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1. I F Field supplied PA See Fig 4a for wiring e pumps over 4A Pump 120V 4A Max Use isolation relay for pumps over 4A 120V See Fig 10 for electronic l oi e thermostat wiring O INN NN O 24V BVS T2 SHL2 T2 S3 S3 n FRS Yellow d T2 sapak Orange R oom o thermostat SHL1 T1 on UE Ti Se Black 24V Effikal a T1 T1 Honeywell S8600 H E P MV GND 24V B MV PV PV BRNIGND 24V K NEN 24V gas Fig 12a valve Legend PA Pump aquastat 104 F BVS Blocked vent switch SHL1 Adjustable high limit 235 F aquastat 194 F FRS Flame roll out switch 140 F SHL1 Fixed manual reset 248 F aquastat 20 Vitogas 050 ECD Series Cast Iron Atmospheric Gas Fired exploded view example of ECD 140 ECD 155 Inspection opening for heat exchanger Fig 13 Note Ref No 19 not shown as only applicable to ECD 180 ECD 200 Note Ref No 35 is at a different location for the ECD 180 ECD 200 21 Ref No Name of Part Part No Silver Orange ECD 100 ECD 115 ECD 140 ECD 155 ECD 180 ECD 200 Left panel 9544 9544 200 201 9543 9544 897 189 Right panel 9544 9544 202 203 9543 9543 Back panel 9544 9544 9544 9544 204 205 206
2. Blocked vent switch activated Flame roll out switch activated Cure Purge air from gas line Wait for boiler to cool down below aquastat setting Increase setting Check power supply Wait for boiler to cool down Reset aquastat Replace Replace pilot orifice Replace ground wire Turn knob to on Check position of main gas shut off valve or purge gas line of air Replace Replace Chimney or vent obstruction needs to be removed Clean heat exchanger Main burner will light and turn off again within safety timing of module Defective igniter sensor Defective module Faulty ground wire Replace Replace Replace Never leave a safety control bypassed Only qualified service technicians shall perform troubleshooting procedures Parts List for Honeywell Intermittent Pilot Ignition System NATURAL GAS PROPANE GAS GAS CONTROL LIST HONEYWELL PART NO HONEYWELL PART NO Gas Valve ECD VR8204P1007 ECD 65 180 VR8204P1049 VR8304P3308 ECD 200 Ignition Control S8600H1006 S8600H1006 Pilot Burner Q3451A2012 Q3451A2012 Pilot Orifice 018 inches dia 014 inches dia 390686 4 390696 24 BCR 18 BBR 14 Pilot burner has ignition cable permanently attached Consult your Viessmann representative for parts replacement 17 Lighting Instructions for Intermittent Pilot Spark to Pilot MN FOR YOUR SAFETY READ BEFORE OPERATING iii WARNING If you do not fol
3. Combustion air opening Each opening shall have an area of one square inch per 1000 Btu h of input C ZC LIIL Concrete non combustible floor ECD Opening size 180 10 x20 200 10 x 20 Left side view Fig F Alcove installation for ECD 180 200 All dimensions shown are minimum Z LZ Z VA o5 4 L A pren esa Vi dlg d YJ i o 8 TOO o oc aS ECD 65 155 4 552 T c 2 8 4 o IL gt N as 4 j of L ONJ n l u j 150mm 25mm Side view Fig 1 ECD 65 155 Closet installation minimum clearances Provisions for combustion and ventilation air must be made in accordance with section 5 3 Air for Combustion and gnon of the National Fuel Gas Code ANSI Z223 1 latest edition or applicable provisions of the local codes In Canada follow CAN CSA B149 1 or 2 Natural Gas Installation Codes latest edition for combustion and ventilation air requirements Whenever possible install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area See example in Fig 2 Refer to national codes for duct sizing Round ducts can be used Electrical on off switch for boiler O Fig 2 Boiler located in dedicated mechanical room with combustion air ducted in from outside AN Warning Failure to provi
4. Drain valve Floor CD drain Level concrete Fig A floor pad Typical hot water piping system Air flow Flushing of existing piping Before boiler is connected to a piping heating system which has previously been in service the ECD is a replacement boiler the piping system should be flushed thoroughly with water in order to remove sludge or other contaminants especially in large piping systems such as old gravity pipe systems Flush from the top of the system with city water pressure Failure to flush out system can lead to deposits in boiler resulting in boiler failure This type of failure is not covered under warranty Boiler foundation Provide a solid level foundation capable of supporting the weight of the boiler filled with water and extending at least 1 past the jacket on all sides Pour a concrete foundation if necessary The boiler must be installed in an indoor heated space The boiler should be located near a floor drain Do not install boilers on carpeting Install on non combustible floor If the boiler is to be installed on combustible floors or on a mezzanine it should be equipped with a special base pan Please reference the Viessmann Price List Typical boiler piping is shown in Fig A Vent damper installation Boilers are sold with a vent damper packaged separately The vent damper must be installed on the boiler to meet minimum federal efficiency standards
5. Installers must follow local regulations with respect to installation of carbon monoxide detectors Follow manufacturer s maintenance schedule of boiler AN Warning Shut off all electrical power and turn off gas or oil supply to boiler before performing any service or maintenance on the boiler burner or control Failure to heed this warning could result in electrical shock serious personal injury or loss of life AN Attention The preferred and safest location for the ECD Series boiler is in a dedicated mechanical room with fresh combustion air intake and ventilation openings made directly to the outside Vitogas 050 ECD Series Technical Data Cut away view left side Draft hood Boiler well for Left view Vent connection S Boiler supply water 114 water flows out Front view VIESMANN capillaries i3 58 120V power in Se i Transformer Er 120V 4A max o Ignition control ko output to pump 58 24V thermostat 24N gas valve s5 8 24N vent damper 88 amp I Burner manifold BB T Gas connection SI S Boiler return 8 water 114 a Ti ot d water flows in TL 2 82 72 LE A 11 00 279 17 50 445 19 75 502 m a Boiler electrical requirements are 120V 60 Hz less than 12A Max pump amperage is 4A Use field supplied relay for pumps ov
6. LI lo ol 14mm Hs LES Law Q3451A igniter sensor pilot burner Fig 9a Q3451A Igniter sensor location Caution Gas burner positioning For ECD boiler with Honeywell intermittent pilot spark ignition the main burner for mounting the Q3451A pilot assembly contains one less group of main burner ports 5 If the burners are disassembled or replaced for any reason they must be reassembled as shown in Figs 9a b c d e Ifthe Q3451A pilot assembly is accidentally assembled into a 6 port burner it will be exposed to the flames from the first row of ports and will overheat and become defective Defective pilot will prevent boiler from operating which could cause property damage from freezing 13 Left Right Fig 9e ECD 180 200 pilot location Blocked vent and flame roll out switches Flame Roll Out Switch Blocked Vent Switch Left Right Fig 9b ECD 65 80 pilot location Left Right E 0 Fig 9c ECD 100 115 pilot location Left Right Fig 9d ECD 140 155 pilot location 14 Model 60T14 140 F Model 60T14 235 F Note Fig 9f shows pilot burner flame with proper flame adjustment Boiler wiring Refer to wirin
