Model

CCB-150
COMBI
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
cod. 3541F060

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com
P/N# 240010632, Rev. B [07/17/2014]
 DIMENSIONS

Figure 1 - Overall Dimensions

Top View

Side View Front View Rear View

1 = 1“ MPT Supply Water to Heating

System (Out)
2 = 3/4” MPT Tap Water Outlet
3 = 3/4” FPT Gas Inlet
4 = 3/4” MPT Tap Water Inlet
5 = 1” MPT Return Water From
Heating System (IN)

Bottom View

2
 TABLE OF CONTENTS

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

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

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

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

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

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

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

6 - Combustion Air And Ventilation....................................................................................... 19

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

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

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

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

11 - General Maintenance And Cleaning ................................................................................ 33

12 - Ratings And Capacities ................................................................................................ 34

13 - Trouble Shooting......................................................................................................... 37

Wiring diagram ............................................................................................................... 38

Repair Parts List .............................................................................................................. 40

3
 1 - INTRODUCTION
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Catagory I or III Venting.
• Direct vent boiler.
• For use with natural gas or liquefied petroleum gases
(LP/propane).
• Directly heat potable water. Indirect heating is
acceptable.

1.2 The unit MUST NOT:

• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 185°F (85°C) system design temperature.
• Exceed MWAP 43.5 PSIG

1.3 Operational Features

• Modulating: 3-1 turn down.
• Integral Dual Limit.

Information and specifications outlined in this manual in effect at the

time of printing of this manual. ECR International, Inc. reserves the right to
discontinue, change specifications or system design at any time without
notice and without incurring any obligation, whatsoever.

4
 2 - IMPORTANT SAFETY INFORMATION
2.1 General 2.3 Installation shall conform to requirements of
Boiler installation shall be completed by qualified agency. authority having jurisdiction or in absence of such
See glossary for additional information. requirements:
• United States
! WARNING • National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Fire, explosion, asphyxiation and electrical • National Electrical Code, NFPA 70.
shock hazard. Improper installation could • Canada
result in death or serious injury. Read this • Natural Gas and Propane Installation Code,
manual and understand all requirements CAN/CSA B149.1.
before beginning installation. • Canadian Electrical Code, Part I, Safety Standard
for Electrical Installations, CSA C22.1

2.2 Become familiar with symbols identifying

potential hazards. 2.4 Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
This is the safety alert symbol. Symbol alerts you to limited to:
potential personal injury hazards. Obey all safety messages • Installation by licensed plumber or gas fitter.
following this symbol to avoid possible injury or death.
2.5
Where required by the authority having jurisdiction, the
installation must conform to the
! DANGER Standard for Controls and Safety Devices for Automatically
Indicates a hazardous situation which, if not Fired Boilers, ANSI/ASME CSD1.
avoided, WILL result in death or serious injury.

! WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.

! CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.

NOTICE
Used to address practices not related to
personal injury.

5
 3 - GENERAL VIEW AND MAIN COMPONENTS

Figure 2 Component Listing

6
 3 - GENERAL VIEW AND MAIN COMPONENTS

Item Description
Number
5 Sealed Chamber
7 Gas Inlet
8 Domestic Hot Water (DHW) Outlet
9 Domestic Cold Water (DHW) Inlet
10 Supply System
11 System Return
16 Modulating Fan
19 Combustion Chamber
20 Burner Assembly
22 Burner
26 Combustion Chamber Insulation
27 Copper Heat Exchanger
28 Exhaust Manifold
29 Exhaust Outlet Manifold
32 Heating circulating pump
36 Automatic Air Vent
39 DHW Flow Regulator
42 DHW Temperature Sensor
44 Gas Valve
81 Ignition and Detection Electrode
95 3 Way Diverter Valve
114 Water Pressure Switch
136 Flow Meter
194 DHW Flate Plate Heat Exchanger
278 Double Sensor - High Limit NTC
297 Air Pressure Switch
364 Condensate Union

Unit Weight - 74 LBS (33.5 kg)

Shipping Weight - ~ 78 LBS (35.5 kg)

7
 3 - GENERAL VIEW AND MAIN COMPONENTS

! WARNING
Fire, explosion, asphyxiation and electrical
shock hazard. Disconnect electrical power
supply and turn off gas at shutoff valve before
attemting to remove boiler jacket. Failure to
follow these instructions could result in death
or serious injury.

Remove Boiler Jacket

1. Unscrew screws (A).
2. Pivot jacket upwards. See figure 3.
3. Raise Jacket up and off boiler. See figure 4.

Figure 3 - Jacket Removal - Screw Figure 4 - Pivot Jacket and Raise to Remove
Locations

2
A
1
A

8
 4 - LOCATING BOILER
4.1 Boiler Location Considerations
Figure 5 - Boiler Clearances
• Ambient room temperature always above 32°F (0°C) to
prevent freezing.
• Approved for installation in closets.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, control replacement,
etc.).
• Wall mount only. B Boiler C
• Access to outdoors to meet minimum and maximum (Front View)
pipe lengths for combustion air and vent piping. See
section 6.
• Drainage of water (or water - antifreeze solution) during
boiler service or from safety relief valve discharge. See
section 5.
• Access to system water piping, gas supply, and electrical
service. See sections 5, 7 and 8.
• Clearances to combustible materials and service F F
clearances. See Table 2 and figure 5.
• The boiler must not be installed on carpeting. FLOOR

Boiler
D (Side View)

Front

TABLE 1: BOILER CLEARANCES

Combustible
Dimension Service(1)(2)
Materials (1)
Top (A) 16” (41cm) 16" (41cm)
Left Side (B)) 0" (0 cm) 1” (3 cm)
Right Side (C) 0" (0 cm) 1” (3 cm)
Front (D) 0" (0 cm) 1" 3 cm)
Back (E) 0" (0 cm) 0” (0 cm)
Bottom (F) 0" (0 cm) 12" (30 cm)
Combustion Air/piping 0" (0 cm) 3/8" (1 cm)
Vent piping 6" (15 cm) 6" (15 cm)
(1)
Required distances measured from boiler jacket.
(2)
Service, proper operation clearance recommendation.

9
 4 - LOCATING BOILER

4.2 Pre-pipe supply and return water connections Figure 6 - Wall Mounting Bracket
with factory fittings before wall mounting.

4.3 Wall Mounting 2⅜” 2⅜”

Mount boiler on wall using wall mounting bracket included (2.4cm) (2.4cm)
with unit.
• Structure must be capable of supporting boiler weight
plus 60 lbs (28 kg). See page 7.
• Wall mount bracket has 2 slots, spaced at 9¼”
(23.5cm) on center.
• Attach wall mount bracket level on wall.
9¼” (23.5cm)
• Boiler must engage with wall mount bracket. See figure 6.

! CAUTION
Boiler weight exceeds 75 pounds (34 kg). Do not
lift boiler onto wall without assistance.

NOTICE
Lift boiler using chassis. Using front jacket, vent
piping, water or gas fittings to lift boiler may cause
damage to the boiler.

