Dunkirk DCB-125, Installation, Operation & Maintenance Manual

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

Page 2: ...DCC 205 ...

Page 3: ...CONTENTS INSTALLATION OPERATION AND MAINTENANCE MANUAL 240011947 APPLICATION GUIDE 240011430 COMMISSIONING GUIDE 240011376 REQUIRED INSPECTION SPECIAL 240011561 BACK COVER ...

Page 4: ...DCB 165 ...

Page 5: ...ational Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com CONDENSING WALL MOUNTED GAS FIRED INSTALLATION OPERATION MAINTENANCE MANUAL Models DCB 125 DCC 150 DCB 165 DCC 205 240011947 REV B 3 31 2018 ...

Page 6: ...nd Plugs 30 PSI Safety Relief Valve Temperature Pressure Gauge 4 ea 17x24x2 Gaskets Includes Essential Documents and Warranty 11x17 Wire Diagrams Drain Valve 5 GPM Flow Restrictor 205 Combi Only Used for Valve Connections Document Package Wall Mount Template Manifold Manifold 165 Heat Only Template 240011947 REV B 03 31 2018 ...

Page 7: ... with Water 40 9 5 Control Panel 41 9 6 Commissioning 42 9 7 Calibration Function 42 9 8 De Aeration Function 43 9 9 Commission Set Up Gas 43 9 10 Chimney Sweep Function CO2 Adjust 44 9 11 Combustion Adjustment Function 44 9 12 Check Firing Rate 44 9 13 Parameter Settings 45 9 14 Description Of Parameters Factory Settings 45 9 15 Adjusting Maximum Heating Power 47 10 Operating instructions 48 10 1...

Page 8: ...Flow Rate 0 55 gpm 2 50 L min 0 55 gpm 2 50 L min Max DHW Temperature 140 F 60 C 140 F 60 C DHW Water Content 0 05 gal 0 23 L 0 10 gal 0 37 L SYSTEM When boiler is operating at maximum operating temperature providing heating with all heat emitters operating pressure gauge should not indicate more than 26 11 psi 1 80 bar If reading exceeds this figure larger expansion tank is required 240011947 REV...

Page 9: ...ttom View Dimensions 205 COMBI Bottom View Dimensions 150 COMBI Bottom View Dimensions 41 2 7 51 2 3 51 2 101 2 125 HEAT ONLY Bottom View Dimensions 101 2 4 D E I G C B D E I G C B F J 31 2 9 1 2 240011947 REV B 03 31 2018 D C E I H G F B A D E I G C 5 B 81 2 F J 5 7 31 2 6 6 5 7 31 2 31 2 6 6 9 91 2 9 B ...

Page 10: ...nformation 1 Safety Information WARNING Do not tamper with or use this boiler for any purpose other than its intended use Failure to follow these instructions could result in death or serious injury Use only manufacturer recommended parts and accessories CAUTION Laceration burn hazard Metal edges and parts may have sharp edges and or may be hot Use appropriate personal protection equipment to incl...

Page 11: ... water DCC 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 DCC 205 180 000 btu h 53 kW capable of providing 5 0 U S gpm 18 9 litres min with temperature rise of 70 F 39 C Integral Low Water Pressure Cutoff Optional Outdoor Temperature Reset Heat exchanger over heat protection Boiler operating at maximum operating temperature providing h...

Page 12: ... Pressure Cutoff 6 3 Way Valve with Motor 7 Water Safety Thermostat 8 NTC Heating sensor Flow Return QTY 2 1 Shown for clarity 9 Flue Sensor 10 Pressure Switch 11 Coaxial Flue Connector 12 Heat Exchanger Temperature Sensor 13 Heat Exchanger 14 Burner not shown 15 Ignition electrode 16 Flame Detection Electrode 17 Air Gas Manifold 18 Venturi 19 Fan 2 1 11 6 9 7 8 15 16 4 14 19 17 18 13 5 25 3 12 10...

