UTICA BOILERS MAH-125 Installation, Operation And Maintenance Manual
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UTICA BOILERS MAH-125 Installation, Operation And Maintenance Manual

Condensing wall mounted gas fired boiler
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MAH-125
MAC-150
MAH-165
MAC-205
CONDENSING
WALL MOUNTED
GAS FIRED BOILER
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com

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Summary of Contents for UTICA BOILERS MAH-125

  • Page 1 MAH-125 MAC-150 MAH-165 MAC-205 CONDENSING WALL MOUNTED GAS FIRED BOILER Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com...
  • Page 2 MAC-205...
  • Page 3 CONTENTS : INSTALLATION, OPERATION, AND MAINTENANCE MANUAL (240011941) APPLICATION GUIDE (240011430) COMMISSIONING GUIDE (240011376) REQUIRED INSPECTION SPECIAL (240011561) BACK COVER...
  • Page 4 MAH-165...
  • Page 5 CONDENSING WALL MOUNTED GAS FIRED INSTALLATION, OPERATION & MAINTENANCE MANUAL Models MAH-125, MAC-150 MAH-165, MAC-205 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com P/N 240011941 REV B, [03/31/2018]...
  • Page 6 VERIFY CONTENTS RECEIVED Metal Wall Bracket Temperature Pressure Fully Assembled Boiler w/ 4 ea Wall Screws 30 PSI Safety Relief Valve Gauge and Plugs Includes Essential Documents and Warranty 4 ea - 17x24x2 Gaskets 11x17 Wire Diagrams *5 GPM Flow Restrictor 205 Used for Valve Drain Valve Document Package...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS 1 - Important Information ........6 9.9 Commission Set Up (Gas) ......43 9.10 Chimney Sweep Function (CO2 Adjust) ..2 - Introduction ............ 7 9.11 Combustion Adjustment Function ....44 3 - Component Listing .......... 8 9.12 Check Firing Rate........44 4 - Locating Boiler ..........
  • Page 8 PHYSICAL DATA Dimensions DIMENSIONS 125 & 150 205 & 165 Height 30" [763 mm] 30 " [763 mm] Width 17 3/4 " [450 mm] 17 3/4 " [450 mm] Depth 13 9/16" [345 mm] 21 1/2" [571 mm] Condensate Trap Connection 13/16"...
  • Page 9 PHYSICAL DATA 125 HEAT Front View 165 HEAT ONLY All Models ONLY Bottom View Bottom View Dimensions Dimensions 7" 5" 31/2" 101/2" 31/2" 6" 4" 6" 9" 5" 81/2" Top View 91/2" All Models Combustion Vent Connector 205 COMBI 150 COMBI Bottom View Bottom View Dimensions...

  • Page 10: Important Information

    1 - IMPORTANT INFORMATION 1. Safety Information WARNING Do not tamper with or use this boiler for any purpose Boiler installation shall be completed by qualified agency. See other than its intended use. Failure to follow these glossary for additional information. instructions could result in death or serious injury.

  • Page 11: Introduction

    2.1 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: • MAH-125 and MAH-165 central heating only. UNITED STATES • Indoor installation. • National Fuel Gas Code, ANSI Z223.1/NFPA 54 •...

  • Page 12: Component Listing

    3 - COMPONENT LISTING UTICA BOILER MAH-125 Utica Boiler ITEM MAH-125 Pump with Air Separator Boiler Drain Tap Boiler Filling Tap Gas Valve Low Water Pressure Cutoff 3-Way Valve with Motor Water Safety Thermostat NTC Heating sensor (Flow/Return) QTY 2, (1 Shown for clarity)
  • Page 13 3 - COMPONENT LISTING UTICA BOILER MAH-165 Utica Boiler ITEM MAH-165 Pump Boiler Drain Tap Low Water Pressure Cutoff Gas Valve NTC Heating sensor (Flow/Return) QTY 2, (1 Shown for clarity) Water Safety Thermostat Flue Sensor Coaxial Connector Heat Exchanger Termperature Sensor Heat Exchanger Burner Door Termperature...
  • Page 14 3 - COMPONENT LISTING UTICA BOILER MAC-150 Utica Boiler ITEM MAC- 150 Pump with Air Separator Boiler Drain Tap Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor Boiler Filling Tap Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor Check Valve DHW Heat Exchanger...
  • Page 15 3 - COMPONENT LISTING UTICA BOILER MAC-205 Utica Boiler ITEM MAC-205 Pump Flow Sensor DHW Priority Sensor DHW Heat Exchanger Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor NTC Heating sensor (Flow/Return) QTY 2, (1 Shown for clarity) Water Safety Thermostat Flue Sensor Coaxial Connector...

