UTICA BOILERS MACF-150 Installation, Operation And Maintenance Manual Download

Page: 1 / 118

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 253 7900

www.ecrinternational.com

MAHF-125

MAHF-165

MACF-150

MACF-205

CONDENSING

GAS FIRED BOILER

Summary of Contents for MACF-150

Page 1: ...Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com MAHF 125 MAHF 165 MACF 150 MACF 205 CONDENSING GAS FIRED BOILER ...

Page 2: ...CONTENTS INSTALLATION OPERATION AND MAINTENANCE MANUAL 240012874 APPLICATION GUIDE 240012875 COMMISSIONING GUIDE 240011376 REQUIRED INSPECTION SPECIAL 240011561 BACK COVER ...

Page 3: ...STALLATION OPERATION MAINTENANCE MANUAL Models MAHF 125 MACF 150 MAHF 165 MACF 205 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240012874 REV A 01 31 2020 ...

Page 4: ...y Boiler Copper Flush Bushing 1 2 x 1 4 NPT Copper Tee 1 1 24 x 1 1 4 x 1 2 Document Package VERIFY CONTENTS RECEIVED Threaded End Non Threaded End Copper Tee NOTICE Using proper brazing or soldering technique insert copper flush bushing into copper tee with threading up and non threaded end down If the threaded end is not UP the TP gauge cannot engage the threads in the bushing 240012874 REV A 01...

Page 5: ...g For The First Time 42 9 8 Automatic Calibration Function 42 9 9 Manual Calibration Function 43 9 10 De Aeration Function 43 9 11 Commission Set Up Gas Changing The Type Of Gas 43 9 12 Chimney Sweep Function CO2 Adjust 44 9 13 Combustion Adjustment Function CO2 44 9 14 Check Firing Rate 44 9 16 Description Of Parameters Factory Settings 45 9 15 Parameter Settings 45 9 16 Description Of Parameters...

Page 6: ...l requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never leave them unattended in bathtub or shower Never ...

Page 7: ...System Return 11 4 Sweat Connection 11 2 Sweat Connection Boiler Filling Connection External to Boiler Primary Water Content 1 gal 3 60 L 11 4 gal 4 73 L Central Heating Sealed System 125 150 165 205 Heat Exchanger Max Allowable Working Pressure 50 psi 3 45 bar Max System Pressure 30 00 psi 2 11 bar Min System Pressure 7 25 psi 0 50 bar Max System temperature 176 F 80 C Pressure Relief Valve Setti...

Page 8: ...2 in 7 92 in 201 mm 201 mm 6 63 in 6 63 in 168 mm 168 mm 4 35 in 4 35 in 111 mm 111 mm 6 12 in 6 12 in 156 mm 156 mm 6 12 in 6 12 in 155 mm 155 mm 7 31 in 7 31 in 186 mm 186 mm 3 42 in 3 42 in 87 mm 87 mm 1 80 in 1 80 in 46 mm 46 mm 43 65 in 43 65 in 1 1 m 1 1 m 40 23 in 40 23 in 1 0 m 1 0 m 37 20 in 37 20 in 95 m 95 m 2 99 in 2 99 in 76 mm 76 mm 3 15 in 3 15 in 80 mm 80 mm 10 in 10 in 255 mm 255 ...

Page 9: ...62 mm 62 mm 2 82 in 2 82 in 71 mm 71 mm 3 32 in 3 32 in 84 mm 84 mm 9 39 in 9 39 in 239 mm 239 mm 6 26 in 6 26 in 159 mm 159 mm 3 07 in 3 07 in 78 mm 78 mm 41 87in 41 87in 1 06 m 1 06 m 7 39 in 7 39 in 187 mm 187 mm 6 26 in 6 26 in 159 mm 159 mm 10 in 10 in 255 mm 255 mm 23 55 in 23 55 in 598 mm 598 mm 9 07 9 07 230 mm 230 mm 1 67in 1 67in 43mm 43mm 8 46 in 8 46 in 215 mm 215 mm 12 02 in 12 02 in ...

Page 10: ... 9 Pump with Air Separator 10 Boiler Drain Tap 11 Heating Return 12 Gas Inlet 13 Optional Indirect Tank Connection 14 Heating Supply Connection 15 Condensate Connection 16 Low Water Pressure Cutoff 17 3 Way Valve with Motor 18 Gas Valve 19 Water Safety Thermostat 20 NTC Heating sensor Flow Return QTY 2 1 Shown for clarity 21 Ignition Electrode 22 Pressure Switch 23 Pressure Relief Valve 9 2 4 1 3 ...

Page 11: ...s Inlet 16 DHW Outlet 17 Heating Supply Connection 18 Condensate Connection 19 DHW Heat Exchanger 20 NTC DHW Sensor 21 Low Water Pressure Cutoff 22 3 Way Valve with Motor 23 Gas Valve 24 Water Safety Thermostat 25 NTC Heating sensor Flow Return QTY 2 1 Shown for clarity 26 Ignition Electrode 27 Pressure Switch 28 Pressure Relief Valve Illustrations are a depiction of the boiler for general locatio...

