ECR International Utica Boilers MAH-125 Installation, Operation And Maintenance Manual
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ECR International Utica Boilers MAH-125 Installation, Operation And Maintenance Manual

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

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Summary of Contents for ECR International Utica Boilers MAH-125

  • Page 1 MAH-125 MAC-150 MAH-165 MAC-205 CONDENSING WALL MOUNTED GAS FIRED BOILER Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com...
  • Page 2 CONTENTS : INSTALLATION, OPERATION, AND MAINTENANCE MANUAL (240011941) APPLICATION GUIDE (240011430) COMMISSIONING GUIDE (240011376) REQUIRED INSPECTION SPECIAL (240011561) BACK COVER...
  • Page 3 CONDENSING WALL MOUNTED GAS FIRED INSTALLATION, OPERATION & MAINTENANCE MANUAL Models MAH-125, MAC-150 MAH-165, MAC-205 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 240011941 REV G, [06/30/2019]...

  • Page 4: Verify Contents Received

    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 5: Table Of Contents

    TABLE OF CONTENTS Verify Contents Received ........2 9.7 Commissioning For The First Time ..... 44 9.8 Automatic Calibration Function ......44 Table Of Contents ..........3 9.9 Manual Calibration Function: ......45 Physical Data............4 9.10 Deaeration Function ........45 1 - Important Information ........

  • Page 6: Physical Data

    PHYSICAL DATA Dimensions DIMENSIONS 125 & 150 205 & 165 Height 30" [763 mm] 30 " [763 mm] Width 17 3/4 " [450 mm] 17 3/4 " [450 mm] Depth 13 9/16" [345 mm] 21 1/2" [571 mm] 13/16" [21 mm] 3/4"...
  • Page 7 PHYSICAL DATA 125 HEAT Front View 165 HEAT ONLY All Models ONLY Bottom View Bottom View Dimensions Dimensions 7" 5" 31/2" 101/2" 31/2" 4" 6" 9" 5" 81/2" Top View 91/2" All Models Combustion Vent Connector 205 COMBI 150 COMBI Bottom View Bottom View Dimensions...

  • Page 8: 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 9: 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 10: Component Listing

    3 - COMPONENT LISTING UTICA BOILER MAH-125 Utica Boiler ITEM MAH-125 Pump with Air Separator Boiler Drain Tap Gas Valve Low Water Pressure Cutoff 3-Way Valve with Motor Water Safety Thermostat NTC Heating sensor (Flow/Return) QTY 2, (1 Shown for clarity) Flue Sensor Pressure Switch Coaxial Flue Connector...
  • Page 11 3 - COMPONENT LISTING UTICA BOILER MAH-165 Utica Boiler ITEM MAH-165 Pump Boiler Drain Tap Low Water Pressure Cutoff Gas Valve NTC Heating sensor (Flow/Return) QTY 2, (1 Shown for clarity) Water Safety Thermostat Flue Sensor Coaxial Connector Heat Exchanger Temperature Protector Heat Exchanger Burner Door Temperature...
  • Page 12 3 - COMPONENT LISTING UTICA BOILER MAC-150 Utica Boiler ITEM MAC- 150 Pump with Air Separator Boiler Drain Tap Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor Controlled Fast Fill Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor Check Valve DHW Heat Exchanger...
  • Page 13 3 - COMPONENT LISTING UTICA BOILER MAC-205 Utica Boiler ITEM MAC-205 Pump Flow Sensor Flow Sensor with Water Filter and Flow Restrictor DHW Priority Sensor DHW Heat Exchanger Gas Valve NTC DHW Sensor Low Water Pressure Cutoff 3-Way Valve with Motor NTC Heating sensor (Flow/Return) QTY 2, (1 Shown for clarity) Water Safety Thermostat...

  • Page 14: 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 15: Clearances

    4 - LOCATING BOILER 4.2 Clearances Service Clearances 125 & 150 165 & 205 13 9/16 in 211/2 in [345 mm] [571.5 mm] Front View of Left Side View Boiler of Boiler 8 5/8 in [220 mm] 17 3/4 in 1 3/4 in 1 3/4 in 13.58 in /...

  • Page 16: 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. Note Lift boiler using chassis. Do not use front jacket, vent piping, water or gas fittings to lift boiler as it may cause damage to the boiler.

