Model CHB-100 CHB-130 WALL MOUNTED GAS BOILER cod. 3541F240 INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured for: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com P/N# 240010633, Rev.
DIMENSIONS Figure 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
TABLE OF CONTENTS 1 - Introduction ................................................................................................................... 4 2 - Important Safety Information........................................................................................... 5 3 - General view and main components .................................................................................. 6 4 - Locating Boiler ..........................................................................................
1 - INTRODUCTION 1.1 Designated Use • Hot water heating boiler. • Indoor installation. • Closet or alcove installation. • Catagory I or III Venting. • For use with natural gas or liquefied petroleum gases (LP/propane). LP kit available. • Indirect heating is acceptable. • Boiler is arranged for connection to an external storage tank for hot water production (optional). All functions relevant to domestic hot water production are only active with the optional water tank sensor connected. 1.
2 - IMPORTANT SAFETY INFORMATION 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. 2.1 General Boiler installation shall be completed by qualified agency. See glossary for additional information. ! WARNING • National Electrical Code, NFPA 70. • Canada • Natural Gas and Propane Installation Code, CAN/CSA B149.1.
3 - GENERAL VIEW AND MAIN COMPONENTS Figure 2 Component Listing 6
3 - GENERAL VIEW AND MAIN COMPONENTS Item Number Description 5 Sealed Chamber 7 Gas Inlet 10 Supply System 11 System Return 16 Modulating Fan 19 Combustion Chamber 22 Burner 27 Copper Heat Exchanger 28 Exhaust Manifold 29 Exhaust Outlet Manifold 32 Heating 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 - Hig
3 - GENERAL VIEW AND MAIN COMPONENTS ! 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. Remove Boiler Jacket 1. Unscrew screws (A). 2. Pivot jacket upwards. See figure 3. 3. Raise Jacket up and off boiler. See figure 4.
4 - LOCATING BOILER 4.1 Boiler Location Considerations Figure 5 - Boiler Clearances • Ambient room temperature always above 32°F (0°C) to prevent freezing. • Approved for installation in closets. • Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.). • Wall mount only. • Access to outdoors to meet minimum and maximum pipe lengths for combustion air and vent piping. See section 6.
4 - LOCATING BOILER 4.2 Pre-pipe supply and return water connections with factory fittings before wall mounting. Figure 6 - Wall Mounting Bracket 4.3 Wall Mounting 2⅜” (2.4cm) Mount boiler on wall using wall mounting bracket included with unit. • Structure must be capable of supporting boiler weight plus 60 lbs (28 kg). See page 7. • Wall mount bracket has 2 slots, spaced at 9¼” (23.5cm) on center. • Attach wall mount bracket level on wall. • Boiler must engage with wall mount bracket. See figure 6.
5 - HYDRONIC PIPING 5.1 General Conditioning chemicals must ensure complete deoxygenation of water and contain specific protective agents for yellow metals (copper and its alloys), anti-fouling agents for limescale at least up to 150 ppm CaCO3, pH neutral stabilizers and, in low temperature systems, specific biocides for use in heating systems. • Install piping in accordance with authority having jurisdiction. NOTICE Use two (2) wrenches when tightening and fitting pipe to boiler's threaded fittings.
5 - HYDRONIC PIPING • 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. Figure 7 - Indirect Tank Performance Chart 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 water production. • See figure 10 for hydronic plumbing.
5 - HYDRONIC PIPING • Size and arrange discharge piping to avoid 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).
5 - HYDRONIC PIPING Figure 10 - Hydronic Piping 8 9 10 11 95 209 210 Domestic Hot Water Outlet Domestic Cold Water Inlet Heating System Supply Heating System Return Diverter Valve Hot Water Tank Delivery Hot Water Tank Return 14
6 - COMBUSTION AIR AND VENT PIPING - CATEGORY I (CHIMNEY VENT) ! WARNING Boiler and venting installations shall be performed by a qualified service agent and in accordance with the appropriate manual. Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide with is odorless and invisible.
6 - COMBUSTION AIR AND VENT PIPING- CATEGORY I (CHIMNEY VENT) 6.2 Minimum Vent Pipe Clearance 6. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use flame of a match or candle, or smoke from a cigarette, cigar, or pipe. • Use Type B vent pipe through crawl space. Where vent pipe passes through combustible wall or partition, use ventilated metal thimble. Thimble should be 4 inches larger in diameter than vent pipe. 7.
