"AT" SERIES ELECTRIC HOT WATER BOILERS FOR FORCED HOT WATER INSTALLATION, OPERATION & MAINTENANCE MANUAL An ISO 9001-2008 Certified Company Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International, Inc.
TABLE OF CONTENTS "AT" Series Boiler Dimensions ����������������������������������������������������������������������������� 3 Important Safety Information ����������������������������������������������������������������������������� 4 Introduction �������������������������������������������������������������������������������������������������������� 5 Voltage Rating Tables ������������������������������������������������������������������������������������������ 6 Locating The Boiler �������������������
"AT" SERIES BOILER DIMENSIONS D C A E B Dimensions A B C D E Inlet & Outlet Pipe Size 14⅝” 18⅝ “ 9¹/₃₂” 14⅜” 16¹⁵/₃₂” 1¼ NPT 3 Approximate Shipping Wt. 70 lbs.
IMPORTANT SAFETY INFORMATION General Boiler installation shall be completed by qualified agency. Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: • United States ! WARNING • National Electrical Code, NFPA 70. 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.
INTRODUCTION Introduction Product Description Electric Hydronic Block is heating device converts electrical energy to heat energy through medium of water. Simplified theory of this conversion is as follows: • Boiler sizing is crucial. Calculate the maximum hourly heat loss for each heated space in accordance with procedures describes in The Hydronics Institute manual H-22 (Heat Loss Calculation Guide), or method suitable for local conditions, provided results are in agreement.
VOLTAGE RATING TABLES Table 1 -AT Boiler Electrical Specifications INSTALLATION MANUAL AND OPERATING INSTRUCTIONS Operating at 240 Vac “AT” Series - 2 Element Boiler Model AT0623 Boiler Size Voltage Nominal (AC) kW *Recommended Wire Element Size Number Accessory (Watts) Elements Load (A) at 240Vac Output Power (Watts) Output Power BTU/Hr. Amperage 6,000 20,500 25.0 3,000 2 6 31.0 38.8 40.
LOCATING THE BOILER ! WARNING Minimum clearances to combustible constructions are: Electrical shock hazard. Do not install boiler under water source. Failure to do so could result in death or serious injury. TOP............................................................ 16 IN. FRONT....................................................... 12 IN. LEFT SIDE ������������������������������������������������ 20 IN. RIGHT SIDE ���������������������������������������������� 20 IN. REAR..........................
HYDRONIC PIPING 5. Outlet or supply pipe line to radiation is located at top ! WARNING Fire, explosion, asphyxiation, burn, scald and electrical shock hazard. System design must incorporate primary/secondary piping to allow boiler pump to prepurge and post purge the unit before and after energizing the heating element. Shortened element life and/or opening of safety relief valve could occur. Failure to follow these instructions could result in death or serious injury. 6.
HYDRONIC PIPING Figure 2 - Primary/Secondary Piping for Multiple Zoning with Circulators Figure 3 - Primary/Secondary Piping For Multiple Zoning With Zone Valves 9
ELECTRICAL CONNECTIONS Boiler Wiring Figure 4 - Stepped Electrical Knock-outs Jacket Bottom NOTICE Field Wiring Entrance Boiler is not designed for use of aluminum wiring. Boiler failure can occur if aluminum wiring is used. 1. Argo Electric Hydronic Boilers are pre-wired for use 2. 3. 4. 5. 6. 7. with 240-volt, 3 wire, single-phase, 50/60-hertz power. For reduction in boiler capacity when line voltage is less than 240 volts see Table 1 page 6.
ELECTRICAL CONNECTIONS Field Wiring - Continued Note: Argo AT Boiler will work with standard and programmable setback thermostats. Limit Control Operation 1. MAIN POWER SUPPLY: Depending on model Thermostat Installation 1. Install thermostat on inside wall five feet above floor. 2. NEVER install thermostat on outside wall. 3.
