UTICA BOILERS MAH-100 Manual
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UTICA BOILERS MAH-100 Manual

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MAH-100
MAC-115
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. 800 325 5479
www.ecrinternational.com

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Summary of Contents for UTICA BOILERS MAH-100

  • Page 1 MAH-100 MAC-115 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. 800 325 5479 www.ecrinternational.com...
  • Page 2 MAC-205...
  • Page 3 CONTENTS : INSTALLATION, OPERATION, AND MAINTENANCE MANUAL (240013354) 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: COMBI MAC-115 MAC-150 MAC-205 HEATING ONLY MAH-100 MAH-125 MAH-165 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com PN 24013354 REV B [09/15/2021]...
  • 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 Verify Contents Received ..........2 9 - Start Up Procedure ..........47 9.1 Central Heating System Connections - Heat Only .. Table Of Contents ............3 9.2 Central Heating System Connections - Combi ..Physical Data..............4 9.3 System Start Up ...........49 1 - Important Information ..........6 9.4 Fill Condensate Trap With Water ......49 9.5 Control Panel ............50...

  • Page 8: Physical Data

    PHYSICAL DATA Dimensions DIMENSIONS 100 / 125 115 / 150 165 / 205 Height 30" [763 mm] Width 17 3/4 " [450 mm] Depth 13 9/16" [345 mm] 21 1/2" [571 mm] 13/16" [21 mm] 3/4" [19.1 mm] Condensate Trap Connection ID Hose DIMENSIONS System Supply...
  • Page 9 PHYSICAL DATA 100 HEAT 125 HEAT 165 HEAT ONLY ONLY ONLY Bottom View Bottom View Bottom View Dimensions Dimensions Dimensions 5" 7" 7" 5" 101/2" 31/2" 31/2" 31/2" 31/2" 9" 9" 6" 6" 4" 5" 81/2" 150 COMBI 115 COMBI 91/2"...

  • Page 10: Important Information

    1 - IMPORTANT INFORMATION 1. Safety Information FOR YOUR SAFETY READ BEFORE OPERATING Boiler installation shall be completed by qualified agency. See DANGER glossary for additional information. WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury.

  • Page 11: Introduction

    • Exceed 176°F (80°C) system design temperature. Additional manual reset low water cutoff may be required. 2.7 Operational Features 2.3 Requirements for Commonwealth of • MAH-100 Modulates input to provide CH Turndown Massachusetts: 5.6:1 Boiler installation must conform to Commonwealth of •...

  • Page 12: Component Listing

    3 - COMPONENT LISTING UTICA BOILER MAH-100 Exhaust Port Intake Port Utica Boiler ITEM MAH-100 Pump with Air Separator Boiler Drain 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-125 Exhaust Port Intake Port Utica Boiler ITEM MAH-125 Pump with Air Separator Boiler Drain 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) Flue Sensor Pressure Switch Coaxial Flue Connector...
  • Page 14 3 - COMPONENT LISTING UTICA BOILER MAH-165 Exhaust Port Intake Port 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 Temperature Protector...
  • Page 15 3 - COMPONENT LISTING UTICA BOILER MAC-115 Exhaust Port Intake Port Utica Boiler ITEM MAC 115 Pump with Air Separator Boiler Drain Tap Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor Controlled Fast Fill Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor Check Valve...
  • Page 16 3 - COMPONENT LISTING UTICA BOILER MAC-150 Exhaust Port Intake Port Utica Boiler ITEM MAC- 150 Pump with Air Separator Boiler Drain Tap Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor Controlled Fast Fill Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor Check Valve...
  • Page 17 3 - COMPONENT LISTING UTICA BOILER MAC-205 Exhaust Port Intake Port Utica Boiler ITEM MAC-205 Pump Flow Sensor Flow Sensor with Water Filter and Flow Restrictor 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)

  • Page 18: 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 19: Clearances

    4 - LOCATING BOILER 4.2 Clearances Service Clearances 100, 115, 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 3/4 in in 1 3/4 3/4 in in 13.58 in /...

  • Page 20: Wall Mounting

    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. Lift boiler using chassis. Do not use front jacket, Note vent piping, water or gas fittings to lift boiler as it may cause damage to the boiler.

