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

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

MCA Pro 45/65/90/115MCA-Pro ISM Rv.4.1 2/2017

Safety and Warranty Information 2

Symbols used 2

2 14

3 15



4 18











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

MCA Pro 45/65/90/115 MCA-Pro ISM Rv.4.1 2/2017

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

 

 

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

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

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.

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

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.

This manual suits for next models

Table of contents

Other DeDietrich Boiler manuals

DeDietrich

DeDietrich MCA 45 - 65 - 90 - 115 Manual

DeDietrich

DeDietrich INIDENS 24 Manual

DeDietrich

DeDietrich VIVADENS MCR Manual

DeDietrich

DeDietrich EMC-M 24 Manual

DeDietrich

DeDietrich MODULENS O AFC 18 User manual

DeDietrich

DeDietrich GT 123 A Manual

DeDietrich

DeDietrich INNOVENS PRO MCA 160 Troubleshooting guide

DeDietrich

DeDietrich INIDENS 24 User manual

DeDietrich

DeDietrich IX 145-50 Manual

DeDietrich

DeDietrich NeOvo EcoNox EFU 36 User manual

DeDietrich

DeDietrich BPB 150 Troubleshooting guide

DeDietrich

DeDietrich MCR 24 User manual

DeDietrich

DeDietrich C 210 ECO Owner's manual

DeDietrich

DeDietrich EASYLIFE CFU 36 F30 User manual

DeDietrich

DeDietrich GTU 120 User manual

DeDietrich

DeDietrich ELIDENS DTG 1300 EcoNOx Plus Series Manual

DeDietrich

DeDietrich MODULENS O AFC 18 Manual

DeDietrich

DeDietrich WHE 2.24 User manual

DeDietrich

DeDietrich LN1GBQ41-C140-45 User manual

DeDietrich

DeDietrich GT 300 A User manual

DeDietrich

DeDietrich DTG 320 Eco.NOx Series User manual

DeDietrich

DeDietrich GTU C 330 User manual

DeDietrich

DeDietrich AGC 25 Manual

DeDietrich

DeDietrich GT 220 A User manual

Popular Boiler manuals by other brands

Vaillant

Vaillant uniSTOR VIH SW GB 500 BES operating instructions

Radijator

Radijator BIO max 23.1 instruction manual

Brunner

Brunner BSV 20 Instructions for use

Buderus

Buderus Logamax GB062-24 KDE H V2 Service manual

Potterton

Potterton 50e Installation and Servicing Manual

UTICA BOILERS

UTICA BOILERS TriFire Assembly instructions

Joannes

Joannes LADY Series Installation and maintenance manual

ECR International

ECR International UB90-125 Installation, operation & maintenance manual

Froling

Froling FHG Turbo 3000 operating instructions

Froling

Froling P4 Pellet 8 - 105 installation instructions

U.S. Boiler Company

U.S. Boiler Company K2 operating instructions

Henrad

Henrad C95 FF user guide

NeOvo

NeOvo EcoNox EF 36 user guide

Potterton

Potterton PROMAX SL 12 user guide

Eco Hometec

Eco Hometec EC 25 COMPACT Technical manual

Viessmann

Viessmann VITODENS 200 Operating instructions and user's information manual

Baxi

Baxi Prime 1.24 installation manual

REXNOVA

REXNOVA ISA 20 BITHERMAL Installation, use and maintenance manual