Page 13: ...or 9 Heat Exchanger Termperature Sensor 10 Heat Exchanger 11 Burner Door Termperature Sensor 12 Burner not shown 13 Ignition Electrode 14 Flame Detection Electrode 15 Air Gas Blend Manifold 16 Air Purge 17 Venturi 18 Silencer 19 Fan Illustrations are a depiction of the boiler for general location of parts and may vary depending on model 2 1 8 7 6 5 13 9 14 4 12 19 15 17 10 16 11 18 3 240011947 REV...

Page 14: ...afety Thermostat 13 NTC Heating sensor Flow Return QTY 2 1 Shown for clarity 14 Flue Sensor 15 Pressure Switch 16 Coaxial Connector 17 Heat Exchanger Temperature Sensor 18 Heat Exchanger 19 Burner not shown 20 Ignition Electrode 21 Flame Detection Electrode 22 Air Gas Blend Manifold 23 Venturi 24 Fan 2 1 3 8 15 7 10 5 14 13 12 11 19 16 20 6 18 22 21 23 17 9 24 4 Illustrations are a depiction of th...

Page 15: ...r 12 Coaxial Connector 13 Heat Exchanger Temperature Sensor 14 Heat Exchanger 15 Burner Door Temperature Sensor 16 Burner not shown 17 Ignition Electrode 18 Flame Detection Electrode 19 Air Gas Manifold 20 Air Purge 21 Venturi 22 Silencer 23 Fan 3 1 2 6 12 4 11 10 9 8 18 13 19 5 17 21 20 23 14 7 3 COMPONENT LISTING Illustrations are a depiction of the boiler for general location of parts and may v...

Page 16: ...ght of the boiler Room sealed boiler installed in a room containing bath or shower shall be installed so person using bath or shower cannot touch any electrical switch or boiler control utilizing line voltage electricity Multiple Boilers can be wall mounted placed side by side or back to back Observe service clearances in all installations For Direct Vent installations air vents are not required i...

Page 17: ... Service and Combustible Clearances 165 205 211 2in 571 5 mm 1 3 4 in 45mm CLEARANCES REQUIRED FOR CLOSET INSTALLATION CLEARANCES FOR COMBUSTIBLES 1 3 4 in 45mm 17 3 4 in Top View Back 1 9 16 in 40mm Closet Installation 0 in 0 mm between Back of Unit and wall 1 3 4 in 45mm 13 4 in 45 mm 13 4 in 45 mm 450 mm Left Side View of Boiler Front View of Boiler Front View of Boiler 240011947 REV B 03 31 20...

Page 18: ...of center of hole for flue 5 Cut hole in wall for coaxial flue See sizing below 125 150 4 3 8 110 mm diameter 165 205 5 5 16 135 mm diameter 6 Pre pipe supply and return water connections with factory fittings before wall mounting 7 Mount boiler on wall using wall mounting bracket included with unit 8 Adjust the position of the boiler verify it is level Note Lift boiler using chassis Do not use fr...

Page 19: ...al Ensure piping in the heating system has an oxygen barrier FIGURE 5 1 Safety Relief Valve Note Boiler rated at 50 psig 345 kPa maximum allowable working pressure Boiler provided with 30 psig 206 kPa safety relief valve WARNING Poison hazard Ethylene glycol is toxic Do not use ethylene glycol Never use automotive or standard glycol antifreeze even ethylene glycol made for hydronic systems Ethylen...

Page 20: ...lbow s if used close to safety relief valve outlet and downstream of union if used Terminate pipe with plain end not threaded Check Local Codes For Maximum Distance To Floor Safety Relief Valve 5 2 Special Conditions Note System piping exposed to freezing conditions Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system Do not use automoti...

Page 21: ...oiler system Considerations Control system requires equivalent water temperatures entering each boiler to properly sequence and adjust system supply temperature WARNING Burn and scald hazard Verify all plastic caps are removed from boiler connections Failure to follow these instructions could result in death or serious injury Thoroughly flush all hydronic piping Secure all valves fittings to boile...

Page 22: ...LACE ISOLATION VALVE BEFORE TEE OR LWCO Note 1 To Drain Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return 5 gpm Limiter Factory Installed 205 Only Note Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdiction Note 240011947 REV B 03 31 201...

Page 23: ...Code CEC Locate LWCO sensing device in the supply piping above the minimum height of boiler See Figure 5 3 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 ...