  • Page 21: Combustion Air And Vent Piping

    5 - COMBUSTION AIR AND VENT PIPING • Venting shall be supported adjacent to each joint using WARNING steel strapping or equivalent. See Figure 5-1. Fire, explosion, and asphyxiation hazard. Improper • Support horizontal sections of vent pipe to prevent sags installation could result in death or serious capable of accumulating condensate.

  • Page 22: Removal Of Existing Boiler From Common Vent System

    5 - COMBUSTION AIR AND VENT PIPING 5.2 Removal of Existing Boiler From Common Vent 5.3 Definitions System Coaxial piping – Exhaust and air intake pipe have a When existing boiler is removed from common venting common axis. system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.

  • Page 23: Approved Venting Materials

    5 - COMBUSTION AIR AND VENT PIPING Venting shall be properly supported. WARNING Boiler shall not support any type of vent system. Manufacturer recommends this condensing boiler be All piping, glue, solvents, cleaners, fittings and vented with approved polypropylene venting material. components must conform to ASTM and ANSI standards.
  • Page 24 5 - COMBUSTION AIR AND VENT PIPING VENT MATERIAL OPTIONS (Maximum Equivalent Vent Length Shown) 100/115/125/150 Intake Exhaust Combined Vent Vent Vent (L1) (L2) (L1+L2) Vent Size Type Material 85 ft 6 ft 85 ft 6 ft 170 ft 12 ft 2"...

  • Page 25: Coaxial Venting Instructions

    5 - COMBUSTION AIR AND VENT PIPING 5.6 Coaxial Venting Instructions WARNING Maximum equivalent flue lengths for Coaxial venting are: Asphyxiation hazard. Before securing the screws Coaxial Pipe Vent Lengths ensure the pipe has been pushed in a minimum of (Includes First Elbow And Termination) 1-3/4"...

  • Page 26: Coaxial Vent Screw Placement

    5 - COMBUSTION AIR AND VENT PIPING 5.7 Coaxial Vent Screw Placement - See Figure 5-2 Two (2) screws shall be fastened through the outer intake pipe behind the gaskets at equal distances, approximately 180° apart. Note the screws used must be no larger than No. 8-3/4 sheet metal screws and must be zinc coated.

  • Page 27: Twin Pipe Systems

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-8 - 2"/60 mm & 3"/80 mm Twin Pipe WARNING Separated Horizontal Flue Termination Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe This Termination Installation Instructions completely and understand all can be used on: requirements before beginning installation.

  • Page 28: Securing Twin Pipe Polypropylene Venting

    5 - COMBUSTION AIR AND VENT PIPING Figure 5-11 - Natalini Clamp WARNING Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe Installation Instructions completely and understand all requirements before beginning installation. 5.9 Securing Twin Pipe Polypropylene Venting Venting manufacturer's use a device to secure Note single wall twin pipe polypropylene vent pieces...
  • Page 29 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-14 - (2"/ 60 mm & 3" / 80 mm) Twin Pipe 12" (305 mm) Min. horizontal separation  Roof Vent CAN BE USED ON ALL SIZES between combustion air intake and vent of same appliance.
  • Page 30 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-17 -Twin Pipe Side Wall Vent (Multiple FIGURE 5-20 - (2"/ 60 mm ONLY) Vent Pipe with T Appliances) CAN BE USED ON ALL SIZES NOTE: 3" shown for clarity. 12" between vent and combustion air of other boilers This Termination required in all multiple boiler installations.

  • Page 31: 3" / 80 Mm Only) Flexible Vent System

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-24 - (3" / 80 mm Only) Flexible Venting 5.10 (3" / 80 mm Only) Flexible Vent System System CAN BE USED ON ALL SIZES Flexible Pipe Minimum & Maximum Vent Lengths 100/115/125/150 165/205 3”...
  • Page 32 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-25 - Flue Terminal Location All vent pipe and combustion air pipe and fittings shall comply with the following: Use only manufacturer approved venting materials or venting materials primer and glue approved to: ULC S636 in Canada, or UL 1738 in the U.S.

  • Page 33: Condensate Piping

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-26 - Condensate Drain WARNING Asphyxiation hazard! Fill condensate trap before starting boiler to avoid combustion products escaping boiler. Failure to follow these instructions could result in death or serious injury. Do not glue cap 5.11 Condensate Piping on if used for •...

  • Page 34: Hydronic Piping

    6 - HYDRONIC PIPING 6.1 General Boiler rated at 50 psig (345 kPa) maximum Note • Primary/Secondary piping required. allowable working pressure. Boiler provided with • Install piping in accordance with authority having 30 psig (206 kPa) safety relief valve. jurisdiction.

