Home

Utica Boilers UB90-200 Operation and Installation Manual

Contents

1. e Before operating smell all around appliance area for gas Be sure to smell next to floor because some gas is heavier than air and will settle to the floor e Use only your hand to turn the gas shutoff valve Never use tools If valve will not turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in fire or explosion e Do not use this appliance if any part has been under water Immediately 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 LI GHTI NG PROCEDURE FOR BOILER WI TH INTERMI TTENT PILOT SYSTEM 1 This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the appliance by hand WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switches do not use any phone in your building e immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department 29 Operating Instructions 1 STOP Read the safety information on this page before operating this appliance 2 Setthe thermostat to the lowest setting 3 Turn off all electrical power to the appliance 4 This appliance does not have a pilot It is equipped with an ignition device which automatically lights the
2. REPLACE IBC NO BOILER OFF ON HIGH LIMIT IS BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT ACTUAL BOILER WATER TEMP GREATER THAN HI LIMIT SET POINT MINUS 30 F CONTROL DIFFERENTIAL AQUASTAT CONTACTS CLOSED SEE TROUBLESHOOTING PATH 2 ABOVE ARE THERMOSTAT CONTACTS OPEN YES REPLACE IBC REMOVE WIRING HARNESS CONNECTION CN9 FROM GAS CONTROL DOES GAS CONTROL CLOSE NO NO REPLACE IBC 46 REPLACE AQUASTAT O REPLACE THERMOSTAT REPLACE GAS CONTROL 15 TROUBLESHOOTI NG Differential Air Pressure Switch Check Differential air pressure switch is safety device which prevents boiler from firing if there is air intake boiler heat exchanger or vent blockage Following steps and diagram indicate location of connection points required to measure offset pressure using inclined Manometer or Differential pressure gauge Only one device is required to measure offset pressure 1 Turn off service switch or lower thermostat setting 2 Remove vinyl caps from Tee 3 Install testing lines as shown to inclined manometer or differential pressure gauge with ability to read 0 01 to at least 6 0 w c 4 Turn on service switch and set thermostat to call for heat 5 If manometer readings do not correspond to Table 11 check for possible causes e Blockage or moisture in suction lines to switch e Blockage or moisture in orifice installed in suction lines t
3. 457mm Minimum Clearance Above Highest Anticipated Snow Maximum of 610mm Above Roof NOTICE Properly support venting Boiler is not designed to bear weight of venting system 3 Diameter PVC D 1 Ei 3 Diameter PVC 41 2 Dia Vent Exhaust 1 v2 VO Intake Combustion Air a 7 COMBUSTION AIR AND VENT PIPE Connections And Termination Installation must conform to requirements of authority having jurisdiction or in absence of such requirements to the section for Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 Installer must clean and remove all shavings from interior of all pipes used on air intake to prevent damage to gas burner and ensure proper operation Boilers require dedicated direct vent system All air for combustion is taken directly from outdoors through combustion air intake pipe All flue products are discharged to outdoors through vent pipe Install vent system in accordance with instructions in this manual 1 Figures 8 and 9 Combustion Air and Vent Pipe Requirements for standard two pipe roof and sidewall terminations and Figures 10 11 and 12 for concentric vent terminations roof termination is preferred Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown Construction through which vent and air intake pipes may be installed is mini
4. DO NOT RELOCATE LIMIT AQUASTAT CONTACTS OPEN OXIDE COATING ON IGNITER PREVENTING FLAME SIGNAL REPLACE IGNITER SENOR IF THE ANSWER IS NO CHECK FLAME SIGNAL gt 0 6uA CHOOSE THE APPROPRIATE CONSULT BOILER MFGR FOR PATH 1 2 OR 3 BASED ON SPECIFIC INSTRUCTIONS SYMPTOMS SHOWN REQUIRES SPECIAL TOOLS YES REPLACE IBC CHART 6 CHART 6 CHART 6 45 Troubleshooting Chart 6 CHART 5 YES p amp K I mi n SET THERMOSTAT BELOW ROOM TEMPERATURE TO END CALL FOR HEAT YES DOES CIRCULATOR PUMP STOP YES VALE LIGHT IS OFF DOES DRAFT BLOWER STOP AFTER 30 SECOND POST PURGE YES SYSTEM OK NO 15 TROUBLESHOOTING CHART 5 CHART 5 NO 3 NO 2 RUNS FOR 25 50 SECONDS THEN TURNS OFF CHECK FIRING RATE OF UNIT IS UNIT FIRING AT THE CORRECT RATE YES CHECK BURNER FOR ANY DETERIORATION IN THE FLAME PORTS ARE BURNER PORTS IN GOOD CONDITION YES CHECK FLAME SIGNAL gt 0 6uA CONSULT BOILER MFGR FOR SPECIFIC INSTRUCTIONS REQUIRES SPECIFIC TOOLS NO YES REPLACE GAS CONTROL YES CHECK GAS ORFICICE SIZE IS GAS ORIFICE SIZE CORRECT CHECK REPAIR PARTS LIST FOR CORRECT SIZE IS GAS ORIFICE CLEAR OF BLOCKAGE YES DOES THE UNIT USE LP GAS NO ADJUST RATE AS DESCRIBED IN THE CHECK OUT PROCEDURE AND ADJUSTMENT SECTION OF THE MANUAL REPLACE WITH CORRECT AIR BAFFLE REPLACE BURNER