Page 24: ...ent errors and lockouts The stainer prevents any sedimentation and debris from your water supply piping from entering the boiler Debris carried from the water supply will clog DHW water flow sensor resulting in error codes and causing boiler to lockout Locate the stainer as close to the boiler as possible and place on DHW domestic hot water inlet connection located at bottom of the boiler 24001194...

Page 25: ...ition in the combustion chamber The flame sensor will acknowledge the presence of the flame in the combustion chamber and send a signal to the control board Temperature sensors will send a signal to the control board allowing the control board to increase decrease the speed of the fan The combustion fan will in turn modulate the gas rate accordingly When the domestic hot water demand ceases the bu...

Page 26: ...STM F891 cellular core CPVC or Radel polyphenolsulfone in venting systems shall be prohibited Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited Failure to follow these instructions could result in death or serious injury Note Follow venting manufacturer s equivalent lengths for specialty fittings 6 2 Removal of Existing Boiler From Common Vent System When exi...

Page 27: ...lini venting system For other venting system suppliers see their instructions 1 Place clamp so etched UP is facing up 2 Open clamp slightly by separating circular areas from each other 3 Slide male end of first pipe through open clamp so the shoulder of the female end of the pipe stops the clamp from sliding off the pipe 4 Insert the male end of of the second pipe into the clamp on the up etched s...

Page 28: ...list for approved Manufacturers Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements USA National Fuel Gas Code ANSI Z223 1 NFPA 54 Canada Natural Gas and Propane Installation Code CAN CSA B149 1 1 Venting shall be properly supported WARNING Manufacturer recommends this condensing boiler be vented with approved polypropylene venting materia...

Page 29: ...mm 45 1 64 ft 0 5m 90 3 28 ft 1 0m 5 3 128mm 80mm 45 1 64 ft 0 5m 90 3 28 ft 1 0m NOTE Coaxial venting can run horizontal or vertical Connect flue elbow to top of boiler and adjust direction of elbow to desired orientation rear right or left Measure distance from outside wall face to elbow this dimension will be known as X add distance Y 2 50mm to X this is the total dimension of the vents See Fig...

Page 30: ...ation A Twin Pipe CPVC System CPVC is approved for boiler exhaust CPVC or PVC are both approved for air intake To transition from Coaxial at the top of the boiler to Twin Pipe CPVC PVC a kit is available B Twin Pipe Polypropylene System Single wall polypropylene is used for both exhaust and air intake piping To transition from Coaxial at the top of the boiler to Twin Pipe polypropylene venting an ...

Page 31: ...ospheric Zone termination can be run horizontal or vertical FIGURE 6 11 Twin Pipe Roof Vent FIGURE 6 12 Twin Pipe Side Wall Vent Multiple Appliances Vent 12 305mm Min Separation Manufacturer Recommends Greater Separation Combustion Air 15 381mm Max Vent Combustion Air 12 305mm US 18 458mm Canada Min Above Anticipated Snow Line Roof Line 12 305mm Min See Grade Snow Ice FIGURE 6 13 Horizontal Twin P...

Page 32: ...ll Vent Vent 3 76mm Min 24 610mm Max Separation 12 305mm Min From Overhang 12 305mm Min 24 610mm Max Separation Between Bottom Of Combustion Air Intake And Bottom Of Vent Combustion Air Opening Separation 24 Min Grade Snow Ice Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof Avoid locations where snow may drift and block vent and combustion ai...

Page 33: ...tings in overall equivalent length calculations Flexible venting installations use single wall polypropylene to pass flue gasses to base of chimney then flexible venting to get them to termination at the top Combustion air is not supplied through masonry chimney Combustion air must be from outside using 3 80 mm single wall polypropylene Position boiler to use minimum of rigid single wall polypropy...

Page 34: ...ithin a height of 15 ft 4 5m above the meter regulator assembly 3 ft 0 9m I Clearance to service regulator vent outlet 3 ft 0 9m 3 ft 0 9m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 305mm 3 ft 0 9m K Clearance to mechanical air supply inlet 3 ft 0 9m 6 ft 1 8m L Clearance above paved sidewalk or paved driveway located on public ...