Page 12: ...n 13 Cold Water DHW Inlet Tap 14 Gas Inlet 15 DHW Outlet 16 Heating Supply Connection 17 Condensate Connection 18 DHW Heat Exchanger 19 NTC DHW Sensor 20 Low Water Pressure Cutoff 21 3 Way Valve with Motor 22 Gas Valve 23 NTC Heating sensor Flow Return QTY 2 1 Shown for clarity 24 Water Safety Thermostat 25 Ignition Electrode 26 Pressure Relief Valve 9 15 2 24 23 18 4 1 25 3 6 5 7 8 26 10 11 13 12...

Page 13: ...parator 10 Boiler Drain Tap 11 Heating Return 12 Heating Supply Connection 13 Gas Inlet 14 Condensate Connection 15 Low Water Pressure Cutoff 16 Inlet Element 17 Gas Valve 19 Over Temperature Thermostat 20 NTC Heating Sensor 21 Ignition Electrode 22 Pressure Relief Valve 2B COMPONENT LISTING 240012874 REV A 01 31 2020 9 2 4 1 3 6 5 7 8 10 12 20 19 21 11 13 14 16 17 22 UTICA BOILER MAHF 165 ...

Page 14: ...e CH Turndown 5 5 1 DHW turndown 7 1 Maximum output available for domestic hot water MACF 150 136 000 btu h 40 kW capable of providing 3 5 U S gpm 13 2 liters min with a temperature rise of 70 F 39 C MACF 205 180 000 btu h 53 kW capable of providing 5 0 U S gpm 18 9 liters min with temperature rise of 70 F 39 C Integral Low Water Pressure Cutoff Optional Outdoor Temperature Reset Heat exchanger ov...

Page 15: ... crated boiler as close to selected location as possible and uncrate boiler Boiler may be moved into position with appliance dolly or 2 two wheel hand truck Insert dolly or hand truck under left hand side of boiler It is possible to slide boiler for short distance on smooth floor or surface Adjust the position of the boiler verify it is level and plumb Select level location central to piping syste...

Page 16: ...n 0 in 0 mm between Back of Unit and wall 0 in 0 mm between Back of Unit and wall 1 3 4 in 45 mm 13 4 in 45 mm 13 4 in 45 mm 450 mm Front View of Boiler 0in 0 mm 0in 0 mm Top View 0 in 0 mm 0 in 0 mm Combustible Clearances TABLE 1 BOILER CLEARANCES Dimension Combustible Materials 1 Manufacturer Recommended for Service 1 2 Top 0 0 cm 8 5 8 220 mm Left Side 1 3 4 45 mm 12 305 mm Right Side 1 3 4 45 ...

Page 17: ...he top of the boiler is included in equivalent length calculations Use U V stabilized polypropylene when it will be exposed to sunlight wind or prone to freeze ups Manufacturer requires use of an approved mechanical fastener which may vary per vent pipe manufacturer at every push fit gasket connection when using a single wall polypropylene vent system 5 2 Removal of Existing Boiler From Common Ven...

Page 18: ...ommon axis 2 Twin Pipe Exhaust and intake air are separate pipes Figure 5 1 Venting Support 5 COMBUSTION AIR AND VENT PIPING can be terminated using single wall terminals from the vent manufacturer or field built configuration using elbows or tees 240012874 REV A 01 31 2020 ...

Page 19: ...or serious injury Coaxial venting shall be fastened with screws Dual flue venting is NOT fastened with screws 1 Venting shall be properly supported 2 Boiler shall not support any type of vent system 3 All piping glue solvents cleaners fittings and components must conform to ASTM and ANSI standards In Canada ULC S636 and in the USA UL 1738 schedule 40 CPVC are the only approved vent system to be us...

Page 20: ...analyzer to verify there is no recirculation of combustion Ensure termination is positioned with slots at the bottom Figure 5 2 Coaxial Screw Placement 5 7 Coaxial Vent Screw Placement See Figure 5 2 Two 2 screws shall be fastened through the outer intake pipe behind the gaskets at equal distances approximately 180 apart Note the screws used must be no larger than No 8 3 4 sheet metal screws and m...

Page 21: ...D ON ALL SIZES Maintain 12 305 mm US 18 457 mm Canada clearance above highest anticipated snow level 24 610 mm above roof or ground Anticipated Snow Line FIGURE 5 5 Coaxial Vertical Exhaust CAN BE USED ON ALL SIZES 12 305 mm Minimum Separation Manufacturer Recommends Greater Separation FIGURE 5 7 Coaxial Horizontal Exhaust CAN BE USED ON ALL SIZES Multiple Appliances Multiple Appliances 24 610 mm ...

Page 22: ...ylene venting an adapter kit is available C Twin Pipe Separated Flue Exhaust and combustion air intake are not located in same general location D Twin Pipe Common Atmospheric Zone Termination Exhaust and combustion air intake are located in same general location and are of equal length Grade Snow Ice Maintain 12 305 mm US 18 457 mm Canada clearance above highest anticipated snow level 24 610 mm ab...

Page 23: ... the pipe 4 Insert the male end of of the second pipe into the clamp on the up etched side Force the two pipes together 5 Verify the two pipes are secure together with clamp in place 5 9 Securing Twin Pipe Polypropylene Venting Figure 5 11 Natalini Clamp UP UP UP NOTICE Venting manufacturer s use a device to secure single wall twin pipe polypropylene vent pieces to each other Proper application of...

