Utica Boilers Cub Series Operation And Installation Manual 3541F240 CHB

2015-05-20

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cod. 3541F240

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION & MAINTENANCE MANUAL

P/N# 240010633, Rev. B [07/17/2014]

Model

CHB-100

CHB-130

Manufactured for:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

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

DIMENSIONS

TABLE OF CONTENTS

1 - Introduction ................................................................................................................... 4

2 - Important Safety Information ........................................................................................... 5

3 - General view and main components .................................................................................. 6

4 - Locating Boiler ............................................................................................................... 9

5 - Hydronic Piping ............................................................................................................11

6 - Combustion Air And Vent Piping - Category I (Chimney Vent) ............................................ 15

6 - Combustion Air And Vent Piping of direct vent and Category III .......................................... 17

7 - Gas Supply Piping ......................................................................................................... 22

8 - Electrical Connections ................................................................................................... 23

9 - Start Up Procedure ....................................................................................................... 24

10 - Operating Instructions ................................................................................................. 26

11 - General Maintenance And Cleaning ................................................................................ 32

12 - Ratings And Capacities ................................................................................................ 33

13 - Trouble Shooting......................................................................................................... 36

Wiring diagram ............................................................................................................... 37

Repair Parts List - CHB-100 ............................................................................................. 38

Repair Parts List - CHB-130 ............................................................................................. 44

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 liqueﬁ ed 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 The unit MUST NOT:

•

Directly heat potable water.

• Heat water with non-hydronic heating system chemicals

present (example, swimming pool water).

• Exceed 185°F (85°C) system design temperature.

• Exceed 43.5 PSIG

1.3 Operational Features

• Modulating: 3-1 turn down.

• Integral Dual Limit.

Information and speciﬁ cations outlined in this manual in effect at the

time of printing of this manual. ECR International, Inc. reserves the right to

discontinue, change speciﬁ cations or system design at any time without

notice and without incurring any obligation, whatsoever.

2 - IMPORTANT SAFETY INFORMATION

NOTICE

Used to address practices not related to

personal injury.

CAUTION

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate

injury.

WARNING

Indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not

avoided, WILL result in death or serious injury.

This is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.

2.2 Become familiar with symbols identifying

potential hazards.

WARNING

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.

2.3 Installation shall conform to requirements of

authority having jurisdiction or in absence of such

requirements:

•

United States

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, NFPA 70.

• Canada

• Natural Gas and Propane Installation Code,

CAN/CSA B149.1.

• Canadian Electrical Code, Part I, Safety Standard

for Electrical Installations, CSA C22.1

2.4 Requirements for Commonwealth of

Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not

limited to:

• Installation by licensed plumber or gas ﬁ tter.

2.5

Where required by the authority having jurisdiction, the

installation must conform to the

Standard for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD1.

2.1 General

Boiler installation shall be completed by qualiﬁ ed agency.

See glossary for additional information.

Figure 2 Component Listing

3 - GENERAL VIEW AND MAIN COMPONENTS

Item

Number

Description

5Sealed Chamber

7Gas 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 - High Limit NTC

297 Air Pressure Switch

364 Condensation Coupling

LBS Kg

Unit Weight CHB 100 61 27.5

CHB 130 65 29.5

Shipping Weight CHB 100 65 29.5

CHB 130 69 31.5

3 - GENERAL VIEW AND MAIN COMPONENTS

Remove Boiler Jacket

Unscrew screws (A).

Pivot jacket upwards. See ﬁ gure 3.

Raise Jacket up and off boiler. See ﬁ gure 4.

Figure 3 - Jacket Removal - Screw

Locations

Figure 4 - Pivot Jacket and Raise to Remove

WARNING

Fire, explosion, asphyxiation and electrical

shock hazard. Disconnect electrical power

supply and turn off gas at shutoff valve before

attemting to remove boiler jacket. Failure to

follow these instructions could result in death

or serious injury.

3 - GENERAL VIEW AND MAIN COMPONENTS

Figure 5 - Boiler Clearances

4 - LOCATING BOILER

4.1 Boiler Location Considerations

• 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.

• Drainage of water (or water - antifreeze solution) during

boiler service or from safety relief valve discharge. See

section 5.

• Access to system water piping, gas supply, and electrical

service. See sections 5, 7 and 8.

• Clearances to combustible materials and service

clearances. See Table 1 and ﬁ gure 5.

• The boiler must not be installed on carpeting.

FLOOR

Boiler

(Side View)

Boiler

(Front View)

Front

TABLE 1: BOILER CLEARANCES

Dimension Combustible

Materials (1) Service(1)(2)

Top (A)

16” (41cm) 16" (41cm)

Left Side (B

)

0" (0 cm) 1” (3 cm)

Right Side (C)

0" (0 cm) 1” (3 cm)

Front (D)

0" (0 cm) 1" 3 cm)

Back (E)

0" (0 cm) 0” (0 cm)

Bottom (F)

0" (0 cm) 12" (30 cm)

Combustion Air/piping

0" (0 cm) 3/8" (1 cm)

Vent piping

6" (15 cm) 6" (15 cm)

(1) Required distances measured from boiler jacket.

(2) Service, proper operation clearance recommendation.

Figure 6 - Wall Mounting Bracket

4 - LOCATING BOILER

4.2 Pre-pipe supply and return water connections

with factory ﬁ ttings before wall mounting.

4.3 Wall Mounting

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 ﬁ gure 6.

CAUTION

Boiler weight exceeds 75 pounds (34 kg). Do not

lift boiler onto wall without assistance.

NOTICE

Lift boiler using chassis. Using front jacket, vent

piping, water or gas ﬁ ttings to lift boiler may cause

damage to the boiler.

9¼” (23.5cm)

2⅜”

(2.4cm)

2⅜”

(2.4cm)

5 - HYDRONIC PIPING

5.1 General

• Install piping in accordance with authority having jurisdiction.

NOTICE

Use two (2) wrenches when tightening and ﬁ tting

pipe to boiler's threaded ﬁ ttings. Boiler's internal

piping can be damaged if subjected to excessive

torque.

• Support system piping and safety relief valve discharge

piping. Boiler's internal piping and wall mount bracket

can be damaged if subjected to excessive weight.

• Size central heating pump (and domestic hot water

pump, if used) for system requirements only. Internal

heat exchanger pump compensates for pressure drop

through boiler internal piping and heat exchanger.

• Thoroughly clean and ﬂ ush system before connecting to boiler.

• If oil is present in system water, use approved detergent to

wash system.

• Flush system to remove any solid objects such as metal chips,

ﬁ bers, or Teﬂ on tape, etc.

5.2 Water System Characteristics

• Water in the heating system must have protection of

metallic materials against corrosion.