Page 35: ...e 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 6 17 Condensate Drain 6 COMBUSTION AIR ...

Page 36: ...y appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fire department 7 GAS SUPPLY PIPING 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 D...

Page 37: ... Of Boiler Illustration shown size 205 illustration is for location purposes wiring knockouts found same general location on all sizes 8 ELECTRICAL CONNECTIONS Note Wiring diagrams can be found in Appendix A of this Manual 8 3 Electrical Connections Boiler requires 120V 60Hz power supply Verify electrical supply is polarized Boiler shall be grounded and on dedicated circuit Shall be one common iso...

Page 38: ...60Hz Fuses 3 15 A are 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 ...

Page 39: ...cess terminal block M2 connect wires of 24V Heat anticipator room thermostat to terminals 6 7 connect bridge between terminals 6 8 turn boiler power on verify 24 V Heat anticipator room thermostat operates per thermostat manufacturer instructions FIGURE 8 4 Thermostat Connections 8 6 Install Room Thermostat Install room thermostat on inside wall Do not install where it will be influenced by drafts...

Page 40: ...the flow temperature calculated according to set Kt coefficient Select required curve by pressing as indicated in chart below for selecting the appropriate curve 00 to 90 Flow temp Outside temp NOTE Temperatures below 40 F 40 C maximum heating flow temperature set point no longer increases curves shown on graph become horizontal 8 ELECTRICAL CONNECTIONS FIGURE 8 5 Outdoor Sensor Connections FIGURE...

Page 41: ... Connect DHW priority sensor NTC to terminals 9 10 on terminal block M2 Insert NTC sensor element in the sensor well of indirect storage tank Verify exchange capacity of the storage boiler coil is appropriate for boiler power Adjust DHW temperature 95 F 140 F 35 C 60 C by pressing on boiler Controll IMPORTANT set parameter P03 05 as described in PARAMETER SETTINGS 8 ELECTRICAL CONNECTIONS FIGURE 8...

Page 42: ... for condensate 13 16 21mm ID Hose 3 4 NPT I Heating supply connection 3 4 22 2mm 1 25 4mm J Optional Indirect DHW connection 1 2 15 9mm na MANIFOLD DCB 125 9 START UP PROCEDURE 9 1 Central Heating System Connections Heat Only DCB 125 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION DCB 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION DCB 165 HEATING ONLY MANIFOLD DCB 165 A C E I B H 24...

Page 43: ...stem filling connection for Combi 1 2 15 9mm 3 4 22 2mm E Gas shutoff connection 3 4 22 2mm F Boiler filling connection 1 2 15 9mm na G DHW outlet indirect storage tank connection 1 2 15 9mm 3 4 22 2mm H Drain connection for condensate 13 16 21mm ID Hose 3 4 NPT I Heating supply connection 3 4 22 2mm 1 25 4mm K 5 gpm DHW flow restrictor Factory installed 205 only na 3 4 22 2mm A B H I G E D C K MA...

Page 44: ...n line with valve Open fill point valve on filling system until water begins to flow To aid venting boiler drain may be open until water flows 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...

Page 45: ...n 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 Off Reset Exit menu functions...

Page 46: ...tion burner may not ignite This may cause boiler to shut down until any air in gas pipes is vented Repeat ignition procedure until gas reaches the burner To reset boiler operation press for at least 2 seconds NOTICE First ignitions immediately after installation system will implement a self learning procedure to reach correct ignition level IMPORTANT INFORMATION A If venting or gas recognition fun...

Page 47: ...twork Correct gas type setting is made by pressing two buttons at the same time see section 9 6 Commissioning Change of gas type is made after the first installation Change parameter P02 See section 9 6 Commissioning and section 9 11 Parameter Settings Check minimum gas pressure is suitable for selected gas Gas A NG 3 5 8 7mbar Gas E LPG 8 0 19 9mbar Place supplied label with indication of gas typ...

Page 48: ...d combustion analyzer for combustion analysis During normal operation boiler performs combustion control cycles In this phase CO values higher than 400 ppm can occur for brief periods of time 9 START UP PROCEDURE Automatically calculated from the PCB 9 12 Check Firing Rate 1 Measure input if a gas meter is installed in the system Turn off gas to all other appliances Activate some heating zones to ...

