UTICA BOILERS MAHF-165 Installation, Operation And Maintenance Manual
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UTICA BOILERS MAHF-165 Installation, Operation And Maintenance Manual

Condensing gas fired boiler
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MAHF-125, MAHF-165
MACF-150, MACF-205
CONDENSING
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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  • Page 1 MAHF-125, MAHF-165 MACF-150, MACF-205 CONDENSING GAS FIRED BOILER Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com...
  • Page 2 CONTENTS : INSTALLATION, OPERATION, AND MAINTENANCE MANUAL (240012874) APPLICATION GUIDE (240012875) COMMISSIONING GUIDE (240011376) REQUIRED INSPECTION SPECIAL (240011561) BACK COVER...
  • Page 3 CONDENSING GAS FIRED INSTALLATION, OPERATION & MAINTENANCE MANUAL Models MAHF-125, MACF-150 MAHF-165, MACF-205 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 240012874 REV. A [01/31/2020]...

  • Page 4: Verify Contents Received

    VERIFY CONTENTS RECEIVED Temperature Pressure 3/4 NPT Ball Gas Fully Assembled Boiler 30 PSI Safety Relief Valve Gauge (2" Shank) Shutoff Valve Includes Essential Documents and Warranty 11x17 Wire Diagrams DHW Optional Pipe Copper Flush Bushing Copper Tee Document Package Heat Only Boiler 1/2”...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Verify contents received ..........2 9.11 Commission Set Up (Gas) - Changing The Type Of Gas Table of contents ............3 ................43 9.12 Chimney Sweep Function (CO Adjust) ....1 - Important Information ..........4 9.13 Combustion Adjustment Function (CO %) ..

  • Page 6: Important Information

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

  • Page 7: Physical Data

    2A - PHYSICAL DATA Dimensions DIMENSIONS 125 & 150 165 & 205 Height (Bottom of boiler top of safety Valve) 43.65" [1.09 m] Overall Width with Manifold 24.70" [628 mm] Depth 17.46" [444 mm] Condensate Trap Connection 3/4" NPT System Supply 11/4”...
  • Page 8 2A- PHYSICAL DATA MODELS - 125 & 150 Top View 125 & 150 10.44 in. 10.44 in. [266 mm] [266 mm] 6.87 in. 6.87 in. MODELS - 125 & 150 [175 mm] [175 mm] 18.56 in. [472 mm] 18.56 in. [472 mm] 20.50 in.
  • Page 9 2A - PHYSICAL DATA MODELS - 165 & 205 Top View 165 & 205 25.80 in. [655 mm] 25.80 in. [655 mm] 16.71 in. 16.71 in. [424 mm] [424 mm] 7.18 in. 7.18 in. [182 mm] [182 mm] 18.56 in. [472 mm] 18.56 in.

  • Page 10: Component Listing

    2B - COMPONENT LISTING UTICA BOILER MAHF-125 Utica Boiler ITEM MAHF-125 Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator Boiler Drain Tap Heating Return Gas Inlet Optional Indirect Tank Connection Heating Supply Connection Condensate Connection...
  • Page 11 2B - COMPONENT LISTING UTICA BOILER MACF-150 Utica Boiler ITEM MACF-150 Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator DHW Priority Sensor Flow Sensor with Water Filter and Flow Restrictor Boiler Drain Tap Heating Return Cold Water DHW Inlet Tap...
  • Page 12 2B - COMPONENT LISTING UTICA BOILER MACF-205 Utica Boiler ITEM MACF-205 Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator DHW Priority Sensor Flow Sensor with Water Filter and Flow Restrictor Heating Return Cold Water DHW Inlet Tap Gas Inlet...
  • Page 13 2B - COMPONENT LISTING UTICA BOILER MAHF-165 Utica Boiler ITEM MAHF-165 Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator Boiler Drain Tap Heating Return Heating Supply Connection Gas Inlet...