ELECTRICAL CONNECTIONS Figure 7 - Wiring on Control Board ELEMENT 1 ÉLÉMENT 1 ELEMENTS ÉLÉMENTS R (T) W (T) C DHW DHW ODT ODT LMC LMC PUMP POMPE DEMAND DEMANDE Figure 8 - Low Voltage Wiring on Control Board Low Volt Connections R (T) W (T) C DHW DHW ODT ODT LMC LMC T Aux T Aux ELEMENT 2 ÉLÉMENT 2 HL HL FLO FLO LWC LWC WT WT CONTROL BOARD T Aux T Aux CIRCUIT DU TABLEAU DE COMMANDE FUSE ELEMENT 4 ÉLÉMENT 4 C1 C2 N N L L FUSIBLE ELEMENT 3 ÉLÉMENT 3 5A HL HL FLO FLO LWC LWC WT WT 24 VAC CO
SEQUENCE OF OPERATION Figure 8A - AT Boiler Controller 3 HEATING ELEMENTS 1 2 3 4 HEATING ELEMENT LED INDICATORS (GREEN) 2 HEATING DEMAND LED INDICATOR (GREEN) DEMAND 4 PUMP PUMP LED INDICATOR (GREEN) 5 1 MODE AND POWER SELECTION BUTTON LED DISPLAY (RED) MODE/PWR UP DOWN 6 UP AND DOWN ADJUSTMENT BUTTONS Figure 1 AT Boiler Controller 1 Mode and Power Selection Button - Turns the boiler on and off, selects mode and configuration settings 2 Heating Demand LED Indicator – Energized when there
SEQUENCE OF OPERATION Setting the AT Boiler Controller User Settings On/Off Mode Display Possible Value ON ON OFF OFF Factory Setting OFF Overview Press and hold the MODE/PWR button for 2 seconds to turn the unit On or Off. Note: When electrical power has been removed and re-applied, when the unit is turned on it will automatically enter a dry fire test mode (If dFt is on, see Configuration). The display will flash dFt. To bypass the test, Press and hold Up ▲ and Down ▼ arrow buttons for 2 seconds.
SEQUENCE OF OPERATION Boiler Display Codes Display Description On Boiler in On mode Off Boiler in Off mode Range Note Comfort Heating Setting 90-180°F (32-82°C) Control prevents setting from being higher than Domestic Hot Water Setting Domestic Hot Water Setting 90-180°F (32-82°C) Control prevents setting from being lower than Comfort Heating Setting dFS Differential Setting 4-20°F (2-11°C) Applies to CHS & dHS DEG Degrees Temperature scale F or C Stg Heating Element Stages 2 or 4 EL
CONTROL OPERATION Initial Start Up When electrical power is applied to AT boiler the control displays firmware revision code. It will then revert to mode it was in prior to power loss (factory setting is OFF mode). Pressing MODE/PWR button for 2 seconds, unit will enter ON mode. Pressing MODE/PWR button again for 2 seconds will return unit to OFF mode.
CONTROL OPERATION Once initiated, Dry Fire Test can be canceled by pressing ▲up and ▼down arrow buttons simultaneously for 2 seconds. This by-pass feature is intended for installer and should only be used when it is clear that dry condition does not exist. Dry Fire Test is selectable in configuration mode and can be set to Y or N. To prevent Dry Fire testing from automatically occurring, change setting for dFt to N in configuration mode.
CONTROL OPERATION Boiler Fault Codes • High Limit Alarm The high limit alarm shall be monitored at all times except while the LMC terminals are open. If the High Limit switch opens the control shall switch off all elements and enter a 60 second purge mode. The audible alarm shall sound and “HL” shall be displayed for a minimum of 30 seconds and until the error clears. The pump shall remain on for a minimum of 30 seconds after the fault clears.
