ECR International Dunkirk DCB-75 Installation, Operation & Maintenance Manual
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ECR International Dunkirk DCB-75 Installation, Operation & Maintenance Manual

Condensing wall mounted gas fired boiler
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DCB-75
DCB-100
DCC-115
DCB-125
DCC-150
DCB-165
DCC-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 ECR International Dunkirk DCB-75

  • Page 1 DCB-75 DCB-100 DCC-115 DCB-125 DCC-150 DCB-165 DCC-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 DCC-205...
  • Page 3 CONTENTS : INSTALLATION, OPERATION, AND MAINTENANCE MANUAL (240013501) APPLICATION GUIDE (240011430) COMMISSIONING GUIDE (240011376) REQUIRED INSPECTION SPECIAL (240011561) BACK COVER...
  • Page 4 DCB-165...
  • Page 5 CONDENSING WALL MOUNTED GAS FIRED INSTALLATION, OPERATION & MAINTENANCE MANUAL Models: COMBI DCC-115, DCC-150 DCC-205 HEATING ONLY DCB-75, DCB-100, DCB-125, DCB-165 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com 240013501 REV A [03/15/2022]...
  • 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 ..........49 9.1 Central Heating System Connections - Central Heat Table Of Contents ............3 Models Only .............49 Physical Data..............4 9.2 Central Heating System Connections - Heating And 1 - Important Information ..........6 Domestic Hot Water Models ........50 2 - Introduction .............7 9.3 System Start Up ..........51...

  • Page 8: Physical Data

    PHYSICAL DATA Dimensions DIMENSIONS 75/100 / 125 115 / 150 165 / 205 Height 30" [763 mm] Width 17 3/4 " [450 mm] Depth 13 9/16" [345 mm] 21 1/2" [546 mm] 13/16" [21 mm] 3/4" [19.1 mm] Condensate Trap Connection ID Hose System Supply 3/4”...
  • Page 9 PHYSICAL DATA 75/100 125 HEAT 165 HEAT 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

    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 12: Component Listing

    3 - COMPONENT LISTING DUNKIRK - DCB-75 & 100 Exhaust Port Intake Port Dunkirk ITEM DCB 75 & 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 (Supply/ Return) QTY 2, (1 Shown for clarity) Flue Sensor...
  • Page 13 3 - COMPONENT LISTING DUNKIRK - DCB 125 Exhaust Port Intake Port Dunkirk ITEM DCB 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 (Supply/ Return) QTY 2, (1 Shown for clarity) Flue Sensor...
  • Page 14 3 - COMPONENT LISTING DUNKIRK - DCB 165 Exhaust Port Intake Port Dunkirk ITEM DCB 165 Pump Boiler Drain Tap Low Water Pressure Cutoff Gas Valve NTC Heating sensor (Supply/ Return) QTY 2, (1 Shown for clarity) Water Safety Thermostat Flue Sensor Coaxial Connector Heat Exchanger Temperature...
  • Page 15 3 - COMPONENT LISTING DUNKIRK - DCC 115 Exhaust Port Intake Port Dunkirk ITEM DCC 115 Pump with Air Separator Boiler Drain Tap Domestic Hot Water Turbine DHW Priority Sensor Controlled Fast Fill Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor Check Valve DHW Heat Exchanger...
  • Page 16 3 - COMPONENT LISTING DUNKIRK DCC-150 Exhaust Port Intake Port Dunkirk ITEM DCC 150 Pump with Air Separator Boiler Drain Tap Domestic Hot Water Turbine DHW Priority Sensor Controlled Fast Fill Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor Check Valve DHW Heat Exchanger...
  • Page 17 3 - COMPONENT LISTING DUNKIRK DCC-205 Exhaust Port Intake Port Dunkirk ITEM DCC-205 Pump Boiler Drain Tap Domestic Hot Water Turbine DHW Priority Sensor DHW Heat Exchanger Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor NTC Heating sensor (Supply/ 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 75, 100, 115, 125 & 150 165 & 205 13 9/16 in 211/2 in [345 mm] [546 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...

  • 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 • Support piping in accordance with pipe manufacturer's WARNING instruction and authority having jurisdiction. In absence Fire, explosion, and asphyxiation hazard. Improper of manufacturer's instruction use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located installation could result in death or serious at intervals of 3 ft.

