DeDietrich MCA Pro 45 Manual

Wall-hung gas-red condensing boilers
MCA Pro 45/65/90/115
MCA-Pro ISM Rv.4.0 3/2014
www.dedietrichboilers.com
Installation
and Service
Manual
DANGER

or explosion may result causing property damage,
personal injury or death.

vapors and liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light or operate any appliance.
•Evacuate all people.
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
 
department.
Installation and service must be performed by a

installer, service agency or the gas supplier.
WARNING
This manual and all instructions must be read in its


within the area of installation. This manual and ALL
documentation MUST BE READ BEFORE installation to
avoid any possible dangerous conditions. Failure to do
so may create a seriously dangerous situation which
may cause death, severe personal injury or substantial
product/property damage.
Product may not be exactly as shown.
DANGER
When using either PVC, CPVC, Polypropylene or
stainless steel venting the components must be

the Installer and Service Manual prior to installing.
Failure to follow the instructions in the manuals
could lead to death, serious personal injury and or
substantial product and or property damage.

MCA Pro 45/65/90/115 MCA-Pro ISM Rv.4.1 2/2017
2
Safety and Warranty Information
Symbols used
Read this manual carefully before installing the boiler or putting it into operation. This manual must be retained

property/product damage, serious personal injury and possibly death. Make sure all the requirements detailed in this
manual are understood and completed.
DANGER Indicates the presence of a hazardous situation which, if ignored, will result in
death, serious injury or substantial product/property damage.
WARNING Indicates a potentially hazardous situation which, if ignored, can result in danger,
serious injury or substantial product/property damage.
CAUTION Indicates a potentially hazardous situation which, if ignored, may result in minor
injury or product/property damage.
☞More
Information
Indicates recommendations made by De Dietrich for the installers which reference
other pages or chapters in this or another manual.
iBest
Practices
Indicates recommendations made by De Dietrich for the installers which help to
ensure optimum operation and longevity of the equipment.
Professional licensed heating contractor
Boiler Documentation
Advice for the owner
Contaminated air
The assembly, installation, adjustment,
service and maintenance of this boiler must
be performed by a professional licensed
heating contractor.
Make sure to read all documentation
related to the product before starting the
installation. The product documentation
should be stored near the boiler where it
can be accessed for future reference.
When the installation has been completed, the
heating contractor has to familiarize the operator/
owner with the installed equipment as well as any
safety precautions and requirements, and shut-down
procedures. The heating contractor also needs to
inform the operator/owner of the need for professional
annual servicing of the boiler prior to the heating
season.
Chemicals can contaminate the air and
cause by-products during the combustion
process. These by-products are poisonous
to the occupants and very destructive to De
Dietrich boilers.
Carbon monoxide
Fresh air
Boiler venting
Warranty

improperly installed, adjusted, serviced or

monoxide which is poisonous.
Adequate ventilation and combustion air must be
provided for the equipment as it requires fresh air for
safe operation. Make sure the equipment is installed
ensuring an adequate supply of fresh air.
Always operate the boiler with an
installed vent system. Carbon monoxide
poisoning can be caused by an improperly
installed vent system. All combustion
products must be vented safely to the
outdoors.
The information in this manual and any
other related manuals must be read and
proper procedures followed.
The warranty is rendered null and void
if the procedures are not followed as
prescribed.
iSome products may not be exactly as
illustrated. Information contained herein is

material supply, pipe sizing, thread type, and
typographical errors should be noted as soon
as possible. Dimensions have been converted
from the Metric standard. Fractional rounding

GT 530A
Installation
Instruction
Manual
Warranty

3
MCA Pro 45/65/90/115MCA-Pro ISM Rv.4.1 2/2017
Safety and Warranty Information 2
Symbols used 2
6
7
10
10
11
12
12
12
12
12
12
13
13
13
13
2 14
14
14
3 15
15
15
16




4 18
18
18


19
19
19
20
21
22
23
25
25

27




32
Safety Information
Safety Information and Codes
Safety Requirements for installations in the state of Massachussetts
Start-up
Shutdown
Lighting and Operating Instructions
Introduction
1.1 Abbreviations
1.2 General
1.2.1 Operator/ultimate owner liability
1.2.2 Manufacturer's liability
1.2.3 Installer's liability
1.3 General information
1.3.1 Gas type
1.3.2 Additional requirements
1.3.3 Factory Tests
Safety Instructions and Recommendations
2.1 Safety instructions
2.2 Recommendations
Technical description
3.1 General description
3.2 Main parts
3.3 Operating principle