Page 24: ... and vent of different appliances 15 381 mm Max horizontal length of vent Min vent intake between different appliances 12 305 mm Max allowable total vertical vent length with outside exposure is 10 ft 3 05 m Abandoned unused masonry chimney may be used as chase way for combustion air and vent Both combustion air and vent pipe must exit above top of chimney with clearances as shown in Figure 5 14 V...

Page 25: ...ers required in all multiple boiler installations FIGURE 5 22 2 60 mm ONLY Twin Pipe Side Wall Vent CAN BE USED ON ALL SIZES 3 80 mm Min 24 610 mm Max Separation See Grade Snow Ice Combustion Air Vent FIGURE 5 20 2 60 mm ONLY Vent Pipe with T CAN BE USED ON ALL SIZES See Grade Snow Ice Combustion Air Vent 3 80 mm Min 24 610 mm Max Separation 6 153 mm Min 24 610 mm Max Separation FIGURE 5 21 2 60 m...

Page 26: ...on assembly and clearances to maintain Avoid sharp bends in flexible venting FIGURE 5 24 3 80 mm Only Flexible Venting System CAN BE USED ON ALL SIZES Combustion Air Vent Terminal Flexible Vent Rigid Vent 5 COMBUSTION AIR AND VENT PIPING NOTICE Flexible vent systems shall only be run vertical Horizontal runs before adapting to flexible must be rigid pipe Flexible Pipe Minimum Maximum Vent Lengths ...

Page 27: ...ch side of center line extended above meter regulator assembly 3 ft 0 9 m within a height of 15 ft 4 5 m above the meter regulator assembly 3 ft 0 9 m I Clearance to service regulator vent outlet 3 ft 0 9 m 3 ft 0 9 m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 305 mm 3 ft 0 9 m K Clearance to mechanical air supply inlet 3 ft 0 9...

Page 28: ... field source condensate pump designated for use with condensing boiler if boiler located below disposal point Condensate pump should have overflow switch Condensate from Boiler is slightly acidic and may cause property damage if overflow Field source condensate neutralizing kit as required by authority having jurisdiction or for environmentally friendly condensate disposal FIGURE 5 26 Condensate ...

Page 29: ...o heat exchange surfaces and accumulate in pump cavities causing reduced efficiency and premature wear Flush system to remove any solid objects such as metal chips fibers or Teflon tape etc Flush system until water runs clean and piping is free of sediment Use purge valve to flush zoned systems each zone separately If purge valves and isolation valves are not installed install them to properly cle...

Page 30: ...NG Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Use pipe suitable for temperatures of 375 F 191 C or greater DO NOT use plastic pipe Install discharge piping per these instructions 6 HYDRONIC PIPING FIGURE 6 1 Safety Relief Valve 6 4 Trim Piping Temperature Pressure Gauge Install temperature pressure gauge in near boiler piping on supply side Some b...

Page 31: ...ALVE BEFORE TEE OR LWCO Note To Drain Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return Purge Valve Magnetic Dirt Separator Position Temperature Pressure Gauge on CH System Supply Side of Boiler Purge Valve Note Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by ...

Page 32: ...CO sensing device in the supply piping above the minimum height of boiler See Figure 6 2 Piping Diagram Position control in HORIZONTAL piping to assure proper boiler protection upright or 90 rotation For proper operation sensing element of the LWCO control shall be positioned in the tee to sense the main water stream Maintain minimum 1 4 spacing from pipe walls Element shall NOT contact the rear o...

Page 33: ...ation and debris from your water supply piping from entering the boiler Debris carried from the water supply will clog DHW water flow sensor potentially resulting in significant operation issues Locate the strainer as close to the boiler as possible and place on DHW domestic hot water inlet connection located at bottom of the boiler 6 HYDRONIC PIPING Potable water IN Potable water OUT 240012874 RE...

Page 34: ...late the gas rate accordingly When the domestic hot water demand ceases the burner will extinguish unless there is a demand for central heating 6 9 Frost Protection Mode Frost protection mode is integrated into the appliance when electricity is connected to the boiler regardless if power is on or off If temperature falls below 41 F 5 C boiler will fire on its minimum setting until flow temperature...

Page 35: ...testing of gas supply piping system at test pressures equal to or less than 1 2 psi 3 5 kPa Install boiler so that gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement condensate trap control replacement etc Gas meter and supply pipes must be capable of delivering the listed quantity of gas in addition to d...

Page 36: ...authority having jurisdiction Do not use matches candles open flames or other methods that can provide ignition source Correct leaks immediately and retest 7 3 Gas Orifice See Figure 7 2 Models 125 150 5 8 mm Natural LP Models 165 205 9 0 mm Natural LP Figure 7 1 Gas Piping NOTICE Sediment trap shall be located upstream of gas controls 7 GAS SUPPLY PIPING NOTICE If overheating occurs or gas supply...

Page 37: ...igh 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 8 ELECTRICAL CONNECTIONS FIGURE 8 2 Junction Box Left side of Boiler Junction Box with Knockouts and grommets 8 2 Install Room Thermostat Install room thermosta...

Page 38: ...incorporated in the power supply terminal block To check or replace fuse pull out black fuse carrier TERMINAL BLOCK M1 L Live brown N Neutral light blue Ground yellow green 1 2 contact for 120V Room Thermostat Place jumper back on terminals 1 2 of boiler terminal block M1 if room thermostat is not used or if Remote Control is not installed FIGURE 8 2 Terminal Block Locations Fuse Holders 2 DANGER ...

