ECR International 75 Instruction manual

H
INSTALLATION,
OPERATION &
MAINTENANCE
MANUAL
P/N # 240008282, REV D [10/2010]
CONDENSING
GAS BOILER
Models 075 & 100

2
DIMENSIONS
FIGURE 1-1 Dimensions
Wall Hanging
Bracket
(D)
Gas
Connection
(G)
Supply Water
(E) Return Water
(E)
User Interface
(B)
(A)
Alternate
Return Water
(E)
Alternate
Supply Water
(E)
Alternate Gas
Connection
(F) (C)
(B)
(F)
Table 1 : Physical Data
Size Width
(A) Height (B) Depth (C) Bracket (D)
Water Connections Gas
Connection
(G)
Condensate Drain Weight
Shipping Unit
Size
(E) Height (F) (H) (I)
075
/100 22-1/16"
(560mm) 35-5/8" (905mm) 16-3/16" (411mm) 27-1/2" (969mm) 1-1/4" NPT 31-1/16" (789mm) 1/2" NPT 7-1/2" 5" 140 lb (63.5 kg) 115 lb (51.2 kg)
Vent Connection Combustion Air
Floor
(D)
(H)
(I)
Condensate
Drain

3
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
TABLE OF CONTENTS

4
1.1 Designated Use
Hot water heating boiler.•
Indoor installation.•
Closet or alcove installation.•
Direct vent boiler.•
For use with natural gas or liquefied 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.•
1 - INTRODUCTION

5
NOTICE
Used to address practices not related to personal
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 fitter.•
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
!
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
This is the safety alert symbol. Symbol alerts you to
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
following this symbol to avoid possible injury or death.
2.2
2.2
Become familiar with symbols identifying
Become familiar with symbols identifying
potential hazards.
potential hazards.
2.1 General
Boiler installation shall be completed by qualified 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 - IMPORTANT SAFETY INFORMATION

6
3.1 Component Listing
User Interface 1. (see Page 8) - Displays information
regarding boiler condition. Allows adjustment of
boiler operating parameters. NOTE: Does not replace
thermostat used to control central heating space.
Combustion Air Inlet (2" PVC)
2. (see page 7 & 8)
Return Water From Heating System (In) 1-1/4"
Return Water From Heating System (In) 1-1/4" 3.
NPT
NPT
(see pages 7 & 8)
(see pages 7 & 8)
-
-
Connections supplied to con-
Connections supplied to con-
nection top and/or bottom of boiler.
nection top and/or bottom of boiler.
Low Voltage Terminal Strip
Low Voltage Terminal Strip 4.
(see pages 7 & 8)
(see pages 7 & 8)
- Connection of all low voltage wiring, including
- Connection of all low voltage wiring, including
thermostat. See section
thermostat. See section
8.
8.
Igniter 5. (see page 8)
Flame Sensor 6. (see page 8)
Sight Glass 7. (see page 8) - Permits observation of
burner flame.
Burner 8. (see page 8)
Combustion Chamber 9. (see page 8)
Condensate Collector 10. (see page 8)
Return Temperature Sensor 11. (see page 8)
Drain Valve 12. (see page 8)
Heat Exchanger Ball Valve 13. (see page 8)
Supply Water Outlet to Heating System (Out)
14.
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. (see page 8)
Condensate Drain 16. (see page 8) - Boiler produces
a liquid (condensate) as a by-product of combustion.
Condensate must be piped to appropriate drain. See
section 6.
Heat Exchanger Pump
Heat Exchanger Pump 17. (see page 8)
Gas Shutoff Valve
Gas Shutoff Valve 18. (see page 8)
- Fuel supply isolation
- Fuel supply isolation
during servicing. See section 7
during servicing. See section 7
Combustion Air Blower
Combustion Air Blower 19. (see page 8)
- Delivers
- Delivers
proper quantity of combustion air, receives fuel from
proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
gas valve, mixes air and fuel sending mixture to burner
for combustion.
for combustion.
Gas (Control) Valve
Gas (Control) Valve 20. (see page 8)
- Delivers
- Delivers
proper quantity of fuel to Combustion Air Blower.
proper quantity of fuel to Combustion Air Blower.
See section 7.
See section 7.
High Temperature Supply Switch
High Temperature Supply Switch 21. (see page 8)
Low Water Cutoff
Low Water Cutoff 22. (see page 8)
-
-
Senses inadequate
Senses inadequate
quantity of water. Turns off boiler before damage can
quantity of water. Turns off boiler before damage can
occur (with test button).
occur (with test button).
Safety Relief Valve 23. (see page 8) - Factory supplied,
Field installed. See section 5.
High Voltage Junction Box 24. (see page 8) - For
connection of 120V components. See section
8
8.
Vent Connector (2" PVC) 25. (see pages 7 & 8) - See
section 6.
Gas Connection
Gas Connection 26. (see page 7)
- Gas supply may be
- Gas supply may be
piped either through top or bottom of boiler. See
piped either through top or bottom of boiler. See
section 7.
section 7.
Bracket for Optional Wall Mount 27. (see page 7) -
Integral to boiler. Allows optional wall mounting when
used with supplied wall mounting bracket. See section 4.
Auxiliary Power Outlet 28. (see page 7) - Convenience
outlet for condensate pump or service. Controlled by
Service Switch (29)
Service Switch 29. (see page 7)
Air Vent 30. (see page 7)
Central Heating Pump Circuit Breaker 31. (see page 7)
5 amp circuit breaker protects control module.
Control Module
Control Module 32. (see page 9)
Internal Access Panel 33. (see page 9) - Gently pull
upward then forward to access control module.
Removable for access to internal components of boiler.
Central Heating Pump Relay 34. (see page 9)
Transformer 35. (see page 9) - Supplies 24V power to low
water cutoff.
Pressure Switch 36. (not shown)
Test Port 37. -(see page 8)
Combustion Analysis Test Port 38. - (see page 8)
3 - COMPONENT LISTING