Installation
4.1 Regulations governing installation
4.2 Package list


4.3 Rating Plate & warning label Location
4.3.1 Rating plate
4.3.2 Minimum Service clearances
4.3.3 Ventilation
4.3.4a Dimensions without bottom connection kit accessory
4.3.4b Dimensions with bottom connection kit accessory
4.4 Mounting the boiler
4.5 Installation examples
4.5.1 MCA Pro Boiler with one heating circuit

4.6 Water connections




4.7 Gas connection
 
Table of Contents
9

MCA Pro 45/65/90/115 MCA-Pro ISM Rv.4.1 2/2017
4
Table of Contents
 
 
4.8 Connections for the air and ue pipes 34
 
 
 
 
4.9 Electrical connections 51
4.9.1 Control unit 51
4.9.2 Recommendations 51
4.9.3 Standard PCB control 52
4.9.4 Connecting the pump 53
4.9.5 Connecting a third party control unit 55
 
 
 
 
 
4.9.11 Release input 59
4.10 Optional electrical connections 59
4.10.1 Box for the control PCBs 59
 
 
4.11 Electrical diagram 63
4.12 Filling the heating system 64
 
 
 
5 Commissioning 65
5.1 Control panel 65
 
 
5.2 Check points before commissioning 66
 
 
 
 
5.3 Commissioning the boiler 67
5.3.1 High Altitude Applicatinos 67
5.4 Gas settings 68
 
 
 
5.5 Finalizing work 71
5.6 Reading out measured values 71
 
 
 
5.7 Changing the settings 75
 
 

5
MCA Pro 45/65/90/115MCA-Pro ISM Rv.4.1 2/2017
Table of Contents
 
 
 
 
 
6 Shutting down the system 82
6.1 Shut-down 82
6.2 Frost protection 82
7 Checking and maintenance 83
7.1 Annual Start-up and general maintenance 83
7.2 Maintenance Message 88
7.3 Preventive maintenance with automated service message 88
 
 
7.4 Standard inspection and maintenance operations 90
 
 
 
 
 
 
 
7.5 Specic maintenance operations 93
 
 
 
8 Troubleshooting 96
8.1 Error codes 96
8.2 Shutdowns and lock-outs 99
 
 
8.3 Error memory 102
 
 
9 Spare parts 104
9.1 General 104
9.2 Spare parts 104
9.2.1 Casing 104
9.2.2 Heat exchanger and burner - MCA 35/45 105
 
 
 
 
 
 
9.2.9 Spare parts list 110
10 Checklists 113
10.1 Checklist for commissioning 113
10.2 Checklist for periodic inspection and maintenance 114
10.3 Lighting instructions 115
- Installation and Service Certicate 116

MCA Pro 45/65/90/115 MCA-Pro ISM Rv.4.1 2/2017

Before operating the boiler, make sure you fully
understand its method of operation. Your heating
contractor should always perform the initial start-up
and explain the system. Any warranty is null and void if
these instructions are not followed.
DANGER
What to do if you smell ue gas
• Ensure all people are evacuated from the house
immediately
• Deactivate heating equipment.
• Open windows and doors.
• Do not try to light any appliances.
• Do not touch any electrical switches, do not use
any phone in your building.
• Immediately call your heating contractor or gas
supplier from a neighbour’s phone. Follow the gas
supplier’s instructions.
 
department.
Working on the equipment
All personnel working on the equipment or the heating

necessary licenses.
Ensure main power to equipment, heating system, and
all external controls has been deactivated. Close main
gas supply valve. Take precautions in all instances to
avoid accidental activation of power during service
work.
Dangerous conditions
• Deactivate main power immediately.
• Close gas supply valve.
CAUTION
Incomplete combustion and poisonous gases result
if the fresh air intakes in the mechanical room are
closed. Never close these openings.
Maintenance and cleaning

contractor is critical to the performance of the boiler.
Neglected maintenance impacts the warranty;
regular cleaning and maintenance ensures clean,


heating contractor.
For safe operation
We recommend that you frequently:
 
gases. The vent or chimney must not be blocked.
Safety Information
Operation A blocked or partially blocked vent or chimney can

leaking into the house can cause injury or death.
Blocked or partially blocked chimneys must have the

pressure gauge for correct system (water) pressure.
 
of the pressure relief valve or any other pipe, pipe
joint, valve or air vent.
- Check for moisture, water, or appearance of rust

dampers, or side wall vent terminals (if so equipped).
 