Page 49: ...is associated 01 close contact with a room thermostat request other than ECR thermostat 02 close contact with a ECR room thermostat request 03 relay for indicating low water pressure 04 relay for error code display 05 relay for kitchen fan function 07 relay for post circulation pump 09 DHW relay on with DHW program setting 10 DHW relay on with DHW request if P64 1 relay on with CH and DHW request ...

Page 50: ...ting output 0 100 100 80 P14 DHW max output 0 100 100 P15 Min heating output 0 100 00 P16 Maximum CH setpoint 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 0...

Page 51: ...4 3 27 200 8 0 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 Btu h kW DCB 164 DCC 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 22 18 65 ...

Page 52: ...iately call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow ...

Page 53: ...rotection is active Burner lit Ignition fault DHW operating mode enabled Boiler system water pressure low Heating mode enabled Call a qualified service technician Programming menu Manual reset fault Boiler information menu Fault in progress Set unit of measurement SYMBOL Key 10 OPERATING INSTRUCTIONS 10 3 Boiler Controls To light boiler correctly proceed as follows Check system pressure is correct...

Page 54: ...l tap is closed Boiler will immediately revert to provide CH if there is demand 10 6 Domestic Hot Water Mode Flow switch senses demand for hot water opening a hot water tap etc the pump starts and burner lights at its ignition output increasing to its maximum output Water in the boiler is diverted from central heating system to domestic hot water heat exchanger heating the incoming supply water Bu...

Page 55: ... turn gas supply OFF to boiler Failure to comply will result in death or serious injury Note 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 11 GENERAL MAINTENANCE AND CLEANING Circulator pump and combustion air blower motor furnished with boil...

Page 56: ...tion of electrodes 7 Check spark gap positioning and height of electrodes 8 Check fan impeller is clean and free to rotate 11 GENERAL MAINTENANCE AND CLEANING 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 Cr...

Page 57: ...ath or serious injury 11 4 Draining 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 2...

Page 58: ...ing supply and return pipes at the boiler Check system for proper volume and pressure See page 4 for acceptable volume and pressure Turn off boiler Thoroughly flush water pipe work Clean filters in heating return and supply water isolating valves Repressurize the system 11 9 Final Assembly Place front jacket in position over boiler Ensure bottom is located behind the control panel Secure in positi...

Page 59: ...the pump will automatically operate for 5 minutes G Explain to User an internal frost thermostat is fitted in boiler and electrical supply to boiler must be left on for thermostat to operate H Show User position of pressure relief valve discharge pipe I Leave this Installation Operation and Maintenance Manual with User for use on future calls 11 14 Automatic Calibration Function Before performing ...

Page 60: ... 2000 Ft 0 610 m 2000 4500 Ft 610 1370 m 0 2000 Ft 0 610 m 2000 4500 Ft 610 1370 m Parameter P71 Fan Speed rpm 115 5 650 60 5 100 65 5 150 40 4 900 Parameter P72 Fan Speed rpm 40 1 150 25 1 000 CO Limit ppm 400 Natural gas A 17 4 mbar 7 0 in w c LP gas E 29 8 mbar 12 0 in w c 0 2000 Ft 0 610 m 2000 4500 Ft 610 1370 m 0 2000 Ft 0 610 m 2000 4500 Ft 610 1370 m Parameter P71 Fan Speed rpm 220 6 700 1...

Page 61: ...5 0 137 22 122 19 DCB 165 147 26 5 137 95 0 DCC 205 147 26 5 137 95 0 184 5 26 5 157 23 4 501 6 500 ft 1372m 1981m DCB 165 135 24 1 126 95 0 DCC 205 135 24 1 126 95 0 168 24 1 143 20 6 501 10 000 ft 1982m 3048m DCB 165 113 20 3 105 95 0 DCC 205 113 20 3 105 95 0 141 20 3 120 17 Max CH Supply temp 176 F 80 C for DCB 125 and DCC 150 Max DHW temp 140 F 60 C DCC 150 Max DHW Flow rate 3 5 GPM 13 2 l mi...

