ECR International Dunkirk DCBF-75 Manual
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ECR International Dunkirk DCBF-75 Manual

Condensing gas fired boiler
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DCBF-75
DCBF-100
DCCF-115
DCBF-125
DCCF-150
DCBF-165
DCCF-150
DCCF-205
CONDENSING
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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  • Page 1 DCBF-75 DCBF-100 DCCF-115 DCBF-125 DCCF-150 DCBF-165 DCCF-150 DCCF-205 CONDENSING GAS FIRED BOILER Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com...
  • Page 2 DCCF-150...
  • Page 3 CONTENTS : INSTALLATION, OPERATION, AND MAINTENANCE MANUAL (240013509) APPLICATION GUIDE (240012875) COMMISSIONING GUIDE (240011376) REQUIRED INSPECTION SPECIAL (240011561) BACK COVER...
  • Page 4 DCBF-125...
  • Page 5 CONDENSING GAS FIRED INSTALLATION, OPERATION & MAINTENANCE MANUAL Models: COMBI DCCF-115 DCCF-150 DCCF-205 HEATING ONLY DCBF-75 DCBF-100 DCBF-125 DCBF-165 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com PN 240013509 REV. A [03/15/2022]...

  • Page 6: Verify Contents Received

    VERIFY CONTENTS RECEIVED 30 PSI Safety Relief Temperature Pressure 3/4 NPT Ball Gas Fully Assembled Boiler 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 7: Table Of Contents

    TABLE OF CONTENTS Verify Contents Received ..........2 9 - Start Up Procedure ..........48 9.1 Central Heating System Connections - Heat Only ...48 Table Of Contents ............3 9.2 Central Heating System Connections - Combi..48 Physical Data..............4 9.3 System Start Up ..........49 1 - Important Information ..........7 9.4 Fill Condensate Trap With Water ......49 2 - Introduction .............8...

  • Page 8: Physical Data

    PHYSICAL DATA DIMENSIONS DIMENSIONS 75 / 100 / 125 115 / 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] 23.55” [598 mm] Condensate Trap Connection 3/4"...
  • Page 9 PHYSICAL DATA MODELS - 75/100/115/125/150 Top View 10.44 in. 10.44 in. [266 mm] [266 mm] 6.87 in. 6.87 in. [175 mm] [175 mm] 18.56 in. [472 mm] 18.56 in. [472 mm] 20.50 in. [521 mm] 20.50 in. [521 mm] 24.70 in. [628 mm] 24.70 in.
  • Page 10 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 11: Important Information

    1 - IMPORTANT INFORMATION Become familiar with symbols identifying potential hazards. FOR YOUR SAFETY READ BEFORE OPERATING DANGER This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death. DANGER Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 12: Introduction

    Check our website frequently for updates: www.ecrinternational.com Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.

  • Page 13: Component Listing

    3 - COMPONENT LISTING DUNKIRK DCBF 75 & 100 Dunkirk ITEM DCBF-75 & 100 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...
  • Page 14 3 - COMPONENT LISTING DUNKIRK DCBF-125 Dunkirk ITEM DCBF-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 Low Water Pressure Cutoff...
  • Page 15 3 - COMPONENT LISTING DUNKIRK DCBF-165 Dunkirk ITEM DCBF-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 Condensate Connection Low Water Pressure Cutoff Inlet Element Gas Valve...
  • Page 16 3 - COMPONENT LISTING DUNKIRK DCCF-115 Dunkirk ITEM DCCF-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...
  • Page 17 3 - COMPONENT LISTING DUNKIRK DCCF-150 Dunkirk ITEM DCCF-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...
  • Page 18 3 - COMPONENT LISTING DUNKIRK DCCF-205 Dunkirk ITEM DCCF-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 19: Locating Boiler

    4 - LOCATING BOILER WARNING WARNING Fire hazard. Do not install boiler on combustible Fire, explosion, and asphyxiation hazard. flooring or carpeting. Failure to follow these Improper installation could result in death or instructions could result in death or serious serious injury.

  • Page 20: Clearances

    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 21: Combustion Air And Vent Piping

    5 - COMBUSTION AIR AND VENT PIPING • Support piping in accordance with pipe WARNING manufacturer's instruction and authority having Fire, explosion, and asphyxiation hazard. jurisdiction. In absence of manufacturer's instruction Improper installation could result in death or use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located at intervals of 3 ft (1 m) serious injury.