  • Page 16: Locating Boiler

    4 - LOCATING BOILER WARNING TABLE 1: BOILER CLEARANCES Fire Hazard! Do not install on carpeting. Failure to Manufacturer Combustible follow these instructions could result in death or Dimension Recommended Materials serious injury. for Service (1)(2) 0" (0 cm) 8-5/8" (220 mm) 4.1 Boiler Location Considerations Left Side 1-3/4"...
  • Page 17 4 - LOCATING BOILER 4.2 Service and Combustible Clearances 125 & 150 165 & 205 13 9/16 in 211/2 in [345 mm] [571.5 mm] Front View of Left Side View Boiler of Boiler 8 5/8 in [220 mm] 17 3/4 in 1 3/4 in 1 3/4 in 13.58 in /...
  • Page 18 4 - LOCATING BOILER FIGURE 4-2 Wall Mount Bracket (Included) CAUTION Boiler weight exceeds 140 pounds (63.5 kg). Do not lift boiler onto wall without assistance. Center brackets. Avoid overhang on sides of wall mount bracket. Note Lift boiler using chassis. Do not use front jacket, vent piping, water or gas fittings to lift boiler as it may cause damage to the boiler.

  • Page 19: Hydronic Piping

    5 - HYDRONIC PIPING Boiler rated at 50 psig (345 kPa) maximum WARNING Note allowable working pressure. Boiler provided with Boiler and its individual shutoff valve shall be 30 psig (206 kPa) safety relief valve. disconnected from gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.40 kPa - 34.47 mbar).

  • Page 20: Special Conditions

    5 - HYDRONIC PIPING FIGURE 5-2 Safety Relief Valve Discharge Piping 5.2 Special Conditions Do not expose boiler and condensate piping to Note freezing temperatures. Safety Relief Valve • System piping exposed to freezing conditions: Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system.

  • Page 21: Trim Piping

    5 - HYDRONIC PIPING 5.4 Trim Piping • Ensure washers supplied are utilized. • Face valves and fittings to rear wall. • Temperature - Pressure Gauge. Install temperature pressure gauge using piping provided with boiler. See • Fit union bends to valves. Figure 5-1.

  • Page 22: Low Water Cut Off

    5 - HYDRONIC PIPING FIGURE 5-3 - Piping Diagram - LWCO Location Arrange piping to prevent Note water dripping onto boiler. Low Water Cutoff (LWCO) (See Figure 5-5 for detail) Illustrations are meant to Note Air Vent show system piping concept only.
  • Page 23 5 - HYDRONIC PIPING 5.6 External Optional Low Water Cut Off FIGURE 5-5 - Low Water Cutoff - Detail These guidelines are supplied when necessary to install an additional Low Water Cut Off (LWCO), for sensing a low water level condition in a boiler, as required by the Authority Having Jurisdiction.
  • Page 24 5 - HYDRONIC PIPING 5.7 Manufacturer Recommendation - Strainer Potable water Potable water Manufacturer Recommendation A strainer filtering potable water before entering the boiler is highly recommended to prevent errors and lockouts. The stainer prevents any sedimentation and debris from your water supply piping from entering the boiler.

  • Page 25: Central Heating System

    5.9 Domestic Hot Water Mode • When the domestic hot water demand ceases the burner will extinguish, unless there is a demand for central Utica Boiler MAC-150 & 205 and MAH-125 & 165 with indirect tank heating. WARNING 5.10 Frost Protection Mode...