5. 12 DETAILED SEQUENCE OF OPERATI ON DRAFT INDUCER TEMPERATURE SAFETY SWITCH If draft inducer temperature reaches temperature safety switch set point safety switch contacts open immediately closing gas valve light goes out Draft inducer runs through 30 second post purge and switches OFF Circulator runs with thermostat on call for heat When temperature safety switch contacts connect before end of call for heat control goes in normal light off sequence LOSS OF FLAME SI GNAL If established flame signal is lost while control expects burner is operating control immediately de energizes gas valve Valve and flame lights go out Draft inducer runs through 30 second post purge Control attempts to light boiler 3 times If flame is not proven control lockout problem establishing flame signal Valve light is blinking Control automatically resets after 1 hour LOSS OF COMBUSTI ON AI RFLOW If combustion airflow is lost while burner is firing Differential air pressure switch contacts open gas valve is de energized Valve and flame lights go out Draft inducer runs through 30 second post purge If call for heat remains IBC waits 5 minutes for airflow to be re established If airflow does not re establish control lockout problem with combustion airflow Purge light blinks Control automatically reset after 15 minutes 31 CASTI NG TEMPERATURE SAFETY SWITCH If burner operates when boiler has no water alu
6. causing low firing rate and high excess air levels 34 13 SEQUENCE OF OPERATI ON DI AGNOSTI CS System Status Indicator lights track operating sequence If system locks out lights indicate point in sequence of operation were lockout occurs Refer to following pages for detailed troubleshooting procedures INDICATES LIGHT STATUS IBC is energized through 24 volt transformer IBC is not energized IBC receives more than 40 VAC IBC is energizing draft inducer and air flow is proven Off during purge cycle draft inducer is not powered on or air flow is not proven Off during igniter and run cycle normal operation purge cycle complete IBC is locked out Problem could indicate false positive proof of air flow Blocked vent intake air pipe flue way or orifice in negative pressure hose IBC is locked out Problem is flame has not been proven in three 3 ignition attempts May be due to broken igniter or lack of low flame signal or no gas Checking for flame signal during trial for ignition IGNITER 14 CHECKOUT PROCEDURE amp ADJ USTMENTS Inspect Venting amp Air Intake System Operate boiler Verify all vent air intake connections are gas tight and water tight Repair any leaks immediately Inspect Condensate Drain Verify all connections are watertight and condensate flows freely Repair any leaks immediately Inspect System Piping Verify all connections are watertight
7. e Connect black hot lead from power supply to either of unused brass screws on service switch e Connect white neutral lead from power supply to white Screw on service switch e Connect green ground lead from power supply to ground green screw on service switch Service Switch e Receptacle on service switch is powered regardless of Junction Box whether switch is on or off and could be used as power supply for external condensate pump if one is used e Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod 22 9 ELECTRICAL WIRING AVOID THE FOLLOWING Dead Spots Cold Spots Corners Alcoves Behind doors Concealed pipes or ducts Stairwells drafts Unheated rooms on the other side of the wall Concealed pipes Fireplaces TVs or radios Lamps Direct sunlight Kitchens 23 Thermostat Installation e Follow instructions included with your thermostat e ocate thermostat five feet above floor on inside wall e Mount directly on wall or vertically mount on outlet box Thermostat should sense average room temperature e Set heat anticipator at 0 7 amps e Connect 24 volt thermostat leads to the two 2 yellow wires located in service switch junction box located on outer jacket of boiler See Figure 15 Page 22 for service switch junction box and thermostat field wiring connections Connect Circul