Page 39: ... CONNECTIONS 8 7 Optional Electrical Connections A 1K Ohm 1K Ω Outdoor Temperature Sensor To connect this accessory see figure 8 5 terminals 4 5 and instructions supplied with 1K Ω sensor B Setting Kt Climate Curve When external 1K Ω sensor is connected to boiler the electronic board adjusts the flow temperature calculated according to set Kt coefficient Select required curve by pressing as indica...

Page 40: ...rer Use of after market sensors will diminish boiler performance 8 ELECTRICAL CONNECTIONS FIGURE 8 7A Kt Indirect Storage Tank 8 9 Management of 0 10V Input P78 1 P78 2 0 10V DC Electrical Signal Input Heating Flow Setpoint Temperature Central Heating Heat Input Gross V F C kW Btu h 0 3 OFF 3 77 25 4 9 16 650 4 95 35 8 4 28 900 5 108 42 12 0 40 800 6 124 51 15 4 52 400 7 140 60 18 5 63 050 8 154 6...

Page 41: ...125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION 9 2 Central Heating System Connections Combi MACF 150 205 COMBI 150 shown LEGEND 150 205 A Heating supply connection 11 4 sweat 11 2 sweat B DHW outlet 1 2 sweat 3 4 sweat C Drain connection for condensate 3 4 NPT D Gas shutoff connection 3 4 NPT E Cold DHW inlet tap 1 2 sweat 3 4 sweat F Heating return connection 11 4 po sweat 11 2 po swea...

Page 42: ... out Close drain as soon as water appears Systems using radiators to remove air Vent each radiator in turn starting with lowest in the system It is important the pump is properly vented to avoid running it dry and damaging its bearings Unscrew and remove cap from center of pump Use screwdriver Rotate exposed spindle about half turn replace cap Check operation of heating pressure relief valve Pull ...

Page 43: ... temperature F C 16 Manufacturing information 07 Thermo fuse status 000 001 17 Fan speed i17 x100 08 Not used 18 Manufacturing information DHW temperature adjustment to increase the temperature and to decrease it Heating water temperature adjustment to increase the temperature and to decrease it Boiler operating information Operating mode DHW DHW Heating Heating Only ON Off Reset Exit menu functio...

Page 44: ...will implement a self learning procedure to reach correct ignition level 9 START UP PROCEDURE 9 8 Automatic Calibration Function Before performing this function verify the door is on the boiler and there are no heat demands in progress During this function ensure there is maximum heat exchange to the system in Heating or DHW mode DHW request to avoid boiler shutting off due to overheating Press an...

Page 45: ...n power is restored Press and together and hold at same time for at least 6 seconds B If display shows fault E118 low pressure in hydraulic circuit during gas recognition function open filling tap on appliance and restore correct pressure C If gas recognition function is interrupted due to fault e g E133 no gas press to reset Then press and for at least 6 seconds to restart the function again If g...

Page 46: ...ombustion Adjustment Function CO2 This function sets out to partially adjust the value of CO2 Use the following procedure 1 Press buttons and together for at least 6 seconds When the function is enabled displays shows On for a few seconds followed by program row 304 alternated with the of boiler power 2 After burner is lit boiler reverts to maximum DHW power 100 When display shows 100 it is possib...

Page 47: ...ire MBH Size 125 125 150 150 165 164 205 205 9 16 Description Of Parameters Factory Settings FACTORY SETTINGS 125 165 150 205 P01 Manufacturer information 01 P02 Gas used 00 Gas A Natural Gas 01 Gas E LPG Gas 00 P03 Hydraulic system 00 instantaneous appliance 03 instantaneous appliance with pre heat function 04 heating only appliance with DHW thermostat 05 appliance with external storage indirect ...

Page 48: ...g output 0 100 100 80 P14 DHW max output 0 100 100 P15 Min heating output 0 100 00 P16 Maximum CH set point C 00 176 F 80 C 01 113 F 45 C 00 P17 Pump overrun time in heating mode 01 240 minutes 03 P18 Burner ignition delay in CH mode 00 10 minutes 00 10 seconds 03 P19 Manufacturer information 07 P20 Pump overrun time in DHW mode seconds 30 P21 Anti legionellosis function 00 Disabled 01 Enabled 00 ...

Page 49: ... 7 6 30 700 9 0 11 9 34 100 10 0 15 12 40 900 12 0 22 18 47 700 14 0 30 24 54 500 16 0 37 29 61 400 18 0 44 35 68 200 20 0 52 41 75 100 22 0 59 47 81 900 24 0 67 53 88 700 26 0 74 59 95 500 28 0 80 65 102 300 30 0 88 71 109 200 32 0 96 75 112 600 33 0 100 80 9 START UP PROCEDURE Btu h kW MAHF 165 MACF 205 27 400 8 0 0 0 31 300 9 2 4 3 35 800 10 5 7 6 41 300 12 1 11 9 46 500 13 6 15 12 55 900 16 4 ...

Page 50: ...omes on at ignition speed closing the air pressure switch allowing power to spark generator and gas valve creating ignition in the combustion chamber 3 Flame sensor acknowledges presence of flame in combustion chamber sending a signal to the control board 4 After initial stabilization period the control board monitors supply and return temperatures and modulates fan speed and gas rate accordingly ...