  • 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 After removal of existing boiler, following steps shall be followed with each appliance remaining connected to...

  • Page 23: Approved Venting Materials

    5 - COMBUSTION AIR AND VENT PIPING 5.4 Approved Venting Materials WARNING Installation shall conform to requirements of authority Manufacturer recommends this condensing boiler having jurisdiction or in absence of such requirements: be vented with approved polypropylene venting • USA - National Fuel Gas Code, ANSI Z223.1/NFPA material.
  • Page 24 5 - COMBUSTION AIR AND VENT PIPING VENT MATERIAL OPTIONS (Maximum Equivalent Vent Length Shown) 75/100/115/125/150 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 Asphyxiation hazard! Before securing screws are: ensure the pipe has been pushed in a minimum of 1-3/4" (45 mm) into the gasket end of the Coaxial Pipe Vent Lengths other pipe.

  • Page 26: Coaxial Vent Screw Placement

    5 - COMBUSTION AIR AND VENT PIPING 5.7 Coaxial Vent Screw Placement - See Figure 5-3 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.

  • 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 This Termination Pipe Installation Instructions completely and can be used on: understand all requirements before beginning 2"...

  • Page 28: Twin Pipe Polypropylene Adapter Kit Installation

    5 - COMBUSTION AIR AND VENT PIPING 5 - COMBUSTION AIR AND VENT PIPING Figure 5-11 - Twin Pipe Adapter Kit 5.9 Twin Pipe Polypropylene Adapter Kit Installation 75-150 Model Boilers for 75/100/110/125/150 Boilers [See Figures 5-11,5-12 & 5-13] Inner Gasket Outer Gasket Inspect Coaxial Connector on top of boiler.

  • Page 29: Twin Pipe Cpvc Adapter Kit Installation

    5 - COMBUSTION AIR AND VENT PIPING 5.11 Twin Pipe Polypropylene Adapter Kit Installation 5.12 Twin Pipe CPVC Adapter Kit Installation 165/205 Boilers 165/205 Boilers [See Figures 5-15 through 5-17] [See Figures 5-11, 5-12, 5-17, 5-18 & 5-19] Inspect Coaxial Connector on top of boiler. Confirm Inspect Coaxial Connector on top of boiler.

  • Page 30: Securing Twin Pipe Polypropylene Venting

    5 - COMBUSTION AIR AND VENT PIPING Figure 5-20 - 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 31 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-23 - (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 32 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-26 -Twin Pipe Side Wall Vent (Multiple FIGURE 5-29 - (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 33: Flexible Vent System

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-33 - (3" / 80 mm Only) Flexible Venting 5.14 (3" /80 mm Only) Flexible Vent System System CAN BE USED ON ALL SIZES Flexible Pipe Minimum & Maximum Vent Lengths 75/100/115/125/150 165/205 3”...
  • Page 34 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-34 - 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 35: Condensate Piping

    5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-35 - Condensate Drain 5.15 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: Hydronic Piping

    6 - HYDRONIC PIPING • Manufacturer recommends installation of magnetic WARNING dirt separator in the hydronic system where there • Poison hazard. Ethylene glycol is toxic. Do are cast iron or steel components, or where the not use ethylene glycol. previous boiler was a cast iron heat exchanger.

  • Page 37: Safety Relief Valve And Air Vent

    6 - HYDRONIC PIPING • Systems with automatic fill valves require back flow WARNING prevention device. Burn and scald hazard. Safety relief valve could • Single boiler system. See Figures 6-2, 6-5, for discharge steam or hot water during operation. general guidance.
  • Page 38 6 - HYDRONIC PIPING FIGURE 6-2 - Piping Diagram - LWCO Location 240013509 REV A, [03/15/2022]...

  • Page 39: 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 40: Manufacturer Recommendation - Strainer

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

  • Page 41: Central Heating System

    6 - HYDRONIC PIPING 6.8 Central Heating System 6.9 Frost Protection Mode Frost protection mode is integrated into the appliance Boiler is designed for use in a sealed central heating when electricity is connected to the boiler, regardless if system. Design the system to operate with flow power is "on"...

  • Page 42: Gas Supply Piping

    7 - GAS SUPPLY PIPING 7.1 General DANGER • Use piping materials and joining methods acceptable Fire Hazard. Do not use matches, candles, open to authority having jurisdiction. In absence of such flames, or other methods providing ignition requirements: source. Failure to comply will result in death or •...

