ECR International 100, Application Manual

Page 1: ...a NY 13501 Tel 800 325 5479 www ecrinternational com PN 240011430 REV P 09 15 2021 This manual has been prepared for use with the appropriate Installation Operation and Maintenance Manual APPLICATION GUIDE FOR USE WITH HEATING ONLY 100 125 165 COMBI 115 150 205 ...

Page 2: ... With Zone Circulators Piping Diagram 20 115 150 205 With Zone Circulators Wiring Diagram 21 115 150 205 With Zone Valves Piping Diagram 22 115 150 205 With Zone Valves Wiring Diagram 23 External Buffer Tank Piping Diagram 24 External Buffer Tank Wiring Diagram 26 Optional Equipment 29 Chart 1 1k Ω Outdoor Air Sensor Data 29 Chart 2 10k Ω Indirect Tank Sensor Data 29 Accessories 30 Outdoor Tempera...

Page 3: ... all requirements before beginning installation 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 ...

Page 4: ...Hose 3 4 NPT I Heating supply connection 3 4 22 2mm 1 25 4mm J Optional Indirect DHW connection 3 4 22 2mm na MANIFOLD 100 125 115 150 LABOR SAVING PIPING MANIFOLDS NEAR BOILER PIPING CONNECTIONS 100 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION 165 HEATING ONLY MANIFOLD 165 A C E I B H 100 125 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 1 1 2 Header 1 1 2 Header PN 240011430 RE...

Page 5: ...Gas shutoff connection 3 4 22 2mm F Cold DHW inlet tap 1 2 15 9mm na G DHW outlet 1 2 15 9mm 3 4 NPT H Drain connection for condensate 13 16 21mm ID Hose 3 4 NPT I Heating supply connection 3 4 22 2mm 1 25 4mm J Manifold 1 1 4 31 75 mm 1 1 2 38 1 mm K 5 gpm DHW flow restrictor Factory installed 205 only na 3 4 22 2mm MANIFOLD 205 205 COMBI 205 COMBI A B H I E C K G D 115 150 COMBI A D C F G E I B ...

Page 6: ... be maintained Limit combined supply and return pipe lengths to maximum linear lengths of 20 ft 6 1 m between boiler and closely spaced tees when minimum in NPT pipe size is used Linear length may be increased if supply and return pipe size is increased to limit pressure drop Manufacturer recommends installing a shutoff and purge valve to use during commissioning to ensure the boiler does not shut...

Page 7: ... cut for use as shown on page 24 increase pipe size to match Buffer tank connections as shown Locate tank as close to boiler as possible Use of Indirect Water Heater DHW Heating Only Boiler Note Sensors supplied with this boiler are proprietary to the manufacturer Use of alternate sensors WILL diminish boiler performance Use DHW sensor kit 550003189 to interface with boiler Wire to M2 terminals 3 ...

Page 8: ...H2O Buffer Tank Reference the zone control manufacturer instruction manual for control operation and priority setting of DHW zones Note DO NOT use 120 V thermostat terminals M1 1 and 2 Provided Wiring and Piping illustrations are meant to show system concepts only Installer is responsible for all equipment required by authority having jurisdiction Note SUPPLY Cord 120V 60HZ BOILER CONTROL 10k Ω DH...

Page 9: ...SS VALVE DIVERTER VALVE T P OR RELIEF VALVE THERMOSTATIC MIXING VALVE DHW INDIRECT TANK INDIRECT TANK AQUASTAT 10K Ω INDIRECT DHW TANK SENSOR TEMPERATURE PRESSURE GAUGE EXPANSION TANK FLAT PLATE HEAT EXCHANGER COMBI ONLY STRAINER PIPING LEGEND PURGE VALVE MAGNETIC DIRT SEPARATOR PN 240011430 REV P 09 15 2021 ...