Page 62: ...mp Check correct connection of NTC sensor on pipe 128 Loss of flame Check sensing electrode and cable flue recirculation electrical continuity between burner and ground Enable automatic calibration Call authorized SERVICE center 130 NTC flue sensor tripped due to over temperature Check thermostat correct circulation of water and pump Check status of primary exchanger 131 Thermo fuse tripped due to...

Page 63: ...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 14 GLOSSARY DIRECT VENT BOILER Boil...

Page 64: ... 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 65: ...61 APPENDIX A WIRING DIAGRAMS A 1 MODELS 125 Heat Only 240011947 REV B 03 31 2018 ...

Page 66: ...62 APPENDIX A WIRING DIAGRAMS A 2 MODELS 165 Heat Only 240011947 REV B 03 31 2018 ...

Page 67: ...63 APPENDIX A WIRING DIAGRAMS A 3 MODELS 150 Combi 240011947 REV B 03 31 2018 ...

Page 68: ...64 APPENDIX A WIRING DIAGRAMS A 4 MODELS 205 Combi 240011947 REV B 03 31 2018 ...

Page 69: ...65 NOTES 240011947 REV B 03 31 2018 ...

Page 70: ...66 NOTES 240011947 REV B 03 31 2018 ...

Page 71: ...___________ 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 240011947 REV B 03 31 2018 ...

Page 72: ...rmit the use of an external energy management system that serves the same function THIS 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 hav...

Page 73: ...Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240011430 REV G 03 31 2018 This manual has been prepared for use with the appropriate Installation Operation and Maintenance Manual APPLICATION GUIDE FOR USE WITH HEATING ONLY 125 165 COMBI 150 205 ...

Page 74: ...165 Indirect Zone Pumps DHW Tank Tank T Stat Wiring Diagram 17 165 With Zone Valves Piping Diagram 18 165 Indirect Zone Valve DHW Tank Tank Sensor Wiring Diagram 19 165 Indirect Zone Valves DHW Tank Tank T Stat Wiring Diagram 20 150 205 With Zone Circulator Pumps Piping Diagram 21 150 205 With Zone Pumps Wiring Diagram 22 150 205 With Zone Valves Piping Diagram 23 150 205 With Zone Valves Wiring D...

Page 75: ...proper 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 Code ANSI Z223 1 NFPA 54 National Electrical Code NFPA 70 Canada Natural Gas and Propane Installation Code CAN CSA B...

Page 76: ... H Drain connection for condensate 13 16 21mm ID Hose 3 4 NPT I Heating supply connection 3 4 22 2mm 1 25 4mm J Optional Indirect DHW connection 1 2 15 9mm na MANIFOLD 125 LABOR SAVING PIPING MANIFOLDS NEAR BOILER PIPING CONNECTIONS 125 HEATING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION 165 HEATING ONLY MANIFOLD 165 A C E I B H PN 240011430...

Page 77: ... connection for Combi 1 2 15 9mm 3 4 22 2mm E Gas shutoff connection 3 4 22 2mm F Boiler filling connection some models 1 2 15 9mm na G DHW outlet indirect storage tank connection 1 2 15 9mm 3 4 22 2mm H Drain connection for condensate 13 16 21mm ID Hose 3 4 NPT I Heating supply connection 3 4 22 2mm 1 25 4mm K 5 gpm DHW flow restrictor Factory installed 205 only na 3 4 22 2mm A B H I G E D C K MA...

Page 78: ...imum 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 Note Provided Wiring and Piping illustrations are meant to show system concepts only Installer is responsible for all equipment required by authority having jurisdiction Note Arrange piping to ...

Page 79: ...n Indirect Domestic Hot Water Tank and optional use of a H2O Buffer Tank Reference the zone control manufacturer instruction manual for control operation and priority sertting 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 juris...

Page 80: ... FLOW CHECK VALVE BYPASS VALVE DIVERTER VALVE T P OR RELIEF VALVE THERMOSTATIC MIXING VALVE INDIRECT DHW TANK INDIRECT TANK AQUASTAT INDIRECT DHW TANK SENSOR TEMPERATURE PRESSURE GAUGE EXPANSION TANK FLAT PLATE HEAT EXCHANGER COMBI ONLY STRAINER PIPING LEGEND PN 240011430 REV G 03 31 18 ...

