80/110/150/199 7ALL -OUNT 'AS &IRED #ONDENSING "OILERS n #OMBI AND (EATING /NLY -ODELS Boiler Manual s )NSTALLATION s -AINTENANCE s 3TARTUP s 0ARTS This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Contents The ECO Tec Gas-fired water boilers . . . . . . . . . . . . . 3 Please read before proceeding . . . . . . . . . . . . . . . . 6 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . 7 Prepare boiler location . . . . . . . . . . . . . . . . . . . . . 9 Wall-mounting the boiler. . . . . . . . . . . . . . . . . . . 10 Boiler hydrostatic test . . . . . . . . . . . . . . . . . . . . 12 Gas conversions . . . . . . . . . . . . .
ECO® Tec GAS-FIRED The WATER BOILER – 80/110/150/199 BOILER MANUAL ECO Tec Gas-fired water boilers 3TAINLESS STEEL lRETUBE HEAT EXCHANGER The corrosion resistant fire tube heat exchanger is our method of transferring heat from the combustion chamber to the water. (EAT EXCHANGER COVER PLATE BURNER MOUNTING PLATE Note ! : Combi shows cover plate (Item 2) (insulation removed for clarity), Heating Only has insulation covering shown.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL The ECO Tec Heating Only Gas-fired water boilers (ECO Tec 80 model shown below) 4 Part number 550-100-260/0520
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL The ECO Tec Combi Gas-fired water boilers (ECO Tec 80 model shown below) Part number 550-100-260/0520 5
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Please read before proceeding )NSTALLER— Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. 5SER — This manual is for use only by a qualified heating installer/service technician. Refer to User’s Information Manual for your reference. 5SER — Have this boiler serviced/inspected by a qualified service technician, at least annually.
ECO® Tec GAS-FIRED WATER BOILER Boiler location Installations must comply with: s s s s s Local, state, provincial, and national codes, laws, regulations and ordinances. National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition. National Electrical Code ANSI/NFPA 70 – latest edition. Electrical installation and grounding must be in accordance with CSA C22.1, Part 1, Canadian Electrical Code, and/or local codes. For Canada only: CAN/CSA B149.
ECO® Tec GAS-FIRED WATER BOILER Boiler location – 80/110/150/199 BOILER MANUAL (continued) Provide clearances for service access — RECOMMENDED Provide clearances from combustible materials — REQUIRED 1. See Figure 1 for recommended service clearances. 2. If you do not provide minimum service clearances shown, it might not be possible to service the boiler without removing it from the space. 1. See Figure 2 for REQUIRED minimum clearances. ALL installation must provide at least these minimums. 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Prepare boiler location Flooring and foundation (WITH +IT OPTION ONLY) Flooring With the optional floor standing pedestal kit, the boiler is approved for installation on combustible flooring, but must never be installed on carpeting. Do not install boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage. Foundation 1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Wall-mounting the boiler Wall-mounting requirements DO NOT attempt to attach the wall mount bracket using anchors or any means other than directly securing to the wall studs (or equivalent wood structure if studs are not on 16-inch centers). 4HE WALL MUST BE VERTICALLY PLUMB AND CAPABLE OF CARRYING THE WEIGHT OF THE BOILER AND ANY ATTACHED PIPING COMPONENTS. 1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Wall-mounting the boiler Pedestal floor stand assembly (continued) &IGURE Boiler mounting bracket Pedestal floor stand (W +IT OPTION ONLY) 4HE BOILER IS HEAVY AND REQUIRES TWO PEOPLE TO LIFT AND PLACE UPRIGHT 5SE CAUTION NOT TO DROP THE BOILER OR CAUSE BODILY INJURY WHILE LIFTING AND HANDLING 7EAR NON SLIP GLOVES TO PREVENT POSSIBILITY OF CUTS FROM SHEET METAL EDGES !FTER THE BOILER IS REMOVED FROM THE SHIPPING CARTON $/ .
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Boiler hydrostatic test $/ ./4 INSTALL A RELIEF VALVE WITH A PRESSURE HIGHER THAN 03)'. This is the maximum allowable relief valve setting for the boiler. Failure to comply could prevent the relief valve from operating as needed, resulting in possibility of severe personal injury, death or substantial property damage. 5SE TWO WRENCHES WHEN TIGHTENING ANY PIPE CONNECTION TO THE BOILER.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Boiler hydrostatic test &IGURE (continued) Install pipe fittings for relief valve and pressure/temperature gauge — $/ .
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Gas conversions Prepare boiler for propane — ECO Tec 80/110/150/199 (if required) Propane operation !,, BOILERS MUST BE CONVERTED FOR PROPANE OPERATION. #ONVERTING AN EXISTING NATURAL GAS lRED BOILER FOR PROPANE — For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding.
ECO® Tec GAS-FIRED WATER BOILER Gas conversions – 80/110/150/199 BOILER MANUAL (continued) Liquefied Petroleum (Propane) to Natural Gas &IGURE Natural gas venturi label identification (White label) conversion kits "OILER -ODEL 0ART .UMBER 'AS 4YPE 6ENTURI 1 80/110 511-050-230 NG 22 562-150-304 ! "# $%& ' ( ) * + 3 ,. #7 $$. * + .# 9 ; % <= > ; ) 1 150 511-050-231 NG 26 , ? @ = ,= % .
ECO® Tec GAS-FIRED WATER BOILER Gas conversions – 80/110/150/199 BOILER MANUAL (continued) &IGURE Venturi removed from blower Label wires before removing Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. 7 9 8 7. Disconnect wire harness from gas valve. 8. Loosen swivel nut (Figure 14, Item 7) on venturi-gas valve connection (Item 6). See Figure 14. Gently set gas valve aside.
ECO® Tec GAS-FIRED WATER BOILER Gas conversions – 80/110/150/199 BOILER MANUAL (continued) Gas Valve Course Adjustments 1. Prior to the boiler’s first ignition, adjust the throttle adjustment screw (2.5mm Allen Head) by first turning the screw clockwise (3) until it bottoms out – do not apply any additional or excess torque. Adjust the throttle screw in a counterclockwise (4) direction with precisely the number of turns listed in Table 2, according to the boiler model/size.