  • Page 17: Combustion Air And Vent Piping

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

  • Page 18: Removal Of Existing Boiler From Common Vent System

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

  • Page 19: Approved Venting Materials

    5 - COMBUSTION AIR AND VENT PIPING Venting shall be properly supported. WARNING Boiler shall not support any type of vent system. Manufacturer recommends this condensing boiler be All piping, glue, solvents, cleaners, fittings and vented with approved polypropylene venting material. components must conform to ASTM and ANSI standards.

  • Page 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 (Includes First Elbow And Termination) 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

    5 - COMBUSTION AIR AND VENT PIPING Figure 5-11 - Natalini Clamp WARNING Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe Installation Instructions completely and understand all requirements before beginning installation. 5.9 Securing Twin Pipe Polypropylene Venting Venting manufacturer's use a device to secure Note single wall twin pipe polypropylene vent pieces...
  • Page 24 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-14 - (2"/ 60 mm & 3" / 80 mm) Twin Pipe 12" (305 mm) Min. horizontal separation  Roof Vent CAN BE USED ON ALL SIZES between combustion air intake and vent of same appliance.
  • Page 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 6.1 General Boiler rated at 50 psig (345 kPa) maximum Note • Primary/Secondary piping required. allowable working pressure. Boiler provided with • Install piping in accordance with authority having jurisdiction. • Support system piping and safety relief valve discharge 30 psig (206 kPa) safety relief valve.

  • Page 30: Safety Relief Valve And Air Vent

    6 - HYDRONIC PIPING FIGURE 6-2 Safety Relief Valve Discharge Piping 6.2 Special Conditions Do not expose boiler and condensate piping to Note freezing temperatures. Safety Relief Valve • System piping exposed to freezing conditions: Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system.

  • Page 31: 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 32 6 - HYDRONIC PIPING FIGURE 6-3 - Piping Diagram - LWCO Location Arrange piping to prevent Low Water Cutoff (LWCO) Note (See Figure 6-6 for detail) water dripping onto boiler. Position LWCO Above Illustrations are meant to Top of Boiler Note show system piping concept Purge Valve...

  • Page 33: 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 34: Manufacturer Recommendation - Strainer

    6 - HYDRONIC PIPING 6.7 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 35: Central Heating System

    6 - HYDRONIC PIPING 6.8 Central Heating System • Flow of water will operate the DHW flow switch which requests the 3 way valve to change position. This will allow Boiler is designed for use in a sealed central heating system. the pump to circulate the primary water through the DHW Design the system to operate with flow temperatures of up to plate heat exchanger.

  • Page 36: 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 37: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING NOTICE FIGURE 7-1 Sediment trap shall be located upstream of gas controls. 7.2 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 38: 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 39: 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 40: Install Room End Switch

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

  • Page 41: Indirect Storage Tank

    8 - ELECTRICAL CONNECTIONS FIGURE 8-7 Kt Indirect Storage Tank 8.8 Indirect Storage Tank Boilers MAH-125 & MAH-165 can be electrically connected to *125 Model shown - See Application Guide for size 165 indirect storage tank as follows: 10K Ω •...

  • Page 42: Start Up Procedure

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

  • Page 43: Central Heating System Connections - Combi

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

  • Page 44: System Start Up

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

  • Page 45: Control Panel

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

  • Page 46: Prior To Commissioning

    9 - START UP PROCEDURE NOTICE Boiler must not shutoff during calibration. Note Open all heating zones in heating or DHW All connections shall be made and water added before mode to ensure boiler does not shutoff. performing this function. 9.8 Automatic Calibration Function Before performing this function verify there are no heat NOTICE...

  • Page 47: 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 48: Chimney Sweep Function (Co2 Adjust)

    9 - START UP PROCEDURE 9.12 Chimney Sweep Function (CO Adjust) For correct boiler operation, content of (CO ) in the combustion flue must be within tolerances indicated in table below. COMBUSTION TABLE Gas A Gas A Gas A Gas A (Natural Gas) (Natural Gas) (Natural Gas)

  • Page 49: 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 @ Example: Natural Gas - Gas flow from 100% Fire (MBH) Meter = 2 cu ft Size Measured time = 72 seconds 3600 x 2 cu ft...
  • Page 50 9 - START UP PROCEDURE FACTORY SETTINGS 9.16 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 51: 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 52: 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. After a 3 minute anti-short cycling stage the combustion If you do not follow these instructions exactly, fan comes on at ignition speed, closing the air pressure a fire or explosion may result causing property switch, allowing power to spark generator and gas valve,...