combustion and ventilation air and no chemicals,
propane tanks, garbage, gasoline, combustible

(not even temporarily) in the vicinity of the boiler.
- Do not allow unsupervised children near the boiler.
- Service/inspection of the boiler and the system must
be serviced yearly. Maintenance, service and cleaning

- Before the heating season begins, the boiler must be

WARNING
• There are no user serviceable parts on the boiler,
burners or control. Failure to heed this warning can
cause property damage, severe personal injury, or
loss of life.
• Improper installation, adjustment, service, or

living space. Flue products contain poisonous
carbon monoxide gas which can cause nausea or
asphyxiation resulting in severe personal injury or
loss of life.
• Should overheating occur or the gas supply fail to


external to the appliance.
Do not use this boiler if any part has been under water.

the boiler and to replace any part of the control system
and any gas control which has been under water.
Do not store chemicals containing chlorine or other
corrosive materials near the boiler, such as bleach,
cleaning solvents, detergents, acids, hair spray, spray
cans, paint thinners, paint, or water softener salt.


MCA Pro 45/65/90/115MCA-Pro ISM Rv.4.1 2/2017
Safety Information and Codes
Boiler modication and spare parts


without the written approval from DDR Americas Inc.
Carbon monoxide
The installation of carbon monoxide detectors is highly
recommended by the U.S. Consumer Product Safety
Commission for buildings with gas burning equipment.
Sources of carbon monoxide include exhaust vents for

properly vented, malfunctioning furnaces and exhaust
fumes from idling cars.
Carbon monoxide is a colourless and odourless gas
that is highly toxic. It can interfere with the delivery
of oxygen by the blood to the body. Exposure to low
levels of CO can cause headaches, confusion, nausea,
dizziness, fatigue, and shortness of breath. High level
exposure of CO can cause impaired vision, convulsions,
coma and possibly death.


yearly basis.
In winter, inspect the exhaust vents for the dryer,

recovery ventilator to ensure they are not obstructed
by snow build-up.
Carbon monoxide detectors should be installed and
maintained in buildings that house gas burning
equipment. It is recommended to use a carbon
monoxide detector that is in compliance with a
nationally recognized standard such as ANSI/UL 2034-

DANGER
Improper installation, adjustment, service, or

living space. Flue products contain poisonous
carbon monoxide gas which can cause nausea or
asphyxiation resulting in severe personal injury or
loss of life.
Codes
Installation, servicing and maintenance of this product
must be performed by a licenced and trained heating
contractor, experienced in hot water heating boilers
as well as gas and oil combustion. The installation
must conform to all national and local codes having
jurisdiction:
• In Canada, CSA B149.1 Gas Code
• In USA, ANSI Z223.1 (NFPA 54) Gas Code, and
ASME CSD-1 Automatically Fired Boilers.
If you have any technical questions or need assistance
with this product, please call your local Sales
Representative or DDR Americas Inc.
Standards applied

hereinafter are in compliance with the latest standards
described, and that they are manufactured and
marketed in compliance with the requirements of the
following North American standards:
• ASME Section IV
• CSA B51
 
water boilers.
 
at high altitude.
• CGA P.2-1991 (R1999) - Testing method for

furnaces and boilers.
• CAN/CSA C22.2 No.0-M91 - General requirements -
Canadian electrical codes part II.
 
burning equipment.