10
 5 - HYDRONIC PIPING
5.1 General Conditioning chemicals must ensure complete deoxygenation
• Install piping in accordance with authority having jurisdiction. of water and contain specific protective agents for yellow
metals (copper and its alloys), anti-fouling agents for
NOTICE limescale at least up to 150 ppm CaCO3, pH neutral
Use two (2) wrenches when tightening and fitting stabilizers and, in low temperature systems, specific biocides
pipe to boiler's threaded fittings. Boiler's internal for use in heating systems.
piping can be damaged if subjected to excessive In systems with continuous intake of oxygen (e.g. floor
torque. systems without anti-diffusion pipes, open expansion
vessels), or intermittent (e.g. in case of frequent
• Support system piping and safety relief valve discharge replenishing), a separator must be provided. Regarding
piping. Boiler's internal piping and wall mount bracket domestic hot water (DHW), no type of treatment which
can be damaged if subjected to excessive weight. could prevent its possible food use can be provided for.
• Size central heating pump (and domestic hot water
pump, if used) for system requirements only. Internal
heat exchanger pump compensates for pressure drop ! WARNING
through boiler internal piping and heat exchanger. • Poison hazard. Ethylene glycol is toxic. Do not
• Thoroughly clean and flush system before connecting to boiler. use ethylene glycol.
• If oil is present in system water, use approved detergent to
• Never use automotive or standard glycol antifreeze,
wash system.
• Flush system to remove any solid objects such as metal chips,
even ethylene glycol made for hydronic systems.
fibers, or Teflon tape, etc. • Ethylene glycol can attack gaskets and seals used
in hydronic systems.
5.2 Water System Characteristics • Use only inhibited propylene glycol solutions
• Water in the heating system must have protection of certified by fluid manufacturer as acceptable for
metallic materials against corrosion.
use with closed water heating system.
• Filling water and subsequent replenishing, must be
clear, with hardness under 150 ppm CaCO3,
• Thoroughly clean and flush any system that used
glycol before installing new Boiler.
A. treated with approved conditioning chemicals
to ensure prevention of corrosion and attack on • Provide user with Material Safety Data Sheet
metals and plastics, that gases do not form, (MSDS) on fluid used.
B. and bacterial or microbial masses do not proliferate
in low temperature systems. NOTICE
• Hardness exceeding 150 ppm CaCO3, appropriate water Do not expose boiler to freezing temperatures.
softening treatment and/or use of suitable anti-fouling
agents must be provided.
Water contained in the system must be checked at least 5.3 Special Conditions
yearly and have: • System piping exposed to freezing conditions: Use
A. pH above 7 and under 8.5 (under 8 with presence inhibited propylene glycol solutions certified by fluid
of components in aluminum or light alloys), manufacturer for use with closed water heating system.
B. iron content (Fe) less than 0.5 mg/l, Do not use automotive or ethylene glycol.
C. copper content (Cu) less than 0.1 mg/l,
D. total content of chlorides, nitrates and sulfates less • Boiler installed above radiation level (or as required by
than 50mg/l, authority having jurisdiction) shall have low water cutoff
E. must contain conditioning chemicals in protection.
concentration sufficient to protect system for a • Boiler used in connection with refrigeration system.
year. Install piping in parallel with boiler, with appropriate
There must be no microbial or bacterial loads in low valves to prevent chilled medium from entering boiler.
temperature systems. • System piping connected to heating coils located in air
Conditioners, additives, inhibitors and anti-freeze fluids can handling unit exposed to refrigerated air circulation. Install
be used only if manufacturer guarantees they are suitable flow control valves or other automatic means to prevent
for use in heating systems and they do not cause damage gravity circulation of boiler water during cooling cycle.
to heat exchanger or other components and/or materials of
boiler and system.
Use of generic chemicals not specifically suitable for use in
heating systems and/or incompatible with boiler materials
and system is forbidden.

11
 5 - HYDRONIC PIPING

Figure 7 - Safety Relief Valve & Air Vent

! WARNING (Viewed from front of boiler)
Burn and Scald Hazard. Safety relief vlave
could discharge steam or hot water during
operation. Install discharge piping per these
instructions. Failure to do so could result in
death or serious injury.

5.4 Safety Relief Valve

NOTICE
Boiler rated at 43.5 psig (.30MPa) maximum allowable
working pressure. Boiler provided with 30 psig
(.21MPa) safety relief valve.
• Install safety relief valve using pipe fittings provided with 1” MPT
boiler. See figure 7.
• Install safety relief valve with spindle in vertical position. Coupling 1” NPT
• Do not install shutoff valve between boiler and safety
relief valve.
• Install discharge piping from safety relief valve. See Safety Relief
figure 8. Nipple 1” x 5”
Valve
• Use ¾” or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent Tee 1” x 1” x ¾”
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum Street Elbow ¾”
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).

12
 5 - HYDRONIC PIPING
Figure 8 - Safety Relief Valve Discharge
Piping

Safety Relief
Valve

Gas Shutoff
Valve
in Open
position

Check Local Codes

for Maximum
Distance to Floor

13
 5 - HYDRONIC PIPING

Figure 9 - Hydronic Piping

278

27

114
36

95

32

241
42
136

10 8 9 11

- Plumbing circuit
8 Domestic Hot Water Outlet
9 Domestic Cold Water Inlet
10 Heating System Supply
11 Heating System Return
27 Copper Exchanger For Heating And Hot Water
32 Heating Circulating Pump
36 Automatic Air Vent
42 DHW Temperature Sensor
95 Diverter Valve
114 Water Pressure Switch
136 Flow Meter
241 Automatic Bypass
278 Double Sensor (Safety + Heating)

14
 6 - COMBUSTION AIR AND VENT PIPING - CATEGORY I (CHIMNEY VENT)
5. Vent connector from boiler to chimney should run as
! WARNING directly as possible with as few elbows as possible.
Boiler and venting installations shall be performed 6. Common venting shall not be allowed. Boiler and
by a qualified expert and in accordance with the other certified appliances. appliances can share same
appropriate manual. Installing or venting boiler chimney vent. Consult appropriate Vent Sizing Tables
or other gas appliance with improper methods or in National Fuel Gas Code for specific requirements of
materials may result in serious injury or death due multiple appliance venting.
to fire or to asphyxiation from poisonous gases such 7. Boiler is only appliance connected to vent, Type B vent
as carbon monoxide with is odorless and invisible. pipe is recommended for vent connector.
8. Slope pipe up from boiler to chimney not less than 1/4”
per foot (21mm/m).
9. End of vent pipe must be flush with inside face of
! WARNING chimney flue. Use sealed-in thimble for chimney
connection.
Do not connect boiler to any portion of mechanical 10. Fasten sections of vent pipe with sheet metal screws to
draft system operating under positive pressure. make piping rigid. Use stovepipe wires to support pipe
from above.
11. Do not connect to fireplace flue.
6.1 Check Your Chimney
Chimney must be clean, right size, properly constructed 12. Do not install damper on this boiler.
and in GOOD CONDITION.
Figure 10 - Combustion Air Fitting
1. Installation must conform to requirements of the
authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or Natural Gas and Propane 3” 3”
Installation Code, CAN/CSA B149.1.
2. Increaser fitting is required on this boiler for Category I
venting, and 4” is minimum permissible vent diameter.
This does not imply vent connector is intended to be 4”
diameter pipe. Vent connector shall be sized according
to appropriate venting tables in the National Fuel
Gas Code and may be required to be larger than 4”
diameter.