  • Page 14: Introduction

    Monoxide monitor may be requirement of local • MACF-150 Modulates input to provide CH Turndown jurisdiction. 5.7:1, DHW Turndown 7:1 • MAHF-165 Modulates input to provide CH Turndown 5.5:1 • MACF-205 Modulates input to provide CH Turndown 5.5:1, DHW turndown 7:1 •...

  • Page 15: Locating Boiler

    4 - LOCATING BOILER WARNING WARNING Fire Hazard! Do not install on carpeting. Failure to Fire, explosion, and asphyxiation hazard. Improper follow these instructions could result in death or installation could result in death or serious serious injury. injury. Read these instructions and understand all requirements before beginning installation.
  • Page 16 4 - LOCATING BOILER 4.3 Clearances TABLE 1: BOILER CLEARANCES Manufacturer Combustible Dimension Recommended for Materials Service (1)(2) 0" (0 cm) 8-5/8" (220 mm) Left Side 1-3/4" (45 mm) 12" (305 mm) Right Side 1-3/4" (45 mm) 1-3/4" (45 mm) Front 17-3/4"(450 mm) 0"...

  • Page 17: Combustion Air And Vent Piping

    5 - COMBUSTION AIR AND VENT PIPING • Support horizontal sections of vent pipe to prevent sags WARNING capable of accumulating condensate. Fire, explosion, and asphyxiation hazard. Improper • Assemble vent materials in accordance with venting installation could result in death or serious manufacturer’s instructions.

  • Page 18: Definitions

    5 - COMBUSTION AIR AND VENT PIPING Figure 5-1 - Venting Support 5.3 Definitions Coaxial piping – Exhaust and air intake pipe have a common axis. Twin Pipe – Exhaust and intake air are separate pipes, can be terminated using single wall terminals from the vent manufacturer or field built configuration using elbows or tees.

  • Page 19: Approved Venting Materials

    5 - COMBUSTION AIR AND VENT PIPING Venting shall be properly supported. 5.4 Approved Venting Materials Boiler shall not support any type of vent system. WARNING All piping, glue, solvents, cleaners, fittings and components must conform to ASTM and ANSI standards. Manufacturer recommends this condensing boiler be In Canada ULC S636 and in the USA UL 1738 schedule 40 vented with approved polypropylene venting material.

  • Page 20: 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 1-3/4"...
  • Page 21 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-4 Roof Mount Coaxial Venting FIGURE 5-6 Side Wall Coaxial Venting CAN BE USED ON ALL SIZES CAN BE USED ON ALL SIZES Maintain 12"(305 mm) US (18"(457 mm) Canada) clearance above highest anticipated snow level Anticipated 18"...

  • Page 22: 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 23: Securing Twin Pipe Polypropylene Venting

    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. NOTICE Venting manufacturer's use a device to secure single wall twin pipe polypropylene vent pieces to each other.
  • Page 24 5 - COMBUSTION AIR AND VENT PIPING This Termination 12" (305 mm) Min. horizontal separation  can be used on: between combustion air intake and vent of 15" 2" / 60 mm ON same appliance. (381 mm) 165/205  12" (305 mm) Min. 84" (2.2 m) Max. vertical Max.
  • Page 25 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 This Termination Note: 3" shown for clarity. 12" between can be used on: vent and combustion air of other boilers 3"...

  • Page 26: 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 125/150 165/205 3”...
  • Page 27 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 28: Condensate Piping

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-26 - Condensate Drain 5.11 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 29: Hydronic Piping

    6 - HYDRONIC PIPING • It is necessary to semi-annually check the water quality of WARNING central heating systems. • Poison hazard. Ethylene glycol is toxic. Do not use • Manufacturer recommends installation of magnetic dirt ethylene glycol. separator in the hydronic system where there are cast iron or steel components, or where the previous boiler was a cast •...