6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III Induced Draft Boilers 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.
6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III 10. If the horizontal vent must go through a crawl space or ! WARNING other unheated space, the cool temperatures will likely cause the flue gases to continuously condense inside the vent pipe. Do not insulate the vent pipe. It must be visible for monthly inspection. Insure 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.
6 - COMBUSTION AIR AND VENTILATION • 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 Mbh of total input rating of all appliances in enclosure. Communicating through horizontal ducts.
6 - COMBUSTION AIR AND VENT PIPING Figure 12 - Horizontal Venting Clearances NOTICE Figure 13 - Two Pipe Venting ( = Combustion Air / Maintain 12” (30cm) US, 18” (46cm) Canada clearance above highest anticipated snow level or grade.
6 - COMBUSTION AIR AND VENT PIPING NOTICE Figure 14 - Chimney Venting with Room Air Single Wall ( = Combustion Air / Refer to section 6.1, numbers 3 through 12, page 15 of this manual for proper installation. = Venting) Figure 15 - Chimney Venting with Outside Air Single Wall ( = Combustion Air / = Venting) 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.
7 - GAS SUPPLY PIPING Figure 16 Manual Main Gas Shutoff Valve Outside Boiler Jacket ! CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. With Manufacturer Suggested Piping With Drip Leg 7.
8 - ELECTRICAL CONNECTIONS ! WARNING Figure 17 - Terminal Block Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. 8.1 General Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to: • USA- National Electrical Code, ANSI/NFPA 70. • Canada - Canadian Electrical Code, Part I, CSA C22.1: Safety Standard for Electrical Installations.
9 - START UP PROCEDURE 9.1 Fill Boiler With Water And Purge Air ! WARNING NOTICE Asphyxiation hazard. Carbon monoxide is odorless, tasteless, clear colorless gas, which is highly toxic. Carbon monoxide production shall not exceed 400ppm. Failure to follow these instructions could result in death or serious injury. To maintain boiler efficiency and prevent boiling inside the heat exchanger, flush entire heating system until clean. • Flush heating system, including all heating zones.
9 - START UP PROCEDURE 9.6 Check Combustion Figure 18 - Test Ports Natural Gas Vent Gases Test Port 1. Measure input. English unitsTurn off gas to all other appliances. • Activate some heating zones to dissipate heat. • Set boiler on high fire. • Use ½, 1 or 2 cu ft dial on gas meter. Measure time required for one or more complete revolutions. Measure time for 1-2 minutes. • Calculate input.
10 - OPERATING INSTRUCTIONS ! WARNING ! CAUTION If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to light this burner by hand.
10 - OPERATING INSTRUCTIONS 10.3 Checks During Operation 10.5 Indicator During Operation • Boiler is arranged for connection to an external storage tank for hot water production (optional). All functions relevant to domestic hot water production are only active with the optional water tank connected. • Check for leaks in piping systems. Correct immediately if found. • Check the efficiency of the flue gases and combustion air ducts while the boiler is working.
10 - OPERATING INSTRUCTIONS Boiler Ignition Summer/Winter Switch over Supply unit with electricity. 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. Boiler ignition For 120 seconds display will show FH which identifies the air venting cycle for the heating system. During the first 5 seconds the display will show the software release of the card also.
10 - OPERATING INSTRUCTIONS Hot water tank exclusion (economy) Hot water tank temperature maintaining/heating can be excluded by the user. If excluded, domestic hot water will not be delivered. The hot water tank can be deactivated by the user (ECO mode) by pressing the ECO/COMFORT button (detail 7 control panel display). In ECO mode the display activates the ECO symbol (detail 12 - on control panel display).
10 - OPERATING INSTRUCTIONS Press the button (see item 6 on the control panel display) for 5 seconds again to exit parallel curve adjustment mode. If the room temperature is lower lower than the required value, it is advisable to set a higher order curve and vice versa. Proceed by increasing or decreasing in steps of one and check the result in the room. Compensation curves Heating Temperature Adjustment Adjustment can be made from the boiler control panel.
10 - OPERATING INSTRUCTIONS Water system pressure adjustment The filling pressure with system cold, read on the boiler water gauge, must be approximately 11 psi. If the system pressure falls to values below minimum, the boiler control will activate fault F37. Low system pressure fault Once the system pressure is restored, the boiler will activate the 120-second air venting cycle indicated on the display by FH.