• Filling water and subsequent replenishing, must be

clear, with hardness under 150 ppm CaCO3,

A. treated with approved conditioning chemicals

to ensure prevention of corrosion and attack on

metals and plastics, that gases do not form,

B. and bacterial or microbial masses do not proliferate

in low temperature systems.

• Hardness exceeding 150 ppm CaCO3, appropriate water

softening treatment and/or use of suitable anti-fouling

agents must be provided.

Water contained in the system must be checked at least

yearly and have:

A. pH above 7 and under 8.5 (under 8 with presence

of components in aluminum or light alloys),

B. iron content (Fe) less than 0.5 mg/l,

C. copper content (Cu) less than 0.1 mg/l,

D. total content of chlorides, nitrates and sulfates less

than 50mg/l,

E. must contain conditioning chemicals in

concentration sufﬁ cient to protect system for a

year.

There must be no microbial or bacterial loads in low

temperature systems.

Conditioners, additives, inhibitors and anti-freeze ﬂ uids can

be used only if manufacturer guarantees they are suitable

for use in heating systems and they do not cause damage

to heat exchanger or other components and/or materials of

boiler and system.

Use of generic chemicals not speciﬁ cally suitable for use in

heating systems and/or incompatible with boiler materials

and system is forbidden.

Conditioning chemicals must ensure complete deoxygenation

of water and contain speciﬁ c 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, speciﬁ c biocides

for use in heating systems.

In systems with continuous intake of oxygen (e.g. ﬂ oor

systems without anti-diffusion pipes, open expansion

vessels), or intermittent (e.g. in case of frequent

replenishing), a separator must be provided. Regarding

domestic hot water (DHW), no type of treatment which

could prevent its possible food use can be provided for.

WARNING

• Poison hazard. Ethylene glycol is toxic. Do not

use ethylene glycol.

• Never use automotive or standard glycol antifreeze,

even ethylene glycol made for hydronic systems.

• Ethylene glycol can attack gaskets and seals used

in hydronic systems.

• Use only inhibited propylene glycol solutions

certiﬁ ed by ﬂ uid manufacturer as acceptable for

use with closed water heating system.

• Thoroughly clean and ﬂ ush any system that used

glycol before installing new Boiler.

• Provide user with Material Safety Data Sheet

(MSDS) on ﬂ uid used.

NOTICE

Do not expose boiler to freezing temperatures.

5.3 Special Conditions

• System piping exposed to freezing conditions: Use

inhibited propylene glycol solutions certiﬁ ed by ﬂ uid

manufacturer for use with closed water heating system.

Do not use automotive or ethylene glycol.

• Boiler installed above radiation level (or as required by

authority having jurisdiction) shall have low water cutoff

protection.

• Boiler used in connection with refrigeration system.

Install piping in parallel with boiler, with appropriate

valves to prevent chilled medium from entering boiler.

H. Extended DHW calls resulting in delayed response

to CH calls.

WARNING

Burn and Scald Hazard. Safety relief vlave

could discharge steam or hot water during

operation. Install discharge piping per these

instructions. Failure to do so could result in

death or serious injury.

5.5 Safety Relief Valve

NOTICE

Boiler rated at 43.5 psig (.30MPa) maximum allowable

working pressure. Boiler provided with 30 psig

(.21MPa) safety relief valve.

• Install safety relief valve using pipe ﬁ ttings provided with

boiler. See ﬁ gure 8.

• Install safety relief valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety

relief valve.

• Install discharge piping from safety relief valve. See

ﬁ gure 9.

• Use ¾” or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C)

or greater.

• Individual boiler discharge piping shall be independent

of other discharge piping.

Figure 7 - Indirect Tank Performance Chart

• System piping connected to heating coils located in air

handling unit exposed to refrigerated air circulation. Install

ﬂ ow control valves or other automatic means to prevent

gravity circulation of boiler water during cooling cycle

5.4 Storage Tank Connection For Domestic Hot

Water Production

• Unit’s electronic board is arranged for managing an

external storage tank for domestic hot water production.

• See ﬁ gure 10 for hydronic plumbing.

• Make electrical connections as shown on wiring diagram

page 36.

• Boiler’s control system recognizes presence of hot water

tank probe and automatically conﬁ gures DHW function,

activating display and controls.

• Match Indirect tank heat exchanger and boiler capacity.

• Indirect tank requires dedicated pump. See ﬁ gure 7 and

indirect tank speciﬁ cation to determine pump.

• Incorrect tank size or insufﬁ cient ﬂ ow may result in:

F. Unsatisfactory indirect tank performance.

G. Boiler short cycling

5 - HYDRONIC PIPING

Figure 8 - Safety Relief Valve & Air Vent

(Viewed from front of boiler)

1” MPT

Coupling 1” NPT

Nipple 1” x 5”

Tee 1” x 1” x ¾”

Safety Relief

Valve

Street Elbow ¾”

5 - HYDRONIC PIPING

Check Local Codes

for Maximum

Distance to Floor

Safety Relief

Valve

Gas Shutoff

Valve

in Open

position

Figure 9 - Safety Relief Valve Discharge

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).

• Terminate pipe with plain end (not threaded).

5 - HYDRONIC PIPING

8 Domestic Hot Water Outlet

9 Domestic Cold Water Inlet

10 Heating System Supply

11 Heating System Return

95 Diverter Valve

209 Hot Water Tank Delivery

210 Hot Water Tank Return

Figure 10 - Hydronic Piping

6 - COMBUSTION AIR AND VENT PIPING - CATEGORY I (CHIMNEY VENT)

6.1 Check Your Chimney

Chimney must be clean, right size, properly constructed

and in GOOD CONDITION.

Installation must conform to requirements of the

authority having jurisdiction or, in absence of such

requirements, to the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 and/or Natural Gas and Propane

Installation Code, CAN/CSA B149.1.

Increaser ﬁ tting is required on this boiler for Category I

venting, and 4” is minimum permissible vent diameter.

This does not imply vent connector is intended to be 4”

diameter pipe. Vent connector shall be sized according

to appropriate venting tables in the National Fuel

Gas Code and may be required to be larger than 4”

diameter.

NOTICE

Boiler installation for chimney venting is not

complete unless increaser ﬁ tting is located and

secured.

These are Category I and Category III high efﬁ ciency

boilers with lower stack or exhaust temperature.

Venting into masonry chimney without liner, line

chimney from top to bottom with either:

A. Listed Type B vent pipe

B. Listed ﬂ exible vent liner

C. Poured ceramic liner.

Outside chimneys should not be used unless they are

(choose one of the following):

A. Enclosed in a chase

B. Lined with Type B vent pipe

C. Use listed ﬂ exible vent liner

D. Use certiﬁ ed chimney lining system

Vent connector from boiler to chimney should run as

directly as possible with as few elbows as possible.