  • Page 22: Definitions

    5 - COMBUSTION AIR AND VENT PIPING 5.2 Definitions 5.3 Removal of Existing Boiler From Common Vent 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 5.5 Vent Termination WARNING • Terminate combustion air and vent pipes with fittings or Manufacturer recommends this condensing boiler be coaxial vent kit. Refer to venting illustrations for details. vented with approved polypropylene venting 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 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 5-3 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. 8-3/4 sheet metal screws and must be zinc coated.

  • Page 27: Twin Pipe Systems

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

  • Page 28: Twin Pipe Polypropylene Adapter Kit Installation

    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 75/100/115/125/150 Boilers [See Figures 5-11, 5-12 & 5-13] Inner Gasket Outer Gasket Inspect Coaxial Connector on top of boiler. Confirm the Fresh Air Cover factory installed inner and outer gaskets are in place.

  • Page 29: Twin Pipe Cpvc Adapter Kit Installation

    5 - COMBUSTION AIR AND VENT PIPING 5.12 Twin Pipe CPVC Adapter Kit Installation 5.11 Twin Pipe Polypropylene Adapter Kit Installation 165/205 Boilers 165/205 Boilers [See Figures 5-11, 5-12, 5-17, 5-18 & 5-19] [See Figures 5-15 through 5-17] Inspect Coaxial Connector on top of boiler. Confirm the 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. 5.13 Securing Twin Pipe Polypropylene Venting Venting manufacturer's use a device to secure Note single wall twin pipe polypropylene vent pieces...
  • 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 NOTE: 3" shown for clarity. 12" between vent and combustion air of other boilers This Termination required in all multiple boiler installations.

  • 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 vent systems shall only be run vertical. Note Horizontal runs before adapting to flexible must be rigid pipe.
  • 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 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. 5.15 Condensate Piping •...

  • Page 36: Hydronic Piping

    6 - HYDRONIC PIPING 6.1 General Boiler rated at 50 psig (3.45 bar) maximum Note • Primary/Secondary piping required. allowable working pressure. Boiler provided with • Install piping in accordance with authority having 30 psig (2.06 bar) safety relief valve. jurisdiction.

  • Page 37: Special Conditions

    6 - HYDRONIC PIPING FIGURE 6-2 Safety Relief Valve Discharge Piping 6.3 Safety Relief Valve and Air Vent • Install safety relief valve using pipe fitting provided with boiler. See Figure 6-2. • Install safety relief valve with spindle in vertical position.

  • Page 38: 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 39 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 40: 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 41: Manufacturer Recommendation - Flter On Dhw Inlet

    6 - HYDRONIC PIPING 6.7 Manufacturer Recommendation - Filter 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 filter prevents any sedimentation and debris from your water supply piping from entering the boiler.

  • Page 42: Central Heating System

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

  • Page 43: 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 source. requirements: Failure to comply will result in death or serious injury.

  • Page 44: 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 45 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 46: 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 47: Electrical Connections

    8 - ELECTRICAL CONNECTIONS DANGER Model 75 & 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 48: 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 49: Install Room Thermostat

    8 - ELECTRICAL CONNECTIONS FIGURE 8-4 Room Thermostat Connections 8.5 Install Room Thermostat Install room 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 50 8 - ELECTRICAL CONNECTIONS FIGURE 8-6 Kt Climate Curves Flow temp Outside temp Centigrade (°C) Fahrenheit (°F) Boiler Boiler Point Point Temp Temp 80 Is Default. Outdoor Temperature 80°C Is Default. Outdoor Temperature NOTE: Températures inférieures à -40 ° F (-40 ° C), le point de jeu maximal de la température de l’eau de la chaudière n’augmente plus, les courbes indiquées sur le graphique deviennent horizontales.

  • Page 51: Options For Indirect Water Heater Connections

    8 - ELECTRICAL CONNECTIONS FIGURE 8-7 Kt Indirect Storage Tank 8.7 Options for Indirect Water Heater Connections *125 Model shown - See Application Guide for size 75, 100 Boilers using optional tank sensor DCB-75, DCB-100 & DCB- 125 can be electrically connected to indirect storage tank as follows: 10K Ω...
  • Page 52 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 240013501 REV A [03/15/2022]...

  • Page 53: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Central Heating System Connections - CENTRAL HEAT MODELS ONLY DCB-75, DCB-100 & DCB-125 HEAT ONLY DCB-165 HEAT ONLY WITH OPTIONAL INDIRECT DHW CONNECTION DCB-75/100 /125 HEAT ONLY Boiler Connections WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND 75 / 100 / 125 Pressure Gauge...
  • Page 54 9 - START UP PROCEDURE 9.2 Raccordements du système de chauffage central - MODÈLES DE CHAUFFAGE ET D’EAU CHAUDE DOMESTIQUE DCC-115 & 150 COMBI DCC-205 COMBI Boiler Connections LEGEND 115 & 150 Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] 3/4"...