  • Page 43: Gas Pipe Recommendations

    7 - GAS SUPPLY PIPING 7.2 Gas Pipe Recommendations • Use of Gas Appliance Connectors (flexible connectors typically used for gas stoves or water heaters) is Configure gas pipe for proper operation and avoid issues prohibited. Refer to national and local building codes. with failure to light or maintenance of proper flame during operation, which could cause error codes related •...
  • Page 44 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 45: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING Figure 7-1 - Gas Piping NOTICE 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 46: Electrical Connections

    8 - ELECTRICAL CONNECTIONS DANGER Model 75 & Size Electrocution Hazard! HIGH VOLTAGE - Power Supply 120V - 60Hz Connections in terminal block M1 are high voltage (120V / 60Hz). Before making Power 118 W 125 W 133 W 142 W 173 W 182 W connections, verify appliance is disconnected...

  • Page 47: 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).

  • Page 48: Install Room Thermostat

    8 - ELECTRICAL CONNECTIONS FIGURE 8-4 Thermostat Connections 8.5 Install Room Thermostat 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.
  • Page 49 FIGURE 8-6 Kt Climate Curves Flow temp Outside temp Centigrade (°C) Fahrenheit (°F) Boiler Boiler Point Point Temp Temp 80 Is Default. 80 Is Default. Outdoor Temperature 80°C Is Default. Outdoor Temperature NOTE: Temperatures below -40 °F (-40 °C), maximum heating flow temperature set point no longer increases, curves shown on graph become horizontal.

  • Page 50: Indirect Storage Tank

    8 - ELECTRICAL CONNECTIONS FIGURE 8-7 Kt Indirect Storage Tank 8.7 Indirect Storage Tank Boilers DCBF - 75, 100, 125 can be electrically *125 Model shown - See Application Guide for sizes 75, 100 connected to indirect storage tank as follows: 10K Ω...
  • Page 51 8 - ELECTRICAL CONNECTIONS FIGURE 8-8 Circulator Pump Connections For more information please review the application guide received with your boiler. A field supplied pump relay is necessary for system pumps. Thermostat or Endswitch from zone valve or valves 240013509 REV A, [03/15/2022]...

  • Page 52: Start Up Procedure

    9 - START UP PROCEDURE - HEAT ONLY 9.2 Central Heating System Connections - Combi Central Heating System Connections DCBF-75,100 & 125 HEATING ONLY DCCF- 115, 150, & 205 COMBI (150 shown) WITH OPTIONAL INDIRECT DHW CONNECTION LEGEND 75/100/115/150 DCBF-75,100,125 HEATING ONLY Heating supply 11/2 "...

  • Page 53: System Start Up

    9 - START UP PROCEDURE FIGURE 9-1 Condensate Drain Assembly 9.3 System Start Up 150 Model shown (location similar in all sizes) 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 Pour 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 If dearation or gas recognition function is interrupted by WARNING power blackout, start function again when power is restored. Asphyxiation hazard! Fill condensate trap before Press together and hold at same time for at least starting boiler to avoid combustion products escaping 6 seconds.

  • Page 56: 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 57: Chimney Sweep Function

    9 - START UP PROCEDURE 9.12 Chimney Sweep Function For correct boiler operation, content of (CO2 - O2) in the combustion flue must be within tolerances indicated in table below. Gas A (Natural Gas) Gas E (LPG) Combustion DCBF-75 & 100 DCBF-165 DCBF-125 DCCF-115 &...

  • Page 58: Check Firing Rate

    9 - START UP PROCEDURE 9.15 Parameter Settings 9.14 Check Firing Rate Measure input, if a gas meter is installed in the Program boiler electronic board parameters as follows: system. • Press together, hold them down • Turn off gas to all other appliances. for 6 seconds until program “P01”...

  • Page 59: Description Of Parameters: Factory Settings

    9 - START UP PROCEDURE FACTORY SETTINGS 9.16 Description Of Parameters: Factory Settings 100,125,165 115,150,205 DHW Fast Modulation 00 =Standard Modulation - on DHW call for heat 10 seconds stabilization time before modulation 01 =Fast Modulation- on DHW call for heat 5 seconds stabilization time before modulation Gas used 00 = Gas A (Natural Gas) 01 = Gas E (LPG Gas)
  • Page 60 9 - START UP PROCEDURE FACTORY SETTINGS 9.16 Description Of Parameters: Factory Settings conti. 115, 100, 150,205 125,165 The values listed below are factory defaults, there may be differences for each application Model Fuel Natural Natural Natural Natural Natural Natural Natural Setting Ignition...