  • Page 35: Special Conditions

    6 - HYDRONIC PIPING FIGURE 6-2 Safety Relief Valve Discharge Piping WARNING Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. Safety Relief Valve 6.3 Safety Relief Valve and Air Vent •...

  • Page 36: Trim Piping

    6 - HYDRONIC PIPING 6.4 Trim Piping • Temperature - Pressure Gauge. Install temperature pressure gauge using piping provided with boiler. See Figure 6-1. • Some boiler models may have integral drain valve located inside jacket directly underneath pump. Install provided external drain valve as required.
  • Page 37 6 - HYDRONIC PIPING FIGURE 6-3 - Piping Diagram - LWCO Location Arrange piping to prevent Low Water Cutoff (LWCO) Note (See Figure 6-5 for detail) water dripping onto boiler. Illustrations are meant to Note show system piping concept Purge Valve only.

  • Page 38: External Optional Low Water Cut Off

    6 - HYDRONIC PIPING 6.6 External Optional Low Water Cut Off FIGURE 6-5 - 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 39: Manufacturer Recommendation - Strainer

    6 - HYDRONIC PIPING 6.7 Manufacturer Recommendation - Strainer on DHW Inlet Potable water Potable water Manufacturer Recommendation Manufacturer strongly recommends the use of a strainer filtering potable water before entering the boiler. The strainer prevents any sedimentation and debris from your water supply piping from entering the boiler.

  • Page 40: Central Heating System

    6 - HYDRONIC PIPING 6.8 Central Heating System • Flow of water, certain minimums are required, will operate the DHW flow switch which requests the 3 way valve to Boiler is designed for use in a sealed central heating system. change position.

  • Page 41: Gas Supply Piping

    • Do not touch any electrical switch; do not use any GAS SUPPLY REQUIRED: phone in your building. NATURAL GAS LIQUID PROPANE MODEL • Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s MAH-100 92 ft3/h 2.60 38 ft3/h 2.61 m3/h) m3/h) instructions.

  • Page 42: Gas Pipe Recommendations

    7 - GAS SUPPLY PIPING 7.2 Gas Pipe Recommendations • Use of Gas Appliance Connectors (flexible connectors Configure gas pipe for proper operation and avoid issues typically used for gas stoves or water heaters) is with failure to light or maintenance of proper flame during prohibited.
  • Page 43 7 - GAS SUPPLY PIPING This chart is sourced from NFPA-54 2015 with the BTU ratings for the material, length, and diameter of gas pipe. INTENDED USE: Pipe Sizing Between Natural Gas Meter, or Propane Single - or Second-Stage (Low-Pressure) Regulator and Appliance.

  • Page 44: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING NOTICE FIGURE 7-1 Sediment trap shall be located upstream of gas controls. 7.3 Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation. • Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

  • Page 45: Electrical Connections

    8 - ELECTRICAL CONNECTIONS DANGER Model Size Electrocution Hazard! HIGH VOLTAGE - Connections Power Supply 120V - 60Hz in terminal block M1 are high voltage (120V / 60Hz). Before making connections, verify appliance is Power 118 W 125 W 133 W 142 W 173 W 182 W disconnected from power supply.

  • Page 46: Electrical Connections

    8 - ELECTRICAL CONNECTIONS FIGURE 8-2 Terminal Block Locations DANGER Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz). Before making connections, verify appliance is disconnected from power supply. Respect the input polarity on terminal block M1: L (LINE) - N (NEUTRAL). Failure to follow these instructions WILL result in death or serious injury.

  • Page 47: Install Room End Switch

    8 - ELECTRICAL CONNECTIONS FIGURE 8-4 End Switch Connections 8.6 Install Room End Switch Install room end switch 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 48 8 - ELECTRICAL CONNECTIONS FIGURE 8-6 Kt Climate Curves Flow temp Outside temp 80 Is Default. NOTE: Temperatures below -40 °F (-40 °C), maximum heating flow temperature set point no longer increases, curves shown on graph become horizontal. Boiler set-point will override sensor set-point. 240013354 REV B [09/15/2021]...