7. refer to gas burner removal procedure page 12 5 Referto Fig 13 for draft hood removal Disconnect vent pipe from draft hood outlet 6 Remove top panel from boiler 4 screws 7 Remove rear panel 6 screws 8 Remove screws securing mid panel upper front panel and control panel to side panels 4 screws per side 9 Remove side panels 3 screws per side 10 Remove top insulation and loosen insulation jacket to reveal screws securing draft hood to cast iron heat exchanger 4 screws Remove screws 11 Carefully pry draft hood from heat exchanger 12 Clean fins by brushing diagonally through sections See Fig 11 13 Inspect combustion chamber by using flashlight between front section legs 14 Before reinserting burner manifold clean stainless steel burners with soft brush 15 Inspect ignition system Check igniter for cracks or other deterioration Replace if necessary 16 Reverse steps 4 through 11 to reassemble boiler Seal draft hood to casting using a high temperature RTV type sealant 16 Diagonal brush application Fig 11 Cleaning heat exchanger Additional check points of annual service inspection Check flue pipe condition chimney connection and chimney itself both inside and outside for rust deterioration blockage or leakage Repair or replace as necessary Check pressure relief valve and system pressure and verify proper operation of automatic feed if insta
8. 207 9543 9543 9543 9543 Top panel 9544 9544 9544 9544 208 209 210 211 9543 9543 9543 9543 Front access panel 9544 9544 9544 9544 212 213 214 215 9543 9543 9543 9543 Front upper panel 9544 9544 9544 9544 216 217 218 219 9543 9543 9543 9543 Mid panel 9544 9544 9544 9544 220 221 222 223 9543 9543 9543 9543 Control pane 9544 9544 9544 9544 224 225 226 227 9543 9543 9543 9543 Drafthood assembly 9544 9544 9544 9544 228 229 230 231 9543 9543 9543 9543 Drafthood strap 9544 9544 735 841 9543 9543 Terminal strip cover 9544 232 9543 Vent cover plate 9544 233 9543 Thermowell 7255 283 7255 Thermowell nipple 7250 7250 Assembled cast iron heat exchanger 9543 9543 9543 9543 931 932 933 934 9543 9543 9543 9543 22 Ref Part No ECD ECD ECD ECD ECD ECD ECD ECD Name of Part No Silver Orange 65 80 100 115 140 155 180 200 16 Section right side 9507 593 9507 593 1 1 1 1 1 1 1 1 17 Section left side 9507 592 9507 592 1 1 1 1 1 1 1 1 18 Section intermediate 9507 596 9507 596 1 1 1 1 2 2 19 Section int with pilot 9507 595 9507 595 1 1 opening on right 20 Section int with pil
9. 3 pole 41 plug Female 7037 464 7037 464 1 1 1 1 1 1 1 1 Male 7270 385 7270 385 1 1 1 1 1 1 1 1 Replacement parts are available from your Viessmann dealer Installation of incorrect replacement parts can cause unsafe operation 24 uoneJedo ejes Joj Ueajo 1d y eq 1snw JebueyoxE Jeay uo seg faesseoeu yi eoejde uoisoJ109 JO poou yup 1oedsu uonejedo ejes einsue 0 pejoeJ100 eq 1snuu Wa sAs JUBA ul 93e seDexoolq sjpejep Auy peuuojied ebeyoo q sepoo O eouejeupe 1S8 uonsnquuoo yeJp Jedoud uomne4ouejep sxee are uonsnqwoo jo 1eBueuoxe yeay 1equnu euoud eweu pue peores Jeuung 100S Jo pejoedsur wa sAs juen Ajddns 4edoud 104 yoeyo Jejioq uka Jojoejjuoo 9lIJ9S Je9A p10081 GOUBU9IUIBIN Viessmann Manufacturing Company U S Inc 45 Access Road Warwick Rhode Island e 02886 e USA Tel 401 732 0667 e Fax 401 732 0590 www viessmann us com e mail viessmann us com Viessmann Manufacturing Company Inc 750 McMurray Road Waterloo Ontario e N2V 2G5 e Canada Tel 519 885 6300 e Fax 519 885 0887 www viessmann ca e mail 9 viessmann ca Printed on environmentally friendly recycled and recyclable paper e 5167 445 Technical information subject to change without notice
10. Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Electronic thermostat connection For those installations where an electronic set back thermostat is used an isolation relay may be necessary see Fig 9g Any electronic thermostat that constantly requires current from the boiler transformer will require an isolation relay For example when installing a Honeywell Chronotherm use an isolation transformer relay as shown in Fig 10 to provide current for the electronic thermostat System start up procedure If the system was shut down for an extended period of time have a qualified service technician restart and recondition your system Refer to lighting instructions on page 18 1 Check if all national and or local rules and regulations have been adhered to on this installation Do not attempt to start the boiler if you smell gas If you smell gas open windows Do not touch electrical switches extinguish any open flame close all gas valves immediately Call your gas supplier immediately from a neighbor s phone 2 Check system for proper water fill cold fill pressure Make sure that complete system is properly vented of air Adjust automatic feed valve to proper desired fill pressure between 12 15 psig Do not tamper with the unit or controls Never burn garbage or paper in the unit or leave combustible materi
11. Warning Never cap or plug pressure relief valve opening or discharge pipe Never install shut off valve between boiler and pressure relief valve Failure to heed this warning can cause explosion resulting in property damage severe personal injury or loss of life If pressure relief valve is discharging frequently locate source of problem and correct Significant amounts of make up water will cause mineral deposits in boiler which may lead to failure This type of failure is not covered under warranty Follow instructions supplied with pressure relief valve Caution Discharge piping of pressure relief valve must be installed so there will be no danger of scalding personnel Boiler is standard equipped with 30 psig ASME rated pressure relief valve This 30 psig pressure relief valve may be exchanged at the job site with a 50 psig ASME rated pressure relief valve only by strictly observing the minimum relief valve capacity in Ib h marked on the nameplate The maximum allowable working pressure is 50 psig Gas piping Before connecting gas boiler to gas line install main gas shut off valve union and capped drip leg see Fig 6 Size gas supply piping to boiler according to local utility requirements Identify the main shut off valve as such with a tag and familiarize owner of boiler with this valve Support piping by proper suspension method Piping must not rest on or be supported by boiler Testing gas p
12. be ordered for the ECD boiler This package includes the appropriate power venter vent terminal and adaptor fittings for each ECD boiler model as well as installation instructions The vent damper must not be installed when the side wall vent system is used For boilers for connection to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of the local building codes Ignition system Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in the ANSI Z21 13 CSA 4 9 boiler standard 11 The gas ignition system and components must be protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc If boiler has been underwater all electrical parts must be replaced Pressure relief valve The pressure valve supplied with this boiler must be installed Install a pressure relief valve according to Figs A 4 5b A discharge pipe of the same diameter or larger as the pressure relief discharge opening must be rigidly installed directly onto the pressure relief valve The discharge should extend to the floor drain and end approximately 6 above the floor The discharge pipe end must not be threaded Do not pipe discharge outdoors AN
13. less than 12 inches above the outside grade Certified combustion air supply equipment may be used in lieu of a duct to provide outside combustion air Viessmann recommends above items 1 8 for all installations even in buildings without airtight construction For structures that do not have tight construction and adequate air can infiltrate through cracks and openings in doors and windows refer to ANSI Z223 1 and CSA B149 1 and 2 guidelines for combustion air supply Buildings without airtight construction 1 Always have air openings or ducts supplying air directly from the outside If there is any doubt about the combustion air supply install ducts directly to the outside for fresh air If the boiler is installed in a confined space within the building a space with a volume less than 50 ft per 1 000 Btu h of input for all gas burning equipment then adequate air for combustion must be provided by two permanent openings one located 6 below the ceiling the other 6 above the floor Each opening shall have a minimum free area of 1 in per 1 000 Btu h of input for all gas burning equipment but not less than 100 in Two openings each with a minimum free area of 200 in will be sufficient for the installation of one ECD 200 Larger openings can be used The volume of the boiler space and the space connected by the air openings must have a volume greater than 50 ft per 1 000 Btu h of input for all gas burning equipment
