ECR International 95M-200 User manual

Control manual and troubleshooting guide
95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
P/N 240006104, Rev. B [06/08]
DO NOT DESTROY THESE INSTRUCTIONS!!
Please read carefully and keep in a safe place
for future reference.
IMPORTANT: Installation must comply
with local requirements and with the Na-
tional Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for
Canadian installations.
This document must only be used by a qualied
heating installer or service technician. Read all
instructions, including the Installation Manual
(P/N# 240006103), the Parameter Guide (P/N#
240006105), the User’s Information Manual (P/N#
240006106), and this Control Manual and Oper-
ating Instructions before attempting to program
the control, and be sure to perform all steps in
the order specied. Failure to comply could re-
sult in severe personal injury, death, or substan-
tial property damage.
Revise boiler control parameters only if you fully un-
derstand the purpose and result of the changes. Tam-
pering without understanding the control settings in
this manual will void the warranty and can result in
unreliable operation, with possible severe personal
injury, death, or substantial property damage.
WARNING
!
WARNING
!

2

3
CONTROL MANUALAND OPERATING INSTRUCTIONS
Printed in USA • Made In USA
95-200M GAS FIRED DIRECT VENT MODULATING HOT WATER BOILER
Keep this manual near boiler
and retain for future reference.
TABLE OF CONTENTS
I - SAFETY SYMBOLS AND WARNINGS
The following dened symbols are used throughout this manual to notify the reader of
potential hazards of varying risk levels.
Indicates an imminently hazardous situation
which, if not avoided, will result in death, seri-
ous injury or substantial property damage.
DANGER
!
Indicatesapotentiallyhazardoussituationwhich,
if not avoided, could result in death, serious in-
jury or substantial property damage.
WARNING
!
Indicates a potential hazardous situation which,
if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
CAUTION
!
IMPORTANT: Read the following instructions
completely before installing!!
I - Safety Symbols and Warnings ...................................................................................................3
II - Operating Information................................................................................................................4
III - Modulating Control Features.................................................................................................... 6
IV - Boiler Startup...........................................................................................................................6
V - Checkout Procedures and Adjustments.................................................................................... 9
VI - Detailed Sequence of Operation............................................................................................ 12
VII- Service Hints..........................................................................................................................13
VIII - Troubleshooting ...................................................................................................................14
IX - User Interface Quick Reference.............................................................................................20

4
DHW HEATING:• Target temperature is determined by
adding Parameter 1 to Parameter 33 (default 150°F and
30°F). Do not change Parameter 1 from the factory de-
fault setting of 150°F unless the application is specially
engineered for other temperature. DHW heating default
setting is 180°F.
High limit operation: If outlet water temperature exceeds tar-
get temperature (or 180°F, whichever is lower), high limit ac-
tion occurs. The control module shuts the burner off showing
“b 9” followed by “26” on the display.
DHW operation (if used): The boiler is factory set to immedi-
ately change target outlet water temperature to 180°F on a
call for heat from the DHW aquastat.
Additional Thermal Overrun Protection: High limit operation
shuts down the burner when the outlet water temperature ex-
ceeds the target temperature. However, adverse conditions
could cause the water temperature to rise too quickly and
overshoot this temperature. The boiler control’s advanced
technology provides protection in the event of thermal over-
run. Using its electronics, the control provides two additional
levels of overrun protection:
LEVEL 1:• Indication would occur if supply water tem-
perature reached 183°F. The control would display a
soft lockout code (“b 9” followed by “18” if on the supply
or “19” if on the return). The control would not operate
the burner again until the water temperature dropped
9°F below target temperature.
LEVEL 2:• Lockout would occur if supply water tempera-
ture reached 200°F or if the return water reached 193°F.
The control would enter hard lockout and display an error
code (“E” followed by “18” if on the supply or “19” if on
the return).
NOTE: Hard lockout requires manually pressing the display
panel reset button to restart operation. Service technician must
troubleshoot the cause of the problem and correct it before placing
the boiler back in operation.
LOW WATER PROTECTION
This boiler comes factory equipped with a manual reset 1.
low water cutoff. In addition, the boiler control uses tem-
peratures sensed at both supply and return areas of the
heat exchanger. If the ow rate is too low (temperature
difference too high) or either temperature is too high, the
control shuts the boiler down. This ensures boiler shut-
down in the event of low water or low ow conditions.
Some codes and jurisdictions may accept these integral
2.
features of the control in lieu of requiring an additional limit
control or low water cutoff. Consult your local jurisdiction
for more information on low water cutoff requirements.
This boiler is controlled by a microprocessor electronic con-
trol that senses outlet water temperature, return water tem-
perature, and outdoor temperature (when a factory supplied,
eld installed outdoor sensor is installed). This information
(plus input from external limit and operating controls) is used
to regulate boiler on/off operation and will modulate boiler r-
ing rate to more closely match output to demand.
ELECTRICAL SPECIFICATIONS
Boilers require 120 vac/60 HZ power supply and are not po-
larity sensitive.
CONTROL SPECIFICATIONS
Supply voltage 120 vac/60 hz
Electrical demand 10 va
Prepurge timing 10 seconds
Postpurge timing 15 seconds
Min. off time, space heating 10.2 seconds
Pump on after space htg. 0 minutes
Min. off time, DHW 10.2 seconds
Pump on after DHW 30.6 seconds
Line voltage fuse, F1 5 amp fast-blow
Low voltage fuse, F3 4 amp slow-blow
BOILER CIRCULATOR
The circulator has sufcient head to handle the boiler pressure
drop plus reasonable pressure drop in the connecting piping.
See the separate Installation Manual (P/N# 240006103) for
piping and ow rate information.
The boiler control’s internal relay contact is suitable for han-
dling only the boiler circulator provided. Do not wire addi-
tional pumps in parallel with the boiler circulator. To operate
a system circulator when the boiler circulator is running, see
the section on “Electrical Wiring” in the Installation Manual for
wiring required.
BOILER TEMPERATURE REGULATION
OPERATING TEMPERATURE (TARGET): The boiler con-
trol senses outlet water temperature and regulates the boiler
ring rate to achieve a target temperature, set by installer
with Parameter 4. Temperature can be set between 120°F
and 194°F.
SPACE HEATING:• Target temperature is xed (equal to
Parameter 4) when outdoor reset is not installed or cal-
culated as described under “Outdoor Reset Operation”
when outdoor sensor is connected.
EXCEPTION:• See explanation of “Supply Temperature
Boost.”
II - OPERATING INFORMATION