ECO® Tec GAS-FIRED WATER BOILER Gas conversions – 80/110/150/199 BOILER MANUAL (continued) 3. Prior to turning on the boiler, review the procedure and control sequence for the operation of the Manual Test Mode in the section of the Boiler Manual titled “Manual Test Mode” starting on page 112. &IGURE Installer conversion label The use of a flue gas analyzer is required to convert this unit and determine proper gas valve settings. Do not perform this conversion without a flue gas analyzer.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Gas piping — sizing gas lines Boiler gas connection is ½" NPT. Size gas lines large enough to provide gas to all connected appliances. Natural Gas: 0IPE SIZING FOR NATURAL GAS 1. Size gas piping from meter outlet to entrance of boiler in accordance with Figure 23 and Figure 24. 2. Use total input of all connected appliances. Divide total input in Btuh by 1,000 to obtain cubic feet per hour of natural gas. a.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Venting/air piping — general Any improper operation of a common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 – latest edition, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Venting/air piping — general 9OU MUST PIPE COMBUSTION AIR TO THE BOILER AIR INTAKE UNLESS USING THE 7EIL -C,AIN $IRECT %XHAUST KIT AND MEETING THE $IRECT %XHAUST REQUIREMENTS. Venting with flexible polypropylene Install air inlet piping for the ECO Tec boiler as described in this manual. Tests have determined that flex vent has a greater pressure drop than rigid polypropylene vent which changes the maximum allowable length of venting.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Venting & air — general (continued) &IGURE Venting and air piping — DIRECT VENT ONLY — OPTIONS and PIPING LIMITS The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the vent/air system. ./4 3(/7. below, but also approved, are the polypropylene piping and terminations listed in Figure 27, page 23.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Venting & air — general (continued) &IGURE Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes (see Figure 125, page 137 for part/kit numbers) )TEM -ATERIAL 06# !"3 PIPE CEMENT PRIMER 0OLYPROPYLENE VENT PIPE lTTINGS TERMINATIONS AND CEMENT 5NITED 3TATES #ANADA (Note 2) 6ENT OR AIR PIPING 6ENT PIPING PVC schedule 40 (Note 1) ANSI/ASTM D1785 ULC S636 PVC-DWV sched
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Commonwealth of Massachusetts installations Commonwealth of Massachusetts — 8IFO UIF CPJMFS JT JOTUBMMFE XJUIJO UIF $PNNPOXFBMUI PG .
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Vent termination requirements &IGURE + E D D E E + J L D ) M O L D @ O D D @ + F Q ( O RF 9 S = &'FQ R ,# ' + F 9 ( O (RF'( R A&#< & + E D J T R O J (
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Boiler room air openings &IGURE Combustion and ventilation air openings for Direct Vent installations. Also follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or applicable provisions of the local building codes.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Vent and air piping and boiler connections Follow termination instructions &IGURE Boiler vent and air connections 1. Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions provided by vent pipe manufacturer. Use only materials from the manufacturers listed in Figure 27, page 23.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Sidewall with separate pipes !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE ).34!,,!4)/. 3%15%.#% — Separate pipes sidewall Use only the vent materials and kits listed in Figure 27, page 23. Provide pipe adapters if specified. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 26, page 22.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Sidewall with separate pipes See notices on previous page. 0REPARE WALL PENETRATIONS 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least 0.4" larger than the vent pipe diameter. b.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Sidewall concentric !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE ).34!,,!4)/. 3%15%.#% — Concentric horizontal 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 27, page 23. Provide pipe adapters if specified. 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Sidewall concentric See notices on previous page. )NSTALL TERMINATION CONCENTRIC PIPES (continued) &IGURE Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of the next 1. Assemble the vent termination as described for concentric terminations, on page 40. If necessary, you can shorten the lengths of the inner and outer pipes for a shorter finished assembly.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Sidewall with W-M vent/air plate !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE ).34!,,!4)/. — W-M sidewall vent/air plate Use only the vent materials and kits listed in Figure 27, page 23. Provide pipe adapters if specified. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 26, page 22.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Sidewall with W-M vent/air plate )NSTALL 7EIL -C,AIN VENT AIR CAP !$!04%23 — Use adapters if using other than 3-inch PVC or CPVC. This is required for different materials (polypropylene or AL29-4C stainless steel) or if using 2-inch pipe. (continued) Vent/air pipes and W-M vent/air plate can be oriented in any of the configurations shown in Figure 38, page 32.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Vertical with separate pipes !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS &IGURE Separate pipes vertical termination Use only the vent materials and kits listed in Figure 27, page 23. Provide pipe adapters if specified. 1. Locate the terminations such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 26, page 22.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Vertical with separate pipes See notices on previous page. (continued) &IGURE Terminations for multiple boilers 0REPARE ROOF PENETRATIONS 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole at least 0.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Vertical concentric !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS 1. The concentric termination kit must be purchased separately. &IGURE ).34!,,!4)/. 3%15%.#% — Concentric vertical Use only the vent materials and kits listed in Figure 27, page 23. Provide pipe adapters if specified. 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Vertical concentric See notices on previous page. (continued) &IGURE Vertical termination — 3" PVC concentric — single or multiple boilers 2. Follow all local codes for isolation of vent pipe when passing through floors, ceilings and roofs. 3. Provide flashing and sealing boots sized for the concentric termination outside diameter. -OUNT CONCENTRIC TERMINATION 1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIRECT VENT — Vertical vent /sidewall air !LLOWABLE VENT AIR PIPE MATERIALS LENGTHS Use only the vent materials and kits listed in Figure 23, page 24. Provide pipe adapters if specified. 1. Locate the terminations such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 22, page 23. &IGURE ).34!,,!4)/. 3%15%.