Common venting shall not be allowed. Boiler and

other certiﬁ ed appliances. appliances can share same

chimney vent. Consult appropriate Vent Sizing Tables

in National Fuel Gas Code for speciﬁ c requirements of

multiple appliance venting.

Boiler is only appliance connected to vent, Type B vent

pipe is recommended for vent connector.

Slope pipe up from boiler to chimney not less than 1/4”

per foot (21mm/m).

10.

End of vent pipe must be ﬂ ush with inside face of

chimney ﬂ ue. Use sealed-in thimble for chimney

connection.

11.

Fasten sections of vent pipe with sheet metal screws to

make piping rigid. Use stovepipe wires to support pipe

from above.

12.

Do not connect to ﬁ replace ﬂ ue.

13.

Do not install damper on this boiler.

WARNING

Boiler and venting installations shall be performed

by a qualiﬁ ed 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 ﬁ re or to asphyxiation from poisonous gases such

as carbon monoxide with is odorless and invisible.

WARNING

Do not connect boiler to any portion of mechanical

draft system operating under positive pressure.

Figure 11 - Combustion Air Fitting

3 3

Horizontal Venting requires ﬁ eld supplied appliance adapter

for the boiler ﬂ ue outlet.

Boiler is provided with a 3” vent connection, 3” x 4”

increaser must be ﬁ eld sourced for chimney application.

This does not mean that the connection to the chimney will

always be 4”.

6 - COMBUSTION AIR AND VENT PIPING- CATEGORY I (CHIMNEY VENT)

6.4 Modulating Fan

• Unit is equipped with an advanced combustion air, vent

ﬂ ow control system, with modulating fan and pressure

sensor.

• Unit automatically adapts its operation to ﬂ ue type

and length, without requiring adjustments during

installation or use of bafﬂ es in combustion circuit.

• Unit consistantly and automatically regulates

combustion air and vent ﬂ ow according to change in

thermal load. Combustion and heat exchange occur in

optimum conditions. Unit’s thermal efﬁ ciency remains

high throughout its power range.

6.5 Venting Materials

• See Table 3

6.2 Minimum Vent Pipe Clearance

• 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.

• Boiler installed with single wall vent, must have 6”

clearance between its surface and any combustible

material. New Type B gas vent or ﬂ exible liner must be

installed in accordance with instructions furnished with

vent. Maintain clearances as speciﬁ ed for vent pipe.

• Verify vent pipe is ﬁ re-stopped where it goes through

ﬂ oor or ceiling. It should have approved vent cap with

clearances from roof. If clearances are less than shown,

have vent checked by local authorities. Figure 13, Page

20.

• Vent connectors serving appliances vented by natural

draft shall not be connected into any portion of

mechanical draft systems operating under positive

pressure.

6.3 Removing Existing Boiler From Common

Venting System

When an existing boiler is removed from a common

venting system, common venting system is likely to be

too large for proper venting of the appliances remaining

connected to it.

At the time of removal of an existing boiler, the

following steps shall be followed with each appliance

remaining connected to the common venting system

placed in operation, while the other appliance

remaining connected to the common venting system

are not in operation.

Seal any unused openings in the common venting

system.

Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion and other deﬁ ciencies

which could cause an unsafe condition.

Insofar as is practical, close all building doors and

windows and all doors between the space in which the

appliances remaining connected to the common venting

system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected

to the common venting system. Turn on any exhaust

fans, such as range hoods and bathroom exhausts, so

they will operate at maximum speed. Do not operate a

summer exhaust fan. Close ﬁ replace dampers.

Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance

will operate continuously.

Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use ﬂ ame of a

match or candle, or smoke from a cigarette, cigar, or

pipe.

After it has been determined that each appliance

remaining connected to the common venting system

properly vents when tested as outlined above, return

doors, windows, exhaust fans, ﬁ replace dampers and

any other gas-burning appliance to their previous

conditions of use.

Any improper operation of the common venting system

should be corrected so the installation conforms with

the National Fuel gas Code, ANSI Z223.1/NFPA 54,

and/or the Natural Gas and Propane Installation Code,

CAN/CSA B149.1. When re-sizing any portion of the

common venting system, the common venting system

should be re-sized to approach the minimum size

determined using the appropriate tables in Chapter 13

of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,

and/or the Natural Gas and Propane Installation Code,

CAN/CSA B149.1.

It is recommended that existing gas vents be checked

to be sure they meet local codes.

Item Material Standards

Vent Pipe & Fittings

Type B Vent UL 441, ULC S605

Masonry Chimney

- must conform to

proper sizing and

materials

National Fuel

Gas Code, ANSI

Z223.1/NFPA 54

Combustion Air

Stainelss Steel,

PVC, CPVC, PP,

Aluminum

ANSI/ASTM

D2564, ANSI/

ASTM F493, UL

1738/ULC636-08

Table 3 - Combustion Air and Vent Pipe Fittings

Category I (Chimney Vent)

6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III

Induced Draft Boilers

Horizontal (Category III) venting systems installation

shall conform to the requirements of the authority having

jurisdiction or, in the absence of such requirements, to

the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/

or Natural Gas and Propane Installation Code, CAN/CSA

B149.1

Boilers may be vented horizontally. Vent pipe is pitched

down from boiler to vent termination. Do not connect

other appliances to this vent.

Vent Pipe Material UL Listed - AL294C Stainless Steel

vent pipe and ﬁ ttings.

Clearance to Combustible Materials: For stainless steel

vent pipe maintain 6” minimum air space clearance to

combustible materials.

Vent Pipe Size: 3” vent pipe connected directly to the

outlet of the induced draft blower.

Vent Pipe Length:

A. For stainless steel vent pipe, the maximum

horizontal vent length is 65 equivalent feet.

B. Minimum horizontal vent length is 5 equivalent

feet.

C. For 3” 90° elbows = 5 equivalent feet of vent

length.

Vent Termination Fitting: For all vent pipe materials,

you may use either:

A. 90° elbow pointing down, ﬁ tted with a minimum

1/4” mesh screen to keep out rodents and birds.

The elbow shall be of the same material and size

as vent pipe. The elbow exit should be at least 6”

away from exterior wall.

-or-

B. Concentric side wall vent hood.

Vent Pipe Termination Location :

A. When venting through combustible walls,

combustible clearances must be considered. ECR

vent termination, 5612601, is a certiﬁ ed direct vent

termination (for Catagory III venting) providing

both the outside vent termination and a double

wall pipe for passing through a combustible

wall up to 10” thick. Vent terminations by other

manufacturers may also be used as long as they

are certiﬁ ed for catagory III venting.