Page 81: ...9 125 WITH ZONE CIRCULATOR PUMPS 125 with Zone Circulator Pumps PN 240011430 REV G 03 31 18 ...

Page 82: ...eating 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 125 WITH INDIRECT ZONE PUMPS DHW TANK W TANK SENSOR PN 240011430 REV G 03 31 18 ...

Page 83: ...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 240011430 REV G 03 31 18 ...

Page 84: ...12 125 WITH ZONE VALVES PIPING DIAGRAM 125 with Zone Valves PN 240011430 REV G 03 31 18 ...

Page 85: ...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 240011430 REV G 03 31 18 ...

Page 86: ...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 240011430 REV G 03 31 18 ...

Page 87: ...15 165 WITH ZONE CIRCULATOR PUMPS PIPING DIAGRAM 165 with Zone Circulator Pumps PN 240011430 REV G 03 31 18 ...

Page 88: ... 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 240011430 REV G 03 31 18 ...

Page 89: ...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 240011430 REV G 03 31 18 ...

Page 90: ...18 165 with Zone Valves 165 WITH ZONE VALVES PIPING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 91: ... 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 240011430 REV G 03 31 18 ...

Page 92: ...Diagram 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 240011430 REV G 03 31 18 ...

Page 93: ...21 150 205 with Zone Circulator Pumps 150 205 WITH ZONE CIRCULATOR PUMPS PIPING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 94: ...22 150 205 WITH ZONE PUMPS WIRING DIAGRAM 150 205 With Zone Pumps PN 240011430 REV G 03 31 18 ...

Page 95: ...23 150 205 with Zone Valves 150 205 WITH ZONE VALVES PIPING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 96: ...24 150 205 WITH ZONE VALVES WIRING DIAGRAM 150 205 With Zone Valves PN 240011430 REV G 03 31 18 ...

Page 97: ... is recommended that 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 PN 240011430 REV G 03 31 18 ...

Page 98: ...ler Wiring with Buffer Tank Connect the buffer tank aquastat to terminals 6 and 7 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 G 03 31 18 ...

Page 99: ...00 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 2 595 50 0 1 840 104 0 575 51 8 1 763 106 0 556 CHART 2 INDIRECT TANK SENSOR DA...

Page 100: ...sired boiler delivery temperature 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 F C Use lower value of range as the desired Kt value example to deliver 186 F water OT of 20 F Kt ...

Page 101: ...st DHW temperature 95 F 140 F 35 C 60 C by pressing buttons on boiler control panel Boiler Control Panel Note Parameter PO3 for Heating Only boiler with no indirect tank remains Factory Set at 08 No change is required If adding an Indirect Tank with a sensor to Heating Only Boiler change PO3 parameter from 08 to 05 If adding an Indirect Tank with a thermostat to Heating Only Boiler change PO3 para...

Page 102: ...30 MODEL 125 Heat Only 125 HEAT ONLY WIRING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 103: ...31 MODEL 165 Heat Only 165 HEAT ONLY WIRING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 104: ...32 MODEL 150 Combi 150 COMBI WIRING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 105: ...33 MODEL 205 Combi 205 COMBI WIRING DIAGRAM PN 240011430 REV G 03 31 18 ...

Page 106: ... 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 240011430 REV G 03 31 18 ...

Page 107: ...115 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 H2O3...

Page 108: ...Wiring 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 109: ...er 1 DO NOT PLACE ISOLATION VALVE BEFORE TEE OR LWCO Note 1 To Drain Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return Note Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdiction Note PN 240011430 REV G 03 31 18 ...

Page 110: ...38 Low Water Cutoff Detail LOW WATER CUTOFF NO NO YES PN 240011430 REV G 03 31 18 ...

Page 111: ...39 NOTES PN 240011430 REV G 03 31 18 ...

Page 112: ......

Page 113: ... 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 114: ...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 115: ......

Page 116: ......

Page 117: ...ark Electrode Clean Set gap according to IOM directions Clean probe with plumbers cloth to remove oxides Flame Sensor Clean probe 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 condensate make sure hose is properly connected ...