G G 19 PUMP POMPE L1 N DEMAND DEMANDE PUMP POMPE HL HL FLO FLO LWC LWC WT WT T Aux T Aux R (T) W (T) C DHW DHW ODT ODT LMC LMC NEUTRAL BLOCK PLAQUE NEUTRE RED RED BLK WHT RED N NEC CLASS 2 LOW VOLT CONNECTIONS NEC CATÉGORIE 2 BASSE TENSION RACCORDEMENTS RED RED TRANSFORMER TRANSFORMATEUR WT SENSOR CAPTEUR WT L1 L2 G RACCORDEMENTS EFFECTUÉS SUR PLACE CONFORMÉMENT AU NEC/CCE ET AUX CODES LOCAUX EN VIGUEUR FIELD SUPPLIED POWER PER NEC, CEC AND LOCAL CODES N Domestic Hot Water Thermostat
G G 20 PUMP POMPE L1 N DEMAND DEMANDE PUMP POMPE HL HL FLO FLO LWC LWC WT WT T Aux T Aux R (T) W (T) C DHW DHW ODT ODT LMC LMC NEUTRAL BLOCK PLAQUE NEUTRE RED RED BLK WHT RED N NEC CLASS 2 LOW VOLT CONNECTIONS NEC CATÉGORIE 2 BASSE TENSION RACCORDEMENTS RED TRANSFORMER TRANSFORMATEUR WT SENSOR CAPTEUR WT L1 L2 G RACCORDEMENTS EFFECTUÉS SUR PLACE CONFORMÉMENT AU NEC/CCE ET AUX CODES LOCAUX EN VIGUEUR FIELD SUPPLIED POWER PER NEC, CEC AND LOCAL CODES N Domestic Hot Water Thermostat Not U
STARTUP AND SEASONAL MAINTENANCE 8. When thermostat calls for heat, circulator will be Use qualified service agency for annual inspection of boiler and heating system. NOTICE Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after service. Placing Hydronic block into service. 1.
GENERAL MAINTENANCE Hydronic block requires minimum periodic maintenance. Annual maintenance allow for trouble free operation. WARNING Electrical shock hazard. Turn OFF electrical power supply at main power switch before servicing unit. Service shall be preformed by a qualified service agent. Failure to do so could result in death or serious injury. 1. Boiler is designed to provide years of trouble free performance under normal operating conditions.
ADDITIONAL WIRING DIAGRAMS Figure 11 - Single Zone with Circulator - 2 Boilers ISOLATION RELAY 1/16 HSP MAX R(T) W(T) ITEM NUMBER R35C Relay 10A 24VAC 240004745 Relay Base, DIN Rail Mount 240004746 DIN Rail Approx. 2" Long R(T) W(T) 1/6Hsp. hp MAX. (1/16 Max.) 1/6Hsp. hp MAX (1/16 Max.
ADDITIONAL WIRING DIAGRAMS Figure 12 - Two Zones with Circulator - 2 Boilers TWO ZONES WITH CIRCULATORS 2 BOILERS ZONE 1 ZONE 2 THERMOSTAT SPST (2 WIRE) 24 VAC TR TW TR TW ZONE 1 ZONE 2 THERMOSTATS ARGO ARM-2P ISOLATED SWITCH X1 X1 X2 X2 ZONE 1 L N 120 VAC L N ZONE 2 L N 120 VAC CIR. CIR. "AT" BOILER CIRCULATOR PUMPS (120 VAC) R(T) TT W(T) TT TT R(T) TT W(T) C1 C2 C1 C2 PRIMARY CIRCULATOR PUMP 120 VAC PRIMARY CIRCULATOR PUMP 120 VAC (1/6 hp MAX) CIR.
ADDITIONAL WIRING DIAGRAMS Figure 14 - Three Zones Control Valves THREE ZONES WITH CONTROL VALVES ZONE 2 ZONE 1 ZONE 3 THERMOSTAT SPST (2 WIRE) T T ZONE 2 T T ZONE 1 ARGO AZ-3 T T ZONE 3 THERMOSTATS END SWITCH X X ZONE 1 ZONE 2 ZONE 3 ZONE VALVE ZONE VALVE ZONE VALVE "AT" BOILER R(T) TT W(T) TT C1 C2 PRIMARY CIRCULATOR PUMP 120 VAC CIR.