ECO® Tec Gas-fired water boiler – 80/110/150/199 Boiler Manual DIRECT VENT — Vertical vent /sidewall air Determine location for air inlet elbow 1. The air inlet of an ECO Tec boiler is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent appliance terminations. 2. Locate the air inlet elbow (termination) using the following guidelines. 3. The air piping must terminate in a down-turned elbow as shown in Figure 49. a.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Concentric termination, typical &IGURE 06# concentric termination assembly — DO NOT attach the rain cap until the termination has been inserted through the roof or wall and all supports have been installed. See LEGEND at right. See kit instructions for details of polypropylene kits. (sidewall or vertical) ,%'%.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Install boiler water piping General piping information &IGURE LWCO 3/4" female NPT port location 5SE PIPING UNIONS NEAR BOILER We recommend installing 1" NPT piping unions on boiler outlet and return to facilitate future service. Pipe unions are Not included with the boiler. !DDITIONAL CONTROLS IF REQUIRED The control uses temperature sensors to provide both high limit protection and modulating temperature control.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Install boiler water piping (continued) General Piping Information &IGURE Head Loss through Boiler – Tables 4 and 5 80/110 HO 1.0 2.2 3.4 4.5 ----- Table 5 4 6 8 10 12 14 16 18 20 Head Loss Through Boiler (Heat Only Unit) 199 HO Head Loss Head Loss Head Loss (ft. w.c.) (ft. w.c.) (ft. w.c.) 6 8 10 12 14 16 18 20 Flow (GPM) 150 HO –– 1.3 3.1 4.8 6.6 8.3 --- –– 0.4 2.6 4.7 6.8 8.9 11.0 13.1 14.0 Head Loss (ft w.c.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Install boiler water piping (continued) Domestic Water Piping – Combi Boiler H o t Wa t e r C a n S c a l d ! s Consumer Product Safety Commission and some states recommend domestic hot water temperature of 130°F or less. s When installing an automatic mixing valve, selection and installation must comply with valve manufacturer’s recommendations and instructions.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Install boiler water piping (continued) Recirculation (if used) Massachusetts code applications require recirculation piping or heat-traced piping if the distance from the water heater to the furthest fixture exceeds 100 feet. &IGURE Domestic Piping - Brazed Plate Heat Exchanger - Ports 2 and 4 Other jurisdictions may also require. Check local codes. Maintaining domestic water temperature in the supply piping 1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Install boiler water piping (continued) &IGURE Recirculation piping diagram (if used) Expansion tank (Figure 55, Item 10) THERMAL EXPANSION TANK — If a backflow preventer, check valve, or pressure reducing valve is piped on cold water inlet of water heater, you must install an expansion tank on cold water supply line to prevent normal thermal expansion from repeatedly forcing open T&P relief valve.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Direct Connect System Piping - Single Boiler System 80/110/150 Boilers only System water piping methods $IRECT CONNECTION PIPING TO BOILER It is recommended, but not required, to use primary/ secondary piping to the boiler. Using primary/ secondary piping will provide the most accurate desired system heating temperature. )NSTALLATIONS USING DIRECT CONNECTION PIPING LAYOUT SHOULD 1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Direct Connect System Piping - Single Boiler System 80/110/150 Boilers only Closed-type expansion tank: &IGURE Piping to diaphragm- (or bladder-) type expansion tank DO NOT use a closed-type tank if connecting to a water heater that is equipped with an automatic air vent or if an automatic air vent is incorporated into the system piping.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Direct Connect System Piping - Single Boiler System (continued) 80/110/150 Boilers only &IGURE Piping to closed-type expansion tank Install relief valve 1. Install relief valve in a 3/4" street elbow along with a 3/4" tee onto the top water pipe – Air elimination/relief valve (Figure 8, page 13). #ONNECT THE RELIEF VALVE /.,9 ON THE TOP BOILER PIPE ./4 the boiler out. Connect the relief valve only as shown in this manual.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Direct Connect System Piping - Single Boiler System (continued) 80/110/150 Boilers only ZONE VALVE zoning – direct connection (Shown with optional DHW piping) See Figure 59. 1. This configuration is for zone valve systems that qualify to use direct connection piping based on the criteria on page 46 only. If system does not qualify, pipe using primary/secondary piping. See pages 51-55 for piping suggestions and guidelines. 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Primary/Secondary System Piping - Single Boiler System Expansion tank location &IGURE Piping to diaphragm (or bladder) expansion tank Figure 60 and Figure 61 show typical installation of the system expansion tank. It is highly recommended that you locate the air separator and expansion tank as shown in the suggested piping drawings on pages 53-55.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Primary/Secondary System Piping - Single Boiler System Correct all leaks in the system or tank piping. Leaks allow air to escape from the system and will cause water-logging of the tank. This will result in water loss through the boiler relief valve due to overpressurization. NEVER use an automatic air vent in a system equipped with a closed-type expansion tank. The air removed from the system will cause waterlogging of the expansion tank.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Primary/Secondary System Piping - Single Boiler System System water piping methods .EAR BOILER PIPING Connect boiler to system only as shown in Figure 60, page 50 and Figure 61, page 51. The primary/secondary piping shown ensures the boiler loop will have sufficient flow. "OILER CIRCULATOR The boiler circulator is factory-installed in the boiler as shown in this manual.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Primary/Secondary System Piping - Single Boiler System (continued ZONE VALVE zoning – primary/secondary &IGURE Zone valve zoning — primary/secondary connection — a system circulator is required See Figure 63. 1. This configuration is for zone valve systems using a boiler loop connected as a secondary circuit off of a primary system loop.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Primary/Secondary System piping Circulator zoning – primary/secondary (continued) &IGURE Circulator zoning plus optional DHW piping (Shown with optional DHW piping) See Figure 64. 1. This configuration is for circulator-zoned systems using a boiler loop connected as a secondary circuit off of a primary system loop. Systems zoned with circulators must pipe the boiler loop as a secondary circuit as show. 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Primary/Secondary System piping Circulator zoning – Multiple temperature zones with primary/ (continued) &IGURE Circulator zoning with high- and lowtemperature heating zones secondary (Shown with optional DHW piping) See Figure 65. 1. This configuration is for circulator-zoned systems with high- and low-temperature heating zones using a boiler loop connected as a secondary circuit off of a primary system loop.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Install condensate drain line & trap assembly Prepare condensate drain line assembly 1. Remove the condensate trap kit from the bag assembly. 2. Remove the flexile drain nut (Item 2) and tube gasket ring (Item 3) from the trap kit bag assembly. 3. Slide nut (Item 2) onto end of flexible tube (Item 1). 4. Push the flexible tube gasket ring (Item 3) onto the end of the flexible tube (Item 1) as shown in Figure 66.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Gas piping 5SE TWO WRENCHES when tightening gas Boilers are shipped ready to operate on natural gas ONLY. You must install the propane mixer (venturi) and orifice if the boiler will be connected to propane. See page 14. Failure to comply could result in severe personal injury, death or substantial property damage. Connecting gas supply piping piping at boiler, using one wrench to prevent the boiler gas line connection from turning.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Field wiring %,%#42)#!, 3(/#+ (!:!2$ — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be NEC Class 1. If original wiring as supplied with boiler must be replaced, use only type 105 °C wire or equivalent.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (continued) 4. Low water cutoff harness should be routed from location shown in Figure 51, page 41 to control module connection shown in Section G, page 63. Provide strain relief and a seal at cabinet entry if mounted external of the cabinet. 5. Bundle all wires together with provided wire ties. Loop wire tie with bundled wires through wire tie mount and secure mount to control bracket in bottom right mounting hole. 6.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (see wiring diagram, Figure 70, page 66) (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW (if needed) and Input 3 for Space Heating applications. A. 120VAC Power Supply – REQUIRED 4ERMINAL 3TRIP 4 1. Provide and install a properly-sized, fused disconnect or service switch as required by applicable codes.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (see wiring diagram, Figure 70, page 66) (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW (if needed) and Input 3 for Space Heating applications. # )NPUTS AND DEMANDS – As needed for systems #ONNECTOR * )NPUT #ONNECTOR * )NPUT 6$# )NPUT 1. 2. 3. 4. 5.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (see wiring diagram, Figure 70, page 66) (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW (if needed) and Input 3 for Space Heating applications. D. System supply and return temperature sensors – Recommended when using primary secondary piping design. Connector J19 1.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (see wiring diagram, Figure 70, page 66) (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW (if needed) and Input 3 for Space Heating applications. 4O CAUSE AUTOMATIC RESET #ONNECTOR * 4HE CONTROL WILL RESET AUTOMATICALLY AFTER CIRCUIT IS INTERRUPTED 1.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (see wiring diagram, Figure 70, page 66) (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW (if needed) and Input 3 for Space Heating applications. J. Proof of closure (flow switch and/or CAD) *UMPER ON #ONNECTOR * 1.