B. If the 90° elbow is the termination ﬁ tting of choice,

then the single wall pipe will be passing through the

side wall. For combustible walls, a UL listed thimble

shall be used where the single wall pipe passes

through the wall.

C. For single wall pipe through non-combustible

walls, the hole through the wall need only be large

enough to maintain the pitch of the vent pipe, and

provide proper sealing. A thimble is not required for

single wall pipe passing through non-combustible

walls.

D. The venting system shall terminate at least 3 feet

0.9m) above any forced air inlet located within

10 feet (3m). The venting system shall terminate

at least 4 feet (1.2m) below, 4 feet (1.2m)

horizontally from, or 1 foot (300 mm) above any

door, window, or gravity air inlet into any building.

The bottom of the vent shall be located at least 12

inches (300mm) above grade. Termination of the

vent shall be not less than 7 feet (2.13m) above

adjacent public walkway. The vent terminal shall

not be installed closer than 3 feet (0.9m) from the

inside corner of an L shaped structure. Termination

of the vent should be kept at least 3 feet (0.9m)

away from vegetation. The venting system shall

terminate at least 4 feet horizontally from, and in

no case above or below, unless a 4 foot horizontal

distance is maintained, from electric meters, gas

meters, regulators, and relief equipment.

• The venting system shall terminate at least 4 feet

below any eave, sofﬁ t, or roof overhang.

• The venting system shall not terminate

underneath any deck, patio, or similar structure.

• Put vent on a wall away from the prevailing

winter wind. Locate or guard the vent to prevent

accidental contact with people or pets.

• Terminate the vent above normal snow-line. Avoid

locations where snow may drift and block the

vent. Ice or snow may cause the boiler to shut

down if the vent becomes obstructed.

• Under certain conditions, ﬂ ue gas will condense,

forming moisture. In such cases, steps should be

taken to prevent building materials at the vent

terminal from being damaged by exhaust of ﬂ ue

gas.

United States - Terminate vent system at least

4 feet (1.22m) horizontally from, and in no case

above or below, unless a 4 feet (1.22m) horizontal

distance is maintained, from electric meters, gas

meters, regulators and relief equipment.

Canada - Terminate vent system at least 6 feet

(1.83 m) horizontally from, and in no case above

or below, unless a 6 feet (1.83m) horizontal

distance is maintained, from electric meters, gas

meters, regulators and relief equipment.

Joining and Sealing the Vent Pipe: The vent pipe needs

to be both watertight and gas tight. Seal all joints and

seams following vent pipe manufacture’s installation

instructions.

Support Spacing: Do not restrict thermal expansion

movement of the vent. The vent pipe must expand

and contract freely with temperature change. Each run

of vent piping shall be supported following vent pipe

manufacture’s instructions.

WARNING

Vent extending through exterior wall shall not

terminate adjacent to wall or below building

extensions such as eaves, balconies, parapets or

decks. Failure to comply could result in death or

serious injury.

Table 4 - Combustion Air and Vent Pipe Fittings

Equivalent Length of Venting Components:

5 ft. equivalent for a 3” 90° elbow.

2 1/2 ft. equivalent for a 3” 45° elbow.

6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III

10.

If the horizontal vent must go through a crawl space or

other unheated space, the cool temperatures will likely

cause the ﬂ ue 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. An insulated enclosure or chase, with

access for inspection and servicing of the vent, may

be required to prevent freezing of liquid condensate.

Consult the vent pipe manufacturer’s instructions for

speciﬁ c guidelines.

11.

At beginning of each heating season and monthly

during the heating season, check all vent pipes and

vent terminal to make sure there are no obstructions.

Periodically clean the screen in the vent terminal.

Type Item Diameter Min Lenght Max Lenght Material Standards

Direct vent

Vent 3” 5 ft 65 ft AL294C Stainless

Steel, Aluminum

UL1738,

ULC S636

Air intake 3” 5 ft 65 ft

Stainelss Steel,

PVC, CPVC, PP,

Aluminum

ANSI/ASTM

D2564, ANSI/

ASTM F493, UL

1738/ULC636-08

Category III Vent 3” 5 ft 65 ft AL294C Stainless

Steel, Aluminum

UL1738,

ULC S636

6 - COMBUSTION AIR AND VENTILATION

Provide combustion air and ventilation air in accordance

with the section “Air for Combustion and Ventilation,”

of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,

or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane

Installation Code, CAN/CSA B149.1, or applicable

provisions of local building codes.

Provide make-up air where exhaust fans, clothes dryers,

and kitchen ventilation equipment interfere with proper

operation.

National Fuel Gas Code recognizes several methods

of obtaining adequate ventilation and combustion air.

Requirements of the authority having jurisdiction may

override these methods.

• Engineered Installations. Must be approved by

authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35

cfm per Mbh for all appliances located within space.

Additional requirements where exhaust fans installed.

Interlock each appliance to mechanical air supply

system to prevent main burner operation when

mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all

appliances in space. Use a different method if

minimum volume not available.

◊ Standard Method. Cannot be used if known air

inﬁ ltration rate is less than 0.40 air changes per

hour. See Table 5 for space with boiler only. Use

equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

◊ Known Air Inﬁ ltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inﬁ ltration rate (ACH)

greater than 0.60.

Volume ≥ 15 ft3/ACH x Total Input [Mbh]

◊ Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

• All Outdoor Air. Provide permanent opening(s)

communicating directly or by ducts with outdoors.

◊ Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second

opening commencing within 12 inches of bottom

enclosure.

Direct communication with outdoors or

communicating through vertical ducts. Provide

minimum free area of 1 in2 per 4 Mbh of total input

rating of all appliances in enclosure.

Communicating through horizontal ducts. Provide

minimum free area of 1 in2 per 2 Mbh of total input

rating of all appliances in enclosure.

◊ One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.

Provide minimum clearance of 1 inch on sides

and back and 6 inches on front of boiler (does not

supersede clearance to combustible materials).

◊ Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements

for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer toNational

Fuel Gas Code for application information. National Gas

and Propane Installation Code Requires providing air

supply in accordance with:

• Section 8.2 and 8.3 when combination of appliances

has a total input of up to and including 400 Mbh

(120kW).

Does not have draft control device.

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code

for speciﬁ c air supply requirements for enclosure or

structure where boiler is installed, including air supply

openings and ducts.