  • Page 26: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING • Assemble vent materials in accordance with venting WARNING manufacturer’s instructions. Fire, explosion, and asphyxiation hazard. Improper • Slope exhaust pipe minimum of 1/4” per foot, or vent installation could result in death or serious manufacturer’s recommendation, whichever is greater;...

  • Page 27: Definitions

    6 - COMBUSTION AIR AND VENT PIPING 6.4 Securing Twin Pipe Polypropylene Venting 6.3 Definitions Coaxial piping – Figure 6-1 exhaust and air intake pipe Venting manufacturer's use a device to secure Note have a common axis. single wall twin pipe polypropylene vent pieces to each other.

  • Page 28: Approved Venting Materials

    6 - COMBUSTION AIR AND VENT PIPING Boiler shall not support any type of vent system. 6.5 Approved Venting Materials All piping, glue, solvents, cleaners, fittings and components must conform to ASTM and ANSI standards. WARNING In Canada ULC S636 and in the USA UL 1738 schedule 40 Manufacturer recommends this condensing boiler be CPVC are the only approved vent system to be used as an vented with approved polypropylene venting material.

  • Page 29: Coaxial Venting Instructions

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 - Coaxial Venting Horizontal or Vertical 6.7 Coaxial Venting Instructions Maximum equivalent flue lengths for Coaxial venting are: Coaxial Pipe Maximum Vent Lengths Boiler Size 125/150 165/205 4"/2" 5"/3" Vent Size [100mm/60mm] [128mm/80mm] Natalini...

  • Page 30: Twin Pipe Systems

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-7 - Twin Pipe Separated Horizontal Flue 6.8 Twin Pipe Systems Termination Twin pipe venting allows exhaust flue and intake flue to be separated from each other. Fresh air is drawn in at a different area from the flue terminal location.
  • Page 31 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-11-Twin Pipe Roof Vent Exhaust and combustion air intake are located in same general location and are of equal length. 12" (305mm) Min. 15" (381mm) Max. Twin Pipe Maximum Vent Lengths Roof Line Terminating in same location 125/150 165/205...
  • Page 32 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-14 -Twin Pipe Side Wall Vent FIGURE 6-15 -Twin Pipe Side Wall with 45° Vent 12"(305mm)Min. 3" (76mm) Min. From Overhang 24" (610mm) Max. Separation 12" (305mm) Min. Vent Opening 24" (610mm) Max. 45°...

  • Page 33: Flexible Vent System

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-17 - Flexible Venting System 6.9 Flexible Vent System Flexible Pipe Maximum Vent Lengths 3” [80 mm] Diameter Pipe 125/150 165/205 Vent Terminal Exhaust 75 ft [22.8m] 50 ft [15.2m] Natalini Intake 50 ft [15.2m] 50 ft [15.2m] Exhaust...
  • Page 34 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-16 - Flue Terminal Location All vent pipe and combustion air pipe and fittings shall comply with the following: Materials used in the U.S. must comply with the following standards: ANSI/ASTM D1785, ANSI/ASTMD2661, ANSI/ ASTM F441. INSIDE CORNER DETAIL Operable...

  • Page 35: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-17 Condensate Drain 6.10 Condensate Piping • Use materials acceptable to authority having jurisdiction. In absence of such authority: • USA - PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493. •...

  • Page 36: Gas Supply Piping

    • Locate leakage using gas detector, noncorrosive supply pressure. detection fluid, or other leak detection method MAH-125 requires a gas rate of 137.60 ft /h (3.90 m acceptable to authority having jurisdiction. Do for Gas A (Natural Gas) and 101.30 ft /h (2.87 m...

  • Page 37: Electrical Connections

    8 - ELECTRICAL CONNECTIONS DANGER Model Size Power Supply 120V - 60Hz Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz). 133 W 142 W 173 W 182 W Power Consumption Before making connections, verify appliance is Internal Fuse (Qty.

  • Page 38: Access To Connection Block

    Place jumper back on terminals 1-2 of boiler terminal block M1 if room thermostat is not used or if Remote Control is Terminals 9 - 10: Indirect storage tank sensor connection for Utica Boiler MAH-125 & 165 model. not installed. 240011941 REV B, [03/31/2018]...