ECO® Tec GAS-FIRED Field wiring WATER BOILER – 80/110/150/199 BOILER MANUAL (see wiring diagram, Figure 70, page 66) (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW (if needed) and Input 3 for Space Heating applications. L. 0–10 VDC Remote MODULATION input – OPTIONAL #ONNECTOR * 1. See illustration at right and Figure 70, page 66 for details. 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Wiring diagram — schematic &IGURE Schematic wiring diagram (see Figure 71, page 68 for legend and notes) 66 Part number 550-100-260/0520
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Wiring diagram — schematic Part number 550-100-260/0520 (continued) 67
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Wiring diagram — ladder &IGURE Ladder wiring diagram (see Figure 70, page 66 for schematic wiring diagram) 68 Part number 550-100-260/0520
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Wiring diagram — ladder Part number 550-100-260/0520 (continued) 69
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Zoning with the ECO Tec Control Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW and Input 3 for Spacing Heating applications. A. Zoning with CIRCULATORS, suggested applications &OUR SPACE HEATING ZONES NO )NDIRECT $(7 (EATING /NLY MODELS SHOWN 1. Review wiring information on page 60 (120VAC outputs) and page 61 (24VAC inputs). 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Zoning with the ECO Tec Control (continued) Combi models use Input/Output pairs 1 and 4 for 3-way valve operation and cannot be used for any other purpose. Use Input 2 for Indirect DHW and Input 3 for Spacing Heating applications. B. Zoning with ZONE VALVES, suggested applications 4WO SPACE HEATING ZONES NO )NDIRECT $(7 (EATING /NLY MODELS SHOWN 1. Review wiring information on page 60 (120VAC outputs) and page 61 (24VAC inputs). 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL ECO Tec control operation ECO Tec CONTROL OVERVIEW s Control inputs and outputs allow operation of multiple heating circuits (space heating and DHW, for example). s Up to three priority levels can be set, providing automatic switch-over on demand. s This manual provides quick set-up information for boiler installations.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL ECO Tec control operation (continued) ❏ Dual temperature sensors on boiler outlet, DHW outlet and flue, ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ providing redundant protection. Boiler is shipped with an outdoor sensor. Blower speed modulation to control boiler firing rate. Alarm relay on error/fault for use with an audible safety.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL ECO Tec control operation ECO Tec control operation (continued) &IGURE Outdoor reset operation The control responds to signals from: s DHW Flow demand. s Room thermostats. s DHW aquastats (if used). s Temperature sensors Boiler Out, Boiler In, flue temperature and when used, outdoor temperature.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL ECO Tec control operation (continued) &IGURE Boiler essential settings (REQUIRED on initial start-up) — see page 84 for explanation Screen branching options 1. Occurs when a control is powered up after being 2. Occurs when a factory-installed control is powered ! " 3.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Control settings menus &IGURE ECO Tec control display screens and typical navigation Keyboard: Appears when editing name of inputs/outputs and contractor information. Navigation controls Swipe: 6OLGH ÀQJHU OHIW RU ULJKW RQ WKH VFUHHQ WR QDYLJDWH IRUZDUG DQG EDFNZDUG RQ DSSOLFDEOH VFUHHQV Press: 7RXFK LFRQV RQ VFUHHQ WR SHUIRUP VSHFLÀHG DFWLRQ Scroll: 3ODFH ÀQJHU RQ VOLGH EDU HPSW\ VSDFH DQG KROG WR VFUROO $SSOLFDEOH VFUHHQV FDQ DOVR E
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Page Intentionally Blank Part number 550-100-260/0520 77
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL EXPRESS SETUP — Example A -ULTI ZONE SPACE HEATING #IRCULATORS WITH CIRCULATOR RELAYS \ DHW (Direct-piped) CONTROL "OILER -ODEL !LTITUDE AND &UEL4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. Incorrect setup or piping can result in severe personal injury, death or substantial property damage.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL EXPRESS SETUP — Example A (continued) -ULTI ZONE SPACE HEATING #IRCULATORS WITH CIRCULATOR RELAYS \ DHW (Direct-piped) LEGEND ECO Tec boiler. Indirect water heater, if used (domestic water piping not shown) — MUST be direct piped to boiler to use default control settings. Relief valve, supplied with boiler, field piped — MUST be piped to Boiler In connection — see Figure 8, page 13 for information.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL EXPRESS SETUP — Example B OR :ONE SPACE HEATING #IRCULATORS WITHOUT CIRCULATOR RELAYS \ DHW (Direct-piped) "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. Incorrect setup or piping can result in severe personal injury, death or substantial property damage.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL EXPRESS SETUP — EXAMPLE B (continued) OR :ONE SPACE HEATING #IRCULATORS WITHOUT CIRCULATOR RELAYS \ DHW (Direct-piped) LEGEND 1 ECO Tec boiler. 2 Indirect water heater, if used (domestic water piping not shown) — MUST be direct piped to boiler to use default control settings. 14 Unions as needed for service. 15 Return temperature sensor. 16 Supply temperature sensor. 20 Make-up water supply.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL EXPRESS SETUP — Example C -ULTI ZONE SPACE HEATING :ONE VALVES \ DHW (Direct-piped) "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. Incorrect setup or piping can result in severe personal injury, death or substantial property damage. Use primary/secondary piping or equivalent unless system meets requirements on page 46.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL EXPRESS SETUP — EXAMPLE C (continued) -ULTI ZONE SPACE HEATING :ONE VALVES \ DHW (Direct-piped) LEGEND ECO Tec boiler. Indirect water heater, if used (domestic water piping not shown) — MUST be direct piped to boiler to use default control settings. Relief valve, supplied with boiler, field piped — MUST be piped to Boiler In connection — see Figure 8, page 13 for information. Return temperature sensor.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Available control settings and system presets &IGURE ECO Tec Control / Priority settings $ ASSIGNED INPUTS options Default setting COMBI default UNITS 1, 2, 3, 4, 0-10V, FLOW See System Type Presets SYSTEM SUPPLY, BOILER OUT, DHW OUT Outdoor Temp, 0-10V, none FLOW 1=COMBI DHW - DHW OUT - None - N/A °F 120 °F N/A °F ON - $ ' * *" &' * " + ON, OFF OFF SYSTEM SUPPLY if