  • Page 49: Indirect Storage Tank

    8 - ELECTRICAL CONNECTIONS FIGURE 8-7 Kt Indirect Storage Tank 8.8 Indirect Storage Tank Boilers MAH-100, MAH-125 can be electrically connected to *125 Model shown - See Application Guide for size 100 indirect storage tank as follows: 10K Ω sensor NTC to terminals 3-4 •...
  • Page 50 8 - ELECTRICAL CONNECTIONS FIGURE 8-8 Circulator Pump Connections For more information please review the application guide received with your boiler. 240013354 REV B [09/15/2021]...

  • Page 51: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Central Heating System Connections - HEAT ONLY MAH-100 & MAH-125 HEAT ONLY MAH-165 HEAT ONLY WITH OPTIONAL INDIRECT DHW CONNECTION MAH-100 & MAH-125 HEAT ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND 100 / 125...

  • Page 52: Central Heating System Connections - Combi

    9 - START UP PROCEDURE 9.2 Central Heating System Connections - Combi MAC-115 & 150 COMBI MAC-205 COMBI LEGEND 115 & 150 Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4" [22.2 mm] 1" [25.4 mm] Cold DHW inlet tap / system filling connection 1/2"...

  • Page 53: 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 season.

  • Page 54: Control Panel

    9 - START UP PROCEDURE 9.5 Control Panel To enter the INFO Menu press and hold for 1 second. Press and hold the button for 1-2 seconds to increment through the selections as shown in the table below. Press to exit. DESCRIPTION DESCRIPTION Secondary fault internal code...

  • Page 55: Prior To Commissioning

    9 - START UP PROCEDURE WARNING Boiler must not shutoff during calibration. Note Open all heating zones in heating or DHW Asphyxiation hazard! Fill condensate trap before mode to ensure boiler does not shutoff. starting boiler to avoid combustion products escaping 9.8 Automatic Calibration Function boiler.

  • Page 56: Manual Calibration Function

    9 - START UP PROCEDURE 9.10 De-Aeration Function NOTICE Used to eliminate air inside the heating circuit when boiler is installed or after maintenance when water is drained from During initial ignition, burner may not ignite. This may primary circuit. cause boiler to shut down until any air in gas pipes is Press buttons together and hold for 6 seconds.

  • Page 57: Chimney Sweep Function

    9.12 Chimney Sweep Function For correct boiler operation, content of (CO ) in the combustion flue must be within tolerances indicated in table below. Gas A (Natural Gas) Gas E (LPG) Combustion MAH-100 MAH-165 MAH-125 Table MAC-115 & 150 MAC-205...

  • Page 58: Parameter Settings

    9 - START UP PROCEDURE Table 9-2 Input Rate @ High Fire (MBH) For Natural Gas : 3600 x cu ft Approximate Rate @ Input (MBH) 100% Fire (MBH) seconds Size Example: Natural Gas - Gas flow from 93.5 Meter = 2 cu ft Measured time = 72 seconds 3600 x 2 cu ft = 100 MBH...
  • Page 59 9 - START UP PROCEDURE FACTORY SETTINGS 9.16 Description Of Parameters: Factory Settings conti. 115, 100, 150,205 125,165 P11..P12 Manufacturer information Max. heating output (0-100%) DHW max. output (0-100%) Min. heating output (0-100%) Maximum CH set-point (°C) 00 = 176°F (80°C) 01 = 113°F (45°C) Selectable Range 20-80 = (20°C to 80°C) 68°F to 176°F Pump overrun time in heating mode (01-240 minutes)

  • Page 60: 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 Section 9.15 Parameter Settings. Boiler Model - PARAMETER P13 (%)/ Heating Output Btu/h MAH-100 MAC-115 17,060 20,473 23,885 27,297 30,709 34,121 10.0...

  • Page 61: Operating Instructions

    10 - OPERATING INSTRUCTIONS 10.2 Boiler Operation FOR YOUR SAFETY READ BEFORE OPERATING Domestic hot water supply always takes priority over central WARNING heating. If you do not follow these instructions exactly, Demand for hot water required during central heating period, a fire or explosion may result causing property boiler automatically switches to hot water mode until demand damage, personal injury or loss of life.

  • Page 62: Frost Protection

    10 - OPERATING INSTRUCTIONS 10.5 Frost Protection Boiler monitors supply and return water temperatures to enable frost protection which automatically turns boiler and pump on. If water in boiler falls below 41°F (5°C), providing boiler is connected to power, boiler will operate until water temperature in the system reaches approximately 86°F (30°C).

