is energized anytime demand
exists regardless of Pump Mode setting or type of demand (CH or
DHW).

69

CH SETT I NGS ▲

Wa rm We at her

Shut down Temp

70°F

▼

CH SETT I NGS ▲

Reset Curve Design

Bo i l e r 180°F

Ou t d o o r 25 °F

▼

CH SETT I NGS ▲

R.Curve Mild Weath.

Bo i l e r 70°F

Ou t d o o r 70 °F

▼

CH SETT INGS ▲

Rese t Curve

Bo i l e r Mi n 070 °F

Bo i l e r Max 180°F

▼

APPENDIX A - CONTROL MODULE

User Interface Display

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

A

Allowed Boiler Range: 60°F to 195°F (40° C
to 91°C)

Default Boiler Setting:180° F (82°C)

B

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

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

CH Settings

Explanation

If outdoor temperature is 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 is 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 & B of Reset
Curve below.

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

Figure A-2 Outdoor Reset Curve

A

D

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

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

C

D

B

C

Note:

Modes only function when outdoor temperature sensor •
connected.

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

Outdoor temperature used for CH set point calculation •
measured once a minute and averaged with
previous measurement to compensate for rapid outdoor
temperature variations.

70

CH SETT I NGS ▲

Boos t F unct ion

Temp 10°F

Time 20min

▼

CH SETT I NGS ▲

Max imum Power CH

Ma x 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

se n s o 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 / 91°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’
setting below.

Note:

Outdoor reset function disabled while operating in DHW •
Mode.
Typical when using a DHW indirect storage tank.•
After DHW demand satisfi ed, boiler enters post purge •

mode and DHW pump continues to run for 15 seconds.

71

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 e s t power

Of f

SYSTEM TEST

Bo i l e r Pump Of f

CH \ Sy s t em Pump Of f

DHW P ump Of f

APPENDIX A - CONTROL MODULE

User Interface Display

Allowed Range: 1 to 60 Minutes

DHW Settings

Default Setting: 30 Minutes

Explanation

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

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

CH demand then has priority until Maximum Priority Time has
elapsed.

Process repeats until either CH or DHW demand satisfi ed.

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

Boiler can be started without CH or DHW demand 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.

The following modes are available:

System Test

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:

!

WARNING

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

Both heat exchanger and CH pumps are activated •
during system test only.

During System Test Mode, boiler will run at fi xed •
power rates until supply water temperature is
93°C/195°F

All other safety functions remain active while in •
System Test Mode.

72

73

74

75

CONDENSING

GAS BOILER

Models 075 & 100

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

www.ecrinternational.com