NOTICE
Boiler installation for chimney venting is not
complete unless increaser fitting is located and
secured.
3. Venting into masonry chimney without liner, line
chimney from top to bottom with either:
A. Listed Type B vent pipe Horizontal Venting requires field supplied appliance adapter
B. Listed flexible vent liner for the boiler flue outlet.
C. Poured ceramic liner. Boiler is provided with a 3” vent connection, 3” x 4”
increaser must be field sourced for chimney application.
4. Outside chimneys should not be used unless they are
This does not mean that the connection to the chimney will
(choose one of the following):
always be 4”.
A. Enclosed in a chase
B. Lined with Type B vent pipe
C. Use listed flexible vent liner
D. Use certified chimney lining system

15
 6 - COMBUSTION AIR AND VENT PIPING- CATEGORY I (CHIMNEY VENT)
6.2 Minimum Vent Pipe Clearance 7. After it has been determined that each appliance
• Use Type B vent pipe through crawl space. Where vent remaining connected to the common venting system
pipe passes through combustible wall or partition, use properly vents when tested as outlined above, return
ventilated metal thimble. Thimble should be 4 inches doors, windows, exhaust fans, fireplace dampers and
larger in diameter than vent pipe. any other gas-burning appliance to their previous
• Boiler installed with single wall vent, must have 6” conditions of use.
clearance between its surface and any combustible
material. New Type B gas vent or fl exible liner must be 8. Any improper operation of the common venting system
installed in accordance with instructions furnished with should be corrected so the installation conforms with
vent. Maintain clearances as specifi ed for vent pipe. the National Fuel gas Code, ANSI Z223.1/NFPA 54,
• Verify vent pipe is fire-stopped where it goes through and/or the Natural Gas and Propane Installation Code,
floor or ceiling. It should have approved vent cap with CAN/CSA B149.1. When re-sizing any portion of the
clearances from roof. If clearances are less than shown, common venting system, the common venting system
have vent checked by local authorities. Figure 12, Page should be re-sized to approach the minimum size
20. determined using the appropriate tables in Chapter 13
• Vent connectors serving appliances vented by natural of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
draft shall not be connected into any portion of and/or the Natural Gas and Propane Installation Code,
mechanical draft systems operating under positive CAN/CSA B149.1.
pressure.
9. It is recommended that existing gas vents be checked
to be sure they meet local codes.
6.3 Removing Existing Boiler From Common
Venting System 6.4 Modulating Fan
• Unit is equipped with an advanced combustion air, vent
When an existing boiler is removed from a common
flow control system, with modulating fan and pressure
venting system, common venting system is likely to be
sensor.
too large for proper venting of the appliances remaining
connected to it. • Unit automatically adapts its operation to flue type
1. At the time of removal of an existing boiler, the and length, without requiring adjustments during
following steps shall be followed with each appliance installation or use of baffles in combustion circuit.
remaining connected to the common venting system • Unit consistantly and automatically regulates
placed in operation, while the other appliance combustion air and vent flow according to change in
remaining connected to the common venting system thermal load. Combustion and heat exchange occur in
are not in operation. optimum conditions. Unit’s thermal efficiency remains
2. Seal any unused openings in the common venting high throughout its power range.
system.
3. Visually inspect the venting system for proper size and 6.5 Venting Materials
horizontal pitch and determine there is no blockage or
• See Table 2
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
4. Insofar as is practical, close all building doors and Table 2 - Combustion Air and Vent Pipe Fittings
windows and all doors between the space in which the Category I (Chimney Vent)
appliances remaining connected to the common venting Item Material Standards
system are located and other spaces of the building.
Type B Vent UL 441, ULC S605
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust Masonry Chimney
Vent Pipe & Fittings National Fuel Gas
- must conform to
fans, such as range hoods and bathroom exhausts, so Code, ANSI Z223.1/
proper sizing and
they will operate at maximum speed. Do not operate a NFPA 54
materials
summer exhaust fan. Close fireplace dampers.
Stainelss Steel, ANSI/ASTM D2564,
5. Place in operation the appliance being inspected. Follow Combustion Air PVC, CPVC, PP, ANSI/ASTM F493,
the lighting instructions. Adjust thermostat so appliance Aluminum UL 1738/ULC636-08
will operate continuously.

6. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use flame of a
match or candle, or smoke from a cigarette, cigar, or
pipe.

16
 6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III

Induced Draft Boilers D. The venting system shall terminate at least 3 feet
Horizontal (Category III) venting systems installation 0.9m) above any forced air inlet located within
shall conform to the requirements of the authority having 10 feet (3m). The venting system shall terminate
jurisdiction or, in the absence of such requirements, to at least 4 feet (1.2m) below, 4 feet (1.2m)
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/ horizontally from, or 1 foot (300 mm) above any
or Natural Gas and Propane Installation Code, CAN/CSA door, window, or gravity air inlet into any building.
B149.1 The bottom of the vent shall be located at least 12
1. Boilers may be vented horizontally. Vent pipe is pitched inches (300mm) above grade. Termination of the
down from boiler to vent termination. Do not connect vent shall be not less than 7 feet (2.13m) above
other appliances to this vent. adjacent public walkway. The vent terminal shall
not be installed closer than 3 feet (0.9m) from the
2. Vent Pipe Material UL Listed - AL294C Stainless Steel inside corner of an L shaped structure. Termination
vent pipe and fittings.
of the vent should be kept at least 3 feet (0.9m)
3. Clearance to Combustible Materials: For stainless steel away from vegetation. The venting system shall
vent pipe maintain 6” minimum air space clearance to terminate at least 4 feet horizontally from, and in
combustible materials. no case above or below, unless a 4 foot horizontal
4. Vent Pipe Size: 3” vent pipe connected directly to the distance is maintained, from electric meters, gas
outlet of the induced draft blower. meters, regulators, and relief equipment.
5. Vent Pipe Length: • The venting system shall terminate at least 4 feet
A. For stainless steel vent pipe, the maximum below any eave, soffit, or roof overhang.
horizontal vent length is 65 equivalent feet. • The venting system shall not terminate
underneath any deck, patio, or similar structure.
B. Minimum horizontal vent length is 5 equivalent
feet. • Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to prevent
C. For 3” 90° elbows = 5 equivalent feet of vent
accidental contact with people or pets.
length.
• Terminate the vent above normal snow-line. Avoid
6. Vent Termination Fitting: For all vent pipe materials, locations where snow may drift and block the
you may use either:
vent. Ice or snow may cause the boiler to shut
A. 90° elbow pointing down, fitted with a minimum down if the vent becomes obstructed.
1/4” mesh screen to keep out rodents and birds. • Under certain conditions, flue gas will condense,
The elbow shall be of the same material and size forming moisture. In such cases, steps should be
as vent pipe. The elbow exit should be at least 6” taken to prevent building materials at the vent
away from exterior wall. terminal from being damaged by exhaust of flue
-or- gas.
B. Concentric side wall vent hood. United States - Terminate vent system at least
7. Vent Pipe Termination Location : 4 feet (1.22m) horizontally from, and in no case
A. When venting through combustible walls, above or below, unless a 4 feet (1.22m) horizontal
combustible clearances must be considered. ECR distance is maintained, from electric meters, gas
vent termination, 5612601, is a certified direct vent meters, regulators and relief equipment.
termination (for Catagory III venting) providing
both the outside vent termination and a double Canada - Terminate vent system at least 6 feet
wall pipe for passing through a combustible (1.83 m) horizontally from, and in no case above
wall up to 10” thick. Vent terminations by other or below, unless a 6 feet (1.83m) horizontal
manufacturers may also be used as long as they distance is maintained, from electric meters, gas
are certified for catagory III venting. meters, regulators and relief equipment.
B. If the 90° elbow is the termination fitting of choice, 8. Joining and Sealing the Vent Pipe: The vent pipe needs
then the single wall pipe will be passing through the to be both watertight and gas tight. Seal all joints and
side wall. For combustible walls, a UL listed thimble seams following vent pipe manufacture’s installation
shall be used where the single wall pipe passes instructions.
through the wall. 9. Support Spacing: Do not restrict thermal expansion
C. For single wall pipe through non-combustible movement of the vent. The vent pipe must expand
walls, the hole through the wall need only be large and contract freely with temperature change. Each run
enough to maintain the pitch of the vent pipe, and of vent piping shall be supported following vent pipe
provide proper sealing. A thimble is not required for manufacture’s instructions.
single wall pipe passing through non-combustible
walls.
17
 6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III

