Viessmann Vitogas 050 ECD Series Installation Manual V2
en
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 neighbors
phone. Follow the gas suppliers 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.
Contents: Page: Technical Data..........................................................................3 Boiler handling location..........................................................3 Flushing of existing piping ........................................................4 Vent damper installation ...........................................................4 Closet installation......................................................................5 Combustion air supply ..............................................................6 Installation on combustible floor ...............................................8 Boiler water piping ....................................................................8 Honeywell adjustable high limit aquastat ..................................9 Circulating pump.......................................................................9 Initial system fill.......................................................................10 Boiler venting ..........................................................................11 Gas piping...............................................................................12 Gas pressure orifice sizes ...................................................12 Main burner.............................................................................13 Blocked vent and flame roll-out switch ...................................14 Wiring......................................................................................14 Electronic thermostat ..............................................................15 System start-up.......................................................................15 Maintenance ...........................................................................15 Troubleshooting ......................................................................17 Lighting instructions ................................................................18 Wiring diagrams................................................................19, 20 Parts list ................................................................21, 22, 23, 24 Maintenance record ................................................................25
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 IMPORTANT: READ AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
5167 445 v1.1 03/2007
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.
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.
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.
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.
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.
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.
Warning:
Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow manufacturers maintenance schedule of boiler. 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.
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.
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.
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 problem and correct. Failure to heed this warning could result in property damage, severe personal injury, or loss of life.
Warning:
The installation, adjustment, service, and maintenance of this boiler must be done by a licensed professional service technician who is qualified 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.
2
Before operating 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/CSAB149.1 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 (1) Front: 150 mm (6) Top: 450 mm (18) Rear: 25 mm (1) Floor: Non-combustible Flue: 150 mm (6). Above clearances apply to all ECD boilers. 3
* With vent damper and intermittent pilot ignition All sizes available with propane gas. Electrical requirement kW figures are approximate For net IBR rating divide output by 1.15. 120V, 60Hz, less than 12A
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 B Sections Efficiency
ECD-65 65,000 Btu/h 53,950 Btu/h 350 mm 5 12 114 3 2 9.9 ltr 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 5 12 114 3 2 9.9 ltr 106 kg 83.5% 83% 23 kW 19 kW 14 2.6 USG 233 lbs
ECD-100 100,000 Btu/h 83,000 Btu/h 450 mm 6 12 114 4 3 13.2 ltr 130 kg 83.5% 83% 29 kW 24 kW 1734 3.5 USG 285 lbs
ECD-115 115,000 Btu/h 95,450 Btu/h 450 mm 6 12 114 4 3 13.2 ltr 130 kg 83.5% 83% 34 kW 28 kW 1734 3.5 USG 285 lbs
ECD-140 140,000 Btu/h 116,200 Btu/h 550 mm 7 12 114 5 4 16.5 ltr 157 kg 83.5% 83% 41 kW 34 kW 2134 4.3 USG 345 lbs
ECD-155 155,000 Btu/h 128,500 Btu/h 550 mm 7 12 114 5 4 16.5 ltr 157 kg 83.4% 83% 45 kW 38 kW 2134 4.3 USG 345 lbs
ECD-180 180,000 Btu/h 149,400 Btu/h 654 mm 7 12 114 6 5 26.8 ltr 192 kg 83.2% 83% 52 kW 44 kW 2534 7.1 USG 423 lbs
ECD-200 200,000 Btu/h 166,000 Btu/h 654 mm 7 12 114 6 5 26.8 ltr 192 kg 83.0% 83% 58 kW 48 kW 2534 7.1 USG 423 lbs
Vitogas 050, ECD Series Technical Data
Cut-away view (left side)
Left view Front view
A
Draft hood
Boiler well for capillaries
Transformer
Ignition control
24V gas valve
Burner manifold
Vent connection
Boiler supply water 114 (water flows out)
120V power in 120V 4A max. output to pump
24V vent damper
Gas connection
Boiler return water 114 (water flows in)
24V thermostat
19.75 (502)
17.50 (445)
11.00 (279) 12
.2 5
( 31
0)
26 .0
0 (
66 0)
E C
D -1
80 /2
00 4
5. 75
(1
16 0m
m )
E C
D -6
5 to
1 55
4 1.
75
(1 06
0m m
)
2.82 (72)
B
Boiler electrical requirements are 120V, 60 Hz, less than 12A Max. pump amperage is 4A. Use field supplied relay for pumps over 4A.
2. 5
( 64
)
Recommended minimum service clearances: Left side: 610 mm (24) Right side: 610 mm (24) Front: 1220 mm (48) Top: 610 mm (24) 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.
General 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 248F. The vast majority of applications operate below 30 psig and below 194F. Standard equipment on the ECD boiler includes a 30 psig relief valve and adjustable aquastat with maximum setting of 194F. An alternate construction is available for operation between 194F and 248F. 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.
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. 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 manufacturers 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 plugs inside the boiler and attach them to the 6-pole plug from the vent damper (see Figs. B, C and D).Fig. A
Typical hot water piping system
Return
ECD boiler
Supply
Strainer location
Bypass
City water Backflow
preventer
Fill valve
Air vent
Globe valve Valve
Circulator Air purger
Gas pipe
Ball valve
Diaphragm expansion tank
Approved gas shut-off valve
Vent connection
Pressure gage
Drain valve
Floor drain
Level concrete floor pad Air flow
30 psig pressure relief valve
Low water cut-off location
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 service access to the vent damper after the installation. Use sheet metal screws (e.g. #8 x 12) 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:
1. Thermostat calls for heat. 2. Vent damper blade opens. 3. Pilot sparks and ignites. 4. Pilot is proven and main valve is energized. 5. 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.