Page 10: ... CIRCULATORS DHW TANK PIPING DIAGRAM 100 125 W ZONE CIRCULATORS DHW TANK PIPING DIAGRAM MAGNETIC DIRT SEPARATOR 1 1 Locate shut off valve after any field installed LWCO Shut off Purge Valve PN 240011430 REV P 09 15 2021 ...

Page 11: ...AY Fuse ZONE MODULE TO EXPANSION Transformer PTC 12A 250V 115 Vac FIELD SUPPLIED POWER PER NEC AND LOCAL CODES Z2 Z3 ZONE THERMOSTATS Domestic Hot Water Tank w Sensor 1 2 3 4 5 6 7 8 9 10 VAC 24 G M2 M2 terminal strip on boiler If adding an indirect tank with sensor to a Heating Only Boiler change P03 from 08 to 05 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manua...

Page 12: ...ELD SUPPLIED POWER PER NEC AND LOCAL CODES Z2 Z3 ZONE T STATS 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 M2 terminal strip G on boiler Domestic Hot Water Tank 100 125 W INDIRECT ZONE CIRCULATORS DHW TANK W T STAT ARGO UZ3 ZONE CONTROL WIRING DIAGRAM Reference zone control manufacturer instructions for details on setting priority if necessary If adding an indirect tank with Thermostat to a Heating Only Boiler ...

Page 13: ...25 WITH ZONE VALVES DHW TANK PIPING DIAGRAM 100 125 WITH ZONE VALVES DHW TANK MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO PN 240011430 REV P 09 15 2021 ...

Page 14: ... NEC AND LOCAL CODES PRIMARY PUMP ZONE THERMOSTATS ZONE VALVES VANNES DE ZONE 4 Wire Valve 3 Wire Valve 1 2 3 4 1 2 3 Domestic Hot Water Tank w Sensor 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 M2 terminal strip on boiler G 100 125 WITH ZONE VALVES DHW TANK W SENSOR WIRING DIAGRAM 100 125 WITH ZONE VALVES DHW TANK W SENSOR ARGO UZ3 ZONE CONTROL If adding an indirect tank with sensor to a Heating Only Boiler c...

Page 15: ...c FIELD SUPPLIED POWER PER NEC AND LOCAL CODES Water Tank PRIMARY PUMP ZONE THERMOSTATS ZONE VALVES VANNES DE ZONE 4 Wire Valve 3 Wire Valve 1 2 3 4 1 2 3 w T Stat 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 G 100 125 ZONE VALVES DHW TANK W T STAT WIRING DIAGRAM 100 125 WITH ZONE VALVES DHW TANK TANK T STAT ARGO UZ3 ZONE CONTROL Reference zone control manufacturer instructions for details on setting priority i...

Page 16: ...16 165 WITH ZONE CIRCULATORS PIPING DIAGRAM MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO 165 WITH ZONE CIRCULATORS PN 240011430 REV P 09 15 2021 ...

Page 17: ...TC 12A 250V Domestic Hot 115 Vac FIELD SUPPLIED POWER PER NEC AND LOCAL CODES DHW Z2 Z3 Water Tank ZONE THERMOSTATS w T Stat 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 G 165 INDIRECT ZONE CIRCULATORS DHW TANK W T STAT WIRING DIAGRAM 165 ZONE CIRCULATORS DHW TANK TANK T STAT ARGO UZ3 ZONE CONTROL Reference zone control manufacturer instructions for details on setting priority if necessary If adding an indirect...

Page 18: ...18 165 WITH ZONE VALVES 165 WITH ZONE VALVES PIPING DIAGRAM MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO PN 240011430 REV P 09 15 2021 ...

Page 19: ...PLIED POWER PER NEC AND LOCAL CODES Water Tank PRIMARY PUMP ZONE THERMOSTATS ZONE VALVES VANNES DE ZONE 4 Wire Valve 3 Wire Valve 1 2 3 4 1 2 3 4 1 2 3 w T Stat 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 G 165 WITH INDIRECT ZONE VALVES DHW TANK TANK T STAT WIRING DIAGRAM 165 INDIRECT ZONE VALVES DHW TANK TANK T STAT ARGO UZ3 ZONE CONTROL If adding an indirect tank with Thermostat to a Heating Only Boiler chan...