  • Page 39: Install Room Thermostat

    8 - ELECTRICAL CONNECTIONS FIGURE 8-4 Thermostat Connections 8.6 Install Room Thermostat Install room thermostat on inside wall. Do not install where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, sun rays or near a fireplace. Dry contact only - do not apply 24 volts between 6 and 7.

  • Page 40: Optional Electrical Connections

    8 - ELECTRICAL CONNECTIONS FIGURE 8-5 Outdoor Sensor Connections 8.7 Optional Electrical Connections A. Outdoor Temperature Sensor To connect this accessory, see figure 8-5, terminals 4-5, and instructions supplied with sensor. B. Setting "Kt" Climate Curve When external sensor is connected to boiler, the electronic board adjusts the flow temperature calculated according to set Kt coefficient.

  • Page 41: Indirect Storage Tank

    8 - ELECTRICAL CONNECTIONS 8.8 Indirect Storage Tank Boilers MAH-125 & MAH-165 can be electrically connected to indirect storage tank as follows: • Connect DHW priority sensor NTC to terminals 9-10 on terminal block M2. • Insert NTC sensor element in the sensor well of indirect storage tank.

  • Page 42: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Central Heating System Connections - Heat Only MAH-125 HEATING ONLY MAH-165 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION MAH-125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4"...

  • Page 43: Central Heating System Combi

    9 - START UP PROCEDURE 9.2 Central Heating System Connections - Combi MAC-150 COMBI MAC-205 COMBI LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4" [22.2mm] 1" [25.4mm] Cold DHW inlet tap / system filling 1/2"...

  • Page 44: System Start Up

    9 - START UP PROCEDURE 9.3 System Start Up FIGURE 9-1 Condensate Drain Assembly Follow all codes and regulations when filling the boiler. Model 205 shown (location similar in all sizes) Use drain taps to allow system to completely drain. Thoroughly flush the heating system before boiler is connected and again after first heating.

  • Page 45: Control Panel

    9 - START UP PROCEDURE 9.5 Control Panel Press and hold for 1 second, to display information as shown in the table below. Press to exit. DESCRIPTION DESCRIPTION Secondary fault internal code Setpoint Central Heating (°F/°C) 10/11 Heating flow temperature (°F/°C) Manufacturing information Outdoor temperature (°F/°C) Flue sensor temperature (°F/°C)

  • Page 46: Commissioning

    9 - START UP PROCEDURE 9.7 Calibration Function: NOTICE Boiler must be in stand by mode (no requests) before initiating the function. All connections shall be made and water added before performing this function. The function consists of an automatic sequence and a manual sequence.

  • Page 47: De-Aeration Function

    9 - START UP PROCEDURE FIGURE 9-3 - Gas Inlet Tap - Pi D. Combustion of this appliance has been factory controlled, calibrated and set for operation with Gas A (Natural Gas). E. During Gas Type Control Function, combustion ratio will increase for a short period of time while gas type is being established.

  • Page 48: Chimney Sweep Function (Co2 Adjust)

    ) in the combustion flue must be within tolerances indicated in table below. COMBUSTION TABLE Gas A Gas A Gas A Gas A (Natural Gas) (Natural Gas) (Natural Gas) (Natural Gas) Gas E (LPG) MAH-125 MAC-150 MAH-165 MAC-205 CO2 % O2 % CO2 % O2 % CO2 % O2 % CO2 %...

  • Page 49: Parameter Settings

    9 - START UP PROCEDURE For Natural Gas : Table 9-2 Input Rate @ High Fire (MBH) 3600 x cu ft Input (MBH) seconds Approximate Rate @ Example: Natural Gas - Gas flow from 100% Fire (MBH) Meter = 2 cu ft Size Measured time = 72 seconds 3600 x 2 cu ft...
  • Page 50 9 - START UP PROCEDURE FACTORY SETTINGS 9.14 Description Of Parameters: Factory Settings conti. 125-165 150-205 Outdoor temperature sensor input configuration 00= with outdoor temperature sensor connected, external temperature value has influence to calculate heating flow temperature setpoint 01= with outdoor temperature sensor connected, display shows external temperature value (no influence) 02…05 = no function is associated 00..02 = No function is associated 03 = This is an input contact for CH request (e.g.