  • Page 53: 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 54: Maintenance And Routine Servicing

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

  • Page 55: 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 56: Hydraulic Unit (Dhw)

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

  • Page 57: User Information

    11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information Advise and demonstrated to User the following important information: A. How to light and turn off boiler. How to operate system controls. B. Importance of annual servicing of boiler to ensure safe and efficient operation.

  • Page 58: Ratings And Capacities

    12 - RATINGS AND CAPACITIES 12 TECHNICAL DATA 12.1 Ratings and Capacity CH Input, MBH Net AHRI (1)(3) Model Heating (1)(2) CH AFUE% Number Capacity, MBH * Maximum Minimum Rating Water, MBH MAH-125 95.0 MAC-150 95.0 MAH-165 29.5 95.0 MAC-205 29.5 95.0 (1) 1000 Btu/hr (British Thermal Units Per Hour)

  • Page 59: 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) Heating Domestic Hot Water (DHW) Circuit Model Altitude AFUE, % Capacity, Max Input, Min Input, Max Output, Min Output,...

  • Page 60: 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 61 13 - TROUBLE SHOOTING 13.1 Error Messages and Resetting the Boiler - continued Error Description Operation 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 Fault flame (parasitic flame).

  • Page 62: 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 63: Glossary

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

  • Page 65: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-1 MODELS 125 - Heat Only 240011941 REV G, [06/30/2019]...
  • Page 66 APPENDIX A - WIRING DIAGRAMS A-2 MODELS 165 - Heat Only 240011941 REV G, [06/30/2019]...

  • Page 67: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-3 MODELS 150 - Combi 240011941 REV G, [06/30/2019]...

  • Page 68: Appendix A - Wiring Diagrams

    APPENDIX A - WIRING DIAGRAMS A-4 MODELS 205 - Combi 240011941 REV G, [06/30/2019]...
  • Page 69 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 • 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. 800 253 7900 ©2019 ECR International, Inc. www.ecrinternational.com BDR THERMEA GROUP...
  • Page 71 COMBI - 150, 205 This manual has been prepared for use with the appropriate Installation, Operation and Maintenance Manual. Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 240011430 REV. M [06/30/2019]...
  • Page 72 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 Zone Circulator Pumps - Piping Diagram .............. 10 W/ Indirect Zone Pumps, DHW Tank, Tank Sensor - Wiring Diagram ......

  • 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

    LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 125 HEATING ONLY 165 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4"...
  • Page 75 LABOR SAVING PIPING MANIFOLDS / NEAR BOILER PIPING CONNECTIONS 150 COMBI 205 COMBI LEGEND Pressure Gauge Pressure Relief Valve 30.00 psi [2.11 bar] Heating return connection 3/4" [22.2mm] 1” [25.4mm] 1/2" Cold DHW inlet tap 3/4" NPT [15.9mm] MANIFOLD Gas shutoff connection 3/4"...

  • Page 76: 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 77 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 78: General Information - Wiring

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

  • Page 79: Piping Legend

    PIPING LEGEND PIPING LEGEND ZONE VALVE BALL VALVE INDIRECT DHW 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 80 125 WITH ZONE CIRCULATOR PUMPS PN 240011430 REV. M [06/30/2019]...

  • Page 81: Indirect Zone Pumps, Dhw Tank, Tank Sensor - Wiring Diagram

    125 W/ INDIRECT ZONE PUMPS & DHW TANK W/ TANK SENSOR - WIRING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 82: Indirect Zone Pumps & Dhw Tank, Tank T-Stat - Wiring Diagram

    125 W/ INDIRECT ZONE PUMPS & DHW TANK W/TANK T-STAT - WIRING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 83: With Zone Valves - Piping Diagram

    125 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 84: With Zone Valves, Dhw Tank, Tank Sensor - Wiring Diagram

    125 WITH ZONE VALVES, DHW TANK & TANK SENSOR - - WIRING DIAGRAM 125 with Zone Valves PN 240011430 REV. M [06/30/2019]...

  • Page 85: Indirect Zone Valves, Dhw Tank W/ Tank T-Stat - Wiring Diagram

    125 INDIRECT ZONE VALVES, DHW TANK W/ TANK T-STAT - WIRING DIAGRAM 125 with Zone Valves PN 240011430 REV. M [06/30/2019]...