  • Page 63: 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 64: Maintenance And Routine Servicing

    11 - GENERAL MAINTENANCE AND CLEANING WARNING 11.2 Maintenance And Routine Servicing Check and service boiler as necessary. Following service procedures must be performed by Frequency of servicing will depend upon installation qualified service agent. Boiler owner shall not attempt conditions and usage, manufacturer recommends annually.

  • Page 65: 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 66: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model MAC-150 SHOWN 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 67: User Information

    11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information NOTICE Advise and demonstrated to User the following important information: When servicing the appliance, check the condition and A. How to light and turn off boiler. How to operate position of flame sensing electrode and replace it if system controls.

  • Page 68: Ratings And Capacities

    12 TECHNICAL DATA 12.1 Ratings and Capacity (1)(3) Net AHRI CH Input, MBH (1)(2) Model CH Heating Rating Water, Number Capacity, MBH * AFUE% Maximum Minimum MAH-100 93.5 16.6 85.4 95.0 MAC-115 93.5 16.6 85.4 95.0 MAH-125 95.0 MAC-150 95.0 MAH-165 29.5...

  • Page 69: High Altitude Ratings

    Input, MBH (KW) Domestic Hot Water (DHW) Circuit Heating Model Altitude AFUE, % Capacity, Max Input, Min Input, Max Output, Min Output, Number Maximum Minimum MBH* MAH-100 88.8 16.5 81.1 95.0 MAC-115 88.8 16.5 81.1 95.0 109.7 16.6 100.2 15.3 MAH-125 95.0...
  • Page 70 12 - RATINGS AND CAPACITIES 12.5 Available Pump Head For Central Heating This is a high static head pump fit for installation on any type of single or double-pipe heating systems. The automatic air valve incorporated in the pump allows quick venting of the heating system. WATER FLOW RATE Minimum speed of modulation HEAD...

  • Page 71: 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 Gas valve command fault Verify all cables. Replace PCB. Central Heating NTC sensor fault Check sensor and cable Flue NTC heat exchanger sensor fault...
  • Page 72 13 - TROUBLE SHOOTING 13.1 Error Messages and Resetting the Boiler - continued Error Description Operation Internal error Verify all cables. Replace PCB. Fan fault Check fan and cable 162/317 Incorrect power supply frequency. Incorrect power supply frequency. Check pressure switch and cable. Flue pressure switch (contact open) Check obstruction on flue pipe 164/384...

  • Page 73: Anomalies Table For The Installer - Use This Table To Report The Anomaly Values

    13 - TROUBLE SHOOTING 13.2 Anomalies Table for the Installer - Use this table to report the anomaly values. SYSTEM STATUS CODES 0 STANDBY 1 DHW "ON" 2 CHIMNEY SWEEP ACTIVE 3 CH "ON" 4 PREHEAT "ON" 5 CH NO FROST "ON" 6 DHW NO FROST "ON"...

  • Page 74: 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 75 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 76: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-2 MODEL 100 - Heat Only 240013354 REV B [09/15/2021]...
  • Page 77 APPENDIX A - WIRING DIAGRAMS A-2 MODEL 125 - Heat Only 240013354 REV B [09/15/2021]...
  • Page 78 APPENDIX A - WIRING DIAGRAMS A-3 MODEL 165 - Heat Only 240013354 REV B [09/15/2021]...
  • Page 79 APPENDIX A - WIRING DIAGRAMS A-1 MODEL 115 - Combi 240013354 REV B [09/15/2021]...
  • Page 80 APPENDIX A - WIRING DIAGRAMS A-4 MODEL 150 - Combi 240013354 REV B [09/15/2021]...
  • Page 81 APPENDIX A - WIRING DIAGRAMS A-5 MODEL 205 - Combi 240013354 REV B [09/15/2021]...
  • Page 82 NOTES 240013354 REV B [09/15/2021]...
  • Page 83 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 84 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 85 APPLICATION GUIDE FOR USE WITH HEATING ONLY - 100, 125, 165 & COMBI - 115, 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 86 TABLE OF CONTENTS Important Safety Information .....................3 Labor Saving Piping Manifolds / Near Boiler Piping Connections ..........4 General Information - Hydronic Piping ..................6 General Information - Wiring ......................8 Piping and Wiring Diagrams Piping Legend ..........................9 100, 125 W/Zone Circulators & DHW Tank - Piping Diagram ............10 100, 125 W/Indirect Zone Circulators, DHW Tank W/Sensor - Wiring Diagram .......