8. e Placed on level surface DO NOT install on carpeting e Condensate drain line must be pitched down to floor drain or external condensate pump with reservoir at 1 4 per foot 21 mm m wood frame or blocks may be used to raise boiler 3 LOCATING THE BOILER Locating The Boiler 1 Select level location central to piping systems served and close to vent and air intake terminals as possible 2 Manufacture recommended accessibility clearances if more stringent i e larger clearances than required fire protection clearances must be used for boiler installation Accessibility clearances may be achieved with use of removable walls or partitions 3 Combustible clearances shown in Table 4 indicate required clearances per CSA listing Minimum 1 25 mm clearance must be maintained between combustible construction and each of the right top and back surfaces of boiler Minimum 8 203 mm clearance is required on left side to allow room for inlet air pipe 18 457 mm clearance must be maintained at front where passage is required for cleaning or servicing inspection or replacement of any parts that normally require such attention Allow 24 610 mm at front and left side and 8 203 mm at top for servicing No combustible clearances are required to venting or combustion air intake piping Table4 BOILER CLEARANCES Combustible Clearance op 1 25 mm 8 203 mm ccessibility Cleaning and Servicing Left
9. systems installed above drain valve Install drain valve in 34 tapping at bottom of boiler Piping installed below drain valve elevation requires additional drain valves installed at low points in piping systems to drain entire system Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions A S M E Rated Pressure Relief Valve e Each boiler must have properly sized and installed A S M E rated pressure relief valve e Water expands as it is heated by the burner boiler sections If no place for water to expand its volume 1 properly sized functioning expansion tank pressure inside of boiler and heating system increases 27 e Furnished relief valve automatically opens at 30 psi to relieve strain on boiler and heating system from increasing pressure e Pipe pressure relief valve discharge with same size as valve discharge opening to open drain tub or sink or other suitable drainage point Do not subject to freezing in accordance with A S M E e Failure to provide pressure relief valve with piping as described may cause water damage and or serious bodily injury Blocked Vent Safety Shutoff e Boiler equipped with blocked vent safety shutoff shuts off main burner gas in event airflow of combustion products through flue way is reduced Air will not be available to support combustion if flue way is blocked IBC locks out
10. 6 8 Measured input rate should be within 0 2 of input rating found in step 2 See Adjustments And Checkout on page 36 36 14 CHECKOUT PROCEDURE amp ADJ USTMENTS Adjustments And Checkout Set Thermostat To Desired Temperature Appliance should operate between 8 5 And 1096 CO2 Set thermostat to desired room temperature and observe Verify boiler is operating in this range Follow steps below several complete cycles to verify proper operation Final Review And Sign Off Under all conditions CO levels should not exceed 3 Review all instructions shipped with this boiler with owner 100ppm De maintenance person Affix instructions on or adjacent to 1 Check incoming gas pressure to appliance using boiler pressure gauge with resolution of 0 1 w c or better and range from 0 to at least 14 w c A Close gas shut off inside boiler jacket B Locate inlet pressure tap on gas valve Figure 18 Page 26 C Open inlet pressure tap screw turn Connect positive side of pressure gauge to inlet pressure tap Open gas shut off E Gas pressure e between 4 and 10 w c natural gas e between 10 and 14 w c propane gas Drill hole in plastic CPVC pipe for combustion analyzer Turn thermostat to closed position to activate boiler Allow boiler to run for 5 minutes Insert combustion analyzer sample probe into hole just drilled about halfway into exhaust gas stream A Take