MCA Pro 45/65/90/115 MCA-Pro ISM Rv.4.1 2/2017
8
Safety Information and Codes
Water pipe freezing hazard
WARNING
Serious property damage and/or personal injury can
occur if the pipes are not protected from
freezing, resulting in the pipes bursting. The boiler
may also shut down. Turn o the water supply and
drain the water pipes or protect them from freezing
when leaving the home unattended for long periods
of time during very cold weather conditions.
The boiler is designed to provide a comfortable
and warm environment and is not designed for the
prevention of frozen water pipes. In case an unsafe
condition occurs, the boiler has been designed and
equipped with several safety devices that will shut
down the boiler and stop it from restarting.
If the boiler is dormant for an extended period of time
during cold winter weather, the water pipes may freeze
and burst which can result in extensive water damage
and lead to mold growth. A variety of molds can cause
serious health and respiratory problems. If water
damage should occur, immediately dry the aected
areas to avoid the possibility of mold growth.
If the building will be empty for an extended period of
time in cold winter conditions, then the following steps
should be taken:
• Turn o the building’s water supply, drain the pipes
and add some antifreeze for potable water for the
toilet tanks and drain traps.
• Open faucets where appropriate.
• Have the building monitored and checked during
cold winter weather and call a qualied service
technician if necessary.
• Remote temperature sensors are available which
will alert someone if freezing conditions occur in the
building.
Combustion sources and
ventilation air contaminants
Contaminants are likely to be found in these areas:
• Auto body shops
• New construction
• Metal manufacturing plants
• Swimming pools
• Refrigeration repair shops
• Garages with workshops
• Furniture renishing shops
• Plastic manufacturing plants
• Hobby rooms and remodelling areas
• Dry cleaners and laundromats
• Photo processing companies
• Beauty salons
Contaminants found in various products:
• Paint and varnish removers
• Chlorinated cleaners and waxes
• Glues and cements
• Swimming pool chemicals containing chlorine
• Refrigerant leaks
• Water softener salt containing sodium chloride
• Cleaning products such as chlorine-based bleaches,
detergents and cleaning solvents
• Spray cans containing chlorouorocarbons
• Muriatic and hydrochloric acid
• Calcium chloride utilized in thawing
• Permanent wave solutions
• Adhesives utilized for building products and other
similar items
• Fabric softeners used in clothing dryers
Boiler Installations within the Commonwealth of Massachusetts must conform to the following requirements:
•Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.
•Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap.
•The vent termination must be located a minimum of 4 feet above grade level. If side-wall venting is used, the installation
must conform to the following requirements extracted from 248 CMR 5.08 (2):
(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or
in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent
termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and
porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS: At the time of installation of the side wall horizontal vented gas fueled
equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and
battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or
gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each
additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be
the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard
wired carbon monoxide detectors.
Requirements for installation in the state of Massachusetts

9
MCA Pro 45/65/90/115MCA-Pro ISM Rv.4.1 2/2017
Safety Information and Codes
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision cannot be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30)
day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector as required in accordance with the above
provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum
height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating
appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS". (Continued)
1. The equipment listed in Section 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA
54 as adopted by the Board; and
2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the
dwelling, building or structure used in whole or in part for residential purposes.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product
Approved side wall horizontally vented gas equipment provides a venting system design or venting system components
with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting
system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a
Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases,
but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:
1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation
instructions; and
2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
……………….[End of Extracted Information From 248 CMR 5.08 (2)]…………………
4. INSPECTION: The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed
in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

MCA Pro 45/65/90/115 MCA-Pro ISM Rv.4.1 2/2017
10
Start-up
Shut-down
Initial start-up
The heating contractor must perform the initial start-up
and explain the operation of the system.
The operation of the boiler control must also be
explained to the system operator/ultimate owner by the
heating contractor. Refer to literature packaged with
boiler control.
Necessary preparations prior to initial start-
up, your contractor will:
 
pipe or the pressure relief valve or any other pipe,
pipe joint, valve or air vent.
If pressure relief valve is discharging, the
contractor will locate the source of the problem and
take corrective measures. Never cap or plug end of
pressure relief valve discharge pipe. Ensure correct
system (water) pressure.
2. Ensure fresh combustion air supply vents to boiler
room are open and unobstructed. Nothing must

3. Open main fuel supply valve.
4. Activate the system. Ensure power supply is
activated and then activate system power switch.
Your heating system is now ready for operation.
Operation
Refer to “Lighting and operation instructions”, page 11.
The boiler control regulates operation of the heating
system automatically in conjunction with the
indoor/outdoor control and any programmed settings (if
applicable).
Changes to the settings or programming can be made
according to separate instructions provided with the
boiler control.
For optimum operation
Keep the boiler and the boiler room clean and free of
dust and dirt.
Ensure proper system pressure by occasionally
checking pressure gauge.

maintain your heating system on a yearly bases.
Neglected maintenance impacts on product warranty;
regular cleaning and maintenance ensures clean,


heating contractor.

contractor, please contact your local Sales
Representative or DDR Americas Inc.
Shut-down procedure
1. Deactivate system power switch.
2. Deactivate main power supply to boiler and control.
3. Close main fuel supply valve.
We recommend that you contact your heating
contractor prior to and after an extended shut-down
period. In this manner, the appropriate precautions,
i.e. system freeze-up protection or heat exchanger
maintenance, can be taken.
WARNING
Do not attempt to start the burner if excessive fuel
has accumulated in the combustion chamber.
Do not open the boiler door or clean outs when the
boiler is hot.