7
3 - COMPONENT LISTING
FIGURE 3-1 Boiler Components
LOW VOLTAGE
LOW VOLTAGE
TERMINAL
TERMINAL
STRIP
STRIP COMBUSTION
AIR INLET- 2" PVC VENT
CONNECTOR - 2" PVC
SAFETY
SAFETY
RELIEF
RELIEF
VALVE
VALVE
AIR VENT
AIR VENT
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
HIGH VOLTAGE
HIGH VOLTAGE
JUNCTION BOX
JUNCTION BOX
SUPPLY WATER TO
SUPPLY WATER TO
HEATING SYSTEM
HEATING SYSTEM
(OUT)
(OUT)
GAS CONNECTION
GAS CONNECTION
SERVICE SWITCH
SERVICE SWITCH
AUXILIARY POWER
AUXILIARY POWER
OUTLET
OUTLET
CENTRAL HEATING
CENTRAL HEATING
PUMP CIRCUIT BREAKER
PUMP CIRCUIT BREAKER
BRACKET FOR
BRACKET FOR
OPTIONAL WALL
OPTIONAL WALL
MOUNT
MOUNT
NOTE:
See Section 5-3
For Safety Relief
Valve Piping
Instructions

8
3 - COMPONENT LISTING
FIGURE 3-2 Boiler Components
LOW
LOW
VOLTAGE
VOLTAGE
TERMINAL
TERMINAL
STRIP
STRIP
HIGH VOLTAGE
HIGH VOLTAGE
JUNCTION BOX
JUNCTION BOX
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
1-1/4" NPT
1-1/4" NPT
IGNITER
IGNITER
SIGHT
SIGHT
GLASS
GLASS
HEAT EXCHANGER
HEAT EXCHANGER
BALL VALVE
BALL VALVE
CONDENSATE
CONDENSATE
DRAIN 1/2" PVC
DRAIN 1/2" PVC
GAS SHUTOFF
GAS SHUTOFF
VALVE
VALVE
LOW WATER
LOW WATER
CUTOFF
CUTOFF
COMBUSTION
COMBUSTION
AIR
AIR
BLOWER
BLOWER
COMBUSTION
COMBUSTION
CHAMBER
CHAMBER
GAS (CONTROL)
GAS (CONTROL)
VALVE
VALVE
USER INTERFACE
USER INTERFACE
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
1-1/4" NPT
1-1/4" NPT
SUPPLY WATER TO
SUPPLY WATER TO
HEATING SYSTEM
HEATING SYSTEM
(OUT) 1-1/4" NPT
(OUT) 1-1/4" NPT
HEAT EXCHANGER
HEAT EXCHANGER
PUMP
PUMP
CONDENSATE
COLLECTOR
DRAIN
VALVE
FLAME
SENSOR
(SHOWN IN OPEN
POSITION)
VENT
TEMPERATURE
SENSOR
SAFETY RELIEF VALVE
SAFETY RELIEF VALVE
VENT CONNECTOR
(2" PVC)
COMBUSTION
AIR INLET
2" PVC
HIGH TEMPERATURE
SUPPLY SWITCH
RETURN TEMPERATURE
SENSOR
COMBUSTION
COMBUSTION
ANALYSIS TEST
ANALYSIS TEST
PORT
PORT
TEST PORT
NOTE:
See Section 5
For Piping
Instructions
IN-LINE
IN-LINE
PRESSURE
PRESSURE
SWITCH
SWITCH
VAPOR
VAPOR
COLLECTOR
COLLECTOR

9
3 - COMPONENT LISTING
INTERNAL ACCESS
PANEL - CLOSED
INTERNAL ACCESS
PANEL -OPEN
CONTROL
MODULE
CENTRAL HEATING
PUMP RELAY TRANSFORMER
Control Module
Fuse and holder
Note: To open
Lift panel up
then pull forward
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

10
TABLE 2: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Top (A) 0" (0 cm) 14" (36 cm)
Left Side (B) 6" (16 cm) 6" (16 cm)
Right Side (C) 0" (0 cm) 1½" (4 cm)
Front (D) 0" (0 cm) 6" (16 cm)
Back (E) 0" (0 cm) 0" (0 cm)
Bottom (F) 0" (0 cm) 0" (0 cm) Floor
12" (32 cm) for
Bottom Piped
Combustion
Air/Vent piping
0" (0 cm) 6" (16 cm)
Hot Water Pip-
ing
½" (1.3 cm) 6" (16 cm)
(1) Required distances measured from boiler.
(2) Service, proper operation clearance recommendation.
4 - LOCATING BOILER
FIGURE 4-1 Clearance to Combustible Materials
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• floors. 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.•
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 figure 4-1.
Multiple Boilers can be placed side by side, back to back• or wall mounted.
FLOOR FLOOR
A
E
ED
B
B
AA
C
C