  • Page 30: Safety Relief Valve And Air Vent

    6 - HYDRONIC PIPING FIGURE 6-1 Safety Relief Valve WARNING Safety Relief Burn and scald hazard. Safety relief valve could Valve discharge steam or hot water during operation. Use pipe suitable for temperatures of 375°F (191°C) or greater. DO NOT use plastic pipe. Install discharge piping per these instructions.
  • Page 31 6 - HYDRONIC PIPING FIGURE 6-2 - Piping Diagram - LWCO Location Arrange piping to prevent Note water dripping onto boiler. Illustrations are meant to Note show system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction.

  • Page 32: External Optional Low Water Cut Off

    6 - HYDRONIC PIPING 6.6 External Optional Low Water Cut Off FIGURE 6-3 - 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 33 6 - HYDRONIC PIPING 6.5 Manufacturer Recommendation - Strainer 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 34: Central Heating System

    6 - HYDRONIC PIPING 6.7 Central Heating System • Once the fan reaches ignition speed the control board will allow power to flow to the spark generator and gas valve Boiler is designed for use in a sealed central heating system. creating ignition in the combustion chamber.

  • Page 35: Gas Supply Piping

    CAUTION MACF-150 143 ft /h (4.00 m 61.15 ft /h (1.72 m WHAT TO DO IF YOU SMELL GAS MAHF-165 153 ft /h (4.30 m 66 ft /h (1.85 m • Do not try to light any appliance. MACF-205 191 ft /h (5.40 m...

  • Page 36: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING Figure 7-1 - Gas Piping NOTICE Sediment trap shall be located upstream of gas controls. NOTICE If overheating occurs or gas supply fails to shut off, do not turn off or disconnect electrical supply to pump. Shut off gas supply at location external to the boiler.

  • 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: 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 39: Optional Electrical Connections

    8 - ELECTRICAL CONNECTIONS FIGURE 8-4 Thermostat Connections 8.6 Install Themostat 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: Indirect Storage Tank

    8 - ELECTRICAL CONNECTIONS FIGURE 8-7A Kt Indirect Storage Tank 8.8 Indirect Storage Tank *125 Model shown Boilers MAHF-125 & 165 can be electrically connected to indirect storage tank as follows: 10K Ω sensor NTC to terminals 3-4 • Connect DHW priority on terminal block M2.

  • Page 41: Start Up Procedure

    Gas shutoff connection 3/4" NPT Cold DHW inlet tap 1/2" sweat 3/4" sweat 11/4 po sweat 11/2 po sweat Heating return connection MAHF-165 HEATING ONLY WITHOUT INDIRECT DHW CONNECTION LEGEND 11/4” sweat 11/2” sweat Heating supply connection Drain Connection for condensate 3/4"...

  • Page 42: System Start Up

    9 - START UP PROCEDURE FIGURE 9-1 Condensate Drain Assembly - 125 Model 9.3 System Start Up shown Follow all codes and regulations when filling the boiler. Use drain taps to allow system to completely drain. Thoroughly flush the heating system before boiler is connected Pour and again after first heating season.

  • Page 43: 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 44: Prior To Commissioning

    9 - START UP PROCEDURE Boiler must not shutoff during calibration. NOTICE Note Open all heating zones in heating or DHW mode to ensure boiler does not shutoff. All connections shall be made and water added before performing this function. 9.8 Automatic Calibration Function Before performing this function verify the door is on the boiler NOTICE...

  • Page 45: Manual Calibration Function

    9 - START UP PROCEDURE FIGURE 9-3 - Gas Inlet Tap - Pi 9.9 Manual Calibration Function: Manual Calibration phase starts at the end of the Automatic Calibration. The Display shows the boiler power and adjustment of the CO2 value (parameter setting) during Manual Calibration sequence.

  • Page 46: Chimney Sweep Function

    Gas A Gas A Gas A Gas A (Natural Gas) (Natural Gas) (Natural Gas) (Natural Gas) Gas E (LPG) MAHF-125 MACF-150 MAHF-165 MACF-205 CO2 % O2 % CO2 % O2 % CO2 % O2 % CO2 % O2 % CO2 %...