  • Page 61: Adjusting Maximum Heating Power

    9 - START UP PROCEDURE 9.17 Adjusting Maximum Heating Power Maximum boiler heating power can be reduced to suit requirements of heating system it serves. Table showing parameter P13 values according to desired maximum power model is shown for each single boiler.

  • Page 62: Operating Instructions

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

  • Page 63: Domestic Hot Water Mode

    10 - OPERATING INSTRUCTIONS WARNING 10.5 Frost Protection Burn, Scald Hazard! Water temperature over Boiler monitors supply and return water temperatures to 125°F (51°C) can cause severe burns and enable frost protection which automatically turns boiler scalding. See User's Manual before setting water and pump on.

  • Page 64: General Maintenance And Cleaning

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

  • Page 65: 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 Frequency of servicing will depend upon installation by qualified service agent. Boiler owner shall not conditions and usage, manufacturer recommends attempt these steps.

  • Page 66: 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 67: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model DCCF-115 & 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 strainer located on DHW hydraulic assembly (B).

  • Page 68: 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 position of flame sensing electrode and A. How to light and turn off boiler. How to operate replace it if necessary.

  • Page 69: Ratings And Capacities

    12 - RATINGS AND CAPACITIES 12 TECHNICAL DATA 12.1 Ratings and Capacity (1)(2) (1)(3) Net AHRI CH Input, MBH Model Heating Rating Water, AFUE% Number Maximum Minimum Capacity, MBH * DCBF-75 16.6 68.2 92.0 DCBF-100 93.5 16.6 85.4 95.0 DCCF-115 93.5 16.6 85.4...

  • Page 70: High Altitude Ratings

    12 - RATINGS AND CAPACITIES 12.3 High Altitude Ratings For elevations between 2000 ft (600 m) and 10,000 ft (3048 m), use the following information: Input, MBH (KW) Domestic Hot Water (DHW) Circuit Heating Model Altitude AFUE, % Min Output, Capacity, Max Input, Number...

  • Page 71: Available Boiler Pump Head

    12 - RATINGS AND CAPACITIES 12.5 Available Boiler Pump Head g 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 72: 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 73 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 74: 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 75: Glossary

    14 - GLOSSARY • APPLIANCE - Device to convert gas into energy; • CONDENSATE - Liquid separated from flue gas due to term includes any component, control, wiring, piping reduction in temperature. or tubing required to be part of the device. •...
  • Page 76 14 - GLOSSARY • METRIC GAS METERS • TWO PIPE SYSTEM - Type of venting that allows for exhaust flue and intake air piping to be separated Natural Gas from each other. Fresh air may be drawn in at a 127,116 x cu meters different area from where flue terminal is located.

  • Page 77: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-1 MODEL 75 & 100 - Heat Only 240013509 REV A, [03/15/2022]...
  • Page 78 APPENDIX A - WIRING DIAGRAMS A-2 MODEL 125 - Heat Only 240013509 REV A, [03/15/2022]...
  • Page 79 APPENDIX A - WIRING DIAGRAMS A-3 MODEL 165 - Heat Only 240013509 REV A, [03/15/2022]...
  • Page 80 APPENDIX A - WIRING DIAGRAMS A-4 MODEL 115 - Combi 240013509 REV A, [03/15/2022]...
  • Page 81 APPENDIX A - WIRING DIAGRAMS A-5 MODEL 150 - Combi 240013509 REV A, [03/15/2022]...
  • Page 82 APPENDIX A - WIRING DIAGRAMS A-6 MODEL 205 - Combi 240013509 REV A, [03/15/2022]...
  • 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 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 325 5479 ©2022 ECR International, Inc. www.ecrinternational.com...
  • Page 85 COMBI - 115F, 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. 800 325 5479 www.ecrinternational.com PN 240012875 REV. D [03/15/2022]...
  • 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 75F, 100F, 125F w/Zone circulators &...