  • Page 87: Important Safety Information

    IMPORTANT SAFETY INFORMATION 3. Installation shall conform to requirements of 1. 1. Become familiar with symbols identifying Become familiar with symbols identifying authority having jurisdiction or in absence of such potential hazards. potential hazards. requirements: • United States • National Fuel Gas Code, ANSI Z223.1/NFPA 54. This is the safety alert symbol.

  • Page 88: Labor Saving Piping Manifolds / Near Boiler Piping Connections

    LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 100 & 125 HEATING ONLY 165 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 100 & 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND 100/125 Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4"...
  • Page 89 LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 205 COMBI 115 & 150 COMBI 205 COMBI LEGEND 115 & 150 Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4" [22.2mm] 1” [25.4mm] 1/2" Cold DHW inlet tap 3/4"...

  • Page 90: General Information - Hydronic Piping

    GENERAL INFORMATION - HYDRONIC PIPING FOR YOUR SAFETY READ BEFORE OPERATING WARNING Burn and scald hazard! Manufacturer requires installation of field supplied anti-scald valve. DANGER Failure to follow these instructions could result in death or serious injury. General Information: Piping installation, materials, and joining methods shall conform to requirements of authority having jurisdiction or in absence of such requirements: •...
  • Page 91 GENERAL INFORMATION - HYDRONIC PIPING Water 1st Degree Burn 2nd and 3rd Degree Burn Use of Indirect Water Heater (DHW) Heating Temperature Exposure Time For Exposure Time For An Setting An Adult Adult Only Boiler: 120° F 1 minute 5 minutes 130°...

  • Page 92: General Information - Wiring

    GENERAL INFORMATION - WIRING Electrical Wiring Information: DO NOT use 120 V thermostat Note terminals (M1- #1 and #2). All field wiring shall conform to the authority having jurisdiction or, in the absence of such requirements to: • USA: National Electrical Code, ANSI/NFPA 70, Provided Wiring and Piping •...

  • Page 93: Piping Legend

    PIPING LEGEND PIPING LEGEND ZONE VALVE BALL VALVE DHW INDIRECT TANK AIR SEPARATOR CIRCULATOR INDIRECT TANK AQUASTAT 10K Ω INDIRECT DHW TANK SENSOR DRAIN TEMPERATURE & PRESSURE GAUGE COMBINATION FILL EXPANSION TANK FLOW CHECK VALVE FLAT PLATE HEAT EXCHANGER (COMBI ONLY) BYPASS VALVE STRAINER DIVERTER VALVE...

  • Page 94: W/Zone Circulators & Dhw Tank- Piping Diagram

    100, 125 W/ZONE CIRCULATORS & DHW TANK- PIPING DIAGRAM PN 240011430 REV. P [09/15/2021]...

  • Page 95: W/Indirect Zone Circulators, Dhw Tank W/Sensor - Wiring Diagram

    100, 125 W/INDIRECT ZONE CIRCULATORS, DHW TANK W/SENSOR - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 96: W/Indirect Zone Circulators & Dhw Tank W/T-Stat - Wiring Diagram

    100, 125 W/INDIRECT ZONE CIRCULATORS & DHW TANK W/T-STAT - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 97: With Zone Valves & Dhw Tank - Piping Diagram

    100, 125 WITH ZONE VALVES & DHW TANK - PIPING DIAGRAM PN 240011430 REV. P [09/15/2021]...

  • Page 98: With Zone Valves, Dhw Tank W/Sensor - Wiring Diagram

    100, 125 WITH ZONE VALVES, DHW TANK W/SENSOR - - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 99: Zone Valves, Dhw Tank W/T-Stat - Wiring Diagram

    100, 125 ZONE VALVES, DHW TANK W/T-STAT - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 100: With Zone Circulators - Piping Diagram

    165 WITH ZONE CIRCULATORS - PIPING DIAGRAM PN 240011430 REV. P [09/15/2021]...

  • Page 101: Indirect Zone Circulators, Dhw Tank W/ T-Stat - Wiring Diagram

    165 INDIRECT ZONE CIRCULATORS, DHW TANK W/ T-STAT - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 102: With Zone Valves - Piping Diagram

    165 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. P [09/15/2021]...