If the vent damper becomes defective:
1. Follow the vent damper manufacturers 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/alcove 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.
5
Fig. B Vent damper harness installation
Molex connector
A Effikal vent damper only
Plastic strain relief
Dim A
ECD-65, -80 47.75
ECD-100, -115 48.25
ECD-140, -155 48.75
ECD-180, -200 52.75
Fig. C Plug connection with vent damper (or power vent)
Fig. D Plug connection without vent damper
3-pole burner plug
3-pole control plug
6-pole vent damper plug
41
41 41
41
41
3-pole burner plug
3-pole control plug
Fig. E Alcove installation for ECD- (180, 200) boiler
1
6
Top view
1
Top clearance 18
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.
Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Ventilation, 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.
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.
6
Fig. 1 ECD- (65-155) Closet installation minimum clearances
ECD-(65-155)
6 (150mm)
1 (25mm)
6 (1
50 m
m )
6 (1
50 m
m )
18
(4 58
m m
)
F re
sh c
om bu
st io
n ai
r ve
nt ila
tio n
op en
in gs
2 op
en in
gs 1
0 x
20 e
ac h
Side view
Fig. F Alcove installation for ECD- (180, 200) All dimensions shown are minimum
Vent pipe
Exp. tank
Return Supply
ECD-(180, 200)
1 Drain valve
24
PRV
18
Concrete non-combustible floor
Left side view
Ventilation opening
Front of alcove must be removable for service access
Combustion air opening
Each opening shall have an area of one square inch per 1000 Btu/h of input
ECD Opening size
180 10 x 20
200 10 x 20
Warning:
Failure to provide 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.
Fig. 2 Boiler located in dedicated mechanical room with combustion air ducted in from outside.
Electrical on/off switch for boiler
Vent
Outside
Air flow
Combustion air ducted from outside
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.
2. For boilers installed above grade and within 2 ft. of an outside wall, openings may be used in lieu of a duct. The openings shall be located within 1 ft. above and 2 ft. horizontally from the burner level of the appliance with the largest Btu/h input.
3. 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. for a 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 5 6
ECD-140, -155 5 6
ECD-180, -200 6 7
Table 1. Combustion air duct sizes
4. 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.
5. Corrosion resistant screens must not have individual grids less than 14 x 14. Screens may not reduce the free area required for combustion air.
6. 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.
7. A combustion air supply inlet opening from the outdoors shall be located not less than 12 inches above the outside grade.
8. 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.
2. If the boiler is installed in a confined space within the building (a space with a volume less than 50 ft3 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 in2 per 1,000 Btu/h of input for all gas burning equipment, but not less than 100 in2. Two openings each with a minimum free area of 200 in2 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 ft3 per 1,000 Btu/h of input for all gas burning equipment.
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 in2 per 4,000 Btu/h for all gas burning equipment. Two openings each with a free area of 50 in2 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 in2 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 in2 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.
3. 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.
4. 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 construction changes, air supply ducts must be installed for safe boiler operation.
5. If windows or doors are used for combustion air openings, they must be locked open.
7
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.
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 Wet base 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 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 (6) 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.
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.
8
Fig. 4 Pressure relief valve installation (Use fittings supplied in accessory pack)
Fig. 3 Suggested base for installation on combustible floor
Note: Minimum base extension 6 beyond all sides of boiler enclosure
6
6
4
Pressure relief valve
Supply piping to radiation
Boiler supply connection
Pressure gage
Fig. 4a Multi-zone system using zone pumps. Piping arrangement for best air elimination (see note on following page)
C F
Combustible floor
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.
Air vent
Air separator Pressure reducing valve
Precharged expansion tank
Pressure gage
ECD boiler
PRV
Backflow preventer
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 systems peak performance. See Fig. 4a for multi-zone system using pumps.
Caution: The boiler warranty does not cover leaks resulting from corrosion caused by 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 140F. Never permanently bypass high limit 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 116F. Alternate aquastat is available at 104F.
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.
The following lists typical water flow rates for the Atola-ECD boiler series:
Flow rate (GPM) Flow rate (GPM) Model for 20F rise for 30F 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.
Fig. 4b Using transformer/relay to switch pumps over 4A current draw.
Separate breakerF
F
F
N L
120V Transformer/Relay Viessmann
24V 120V
Jumper
Boiler terminal strip
L
N
G
N
L
T
T
120V power input
120V pump output
Thermostat connections 24V
120V pump over 4A
Field supplied
Fig. 4c Honeywell L4008A adjustable high limit aquastat is located behind access panel
Adjustment screw set to 140F minimum
140
Boiler 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.
Low water cut-off If the 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 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 140F or higher. Use globe valve or ball valve.
3. Bypass line should be minimum 12 long. 4. 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.
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 freezing 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 (70F) 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 40% antifreeze content will give freeze-up protection to approximately -10F (-23.3C). 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
10
Fig. 5b Low water cut-off location
Low water cut-off
2 min.
Fig. 5a Boiler piping in a heating/cooling application
Heating/ Cooling unit
Heating/ Cooling unit
Water chiller
Heating/ Cooling unit
V FC AFV V
V2 FC V
V1
VFCCP
required to reduce the incoming water pressure to between 12 and 15 psig.
Boiler venting (Category I) 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 must be suitably supported to prevent the draft hood from supporting the weight of the chimney.
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. Always 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 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 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. Test for 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 17 must be followed for new installations involving single or multiple ECD boilers.
Side wall vent system A side wall power vent system can 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
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.
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. D