10. If the horizontal vent must go through a crawl space or ! WARNING

other unheated space, the cool temperatures will likely
cause the flue gases to continuously condense inside Vent extending through exterior wall shall not
the vent pipe. Do not insulate the vent pipe. It must be terminate adjacent to wall or below building
visible for monthly inspection. Insure that the vent pipe extensions such as eaves, balconies, parapets or
is properly pitched away from the boiler, with no low decks. Failure to comply could result in death or
spots, so that condensate in the vent will drain away serious injury.
from the boiler. An insulated enclosure or chase, with
access for inspection and servicing of the vent, may
be required to prevent freezing of liquid condensate.
Consult the vent pipe manufacturer’s instructions for
specific guidelines.
11. At beginning of each heating season and monthly
during the heating season, check all vent pipes and
vent terminal to make sure there are no obstructions.
Periodically clean the screen in the vent terminal.

Table 3 - Combustion Air and Vent Pipe Fittings

Type Item Diameter Min Lenght Max Lenght Material Standards
AL294C Stainless UL1738,
Vent 3” 5 ft 65 ft
Steel, Aluminum ULC S636
Direct vent ANSI/ASTM
Stainelss Steel,
D2564, ANSI/
Air intake 3” 5 ft 65 ft PVC, CPVC, PP,
ASTM F493, UL
Aluminum
1738/ULC636-08
AL294C Stainless UL1738,
Category III Vent 3” 5 ft 65 ft
Steel, Aluminum ULC S636

Equivalent Length of Venting Components:

5 ft. equivalent for a 3” 90° elbow.
2 1/2 ft. equivalent for a 3” 45° elbow.

18
 6 - COMBUSTION AIR AND VENTILATION
Provide combustion air and ventilation air in accordance • All Outdoor Air. Provide permanent opening(s)
with the section “Air for Combustion and Ventilation,” of the communicating directly or by ducts with outdoors.
National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections ◊ Two Permanent Opening Method. Provide opening
8.2, 8.3 or 8.4 of Natural Gas and Propane Installation commencing within 12 inches of top and second
Code, CAN/CSA B149.1, or applicable provisions of local opening commencing within 12 inches of bottom
building codes. enclosure.
 Direct communication with outdoors or
Provide make-up air where exhaust fans, clothes dryers, communicating through vertical ducts. Provide
and kitchen ventilation equipment interfere with proper minimum free area of 1 in 2 per 4 Mbh of total
operation. input rating of all appliances in enclosure.
 Communicating through horizontal ducts. Provide
National Fuel Gas Code recognizes several methods minimum free area of 1 in2 per 2 Mbh of total input
of obtaining adequate ventilation and combustion air. rating of all appliances in enclosure.
Requirements of the authority having jurisdiction may
override these methods. ◊ One Permanent Opening Method. Provide opening
commencing within 12 inches of top of enclosure.
• Engineered Installations. Must be approved by
Provide minimum clearance of 1 inch on sides
authority having jurisdictions.
and back and 6 inches on front of boiler (does not
• Mechanical Air Supply. Provide minimum of 0.35 supersede clearance to combustible materials).
cfm per Mbh for all appliances located within space.
◊ Combination Indoor and Outdoor Air. Refer to
Additional requirements where exhaust fans installed.
National Fuel Gas Code for additional requirements
Interlock each appliance to mechanical air supply
for louvers, grilles, screens and air ducts.
system to prevent main burner operation when
mechanical air supply system not operating. • Combination Indoor and Outdoor Air. Refer toNational
Fuel Gas Code for application information. National Gas
• All Indoor Air. Calculate minimum volume for all
and Propane Installation Code Requires providing air
appliances in space. Use a different method if minimum
supply in accordance with:
volume not available.
◊ Standard Method. Cannot be used if known air • Section 8.2 and 8.3 when combination of applianceshas
infiltration rate is less than 0.40 air changes per a total input of up to and including 400 Mbh (120kW).
hour. See Table 4 for space with boiler only. Use  Does not have draft control device.
equation for multiple appliances.
• Section 8.4 when combination of appliances has total
Volume ≥ 50 ft3 x Total Input [Mbh] input exceeding 400 Mbh (120 kW).
◊ Known Air Infiltration Rate. See Table 3 for space • Refer to Natural Gas and Propane Installation Code
with boiler only. Use equation for multiple appliances. for specific air supply requirements for enclosure or
Do not use an air infiltration rate (ACH) greater than structure where boiler is installed, including air supply
0.60. openings and ducts.
Volume ≥ 15 ft3/ACH x Total Input [Mbh]
◊ Refer to National Fuel Gas Code for opening
requirements between connection indoor spaces.

Table 4 - Air Infiltration

Standard Known Air Infiltration Rate Method (Air Changes Per Hour)
Input Mbh
Method 0.1 0.2 0.3 0.4 .05 0.6
150 7500 22,500 11,250 7,500 5,625 4,500 3,750

19
 6 - COMBUSTION AIR AND VENT PIPING

Figure 11 - Horizontal Venting Clearances

NOTICE
Maintain 12” (30cm) US, 18” (46cm) Canada
Figure 12 - Two Pipe Venting
clearance above highest anticipated snow level
or grade.