  • Page 103: With Indirect Zone Valves, Dhw Tank, Tank T-Stat -Wiring Diagram

    165 WITH INDIRECT ZONE VALVES, DHW TANK, TANK T-STAT -WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 104: 205 With Zone Circulators - Piping Diagram

    115, 150 & 205 WITH ZONE CIRCULATORS - PIPING DIAGRAM PN 240011430 REV. P [09/15/2021]...

  • Page 105: 205 With Zone Circulators - Wiring Diagram

    115, 150 & 205 WITH ZONE CIRCULATORS - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 106: 205 With Zone Valves - Piping Diagram

    115, 150 & 205 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. P [09/15/2021]...

  • Page 107: 205 With Zone Valves - Wiring Diagram

    115, 150 & 205 WITH ZONE VALVES - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. P [09/15/2021]...

  • Page 108: External Buffer Tank - Piping Diagram

    EXTERNAL BUFFER TANK - PIPING DIAGRAM Buffer Tank 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 Using Internal Boiler Circulator Note: •...
  • Page 109 EXTERNAL BUFFER TANK - PIPING DIAGRAM Buffer Tank On Central Heat Circuit With Primary Pump and Supplied Manifold NOTE : Acceptable primary pump locations: Either 1 or 2. For pump wiring see diagrams on pages 26-29. PN 240011430 REV. P [09/15/2021]...

  • Page 110: External Buffer Tank - Wiring Diagram

    EXTERNAL BUFFER TANK - WIRING DIAGRAM Buffer Tank Pump Wiring Controlling A Primary Pump On A Combi Boiler With Zone Valves, No Indirect Tank PN 240011430 REV. P [09/15/2021]...
  • Page 111 EXTERNAL BUFFER TANK - WIRING DIAGRAM Buffer Tank Pump Wiring Controlling A Primary Pump On A Combi Boiler With Zone Pumps, Argo ARM 4P Zone Control and A822-II PN 240011430 REV. P [09/15/2021]...
  • Page 112 EXTERNAL BUFFER TANK - WIRING DIAGRAM Buffer Tank Pump Wiring Controlling A Primary Pump On A Combi Boiler With Zone Valves and Indirect Tank With Priority Argo UZ3 and AR22II Zone Controls ZONE VALVES ZONE VANNES DE ZONE THERMOSTATS 4 Wire Valve Domestic Hot Water Tank Buffer Tank...

  • Page 113: Optional Equipment

    OPTIONAL EQUIPMENT Optional Equipment IMPORTANT: Sensors supplied with this boiler are proprietary to the manufacturer. Use of alternate market sensors WILL diminish boiler performanc Outdoor Air Sensor, if used. 1k Ω A. Boiler automatically recognizes sensor when used. B. See Chart 1 for sensor data. Sensor part number BD710487302V C.

  • Page 114: Accessories

    ACCESSORIES 1. 1K Ohm (1K Ω) Outdoor Temperature 1k Ω Sensor Kit - BD710487302V • Use the Outdoor Sensor (OAS) Kit with Heating Only or Combi Boilers. • Wire Control to boiler M2 terminal strip, terminals 4 and 5 as shown. •...
  • Page 115 ACCESSORIES 2. 10k Ω Indirect Storage Tank Sensor Kit Parameter PO3 for Heating Only boiler, with no Note indirect tank remains Factory Set at 08. No change Heating Only boiler can be electrically connected to is required. Indirect Storage Tank. Diagram of electrical connection of external indirect If adding an Indirect Tank with a sensor to storage tank is shown below.

  • Page 116: Single Zone Circulator Wiring Using Argo Ar822-I

    CIRCULATOR CONNECTIONS - WIRING DIAGRAM Single Zone Circulator Wiring Using ARGO AR822-II PN 240011430 REV. P [09/15/2021]...

  • Page 117: Heat Only Wiring Diagram

    100 - HEAT ONLY WIRING DIAGRAM MODEL 100 - Heat Only PN 240011430 REV. P [09/15/2021]...
  • Page 118 125 - HEAT ONLY WIRING DIAGRAM MODEL 125 - Heat Only PN 240011430 REV. P [09/15/2021]...

  • Page 119: Heat Only Wiring Diagram

    165 - HEAT ONLY WIRING DIAGRAM MODEL 165 - Heat Only PN 240011430 REV. P [09/15/2021]...