  • Page 55: 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 56: 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 57: Prior To Commissioning

    9 - START UP PROCEDURE If dearation or gas recognition function is interrupted WARNING by power blackout, start function again when power is Asphyxiation hazard! Fill condensate trap before restored. Press together and hold at same starting boiler to avoid combustion products escaping time for at least 6 seconds.

  • Page 58: 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. The process begins at minimum power.

  • Page 59: Chimney Sweep Function

    9 - START UP PROCEDURE Gas A (Natural Gas) Gas E (LPG) Combustion DCB-75 & 100 DCB-165 DCB-125 Table DCC-115 & 150 DCC-205 CO2 % O2 % CO2 % O2 % CO2 % O2 % CO2 % O2 % Nominal value 10.0 Maximum Power...

  • Page 60: Check Firing Rate

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

  • Page 61: 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 62 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 Natural Natural Natural Natural Natural Natural Natural Fuel Setting Ignition...

  • Page 63: 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. To access and edit P13 values, proceed as described in Section 9.15 Parameter Settings.

  • Page 64: 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 65: Domestic Hot Water Mode

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

  • Page 66: 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 67: 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 conditions qualified service agent. Boiler owner shall not attempt and usage, manufacturer recommends annually.

  • Page 68: 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 69: Hydraulic Unit (Dhw)

    11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model DCC-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 70: User Information

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

  • Page 71: Ratings And Capacities

    12 - 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 DCB-75 16.6 68.2 60.0 92.0 DCB-100 93.5 16.6 85.4 95.0 DCC-115 93.5...

  • Page 72: 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 Capacity, AFUE, % Max Input, Min Input, Max Output, Min Output,...
  • Page 73 12 - RATINGS AND CAPACITIES 12.5 Available Boiler Pump Head 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 74: 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 75 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 76: Anomalies Table For The Installer

    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 77: 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 78 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 79: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-2 MODEL 75 & 100 - Heat Only 240013501 REV A [03/15/2022]...
  • Page 80 APPENDIX A - WIRING DIAGRAMS A-2 MODEL 125 - Heat Only 240013501 REV A [03/15/2022]...
  • Page 81 APPENDIX A - WIRING DIAGRAMS A-3 MODEL 165 - Heat Only 240013501 REV A [03/15/2022]...
  • Page 82 APPENDIX A - WIRING DIAGRAMS A-1 MODEL 115 - Combi 240013501 REV A [03/15/2022]...
  • Page 83 APPENDIX A - WIRING DIAGRAMS A-4 MODEL 150 - Combi 240013501 REV A [03/15/2022]...
  • Page 84 APPENDIX A - WIRING DIAGRAMS A-5 MODEL 205 - Combi 240013501 REV A [03/15/2022]...
  • Page 85 NOTES 240013501 REV A [03/15/2022]...
  • Page 86 NOTES 240013501 REV A [03/15/2022]...
  • Page 87 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 88 • 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 89 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. 800 325 5479 www.ecrinternational.com PN 240011430 REV. Q [03/15/2022]...
  • Page 90 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 75, 100, 125 w/Zone circulators &...

  • Page 91: 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 92: Labor Saving Piping Manifolds / Near Boiler Piping Connections

    LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 75, 100 & 125 HEATING ONLY 165 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 75, 100 & 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND 75/100/125 Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating Return Connection 3/4"...
  • Page 93 LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 115 & 150 COMBI 205 COMBI LEGEND 115 & 150 Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating Return Connection 3/4" [22.2 mm] 1” [25.4 mm] 1/2" Domestic Cold Water Inlet 3/4"...

  • Page 94: 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 95 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 96: 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 97: 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 98: W/Zone Circulators & Dhw Tank- Piping Diagram

    75, 100, 125 W/ZONE CIRCULATORS & DHW TANK- PIPING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 99: W/Indirect Zone Circulators, Dhw Tank W/Sensor - Wiring Dia

    75, 100, 125 W/INDIRECT ZONE CIRCULATORS, DHW TANK W/SENSOR - WIRING DIA. PN 240011430 REV. Q [03/15/2022]...

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

    75, 100, 125 W/INDIRECT ZONE CIRCULATORS & DHW TANK W/T-STAT - WIRING DIA. NEC Class 2 Low Voltage PN 240011430 REV. Q [03/15/2022]...