  • Page 47: Description Of Parameters: Factory 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 @ 100% Fire (MBH) Example: Natural Gas - Gas flow from Size Meter = 2 cu ft Measured time = 72 seconds 3600 x 2 cu ft = 100 MBH...

  • Page 48: Description Of Parameters: Factory Settings Conti

    9 - START UP PROCEDURE FACTORY SETTINGS 9.16 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 set-point 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 49: Adjusting Maximum Heating Power

    To access and edit P13 values, proceed as described in Section 9.15 Parameter Settings. Boiler Model - PARAMETER P13 (%)/ Heating Output Btu/h MAHF-125 MACF-150 Btu/h MAHF-165 MACF-205 20,400 27,400 23,800 31,300 27,200 35,800 10.5...

  • Page 50: Operating Instructions

    10 - OPERATING INSTRUCTIONS 10.3 Central Heating Mode FOR YOUR SAFETY READ BEFORE OPERATING With demand for heating, pump circulates water through WARNING the primary circuit. Combustion fan comes on at ignition speed, closing the air If you do not follow these instructions exactly, pressure switch, allowing power to spark generator and a fire or explosion may result causing property gas valve, creating ignition in the combustion chamber.

  • Page 51: 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 52: Maintenance And Routine Servicing

    11 - GENERAL MAINTENANCE AND CLEANING 11.2 Maintenance And Routine Servicing WARNING 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 53: 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 54: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model MACF-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 55: User Information

    11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information 11.13 Replacement Parts Advise and demonstrated to User the following important Perform Automatic Calibration procedure described in section information: 9.8 if one or more of the following components are replaced. Check and adjust CO2% value as indicated in the Combustion A.

  • Page 56: Ratings And Capacities

    Maximum Minimum Rating Water, MBH MAHF-125 95.0 MACF-150 95.0 MAHF-165 29.5 95.0 MACF-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 57: High Altitude Ratings

    Capacity, Max Input, Min Input, Max Output, Min Output, Number Maximum Minimum MBH* MAHF-125 95.0 MACF-150 95.0 2,000-4,500 ft (600m-1350m) MAHF-165 26.5 95.0 MACF-205 26.5 95.0 184.5 26.5 MAHF-165 24.1 95.0 4,501-6,500 ft (1372 m -1981 m) MACF-205 24.1 95.0 24.1...

  • Page 58: 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 59 13 - TROUBLE SHOOTING 13.1 Error Messages and Resetting the Boiler - continued Error Description Operation Check pressure switch and cable. Flue pressure switch (contact open) Check obstruction on flue pipe 164/384 Fault flame (parasitic flame). Check correct operation of T. gas valve. 165/385 Input voltage too low.

  • Page 60: 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 61: 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 62 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 63: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-1 MODELS 125 - Heat Only 240012874 REV A, [01/31/2020]...
  • Page 64 APPENDIX A - WIRING DIAGRAMS A-2 MODELS 165 - Heat Only 240012874 REV A, [01/31/2020]...
  • Page 65 APPENDIX A - WIRING DIAGRAMS A-2 MODELS 150 - Combi 240012874 REV A, [01/31/2020]...
  • Page 66 APPENDIX A - WIRING DIAGRAMS A-4 MODELS 205 - Combi 240012874 REV A, [01/31/2020]...
  • Page 67 NOTES 240012874 REV A, [01/31/2020]...
  • Page 68 NOTES 240012874 REV A, [01/31/2020]...

  • Page 69: Check Out Certificate

    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 70 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 71 APPLICATION GUIDE FOR USE WITH FLOOR STANDING HEATING ONLY - 125F, 165F & FLOOR STANDING COMBI - 150F, 205F 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 72 TABLE OF CONTENTS Important Safety Information ..................3 Labor Saving Piping Manifolds / Near Boiler Piping Connections........4 General Information - Hydronic Piping ................5 General Information - Wiring ..................7 Piping And Wiring Diagrams Piping Legend ........................8 125F Zone Circulator Pumps ...................9 125F W/ Indirect Zone Pumps &...