  • Page 51: Adjusting Maximum Heating Power

    Table showing parameter P13 values according to desired maximum power model is shown for each single boiler. To access and edit P13 values, proceed as described in Parameter Settings. Boiler Model - PARAMETER P13 (%)/ Heating Output Btu/h MAH-125 MAC-150 Btu/h MAH-165 MAC-205 20,400 27,400 23,800...

  • Page 52: Operating Instructions

    10 - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WARNING WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. If you do not follow these instructions exactly, a fire or explosion may result causing property •...

  • Page 53: Boiler Controls

    10 - OPERATING INSTRUCTIONS 10.3 Boiler Controls To light boiler correctly, proceed as follows: • Check system pressure is correct; • Power boiler; • Open gas tap (positioned under boiler); • Select required heating mode. See section 10.4 Operating Modes. BUTTON Key DHW temperature adjustment (+ to increase the temperature and –...

  • Page 54: Boiler Operation

    10 - OPERATING INSTRUCTIONS 10.4 Boiler Operation 10.7 Frost Protection Domestic hot water supply always takes priority over central Boiler has a built in frost thermostat which automatically turns heating. boiler and pump on. Demand for hot water required during central heating period, If water in boiler falls below 41°F (5°C), providing the display boiler automatically switches to hot water mode until demand is switched on, boiler will operate until water temperature in...

  • Page 55: General Maintenance And Cleaning

    11 - GENERAL MAINTENANCE AND CLEANING • Circulator pump and combustion air blower motor furnished DANGER with boiler are permanently lubricated from factory and require no further lubrication. Lubricate field sourced Before servicing, turn off electrical power to boiler at pumps and/or motors according to pump and/or motor service switch.

  • Page 56: Maintenance And Routine Servicing

    11 - GENERAL MAINTENANCE AND CLEANING WARNING NOTICE Following service procedures must be performed by Perform regular service and maintenance by qualified qualified service agent. Boiler owner shall not attempt service agency at least once every 12 months to assure these steps.

  • Page 57: Draining The Boiler

    11 - GENERAL MAINTENANCE AND CLEANING DANGER Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury. 11.4 Draining the Boiler •...

  • Page 58: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model MAC-150 For special areas, where water is harder than 200 ppm or 12 grains/ gallon, install polyphosphate dispenser or equivalent treatment system, compliant with current regulations. 11.7 Cleaning The Cold Water Filter Boiler is fitted with cold water filter located on DHW hydraulic assembly (B).

  • Page 59: User Information

    11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information 11.14 Automatic Calibration Function Advise and demonstrated to User the following important Before performing this function verify there are no heat information: demands in progress. A. How to light and turn off boiler. How to operate During this function ensure there is maximum heat exchange to the system in Heating or DHW mode (DHW request) to system controls.

  • Page 60: Ratings And Capacities

    Net AHRI (1)(3) Model Heating (1)(2) CH AFUE% Number Capacity, MBH * Maximum Minimum Rating Water, MBH MAH-125 95.0 MAC-150 95.0 MAH-165 29.5 95.0 MAC-205 29.5 95.0 (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.

  • Page 61: High Altitude Parameter

    95.0 20.3 **MAC-150 Max DHW Flow rate 3.5 GPM (13.2 l/min) Max CH Supply temp 176° F (80° C) for MAH-125 and MAC-150 Max DHW temp 140° F (60° C) MAC-205 Max DHW flow rate 5.0 GPM (18.9L/min) 240011941 REV B, [03/31/2018]...

  • Page 62: Trouble Shooting

    13 - TROUBLE SHOOTING 13.1 Error Messages And Resetting The Boiler Error Description Operation Gas valve connection fault Check cable PCB/gas valve and gas valve plug Outdoor sensor fault Check sensor and cable Verify all cables. Replace PCB. Gas valve command fault Call authorized SERVICE center Central Heating NTC sensor fault Check sensor and cable...