( = Combustion Air / = Venting)

20
 6 - COMBUSTION AIR AND VENT PIPING

Figure 13 - Chimney Venting with Room Air NOTICE

Single Wall
Refer to section 6.1, numbers 3 through 12,
page 15 of this manual for proper installation.

( = Combustion Air / = Venting)

Figure 14 - Chimney Venting with Outside Air

Single Wall

( = Combustion Air / = Venting)

DIRECT VENT BOILER - Boiler constructed and installed

so all combustion air is derived directly from outdoors and
all vent gases are discharged to outdoors. See Figure 14.

21
 7 - GAS SUPPLY PIPING

Figure 15 Manual Main Gas Shutoff Valve

CAUTION
Outside Boiler Jacket
WHAT TO DO IF YOU SMELL GAS With Manufacturer Suggested Piping With Drip Leg
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the fire
department.

7.1 General
• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:
• USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
• Size and install gas piping system to provide sufficient
gas supply to meet maximum input at not less than Gas
minimum supply pressure. See Table 5. Connection
• Support piping with hooks straps, bands, brackets,
Nipple
hangers, or building structure components to prevent or
¾” x 3” NPT
dampen excessive vibrations and prevent strain on gas
connection. Boiler will not support piping weight. Tee ¾” NPT
• Use thread (joint) compound (pipe dope) suitable for ¾” Gas
liquefied petroleum gas. Nipple Shutoff
Nipple ¾ x ¾ x 3” Valve in ON
• Provide sediment trap up stream of gas valve. 3” NPT NPT Postion
• Install manual main shutoff valve outside of jacket. See
figure 16. ¾” Pipe Cap

7.2 Conversion To LP
Refer to Gas Conversion Kit Instructions.
Manufacturer suggested gas piping with drip leg.
DANGER
Fire Hazard. Do not use matches, candles, open
flames, or other methods providing ignition source.
Failure to comply will result in death or serious
Table 5 - Gas Supply Pressure
injury.
7.3 Leak Check Gas Piping
Pressure test boiler and gas connection before placing Gas Supply Pressure
boiler in operation. Natural Gas
• Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas Min. Max.
supply system. 3.5" w.c. 14" w.c. (3.3
(0.7 kPa) kPa)
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve. See figure 16.
• Locate leakage using gas detector, noncorrosive
detection fluid, or other leak detection method
acceptable to authority having jurisdiction. Do not use
matches, candles, open flames, or other methods that
can provide ignition source.
• Correct leaks immediately and retest.
22
 8 - ELECTRICAL CONNECTIONS

! WARNING Figure 16 - Terminal Block

Electrical shock hazard. Turn OFF electrical power

supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.
8.1 General
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:
• USA- National Electrical Code, ANSI/NFPA 70.
• Canada - Canadian Electrical Code, Part I, CSA C22.1:
Safety Standard for Electrical Installations.

8.2 Line Voltage Connections - Boiler 2

Provide individual 120V, 15 amp circuit (recommended)
with fused disconnect or service switch as required by
authority having jurisdiction.

8.3 Central Heating Thermostat 1 - Thermostat or dry contacts

A. Use thermostat or boiler system control with
dry contacts rated 0.5 amps @ 120 VAC. Boiler
control does not provide 24 VAC power to central 2 - 138 = Optional External Outdoor Reset Sensor
heating thermostat. Do not use to power 24VAC 370 = Low Water Cutoff (LWCO) - field source
thermostat. Connections on 1 & 2 terminals are 120 Volts A/C.
Connections on 3 & 4 are dry contact only.
B. Locate and install thermostat per manufacturer's
instructions. Maximum wire length is 330 ft (100m)
for 22 ga. wire.
C. Connect wires to terminals 1 and 2 as shown in
figure 17. Wires are interchangeable.

23
 9 - START UP PROCEDURE
9.1 Fill Boiler With Water And Purge Air
WARNING
NOTICE
Asphyxiation hazard. Carbon monoxide is odorless,
To maintain boiler efficiency and prevent boiling tasteless, clear colorless gas, which is highly toxic.
inside the heat exchanger, flush entire heating Carbon monoxide production shall not exceed
system until clean. 400ppm. Failure to follow these instructions could
result in death or serious injury.
• Flush heating system, including all heating zones.
• Fill boiler with potable water.
• Fill boiler and system piping with water (or WARNING
antifreeze-water solution, if used). See antifreeze
information Section 5.3 page 11. Purge air from Asphyxiation hazard. Verify cap is firmly placed on
boiler using air vent. Purge air from system piping. combustion analyzer port to prevent CO emission.
• Inspect system piping and boiler connections. Failure to do so could result in death or serious
Repair any leaks immediately. injury.
• Activate all heating zones and calls for heat,
9.3 Burner Pressure Adjustment
including CH calls and DHW calls (if available).
• Close manual gas shut off valve. Let system run for Unit has flame modulation, with two fixed pressure values:
30 minutes. When boiler goes into lockout, reset minimum and maximum. See Sec. 12, page 34.
boiler by pressing “Reset” button until boiler resets. Connect pressure gauge to pressure point “B” downstream
• Do not open gas shutoff valve until all air is purged of the gas valve.
from system. 1. Remove protection cap “D”.
2. Operate boiler in TEST mode.
3. Adjust maximum pressure by turning screw “G”
9.2 Boiler Start-up and Operational Test
clockwise ↷ to increase pressure and counter clockwise
1. Verify air is purged from hydronic piping
2. System test pumps - verify each pump is
↶ to decrease.
operational
4. Disconnect one of two connectors “C” from modulation
regulator “F” on the gas valve.
3. Verify gas piping
5. Adjust minimum pressure by turning screw “E” clockwise
• Confirm pressure test. See section 7.3 page 20.
↷ to increase the pressure and counter clockwise↶ to
• Visually inspect piping to determine there are no decrease it.
open fittings or ends, and all valves at unused 6. Turn burner on and off, verify minimum pressure
outlets are closed and plugged/capped. remains stable.
• Purge air from piping 7. Reconnect connector “C” detached from modulation
• Check piping and connections for leaks immediately regulator “F” on the gas valve.
after gas is turned on. Shut off gas supply and 8. Verify maximum pressure has not changed.
make necessary repairs if leaks found. 9. Replace protection cap “D”.
4. Follow OPERATING INSTRUCTIONS to initiate boiler 10. To end TEST mode, repeat activation sequence or wait
operation. See section 10. 15 minutes.
5. Inspect combustion air and vent piping. Verify pipe
9.4 To Enter Test Mode/Adjust Heating Power
is not leaking and terminations are unobstructed and
vent gas discharge is not a nuisance or hazard. Press CH+/- buttons at the same time for 5 seconds.
6. Verify boiler operates. • 3 way valve is in CH position and burner is forced at
100%. Boiler automatically exits test mode after 15
7. Check control module operation.
minutes or to exit test mode manually press CH +/-
8. Check field sourced limits, low water cutoffs, etc. per
buttons together for 5 seconds.
manufacturer's instructions.
• With Ch +/- buttons you can adjust Max power from (0
to 100%)

9.5 Ignition Adjustment

To adjust ignition, switch boiler to TEST mode (See Start
up Procedure). Press DHW buttons to increase or decrease
power (min.= 00, max. = 60). Press RESET button within
5 seconds and ignition remains set. Exit TEST mode.

