ECR CHB-100, Installation, Operation & Maintenance Manual

Page 1: ...MOUNTED GAS BOILER INSTALLATION OPERATION MAINTENANCE MANUAL P N 240010633 Rev B 07 17 2014 Model CHB 100 CHB 130 Manufactured for ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

Page 2: ... 1 Overall Dimensions 7 Gas Inlet 3 4 FPT 10 System Delivery 1 MPT 11 System Return 1 MPT 209 Hot Water Tank Delivery 3 4 Capped 210 Hot Water Tank Return 3 4 Capped BSPT To NPT Adapters Included 2 DIMENSIONS ...

Page 3: ...t Piping Category I Chimney Vent 15 6 Combustion Air And Vent Piping of direct vent and Category III 17 7 Gas Supply Piping 22 8 Electrical Connections 23 9 Start Up Procedure 24 10 Operating Instructions 26 11 General Maintenance And Cleaning 32 12 Ratings And Capacities 33 13 Trouble Shooting 36 Wiring diagram 37 Repair Parts List CHB 100 38 Repair Parts List CHB 130 44 ...

Page 4: ... only active with the optional water tank sensor connected 1 2 The unit MUST NOT Directly heat potable water Heat water with non hydronic heating system chemicals present example swimming pool water Exceed 185 F 85 C system design temperature Exceed 43 5 PSIG 1 3 Operational Features Modulating 3 1 turn down Integral Dual Limit Information and specifications outlined in this manual in effect at th...

Page 5: ...injury Read this manual and understand all requirements before beginning installation 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 Standa...

Page 6: ...Figure 2 Component Listing 6 3 GENERAL VIEW AND MAIN COMPONENTS ...

Page 7: ...ating circulating pump 36 Automatic Air Vent 44 Gas Valve 81 Ignition and Detection Electrode 95 3 Way Diverter Valve 114 Water Pressure Switch 209 Hot Water Tank Delivery 210 Hot Water Tank Return 278 Double Sensor High Limit NTC 297 Air Pressure Switch 364 Condensation Coupling LBS Kg Unit Weight CHB 100 61 27 5 CHB 130 65 29 5 Shipping Weight CHB 100 65 29 5 CHB 130 69 31 5 7 3 GENERAL VIEW AND...

Page 8: ...moval Screw Locations Figure 4 Pivot Jacket and Raise to Remove WARNING Fire explosion asphyxiation and electrical shock hazard Disconnect electrical power supply and turn off gas at shutoff valve before attemting to remove boiler jacket Failure to follow these instructions could result in death or serious injury 8 3 GENERAL VIEW AND MAIN COMPONENTS ...

Page 9: ... 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 1 and figure 5 The boiler must not be installed on carpeting A D F L O O R F F Boiler Side View Boiler Front View F B C Front A TABLE 1 BOILER CLEARANCES Dimension Combustible Materia...

Page 10: ...supporting boiler weight plus 60 lbs 28 kg See page 7 Wall mount bracket has 2 slots spaced at 9 23 5cm on center Attach wall mount bracket level on wall Boiler must engage with wall mount bracket See figure 6 CAUTION Boiler weight exceeds 75 pounds 34 kg Do not lift boiler onto wall without assistance NOTICE Lift boiler using chassis Using front jacket vent piping water or gas fittings to lift bo...

Page 11: ... additives inhibitors and anti freeze fluids can be used only if manufacturer guarantees they are suitable for use in heating systems and they do not cause damage to heat exchanger or other components and or materials of boiler and system Use of generic chemicals not specifically suitable for use in heating systems and or incompatible with boiler materials and system is forbidden Conditioning chem...

Page 12: ...mance Chart System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 4 Storage Tank Connection For Domestic Hot Water Production Unit s electronic board is arranged for managing an external storage tank for domestic hot wate...

Page 13: ...d 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 ...

Page 14: ...IC PIPING 8 Domestic Hot Water Outlet 9 Domestic Cold Water Inlet 10 Heating System Supply 11 Heating System Return 95 Diverter Valve 209 Hot Water Tank Delivery 210 Hot Water Tank Return Figure 10 Hydronic Piping ...