11. FURNISHED NOT REQUIRED WHEN USING PP INSTALL FIELD SUPPLIED 0 ZBY3 TRANSITIONIN SG THE VERTICAL POSITION ONLY TE 0 x 5 1 5m Minimum PX 2 50 8MMI CPVC VENT PIPING IFURNISHED amp REQUIRED 2 50 8MM COMBUSTION AIR INTAKE PIPING EXHAUSTTEE FURNISHED NOT IN HORIZONAL SECTION 18 7 COMBUSTI ON AIR AND VENT PIPE NOTICE Exhaust transition from 2 pipe to 3 pipe must be made in vertical run Transition pieces not included 6 General Installation Requirements A Position termination where vent vapors will not damage plants shrubs air conditioning equipment or siding on the house B Position termination so it will not be effected by wind eddy air born leaves snow or recirculated flue gases For high wind location termination tees are required C Position termination where it will not be subjected to potential damage by foreign objects such as stones balls etc D Position termination where vent vapors are not objectionable E Put vent on wall away from prevailing winter wind Locate or guard vent to prevent accidental contact with people or pets F Avoid locations where snow may drift and block vent Ice or snow may cause boiler to shut down if vent becomes obstructed G Under certain conditions flue gas will condense forming moisture and may be corrosive In such cases take steps to prevent building materials at vent from being d
12. NOTE USE COPPER CONDUCTORS ONLY 24 9 ELECTRICAL WIRING Figure 18 Ladder Wiring Diagram NOTE If any of the original wire as supplied with this appliance must be replaced it must be replaced with type 150 C Thermoplastic wire or its equivalent 120 VOLT POWER SUPPLY NOTE USE COPPER CONDUCTORS ONLY L1 2 HOT BK W ON OFF SWITCH RECEPTICAL P7 2 P7 1 P7 3 2K1 P4 1 P4 3 r X A X XE 1K1 P10 1 CIRCULATOR FIELD WIRED P10 2 P533 P5 1 J BLOWER ER 5K1 P6 1 P12 1 HOT SURFACE IGNITER P12 2 P6 2 5K2 BK 120 VAC P1 1 P1 3 TRANSFORMER nee CASTING TEMPERATURE SAFETY SWITCH MANUAL RESET 4K1 3K1 GAS VALVE DIFFERENTIAL I AIR PRESSURE O Eu es N O LOGIC amp TIMERS SET AT DIFFERENTIAL AIR 0 5 WC PRESSURE SWITCH N C SET AT INDICATOR LIGHTS 43 5 W C POWER LS PURGE P3 6 IGNITER VALVE P3 9 P3 4 P3 7 THERMOSTAT R W bi THERMOSTAT O 2 1 E HYDROSTAT 3000 25 10 CONTROLS AND ACCESSORI ES See Troubleshooting on page 31 for detailed sequences of operation and troubleshooting procedures See separately provided Repair Parts Manual for locations of control components and accessories described Integrated Boiler Control 1 e Integrated Boiler Control IBC is a microprocessor based controller for high efficiency gas boilers e Control
13. Pressure test at 1 2 psig 3 5 kPa or less Isolate boiler from gas supply system by closing manual gas shutoff valve e Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition source e Correct leaks immediately and retest 9 ELECTRICAL WI RING Figure 16 Field Wiring Connection Electrical shock hazard Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury 120 Volt Circulator WIRE COLOR CODE NOTI CE im WaWiME Thermostat G GREEN Use copper conductors only Y YELLOW NS jE cH BR BROWN Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to NEUTRAL National Electrical Code ANSI NFPA 70 hu om HC re P GROUND POWER SUPPLY Electric Power Supply L Turn OFF electrical power supply at service panel and boiler BEE SWITCH before making electrical connections FIELD WIRING COMNECTIONS e Run 120 volt circuit from separate over current protection device in electrical service entrance panel 15 ampere Circuit e Service switch is pre wired and located on exterior boiler jacket See Figure 15 for location of service switch junction box and power supply connection points
14. Repair any leaks immediately Test Ignition System Safety Shutoff 1 Turn off manual gas shut off valve 2 Setthermostat to call for heat 3 Boiler begins normal sequence of operation 4 After approximately 30 seconds pre purge and igniter warm up period lamp D illuminates indicating gas valve is powered 5 After 4 seconds gas valve closes lamp D goes out as integrated boiler control senses flame is not present 6 To restart system follow operating instructions See Startup on page 29 Test And Adjust High Limit Control e At initial start up with Economy Feature activated control establishes 145 F target temperature While burner is operating adjust setting on high limit control below actual boiler water temperature Burner should go off while circulator continues to operate Raise limit setting above boiler water temperature and burner should re ignite after pre purge and igniter warm up period Set high limit control to design temperature requirements of system Maximum high limit setting is 190 F Minimum high limit setting is 100 F After testing restore Economy setting If heating demand is high target will increase over time to satisfy heat load e See Manufacturer provided literature for specific features of high limit control Test Other Safety Controls If boiler is equipped with low water cut off manual reset high limit or additional safety controls test for operation as outl