Table 5 - Air Inﬁ ltration

Input Mbh Standard

Method

Known Air Inﬁ ltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 .05 0.6

100 5000 15,000 7,500 5,000 3,750 3,000 2,500

130 6500 19,500 9,750 6,500 4,875 3,900 3,250

6 - COMBUSTION AIR AND VENT PIPING

( = Combustion Air / = Venting)

Figure 12 - Horizontal Venting Clearances

Figure 13 - Two Pipe Venting

NOTICE

Maintain 12” (30cm) US, 18” (46cm) Canada

clearance above highest anticipated snow level

or grade.

6 - COMBUSTION AIR AND VENT PIPING

Figure 14 - Chimney Venting with Room Air

Single Wall

( = Combustion Air / = Venting)

Figure 15 - Chimney Venting with Outside Air

Single Wall

NOTICE

Refer to section 6.1, numbers 3 through 12,

page 15 of this manual for proper installation.

DIRECT VENT BOILER - Boiler constructed and installed

so all combustion air is derived directly from outdoors and

all vent gases are discharged to outdoors. See Figure 15.

7 - GAS SUPPLY PIPING

7.1 General

• Use piping materials and joining methods acceptable

to authority having jurisdiction. In absence of such

requirements:

• USA - National Fuel Gas Code, ANSI Z223.1/NFPA

• Canada - Natural Gas and Propane Installation Code,

CAN/CSA B149.1

• Size and install gas piping system to provide sufﬁ cient

gas supply to meet maximum input at not less than

minimum supply pressure. See Table 6.

• Support piping with hooks straps, bands, brackets,

hangers, or building structure components to prevent or

dampen excessive vibrations and prevent strain on gas

connection. Boiler will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for

liqueﬁ ed petroleum gas.

• Provide sediment trap up stream of gas valve.

• Install manual main shutoff valve outside of jacket. See

ﬁ gure 16.

7.2 Conversion To LP

Refer to Gas Conversion Kit Instructions.

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 ﬁ re

department.

Figure 16 Manual Main Gas Shutoff Valve

Outside Boiler Jacket

With Manufacturer Suggested Piping With Drip Leg

Manufacturer suggested gas piping with drip leg.

Gas Supply Pressure

Natural Gas

Min. Max.

3.5" w.c.

(0.7 kPa)

14" w.c. (3.3

kPa)

Table 6 - Gas Supply Pressure

DANGER

Fire Hazard. Do not use matches, candles, open

ﬂ ames, or other methods providing ignition source.

Failure to comply will result in death or serious

injury.

7.3

Leak Check Gas Piping

Pressure test boiler and gas connection before placing

boiler in operation.

• Pressure test over 1/2 psig (3.5 kPa). Disconnect

boiler and its individual gas shutoff valve from gas

supply system.

• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate

boiler from gas supply system by closing manual gas

shutoff valve. See ﬁ gure 16.

• Locate leakage using gas detector, noncorrosive

detection ﬂ uid, or other leak detection method

acceptable to authority having jurisdiction. Do not use

matches, candles, open ﬂ ames, or other methods that

can provide ignition source.

• Correct leaks immediately and retest.

Nipple

¾” x 3” NPT

Tee ¾” NPT

Nipple ¾ x

3” NPT

¾” Pipe Cap

Gas

Connection

¾” Gas

Shutoff

Valve in ON

Postion

Nipple

¾ x 3”

NPT

8 - ELECTRICAL CONNECTIONS

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.

8.2 Line Voltage Connections - Boiler

Provide individual 120V, 15 amp circuit (recommended)

with fused disconnect or service switch as required by

authority having jurisdiction.

WARNING

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.

8.3 Central Heating Thermostat

A. Use thermostat or boiler system control with

dry contacts rated 0.5 amps @ 120 VAC. Boiler

control does not provide 24 VAC power to central

heating thermostat. Do not use to power 24VAC

thermostat.

B. Locate and install thermostat per manufacturer's

instructions. Maximum wire length is 330 ft (100m)

for 22 ga. wire.

C. Connect wires to terminals 1 and 2 as shown in

ﬁ gure 17. Wires are interchangeable.

Figure 17 - Terminal Block

1 - Thermostat or dry contacts

2 - 138 = Optional External Outdoor Reset Sensor

Connections on 5 & 6 terminals

155 = Optional Indirect Tank Sensor

Connections on 7 & 8 terminals

370 = Low Water Cutoff (LWCO) - ﬁ eld source

Connections on 1 & 2 terminals are 120 Volts A/C.

Connections on 3 & 4 are dry contact only.

9.2 Boiler Start-up and Operational Test

Verify air is purged from hydronic piping

System test pumps - verify each pump is

operational

Verify gas piping

• Conﬁ rm pressure test. See section 7.3 page 22.

• Visually inspect piping to determine there are no

open ﬁ ttings or ends, and all valves at unused

outlets are closed and plugged/capped.

• Purge air from piping

• Check piping and connections for leaks immediately

after gas is turned on. Shut off gas supply and

make necessary repairs if leaks found.

Follow OPERATING INSTRUCTIONS to initiate boiler

operation. See section 10.

Inspect combustion air and vent piping. Verify pipe

is not leaking and terminations are unobstructed and

vent gas discharge is not a nuisance or hazard.

Verify boiler operates.

Check control module operation.

Check ﬁ eld sourced limits, low water cutoffs, etc. per

manufacturer's instructions.

WARNING

Asphyxiation hazard. Verify cap is ﬁ rmly placed on

combustion analyzer port to prevent CO emission.

Failure to do so could result in death or serious

injury.

WARNING

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.

9 - START UP PROCEDURE

9.1 Fill Boiler With Water And Purge Air

NOTICE

To maintain boiler efﬁ ciency and prevent boiling

inside the heat exchanger, ﬂ ush entire heating

system until clean.

• Flush heating system, including all heating zones.

• Fill boiler with potable water.

• Fill boiler and system piping with water (or

antifreeze-water solution, if used). See antifreeze

information Section 5.3 page 11. Purge air from

boiler using air vent. Purge air from system piping.

• Inspect system piping and boiler connections.

Repair any leaks immediately.

• Activate all heating zones and calls for heat,

including CH calls and DHW calls (if available).

• Do not open gas shutoff valve until all air is purged

from system.

9.3 Burner Pressure Adjustment

Unit has ﬂ ame modulation, with two ﬁ xed pressure values:

minimum and maximum. See sec. 12, page 33.

Connect pressure gauge to pressure point “B” downstream

of the gas valve.

Remove protection cap “D”.

Operate boiler in TEST mode.

Adjust maximum pressure by turning screw “G”

clockwise

↷

to increase pressure and counter clockwise

↶ to decrease.

Disconnect one of two connectors “C” from modulation

regulator “F” on the gas valve.

Adjust minimum pressure by turning screw “E” clockwise

↷

to increase the pressure and counter clockwise ↶ to

decrease it.