  • Page 73: 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 74: Labor Saving Piping Manifolds / Near Boiler Piping Connections

    NEAR BOILER PIPING CONNECTIONS 125F HEATING ONLY 150F/205F COMBI (150 shown) WITH OPTIONAL INDIRECT DHW CONNECTION LEGEND 125F HEATING ONLY Heating supply connection 11/4” sweat 11/2” sweat WITHOUT OPTIONAL INDIRECT DHW outlet 1/2" sweat 3/4" sweat DHW CONNECTION Drain connection for condensate 3/4"...

  • Page 75: 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 76 GENERAL INFORMATION - HYDRONIC PIPING Provided Wiring and Piping illustrations Water 1st Degree Burn 2nd and 3rd Degree Burn Note are meant to show system concepts only. Temperature Exposure Time For Exposure Time For An Installer is responsible for all equipment Setting An Adult Adult...

  • Page 77: 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 78: Piping Legend

    PIPING LEGEND PIPING LEGEND ZONE VALVE BALL VALVE INDIRECT DHW 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 79: Zone Circulator Pumps

    125F WITH ZONE CIRCULATOR PUMPS PN 240012875 REV. A [01/31/2020]...

  • Page 80: W/ Indirect Zone Pumps & Dhw Tank W/Tank Sensor - Wiring Diagram

    125F W/ INDIRECT ZONE PUMPS & DHW TANK W/TANK SENSOR - WIRING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 81: W/ Indirect Zone Pumps & Dhw Tank W/Tank T-Stat - Wiring Diagram

    125F W/ INDIRECT ZONE PUMPS & DHW TANK W/TANK T-STAT - WIRING DIAGRAM PN 240012875 REV. A [01/31/2020]...
  • Page 82 125F WITH ZONE VALVES - PIPING DIAGRAM 125F WITH ZONE VALVES PN 240012875 REV. A [01/31/2020]...
  • Page 83 125F WITH ZONE VALVES, DHW TANK & TANK SENSOR - - WIRING DIAGRAM 125F with Zone Valves PN 240012875 REV. A [01/31/2020]...

  • Page 84: Indirect Zone Valves, Dhw Tank W/Tank T-Stat - Wiring Diagram

    125F INDIRECT ZONE VALVES, DHW TANK W/TANK T-STAT - WIRING DIAGRAM 125F with Zone Valves PN 240012875 REV. A [01/31/2020]...
  • Page 85 165F WITH ZONE CIRCULATOR PUMPS - PIPING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 86: Indirect Zone Pumps, Dhw Tank, Tank T-Stat - Wiring Diagram

    165 INDIRECT ZONE PUMPS, DHW TANK, TANK T-STAT - WIRING DIAGRAM PN 240012875 REV. A [01/31/2020]...
  • Page 87 165 WITH ZONE VALVES - PIPING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 88: Indirect Zone Valves, Dhw Tank, Tank T-Stat -Wiring Diagram

    165 INDIRECT ZONE VALVES, DHW TANK, TANK T-STAT -WIRING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 89: 205F With Zone Circulator Pumps - Piping Diagram

    150F / 205F WITH ZONE CIRCULATOR PUMPS - PIPING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 90: 205F With Zone Pumps - Wiring Diagram

    150F / 205F WITH ZONE PUMPS - WIRING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 91: 205F With Zone Valves - Piping Diagram

    150F / 205F WITH ZONE VALVES - PIPING DIAGRAM PN 240012875 REV. A [01/31/2020]...