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Available control settings and system presets &IGURE ECO Tec Control / Priority settings (continued) options Default setting COMBI default UNITS 1 - 30 N/A 10 °F $ ECO BOOST OFF DIFF &' * " + $ ! * " ! YES, NO Yes Yes - $ ! ! ! ! YES, NO No No - OFF, 1 - 240 OFF OFF S 10 30 OFF S $ ! 11 - 100 100 100 % $ ! 10 - 99 10
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL HOMEOWNER NAVIGATION menus "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. -%.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL CONTRACTOR menus "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. &IGURE ECO Tec control menu access — accessing contractor menus -ORE INFORMATION -%.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL BOILER SETTINGS menu "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. &IGURE ECO Tec BOILER SETTINGS options -%.5 )TEM $%3#2)04)/.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Priority Setting screens "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. &IGURE ECO Tec PRIORITY options -%.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Priority Setting screens (continued) "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. &IGURE ECO Tec PRIORITY options -%.5 )TEM $%3#2)04)/.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL System Settings "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. &IGURE ECO Tec Priorities and Inputs -%.5 )TEM $%3#2)04)/.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Configure Inputs and Outputs "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options. &IGURE Usage and Priorities -%.5 )TEM $%3#2)04)/.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL AUX Pump/Output "OILER -ODEL !LTITUDE AND &UEL 4YPE ARE CRITICAL SETTINGS Failure to set correctly could result in severe personal injury, death or substantial property damage. 1. Access contractor menus by pressing and holding the WM Logo for 7 seconds from the home screen. 2. See the following pages for explanations of control setting options.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL DIAGNOSTIC menu &IGURE DIAGNOSTICS menu -ENU )TEM #OMMENT 4EMPERATURES "OILER Out1 Current operating status of the boiler.
ECO® Tec GAS-FIRED WATER BOILER DIAGNOSTICS menu – 80/110/150/199 BOILER MANUAL (continued) &IGURE DIAGNOSTICS menu (continued) -ENU )TEM #OMMENT 2UN 4IMES "URNER 4IME )NPUT 4IME $(7 4IME )NPUT 4IME )NPUT 4IME )NPUT 4IME 02%(%!4 4IME )GNITION #OUNT ,AST 0ROOF OF )GNITION ,AST 3TABILIZATION ,AST &ACTORY 2ESET ,AST 0OWER #YCLE Displays cumulative time the burner has been active (can be increased by user) Displays cumulative time that Input 1 has been closed (Changes to DHW Tim
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL SERVICE menus &IGURE SERVICE menus — navigation 3ERVICE )NFO Name Phone Model CP Number Installed Last Maintenance Performed Next Maintenance Due Interval Settings Reset Reminder Last Calibration Date #OMMENT Contractor name to appear in maintenance reminders and during lockouts Contractor phone number Displays the boiler model selected in the boiler setup Enter the CP# of the boiler Enter the date the boiler was installed Date automatica
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — fill the system #LEAN SYSTEM TO REMOVE SEDIMENT !NTIFREEZE AND #ORRECT $OSAGE !MOUNT 1. The system must be thoroughly flushed (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by buildup or corrosion due to sediment. 2. For zoned systems, flush each zone separately through a purge valve.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — fill the system Freeze protection (if used) Follow these guidelines to prevent possibility of severe personal injury, death or substantial property damage: 5SE ONLY THE PRODUCTS LISTED BY 7EIL -C,AIN FOR USE WITH THIS BOILER 3EE PAGE FOR INFORMATION 4HOROUGHLY mUSH ANY SYSTEM THAT HAS USED GLYCOL before installing the new boiler. 2EVIEW THE MATERIAL SAFETY DATA SHEETS -3$3 are available online.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — final checks Inspect/fill condensate system Check for gas leaks Before starting the boiler, and during initial operation, use a leak detector or smell near the floor and around the boiler for gas odorant or any unusual odor. Remove boiler jacket door and smell the interior of the boiler jacket. $O NOT PROCEED WITH STARTUP IF THERE IS ANY INDICATION OF A GAS LEAK 2EPAIR ANY LEAK AT ONCE. $/ .
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — final checks (continued) Final checks before starting boiler ❏ Read the instructions to adjust and set up the control. ❏ Verify that the boiler model is set correctly in the control, and that it displays correctly. ❏ Verify that the boiler and system are full of water and all system components are correctly set for operation. ❏ Verify that condensate trap is filled with water.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — final checks (continued) &IGURE Operating instructions (WARNING -Verify that the control is set for the correct boiler model before proceeding.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — final checks If combustion at either high or low fire is outside the range given in Figure 95, page 105, follow the procedure given on this page or page 105 for adjusting the gas valve. If adjustment does not correct the problem, then shut down the boiler and contact your local WeilMcLain representative. The gas valve adjustment must be done only by a qualified technician, using calibrated test instruments.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — final checks (continued) &IGURE Acceptable combustion values — measured values must be within the ranges given below "OILER MODEL (IGH lRE ,OW lRE &UEL % CO2 CO ppm % CO2 CO ppm NG 9.25 ± 0.5 < 100 8.75 ± 0.5 < 50 LP 10.50 ± 0.5 < 150 10.15 ± 0.5 < 50 NG 9.25 ± 0.5 < 100 8.75 ± 0.5 < 50 LP 10.50 ± 0.5 < 150 10.15 ± 0.5 < 50 80 110 NG 9.25 ± 0.5 < 100 8.80 ± 0.5 < 50 LP 10.50 ± 0.5 < 150 9.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Startup — final checks ❏ (continued) #HECK 4HERMOSTATIC -IXING 6ALVE /PERATION (Combi Model Only) s Ensure an ASSE 1070 Thermostatic Mixing Valve is installed on the domestic hot water outlet pipe from the combi boiler and is installed per the manufacturer’s instructions.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Annual startup HANDLING CERAMIC FIBER MATERIALS 2%-/6).' "52.%2 #/6%2 0,!4% OR #/6%2 0,!4% #/-0/.%.43 The cover plate components, refractory insulation, and gaskets contain ceramic fiber materials that have been identified as carcinogenic, or possibly carcinogenic, to humans. Ceramic fibers can be converted to cristobalite in very high temperature applications.