5
FREEZE PROTECTION
Do not install the boiler in a room likely to freeze.
NOTE: The following integral feature of the boiler control pro-
vides some protection for the boiler only, not for the system.
The control module provides freeze-up protection as follows
when the boiler water temperature drops below 45° F:
Below 45° F, the boiler circulator operates constantly.
•
Below 37° F, the boiler turns on at low re.•
Boiler and circulator turn off if boiler water temperature •
rises above 50° F.
This feature of the boiler control does not eliminate the
possibility of freezing. The installation must still use rec-
ognized design, installation and maintenance practice to
prevent freeze potential for the boiler and system.
CAUTION
!
SUPPLY TEMPERATURE BOOST
In outdoor reset operation (factory supplied, eld installed
outdoor sensor connected), the boiler control automatically
increases the target outlet water temperature if a call for heat
exceeds 10 minutes. At each 10 minutes of a continuous call
for heat, the control module increases the target temperature
by 18°F. The module will continue increasing target tempera-
ture until it reaches the value set in Parameter 4.
When the call for heat ends while target temperature is
“boosted,” the target temperature drops about 2°F for each
minute the thermostat is open.
Purpose of “boosting” : If the target temperature happens
to be too low, the control “boosts” the target temperature until
the supply water meets the system’s needs.
OUTDOOR RESET OPERATION (IF USED)
Target temperature with outdoor reset: All boilers are
shipped with an outdoor temperature sensor. When this sen-
sor is installed (low voltage terminal strip terminals A1 and
A2), the boiler control regulates target outlet water temper-
ature based on outside temperature. Set the temperature
curve by setting Parameter 4 to:
ODT (outdoor design temperature for the area).
•
For ODT of 0°F or lower, set Parameter 4 to the desired •
supply temperature at the ODT.
For ODT above 0°F, set Parameter 4 to the desired sys-
•
tem temperature when outdoor temperature is 0°F.
Target Outlet Temperature, °F
Outside Temperature, °F
Outdoor Reset Target Temperature
210
50
70 60 50 40 30 20 10 0 -10 -20
70
90
110
130
150
170
160
190
120
Parameter 4 = 190°F
Parameter 4 = 150°F
Parameter 4 = 170°F
Reset Curve Calculations
RESET CURVE: The graph below shows how the boiler con-
trol calculates target temperature.
For outdoor temperature at or below 0°F, the target tem-
•
perature equals Parameter 4 and never higher.
For outdoor temperature above 0°F, the target tempera-
•
ture is reduced on a curve that would result in 60°F supply
temperature at 70°F outdoor temperature.
Summer/winter switch option: Install a summer/winter switch, if
desired, to disable the boiler (space heating) circulator during
non-heating months. Connect switch across the outdoor sensor
terminals. When switch closes, the boiler circulator is disabled
and the boiler operates only on call for DHW heating.
Target Outlet Temperature, °F
Outside Temperature, °F
Default Reset Curve
Outdoor Reset Target Temperature
210
50
70 60 50 40 30 20 10 0 -10 -20
70
90
110
130
150
170
160
190
180
120
Parameter 7 = 60°F
Parameter 4 = 180°F
Parameter 6 = 0°F
II - OPERATING INFORMATION