14. If possible install vent damper at the top of the draft hood Otherwise install vent damper as close to the boiler as possible The vent damper must be field installed on the boiler Read the vent damper manufacturer s instructions before installing the vent damper Vent damper must be installed as close as possible to the boiler flue outlet The closing and opening action of the vent damper is driven by a motor Spring action is not used to move the vent damper blade Do not force vent damper blade by hand Forcing the vent damper blade by hand will damage the motor To observe the vent damper blade move turn thermostat up and down after the vent damper has been installed Vent damper blade must be in open position when burner is firing The vent damper must be installed according to Fig B The vent damper may be placed directly on top of the ECD boiler Ensure that damper blade rotates freely and is not obstructed in any way Read and save the vent damper manufacturers instructions packaged with the vent damper After vent damper has been installed on boiler connect the vent damper cable using the following instructions 1 Remove ECD front panel 2 Route the end of the vent damper cable with the Molex connector through the plastic strain relief on the ECD left side panel 3 Attach Molex connector to vent damper motor using the metallic strain relief on the vent damper motor to secure the cable 4 Unplug the two 3 pole 41 plug
15. Installation Service Manual for use by heating contractor Vitogas 050 ECD Series Gas fired atmospheric cast iron boiler 65 to 200 MBH 19 to 59 kW Vi E2MANN IMPORTANT READ AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE LK 7 VIESMANN VITOGAS 050 Warning If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliances Do not touch any electrical switches 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 fire department Installation and service must be performed by a qualified installer service agency or the gas supplier WARNING Should overheating occur or the gas supply fail to shut off do not disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance CERTIFIED 5167 445 v1 1 03 2007 Contents Page Technical Data vw pot aa ane baker retentione ote nec 3 Boiler handling location e 3 Flushing of existing piping 4 Vent damper
16. a When the boiler is in a confined space and the openings can be made directly on an outside wall to allow outside air into the boiler room each opening shall have a minimum area of 1 in per 4 000 Btu h for all gas burning equipment Two openings each with a free area of 50 in will be sufficient for the installation of one ECD 200 b When the boiler is in a confined space and horizontal ducts are connected to crawl spaces or attics which can freely communicate to the outdoors the openings shall be a minimum of 1 in per 2 000 Btu h of input for all gas burning equipment c When the boiler is in a confined space and vertical ducts are connected to crawl spaces or attics which can freely communicate to the outside the openings shall be a minimum of 1 in per 4 000 Btu h of input for all gas burning equipment When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 inches Wherever possible it is recommended to supply air directly from the outdoors through wall openings or ducts even if previous experience with fuel burning equipment was satisfactory Any change to the construction of the building such as weather stripping caulking around cracks installation of exhaust fans adding insulation etc can prevent adequate air supply and can make the building airtight When required by constructio
17. als around it Additional attention must be given to the following paragraphs 1 Once system water is heated deactivate circulating pump boiler and vent system of any remaining air within piping radiation and boiler 2 Check for proper boiler circulation pump zone valve thermostat or operating control functions 3 Check high limit aquastat by dialing it to a setting below the water temperature in the boiler The gas burner must be deactivated Turning the dial back to a setting higher than the present boiler water temperature must result in reactivation of gas burner 4 Cycle boiler on and off with the room thermostat or other operating control to verify that the burner shuts down when the room thermostat is adjusted below room temperature Honeywell Chronotherm electronic set back room thermostat H 9 120V 24V N NO G A WR 8A02A 8 Isolation transformer relay To boiler thermostat J connections T T on terminal strip Fig 10 Isolation relay for electronic thermostat Annual shut down If boiler is used for comfort heating only and not used with an indirect fired domestic hot water storage tank the boiler heating system should be shut down during the summer time 1 Turn down operating control thermostat 2 Disconnect main power switch 3 Close main gas shut off valve and turn knob on
18. anifold orifices natural gas 1 000 Btu cu ft Boiler Orifices Low Altitude High Altitude Gas valve manifold size required 0 610m 610 1370m pressure ECD 0 2000ft 2000 4500ft w c Orifice size Orifice size 65 2 2 65 2 55 3 5 80 2 2 95 2 80 3 5 100 3 2 70 2 60 3 5 115 3 2 85 2 75 3 5 140 4 2 75 2 65 3 5 155 4 2 85 2 80 3 5 180 5 2 80 2 65 3 5 200 5 2 95 2 80 3 5 Manifold orifices propane 2 500 Btu cu ft Boiler Orifices Orifice Low Altitude High Altitude size required size 0 610m 610 1370m ECD 0 2000ft 2000 4500ft Gas valve manifold Gas valve manifold pressure w c pressure w c 65 2 1 60 10 9 80 2 1 80 107 8 100 3 1 65 107 8 115 3 1 75 107 8 140 4 1 70 10 8 155 4 1 75 107 8 180 5 1 70 10 8 200 5 1 80 107 8 All orifice sizes given in mm Orifice size is stamped onto each orifice for identification When ordering orifices state boiler size type of gas number of orifices required and orifice size Gas burner removal see Fig 7 The main gas burner manifold with the individual stainless steel burners mounted may be easily removed from the boiler by 1 Closing the main gas shut off valve external to boiler 2 Disconnecting all power to boiler 3 Removing front cover panel from boiler 4 Breaking ground joint union before gas valve remove gas pipe Disconnecting wiring to gas valve Disconnect wiring from igniter sensor and ground connection 6 L
19. aquastats Circulating pump The pump aquastat is located behind the control panel Connect the circulating pump wires to the boiler terminal strip Circulating pump supplied by others Failure to connect pump aquastat will significantly shorten life expectancy of boiler heat exchanger Pump aquastat is factory set at 116 F Alternate aquastat is available at 104 F Note to Fig 4a For multi zone systems using zone pumps one pump usually the one serving the main living area should be dedicated to operate with the pump aquastat located on the boiler see wiring diagram For multi zone systems a bypass pipe must be installed See page 10 for bypass piping details Do not wire more than one thermostat end switch from the zone valves into the boiler thermostat T T connection Wiring more than one thermostat into the boiler thermostat T T connection will lead to burner short cycling which can cause reduction in life span of the boiler due to probable flue gas condensation This type of failure is not covered under the boiler warranty F Separate breaker Boiler terminal strip i 120V power O L Transformer Relay EM 7 N 120V viessmann noi 11O G 20v pump O N T 24V j j 120v output NG L E gt T Thermostat rO T connections 24V 120V pump F over 4A al Fig 4b F Field supplied Using transformer relay to switch pumps over 4A current d