15. Side 8 203 mm 24 610 mm Right sige resm base Piping All distances measured from boiler cabinet 4 Keep boiler area clean of debris and free of flammable and combustible materials liquids and vapors 5 Install equipment in location which facilitates operation of venting and combustion air intake piping systems as described in this manual 6 Advise owner to keep venting and combustion air intake passages free of obstructions Both venting and combustion air intake piping systems connected to outdoors must permit flow through piping systems without restrictions for boiler to operate T Boiler shall be installed such that automatic gas ignition system components are protected from water dripping spraying rain etc during operation and service circulator replacement condensate trap control replacement etc 8 Boiler must be located where ambient temperatures minimum possible room temperatures where boiler is installed assuming boiler is not in operation and therefore contributes no heat to space are always above freezing temperature 9 If boiler is not level condensate drain lines will not function properly Adjustable feet are located on boiler to make up for minor surface irregularities or tilt 10 Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir 11 Provide means for condensate d
16. burner Do NOT try to light this burner by hand 5 Remove the front jacket panel 6 Turn off the gas shut off valve Valve handle should be perpendicular to the gas pipe T Wait five minutes for any gas to clear Then smell for gas including near the floor If you smell gas STOP Follow instructions at left under What To Do If You Smell Gas f you do not smell gas go to the next step 8 Turn the gas shut off valve to the On position The handle on the valve should be parallel to the gas pipe 9 Replace the front jacket panel 10 Turn on all electrical power to the appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow instructions in To Turn Off Gas To Appliance below and call your service technician or gas supplier To Turn Off Gas To Appliance 1 Set thermostat to lowest setting 2 Turn off all electric power to appliance if service is to be performed 3 Remove the front jacket panel 4 Turn gas shut off valve off Handle should be perpendicular to the gas pipe 5 Replace the front jacket panel Safe lighting and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in ANSI Z21 13 latest revision 11 STARTUP If Burner Appears To Pulsate During Ignition 1 Turn off boiler power Shut off gas supply to boiler 2 Take burner assembly apart by removing combustion air blowe
17. due to loss of adequate air flow Pressure switches monitor air flow by sensing differential pressure Contacts normally open and close when draft inducer is running causing differential pressure at switch to exceed settings Closed switch proves adequate air flow for combustion Pressure switch shuts off main burner if differential pressure is inadequate due to blocked vent pipe blocked air intake blocked boiler section or blocked air inducer After 5 minutes of inadequate differential pressure IBC will lock out Purge indicator lamp blinks see Figure 19 Page 26 indicating failure to prove adequate combustion air flow or flue gas flow IBC automatically resets after 15 minutes or manually reset as noted see C page 26 Boiler cannot be restored to normal operating condition by resetting control contact qualified service agency to check heat exchanger flue ways for blockage High Limit Low Water Cut Off Unit equipped with high limit low water cut off control protects against over temperature and dry firing Control provides burner cut off if unsafe water loss which can result from broken or leaking radiator pipe or boiler Use water glycol mixture 5096 with low water cut off Refer to manufacturer provided literature for specific features External Condensate Pump Optional Installations where no floor drain or other appropriate drainage available external float activated condensate pump with integral sump not su
18. hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions Safety Relief Valve Temperature Pressure Gauge Boiler is furnished with safety relief valve and temperature pressure gauge e nstall safety relief valve using pipe fittings provided with boiler Figure 2 e Install safety relief valve with spindle in vertical position e Do not install shutoff valve between boiler and safety relief valve e Install discharge piping from safety relief valve A Use 3 4 or larger pipe B Use pipe suitable for temperatures of 375 F 191 C or greater C Individual boiler discharge piping shall be independent of other discharge piping D Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate E Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping F Install union if used close to safety relief valve outlet G Install elbow s if used close to safety relief valve outlet and downstream of union if used H Terminate pipe with plain end not threaded 4 NEAR BOILER PIPING Figure 4 Diaphragm Type Expansion Tank Piping wiy GATE VALVE OR FULL PORT BALL VALVE AUTOMATIC AIR VENT 3 4 x1 8 BUSHING COMBINATION QUICK FILL VALVE STRAINER CHECK VALVE AND PRESSURE FURNISHED