  • Page 86: With Zone Circulator Pumps - Piping Diagram

    165 WITH ZONE CIRCULATOR PUMPS - PIPING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 87: Indirect Zone Pumps, Dhw Tank, Tank T-Stat - Wiring Diagram

    165 INDIRECT ZONE PUMPS, DHW TANK, TANK T-STAT - WIRING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 88: With Zone Valves - Piping Diagram

    165 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. M [06/30/2019]...

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

    165 INDIRECT ZONE VALVES, DHW TANK, TANK T-STAT -WIRING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 90: 205 With Zone Circulator Pumps - Piping Diagram

    150 & 205 WITH ZONE CIRCULATOR PUMPS - PIPING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 91: 205 With Zone Pumps - Wiring Diagram

    150 & 205 WITH ZONE PUMPS - WIRING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 92: 205 With Zone Valves - Piping Diagram

    150 & 205 WITH ZONE VALVES - PIPING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 93: 205 With Zone Valves - Wiring Diagram

    150 & 205 WITH ZONE VALVES - WIRING DIAGRAM PN 240011430 REV. M [06/30/2019]...

  • Page 94: Low Mass - Piping Diagram

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

  • Page 95: Low Mass - Wiring Diagram

    LOW MASS - WIRING DIAGRAM Low Mass Boiler Wiring with Buffer Tank Connect the buffer tank aquastat to terminals 3 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 240011430 REV.

  • Page 96: Optional Equipment & Accessories

    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 97 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 98 ACCESSORIES 2. 10k Ω Indirect Storage Tank Sensor Kit Parameter PO3 for Heating Only boiler, with no Note indirect tank remains Factory Set at 08. No change Heating Only boiler can be electrically connected to is required. Indirect Storage Tank. Diagram of hydraulic connection of external indirect If adding an Indirect Tank with a sensor to storage tank is shown below.

  • Page 99: Heat Only Wiring Diagram

    125 - HEAT ONLY WIRING DIAGRAM MODEL 125 - Heat Only PN 240011430 REV. M [06/30/2019]...
  • Page 100 165 - HEAT ONLY WIRING DIAGRAM MODEL 165 - Heat Only PN 240011430 REV. M [06/30/2019]...

  • Page 101: Combi Wiring Diagram

    150 - COMBI WIRING DIAGRAM MODEL 150 - Combi PN 240011430 REV. M [06/30/2019]...
  • Page 102 205 - COMBI WIRING DIAGRAM MODEL 205 - Combi PN 240011430 REV. M [06/30/2019]...

  • Page 103: 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 104: 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 105 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 106 LOW WATER CUTOFF Piping Diagram - LWCO Location Low Water Cutoff (LWCO) (See Figure 3 for detail) Arrange piping to prevent water Note dripping onto boiler. Air Vent Illustrations are meant to show Note system piping concept only. Installer Supply is responsible for all equipment and Position LWCO Above Top of Boiler...
  • Page 107 LOW WATER CUTOFF Low Water Cutoff - Detail PN 240011430 REV. M [06/30/2019]...

  • Page 108: 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 109: Troubleshooting Chart

    TROUBLESHOOTING CHART PN 240011430 REV. M [06/30/2019]...
  • Page 110 TROUBLESHOOTING CHART PN 240011430 REV. M [06/30/2019]...

  • Page 111: 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 112 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 113 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 114 FAULT SOLUTION SECTIONS PCB connector x22 Hall effect sensor terminals. PCB connector x22 Hall Is main water filter and assembly With water running effect sensor terminals. Check that the voltage is approximately Replace Hall Effect Sensor Is main water filter and clean and rotor free to move? through DHW circuit, Check the voltage is...
  • Page 115 NOTES PN 240011430 REV. M [06/30/2019]...
  • Page 116 NOTES PN 240011430 REV. M [06/30/2019]...
  • Page 118 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 119 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 120 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:

Utica boilers mac-150Utica boilers mah-165Utica boilers mac-205

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