24
 9 - START UP PROCEDURE

9.6 Check Combustion Figure 17 - Test Ports

Natural Gas
1. Measure input. English unitsTurn off gas to all other Vent Gases
appliances. Test Port
• Activate some heating zones to dissipate heat.
• Set boiler on high fire.
• Use ½, 1 or 2 cu ft dial on gas meter. Measure
time required for one or more complete
revolutions. Measure time for 1-2 minutes.
• Calculate input.
3600 x cu ft
Input (MBH) =
seconds
Combustion Air Test
Example: Gas flow from Port
Meter = 2 cu ft
Measured time = 72 seconds

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

Table 11 - Combustion Table

Combustion Minimum/Maximum
Natural Gas
High Fire - CO2 at 100 (%) 7.3 - 7.8
Low Fire - CO2 at 33 (%) 3.0 - 5.0
Figure 18 - Gas Valve

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

for venting and the other for combustion air. To sample:
Open the air/vent outlet plug.
Insert probes all the way in.
Turn on TEST mode, wait 10 minutes for boiler to stabilize;
Take measurement.

N
N
G B
C F C
A Pressure point upstream
B Pressure point downstream D D
C Modureg electrical connection
D Protection cap
E Minimum pressure adjustment I
F Modureg
G Maximum pressure adjustment
I Gas valve electrical connection
N Compensation tube
A

25
 10 - OPERATING INSTRUCTIONS

WARNING CAUTION
If you do not follow these instructions WHAT TO DO IF YOU SMELL GAS
exactly, a fire or explosion may result • Do not try to light any appliance.
causing property damage, personal injury
• Do not touch any electrical switch; do not use
or loss of life.
any phone in your building.
• This appliance is equipped with an ignition device
which automatically lights burner. Do NOT try to • Immediately call your gas supplier from a
light this burner by hand. neighbor’s phone. Follow the gas supplier’s
• Before operating smell all around appliance area instructions.
for gas. Be sure to smell next to floor because • If you cannot reach your gas supplier, call the fire
some gas is heavier than air and will settle to the department.
floor.
• Use only your hand to turn the gas shutoff 10.2 TO TURN OFF GAS TO APPLIANCE
valve. Never use tools. If valve will not turn • Set thermostat to lowest setting.
by hand, do not try to repair it, call a qualified • Turn "OFF" all electric power to appliance if service is
service technician. Force or attempted repair may to be performed.
result in fire or explosion. • Turn gas shutoff valve handle to closed position.
• Do not use this appliance if any part has Handle should be perpendicular to gas pipe.
been under water. Immediately call a qualified
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
Figure 19 Gas Shutoff Valve - Open Position

10.1 OPERATING INSTRUCTIONS

Stop! Read Safety information above.
• Set thermostat to lowest setting.
• Turn "OFF" all electrical power to appliance.
• This appliance is equipped with an ignition device which
automatically lights the burner. Do not try to light
burner by hand!
OPEN
• Turn gas shutoff valve to closed position. Handle
should be perpendicular to gas pipe.
• Wait 5 minutes for any gas to clear. Smell for gas,
including near floor. If you smell gas, STOP! Follow Figure 20 Gas Shutoff Valve - Closed Position
instructions on this page: “What To Do If You Smell
Gas.” If you do not smell gas, go to next step.
• Turn gas shutoff valve to open position. Handle
should be parallel to gas pipe.
• Turn "ON" electrical power to appliance.
• Set thermostat to desired setting.
• If the appliance will not operate, follow instructions TO
TURN OFF GAS TO APPLIANCE and call your service
technician or gas supplier.

CLOSED

26
 10 - OPERATING INSTRUCTIONS

10.3 Checks During Operation 10.5 Indicator During Operation

• Check for leaks in piping systems. Correct immediately
if found. Heating
• Check the efficiency of the flue gases and combustion Call for heat (generated by Room Thermostat) is indicated
air ducts while the boiler is working. by hot air flashing above radiator symbol on the control.
• Check water is circulating between boiler and systems.
• Verify the gas valve modulates correctly in both
heating and hot water production phases.
• Check proper ignition of the boiler by turning it on and
off with the room thermostat.
• Verify with no call for heating burner correctly ignites
on opening hot water tap. Check that during heating
operation, on opening hot water tap, heating circulator
stops and there is regular production of hot water.
• Check parameters are programmed correctly and
perform any required customization (compensation Hot water
curve, power, temperatures, etc.)
Call for hot water (generated by drawing off hot tap water) is
indicated by hot water flashing under the tap on the control.
10.4 Control Panel
3 6 4 14

64

13

15
10
11

12 10.6 Turning on and off

5 NO electrical power to the boiler
8

1 7 2 9

Key
1 = DHW temperature setting decrease button
2 = DHW temperature setting increase button The antifreeze system does not work when power and/or
3 = Heating system temperature setting decrease button - CH gas to the unit are turned off. To avoid damage caused by
4 = Heating system temperature setting increase button - CH
5 = Display
freezing during long idle periods in winter, it is advisable to
6 = Summer/Winter mode selection - Reset button drain all water from the boiler, DHW circuit and system; or
7 = Unit On/Off - Economy/Comfort mode selection button drain just the DHW circuit and add a suitable antifreeze to
8 = DHW symbol the heating system. See Section 5.2 page 11.
9 = DHW mode
10 = Summer mode
11 = Multifunction - Temperature
12 = Eco (Economy) mode
13 = Heating
14 = Heating symbol
15 = Burner On and actual power
64 = C.H. temperature pressure gauges

27
 10 - OPERATING INSTRUCTIONS

Boiler Ignition Summer/Winter Switchover

Supply unit with electricity. Press the button for 2 seconds.

Display will activate Summer symbol (see item 10 on the

control panel display). Boiler will deliver tap water only.
Boiler ignition Antifreeze system stays on.
For 120 seconds display will show FH which identifies the To turn off Summer mode, press button again for 2
air venting cycle for the heating system. seconds.
During the first 5 seconds the display will show the
software release of the card also.
Heating temperature setting
Open the gas valve before the boiler. Use heating buttons (see items 3 and 4 on the control
When FH vanishes, boiler is ready to automatically work panel display) to change the temperature from minimum of
whenever hot tap water is drawn or room thermostat 86°F (30C) to a maximum of 185°F (85C); it is advisable to
requests heating. not operate boiler below 113°F (45C).

Turning the boiler off

Press the button below (see item 7 on the control panel
display) for 5 seconds.

Domestic hot water temperature adjustment

Operate DHW buttons (see items 1 and 2 on the control
When the boiler is turned off, the electronic board is still panel display) to vary the temperature from a minimum of
powered. 50°F (40C) to a maximum of 149°F (55C)
Domestic hot water and heating operation are disabled. The
antifreeze system remains activated.
To re-light the boiler, press the button (see item 7 on the
control panel display) again for 5 seconds.