ECO® Tec GAS-FIRED WATER BOILER Annual startup – 80/110/150/199 BOILER MANUAL (continued) Clean condensate trap The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Figure 95, page 105 and explained on the following pages must be performed to assure maximum boiler efficiency and reliability.
ECO® Tec GAS-FIRED WATER BOILER Annual startup – 80/110/150/199 BOILER MANUAL (continued) Check air openings 1. Verify that combustion and ventilation air openings to the boiler room and/or building are open and unobstructed. 2. Check operation and wiring of automatic combustion air dampers, if used. 3. Verify that boiler vent discharge and air intake are clean and free of obstructions. Flue vent system and air piping 1.
ECO® Tec GAS-FIRED WATER BOILER Annual startup – 80/110/150/199 BOILER MANUAL (continued) Check ignition wiring Check flame signal 1. Check ignition cable electrical resistance. A good cable will have resistance between 950 and 1050 ohms. Replace if not acceptable. 2. Inspect boiler ground wire from heat exchanger access cover to ground terminal screw. 3. Verify all wiring is in good condition and securely attached. 4. Check ground continuity of wiring using continuity meter. 5.
ECO® Tec GAS-FIRED WATER BOILER Annual startup &IGURE – 80/110/150/199 BOILER MANUAL (continued) Natural gas ! ! % % up to 2,000 feet (default settings) and high altitude (above 2,000 feet). Model Fuel Altitude (feet) Type 80 % 110 BTU/Hr Note 1 % " & 150 BTU/Hr Note 1 % 199 BTU/Hr Note 1 % BTU/Hr Note 1 Low Fire NG 0-2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 6,500 7,000.
ECO® Tec GAS-FIRED WATER BOILER Annual startup &IGURE – 80/110/150/199 BOILER MANUAL (continued) Propane (LP) gas firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 2,000 feet (default settings) and high altitude (above 2,000 feet). Model Fuel Altitude (feet) Type 80 % 110 BTU/Hr Note 1 % 150 BTU/Hr Note 1 % 199 BTU/Hr Note 1 % BTU/Hr Note 1 Low Fire LP 0-2,000 2,500 3,000 3,500 4,000 4,500 5,000 5,500 6,000 6,500 7,000.
ECO® Tec GAS-FIRED WATER BOILER Annual startup – 80/110/150/199 BOILER MANUAL (continued) Check blower speeds (continued) Check Inlet gas pressure 8. Write down the blower RPM value. It should be within 50 RPM of the value given in Figure 98, page 110 for Natural gas, Figure 99, page 111 for LP propane gas. 9. If any of the values are outside the ranges listed in the previous steps, contact the factory for technical assistance.
ECO® Tec GAS-FIRED WATER BOILER Annual startup – 80/110/150/199 BOILER MANUAL (continued) Check boiler relief valve 1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufacturer’s warning label. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. 2. Read page 48 or 51 before proceeding further. 3.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Troubleshooting Before calling for troubleshooting assistance, fill in the “ECO Tec 'AS $ATA #OLLECTION 3HEET” (starting on page 152).Record the boiler size and Consumer Protection (CP) number (located on the right side exterior of the boiler jacket). &AILURE TO ADHERE TO THESE GUIDELINES CAN RESULT IN SEVERE PERSONAL INJURY DEATH OR SUBSTANTIAL PROPERTY DAMAGE ELECTRICAL SHOCK HAZARD 452. /&& !,, 0/7%24/4(% "/),%2 7(%. 3%26)#).'.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) Check control fuses &IGURE Control fuses ALWAYS check control fuses before replacing the control or any major components (blower, etc.). If one of these fuses is blown, it can prevent the control or other components from operating. 1. Turn OFF power to boiler at external line switch. Then remove the control access door. 2. Locate fuses using Figure 102. 3.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) -AKE SURE TO DETERMINE THE CAUSES OF OUTAGES $O NOT LEAVE THE BOILER OPERATING WITHOUT A COMPLETE DIAGNOSIS Control fault indications 1. The control provides diagnostic information for both automatic reset conditions and manual reset conditions. See Figure 76, page 76 for information available on the control display and navigation instructions for all menus. &IGURE 116 2.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — CONTROL %RROR #ONDITION ,OG RESTART WIZARD The user must hold the button for a specified length of time. Upon completion, this will erase user specific parameter settings and take the user back through the wizard. 2. Reset to Factory Default can be found on the BOILER SETTINGS menu, see Figure 80, page 87. ONCE THIS IS CHOSEN, PREVIOUS SETTINGS CANNOT BE RECOVERED.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Faults Display Condition Nothing shown Control is not receiving 24V on display power. screen and boiler will not respond to call for heat Nothing is Control is not receiving 120V shown in display power.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Faults Display LOW WTR CUTOFF OPEN Condition Occurs if internal low water cutoff contacts open. Diagnostics Manual reset of control if contacts are open. Corrective Action(s) Check for low water condition in system. Repair system as necessary refer to piping section of this manual.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Faults Display LIMIT OPEN HIGH TEMP LIMIT Condition Diagnostics Corrective Action(s) Occurs if manual or automatic reset limit opens. Automatic external limit will reset 2½ minutes after external limit device closes.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Faults Display IGNITION 1 FAULT IGNITION 2 FAULT FLAME LOSS FAULT Condition Boiler went through 5 ignition attempts and never detected flame or flame sense value never reached minimum threshold for boiler model. Diagnostics Automatically resets after 1 hour or can be reset by performing manual reset on boiler.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Faults Display Configuration fault DHW Outlet > Boiler Out Condition Diagnostics Configuration data in the control safety micro does not match that in the control’s application micro. Correct the invalid configuration information. *Combi Only* Clears when the DHW Outlet sensor < Boiler Outlet sensor plus 7°F.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Faults Display Blower Fault 2 Condition Blower unable to reach required pre-purge speed or ignition speed. Diagnostics Clears automatically after 1 hour. Corrective Action(s) Check for loose or damaged wires on high voltage and low voltage blower motor harnesses.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Warnings Display Condition Diagnostics Corrective Action(s) Supply Sensor Occurs when Supply Sensor are chosen as the Target Modulation sensors and the Boiler In sensor is either open or short. Clears warning when a valid sensor is detected.