20. de an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space which can cause severe personal injury or loss of life Outside air must enter the house to replace the air used by the boiler When the boiler operates the burner needs a continuous supply of oxygen which is supplied by the air entering the structure Without a continuous supply of oxygen the flames will incompletely burn and can allow poisonous carbon monoxide gas to circulate into the living space Any home with bathroom or kitchen exhaust fans or heat recovery ventilator units should have outside air intake You must check with local authorities municipal building department gas utility for combustion air requirements particular to your area Caution Whenever your boiler is installed in a structure with airtight features such as vapor barrier or tight insulation there must be a combustion air duct installed to supply air from the outside even though the boiler may be installed in a space with a volume large relative to the boiler The following guidelines are from the CSA B149 Code for combustion air supply in buildings with airtight construction 1 When the boiler is installed in buildings with airtight construction air supply openings or ducts connected directly to the outside must be installed For boilers installed above grade and within 2 ft of an outside wall openings may be used in lieu of a duct The o
21. ed and experienced in the installation service and maintenance of gas fired hot water boilers There are no user serviceable parts on the boiler burner or control Failure to heed this warning can cause property damage severe personal injury or loss of life AN Warning Improper installation adjustment service or maintenance can cause flue products to flow into living space Flue products contain poisonous carbon monoxide gas which can cause nausea or asphyxiation resulting in severe personal injury or loss of life AN Warning Before each heating season begins have the following service and maintenance done by a professional service technician 1 Boiler heat exchanger inspected and cleaned 2 Vent system inspected for deterioration leaks corrosion proper draft and proper operation Check vent system for compliance with local and national code requirements Repair or replace as required 3 Burner inspected and if necessary cleaned to ensure proper combustion and operation Check for adequate supply of fresh outside combustion and ventilation air Neglecting to perform necessary maintenance can cause unsafe operation AN Warning If flame roll out or blocked vent switch trips during start up or normal operation it indicates a hazardous condition to be corrected immediately Do not attempt to put boiler in operation Immediately contact a qualified service professional to locate source of p
22. eneral information Please read and observe the following instructions carefully before installing the boiler Install boiler according to these instructions Installation service and maintenance work must be done by qualified and experienced technicians only Improper installation Service or maintenance could create a hazard resulting in property damage severe personal injury or loss of life The ECD Series boiler is for use in closed loop forced circulation hot water heating systems only Boiler operation is limited by ASME Code to maximum water pressure of 50 psig and maximum water temperature of 248 F The vast majority of applications operate below 30 psig and below 194 F Standard equipment on the ECD boiler includes a 30 psig relief valve and adjustable aquastat with maximum setting of 194 F An alternate construction is available for operation between 194 F and 248 F Consult a Viessmann representative for alternate construction before ordering boiler Necessary permits from local authorities must be obtained before installing boiler Installation must be made in accordance with local ordinances which may differ from the instructions in this manual City water Backflow 2 preventer Fill valve Return Ne Bypass Strainer locatiori Air purger Gas pipe amp Approved gas shut off valve Diaphragm expansion tank 30 psig pressure relief valve Low water cia ES LA ECD boiler
23. er 4A Model CSA input DOE heating Width Vent Gas Water Cast Burners Water Weight AFUE Steady capacity A Conn Conn Conn Iron Content State CGA output BO Sections Efficiency ECD 65 65 000 Btu h 53 950 Btu h 350mm 57 w 14 3 2 9 9 Itr 106 kg 83 7 83 19 kW 16 kW 14 2 6 USG 233lbs ECD 80 80 000 Btu h 66 400 Btu h 350 mm Bi w 114 3 2 9 9 Itr 106 kg 83 5 83 23 kW 19 kw 147 2 6USG 233 Ibs ECD 100 100 000 Btu h 83 000 Btu h 450 mm 6 VA 114 4 3 13 21tr 130 kg 83 5 83 29 kW 24 kW 17947 3 5USG 285 lbs ECD 115 115 000 Btu h 95 450 Btu h 450 mm 6 w 14 4 3 13 2 Itr 130 kg 83 5 83 34 kW 28 kW 17947 3 5USG 285 Ibs ECD 140 140 000 Btu h 116 200 Btu h 550 mm T VA 114 5 4 16 5 ltr 157 kg 83 5 83 41 kW 34 kW 21947 4 3USG 345 Ibs ECD 155 155 000 Btu h 128 500 Btu h 550 mm T w 114 5 4 16 5 ltr 157 kg 83 4 83 45 kW 38 kW 21947 4 3USG 345 Ibs ECD 180 180 000 Btu h 149 400 Btu h 654 mm T V 114 6 5 26 8 Itr 192 kg 83 2 83 52 kW 44 kW 25 7 1USG 423 Ibs ECD 200 200 000 Btu h 166 000 Btu h 654 mm TO w 14 6 5 26 8 Itr 192 kg 83 0 83 58 kW 48 kW 2594 7 1 USG 423 Ibs With vent damper and intermittent pilot ignition kW figures are approximate All sizes available with propane gas For net IBR rating divide output by 1 15 Electrical requirement 120V 60Hz less than 12A Before operat
24. ervice access to the vent damper after the installation Use sheet metal screws e g 8 x 157 to fasten vent damper to boiler and vent pipe Thermostat anticipator should be set at 0 8A There are no serviceable parts on the vent damper Defective vent dampers must be replaced If the side wall vent system is used the vent damper must not be installed Refer to separate side wall vent system instructions for series boiler The side wall vent system must be purchased separately from the ECD boiler Sequence of operation with vent damper Thermostat calls for heat Vent damper blade opens Pilot sparks and ignites Pilot is proven and main valve is energized Main burner and pilot will continue to operate until thermostat is satisfied Burner may turn off and on in response to the adjustable high limit aquastat SHL1 setting during a call for heat oc RONMN If the vent damper becomes defective 1 Follow the vent damper manufacturer s instructions to leave the vent damper in the Service or Hold Open Damper Effikal mode by using the service switch on the damper motor Vent damper blade should stay open and boiler should operate normally 2 If the procedure in 1 does not work remove vent damper install transitional piece of vent pipe and disconnect 6 pole plug from 3 pole plugs Connect the 3 pole plugs together as shown in Fig D Refer to wiring diagrams Boiler will operate without vent damper Closet alco