  • Page 63: Glossary

    14 - GLOSSARY • APPLIANCE - Device to convert gas into energy; term • DIRECT VENT BOILER - Boiler constructed and installed so includes any component, control, wiring, piping or tubing all combustion air is derived directly from outdoors and all required to be part of the device.
  • Page 64 14 - GLOSSARY • METRIC GAS METERS • TWO PIPE SYSTEM - Type of venting that allows for exhaust flue and intake air piping to be separated from each Natural Gas other. Fresh air may be drawn in at a different area from 127,116 x cu meters where flue terminal is located.

  • Page 65: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-1 MODELS 125 - Heat Only 240011941 REV B, [03/31/2018]...
  • Page 66 APPENDIX A - WIRING DIAGRAMS A-2 MODELS 165 - Heat Only 240011941 REV B, [03/31/2018]...
  • Page 67 APPENDIX A - WIRING DIAGRAMS A-3 MODELS 150 - Combi 240011941 REV B, [03/31/2018]...
  • Page 68 APPENDIX A - WIRING DIAGRAMS A-4 MODELS 205 - Combi 240011941 REV B, [03/31/2018]...
  • Page 69 NOTES 240011941 REV B, [03/31/2018]...
  • Page 70 NOTES 240011941 REV B, [03/31/2018]...
  • Page 71 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________  Installation instructions have been followed  Checkout procedure and adjustments performed  Maintenance and Service issues reviewed with owner/ maintenance person  Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone...
  • Page 72 IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
  • Page 73 APPLICATION GUIDE FOR USE WITH HEATING ONLY - 125, 165 & COMBI - 150, 205 This manual has been prepared for use with the appropriate Installation, Operation and Maintenance Manual. Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel.
  • Page 74 TABLE OF CONTENTS Important Safety Information ....................3 Labor Saving Piping Manifolds / Near Boiler Piping Connections ..........4 General Information - Hydronic Piping ..................6 General Information - Wiring......................7 Piping and Wirimg Diagrams Piping Legend........................8 Zone Circulator Pumps - Piping Diagram ..............9 W/ Indirect Zone Pumps, DHW Tank, Tank Sensor - Wiring Diagram ......

  • Page 75: Important Safety Information

    IMPORTANT SAFETY INFORMATION 1. General 3. Installation shall conform to requirements of Boiler installation shall be completed by qualified agency. authority having jurisdiction or in absence of such See Installation, Operation & Maintenance Manual for requirements: additional information. • United States •...

  • Page 76: Labor Saving Piping Manifolds / Near Boiler Piping Connections

    LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 125 HEATING ONLY 165 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4"...
  • Page 77 LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 150 COMBI 205 COMBI LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4" [22.2mm] 1” [25.4mm] Cold DHW inlet tap / system filling 1/2" 3/4" connection for Combi [15.9mm] [22.2mm] MANIFOLD...

  • Page 78: General Information - Hydronic Piping

    GENERAL INFORMATION - HYDRONIC PIPING WARNING Provided Wiring and Piping illustrations Note are meant to show system concepts only. Burn and scald hazard! Manufacturer requires Installer is responsible for all equipment installation of field supplied anti-scald valve. required by authority having jurisdiction. Failure to follow these instructions could result in death or serious injury.

  • Page 79: General Information - Wiring

    GENERAL INFORMATION - WIRING Electical Wiring Information: DO NOT use 120 V thermostat Note All field wiring shall conform to the authority having terminals (m1- #1 and #2). jurisdiction or, in the absence of such requirements to: • USA: National Electrical Code, ANSI/NFPA 70, •...

  • Page 80: Piping Legend

    PIPING LEGEND PIPING LEGEND ZONE VALVE BALL VALVE AIR SEPERATOR INDIRECT DHW TANK CIRCULATOR DRAIN COMBINATION FILL INDIRECT TANK AQUASTAT INDIRECT DHW TANK SENSOR FLOW CHECK VALVE TEMPERATURE & PRESSURE GAUGE BYPASS VALVE EXPANSION TANK DIVERTER VALVE FLAT PLATE HEAT EXCHANGER (COMBI ONLY) T&P OR RELIEF VALVE STRAINER...
  • Page 81 125 WITH ZONE CIRCULATOR PUMPS PN 240011430 REV G, [03/31/18]...