Turn burner on and off, verify minimum pressure

remains stable.

Reconnect connector “C” detached from modulation

regulator “F” on the gas valve.

Verify maximum pressure has not changed.

Replace protection cap “D”.

10.

To end TEST mode, repeat activation sequence or wait

15 minutes.

9.4 To Enter Test Mode/Adjust Heating Power

Press CH+/- buttons at the same time for 5 seconds.

• 3 way valve is in CH position and burner is forced at

100%. Boiler automatically exits test mode after 15

minutes or to exit test mode manually press CH +/-

buttons together for 5 seconds.

• With Ch +/- buttons you can adjust Max power from (0

to 100%)

9.5 Ignition Adjustment

To adjust ignition, switch boiler to TEST mode (See Start

up Procedure). Press DHW buttons to increase or decrease

power (min.= 00, max. = 60). Press RESET button within

5 seconds and ignition remains set. Exit TEST mode.

9.6 Check Combustion

Natural Gas

1. Measure input. English unitsTurn off gas to all other

appliances.

•

Activate some heating zones to dissipate heat.

•

Set boiler on high ﬁ re.

•

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.

Input (MBH) = 3600 x cu ft

seconds

Example: Gas ﬂ ow from

Meter = 2 cu ft

Measured time = 72 seconds

Rate (MBH) = 3600 x 2 cu ft = 100 MBH

72 seconds

Two sampling points are available at top of the boiler, one

for venting and the other for combustion air. To sample:

Open the air/vent outlet plug.

Insert probes all the way in.

Turn on TEST mode, wait 10 minutes for boiler to stabilize;

Take measurement.

Vent Gases Test

Port

Combustion Air Test

Port

A Pressure point upstream

B Pressure point downstream

C Modureg electrical connection

D Protection cap

E Minimum pressure adjustment

F Modureg

G Maximum pressure adjustment

I Gas valve electrical connection

N Compensation tube

9 - START UP PROCEDURE

Figure 18 - Test Ports

Figure 19 - Gas Valve

Combustion Minimum/Maximum

Natural Gas

High Fire - CO2 at 100 (%) 7.3 - 7.8

Low Fire - CO2 at 33 (%) 3.0 - 5.0

Table 7 - Combustion Table

WARNING

If you do not follow these instructions

exactly, a ﬁ re or explosion may result

causing property damage, personal injury

or loss of life.

• This appliance is equipped with an ignition device

which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area

for gas. Be sure to smell next to ﬂ oor because

some gas is heavier than air and will settle to the

ﬂ oor.

• Use only your hand to turn the gas shutoff

valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualiﬁ ed

service technician. Force or attempted repair may

result in ﬁ re or explosion.

• Do not use this appliance if any part has

been under water. Immediately call a qualiﬁ ed

service technician to inspect appliance and to

replace any part of control system and any gas

control which has been under water.

10.1 OPERATING INSTRUCTIONS

Stop! Read Safety information above.

• Set thermostat to lowest setting.

• Turn "OFF" all electrical power to appliance.

• This appliance is equipped with an ignition device which

automatically lights the burner. Do not try to light

burner by hand!

• Turn gas shutoff valve

to closed position. Handle

should be perpendicular to gas pipe.

• Wait 5 minutes for any gas to clear. Smell for gas,

including near ﬂ oor. If you smell gas, STOP! Follow

instructions on this page: “What To Do If You Smell

Gas.” If you do not smell gas, go to next step.

• Turn gas shutoff valve to open position. Handle

should be parallel to gas pipe.

• Turn "ON" electrical power to appliance.

• Set thermostat to desired setting.

• If the appliance will not operate, follow instructions TO

TURN OFF GAS TO APPLIANCE and call your service

technician or gas supplier.

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 the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the ﬁ re

department.

10.2 TO TURN OFF GAS TO APPLIANCE

• Set thermostat to lowest setting.

• Turn "OFF" all electric power to appliance if service is

to be performed.

• Turn gas shutoff valve handle to closed position.

Handle should be perpendicular to gas pipe.

Figure 20 Gas Shutoff Valve - Open Position

Figure 21 Gas Shutoff Valve - Closed Position

10 - OPERATING INSTRUCTIONS

OPEN

CLOSED

10.4 Control Panel

217

Key

1 = DHW Temperature Setting Decrease Button

2 = DHW Temperature Setting Increase Button

3 = Heating System Temperature Setting Decrease Button - CH

4 = Heating System Temperature Setting Increase Button - CH

5 = Display

6 = Summer/Winter Mode Selection - Reset Button

7 =

Unit On/Off - Economy/Comfort Mode Selection Button

8 = DHW Symbol

9 = DHW Mode

10 = Summer Mode

11 = Multifunction - Temperature

12 = Eco (Economy) Mode

13 = Heating

14 = Heating Symbol

15 = Burner On And Actual Power

64 = C.H. Temperature Pressure Gauges

10.5 Indicator During Operation

Heating

Call for heat (generated by Room Thermostat) is indicated

by hot air ﬂ ashing above radiator symbol on the control.

Hot water

If optional tank sensor is installed call for hot water is

indicated by hot water ﬂ ashing under the tap on the control.

10.6 Turning on and off

NO electrical power to the boiler

The antifreeze system does not work when power and/or

gas to the unit are turned off. To avoid damage caused by

freezing during long idle periods in winter, it is advisable to

drain all water from the boiler, DHW circuit and system; or

drain just the DHW circuit and add a suitable antifreeze to

the heating system. See Section 5.3 page 11.

10 - OPERATING INSTRUCTIONS

10.3 Checks During Operation

• Boiler is arranged 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 efﬁ ciency of the ﬂ ue gases and combustion

air ducts while the boiler is working.

• Check water is circulating between boiler and systems.

• Verify the gas valve modulates correctly in both

heating and hot water production phases.

• Check proper ignition of the boiler by turning it on and

off with the room thermostat.

• Check parameters are programmed correctly and

perform any required customization (compensation

curve, power, temperatures, etc.)

Boiler Ignition

Supply unit with electricity.

Boiler ignition

For 120 seconds display will show FH which identiﬁ es the

air venting cycle for the heating system.

During the ﬁ rst 5 seconds the display will show the

software release of the card also.

Open the gas valve before the boiler.

When FH vanishes, boiler is ready to automatically work

whenever indirect tank sensor or room thermostat requests

heating.

Turning the boiler off

Press the button below (see item 7 on the control panel

display) for 5 seconds.

When the boiler is turned off, the electronic board is still

powered.

Domestic hot water and heating operation are disabled. The

antifreeze system remains activated.

To re-light the boiler, press the button (see item 7 on the

control panel display) again for 5 seconds.