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26. g diagrams on pages 19 20 All wiring must be properly grounded Before attempting to wire unit disconnect power supply at main service panel first In the United States all electrical wiring must be in accordance with the National Electrical Code ANSI NFPA 70 latest edition In Canada all electrical connections must be in accordance with Canadian Electrical Code C22 1 Part 1 latest edition Proper x m flame Ja to V5 adjustment 6 to 13 mm I O Igniter sensor oj LU 3 Sensor tip must be in pilot flame Fig 9f Pilot burner flame for 0345142012 PILOT PRESSURE FOR Q345A PILOT Natural Gas 5 7 w C Propane Gas 8 10 w c If an external electrical source is utilized the boiler when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 Boiler electrical requirements are 120V 60 Hz less than 12A The thermostat connections on the boiler must be connected to a potential free or dry contact such as a room thermostat end switch of a zone valve or dry contact of an indoor outdoor control See wiring diagram in rear of manual and wiring label on boiler Viessmann reserves the right to substitute electrical components as necessary The boiler wiring label takes precedence
27. gas valve to off see Figs 6 and 7 ATTENTION If system is shut down during the heating season and subject to freezing temperatures and is not filled with antifreeze for protection the system including the boiler must be drained of water Valve before automatic feed valve if installed must be closed any other valves air vents and drain valves must stay open Advise the operator ultimate owner 1 Ofthe proper system operation sequence 2 Explain the equipment as well as the need for combustion air 3 Demonstrate an emergency shut down what to do and what not Refer to lighting instructions on page 18 4 Explain that there is no substitute for proper maintenance to help ensure safe operation Before leaving jobsite Fill in and sign warranty card for boiler and hand over to owner for record keeping Maintenance Inspections during heating season 15 Boiler servicing heat exchanger cleaning A service inspection of the boiler and the system is mandatory once a year Before heating season starts boiler burner should be serviced by a qualified service agency The owner should establish a service contract with a qualified service agency Cleaning heat exchanger flue gas passageways see Fig 11 1 Disconnect power supply to boiler and all heating related components 2 Close main gas shut off valve Allow boiler to cool if necessary 3 Remove front panel 4 Remove gas burner assembly from boiler
28. gested base for installation on combustible floor Pressure relief valve Boiler supply connection Supply piping to radiation Fig 4 Pressure relief valve installation Use fittings supplied in accessory pack Do Dg Air vent Pressure 2 Air separator reducing Backflow valve preventer A Saa Tha ER Precharged PRV Tm expansion tank E 0 Pressure o gage DP tog gt lt aa a n ECD boil Fig 4a 2d Multi zone system using zone pumps Piping arrangement for best air elimination see note on following page Before boiler is connected to a piping heating system which has previously been in service boiler is a replacement boiler the piping system should be flushed thoroughly with water in order to remove sludge or other contaminants especially in large piping systems such as old gravity pipe systems Check system for pipe leaks defective valves etc and make required corrections immediately Be aware that best overall system performance is achieved when all components are properly sized Sizing of the required circulation pump according to the pipe layout and calculation of a proper volume expansion tank is vital to obtain the system s peak performance See Fig 4a for multi zone system using pumps Caution The boiler warranty does not cover leaks resulting from corrosion caused by
29. ing this boiler burner unit make sure you fully understand its method of operation Your heating contractor should always perform the initial start up and explain the system and the need for regular inspection and maintenance The installation must 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 latest edition In Canada follow CAN CSA B149 1 or 2 Installation Codes latest edition These instructions must be placed in an envelope and affixed to the boiler Boiler handling The boiler is shipped on a wooden pallet in a cardboard crate Crate and wooden pallet must be removed Vent damper is shipped separately Boiler location Minimum clearances to combustibles all measurements from boiler enclosure Left side 150 mm 6 Right side 25 mm 17 Front 150 mm 6 Top 450 mm 187 Rear 25 mm 17 Floor Non combustible Flue 150 mm 67 Above clearances apply to all ECD boilers Recommended minimum service clearances Left side 610 mm 24 Right side 610 mm 247 Front 1220 mm 487 Top 610 mm 247 Rear 610 mm 24 Recommendation If boiler is located in a confined space install main gas shut off valve gas cock and main power supply switch in easily accessible location outside the confined space The boiler model selected should be based on an accurate heat loss calculation of the building G
30. installation u u 4 Glosetinstallation LL unn u a nennen 5 Combustion air supply eese 6 Installation on combustible floor 8 Boiler water PIPING cocco aus aaa 8 Honeywell adjustable high limit aquastat 9 Circulatirig PUMP iini uqa receta Sce ee ck tva kape ee pise sea ceo an 9 Initial syster fill u eiie ona pe Free gen entera phe 10 Boiler venting LM 11 Gas piping paaa NANU NANG BAG sS ob siek a 12 Gas pressure orifice sizes u a 12 METRI 13 Blocked vent and flame roll out switch 14 WIND AA 14 Electronic thermostatic as 15 System start up eet tentent tti DA gh Pe nae pasasaq 15 MaIntenmange DER 15 Troubleshooting uU eec mee baa 17 Lighting IhSETUCETIOTIS os oir uu uu terere 18 Wiring diagratms aa reri teen neben kek 19 20 Parts list inerti AA AA 21 22 23 24 Maintenance record eese 25 ER IE rn VERIFIED AN This Attention symbol is located beside all important safety recommendations Please follow the instructions in detail to avoid property damage severe personal injury or loss of life AN Warning The installation adjustment service and maintenance of this boiler must be done by a licensed professional service technician who is qualifi
31. ipe The boiler and its gas connection must be leak tested before placing the boiler in operation Use only the gas stated on the boiler rating plate The boiler and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at pressures in excess of psig 3 5 kPa 12 Manual gas shut off valve Ground ap VISSMANN joint union Drip leg 3 75mm T L Fig 6 Gas pipe installation The boiler must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at a test pressure equal to or less than 7 psig 3 5 kPa Unions and manifold have been factory tested Leak test must be repeated during initial trial operation of burner by mechanical contractor Never check for gas leaks with an open flame Use approved spray liquid or soap water solution for bubble test Gas pressure Orifice sizes Natural Gas Minimum gas valve inlet pressure 4 5 W C Maximum gas valve inlet pressure 14 w c Propane Gas Minimum gas valve inlet pressure 12 w c Maximum gas valve inlet pressure 14 w c Flame roll out switch SS 13mm Burner tubes socket Manifold attachment screws 2 per side Manifold pressure test port Fig 7 Gas manifold removal M
32. jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 latest edition Bypass piping see Fig 5a and Fig 5b In some cases it is necessary to install a bypass If you find the bypass is not needed then simply close the bypass valve Install a bypass in order to prevent flue gas condensation from occurring in the heat exchanger casting and vent system when installing the boiler in a large water volume system i e converted gravity system with tube type cast iron radiators A bypass is not a substitute for a mixing valve driven by an indoor outdoor control for proper weather responsive control of an underfloor heating system 1 Install full size bypass as shown below 2 Use valve in bypass and valve in supply line to balance flow so that boiler water temperature quickly reaches 140 F or higher Use globe valve or ball valve Bypass line should be minimum 12 long Bypass will lower flow rate through boiler to allow higher average water temperature rise Water flow will bypass boiler depending on setting of bypass valve 5 If the bypass is not needed simply close the bypass valve 6 The water flow direction must be as shown Water flows in at bottom and out at top Po Initial system fill Treatment for boiler feed water should be considered in areas of known problems such as high mineral content and hardness In areas where freezi