  • Page 82: Indirect Zone Pumps, Dhw Tank, Tank Sensor - Wiring Diagram

    125 W/ INDIRECT ZONE PUMPS & DHW TANK W/ TANK SENSOR - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 83: Indirect Zone Pumps & Dhw Tank, Tank T-Stat - Wiring Diagram

    125 W/ INDIRECT ZONE PUMPS & DHW TANK W/TANK T-STAT - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 84: With Zone Valves - Piping Diagram

    125 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 85: With Zone Valves, Dhw Tank, Tank Sensor - Wiring Diagram

    125 WITH ZONE VALVES, DHW TANK & TANK SENSOR - - WIRING DIAGRAM 125 with Zone Valves PN 240011430 REV G, [03/31/18]...

  • Page 86: Indirect Zone Valves, Dhw Tank W/ Tank T-Stat - Wiring Diagram

    165 INDIRECT ZONE VALVES, DHW TANK W/ TANK T-STAT - WIRING DIAGRAM 125 with Zone Valves PN 240011430 REV G, [03/31/18]...

  • Page 87: With Zone Circulator Pumps - Piping Diagram

    165 WITH ZONE CIRCULATOR PUMPS - PIPING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 88: Indirect Zone Pumps, Dhw Tank, Tank Sensor - Wiring Diagram

    165 INDIRECT ZONE PUMPS, DHW TANK, TANK SENSOR - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 89: Indirect Zone Pumps, Dhw Tank, Tank T-Stat - Wiring Diagram

    165 INDIRECT ZONE PUMPS, DHW TANK, TANK T-STAT - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 90: With Zone Valves - Piping Diagram

    165 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 91: Indirect Zone Valve, Dhw Tank, Tank Sensor - Wiring Diagram

    165 INDIRECT ZONE VALVE, DHW TANK, TANK SENSOR - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 92: Indirect Zone Valves, Dhw Tank, Tank T-Stat -Wiring Diagram

    165 INDIRECT ZONE VALVES, DHW TANK, TANK T-STAT -WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 93: 205 With Zone Circulator Pumps - Piping Diagram

    150 & 205 WITH ZONE CIRCULATOR PUMPS - PIPING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 94: 205 With Zone Pumps - Wiring Diagram

    150 & 205 WITH ZONE PUMPS - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 95: 205 With Zone Valves - Piping Diagram

    150 & 205 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 96: 205 With Zone Valves - Wiring Diagram

    150 & 205 WITH ZONE VALVES - WIRING DIAGRAM PN 240011430 REV G, [03/31/18]...

  • Page 97: Low Mass - Piping Diagram

    LOW MASS - PIPING DIAGRAM Low Mass Piping When installing low mass systems, additional water mass may be required to avoid short cycling by the boiler. In these applications it is recommended that a buffer tank be installed. Buffer Tank on Central Heat Circuit Note: •...

  • Page 98: Low Mass - Wiring Diagram

    LOW MASS - WIRING DIAGRAM Low Mass Boiler Wiring with Buffer Tank Connect the buffer tank aquastat to terminals 6 and 7 on terminal block M2. System wiring remains as shown in the previous wiring diagrams. H20 BUFFER TANK H2O Stainless Steel Buffer Tank PN 240011430 REV G, [03/31/18]...
  • Page 99 OPTIONAL EQUIPMENT Optional Equipment Outdoor Air Sensor, if used. A. Boiler automatically recognizes sensor when used. B. See Chart 1 for sensor data. Sensor part number BD710487302V C. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor. D.

  • Page 100: Outdoor Temperature Sensor

    ACCESSORIES Accessories: • Use lower value of range as the desired Kt value. 1. Outdoor Temperature Sensor Kit - BD710487302V (example): to deliver 186°F water @ OT of -20°F = Kt range is 90 thru 25. Select 25. Use Outdoor Sensor Kit with Heating Only or Combi Boilers. •...
  • Page 101 ACCESSORIES 2. Indirect Storage Tank Sensor Kit Parameter PO3 for Heating Only boiler, with Note Heating Only boiler can be electrically connected to no indirect tank remains Factory Set at 08. No Indirect Storage Tank. change is required. Diagram of hydraulic connection of external indirect If adding an Indirect Tank with a sensor storage tank is shown below.