Page 51: ... Verify proper operation after servicing Note Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe trouble free operation and maximum efficiency Circulator pump and combustion air blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication Lubricate field sourced pumps and or motors accord...

Page 52: ... Check spark gap positioning and height of electrodes 7 Check fan impeller is clean and free to rotate WARNING Combustion chamber insulation in this product contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristo...

Page 53: ...the Boiler turn boiler off isolate electrical supply close boiler gas service cock allow boiler to cool drain boiler through onboard drain if available or external drain valve 11 5 Draining the Heating Circuit Follow all steps in 11 4 Close central heating flow and return valves Connect suitable pipe to drain point Route it to suitable container Open drain tap 11 GENERAL MAINTENANCE AND CLEANING 2...

Page 54: ...ptable volume and pressure Turn off boiler Thoroughly flush water pipe work Repressurize the system 11 9 Final Assembly Place front jacket in position over boiler Secure in position at top using screws previously removed If boiler is to be left in service with the User set controls and room thermostat If boiler is not to be handed over immediately close boiler gas service valve and turn off electr...

Page 55: ...cient operation C Servicing or replacement of parts shall be carried out by a qualified personnel D Ensure boiler controls and room thermostat if fitted are set to User s requirements E Tell User about sealed system pressure F Tell User if display is active and boiler has not operated for 24 hours for heating or hot water the pump will automatically operate for 1 minute G Explain to User an intern...

Page 56: ...W temp 140 F 60 C Model Number CH Input MBH 1 1 2 CH Heating Capacity MBH 1 3 Net AHRI Rating Water MBH 2 AFUE Maximum Minimum MAHF 125 125 22 113 98 95 0 MACF 150 125 22 113 98 95 0 MAHF 165 164 29 5 153 133 95 0 MACF 205 164 29 5 153 133 95 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Efficiency are based on DOE Department of Energy test proc...

Page 57: ...3 105 95 0 141 20 3 120 17 Max CH Supply temp 176 F 80 C for MAHF 125 and MACF 150 Max DHW temp 140 F 60 C MACF 150 Max DHW Flow rate 3 5 gpm 13 2 l min MACF 205 Max DHW flow rate 5 0 gpm 18 9 L min 12 3 High Altitude Ratings 12 4 High Altitude Chart GAS Natural LP Model Altitude 0 2 000 ft 0 610 m 2 000 10 000 ft 610 3 048 m 0 2 000 ft 0 610 m 2 000 10 000 ft 610 3 048 m Parameter P71 High Fire F...

Page 58: ...ck correct circulation of water and pump 118 Hydraulic pressure too low Refill heating system by opening cold water tap 117 Hydraulic pressure too high Relieve pressure via relief valve or drain Ensure water feed is operating correctly 125 No circulation of water control performed via temperature sensor Check correct circulation of water and pump Check correct connection of NTC sensor on pipe 128 ...

Page 59: ...of the flue duct E69 Combustion level out of range Check flue recirculation and the combustion levels E70 Flame signal problem micro interruption of the flame signal Check cable and integrity of the sensing electrode verify the continuity between burner and earth E73 Combustion adjustment modified during operation Review and monitor other codes such as E53 E92 and E128 Error Description Operation ...

Page 60: ...36 C04 P37 C05 P38 C06 RESET ANOMALY P39 C07 P40 C08 P41 C09 FAILURE CODE NUMBER OF TIMES OCCURRED 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 8 THERMOSTATIC POST CIRCULATION TEMPERATURE C00 LAST FAILURE C06 FIRST FAILURE C07 LAST LOCKOUT C09 FIRST LOCKOUT PHASE STATUS CODES 0 STANDBY 1 PREPURGE 3 INTERPURGE 4 SAFETY TIME 5 ...

Page 61: ...h wood compressed paper plant fibers or other materials capable of being ignited and burned Such material shall be considered combustible even though flame proofed fire retardant treated or plastered COMBUSTION AIR Air that is drawn into an appliance to mix with fuel and support combustion CONDENSATE Liquid separated from flue gas due to reduction in temperature DIRECT VENT BOILER Boiler construct...

Page 62: ... or servicing of appliances and equipment Experienced in such work Familiar with all precautions required Complies with all requirements of authority having jurisdiction SAFETY RELIEF VALVE Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner in event sour...

Page 63: ...61 A 1 MODELS 125 Heat Only APPENDIX A WIRING DIAGRAMS 240012874 REV A 01 31 2020 ...

Page 64: ...62 APPENDIX A WIRING DIAGRAMS A 2 MODELS 165 Heat Only 240012874 REV A 01 31 2020 ...

Page 65: ...63 A 2 MODELS 150 Combi APPENDIX A WIRING DIAGRAMS 240012874 REV A 01 31 2020 ...

Page 66: ...64 A 4 MODELS 205 Combi APPENDIX A WIRING DIAGRAMS 240012874 REV A 01 31 2020 ...

Page 67: ...65 NOTES 240012874 REV A 01 31 2020 ...

Page 68: ...66 NOTES 240012874 REV A 01 31 2020 ...

Page 69: ...TU 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 Installer s Name Signature ...

Page 70: ...S OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating 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...

Page 71: ...l 800 253 7900 www ecrinternational com PN 240012875 REV A 01 31 2020 This manual has been prepared for use with the appropriate Installation Operation and Maintenance Manual APPLICATION GUIDE FOR USE WITH FLOOR STANDING HEATING ONLY 125F 165F FLOOR STANDING COMBI 150F 205F ...