Page 15: ...ld run as directly as possible with as few elbows as possible 7 Common venting shall not be allowed Boiler and other certified appliances appliances can share same chimney vent Consult appropriate Vent Sizing Tables in National Fuel Gas Code for specific requirements of multiple appliance venting 8 Boiler is only appliance connected to vent Type B vent pipe is recommended for vent connector 9 Slop...

Page 16: ...e common venting system 3 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 4 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are ...

Page 17: ...pe passing through non combustible walls D The venting system shall terminate at least 3 feet 0 9m above any forced air inlet located within 10 feet 3m The venting system shall terminate at least 4 feet 1 2m below 4 feet 1 2m horizontally from or 1 foot 300 mm above any door window or gravity air inlet into any building The bottom of the vent shall be located at least 12 inches 300mm above grade T...

Page 18: ...ure that the vent pipe is properly pitched away from the boiler with no low spots so that condensate in the vent will drain away from the boiler An insulated enclosure or chase with access for inspection and servicing of the vent may be required to prevent freezing of liquid condensate Consult the vent pipe manufacturer s instructions for specific guidelines 11 At beginning of each heating season ...

Page 19: ...irements between connection indoor spaces All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors Two Permanent Opening Method Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure Direct communication with outdoors or communicating through vertical ducts Provide minimum free area of 1 in2 per 4 Mb...

Page 20: ...TION AIR AND VENT PIPING Combustion Air Venting Figure 12 Horizontal Venting Clearances Figure 13 Two Pipe Venting NOTICE Maintain 12 30cm US 18 46cm Canada clearance above highest anticipated snow level or grade ...

Page 21: ... Venting Figure 15 Chimney Venting with Outside Air Single Wall NOTICE Refer to section 6 1 numbers 3 through 12 page 15 of this manual for proper installation DIRECT VENT BOILER Boiler constructed and installed so all combustion air is derived directly from outdoors and all vent gases are discharged to outdoors See Figure 15 ...

Page 22: ...ighbor s phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fire department Figure 16 Manual Main Gas Shutoff Valve Outside Boiler Jacket With Manufacturer Suggested Piping With Drip Leg Manufacturer suggested gas piping with drip leg Gas Supply Pressure Natural Gas Min Max 3 5 w c 0 7 kPa 14 w c 3 3 kPa Table 6 Gas Supply Pressure DANGER Fire Hazard Do not use...

Page 23: ...do so could result in death or serious injury 8 3 Central Heating Thermostat A Use thermostat or boiler system control with dry contacts rated 0 5 amps 120 VAC Boiler control does not provide 24 VAC power to central heating thermostat Do not use to power 24VAC thermostat B Locate and install thermostat per manufacturer s instructions Maximum wire length is 330 ft 100m for 22 ga wire C Connect wire...

Page 24: ... antifreeze water solution if used See antifreeze information Section 5 3 page 11 Purge air from boiler using air vent Purge air from system piping Inspect system piping and boiler connections Repair any leaks immediately Activate all heating zones and calls for heat including CH calls and DHW calls if available Do not open gas shutoff valve until all air is purged from system 9 3 Burner Pressure ...

Page 25: ...p of the boiler one for venting and the other for combustion air To sample Open the air vent outlet plug Insert probes all the way in Turn on TEST mode wait 10 minutes for boiler to stabilize Take measurement Vent Gases Test Port Combustion Air Test Port A Pressure point upstream B Pressure point downstream C Modureg electrical connection D Protection cap E Minimum pressure adjustment F Modureg G ...

Page 26: ...ghts the burner Do not try to light burner by hand Turn gas shutoff valve to closed position Handle should be perpendicular to gas pipe Wait 5 minutes for any gas to clear Smell for gas including near floor 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 to open position Handle should be parallel to g...