Page 20: ... 205 WITH ZONE CIRCULATOR PUMPS 115 150 205 WITH ZONE CIRCULATORS PIPING DIAGRAM MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO PN 240011430 REV P 09 15 2021 ...

Page 21: ... 4 3 2 1 4 3 2 1 4 3 2 1 NEC Class 2 Low Voltage 24Vac W R T T C W R T T C PRI PUMP ZC ZR DIGITAL LCD USER DISPLAY Fuse ZONE MODULE TO EXPANSION Transformer PTC 12A 250V 115 Vac FIELD SUPPLIED POWER PER NEC AND LOCAL CODES Z2 Z3 ZONE THERMOSTATS 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 G M2 terminal strip on boiler 115 150 205 WITH ZONE CIRCULATORS WIRING DIAGRAM 115 150 205 WITH ZONE CIRCULATORS ARGO UZ3 Z...

Page 22: ...115 150 205 WITH ZONE VALVES 115 150 205 WITH ZONE VALVES PIPING DIAGRAM MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO PN 240011430 REV P 09 15 2021 ...

Page 23: ... Low Voltage 24Vac W R T T C W R T T C PRI PUMP ZC ZR DIGITAL LCD USER DISPLAY Fuse ZONE MODULE TO EXPANSION Transformer PTC 12A 250V 115 Vac FIELD SUPPLIED POWER PER NEC AND LOCAL CODES ZONE THERMOSTATS ZONE VALVES VANNES DE ZONE 4 Wire Valve 3 Wire Valve 1 2 3 4 1 2 3 4 1 2 3 PRIMARY PUMP 1 2 3 4 5 6 7 8 9 10 VAC 24 M2 G M2 terminal strip on boiler 115 150 205 WITH ZONE VALVES WIRING DIAGRAM 115...

Page 24: ...uit Using Internal Boiler Circulator Buffer Tank Piping When installing low mass systems additional water mass may be required to avoid short cycling by the boiler In these applications it is recommended that a buffer tank be installed H2O Stainless Steel Buffer Tank MAGNETIC DIRT SEPARATOR PURGE VALVE Cut Manifold Use Stubs To Connect To Boiler Increase Pipe Size to Match Buffer Tank Connections ...

Page 25: ...ANK PIPING DIAGRAM NOTE Acceptable primary pump locations Either 1 or 2 For pump wiring see diagrams on pages 26 29 Buffer Tank On Central Heat Circuit With Primary Pump and Supplied Manifold PN 240011430 REV P 09 15 2021 ...

Page 26: ...26 EXTERNAL BUFFER TANK WIRING DIAGRAM Buffer Tank Pump Wiring Controlling A Primary Pump On A Combi Boiler With Zone Valves No Indirect Tank PN 240011430 REV P 09 15 2021 ...

Page 27: ...27 EXTERNAL BUFFER TANK WIRING DIAGRAM Buffer Tank Pump Wiring Controlling A Primary Pump On A Combi Boiler With Zone Pumps Argo ARM 4P Zone Control and A822 II PN 240011430 REV P 09 15 2021 ...

Page 28: ... W R NEC Class 2 Low Voltage T T C THERMOSTATS ZONE VALVES ZONE 3 ZONE 2 4 3 2 1 4 3 2 1 4 3 2 1 NEC Class 2 Low Voltage 24Vac W R T T C W R T T C PRI PUMP ZC ZR DIGITAL LCD USER DISPLAY Fuse ZONE MODULE TO EXPANSION Transformer PTC 12A 250V Buffer Tank 115 Vac FIELD SUPPLIED POWER PER NEC AND LOCAL CODES PRIMARY PUMP ZONE THERMOSTATS ZONE VALVES VANNES DE ZONE 4 Wire Valve 1 2 3 4 1 2 3 4 CH N L1...