  • Page 92: 205F With Zone Valves - Wiring Diagram

    150F / 205F WITH ZONE VALVES - WIRING DIAGRAM PN 240012875 REV. A [01/31/2020]...
  • Page 93 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 94 LOW MASS - WIRING DIAGRAM Low Mass Boiler Wiring with Buffer Tank Connect the buffer tank aquastat to terminals 4 and 4 on terminal block M2. System wiring remains as shown in the previous wiring diagrams. H20 BUFFER TANK H2O Stainless Steel Buffer Tank PN 240012875 REV.

  • Page 95: 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 96 ACCESSORIES Accessories: • Use lower value of range as the desired Kt value. 1. 1k Ω Outdoor Temperature Sensor Kit - (Example): to deliver 186°F water @ OT of -20°F = Kt range is 90 thru BD710487302V 25. Select 25. Use Outdoor Sensor Kit with Heating Only or Combi Boilers.
  • Page 97 ACCESSORIES 2. 10k Ω 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 98: Heat Only Wiring Diagram

    125F FLOOR STANDING - HEAT ONLY WIRING DIAGRAM MODEL 125F - Heat Only PN 240012875 REV. A [01/31/2020]...

  • Page 99: Floor Standing - Combi Wiring Diagram

    150F FLOOR STANDING - COMBI WIRING DIAGRAM MODEL 150F - Combi PN 240012875 REV. A [01/31/2020]...

  • Page 100: Heat Only Wiring Diagram

    165F FLOOR STANDING - HEAT ONLY WIRING DIAGRAM MODEL 165F - Heat Only PN 240012875 REV. A [01/31/2020]...

  • Page 101: Floor Standing - Combi Wiring Diagram

    205F FLOOR STANDING - COMBI WIRING DIAGRAM MODEL 205F - Combi PN 240012875 REV. A [01/31/2020]...

  • Page 102: 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 103: 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 104 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 105: Low Water Cutoff Application

    LOW WATER CUTOFF Piping Diagram - LWCO Location Arrange piping to prevent Note water dripping onto boiler. Illustrations are meant to Note show system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction. Low Water Cutoff (LWCO) (See Figure 6-5 for detail) Purge Valve...
  • Page 106 LOW WATER CUTOFF Low Water Cutoff - Detail PN 240012875 REV. A [01/31/2020]...

  • Page 107: Error Code Table

    ERROR CODE TABLE NOTE: When instructed press and hold the 'Reset' for between 1-3 seconds to reset the boiler. Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available at the boiler. Table Of Error Codes 2.

  • Page 108: Troubleshooting Chart

    TROUBLESHOOTING CHART PN 240012875 REV. A [01/31/2020]...
  • Page 109 TROUBLESHOOTING CHART Domestic hot water 15 and 384 is flashing or re-occurs regularly Turn on mains power. check all PCB connections, if this has no effect replace Go to section 'A' the PCB. The display illuminates Error 110 or 133 or 134 or 135 or 125 or 384 or If the E11 o is still flashing.

  • Page 110: 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 PCB - X1 0 connector illuminated Check wiring Mains terminals L &...
  • Page 111 FAULT SOLUTION SECTIONS Temperature sensor faulty. Check correct location and wiring Temperature sensors faulty. _ _ �.,, Replace sensor , _ _ Cold resistance approximately ° 10k0 @ 77 F (CH sensor) ° 20k0 @ 77 F (Flue sensor) (resistance reduces with increase in temp.) Gas at burner Ensure gas is on and purged .----------------, NO...
  • Page 112 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 113 FAULT SOLUTION SECTIONS PCB connector x22 Hall effect sensor terminals. With water running PCB connector x22 Is main water filter and Check DHW NTC Check the voltage is through DHW circuit, Hall effect sensor terminals. assembly clean and senor for proper OHM approximately 5 VDC Replace PCB Is main water filter and assembly...
  • Page 114 NOTES PN 240012875 REV. A [01/31/2020]...
  • Page 115 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 253 7900 ©2019 ECR International, Inc. www.ecrinternational.com BDR THERMEA GROUP...
  • Page 116 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 117 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 118 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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