Page 27: ...reeze system does not work when power and or gas to the unit are turned off To avoid damage caused by freezing during long idle periods in winter it is advisable to drain all water from the boiler DHW circuit and system or drain just the DHW circuit and add a suitable antifreeze to the heating system See Section 5 3 page 11 10 OPERATING INSTRUCTIONS 10 3 Checks During Operation Boiler is arranged ...

Page 28: ...oiler will be immediately ready to operate whenever indirect tank sensor or room thermostat demand Summer Winter Switch over NOTICE Activating this button will keep your boiler from operating Verify that boiler is not required to run Domestic Hot Water DHW needs Press the button for 2 seconds Display will activate Summer symbol see item 10 on the control panel display If optional tank sensor is in...

Page 29: ...cific compensation curve With Sliding Temperature adjustment the temperature set with the heating buttons details 3 and 4 on control panel display become the maximum system delivery temperature Manufacture recommends setting the maximum value to allow system adjustment throughout its useful working range Boiler must be adjusted at time of installation by qualified service agent Adjustments can be ...

Page 30: ...c Hot Water Temperature Adjustment can be made from the boiler control panel Summer Winter Switchover Summer mode has priority over a possible heating demand Eco Comfort Selection On disabling DHW from the menu the boiler selects the Economy mode In this condition the button 7 from control panel display is disabled On enabling DHW from menu the boiler selects the Comfort mode In this condition it ...

Page 31: ...ssure is restored the boiler will activate the 120 second air venting cycle indicated on the display by FH TEST mode heating power 100 Press the heating buttons simultaneously for 5 seconds to turn on TEST mode The boiler will ignite at the maximum heating power set as described in the following paragraph On the display the heating and tap water symbols will blink alongside it will show the heatin...

Page 32: ...d from factory and require no further lubrication Lubricate field sourced pumps and or motors 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 air inlet for blockage and clean as required check boiler for any sign of leaks Check heating system expansion tank Check the Air pressure tu...

Page 33: ...33 12 RATINGS AND CAPACITIES ...

Page 34: ...thority having jurisdiction for installations above 4500 feet 1350 m above sea level 34 SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net AHRI Rating Water MBH 1 3 AFUE 2 Maximum Minimum CHB 100 100 31 5 85 73 0 85 CHB 130 130 43 5 110 96 0 85 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Efficie...

Page 35: ...d Gas Pressure W C 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 0 00 2 00 4 00 6 00 8 00 14 00 16 00 20 00 Water Flow GPM Pump Head feet w c 18 00 12 00 10 00 3 2 1 Losses of load head of circulators A Boiler losses of head 1 2 3 Circulator speed ...

Page 36: ...t it is clean A06 No flame after the ignition stage Low pressure in the gas system Check the gas pressure Burner minimum pressure setting Check the pressures F10 Delivery sensor 1 fault Sensor damaged Check the wiring or replace the sensor Wiring shorted Wiring disconnected F11 DHW sensor fault Sensor damaged Check the wiring or replace the sensor Wiring shorted Wiring disconnected F14 Delivery se...

Page 37: ...lating pump 42 DHW temperature sensor see kit 44 Gas valve 47 Modulation Regulator 24V 72 Room thermostat field sourced 81 Ignition detection electrode 114 Water pressure switch 138 External probe not fitted 155 Hot water tank temperature probe field sourced 278 Double sensor Safety Heating 297 Air pressure transducer 370 Low Water Cutoff LWCO field sourced Important Before connecting the room the...

Page 38: ...KEY Part Number Description Qty A01 FE3980B830 CASING CTR 1 38 REPAIR PARTS LIST CHB 100 ...

Page 39: ... FE3980C200 KIT CONTROL BOX 1 B02 FE3980B850 KIT CONTROL BOARD DBM34 2 B03 FE3980C210 KIT FRONT COVER CTR 1 B04 FE3980B840 KIT PRESS TEMP GAUGE 1 B05 FE3980C860 KIT WIRING 1 B06 FE3980C220 KIT MONO CABLE EL 1 39 REPAIR PARTS LIST CHB 100 ...