Boiler will be immediately ready to operate whenever

domestic hot water is drawn or room thermostat demand.

28
 10 - OPERATING INSTRUCTIONS

ECO/COMFORT selection
The unit has a function that ensures a high domestic
hot water delivery speed and maximum comfort for the
user. When the device is activated (COMFORT mode), the
water contained in the boiler remains hot, ensuring faster
availability of domestic hot water.
The device can be deactivated by the user (ECO mode)
by pressing the eco/comfort button (see item 7 on the
control panel display). To activate the COMFORT mode,
press the eco/comfort button (see item 7 on the control
panel display) again.

Outdoor temperature
• When the optional external probe is installed, the boiler
control system operates with “Sliding Temperature”.
In this mode, the temperature of the heating system is
controlled according to the outside weather conditions,
in order to ensure high comfort and energy saving
throughout the year. As the outside temperature
increases the system delivery temperature decreases
according to a specific “compensation curve”.

• With Outdoor Temperature adjustment, the temperature

set with the heating buttons (see items 3 and 4 on
the control panel display) becomes the maximum
system delivery temperature. It is advisable to set the
maximum value to allow system adjustment throughout
its useful working range.

• The boiler must be adjusted at the time of installation

by qualified personnel. Adjustments can in any case be
made by the user to improve comfort.

29
 10 - OPERATING INSTRUCTIONS

Compensation curve and curve offset

Press the button (see item 6 on the control panel display)
for 5 seconds once to display the actual compensation
curve, which can be modified with the DHW buttons (see
items 1 and 2 on the control panel display).
Adjust the required curve from 1 to 10 according to the
characteristic.
By setting the curve to 0, sliding temperature adjustment is
disabled.
Compensation curve

|| || ||
|| | | ||

||
|| | ||
|

|| | ||
|

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

panel display) to access parallel curve offset modifiable
with the DHW buttons (see items 1 and 2 on the control
panel display).

Parallel curve shift

|| || ||
|| | | ||

||
|| | ||
|

|| | ||
|

30
 10 - OPERATING INSTRUCTIONS
Example of parallel compensation curve shift

Press the button (see item 6 on control panel display) for 5

seconds again to exit parallel curve adjustment mode.
If the room temperature is lower lower than the required
value, it is advisable to set a higher order curve and vice
versa. Proceed by increasing or decreasing in steps of one
and check the result in the room.

Compensation curves

31
 10 - OPERATING INSTRUCTIONS

Water system pressure adjustment

The filling pressure with system cold, read on the boiler
water gauge, must be approximately 11 psi.
If the system pressure falls to values below minimum, the
boiler control will activate fault F37.

Low system pressure fault

Once the system pressure is restored, the boiler will

activate the 120-second air venting cycle indicated on the
display by FH.

TEST mode (heating power = 100%)

Press heating buttons simultaneously for 5 seconds to

turn on TEST mode. The boiler will ignite at the maximum
heating power set as described in the following paragraph.
On the display, the heating and tap water symbols will
blink; alongside, it will show the heating power and the
ignition power respectively.

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

on.

32
 11 - GENERAL MAINTENANCE AND CLEANING
11.1 Beginning of Each Heating Season 11.2 Annual Shut Down Procedure
• Check boiler area is free from combustible materials, • Follow instructions “To Turn Off Gas To Appliance” unless
gasoline, and other flammable vapors and liquids. boiler is also used to supply domestic hot water. See
• Visually inspect combustion air and vent piping for section 10, page 26.
proper operation. Check for and remove any obstruction • Drain system completely if system does not have
to flow of combustion air or vent gases. Immediately antifreeze when heating system is to remain out of
repair or replace pipe showing deterioration or leakage. service during freezing weather.
Reassemble per instructions in section 6. Ensure proper
reassembly and resealing of system. ! WARNING
• Test safety relief valve for proper operation. Refer to Following service procedures must be performed
valve manufacturer's instructions packaged with relief by qualified service agent. Boiler owner shall not
valve. attempt these steps. Failure to do so could result in
• Examine flue passages in heat exchanger, burner and death or serious injury.
cleaning (if necessary) by following instructions in
“Annual Inspection and Cleaning of Boiler Components” in
this section. 11.3 Annual Inspection and Cleaning of Boiler
• Circulator pump and combustion air blower motor Components
furnished with boiler are permanently lubricated from • Burner and heat exchanger inspection and cleaning.
factory and require no further lubrication. Lubricate field • Remove any remaining loosened sediment using shop
sourced pumps and/or motors according to pump and/or vacuum with snorkel attachment.
motor manufacturer’s instruction.
• Check following components are operating properly and
are free of blockages or obstructions: ! WARNING
• air vent; “Caution: Label all wires prior to disconnection when
• check air inlet for blockage and clean as required; servicing controls. Wiring errors can cause
• check boiler for any sign of leaks. improper and dangerous operation.”
• Check heating system expansion tank. “Verify proper operation after servicing.”
• Check the Air pressure tubing

33
12 - RATINGS AND CAPACITIES

34
 12 - RATINGS AND CAPACITIES

Table 13 - Sea Level Ratings

SEA LEVEL RATINGS

NATURAL AND PROPANE GASES

Boiler Input Rate Net AHRI

Heating
(MBH)(1) Rating, Water
Size Capacity AFUE(2)
Maximum Minimum (MBH)(1)(3)
(MBH)(1)(2)

CCB-150 150 50 130 110 85.0

(1)
1000 Btu/hr (British Thermal Units Per Hour)
(2)
Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test
procedures.
(3)
Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for
installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems,
etc.

12.1 Ratings and Capacities

• Constructed and hydrostatically tested for maximum
allowable working pressure of 43.5 psig (pounds per
square inch gauge) 43.5 psig (.30MPa) in accordance
with ASME Boiler and Pressure Vessel Code, Section IV,
Rules for Construction of Heating Boilers.
• USA - Input rates are derated 4% for each 1000 ft (300m)
above sea level, beyond 2000 ft (600m).
• CANADA - Ratings in table 13 used for elevations up to
2000 ft (600m) above sea level
- For elevations between 2000 ft (600m) and 4500
ft (1350m), derate 10% using high altitude kit.
- Contact Provincial authority having jurisdiction
for installations above 4500 feet (1350 m) above
sea level.

35
 12 - RATINGS AND CAPACITIES

Diagrams

Pressure - power diagrams

“wc
6

CCB 150
5

0
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45
kW
A LPG
B NATURAL GAS

Losses of load / head of circulators

A Boiler losses of head

1 - 2 - 3 Circulator speed

20,00

18,00

16,00
Pump Head [feet w.c.]