Page 72: ...rect Zone Pumps Dhw Tank Tank T Stat Wiring Diagram 16 165F Indirect Zone Pumps Dhw Tank Tank T Stat 16 165F W Zone Valves Piping Diagram 17 165F Indirect Zone Valves Dhw Tank Tank T Stat Wiring Diagram 18 165F Indirect Zone Valves Dhw Tank Tank T Stat Wiring Diagram 18 150F 205F With Zone Circulator Pumps Piping Diagram 19 150F 205F With Zone Pumps Wiring Diagram 20 150F 205F With Zone Pumps 20 1...

Page 73: ... Maintenance Manual for additional information WARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation 3 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements United States National Fuel Gas Cod...

Page 74: ...INDIRECT DHW CONNECTION 125F HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION 150F 205F COMBI 150 shown LEGEND 150 205 A Heating supply connection 11 4 sweat 11 2 sweat B DHW outlet 1 2 sweat 3 4 sweat C Drain connection for condensate 3 4 NPT D Gas shutoff connection 3 4 NPT E Cold DHW inlet tap 1 2 sweat 3 4 sweat F Heating return connection 11 4 sweat 11 2 sweat A E A B A A A E A A A B A C...

Page 75: ...ined supply and return pipe lengths to maximum linear lengths of 20 ft 6 1 m between boiler and closely spaced tees when minimum NPT pipe size is used Linear length may be increased if supply and return pipe size is increased to limit pressure drop Manufacturer recommends installing a shutoff and purge valve to use during commissioning to ensure the boiler does not shut down due to over temperatur...

Page 76: ... Locate tank as close to boiler as possible Size DHW tank piping and system to use only internal boiler pump See available pump flow rate chart page 35 of this manual Change P03 on boiler for application as specified on the wire diagram and Boiler Control section of Installation Operation Maintenance Manual supplied with the boiler GENERAL INFORMATION HYDRONIC PIPING Water Temperature Setting 1st ...

Page 77: ... of a H2O Buffer Tank Reference the zone control manufacturer instruction manual for control operation and priority setting of DHW zones Note DO NOT use 120 V thermostat terminals m1 1 and 2 Provided Wiring and Piping illustrations are meant to show system concepts only Installer is responsible for all equipment required by authority having jurisdiction Note SUPPLY Cord 120V 60HZ BOILER CONTROL 10...

Page 78: ...SS VALVE DIVERTER VALVE T P OR RELIEF VALVE THERMOSTATIC MIXING VALVE INDIRECT DHW TANK INDIRECT TANK AQUASTAT 10K Ω INDIRECT DHW TANK SENSOR TEMPERATURE PRESSURE GAUGE EXPANSIONTANK FLAT PLATE HEAT EXCHANGER COMBI ONLY STRAINER PIPING LEGEND PURGE VALVE MAGNETIC DIRT SEPARATOR PN 240012875 REV A 01 31 2020 ...

Page 79: ...9 125F WITH ZONE CIRCULATOR PUMPS 125F WITH ZONE CIRCULATOR PUMPS MAGNETIC DIRT SEPARATOR PN 240012875 REV A 01 31 2020 ...

Page 80: ...ating Only Boiler change P03 from 08 to 05 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manual for details Reference zone control manufacturer instructions for details on setting priority if necessary 125F WITH INDIRECT ZONE PUMPS DHW TANK W TANK SENSOR PN 240012875 REV A 01 31 2020 ...

Page 81: ...NG DIAGRAM Reference zone control manufacturer instructions for details on setting priority if necessary If adding an indirect tank with Thermostat to a Heating Only Boiler change P03 from 08 to 04 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manual for details PN 240012875 REV A 01 31 2020 ...

Page 82: ...12 125F WITH ZONE VALVES PIPING DIAGRAM 125F WITH ZONE VALVES MAGNETIC DIRT SEPARATOR 125F WITH ZONE VALVES DHW TANK TANK SENSOR PN 240012875 REV A 01 31 2020 ...

Page 83: ...K SENSOR If adding an indirect tank with sensor to a Heating Only Boiler change P03 from 08 to 05 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manual for details Reference zone control manufacturer instructions for details on setting priority if necessary PN 240012875 REV A 01 31 2020 ...

Page 84: ...TANK T STAT Reference zone control manufacturer instructions for details on setting priority if necessary If adding an indirect tank with Thermostat to a Heating Only Boiler change P03 from 08 to 04 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manual for details PN 240012875 REV A 01 31 2020 ...

Page 85: ...F WITH ZONE CIRCULATOR PUMPS PIPING DIAGRAM 165F with Zone Circulator Pumps MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO PN 240012875 REV A 01 31 2020 ...

Page 86: ...eference zone control manufacturer instructions for details on setting priority if necessary If adding an indirect tank with Thermostat to a Heating Only Boiler change P03 from 08 to 04 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manual for details PN 240012875 REV A 01 31 2020 ...

Page 87: ...17 165 Fwith Zone Valves 165 WITH ZONE VALVES PIPING DIAGRAM MAGNETIC DIRT SEPARATOR 1 Shut off Purge Valve 1 Locate shut off valve after any field installed LWCO PN 240012875 REV A 01 31 2020 ...