Boiler will be immediately ready to operate whenever

indirect tank sensor or room thermostat demand.

Summer/Winter Switch over

NOTICE

Activating this button will keep your boiler from operating.

Verify that boiler is not required to run Domestic Hot

Water (DHW) needs.

Press the button for 2 seconds.

Display will activate Summer symbol (see item 10 on the

control panel display). If optional tank sensor is installed

boiler will activate DHW circuit only. Antifreeze system

stays on.

To turn off Summer mode, press button again for 2

seconds.

Heating temperature setting

Use heating buttons (see items 3 and 4 on the control

panel display) to change the temperature from minimum of

86°F (30C) to a maximum of 185°F (85C); it is advisable to

not operate boiler below 113°F (45C).

Domestic hot water temperature adjustment

Operate DHW buttons (see items 1 and 2 on the control

panel display) to vary the temperature from a minimum of

50°F (40C) to a maximum of 149°F (55C).

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). To

activate COMFORT mode, press the ECO/COMFORT button

(detail 7 - on control panel display) again.

Sliding temperature

• When the optional external probe is installed, the boiler

control system operates with “Sliding Temperature”.

In this mode, the temperature of the heating system is

controlled according to the outside weather conditions,

in order to ensure high comfort and energy saving

throughout the year.

• As the outside temperature increases the system

delivery temperature decreases according to a speciﬁ c

“compensation curve”.

• With Sliding Temperature adjustment, the temperature

set with the heating buttons (details 3 and 4 on control

panel display) become the maximum system delivery

temperature.

• Manufacture recommends setting the maximum value

to allow system adjustment throughout its useful

working range.

• Boiler must be adjusted at time of installation by

qualiﬁ ed service agent. Adjustments can be made by

user to improve comfort.

Compensation curve and curve offset

Press the button (see item 6 on the control panel display)

for 5 seconds once to display the actual compensation

curve, which can be modiﬁ ed with the DHW buttons (see

items 1 and 2 on the control panel display).

Adjust the required curve from 1 to 10 according to the

characteristic.

By setting the curve to 0, sliding temperature adjustment is

disabled.

Compensation curve

Press the heating buttons (see items 3 and 4 on the control

panel display) to access parallel curve offset modiﬁ able

with the DHW buttons (see items 1 and 2 on the control

panel display).

Parallel curve shift

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.

Domestic Hot Water Temperature Adjustment can be made from the boiler control panel.

Summer/Winter Switchover Summer mode has priority over a possible heating demand.

Eco/Comfort Selection

On disabling DHW from the menu, the boiler selects the Economy mode. In this condition, the

button 7 from control panel display is disabled.

On enabling DHW from menu, the boiler selects the Comfort mode. In this condition it is

possible to select on of the two modes with the button 7 from control panel display.

Sliding Temperature Boiler card manages Sliding Temperature adjustment: the boiler card Sliding

Temperature has priority.

10 - OPERATING INSTRUCTIONS

Water system pressure adjustment

The ﬁ lling 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.

TEST mode (heating power = 100%)

Press the heating buttons simultaneously for 5 seconds to

turn on TEST mode. The boiler will ignite at the maximum

heating power set as described in the following paragraph.

On the display, the heating and tap water symbols will

blink; alongside, it will show the heating power and the

ignition power respectively.

To turn off TEST mode, repeat the sequence for turning it

on.

11 - GENERAL MAINTENANCE AND CLEANING

11.1 Beginning of Each Heating Season

• Check boiler area is free from combustible materials,

gasoline, and other ﬂ ammable vapors and liquids.

• Visually inspect combustion air and vent piping for

proper operation. Check for and remove any obstruction

to ﬂ ow 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.

• Test safety relief valve for proper operation. Refer to

valve manufacturer's instructions packaged with relief

valve.

• Examine ﬂ ue passages in heat exchanger, burner and

cleaning (if necessary) by following instructions in

“Annual Inspection and Cleaning of Boiler Components” in

this section.

• Circulator pump and combustion air blower motor

furnished with boiler are permanently lubricated from

factory and require no further lubrication. Lubricate ﬁ eld

sourced pumps and/or motors according to pump and/or

motor manufacturer’s instruction.

• Check following components are operating properly and

are free of blockages or obstructions:

• air vent;

• check air inlet for blockage and clean as required;

• check boiler for any sign of leaks.

• Check heating system expansion tank.

• Check the Air pressure tubing

11.2 Annual Shut Down Procedure

• Follow instructions “To Turn Off Gas To Appliance” unless

boiler is also used to supply domestic hot water. See

section 10, page 26.

• Drain system completely if system does not have

antifreeze when heating system is to remain out of

service during freezing weather.

WARNING

Following service procedures must be performed

by qualiﬁ ed service agent. Boiler owner shall not

attempt these steps. Failure to do so could result in

death or serious injury.

11.3 Annual Inspection and Cleaning of Boiler

Components

• Burner and heat exchanger inspection and cleaning.

• Remove any remaining loosened sediment using shop

vacuum with snorkel attachment.

12 - RATINGS AND CAPACITIES

12.1 Ratings and Capacities

• Constructed and hydrostatically tested for maximum

allowable working pressure of 43.5 psig (pounds per

square inch gauge)

43.5 psig (.30MPa)

in accordance

with ASME Boiler and Pressure Vessel Code, Section IV,

Rules for Construction of Heating Boilers.

• USA - Input rates are derated 4% for each 1000 ft (300m)

above sea level, beyond 2000 ft (600m).

• CANADA -

Ratings in table 13 used for elevations up to 2000

ft (600m) above sea level

- For elevations between 2000 ft (600m) and 4500

ft (1350m), derate 10% using high altitude kit.

- Contact Provincial authority having jurisdiction

for installations above 4500 feet (1350 m) above

sea level.

SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Size

Boiler Input Rate

(MBH)(1) Heating

Capacity

(MBH)(1)(2)

Net AHRI

Rating, Water

(MBH)(1)(3) AFUE(2)

Maximum Minimum

CHB-100 100 31.5 85 73.0 85

CHB-130 130 43.5 110 96.0 85

(1) 1000 Btu/hr (British Thermal Units Per Hour)

(2) Heating Capacity and AFUE (Annual Fuel Utilization Efﬁ ciency) are based on DOE (Department of Energy) test

procedures.

(3)

Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for

installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems,

etc.

12 - RATINGS AND CAPACITIES

Table 8 - Sea Level Ratings

12 - RATINGS AND CAPACITIES

Diagrams

Manifold Gas Pressure W.C.

0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0

0,00

2,00

4,00

6,00

8,00

14,00

16,00

20,00

Water Flow [GPM]

Pump Head [feet w.c.]