Page 29: ...2 2 4 804 69 8 1 170 14 0 4 574 71 6 1 125 15 8 4 358 73 4 1 081 17 6 4 152 75 2 1 040 19 4 3 958 77 0 1 000 21 2 3 774 78 8 962 23 0 3 600 80 6 926 24 8 3 435 82 4 892 26 6 3 279 84 2 858 28 4 3 131 86 0 827 30 2 2 990 87 8 796 32 0 2 857 89 6 767 33 8 2 730 91 4 740 35 6 2 610 93 2 713 37 4 2 496 95 0 687 39 2 2 387 96 8 663 41 0 2 284 98 6 640 42 8 2 186 100 4 617 44 6 2 093 102 2 595 46 4 2 00...

Page 30: ...ur Kt setting To change default Kt value on boiler control use or CH Heating buttons Restrict the upper limit of the Kt curve by using Parameter P16 to set the maximum boiler water temperature P16 Default is 176 F 3 When OAS is installed pressing or buttons will no longer display boiler CH setpoint temperature It now displays the Kt value which can range from 10 to 90 4 When scrolling has stopped ...

Page 31: ... 4 52 4 19 2 65 5 25 5 87 0 7 57 135 18 5 63 1 23 4 80 0 31 1 106 0 8 65 149 22 2 75 7 27 7 94 5 36 6 125 0 9 73 163 25 3 86 2 31 9 109 0 42 5 145 0 10 80 176 27 4 93 6 36 9 125 0 48 1 164 0 To activate the 0 10v function parameter 82 must be set to 3 There must be at or above 3 V DC present for the control to recognize a call for heat When P78 1 the 0 10v input manages CH heating setpoint directl...

Page 32: ...32 CIRCULATOR CONNECTIONS WIRING DIAGRAM Single Zone Circulator Wiring Using ARGO AR822 II PN 240011430 REV P 09 15 2021 ...

Page 33: ... NTC retour 10 NTC flow sensor Sonde NTC départ 11 Remote User Interface or Open Therm 12 Prov for Outside Sensor Pred Sonde Extérieure 13 Link 24V Joint 24V 14 Flame Sensing Electrode Electrode présence veilleuse 15 Ignition Electrode Electrode d allumage 16 Three Way Valve Soupape Trois Voies 17 Pump Pompe 18 Flue Safety Thermostat Thermostat Fumées 19 Link 0 10V Joint 0 10V 20 Condensate sensor...

Page 34: ...34 MODEL 125 Heat Only 125 HEAT ONLY WIRING DIAGRAM PN 240011430 REV P 09 15 2021 ...

Page 35: ...35 MODEL 165 Heat Only 165 HEAT ONLY WIRING DIAGRAM PN 240011430 REV P 09 15 2021 ...

Page 36: ...36 115 COMBI WIRING DIAGRAM MODEL 115 Combi PN 240011430 REV P 09 15 2021 ...

Page 37: ...37 MODEL 150 Combi 150 COMBI WIRING DIAGRAM PN 240011430 REV P 09 15 2021 ...

Page 38: ...38 MODEL 205 Combi 205 COMBI WIRING DIAGRAM PN 240011430 REV P 09 15 2021 ...

Page 39: ... 160 000 180 000 200 000 220 000 0 2 000 4 000 6 000 8 000 10 000 BOILER INPUT BTUH ALTITUDE FEET MODELS 165 205 CALCULATED EFFECTS OF HI ALTITUDE ON BOILER PERFORMANCE DHW MODE HEAT MODE NET RATNG HEAT MODE 50 000 60 000 70 000 80 000 90 000 100 000 110 000 120 000 0 1 000 2 000 3 000 4 000 5 000 6 000 7 000 8 000 9 000 10 000 BOILER INPUT BTUH ALTITUDE FEET MAC 115 CALCULATED EFFECTS OF HI ALTIT...