33. lights the pilot Do not try to light the pilot by hand Position Gas Indicator Control Knob 10 11 12 Remove control access panel Turn gas control knob clockwise ag to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn gas control knob counterclockwise BN to ON Replace control access panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier EE TO TURN OFF GAS TO APPLIANCE wiswi 1 Setthe thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove control access panel 4 5 Turn gas control knob clockwise AA to OFF Do not force Replace control access panel 18 p
34. lled Check heating pipe joints valves air vents etc System leaks must be corrected immediately to avoid damages The cause of any system defect must be determined and corrected in order to prevent property damage personal injury or loss of life Check for proper combustion air supply and ventilation for the boiler Check to ensure that combustible material or chemicals are not stored close to the boiler Operate high limits by dialing lower settings switching burner on off to verify function of same If low water cut off is installed check and verify proper function according to manufacturer s instructions If oil lubricated circulating pump is used check for proper lubrication Check for gas tight connection of gas piping unions gas valve and manifold Check proper ignition and gas burner operation Combustion test must be performed by a competent service technician Do not tamper with boiler or controls INTERMITTENT PILOT IGNITION TROUBLE SHOOTING GUIDE Trouble Pilot will not light Cause Air in gas line Boiler temperature too high adjustable high limit aquastat activated Room thermostat setting too low No power Manual reset aquastat activated Pilot burner defective Pilot orifice clogged or defective Faulty ground connection from burner to module Gas valve knob in off position No gas or gas supply has been temporarily interrupted Ignition module defective Gas valve defective
35. low these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Rn OPERATING INSTRUCTIONS AA 1 STOP Read the safety information above on this page 2 Setthe thermostat to the lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically
36. n changes air supply ducts must be installed for safe boiler operation If windows or doors are used for combustion air openings they must be locked open The boiler location must never be under negative pressure Exhaust fans attic fans or dryer fans may cause air to be exhausted at a rate higher than air can enter the structure for safe combustion A Warning Never cover the boiler or store debris or other materials near the boiler or in any way block the flow of adequate fresh air to the boiler Never cover the combustion air duct Excerpt from our warranty terms Boiler is not covered under any warranty terms for damages resulting from the following Improper application and installation installation by unqualified personnel ignorance of instructions improper service and maintenance work incorrect replacement component selection or application incorrect field wiring Full warranty applies only when boiler is installed and operated according to instructions and used only with the proper gas and the applicable gas pressures Please read boiler warranty card Standard equipment e Wetbase sectional cast iron heat exchanger with stainless steel burners Boiler completely assembled with vertical draft diverter Electronic ignition 24 VAC redundant seat gas valve Boiler fully insulated with 112 fiberglass wrap around blanket Boiler control panel with fixed high limit and temperature gage Pump aquastat to
37. ng might occur an antifreeze may be added to the system water to protect the system Please adhere to the specifications given by the antifreeze manufacturer Do not use silicate based automotive antifreeze solutions Install a strainer on return pipe when necessary Wait for fill water to warm up to room temperature 70 F before firing boiler Firing boiler with cold water will stress the casting and could cause failure Please observe that an antifreeze water mixture may require a backflow preventer within the automatic water feed and influence components such as diaphragm expansion tanks radiation and pumps selection A 4096 antifreeze content will give freeze up protection to approximately 10 F 23 3 C Do not use antifreeze other than specific brands made for hot water heating systems System also may contain components which might be negatively affected by antifreeze Check total system frequently when filled with antifreeze A field supplied pressure reducing valve or fill valve is required to reduce the incoming water pressure to between 12 and 15 psig Boiler venting Category l The mounted boiler draft hood must not be altered or modified in the field The boiler should be located as close to the chimney as possible The vent connection must be made in the shortest possible way with a minimum quantity of elbows The ECD boiler draft hood must not support the weight of the chimney The chimney and vent connectors mu
38. noeuuoosip paiddns seum peulbuo eu jo Aue J 0 Joud Salim e jeger pay ig uonne5 ped pay IBA peu n Sas 4046 D SE Ye Jo dwnq Aejo y1ouwojsuen uonejos o A r01 9 07 Ye uo dung 8 VZ0V8 HM lem 1urod 1noj Eg 4 582 youms 4 8r2 s6unes paxy ui jonuoo 1ejsenbe dung Vd 1 lloq uo Aini din Jes juan yeysenbe yeysenbe Suono uuoo ana Led esu uo uedo sjoejuoo pexoolg rene TEN dung peiiddns pai 3 mi I 4 964 08 L 1elsenbe AS vd Ajayes lui yBiy elqelsn pe Ba R uejeAnbe 10 Y80077 LIHS O VM Fi H slayjo Aq paijddns 1e1souueu 5 4 872 D 0ZL Te SOWJAY 21u0J129J8 YIM 1 loq SIY jo DULIM ee ka a ren ede bandi suononulsul MOIJO Jaye jou oq siejsenbe ssed q jou oq Bumes wnwxew JeuuojJsueJy e eJ uone osi esn ueui 40761 0 06 Jeisenbe pwi yoy ejqeisnfpv LIHS Telsouueur9luonosia WiIoUJOUOJYI j emkouoy o l pesn si 49 109 Bus 940J8q JE SOWIBY WOO 2IU0JI99J8 JI ALON Jamod 09UU0051 iBululem sjejsenbe Ajajes a l Fig 12 19 s6njd yum ord o eds uoniuBi ojd juemiuue1ur jjew euoH YUM sanas JIA 090 seBollA Vitogas 050 ECD Series with Honeywell intermittent pilot and vent damper Ladder diagram 120V 60Hz less than 12A
39. oiler piping in heating cooling application The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler Fig 5a The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Check installation instructions of chiller manufacturer carefully for additional requirements Cooling season starts Close valve V1 and open valve V2 Heating season starts Close valve V2 and open valve V1 A metal tag should be attached to these valves as to purpose _ l HB l VIEEMANN p L I II l 2 min i l A Low water cut off TT Fig 5b Low water cut off location 10 Low water cut off Ifthe ECD boiler is installed above radiation level then a low water cut off device must be installed See Fig 5b for location of low water cut off device Note Flow direction must be as shown in Fig 5b Low water cut off is field supplied Follow instructions provided with low water cut off When required by the authority having