18,00

12,00

10,00

Losses of load / head of circulators

A Boiler losses of head

1 - 2 - 3 Circulator speed

13 - TROUBLE SHOOTING

Diagnostics

The boiler is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will ﬂ ash 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 ﬁ rst eliminate the fault.

Other faults (marked with the letter “F”) cause temporary shutdowns that are automatically reset as soon as the value

returns within the boiler’s normal working range.

Table of faults

- List of faults

Fault

code Fault Possible cause Cure

A01 No burner ignition

No gas Check the regular gas ﬂ ow to the boiler and that the air has

been eliminated from the pipes

Ignition/detection electrode fault Check the wiring of the electrode and that it is correctly

positioned and free of any deposits

Faulty gas valve Check the gas valve and replace it is necessary

Ignition power too low Adjust the ignition power

A02 Flame present signal with burner

off

Electrode fault Check the ionisation electrode wiring

Card fault Check the card

A03 Overtemperature protection

activation

Heating sensor damaged Check correct heating sensor positioning and operation

No water circulation in the system Check the circulating pump

Air in the system Vent the system

F05

The air pressure transducer does

not receive a sufﬁ cient minimum

value within 25 seconds

Incorrect air pressure transducer wiring Check the wiring

Flue not correctly sized or obstructed Check the length of ﬂ ue and that it is clean

A06 No ﬂ ame after the ignition stage Low pressure in the gas system Check the gas pressure

Burner minimum pressure setting Check the pressures

F10 Delivery sensor 1 fault

Sensor damaged

Check the wiring or replace the sensorWiring shorted

Wiring disconnected

F11 DHW sensor fault

Sensor damaged

Check the wiring or replace the sensorWiring shorted

Wiring disconnected

F14 Delivery sensor 2 fault

Sensor damaged

Check the wiring or replace the sensorWiring shorted

Wiring disconnected

A15 Air signal protection activation Fault F05 generated 5 times in the last

15 minutes See fault F05

F34 Supply voltage under 170V. Electric mains trouble Check the electrical system

F35 Faulty mains frequency Electric mains trouble Check the electrical system

F37 Incorrect system water pressure Pressure too low Fill the system

Sensor damaged Check the sensor

F39 External probe fault

Probe damaged or wiring short circuit Check the wiring or replace the sensor

Probe disconnected after activating the

sliding temperature

Reconnect the external probe or disable the sliding

temperature

A41 Sensor positioning Delivery sensor detached from the pipe Check correct heating sensor positioning and operation

F42 Heating sensor fault Sensor damaged Replace the sensor

F43 Exchanger protection activation. No system H2O circulation Check the circulating pump

Air in the system Vent the system

A44 DHW sensor disconnected Sensor disconnected Check the correct positioning and operation of the DHW

sensor.

A48 Air signal protection activation Fault F05 for 150 seconds See Fault F05

F50 Modulation regulator fault Wiring disconnected Check the wiring

F51 Low water cutoff warning Pressure too low Fill the system

Low water cutoff damaged Check the contact

278

1 4

120V

60Hz

138

56783412

138

370

278

297

114

GND

+15V

OUT

155

AUX

X11

LLNN

DBM34

kOhm

1,8

kOhm

138 - Optional Outdoor Sensor

155 - Optional Indirect Tank Sensor

Key

16 Modulating fan

32 Heating circulating pump

42 DHW temperature sensor (see kit)

44 Gas valve

47 Modulation Regulator (24V)

72 Room thermostat (ﬁ eld sourced)

81 Ignition/detection electrode

114 Water pressure switch

138 External probe (not ﬁ tted)

155 Hot water tank temperature probe (ﬁ eld sourced)

278 Double sensor (Safety + Heating)

297 Air pressure transducer

370 Low Water Cutoff (LWCO) - (ﬁ eld sourced)

Important: Before connecting the room thermostat, remove the jumper on terminal block.

WIRING DIAGRAM

370 - Field Source LWCO

KEY Part Number Description Qty

A01 FE3980B830 CASING "CTR" 1

REPAIR PARTS LIST - CHB-100

KEY Part Number Description Qty

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. 1

REPAIR PARTS LIST - CHB-100

KEY Part Number Description Qty

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 KIT 3/4” SAFETY VALVE 1

C13 FE3980B920 KIT NPT ADAPTERS 1

P01 FE34226300 CH FLOW PIPE 1

P02 FE34225470 CH RETURN PIPE 1

P03 FE3841B170 BYPASS PIPE 1

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 0.85mm LP 2

D09 FE3980C120 IGNITION ELECTRODE 17

D10 FE3980C180 KIT PLUGS CASING 17

D11 FE3980C310 KIT COMBUSTION CHAMBER INSULATION

SR.AEO4 1

D12 FE3980B960 GAS VALVE VGU 54S 1

D13 FE3980C170 PRESSURE TRANSDUCER 1

D14 FE3980C190 COUPLING CONDENSATION 1

D15 FE3980B970 WALL MOUNT BRACKET 1

D16 FE3980B980 KIT VENT. ADAPTERS FM 1

D17 FE3980D800 KIT AIR PRESSURE TEST POINT US (35101150) 1

P04 FE3841L460 GAS PIPE 1

REPAIR PARTS LIST - CHB-100

KEY Part Number Description Qty

A01 FE3980B830 CASING "CTR" 1

REPAIR PARTS LIST - CHB-130

KEY Part Number Description Qty

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. 1

REPAIR PARTS LIST - CHB-130

KEY Part Number Description Qty

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 3/4” SAFETY VALVE 1

C13 FE3980B920 KIT NPT ADAPTERS 1

P01 FE34226280 CH FLOW PIPE 1

P02 FE34202130 CH RETURN PIPE 1

P03 FE3841B170 BYPASS PIPE 1

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 0.85mm LP 2

D09 FE3980C120 KIT IGNITION ELECTRODE 17

D10 FE3980C180 KIT PLUGS CASING 17

D11 FE3980C320 COMBUSTION CHAMBER INSULATION SR.AEO7 1

D12 FE3980B960 KIT GAS VALVE VGU 54S 1

D13 FE3980C170 KIT PRESSURE TRANSDUCER 1

D14 FE3980C190 KIT COUPLING CONDENSATION 1

D15 FE3980B970 WALL MOUNT BRACKET 1

D16 FE3980B980 KIT VENT.ADAPTERS FM 1

D17 FE3980D800 KIT AIR PRESSURE TEST POINT US (35101150) 1

P04 FE3841L370 GAS PIPE 1

REPAIR PARTS LIST - CHB-130

NOTES

ECR International, Inc

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Utica Boilers Cub Series Operation And Installation Manual 3541F240 CHB

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