Page 40: ...T WATER TANK PERFORMANCE CHART HEATING ONLY BOILERS 100 125 165 Notes 176 F Boiler Supply Water Temperature AHRI Conditions 50 F Inlet Water 240 GPH Flow Rate BOILER OUTPUT NEEDED FOR MAXIMUM PERFORMANCE PN 240011430 REV P 09 15 2021 ...

Page 41: ... CEC LWCO Wiring Diagram Low Water Cutoff LWCO Electrical Conduit J Box 120 V 60 HZ Conduit or Power Supply cord Polarized L1 N G GND L1 N GND BLK WHT 120 V 60 HZ Socket Polarized 120 V 60 HZ Cord Set From Boiler N O Locate LWCO sensing device in the supply piping above the minimum height of boiler See Figure page 42 Piping Diagram Position control in piping above boiler to assure proper boiler pr...

Page 42: ... Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return 5 gpm Limiter Factory Installed 205 Only Magnetic Dirt Separator Purge Valve Purge Valve Note Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdiction Note PN 240011430 REV P 09 15 2021 ...

Page 43: ...43 Low Water Cutoff Detail LOW WATER CUTOFF NO NO YES PN 240011430 REV P 09 15 2021 ...

Page 44: ...ity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding 5 Ensure all external controls are calling for heat and check all external and internal fuses Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated 1 If a fault occurs on the boiler an error code may show on the facia display E 20 E 28 E 40 E 50 E 160 E 321 a...

Page 45: ... flashing NO 3 way valve open to central heating circuit YES Burner output modulates to maintain the temperature set YES YES YES YES YES Error E130 flashing NO YES Burner goes out YES Go to section I NO NO Ensure all controls and Programmers are calling for heat NO Error 160 flashing Go to section C NO Error 160 flashing Go to section C NO Error 133 flashing Go to section E Burner does not stay al...

Page 46: ...econds and for 5 attempts YES NO YES Burner lights YES YES Error E109 flashing NO Error E110 flashing YES NO NO NO NO DHW flow rate more than 21 min Error 160 flashing Go to section C Error 160 flashing Go to section C Error 133 flashing Go to section E Burner does not stay alight after 5 seconds Error E125 flashing after 1 minute Go to section H NO Go to section L NO If E53 is displayed go to sec...

Page 47: ... Wiring Diagram NO Replace PCB Fan connections correct at fan and PCB Connectors X11 X23 See Wiring Diagram YES NO 120V between PCB connector x13 pump terminal Blue and PCB connector x11 pump terminal Black See Wiring Diagram NO Replace PCB Make connections Main or Display PCB fault 120V at Pump NO Check wiring Replace Pump YES YES Is there 120V AC at fan terminals connector X11 blue to brown See ...

Page 48: ...48 3 FAULT SOLUTION SECTIONS PN 240011430 REV P 09 15 2021 ...

Page 49: ...22 is there approx 5 V DC between the green and black NO terminals Check flow temperature sensor connections and position Sensors swapped Cold resistance approximately 1OkO 77 F CH sensors resistance reduces with increase in temp YES I I I I Is E11O is still flashing Replace pressure sensor Replace PCB I Replace sensor Go to section B Is there 120V at PCB connector x13 3 way valve terminals Blue t...

Page 50: ...s approximately 5 VDC between the Red and Blue wires See Wiring Diagrams With water running through DHW circuit measure red and white wire for 2 8 VDC for flow triggering Check DHW NTC senor for proper OHM value Replace PCB YES YES YES YES Clean or Replace Replace PCB Replace Hall Effect Sensor Replace DHW NTC sensor NO NO NO NO PN 240011430 REV P 09 15 2021 ...

Page 51: ...51 Parameter ID Changed From Changed To Date Reason PARAMETER CHANGE HISTORY PN 240011430 REV P 09 15 2021 ...

Page 52: ...All specifications subject to change without notice 2021 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com ...