Page 40: ...40 REPAIR PARTS LIST CHB 100 ...

Page 41: ...50 KIT 3 WAY VALVE 1 C07 FE3980C060 KIT MOTOR 3 WAY VALVE TP 1 C08 FE3980B890 KIT PUMP FX3 FP 1 C09 FE3980B900 KIT AIR SEPARATOR 5 C10 FE3980C070 KIT WATER PRESSURE SWITCH 1 C11 FE3980C080 KIT X10 N R BYPASS VALVE 1 C12 FE3980B910 KIT 3 4 SAFETY VALVE 1 C13 FE3980B920 KIT NPT ADAPTERS 1 P01 FE34226300 CH FLOW PIPE 1 P02 FE34225470 CH RETURN PIPE 1 P03 FE3841B170 BYPASS PIPE 1 41 REPAIR PARTS LIST ...

Page 42: ...42 REPAIR PARTS LIST CHB 100 ...

Page 43: ...mm NG 1 D08 FE3980C300 KIT 11 INJECTOR 0 85mm LP 2 D09 FE3980C120 IGNITION ELECTRODE 17 D10 FE3980C180 KIT PLUGS CASING 17 D11 FE3980C310 KIT COMBUSTION CHAMBER INSULATION SR AEO4 1 D12 FE3980B960 GAS VALVE VGU 54S 1 D13 FE3980C170 PRESSURE TRANSDUCER 1 D14 FE3980C190 COUPLING CONDENSATION 1 D15 FE3980B970 WALL MOUNT BRACKET 1 D16 FE3980B980 KIT VENT ADAPTERS FM 1 D17 FE3980D800 KIT AIR PRESSURE T...

Page 44: ...KEY Part Number Description Qty A01 FE3980B830 CASING CTR 1 44 REPAIR PARTS LIST CHB 130 ...

Page 45: ... FE3980C200 KIT CONTROL BOX 1 B02 FE3980B850 KIT CONTROL BOARD DBM34 2 B03 FE3980C210 KIT FRONT COVER CTR 1 B04 FE3980B840 KIT PRESS TEMP GAUGE 1 B05 FE3980B860 KIT WIRING 1 B06 FE3980C220 KIT MONO CABLE EL 1 45 REPAIR PARTS LIST CHB 130 ...

Page 46: ...46 REPAIR PARTS LIST CHB 130 ...

Page 47: ...06 FE3980C050 KIT 3 WAY VALVE 1 C07 FE3980C060 MOTOR 3 WAY VALVE TP 1 C08 FE3980B890 PUMP FX3 FP 1 C09 FE3980B900 KIT AIR SEPARATOR 5 C10 FE3980C070 WATER PRESSURE SWITCH 1 C11 FE3980C080 KIT X10 N R BYPASS VALVE 1 C12 FE3980B910 KIT 3 4 SAFETY VALVE 1 C13 FE3980B920 KIT NPT ADAPTERS 1 P01 FE34226280 CH FLOW PIPE 1 P02 FE34202130 CH RETURN PIPE 1 P03 FE3841B170 BYPASS PIPE 1 47 REPAIR PARTS LIST C...

Page 48: ...48 REPAIR PARTS LIST CHB 130 ...

Page 49: ... NG 1 D08 FE3980B950 KIT 15 INJECTOR 0 85mm LP 2 D09 FE3980C120 KIT IGNITION ELECTRODE 17 D10 FE3980C180 KIT PLUGS CASING 17 D11 FE3980C320 COMBUSTION CHAMBER INSULATION SR AEO7 1 D12 FE3980B960 KIT GAS VALVE VGU 54S 1 D13 FE3980C170 KIT PRESSURE TRANSDUCER 1 D14 FE3980C190 KIT COUPLING CONDENSATION 1 D15 FE3980B970 WALL MOUNT BRACKET 1 D16 FE3980B980 KIT VENT ADAPTERS FM 1 D17 FE3980D800 KIT AIR ...

Page 50: ...NOTES 50 ...

Page 51: ...NOTES 51 ...

Page 52: ...ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...