19. in boiler sections reducing efficiency and ultimately shutting down boiler due to lack of combustion air flow Regular service and maintenance by qualified service agency must be performed to assure safe trouble free operation and maximum efficiency It is recommended to service boiler at least once every 12 months Beginning Of Each Heating Season 1 Schedule annual service call by qualified service agency which includes A Examine flue passages between boiler sections burner and condensate lines and clean if necessary following annual examination and cleaning instructions in paragraph F below Visually inspect venting and air intake system for proper operation If vent or air intake show any signs of deterioration or leakage repair or replace immediately Ensure proper re assembly and re sealing of vent and air intake system Check for and remove any obstruction to flow of combustion air or venting of flue gases Follow instructions for Startup on page 28 Follow Checkout Procedure amp Adjustments on page 35 Visually inspect condensate drain line for proper operation Check for deteriorated or plugged condensate drain line Check all gasket joints for leakage and tighten bolts or replace gaskets if necessary Remove jacket front and top panels and check for piping leaks around relief valve and other fittings Repair if found DO NOT use stop leak compounds Check boiler area is free from combus
20. 6m below from an operable opening in an adjacent building Canadian Installation Requirements Venting system shall terminate at least 6 ft 1 8m away from any forced mechanical air inlet to any building Venting system shall terminate a minimum of 1 ft 0 3m above grade or expected snow level such a way that it cannot be blocked by snow Termination shall be not less than 7 ft 2 1m above adjacent public walkway paved driveway or sidewalk Vent terminal shall not be installed closer than 3 ft from inside corner of L shaped structure Vent shall not terminate within 1 ft 0 3 m for inputs up to and including 100 000 Btu hr 30kW and 3 ft 0 9 m for inputs exceeding 100 000 Btu hr 30kW of window or door that can be opened in any building of any non mechanical air supply inlet to any building or of combustion air inlet of any other appliance Venting system shall terminate at least 4 ft horizontally from and in no case above or below unless 4 ft 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Venting system shall not terminate where hot gases can cause property damage personal injury or where condensate may cause hazardous frost or ice accumulations First 3 feet 900mm of plastic venting must be readily accessible for visual inspection Vent shall not terminate underneath veranda porch or deck unless a The veranda porch
21. ENANCE AND CLEANING INSTRUCTIONS YES CHECK DRAFT INDUCER NO REPLACE MOTOR RPM IS IT BLOWER 3400 3600 YES CHECK FOR BROKEN OR LOOSE IMPELLER ON DRAFT INDUCER AND REPLACE BLOWER IF FOUND TO BE BROKEN OR LOOSE 15 SECOND PRE PURGE COMPLETE IBC PURGE LIGHT IS OFF SIMULTANEOUSL IGNITOR LIGHT IS ON AS IGNITOR CIRCUIT NO REPLACE IBC 43 Troubleshooting Chart 4 CHART 3 YES IGNITER SENSOR WARMS UP AND GLOWS YELLOW ORANGE DURING 20 SECOND WARM UP YES AFTER 20 SECOND IGNITER WARM UP GAS VALVE IS ENERGIZED VALVE LIGHT IS ON 2 SECONDS LATER POWER IS REMOVED FROM IGNITER SENSOR IGNITER LIGHT IS OFF DOES MAIN BURNER LIGHT YES CHART 5 15 TROUBLESHOOTI NG CHECK FOR 120 VAC BETWEEN TERMINALS 1 AND 2 AT CONNECTOR CN1 ON IBC DURING IGNITER WARM UP YES CHECK FOR 120 VAC AT IGNITER SENSOR LEADS ON WIRING HARNESS DURING IGNITER WARM UP YES CHECK FOR 24 VAC ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON YES CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER YES CHECK GAS SUPPLY PRESSURE AT INLET PRESSURE TAPPING ON GAS CONTROL IS GAS PRESSURE GREATER THAN 4 0 W C YES CHART 5 44 REPLACE IBC REPAIR REPLACE WIRING FROM IBC TO IGNITER SENSOR REPLACE IGNITER SENSOR CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE
22. EPLACE TRANSFORMER NO PUSH RESET BUTTON ON CASTING TEMP SAFETY SWITCH CHECK CONTINUITY OF CASTING TEMP SAFETY SWITCH CONTACTS CONTACTS OPEN OR CLOSED CLOSED OPEN REPLACE CAST TEMP SAFETY SWITCH REPLACE REPAIR WIRING FROM TRANSFORMER TO IBC NO REPLACE IBC NO REPLACE REPAIR WIRING FROM IBC TO CIRCULATOR 42 15 TROUBLESHOOTING Troubleshooting Chart 3 CHART 1 OPEN NO CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND REPLACE IBC AT CONNECTOR CN4 ON IBC YES YES REPAIR REPLACE WIRING FROM IBC CHECK FOR 120 VAC AT BLOWER LEADS ON WIRING HARNESS YES REPAIR REPLACE BLOWER TO BLOWER PRESSURE SWITCH CONTACTS OPEN IBC WAITS UP TO 5 MINUTES FOR NORMALLY NO OPEN AIR PRESSURE SWITCH ARE ORIFICE IN NO NEGATIVE PRESSURE CLEAN OUT BLOCKAGE IBC PURGE LIGHT ON AT ORIFICE CONTACTS TO CLOSE INDICATING BLOWER SUCTION IS PRESENT HOSE CLEAR YES YES CLEAN OUT VENT PIPE AND OR AIR INTAKE PIPE CHECK FOR SAGS OR LOW SPOTS WHERE CONDENSATE MAY PUDDLE AND BLOCK YES THE VENT ARE VENT PIPE AND AIR INTAKE PIPE CLEAR NO BLOCKAGE CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY CLEAN OUT SAMPLING LINES OR REPLACE DEFECTIVE SWITCH YES CHECK FLUE PASSAGES IN BOILER PER MAINTENACE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN1 CLEAN BOILER FLUE PASSAGES PER MAINT
23. FLAME LED IS LIT NO REPLACE IBC YES REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL RESTORE IGNITER SENSOR TO CORRECT POSITION DO NOT RELOCATE ARE ALL MANUAL SHUT OFFS IN THE GAS SUPPLY LINE AND ON THE GAS CONTROL IN THE OPEN OR ON POSITION OPEN OR TURN ON ALL MANUAL SHUTOFFS YES CONTACT THE GAS UTILITY TO TURN THE GAS ON 15 TROUBLESHOOTI NG Troubleshooting Chart 5 CHART 4 CHART 4 YES YES POSSIBLY MIXTURE TOO LEAN CHECK GAS LINES DOWNSTREAM OF GAS VALVE FOR BLOCKAGE CLEAN REPLACE GAS LINES ARE GAS LINES CLEAR BE SURE TO USE CORRECT GAS VENTURI VALVE SIZE IS GAS VENTURI VALVE CORRECT SIZE SEE REPAIR PARTS DIAGRAM YES POSSIBLY MITURE TOO RICH CHECK FLUE PASSAGES IN BOILER PER CLEAN BOILER FLUE PASSAGES PER MAINTENANCE MAINTENANCE AND CLEANING ARE AND CLEANING INSTRUCTIONS FLUE PASSAGES IN BOILER CLEAN YES CHECK MIXER AND BURNER FOR NNN CLEAN MIXER AND BURNER PER MAINTENANCE AND CLEANING INSTRUCTIONS ARE AIR CLEANING INSTRUCTIONS PASSAGES IN MIXER AND BURNER CLEAN CHECK AIR ORIFICE AT BURNER INLET FOR CORRECT SIZE SEE REPAIR PARTS REPLACE BURNER DIAGRAM IS ORIFICE CORRECT SIZE NO 1 RUNS SMOOTHLY FOR ABOUT 6 DOES MAIN BURNER SECONDS THEN SHUTS OFF RUN UNTIL CALL FOR INDICATES POOR FLAME SIGNAL HEAT ENDS OR HI NO 2 CHECK IGNITER SENSOR POSITION TIP SHOULD BE SLANTED TOWARDS BURNER NO 3 YES RESTORE IGNITER SENSOR TO CORRECT POSITION
24. IN REDUCING VALVE PARTS BAG DIELECTRIC UNION PRESSURE REDUCING VALVE GATE VALVE gy COLD WATER z FILL REDUCED PRESSURE BACKFLOW PREVENTER E GATE VALVE Z d 4 FEED WATER 1ST OPTION FOR FEED WATER EXPANSION TANK Figure 5 Single Zone Boiler Piping SERVICE SUPPLY TO VALVE SYSTEM I al CIRCULATOR i GATE VALVE p CAN VENT P dy l A Le D SHUT OFF VALVE OV 227 E FEED m Cal Ww WATER PURGE VALVE _ AX REDUCED PRESSURE N BACKFLOW PREVENTER PRESSURE REDUCING VALVE SERVICE RETURN FROM SYSTEM d s EN B EXPANSION TANK gt DIELECTRIC UNIONS 4 NEAR BOILER PIPING Figure 6 Multi zone Boiler Piping with Circulators FLOW CHECK ZONE SERVICE VALVE SUPPLY TO VALVE uv 2 ZONES aC ZONE SERVICE SIN S VALVE CIRCULATORS IA a FLOW CHECK PRESSURE REDUCING VALVE SP es GATE VALVE SAMEN 255 a REDUCED PRESSURE AIR SCOOP A Ds EA one BACKFLOW PREVENTER 3 WATER D RETURN FROM H 4 Q ZONES EXPANSION TANK AQ E LA 2 ANG C g ker SERVICE VALVE ZONE SERVICE VALVE DIELECTRIC UNIONS NOTE When zoning with circulators use furnished circulator 2 pump as one of zone pumps Tape or wire nut each stripped end of electrical wire for circulator pump Inside junction box to prevent short circuits Unplug circulator pump PA wiring at integrated boiler control Figur
25. ITOR VALVE FLAME 7 UT 1013 INTEGRATED BOILER CONTROL 40 VA TRANSFORMER CONTROL CONTROL PANEL High Limit Control NOTICE Maximum set point of limit control must not exceed 190 F e High limit control determines maximum boiler water temperature and provides means for protecting boiler and heating system from unsafe operating conditions which could damage boiler e Control is mounted in 12 NPT control well and 34 x 1 2 bushing on top of front boiler section at hot water outlet e Control is tied in with IBC and factory set at 190 F water temperature e High limit set point is field adjustable and may be set between 100 F and 190 F e Field set point adjustment for each installation depends on heating system requirements e Differentials are automatic vary based on control settings and boiler temperature e Refer to limit manufacturer instructions provided with limit control Casting Temperature Safety Switch NOTICE Never run cold water into hot empty boiler Casting temperature safety switch 230 F set point shuts off boiler by shutting off power to IBC result of lack or loss of boiler water Power indicator light goes out Switch is installed on top of aluminum boiler section behind supply piping Fault requires manual reset of casting temperature safety switch restarting boiler Verify boiler is filled with water before resetting switch 10 CONTROLS AND ACCESSORI ES Different