  • Page 120: Combi Wiring Diagram

    115 - COMBI WIRING DIAGRAM MODEL 115-Combi PN 240011430 REV. P [09/15/2021]...
  • Page 121 150 - COMBI WIRING DIAGRAM MODEL 150 - Combi PN 240011430 REV. P [09/15/2021]...

  • Page 122: Combi Wiring Diagram

    205 - COMBI WIRING DIAGRAM MODEL 205 - Combi PN 240011430 REV. P [09/15/2021]...

  • Page 123: Altitude Effects On Boiler Performance

    ALTITUDE EFFECTS ON BOILER PERFORMANCE MODELS 100/115 MAC-115 CALCULATED EFFECTS OF HI-ALTITUDE ON BOILER PERFORMANCE 120,000 110,000 100,000 90,000 DHW MODE 80,000 HEAT MODE Net Ra�ng Heat Mode 70,000 60,000 50,000 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 ALTITUDE (FEET) MODELS 125/150...

  • Page 124: Application Table - Indirect Hot Water Tank Performance Chart

    APPLICATION TABLE - INDIRECT HOT WATER TANK PERFORMANCE CHART HEATING ONLY BOILERS 100, 125, 165 BOILER OUTPUT NEEDED FOR MAXIMUM PERFORMANCE Notes: 176 °F Boiler Supply Water Temperature, AHRI Conditions -50 °F Inlet Water @ 240 GPH Flow Rate. PN 240011430 REV. P [09/15/2021]...

  • Page 125: Lwco Wiring Diagram

    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. See Figure page 42, Piping Diagram. These guidelines are supplied when necessary to install an additional Low Water Cut Off (LWCO), for sensing a •...

  • Page 126: Piping Diagram -Lwco Location

    LOW WATER CUTOFF Piping Diagram - LWCO Location Arrange piping to prevent water dripping onto boiler. Note Illustrations are meant to show system piping concept only. Installer Note is responsible for all equipment and detailing required by authority having jurisdiction. Air Vent Position LWCO Above Top of Boiler...

  • Page 127: Low Water Cutoff - Detail

    LOW WATER CUTOFF Low Water Cutoff - Detail PN 240011430 REV. P [09/15/2021]...

  • Page 128: Error Code Table

    ERROR CODE TABLE Initial Fault Finding Checks Note: When instructed press and hold “RESET” for between 1-3 seconds to reset the boiler. Check gas, water and electrical supplies are available at the boiler Table of Error Codes Electrical supply = 120V ~60 HZ Gas Valve Connection Cable The preferred minimum gas pressure is 3.5”...

  • Page 129: Troubleshooting Chart

    TROUBLESHOOTING CHART PN 240011430 REV. P [09/15/2021]...
  • Page 130 TROUBLESHOOTING CHART PN 240011430 REV. P [09/15/2021]...

  • Page 131: Fault Solution Sections

    FAULT SOLUTION SECTIONS Fault Finding Solutions Sections Power supply 120V Main terminals L and N Check electrical supply Connection OK at connector x1 0 Integrity of the fuse Replace fuse Main or Display Display PCB fault illuminated PCB - X1 0 connector Check wiring Mains terminals L &...
  • Page 132 FAULT SOLUTION SECTIONS PN 240011430 REV. P [09/15/2021]...
  • Page 133 FAULT SOLUTION SECTIONS Overheat thermostat operated or Check for and correct any system faulty. faults (water circulation). Allow to cool. Continuity �I across thermostat terminals � Replace safety thermostat '---------------' more than 1.5 ohm Is E11 O is still flashing Check Flow, Return, Replace PCB sensors.
  • Page 134 FAULT SOLUTION SECTIONS PCB connector x22 Hall With water running effect sensor terminals. Is main water filter and through DHW circuit, Check the voltage is Check DHW NTC assembly clean and measure red and white Replace PCB approximately 5 VDC senor for proper OHM rotor free to move? wire for 2.8 VDC for...

  • Page 135: Parameter Change History

    PARAMETER CHANGE HISTORY Parameter Changed Changed Date Reason From PN 240011430 REV. P [09/15/2021]...
  • Page 136 All specifications subject to change without notice. 2201 Dwyer Avenue, Utica, NY 13501 ©2021 ECR International, Inc. Tel. 800 325 5479 www.ecrinternational.com...
  • Page 137 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 Commissioning Function wihich includes 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 138 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 139 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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