14,00

12,00

10,00

8,00 3

6,00 2
1
4,00

2,00

0,00
0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0
Water Flow [GPM]

36
 13 - TROUBLE SHOOTING
Diagnostics
The boiler is equipped with an advanced self-diagnosis system. In case of a boiler fault, the display will flash indicating the
fault code.
There are faults that cause permanent shutdown (marked with the letter “A”): to restore operation just press the RESET
button (detail 6 - Section 10.4, Control, page 25) for 1 second or RESET on the optional remote timer control if installed;
if the boiler fails to start, it is necessary to first eliminate the fault.
Other faults (marked with the letter “F”) cause temporary shutdowns that are automatically reset as soon as the value
returns within the boiler’s normal working range.
Table of faults

- List of faults
Fault
Fault Possible cause Cure
code
Check the regular gas flow to the boiler and that the air has
No gas
been eliminated from the pipes
Check the wiring of the electrode and that it is correctly
A01 No burner ignition Ignition/detection electrode fault
positioned and free of any deposits
Faulty gas valve Check the gas valve and replace it is necessary
Ignition power too low Adjust the ignition power
Flame present signal with burner Electrode fault Check the ionisation electrode wiring
A02
off Card fault Check the card

Heating sensor damaged Check correct heating sensor positioning and operation
Overtemperature protection
A03
activation No water circulation in the system Check the circulating pump
Air in the system Vent the system
The air pressure transducer does Incorrect air pressure transducer wiring Check the wiring
F05 not receive a sufficient minimum
Flue not correctly sized or obstructed Check the length of flue and that it is clean
value within 25 seconds
Low pressure in the gas system Check the gas pressure
A06 No flame after the ignition stage
Burner minimum pressure setting Check the pressures
Sensor damaged
F10 Delivery sensor 1 fault Wiring shorted Check the wiring or replace the sensor
Wiring disconnected
Sensor damaged
F11 DHW sensor fault Wiring shorted Check the wiring or replace the sensor
Wiring disconnected
Sensor damaged
F14 Delivery sensor 2 fault Wiring shorted Check the wiring or replace the sensor
Wiring disconnected
Fault F05 generated 5 times in the last
A15 Air signal protection activation See fault F05
15 minutes
F34 Supply voltage under 170V. Electric mains trouble Check the electrical system
F35 Faulty mains frequency Electric mains trouble Check the electrical system
Pressure too low Fill the system
F37 Incorrect system water pressure
Sensor damaged Check the sensor
Probe damaged or wiring short circuit Check the wiring or replace the sensor
F39 External probe fault Probe disconnected after activating the Reconnect the external probe or disable the sliding
sliding temperature temperature
A41 Sensor positioning Delivery sensor detached from the pipe Check correct heating sensor positioning and operation
F42 Heating sensor fault Sensor damaged Replace the sensor
No system H2O circulation Check the circulating pump
F43 Exchanger protection activation.
Air in the system Vent the system
A44 Check the correct positioning and operation of the DHW
DHW sensor disconnected Sensor disconnected
sensor.
A48 Air signal protection activation Fault F05 for 150 seconds See Fault F05
F50 Modulation regulator fault Wiring disconnected Check the wiring
Pressure too low Fill the system
F51 Low water cutoff warning
Low water cutoff damaged Check the contact

37
 WIRING DIAGRAM

370 370 - Field Source LWCO

138 138 - Optional Outdoor Sensor

M

120Vac
60Hz
1 2 3 4 5 6
L N

95

AUX
T °T

278 X2 1
°

L N
4
1

X7 44
DBM34 16

GND
297 + 15V
OUT

47
72
32
42
114
GND
136 OUT
+5V

81
1k

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

Key
16 Modulating fan 114 Water pressure switch
32 Heating circulating pump 136 Flow meter
42 DHW temperature sensor 138 External probe (field sourced)
44 Gas valve 278 Double sensor (Safety + Heating)
47 Modulation Regulator 297 Air pressure transducer
72 Room thermostat (field sourced) 370 LWCO - field sourced (field sourced)
81 Ignition/detection electrode
95 Diverter valve

38
39
 REPAIR PARTS LIST

KEY Part Number Description Qty

A01 FE3980B990 CASING "CTR" 1

40
 REPAIR PARTS LIST

KEY Part Number Description Qty

B01 FE3980C200 KIT CONTROL BOX 1
B02 FE3980B850 KIT CONTROL BOARD DBM34 2
B03 FE3980C210 KIT FRONT COVER "CTR" 1
B04 FE3980B840 KIT PRESS.TEMP. GAUGE 1
B05 FE3980C330 KIT WIRING 1
B06 FE3980C220 KIT MONO CABLE EL. 1

41
REPAIR PARTS LIST

42
 REPAIR PARTS LIST

KEY Part Number Description Qty

C01 FE3980C000 KIT GASKETS SET 10

C02 FE3980C010 KIT 20 GASKET ORING 1

C03 FE3980C020 KIT 10 CLIP 10

C04 FE3980C030 MONO HEAT EXCHANGER 2

C05 FE3980C040 SENOR TEMP DP 1

C06 FE3980C340 SENFOR TEMP 14 1

C07 FE3980C350 5 FLOW CONTROLLER 1

C08 FE3980C360 KIT FLOWMETER ELTEK 1

C09 FE3980C370 x5 H2O FILTERS 5

C10 FE3980C410 KIT NPT ADAPTERS 1

C11 FEF3980B890 KIT PUMP FX3-FP 1

C12 FE3980C380 3-WAY VALVE 1

C13 FE3980C060 MOTOR 3-WAY VALVE 1

C14 FE3980B900 AIR SEPARATOR 1

C15 FE3980C070 WATER PRESSURE SWITCH 1

C16 FE3980B910 3/4" SAFETY VALVE 1

C17 FE3980C400 DHW R. PLATE CONNECTION 1

C18 FE3980C390 PLATE EXCHANGER 20P. 1

C19 FE3980C080 BYPASS VALVE x 10 N/R 1

P01 FE34226290 CH FLOW PIPE 1

P02 FE34202290 CH RETURN PIPE 1

P03 FE3841L390 DHW OUTLET PIPE 1

P04 FE3840V700 FLOW METER PIPE 1

P05 FE3841E380 BYPASS PIPE 1

43
REPAIR PARTS LIST

44
 REPAIR PARTS LIST

KEY Part Number Description Qty

D01 FE3980B930 KIT GASKETS SET 1

D02 FE3980C090 PRESSURE TEST POINT "VENTURI" 1

D03 FE3980C100 FAN GASKET 1

D04 FE3980B940 FAN 2

D05 FE3980C110 COMBUSTION CHAMBER INSULATION 1

D06 FE3980C120 IGNITION ELECTRODE 1

D07 FE3980C130 BURNER 17 R.m. 1

D08 FE3980B960 GAS VALVE VGU 54S 2

D09 FE3980C140 17 INJECTOR 1.35mm NG 17

D10 FE3980C150 17 INJECTOR 0.85mm LP 17

D11 FE3980C160 KIT FLUE GASES OUTLET BEND 1

D12 FE3980C170 PRESSURE TRANSDUCER 1

D13 FE3980C180 CASING PLUGS KIT 1

D14 FE3980C190 COUPLING CONDENSATION 1

D15 FE3980B970 WALL MOUNT BRACKET 1

D16 FE3980B980 KIT VENT. ADAPTERS FM 1

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

P06 FE3841L410 GAS PIPE 1

45
NOTES

46
NOTES

47
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