VALVE FLOW VALVE VALVE VALVE 26 BOILER PUMP DRAIN VALVE ARGO ELECTRIC BOILER VALVE VALVE AIR SEPERATOR FLOW 12" MAX AUTOMATIC AIR VENT CIRCULATOR PUMP CIRCULATOR PUMP PRESSURE/TEMPERATURE GAUGE EXPANSION TANK FILL VALVE FLOW FLOW FLOW CIRCULATOR PUMP PRIMARY LOOP DRAIN FLOOR VALVE FLOW 12" MAX VALVE VALVE VALVE ARGO ELECTRIC BOILER VALVE BOILER PUMP FLOW PRESSURE/TEMPERATURE GAUGE PIPE TO WITHIN 6" OF FLOOR PRESSURE RELIEF VALVE SECONDARY LOOP FLOW SUPPLY HEADER HE
TROUBLESHOOTING This section is to assist service technician when trouble shooting electric boiler. It is important to isolate before proceeding. Control error codes can be helpful identifying cause of problem. If you suspect wiring fault, check all external wiring and wiring connections following wiring diagram label on inside of boiler's cover. Additional wiring diagram is included with this manual. 7. After element has been removed, carefully clean any remaining gasket material from casting surface.
TROUBLESHOOTING WARNING Electrical shock hazard. Turn OFF electrical power supply at main power switch before servicing unit. Service shall be preformed by a qualified service agent. Failure to do so could result in death or serious injury. AT Boiler Trouble Shooting Fault HL - High Limit Trip AbP - Abnormal Power Alarm Water temperature overshoots set point temperature. Possible Cause Corrective action Is circulator pump functional? If pump is not working replace.
TROUBLESHOOTING N - Check control board jumper is in place and secure. Tighten FLO screws if needed. FLO Flow Switch Alarm Y - System air locked - Purge system and add venting as needed. Is flow switch installed? Y - Check that flow switch is functioning properly. Conduct self test on flow switch (Consult manufactures instructions). N - Check control board jumper is in place and secure. Tighten LWC screws if needed. Y - System air locked - Purge system, add venting as needed.
RESISTANCE VS. TEMPERATURE TABLE Resistance Vs. Temperature Table Temp Temp Ohms (Ω) (°C) (°F) 0 32.0 32,650 5 41.0 25,392 10 50.0 19,901 15 59.0 15,712 20 68.0 12,493 25 77.0 10,000 30 86.0 8,057 35 95.0 6,531 40 104.0 5,326 45 113.0 4,368 50 122.0 3,602 55 131.0 2,986 60 140.0 2,488 65 149.0 2,083 70 158.0 1,752 75 167.0 1,480 80 176.0 1,255 85 185.0 1,070 90 194.0 916 95 203.0 787 100 212.
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PARTS LIST - 2 & 4 ELEMENT BOILER 16 15 1 17 2 18 3 4 14 5 13 6 13a 13B 12 8 9 11 10 7 32
PARTS LIST - 2 & 4 ELEMENT BOILER 2 & 4 Element Electric Boiler Item Part Number Description 1 V1 Relief Valve - 30 PSI 2 E1 Elbow 3/4" x 90° 3 N1 Nipple 3/4" x 2" 4 B28 Circuit Breaker 15 A - 1 Pole - G.E. THQP 115 5 B27 Circuit Breaker 40 A - 2 Pole - G.E. THQP 240 6 I25 Load Center Assemly - G. E.
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Date Service Performed Company Name & Tech Initials Company Address & Phone #
HOMEOWNER'S REFERENCE TABLE Model Number:______________________________________________ Serial Number:_______________________________________________ Date Installed:_______________________________________________ Contractor:__________________________________________________ Contact:____________________________________________________ Address:____________________________________________________ ___________________________________________________________ Telephone Number:_____________________________________