40. oosening manifold bolts Do not remove only loosen Use socket with extension to access bolts through holes in side panel 7 Removing burners once manifold is loose 8 Slide out on an upper angle to remove manifold a Gas input CAUTION Do not exceed input rating stamped on rating plate of boiler 1 Close main gas shut off valve 2 Disconnect main power supply to boiler 3 Remove plug 147 on manifold Install test plug and connect U tube manometer or equivalent 4 Place boiler burner in operation 5 Read manifold gas pressure and compare with stamped rating on rating plate If necessary adjust pressure on gas valve If using meter clocking method Ensure there is no gas flow through the meter other than to the boiler being checked Other appliances must remain off including their pilot burners 6 Deactivate boiler reinstall 1 plug place boiler in operation again 7 Repeat gas leak test at plug 14 and ensure tightness Main burner see Fig 8 Proper flame Upper main flame cone with light orange coloring sharply defined individual flames Fig 8 Underfired Lazy burning main flame cone mushy flame appearance throughout smaller flame sizes than in Fig 8 Overfired Increased burner noise higher flame sizes than in Fig 8 Main flame cone Light blue Blue Inner flame cone Fig 8 Front view of single burner 124mm _ 448 I ri Hitt
41. ot 9507 594 9507 594 1 1 1 1 1 1 1 1 opening on left 21 Manifold 7255 277 7255 277 1 1 7255 278 7255 278 1 1 7255 279 7255 279 1 1 7255 280 7255 280 1 1 22 Pipe plug 1 9543 412 9543 412 1 1 1 1 1 1 1 1 23 Manifold orifices Natural Gas 0 2000 ft 9507 072 9507 327 9507 073 9507 615 9507 074 9507 615 9507 075 9507 327 2000 4500 ft 9507 071 9507 075 9507 614 9507 074 9507 072 9507 075 9507 072 9507 075 4500 7000 ft 9507 070 9507 073 9507 071 9507 073 9507 071 9507 072 9507 614 9507 073 LP 0 2000 ft 9507 652 9537 208 9507 640 9507 653 9507 641 9507 653 9507 641 9537 208 2000 4500 ft 9507 652 9537 208 9507 640 9507 653 9507 641 9507 653 9507 641 9537 208 4500 7000 ft 9507 652 9507 653 9507 652 9507 641 9507 640 9507 641 9507 640 9507 653 24 Stainless steel 9507 642 9507 642 1 1 2 2 3 3 4 4 burner tube 25 Burner mounting 9507 051 9507 051 2 2 3 3 4 4 5 5 saddle 26 Burner tube for 9543 939 9543 939 1 1 1 1 1 1 1 1 pilot mounting 27 Pilot igniter 9543 722 9543 722 1 1 1 1 1 1 1 1 assembly Q3451A2012 28 Ignition control 9543 876 9543 876 1 1 1 1 1 1 1 1 module S8600H 30 Gas valve NG 9549 246 1 1 1 1 1 1 1 VR8204P1007 Gas valve NG 9544 199 1 VR8304P3308 Gas valve LP 9543 716 1 1 1 1 1 1 1 1 VR8204P1049 32 Pilot orifice NG 0207 9543 391 9543 391 1 1 1 1 1 1 1 1 LP 014 9543 392 9543 392 1 1 1 1 1 1 1 1 Note When ordering
42. penings shall be located within 1 ft above and 2 ft horizontally from the burner level of the appliance with the largest Btu h input For boilers installed below grade the combustion air duct must terminate within 1 ft above and within 2 ft horizontally from the burner level of the appliance having the largest Btu h input According to the CSA B149 Code the following diameters can be used for round corrosion resistant air supply ducts with smooth internal surfaces Use equivalent lengths of 10 ft per 90 elbow and 5 ft per 45 elbow and 15 ft fora grill or louver See Table 1 Model Dia for up to Dia for up to 20 ft of equivalent 50 ft of equivalent length air duct length air duct ECD 65 80 4 5 ECD 100 115 57 6 ECD 140 155 57 6 ECD 180 200 6 r d Table 1 Combustion air duct sizes The outside inlet of the combustion air duct must not permit the entry of rain or wind and must not reduce the free area of the air supply opening It must not be blocked by snow Corrosion resistant screens must not have individual grids less than 4 x 4 Screens may not reduce the free area required for combustion air Manually operated combustion air dampers are not allowed The air opening must be not of a type that could lead to situations where the air supply may be closed off while the burner is running A combustion air supply inlet opening from the outdoors shall be located not
43. raw The following lists typical water flow rates for the Atola ECD boiler series Flow rate GPM Flow rate GPM Model for 20 F rise for 30 F rise ECD 65 5 3 3 5 ECD 80 6 6 4 4 ECD 100 8 3 5 5 ECD 115 9 5 6 3 ECD 140 11 6 7 7 ECD 155 12 8 8 5 ECD 180 14 9 9 9 ECD 200 16 6 11 0 The water pressure drop for ECD 65 200 is GPM Pressure drop ft of water 10 33 15 60 20 1 20 Refer to wiring diagrams on pages 19 20 for wiring a pump less than 4A to the ECD boiler terminal strip For pumps greater than 4A use a field supplied switching device to Switch separate 120V power to the pump see Fig 4b 120V 4A is switched from the boiler terminal strip when the boiler pump aquastat exceeds its setting Caution Do not connect pumps with continuous or inrush currents greater than 4A For pumps over 4A add a field supplied switching relay See Fig 4b for an example WOS 140 Adjustment screw ee 9 set to 140 F minimum Fig 4c Honeywell L4008A adjustable high limit aquastat is located behind access panel Heating Cooling unit jH roang I ooling unit X I M velpum Heating Cooling unit CP FC V LAng E V2 FC V pla Water chiller V FCAFV V X ek vi O Fig 5a Boiler piping in a heating cooling application B
44. replacement boiler sections order 4 push nipples per intermediate section and 2 push nipples per side section 23 Ref Name oPiPant Part No ECD ECD ECD ECD ECD ECD ECD ECD No Silver Orange 65 80 100 115 140 155 180 200 33 Pilot bracket for 9543 384 9543 384 1 1 1 1 1 1 1 1 Q3451A 34 Manual reset safety 9509 899 9509 899 1 1 1 1 1 1 1 1 high limit control 35 Adjustable 9543 875 9543 875 1 1 1 1 1 1 1 1 aquastat 36 Thermometer 9506 884 9506 884 1 1 1 1 1 1 1 1 37 Pump aquastat 9519 214 9519 214 1 1 1 1 1 1 1 1 38 Support bracket upper 9543 731 9543 731 2 2 2 2 2 2 2 2 lower 9543 732 9543 732 2 2 2 2 2 2 2 2 39 Insulation steel cover Left side 5130 822 5130 822 1 1 1 1 1 1 1 1 Right side 5130 825 5130 825 1 1 1 1 1 1 1 1 40 Insulation fiber plate Left side 7205 515 7205 515 1 1 1 1 1 1 1 1 Right side 7205 514 7205 514 1 1 1 1 1 1 1 1 41 Hex bushing 9543 718 9543 718 2 2 2 2 2 2 2 2 1 x 14 42 Pressure relief valve 9542 940 9542 940 1 1 1 1 1 1 1 1 Ja 30 psig 43 Pressure gage 9542 939 9542 939 1 1 1 1 1 1 1 1 0 100 psig 44 Flame roll out switch 9543 878 9543 878 1 1 1 1 1 1 1 1 60T14 140F 140 F 45 Transformer 9543 945 9543 945 1 1 1 1 1 1 1 1 120 24V 40VA 46 Terminal strip 9543 458 9543 458 1 1 1 1 1 1 1 1 47 Blocked vent switch 9543 729 9543 729 1 1 1 1 1 1 1 1 60T15 235F 235 F 48
45. roblem and correct Failure to heed this warning could result in property damage severe personal injury or loss of life AN Warning Never operate the boiler without an installed venting system which safely vents all products of combustion to the outdoors The vent system must comply with all applicable local and or national codes Improper incomplete obstructed or deteriorated vent systems can present a serious risk of flue gases leaking into living space which could cause carbon monoxide poisoning Failure to heed this warning can cause severe personal injury or loss of life Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water AN Warning Never operate the boiler without an adequate supply of fresh combustion air This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air All combustion and ventilation air must be supplied from the outside Failure to heed this warning can cause severe personal injury or loss of life Do not store chemicals containing chlorine or other corrosive materials near the boiler such as bleach cleaning solvents detergents acids hair spray spray cans paint thinners paint water softener salt refrigerants AN Warning