ECO® Tec GAS-FIRED WATER BOILER Troubleshooting – 80/110/150/199 BOILER MANUAL (continued) &IGURE Troubleshooting suggestions — &AULT DISPLAYS DIAGNOSTICS AND CORRECTIVE ACTIONS Warnings Display Outdoor Sensor Error Condition Outdoor temperature sensor short or OPEN. Diagnostics Will automatically reset if the condition clears. Warning only. Max Target Temp is targeted until Outdoor Temp is restored, if used for target adjustment.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Maintenance DO NOT SERVICE THE BOILER WITHOUT A ECO Tec MAINTENANCE KIT AVAILABLE The maintenance kit includes components that may have to be replaced when accessing or disassembling parts of the boiler. Failure to replace damaged components and to use only the parts specifically intended for the boiler can result in severe personal injury, death or substantial property damage. See Figure 125, page 137 for part number.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning heat exchanger flue side Cleaning the heat exchanger FLUE SIDE or accessing the burner, if required The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 106 of this manual. Failure to comply could result in severe personal injury.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning heat exchanger flue side (continued) )NSPECT AND CLEAN THE BURNER 2EINSTALL COMPONENTS 1. See Figure 115, page 130 part G. a. Slide the bottom cover plate insulation with integrated seal (Item 19) off of the burner. Set the insulation aside where it will be kept clean and protected from damage. If the insulation and/or the seal is damaged, it must be discarded and replaced with a new one. b.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning heat exchanger flue side the gas valve, gas line and swivel nut (Item 5) onto the venturi (Item 7) gas inlet. Inspect the gas valve flex line, making sure there are no signs of wear or damage. Replace if necessary. For LP models, confirm LP Gas Orifice is inserted into venturi gas inlet before making the connection. 11. Using two (2) wrenches reconnect gas valve to venturi gas inlet. 12.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning heat exchanger flue side (continued) &IGURE Accessing the burner , heat exchanger, blower assembly and venturi removal. (See Legend, page 129).
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning DHW and Brazed Plate Heat Exchanger Procedure for chemical cleaning of DHW circuit Carefully read and follow the instructions contained. Chemical cleaning and maintenance must be carried out by professionally qualified personnel, in compliance with the current regulations and according to the manufacturer’s instructions. Do not carry out any operation on the sealed control parts.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning DHW and Brazed Plate Heat Exchanger Actions for chemical cleaning of Domestic hot water circuit &IGURE Domestic water circuit cleaning diagram instructions (Refer to Figure 117) 1. Shut down the boiler: a. Follow “To Turn Off Gas to Appliance” instructions on boiler and Operating instructions. b. Close the boiler manual gas valve. 2. Close off the of cold water inlet valve (Item 6a) placed before the boiler inlet. 3.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning DHW and Brazed Plate Heat Exchanger Before servicing Brazed Plate Heat Exchanger Assembly &IGURE Removal of brazed plate heat exchanger by loosening the two (2) screws. 1. Cool down boiler and brazed plate heat exchanger assembly. The following procedure may be used to cool down boiler and components. First follow the operating instructions on page 101 to properly shut off gas supply, but not the power to the boiler.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning/maintenance for Domestic Water Inlet & Outlet Manifolds Brazed plate heat exchanger reinstalled Four (4) new gaskets must be placed in the DHW inlet and DHW return plate connections to seal brazed plate heat exchanger. See Figure 132, page 144 for service part numbers. 1. Slide the brazed plate heat exchanger into rear of enclosure (ensure brazed plate is in proper orientation; label stating “This side up” should be facing up) 2.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Cleaning/maintenance for Domestic Water Inlet & Outlet Manifolds 12. Open valves of the domestic cold water inlet and the domestic hot water outlet. Flush water through system by opening a fixture. Check all water joints and ensure no leaks are present. Cleaning and maintenance for Domestic Water Outlet Manifold (Refer to Figure 122 and Figure 123) 1.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Replacement parts DO NOT SERVICE THE BOILER WITHOUT A MAINTENANCE KIT AVAILABLE The maintenance kit includes components that may have to be replaced when accessing or disassembling parts of the boiler. Failure to replace damaged components and to use only the parts specifically intended for the boiler can result in severe personal injury, death or substantial property damage. See Figure 125, page 137 for part number.
ECO® Tec GAS-FIRED WATER BOILER Replacement parts &IGURE – 80/110/150/199 BOILER MANUAL (continued) Miscellaneous service parts and kits Description Part Number CHEMICALS Antifreeze, Sentinel X500, 1 Gallon . . . . . . 592-900-029 Corrosion inhibitor, Sentinel X100 . . . . . . . 592-900-002 Sentinel X100 Quick Test Kit. . . . . . . . . .