  • Page 102: Heat Only Wiring Diagram

    125 - HEAT ONLY WIRING DIAGRAM MODEL 125 - Heat Only PN 240011430 REV G, [03/31/18]...
  • Page 103 165 - HEAT ONLY WIRING DIAGRAM MODEL 165 - Heat Only PN 240011430 REV G, [03/31/18]...

  • Page 104: Combi Wiring Diagram

    150 - COMBI WIRING DIAGRAM MODEL 150 - Combi PN 240011430 REV G, [03/31/18]...
  • Page 105 205 - COMBI WIRING DIAGRAM MODEL 205 - Combi PN 240011430 REV G, [03/31/18]...

  • Page 106: Altitude Effects On Boiler Performance

    ALTITUDE EFFECTS ON BOILER PERFORMANCE MODELS 125/150 CALCULATED EFFECTS OF HI-ALTITUDE ON BOILER PERFORMANCE 160,000 140,000 120,000 DHW MODE 100,000 HEAT MODE 80,000 60,000 NET RATNG HEAT MODE 40,000 2,000 4,000 6,000 8,000 10,000 ALTITUDE (FEET) MODELS 165/205 CALCULATED EFFECTS OF HI-ALTITUDE ON BOILER PERFORMANCE 220,000 200,000...

  • Page 107: Application Table - Indirect Tank Sizing

    APPLICATION TABLE - INDIRECT TANK SIZING 'HEATING ONLY' BOILER (125,000 BTUH) BOILER OUTPUT (BTUH/HR) 50,000 60,000 80,000 100,000 H2O30 1st HOUR RATING 140 F (GAL/HR) 115 F CONTINUOUS 140 F RATING (GAL/HR) 115 F H2O40 / H2O40L 1st HOUR RATING 140 F (GAL/HR) 115 F...
  • Page 108 A - LOW WATER CUTOFF • Locate LWCO sensing device in the supply Low Water Cut Off - Heating Only and Combi Boilers piping, above the minimum height of boiler. These guidelines are supplied when necessary to install See Figure A-2, Piping Diagram. an additional Low Water Cut Off (LWCO), for sensing a low water level condition in a boiler, as required by the •...

  • Page 109: Low Water Cutoff

    LOW WATER CUTOFF Piping Diagram - LWCO Location Arrange piping to prevent water Note dripping onto boiler. Low Water Cutoff (LWCO) (See Figure 3 for detail) Illustrations are meant to show Note Air Vent system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction.
  • Page 110 LOW WATER CUTOFF Low Water Cutoff - Detail PN 240011430 REV G, [03/31/18]...
  • Page 111 NOTES PN 240011430 REV G, [03/31/18]...
  • Page 113 IMPORTANT INFORMATION READ THIS LEAFLET BEFORE COMMISSIONING THE BOILER IMPORTANT: Upon startup of this new boiler please call ECR International, Inc. Technical Support for installation assistance and registration. Technical Support and Product Registration Monday - Friday 8AM to 6PM Eastern time. 1.800.253.7900 Described below is the procedure to activate the De-Aeration Function/Gas Type Check when power is first supplied to the boiler and the actions required when on a Gas E (LPG) supply.
  • Page 114 INFORMATIONS IMPORTANTES LIRE CET IMPRIMÉ AVANT DE METTRE LA CHAUDIÈRE EN MARCHE IMPORTANT : Lors du démarrage de cette nouvelle chaudière veuillez appeler recueil International, Inc. de support technique pour l'assistance à l'installation et l'enregistrement. Support technique et enregistrement du produit lundi - vendredi 8h00 à...
  • Page 116 Required Inspection Schedule To Be Completed By Qualified Service Technician Date Completed Inspection Items Year Year Year Year Check boiler and system piping for any sign of Near boiler piping leakage, verify pipes are properly supported. Check condition of all vent pipes and joints. Verify Vent vent piping terminations are free of obstructions Piping...

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