  • Page 101: With Zone Valves & Dhw Tank - Piping Diagram

    75, 100, 125 WITH ZONE VALVES & DHW TANK - PIPING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 102: With Zone Valves, Dhw Tank W/Sensor - Wiring Diagram

    75, 100, 125 WITH ZONE VALVES, DHW TANK W/SENSOR - WIRING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 103: Zone Valves, Dhw Tank W/T-Stat - Wiring Diagram

    75, 100, 125 ZONE VALVES, DHW TANK W/T-STAT - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. Q [03/15/2022]...

  • Page 104: With Zone Circulators - Piping Diagram

    165 WITH ZONE CIRCULATORS - PIPING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 105: Indirect Zone Circulators, Dhw Tank W/ T-Stat - Wiring Dia

    165 INDIRECT ZONE CIRCULATORS, DHW TANK W/ T-STAT - WIRING DIA. NEC Class 2 Low Voltage PN 240011430 REV. Q [03/15/2022]...

  • Page 106: With Zone Valves - Piping Diagram

    165 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 107: 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. Q [03/15/2022]...

  • Page 108: 205 With Zone Circulators - Piping Diagram

    115, 150 & 205 WITH ZONE CIRCULATORS - PIPING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 109: 205 With Zone Circulators - Wiring Diagram

    115, 150 & 205 WITH ZONE CIRCULATORS - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. Q [03/15/2022]...

  • Page 110: 205 With Zone Valves - Piping Diagram

    115, 150 & 205 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. Q [03/15/2022]...

  • Page 111: 205 With Zone Valves - Wiring Diagram

    115, 150 & 205 WITH ZONE VALVES - WIRING DIAGRAM NEC Class 2 Low Voltage PN 240011430 REV. Q [03/15/2022]...

  • Page 112: 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 113 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. Q [03/15/2022]...

  • Page 114: 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. Q [03/15/2022]...
  • Page 115 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. Q [03/15/2022]...
  • Page 116 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 117: 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 118: 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 119: Indirect Storage Tank Sensor Kit

    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 120: Single Zone Circulator Wiring Using Argo Ar822-Ii

    CIRCULATOR CONNECTIONS - WIRING DIAGRAM SINGLE ZONE CIRCULATOR WIRING USING ARGO AR822-II PN 240011430 REV. Q [03/15/2022]...

  • Page 121: 100 - Heat Only Wiring Diagram

    75 & 100 - HEAT ONLY WIRING DIAGRAM MODEL 75 & 100 - HEAT ONLY PN 240011430 REV. Q [03/15/2022]...

  • Page 122: Heat Only Wiring Diagram

    125 - HEAT ONLY WIRING DIAGRAM MODEL 125 - HEAT ONLY PN 240011430 REV. Q [03/15/2022]...
  • Page 123 165 - HEAT ONLY WIRING DIAGRAM MODEL 165 - HEAT ONLY PN 240011430 REV. Q [03/15/2022]...

  • Page 124: Combi Wiring Diagram

    115 - COMBI WIRING DIAGRAM MODEL 115 - COMBI PN 240011430 REV. Q [03/15/2022]...
  • Page 125 150 - COMBI WIRING DIAGRAM MODEL 150 - COMBI PN 240011430 REV. Q [03/15/2022]...

  • Page 126: Combi Wiring Diagram

    205 - COMBI WIRING DIAGRAM MODEL 205 - COMBI PN 240011430 REV. Q [03/15/2022]...

  • Page 127: 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 128 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 129: Application Table - Indirect Hot Water Tank Performance Chart

    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 130: 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 131: 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 jurisdiction. Air Vent Position LWCO Above Top of Boiler...

  • Page 132: Low Water Cutoff - Detail

    LOW WATER CUTOFF LOW WATER CUTOFF - DETAIL PN 240011430 REV. Q [03/15/2022]...

  • Page 133: 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 134: Troubleshooting Chart

    TROUBLESHOOTING CHART PN 240011430 REV. Q [03/15/2022]...
  • Page 135 TROUBLESHOOTING CHART PN 240011430 REV. Q [03/15/2022]...

  • Page 136: 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 137 FAULT SOLUTION SECTIONS PN 240011430 REV. Q [03/15/2022]...
  • Page 138 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 139 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 140: 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 141 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 142 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 143 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...

This manual is also suitable for:

Dunkirk dcb-100Dunkirk dcb-115Dunkirk dcb-125Dunkirk dcb-150Dunkirk dcb-165Dunkirk dcc-205

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