11 - GENERAL MAINTENANCE AND CLEANING 11.1 Beginning of Each Heating Season • Check boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids. • Visually inspect combustion air and vent piping for proper operation. Check for and remove any obstruction to flow of combustion air or vent gases. Immediately repair or replace pipe showing deterioration or leakage. Reassemble per instructions in section 6. Ensure proper reassembly and resealing of system.
12 - RATINGS AND CAPACITIES 33
12 - RATINGS AND CAPACITIES Table 8 - Sea Level Ratings SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate (MBH)(1) Maximum Minimum Heating Capacity (MBH)(1)(2) 100 130 31.5 43.5 85 110 CHB-100 CHB-130 Net AHRI Rating, Water (MBH)(1)(3) 73.0 96.0 AFUE(2) 85 85 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
12 - RATINGS AND CAPACITIES Diagrams Manifold Gas Pressure W.C. Losses of load / head of circulators 20,00 18,00 Pump Head [feet w.c.
13 - TROUBLE SHOOTING Diagnostics The boiler is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will flash indicating the fault code. There are faults that cause permanent shutdown (marked with the letter “A”): to restore operation just press the RESET button for 1 second or RESET; if the boiler fails to start, it is necessary to first eliminate the fault.
WIRING DIAGRAM 155 10 kOhm 370 M 1 1,8 kOhm 138 138 2 3 4 5 6 7 138 - Optional Outdoor Sensor 155 - Optional Indirect Tank Sensor 370 - Field Source LWCO 8 120V 60Hz N L X9 AUX X6 X2 1 L N X1 1 N L X4 1 4 278 278 TT 95 95 44 X7 16 DBM34 297 GND +15V OUT X5 47 72 X4 32 114 X11 X7 81 1k Important: Before connecting the room thermostat, remove the jumper on terminal block.
REPAIR PARTS LIST - CHB-100 KEY Part Number Description Qty A01 FE3980B830 CASING "CTR" 1 38
REPAIR PARTS LIST - CHB-100 KEY Part Number Description B01 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.
REPAIR PARTS LIST - CHB-100 40
REPAIR PARTS LIST - CHB-100 KEY Part Number Description C01 FE3980B870 KIT GASKETS SET 10 C02 FE3980C230 MONO HEAT EXCHANGER 1 C03 FE3980C010 KIT GASKET 10 C04 FE3980C020 KIT CLIP D18 2 C05 FE3980C040 TEMP SENSOR DP 1 C06 FE3980C050 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 K
REPAIR PARTS LIST - CHB-100 42
REPAIR PARTS LIST - CHB-100 KEY Part Number Description Qty D01 FE3980B930 KIT GASKETS SET 1 D02 FE3980C160 KIT FLUE GASES OUTLET BEND 1 D03 FE3980C100 FAN GASKET 1 D04 FE3980C250 KIT FAN 2 D05 FE3980C090 PRESSURE TEST POINT “VENTURI” 1 D06 FE3980C260 KIT BURNER 11 R.m. 1 D07 FE3980C280 KIT 11 INJECTOR 1.35mm NG 1 D08 FE3980C300 KIT 11 INJECTOR 0.
REPAIR PARTS LIST - CHB-130 KEY Part Number Description Qty A01 FE3980B830 CASING "CTR" 1 44
REPAIR PARTS LIST - CHB-130 KEY Part Number Description B01 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.
REPAIR PARTS LIST - CHB-130 46
REPAIR PARTS LIST - CHB-130 KEY Part Number Description C01 FE3980B870 KIT GASKETS SET 10 C02 FE3980B880 KIT MONO HEAT EXCHANGER 1 C03 FE3980C010 KIT 20 GASKET 10 C04 FE3980C020 KIT 10 CLIP D18 2 C05 FE3980C040 TEMP SENSOR DP 1 C06 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
REPAIR PARTS LIST - CHB-130 48
REPAIR PARTS LIST - CHB-130 KEY Part Number Description Qty D01 FE3980B930 KIT GASKETS SET 1 D02 FE3980C160 KIT FLUE GASES OUTLET BEND 1 D03 FE3980C100 KIT FAN GASKET 1 D04 FE3980B940 KIT FAN 2 D05 FE3980C090 KIT PRESSURE TEST POINT “VENTURI” 1 D06 FE3980C270 KIT BURNER 15 R.m. 1 D07 FE3980C290 KIT 15 INJECTOR 1.35mm NG 1 D08 FE3980B950 KIT 15 INJECTOR 0.
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ECR International, Inc 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.