  • Page 87: Important Safety Information

    IMPORTANT SAFETY INFORMATION 1. 1. Become familiar with symbols identifying Become familiar with symbols identifying 3. Installation shall conform to requirements of potential hazards. potential hazards. authority having jurisdiction or in absence of such 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 75F, 100F & 125F HEATING ONLY 165F HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 75F, 100F & 125F HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND 75/100/125 sweat sweat 11/4” 11/2” Heating Supply Connection [31.75 mm] [38.1 mm]...
  • Page 89 LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 115F & 150F/205F COMBI (150 shown) LEGEND 115/150 sweat sweat 11/4” 11/2” Heating Supply Connection [31.75 mm] [38.1 mm] sweat sweat 1/2" 3/4" Domestic Hot Water Outlet [12.7 mm] [22.2 mm] Condensate Drain Connection 1/2"...

  • 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 Use of Indirect Water Heater (DHW) Heating Water 1st Degree Burn 2nd and 3rd Degree Burn Only Boiler: Temperature Exposure Time For Exposure Time For An Setting An Adult Adult 120° F 1 minute 5 minutes Note Sensors supplied with this boiler are 130°...

  • Page 92: General Information - Wiring

    GENERAL INFORMATION - WIRING Electrical 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 93: Piping Legend

    PIPING LEGEND PIPING LEGEND ZONE VALVE BALL VALVE DHW INDIRECT TANK AIR SEPERATOR 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: 100F, 125F W/Zone Circulators & Dhw Tank- Piping Diagram

    75F, 100F, 125F W/ZONE CIRCULATORS & DHW TANK- PIPING DIAGRAM PN 240012875 REV. D [03/15/2022]...

  • Page 95: 100F, 125F W/Indirect Zone Circulators, Dhw Tank W/Sensor - Wiring Dia

    75F, 100F, 125F W/INDIRECT ZONE CIRCULATORS, DHW TANK W/SENSOR - WIRING DIA. PN 240012875 REV. D [03/15/2022]...

  • Page 96: 100F, 125F W/Indirect Zone Circulators & Dhw Tank W/T-Stat - Wiring Dia

    75F, 100F, 125F W/INDIRECT ZONE CIRCULATORS & DHW TANK W/T-STAT - WIRING DIA. NEC Class 2 Low Voltage PN 240012875 REV. D [03/15/2022]...

  • Page 97: 100F, 125F With Zone Valves & Dhw Tank - Piping Diagram

    75F, 100F, 125F WITH ZONE VALVES & DHW TANK - PIPING DIAGRAM PN 240012875 REV. D [03/15/2022]...

  • Page 98: 100F, 125F With Zone Valves, Dhw Tank W/Sensor - Wiring Dia

    75F, 100F, 125F WITH ZONE VALVES, DHW TANK W/SENSOR - WIRING DIA. PN 240012875 REV. D [03/15/2022]...

  • Page 99: 100F, 125F Zone Valves, Dhw Tank W/T-Stat - Wiring Diagram

    75F, 100F, 125F ZONE VALVES, DHW TANK W/T-STAT - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240012875 REV. D [03/15/2022]...

  • Page 100: With Zone Circulators - Piping Diagram

    165F WITH ZONE CIRCULATORS - PIPING DIAGRAM PN 240012875 REV. D [03/15/2022]...

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

    165F INDIRECT ZONE CIRCULATORS, DHW TANK W/ T-STAT - WIRING DIA. NEC Class 2 Low Voltage PN 240012875 REV. D [03/15/2022]...

  • Page 102: With Zone Valves - Piping Diagram

    165F WITH ZONE VALVES - PIPING DIAGRAM PN 240012875 REV. D [03/15/2022]...

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

    165F WITH INDIRECT ZONE VALVES, DHW TANK, TANK T-STAT - WIRING DIA. NEC Class 2 Low Voltage PN 240012875 REV. D [03/15/2022]...

  • Page 104: 150F & 205F With Zone Circulators - Piping Diagram

    115F, 150F & 205F WITH ZONE CIRCULATORS - PIPING DIAGRAM PN 240012875 REV. D [03/15/2022]...

  • Page 105: 150F & 205F With Zone Circulators - Wiring Diagram

    115F, 150F & 205F WITH ZONE CIRCULATORS - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240012875 REV. D [03/15/2022]...

  • Page 106: 150F & 205F With Zone Valves - Piping Diagram

    115F, 150F & 205F WITH ZONE VALVES - PIPING DIAGRAM PN 240012875 REV. D [03/15/2022]...