Page 88: ...iagram If adding an indirect tank with Thermostat to a Heating Only Boiler change P03 from 08 to 04 See Section 9 Parameter Settings in Boiler Installation Operation Maintenance Manual for details Reference zone control manufacturer instructions for details on setting priority if necessary PN 240012875 REV A 01 31 2020 ...

Page 89: ...19 150F 205F WITH ZONE CIRCULATOR PUMPS 150F 205F WITH ZONE CIRCULATOR PUMPS PIPING DIAGRAM MAGNETIC DIRT SEPARATOR PN 240012875 REV A 01 31 2020 ...

Page 90: ...20 150F 205F WITH ZONE PUMPS WIRING DIAGRAM 150F 205F WITH ZONE PUMPS PN 240012875 REV A 01 31 2020 ...

Page 91: ...21 150F 205F WITH ZONE VALVES 150F 205F WITH ZONE VALVES PIPING DIAGRAM MAGNETIC DIRT SEPARATOR PN 240012875 REV A 01 31 2020 ...

Page 92: ...22 150F 205F WITH ZONE VALVES WIRING DIAGRAM 150F 205F WITH ZONE VALVES PN 240012875 REV A 01 31 2020 ...

Page 93: ...t a buffer tank be installed Note DHW piping not shown for clarity Reference applicable sections of this manual for DHW piping details Internal Boiler circulator used on Primary circuit Reference Buffer Tank Installation Manual for proper sizing and installation Buffer Tank on Central Heat Circuit H2O Stainless Steel Buffer Tank MAGNETIC DIRT SEPARATOR PURGE VALVE PN 240012875 REV A 01 31 2020 ...

Page 94: ...er Wiring with Buffer Tank Connect the buffer tank aquastat to terminals 4 and 4 on terminal block M2 System wiring remains as shown in the previous wiring diagrams H20 BUFFER TANK H2O Stainless Steel Buffer Tank PN 240012875 REV A 01 31 2020 ...

Page 95: ...4 71 6 1 125F 15 8 4 358 73 4 1 081 17 6 4 152 75 2 1 040 19 4 3 958 77 0 1 000 21 2 3 774 78 8 962 23 0 3 600 80 6 926 24 8 3 435 82 4 892 26 6 3 279 84 2 858 28 4 3 131 86 0 827 30 2 2 990 87 8 796 32 0 2 857 89 6 767 33 8 2 730 91 4 740 35 6 2 610 93 2 713 37 4 2 496 95 0 687 39 2 2 387 96 8 663 41 0 2 284 98 6 640 42 8 2 186 100 4 617 44 6 2 093 102 2 595 46 4 2 004 100 4 617 48 2 1 920 102 2 ...

Page 96: ...erature based on average extreme outdoor temperature range expected for climate location Flow Temp Outside Temp Boiler Control Panel Note For temperatures below 40 F 40 C maximum heating flow temperature set point no longer increases and curves on the graph become horizontal Boiler set point will override sensor setpoint F C Use lower value of range as the desired Kt value Example to deliver 186 F...

Page 97: ...nge PO3 parameter from 08 to 04 See Section 9 Parameter Settings in boiler s Installation Operation and Maintenance Manual Parameter PO3 for COMBI boiler factory set at OO requires no change S Indirect DHW Tank Sensor Wiring 125F Unit ONLY Indirect DHW Tank End Switch Wiring 10k Ω Management of 0 10V Input P78 1 P78 2 0 10V DC Electrical Signal Input Heating Flow Setpoint Temperature Central Heati...

Page 98: ...28 MODEL 125F Heat Only 125F FLOOR STANDING HEAT ONLY WIRING DIAGRAM PN 240012875 REV A 01 31 2020 ...

Page 99: ...29 MODEL 150F Combi 150F FLOOR STANDING COMBI WIRING DIAGRAM PN 240012875 REV A 01 31 2020 ...

Page 100: ...30 165F FLOOR STANDING HEAT ONLY WIRING DIAGRAM MODEL 165F Heat Only PN 240012875 REV A 01 31 2020 ...

Page 101: ...31 205F FLOOR STANDING COMBI WIRING DIAGRAM MODEL 205F Combi PN 240012875 REV A 01 31 2020 ...

Page 102: ...150 CALCULATED EFFECTS OF HI ALTITUDE ON BOILER PERFORMANCE DHW MODE HEAT MODE NET RATNG HEAT MODE 60 000 80 000 100 000 120 000 140 000 160 000 180 000 200 000 220 000 0 2 000 4 000 6 000 8 000 10 000 BOILER INPUT BTUH ALTITUDE FEET MODELS 165 205 CALCULATED EFFECTS OF HI ALTITUDE ON BOILER PERFORMANCE DHW MODE HEAT MODE NET RATNG HEAT MODE PN 240012875 REV A 01 31 2020 ...

Page 103: ...15 F 92 111 147 147 140 F 121 133 147 147 115 F 146 165 208 208 140 F 67 79 93 93 115 F 92 111 154 154 Notes 176 F Boiler Supply Water Temperature AHRI Rating Conditions 50 F Inlet Water 4 0 GPM FLOW RATE 1st HOUR RATING GAL HR CONTINUOUS RATING GAL HR H2O60 H2O60L 1st HOUR RATING GAL HR CONTINUOUS RATING GAL HR 1st HOUR RATING GAL HR CONTINUOUS RATING GAL HR HEATING ONLY BOILER 125 000 BTUH H2O30...