ECO® Tec GAS-FIRED WATER BOILER Replacement parts &IGURE – 80/110/150/199 BOILER MANUAL (continued) Jacket parts — ECO Tec 80/110/150/199 (see Figure 127, page 139 for illustration) Item Name Description / contents Part Number 100 Jacket door Jacket door, gaskets and labels 383-700-269 110 Gasket bottom, top & sides for jacket door Seals for door bottom, sides and top of cabinet 383-700-363 120 Jacket Assembly Jacket panels, gaskets and hardware 383-700-271 130 Flue pipe 80mm Poly
ECO® Tec GAS-FIRED WATER BOILER Replacement parts &IGURE – 80/110/150/199 BOILER MANUAL (continued) Jacket assembly — ECO Tec 80/110/150/199 (see Figure 126, page 138 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-260/0520 139
ECO® Tec GAS-FIRED WATER BOILER Replacement parts &IGURE Item – 80/110/150/199 BOILER MANUAL (continued) Heat exchanger parts ECO Tec 80/110/150/199 (see Figure 129, page 141 for illustration) Name Part Number Model Model Model Model 80 110 150 199 383-700-284 100 110 Heat exchanger Heat exchanger, condensate dish, cover plate, burner, igniter, sight glass, refractory, water sensors, gaskets, silicone, and hardware (includes Items 100, 120, 130, 140, 150,160,170,180, 210, 220, and 230) —
ECO® Tec GAS-FIRED WATER BOILER Replacement parts – 80/110/150/199 BOILER MANUAL (continued) &IGURE Heat exchanger assembly ECO Tec 80/110/150/199 (see Figure 128, page 140 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-260/0520 141
ECO® Tec GAS-FIRED WATER BOILER Replacement parts &IGURE – 80/110/150/199 BOILER MANUAL (continued) Combustion components parts ECO Tec 80/110/150/199 (see Figure 131, page 143 for illustration) Item Name Part Number 100 Air silencer, clip and gasket 383-700-294 110 Kit - Service Silencer O-ring, blower gasket, gas flex line, and igniter gaskets 383-700-360 120 Blower, gasket and hardware Model Model Model 80/110 150 199 — 383-700-303 383-700-304 — 383-700-305 130 Venturi — 383-7
ECO® Tec GAS-FIRED WATER BOILER Replacement parts – 80/110/150/199 BOILER MANUAL (continued) &IGURE Combustion components parts ECO Tec 80/110/150/199 (see Figure 130, page 142 for part numbers) Part number 550-100-260/0520 143
ECO® Tec GAS-FIRED WATER BOILER Replacement parts &IGURE Item – 80/110/150/199 BOILER MANUAL (continued) Combi water piping for ECO Tec 80/110/150/199 (see Figure 134, page 145 for illustration) Name Description / contents Part Number 100 Grommet - water pipe sealing 383-700-361 110 Pipe - water top 383-700-377 120 Condensate drain tube 130 Pipe - water flex 1" 383-700-378 140 Pipe - water return 383-700-375 150 Brazed plate heat exchange includes Item 230 383-700-355 160 DHW
ECO® Tec GAS-FIRED WATER BOILER Replacement parts – 80/110/150/199 BOILER MANUAL (continued) &IGURE Combi and Heating Only water piping for ECO Tec 80/110/150/199 (see Figure 132, page 144 or Figure 133, page 144 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-260/0520 145
ECO® Tec GAS-FIRED WATER BOILER Replacement parts – 80/110/150/199 BOILER MANUAL (continued) &IGURE Controls and electrical components - ECO Tec 80/110/150/199 (see Figure 136, page 147 for illustration) Item Name Description / contents Part Number 100 Flue temperature sensor & grommet One (1) sensor & grommet 383-500-600 110 Outdoor temperature sensor 120 System temperature sensor Two (2) sensors 383-700-371 130 Transformer 120V/50V/24V 50 VA transformer 383-700-320 140 Display
ECO® Tec GAS-FIRED WATER BOILER Replacement parts – 80/110/150/199 BOILER MANUAL (continued) &IGURE Controls and electrical assemblies - ECO Tec 80/110 /150/199 (see Figure 135, page 146 for part numbers) 'O TO WWW WEIL MCLAIN COM TO LOCATE 7EIL -C,AIN DISTRIBUTORS Part number 550-100-260/0520 147
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Dimensions &IGURE 148 Dimensional data — ECO Tec 80/110/150/199 (all dimensions in inches) Boiler Out tapping — 1" Male NPT Boiler In tapping — 1" Male NPT Control display and navigation buttons DHW In/Out tapping — 3/4" Male NPT Vent connection: 3" PVC/PP/SS Gas connection 1/2" Male NPT Condensate tube connection Air connection: 3" PVC/PP/SS Boiler tapping for relief valve - 3/4" Male NPT Electrical entrance ope
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Ratings — ECO Tec boilers &IGURE Ratings and engineering data — ECO Tec 80/110/150/199 $ ' = ^ % Input derate vs vent length Boiler Model CSA Input Heating Seasonal Capacity _ \ Net Water Vent/ Boiler Comb.
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Ratings— ECO Tec boilers &IGURE Engineering Data — ECO Tec 80/110/150/199 boilers Shipping weight Boiler Model Operating weight Water content % `? per boiler 6ENT AIR PIPE SIZE (Provide a separate vent for each boiler) Pounds per boiler Pounds per boiler %LECTRICAL SERVICE REQUIRED Amps per boiler Note 1 GPM @ 20°F rise GPM @ 40°F rise Note 2 Note 3 HO / Combi HO / Combi Gallons per boiler 80 138 / 147 141 /
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL Installation and Service Certificate "OILER $ATA "OILER -ODEL 3ERIES ECO Tec ???????????? 3ERIES ????????? $ATE INSTALLED ????????????????????? #ONSUMER 0ROTECTION #0 .UMBER ????????????? "TU )NPUT #%24)&)%$ 4(!4: ❏ ❏ ❏ ❏ &5%, .ATURAL ?????? ,0 ?????? ??????????????????? Installation instructions have been followed. Check-out sequence has been performed. Information on next two pages is certified to be correct.
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ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL ECO Tec Gas Boiler Data Collection Sheet #USTOMER )NFO -AINTENANCE )NFO Contact: Contractor: Job name: City, state: Distributor: Name: Phone: Model: CP#: Installed: "OILER 3YSTEM 0IPING $ETAILS 0LEASE 3KETCH 3YSTEM #OMPONENTS Near boiler pipe size: DHW tank (yes/no): DHW direct/system: DHW model: DHW pipe size: DHW circulator model: Is there air in system?: $IAGNOSTIC %RRORS Ignition retries: Manual reset CNT: Auto reset CNT: 3OFTWA
ECO® Tec GAS-FIRED ,OCKOUT (ISTORY Fault Name: Fault Type: Fault Time: Fault Date: Status: 4EMPERATURES Status: Boiler out 1: Boiler out 2: DHW out 1: DHW out 2: Boiler in: Flue 1: Flue 2: Outdoor: )NPUTS Status: Input 1: Input 2: Input 3: Input 4: Manual limit: Auto limit: Low WTR Cutoff: Air Pressure Switch: Closure Switch: Blower Speed: Flame signal: DHW Flow: /UTPUTS Status: Gas valve: ,OCKOUT (ISTORY Fault Name: Fault Type: Fault Time: Fault Date: Status: 4EMPERATURES Status: Boiler out 1: Bo
ECO® Tec GAS-FIRED WATER BOILER – 80/110/150/199 BOILER MANUAL