  • Page 107: 150F & 205F With Zone Valves - Wiring Diagram

    115F, 150F & 205F WITH ZONE VALVES - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240012875 REV. D [03/15/2022]...

  • 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 ZONE PUMPS OR ZONE VALVES Optional Indirect Tank CH System Pump PURGE VALVE MAGNETIC DIRT H2O Stainless SEPARATOR Steel Buffer Tank NOTE : Acceptable primary pump locations: Either 1 or 2.

  • 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 240012875 REV. D [03/15/2022]...
  • 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 240012875 REV. D [03/15/2022]...
  • 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 AR822-II 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. If adding an Indirect Tank with a sensor to Diagram of electrical connection of external indirect Heating Only Boiler - change PO3 parameter...

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

    CIRCULATOR CONNECTIONS - WIRING DIAGRAM SINGLE ZONE CIRCULATOR WIRING USING ARGO AR822-II PN 240012875 REV. D [03/15/2022]...

  • Page 117: 100 - Heat Only Wiring Diagram

    75 & 100 - HEAT ONLY WIRING DIAGRAM MODEL 75 & 100 - HEAT ONLY PN 240012875 REV. D [03/15/2022]...

  • Page 118: Heat Only Wiring Diagram

    125 - HEAT ONLY WIRING DIAGRAM MODEL 125 - HEAT ONLY PN 240012875 REV. D [03/15/2022]...
  • Page 119 165 - HEAT ONLY WIRING DIAGRAM MODEL 165 - HEAT ONLY PN 240012875 REV. D [03/15/2022]...

  • Page 120: Combi Wiring Diagram

    115 - COMBI WIRING DIAGRAM MODEL 115 - COMBI PN 240012875 REV. D [03/15/2022]...
  • Page 121 150 - COMBI WIRING DIAGRAM MODEL 150 - COMBI PN 240012875 REV. D [03/15/2022]...

  • Page 122: Combi Wiring Diagram

    205 - COMBI WIRING DIAGRAM MODEL 205 - COMBI PN 240012875 REV. D [03/15/2022]...

  • Page 123: Altitude Effects On Boiler Performance

    ALTITUDE EFFECTS ON BOILER PERFORMANCE MODEL 75 CALCULATED EFFECTS OF HI-ALTITUDE ON BOILER PERFORMANCE 80,000 75,000 70,000 65,000 60,000 HEAT MODE 55,000 Net Rating Heat Mode 50,000 45,000 40,000 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 ALTITUDE (FEET) MAC-115 MODELS 100/115 CALCULATED EFFECTS OF HI-ALTITUDE ON BOILER...
  • Page 124 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 125 APPLICATION TABLE - INDIRECT HOT WATER TANK PERFORMANCE CHART HEATING ONLY BOILERS 75, 100, 125, 165 Boiler Output Boiler Pressure Continuous Max. First Needed For Water Flow Drop Rating Hour Rating Maximum Through Through Coil Performance Coil Model Gal/Hr. @ Gal/Hr @ (BTU/Hr) Gal/Min...

  • Page 126: 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 127: Piping Diagram - Lwco Location

    LOW WATER CUTOFF PIPING DIAGRAM - LWCO LOCATION Arrange piping to prevent water Note dripping onto boiler. Illustrations are meant to show system piping concept only. Installer Note is responsible for all equipment and detailing required by authority having Air Vent jurisdiction.

  • Page 128: Low Water Cutoff - Detail

    LOW WATER CUTOFF LOW WATER CUTOFF - DETAIL PN 240012875 REV. D [03/15/2022]...

  • Page 129: 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 130: Troubleshooting Chart

    TROUBLESHOOTING CHART PN 240012875 REV. D [03/15/2022]...
  • Page 131 TROUBLESHOOTING CHART PN 240012875 REV. D [03/15/2022]...

  • Page 132: 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 133 FAULT SOLUTION SECTIONS PN 240012875 REV. D [03/15/2022]...
  • Page 134 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 135 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 136: Parameter Change History

    PARAMETER CHANGE HISTORY Parameter Changed Changed Date Reason From All specifications subject to change without notice. 2201 Dwyer Avenue, Utica, NY 13501 ©2022 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.
  • 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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Dunkirk dcbf-100Dunkirk dccf-115Dunkirk dcbf-125Dunkirk dccf-150Dunkirk dcbf-165Dunkirk dccf-205 ... Show all

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