Page 104: ...iring Diagram Low Water Cutoff LWCO Electrical Conduit J Box 120 V 60 HZ Conduit or Power Supply cord Polarized L1 N G GND L1 N GND BLK WHT 120 V 60 HZ Socket Polarized 120 V 60 HZ Cord Set From Boiler N O Locate LWCO sensing device in the supply piping above the minimum height of boiler See Figure A 2 Piping Diagram Position control in HORIZONTAL piping to assure proper boiler protection upright ...

Page 105: ...in Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return Purge Valve Magnetic Dirt Separator Position Temperature Pressure Gauge on CH System Supply Side of Boiler Purge Valve Note Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdiction Note ...

Page 106: ...36 Low Water Cutoff Detail LOW WATER CUTOFF NO NO YES PN 240012875 REV A 01 31 2020 ...

Page 107: ...Circuit and Polarity wilh a suitable meter NOTE These checks must be repeated after any servicing or fault finding 5 Ensure all external controls are calling for heat and check all external and internal fuses Before any servicing or replacement of parts ensure th gas and electrical supplies are isolated 1 If a fault occurs on the boiler an error code may be shown by the facia display 20 fs28 40 5o...

Page 108: ...flashing NO Error E11O flashing NO 3 way valve open to central heating circuit YES Burner output modulates to maintain the temperature set YES YES YES YES YES Error E130 flashing NO YES Burner goes out YES Go to section I NO NO Ensure all controls and Programmers are calling for heat NO Error 160 flashing Go to section C NO Error 160 flashing Go to section C NO Error 133 flashing Go to section E B...

Page 109: ...lectrodes for up to 5 seconds and for 5 attempts YES NO YES Burner lights YES YES Error E109 flashing NO Error E110 flashing YES NO NO NO NO DHWflow rate more than 21 min Error 160 flashing Go to section C Error 160 flashing Go to section C Error 133 flashing Go to section E Burner does not stay alight after 5 seconds Error E125 flashing after 1 minute Go to section H NO Go to section L NO If E53 ...

Page 110: ...minals Blue to Brown See Wiring Diagram NO Replace PCB Fan connections correct at fan and PCB Connectors X11 X23 See Wiring Diagram YES NO 120V between PCB connector x13 pump terminal Blue and PCB connector x11 pump terminal Black See Wiring Diagram NO Replace PCB Make connections Main or Display PCB fault 120V at Pump NO Check wiring Replace Pump YES YES Is there 120V AC at fan terminals connecto...

Page 111: ...trode and lead 3 Electrode connection 4 Spark gap and position 5 continuity between burner and earth 6 Condensate trap blocked Check the gas supply pressure For Natural Gas greater than 3 5 wc For LPG greater than 8 wc Check and correct if necessary 1 Flame sensing electrode position YES f Check the resistance of the coils Pin 1 and 3 20 30 Ohm Pin 2 and 4 60 70 Ohm Check wiring See Wiring Diagram...

Page 112: ...onnection at connector x22 is there approx 5 V DC between the green and black NO terminals Check flow temperature sensor connections and position Sensors swapped Cold resistance approximately 1OkO 77 F CH sensors resistance reduces with increase in temp YES I I I I Is E11O is still flashing Replace pressure sensor Replace PCB I Replace sensor Go to section B Is there 120V at PCB connector x13 3 wa...

Page 113: ...e heat exchanger 1 Display blank Verify the position of the Service key Check obstruction in the flue duct YES Remove the obstruction on the flue pipe NO Performs the calibration function see the Service manual Check the electrical connection between Ru and pcb Replace Hall Effect Sensor Is main water filter and assembly clean and rotor free to move L PCB connector x22 Hall effect sensor terminals...

Page 114: ...44 NOTES PN 240012875 REV A 01 31 2020 ...

Page 115: ...All specifications subject to change without notice 2019 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com BDR THERMEA GROUP ...

Page 116: ... THIS INSTRUCTION ASSURE FACTORY SUPPLIED CONVERSION LABEL IS APPLIED TO PRODUCT IF CONVERTING TO LP IMPORTANT Gas type Check Ensure the maximum heat exchange to the system in Heating or DHW mode DHW request in order to avoid the boiler shutoff for overheating FUNCTION INTERRUPT If either De aeration or Gas Check is interrupted by electrical power failure is necessary to reactivate the function by...

Page 117: ...l installation de chauffage ou de production d ECS afin d éviter que la chaudière ne s éteigne suite à un problème de surchauffe INTERRUPTION DE LA FONCTION Si la fonction de désaération ou d identification du gaz est interrompue par une coupure de l alimentation électrique une fois que le courant est rétabli réactiver la fonction en appuyant simultanément sur les touches et pendant au moins 6 sec...

Page 118: ...ever checking combustion chamber Spark Electrode Clean Set gap according to IOM directions Clean electrode with plumbers cloth to remove oxides Flame Sensor Clean sensor Condensate Neutralizer Check condensate neutralizer replace if necessary Condensate pipe trap Disconnect condensate pipe Clean out any dirt or accumulation Fill with water level of outlet and reinstall NOTE verify flow of condensa...

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UTICA BOILERS MACF-150, Installation, Operation And Maintenance Manual

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