46. s inside the boiler and attach them to the 6 pole plug from the vent damper see Figs B C and D Bim ECD 65 80 47 75 ECD 100 115 48 25 ECD 140 155 48 75 ECD 180 200 52 75 Molex connector 4 A Effikal vent damper only Plastic strain relief Fi Vent damper harness installation 3 pole burner plug 2 aE 6 pole 3 pole vent damper control plug plug Fig C Plug connection with vent damper or power vent L _ e HD T e T al amp 3 pole 3 pole burner plug control plug Fig D Plug connection without vent damper The cable must not touch the vent pipe and any excess cable must be suitably supported with cable clamps screwed to the side of the boiler if required Refer to wiring diagrams Do not attach vent damper cable to water or vent pipes Damper must be in the open position when main burners are operating The damper position indicator arrow must be in a visible location following boiler installation The venting system must be arranged so that only the ECD boiler is served by the vent damper Maintain a minimum clearance of 6 between the vent damper and combustible construction There must be provision for s
47. s 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 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 fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Testfor spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or a candle 6 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 fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 latest edition When resizing any portion of the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the National Fuel Gas Code Z223 1 latest edition The above steps 1 7 must be followed for new installations involving single or multiple ECD boilers Side wall vent system A side wall power vent system can
48. st be suitably supported to prevent the draft hood from supporting the weight of the chimney AN Warning Improper sizing maintenance termination of vent or chimney can cause flue gases to enter living space Any blockage of vent or chimney by birds nests ice snow debris or other materials can cause flue gases to enter living space Flue gases entering living space can cause carbon monoxide poisoning which can result in severe personal injury or loss of life Avoid long horizontal runs of vent pipe Horizontal runs must be supported by appropriate means to prevent sagging and should have not less than 14 rise per ft from the boiler to the vertical vent connection Metal strapping must be used to support horizontal runs every 3 ft Use approved vent materials only For venting purposes a B vent may be used With this boiler installation it is recommended to install a corrosion resistant approved liner within a masonry or unlined chimney Observe and follow local rules and regulations The vent connector of this boiler must not be connected into any portion of mechanical draft systems operating under positive pressure Based upon proper chimney and breeching size the boiler may be vented into a chimney breeching with a direct fired atmospheric fired gas water heater Observe national codes local rules and regulations In Canada follow CSA B149 1 or 2 in USA follow National Fuel Gas Code ANSI Z223 1 Al
49. the use of underfloor plastic tubing without an oxygen diffusion barrier Such systems must have the non oxygen diffusion barrier tubing separated from the boiler with a heat exchanger Viessmann recommends the use of underfloor plastic tubing with an oxygen diffusion barrier Caution This boiler is not for use in systems where water is constantly or frequently replenished Minerals such as calcium in make up water can deposit on heat exchanger causing overheating and eventually the boiler will leak This type of failure is not covered by warranty Water must not be drained from system for use by cleaning personnel Do not use this boiler to directly heat swimming pool water Use a heat exchanger to separate the boiler water from the pool water Caution For underfloor heating applications an additional immersion or strap on aquastat must be installed in the low temperature underfloor loop ahead of the mixing valve to de energize the pump and or boiler to prevent overheating High water temperatures can damage concrete slabs Adjustable high limit aquastat see Fig 4c The adjustable high limit aquastat limits the boiler water temperature during a call for heat from the room thermostat or other operating control It is located behind the front access panel Honeywell L4008A aquastat or equivalent may be used Ensure sensing bulb is fully inserted in well see Fig 4c Set to a minimum of 140 F Never permanently bypass high limit
50. turn pump on One 120 24 VAC transformer 30 psig pressure relief valve pressure gage and fittings One cleaning brush Adjustable high limit Installation on combustible floor Placement of boiler 1 Verify that base size and material are in conformity with local codes 2 Locate the base so that the minimum clearances of boiler to combustible materials are maintained as outlined on page 3 3 Base must be constructed of hollow concrete blocks minimum height 100 mm 4 covered with sheet metal at least 24 ga thick 4 The base must extend beyond the boiler enclosure by at least 150 mm 67 on all sides 5 The blocks must be placed to provide an unbroken concrete surface under the boiler with the hollows running continuously and horizontally to allow air circulation Boiler water piping Install pressure relief valve and pressure gage directly to boiler supply No isolation valve must be installed between boiler supply and pressure relief valve Install pressure relief valve as shown in Fig 4 Water piping must be supported by pipe hangers Boiler must not support weight of water piping r ka 6 i cuni ae I l l Ps a pin t s I u eS tee K I l Si ai at ab Ne i vi Combustible floor 7771 Note Minimum base extension 6 beyond all sides of boiler enclosure Fig 3 Sug
51. ve installation Models ECD 65 155 are approved for closet installation with the clearances shown in Fig 1 Models ECD 180 200 are approved for alcove installation with the clearances shown in Figs E and F Do not use Models ECD 180 200 in closet installations Please note that the minimum clearance to combustibles listed will apply when the boiler is located in a room large in comparison to the size of the equipment Please see the Uniform Mechanical Code for definition If the boiler is installed in a space that does not fit the definition of a room large in comparison with the size of the equipment then it is considered a closet or an alcove installation and the closet or alcove installation instructions apply KN NF S A Top view Fig E Alcove installation for ECD 180 200 boiler ATTENTION Follow local regulations with respect to CO detectors Follow all safety information from LP or gas supplier Combustion air supply see Fig 2 This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air Refer to requirements of local jurisdictions in addition to the information in this manual All combustion air must come from the outside Vent pipe VZZ7 777 ZZZ Z W ECD 180 200 Vi Front of alcove must be removable for V Return upp d service access I 187 Ventilation opening
52. ways use latest edition of national codes for all venting installation requirements Before connecting boiler to existing chimney inspect chimney for inside and outside conditions Deteriorated chimneys are unsafe Terminate venting system outside with approved termination at least 6 ft above the boiler Vent pipe must extend at least 3 ft above the point where it passes through the roof Vent termination must be at least 2 ft higher than any portion of building within 10 ft horizontal and vent termination must be at least 2 ft higher than roof peaks within 10 ft horizontal Downdraft problems due to negative building pressure must be corrected Chimney condensation problems must be corrected Removal of existing boiler When an existing boiler is removed from a common venting system the common venting 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 appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiency which would cause an unsafe condition 3 Insofar a

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