26. KING RESET SYSTEM BY TURNING SERVICE SWITCH OFF THEN ON IF NOT LOCKED OUT SET THERMOSTAT TO CALL FOR HEAT NO CIRCULATOR STARTS YES CHART 2 FALSE POSITIVE PROOF OF AIRFLOW CHECK AIR PRESSURE SWITCH CONTACTS CLOSED IBC CHECKS NORMALLY OPEN AIR IF CONTACTS ARE CLOSED WITH NO AIRFLOW REPLACE PRESSURE SWITCH PRESSURE SWITCH CONTACTS OPEN CHART 3 41 15 TROUBLESHOOTI NG Troubleshooting Chart 2 NO CHECK THAT CIRCUIT BREAKER IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL CHART 1 OK CHECK THAT SERVICE SWITCH IS ON OK CHECK CASTING TEMPERATURE SAFETY SWITCH PUSH RESET BUTTON ON SWITCH CONTACTS OPEN BUTTON UP OR CLOSED BUTTON DOWN CLOSED CHECK WIRING TO IBC 120 VAC BETWEEN TERMINAL 1 AND 3 AT WIRING HARNESS PLUG CN7 YES 120 VAC BETWEEN TERMINALS 1 AND 3 AT CONNECTOR CN3 ON IBC YES 120 VAC AT TRANSFORMER PRIMARY TERMINALS YES 24 VAC AT TRANSFORMER SECONDARY TERMINALS YES 24 VAC AT WIRING HARNESS PLUG CN2 YES REPLACE IBC NO CHECK FOR 120 VAC BETWEEN TERMINALS 1 AND AT CONNECTOR CN5 ON IBC YES CHART 1 CHECK FOR 120 VAC AT CIRCULATOR YES REPAIR REPLACE CIRCULATOR CHECK WATER LEVEL IN BOILER CHECK OPEN FOR AIR TRAPPED IN TOP OF BOILER CONTACTS WILL NOT STAY CLOSED UNTIL BOILER COOLS OFF NO REPLACE REPAIR WIRING FROM SERVICE SWITCH TO IBC NO REPLACE IBC NO REPAIR WIRING TO TRANSFORMER NO R
27. OPERATI ON SERVI CE HINTS POWER ON STAND BY THERMOSTAT CALLS FOR HEAT IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS CONTROL LOCKOUT VALVE FLAME LIGHT BLINKS RESET IS REQUIRED THIS PROBLEM IS A RESULT OF NOT ESTABLISHING FLAME SIGNAL CIRCULATOR ENERGIZES THRU 2K1 CONTACTS IBC SELFCHECK OF INTERNAL CIRCUITRY 1 2 SEC CONTROL WILL ATTEMPT 2 ADDITTIONAL IGNITION SEQUENCES STARTING WITH PREPURGE NO FALSE DOES IBC POSITIVE MAIN CHECKS PROOF OPF BURNER PROVE N O AIR CLOSED AIRFLOW IBC WAITS CLOSED FLAME WITHIN INITIAL YES NORMAL PRESSURE FOR 45 SEC TRIAL FOR OPERATION SWITCH FOR AIR PRESSURE IGNITION CONTACTS SWITCH CONTACTS PERIOD DRAFT INDUCER ENERGIZES THRU 1K1 CONTACTS DURING THE LAST 2 SEC OF THE 5 SEC IGNITION TRIAL MAIN BURNER FLAME IS PROVED BY FLAME RECTIFICATION A FLAME SIGNAL TO IBC GAS VALVE REMAINS ENERGIZED BOILER RUNS IBC WAITS FOR UP TO 5 MINUTES FOR AIR PRESSURE SWITCH CONTACTS TO CLOSE INDICATING FAN SUCTION PRESENT 2 SEC INTO THE 5 SEC IGNITION TRIAL POWER IS TURNED OFF TO THE HOT SURFACE IGNITER IGNITER LIGHT IS OFF GAS VALVE OPENS FOR 5 SEC TRIAL FOR IGNITION BLUE ORANGE GLOW OF THE BURNER CAN BE SEEN THRU OBSERVATION PORT CONTROL LOCKOUTPURGE LIGHT BLINKS RESET REQUIRED CIRCULATOR GAS VALVE ENERGIZED THRU 3K1 AND 4K1 REMAINS ENERGIZED AS LONG AS CONTACTS VALVE LIGHT IS ON THERMO
28. PVC ASTM F891 cellular core CPVC or Radel polypenolsulfone in venting system could result in death serious injury Table 6 Combustion Air and Vent Pipe Length Requirement 3 in Pipe Minimum Venting 3 in Pipe Maximum Venting 60 ft 18 3 m in length and 6 ft 1 8 m in length up to four 4 90 elbows 1 90 elbow 5 ft 1 6 m 1 45 elbow 3 5 ft 1 1 m 1 2 x 3 adapter 0 ft 0 m All field installed vent pipe must be 3 Past first 2 section provided with boiler 7 COMBUSTI ON AIR AND VENT PIPE Table7 Combustion air and vent pipe fittings must conform with the following Item Material USA Standard Canadian Standard UL1738 RAS ode Pipe amp Fittings Exhaust ASTM D2241 d Fittings D2466 and or 011738 Intake uc 5636 ut pa Air Pipe Fittings t F439 and Fittings UL1738 Pipe amp Fittings Polypropylene PP ULC 636 ULC 636 DWV Wa B181 2 ONLY Pipe and Fittings ASTM D3965 ULC S636 Exhaust amp Air Intake ha eee CSA AEn 3 Air Intake ONLY Pipe CSA B181 2 Air Intake ONLY Cement ULC S636 ULC S636 Exhaust amp Air Intake And CPVC ASTM F493 CSA B 6 Air Intake ONLY Primer CSA B181 2 Air Intake ONLY ULC S636 Exhaust amp Air Intake o MS nouae CSA B181 1 Air Intake ONLY Figure 14 Combustion Air amp Vent Piping INCH INTAKE AND x EXHAUST TER MINATIONS ine NOT REQUIRED WHEN USING PP 2 50 8MM CPVC COUPLING
29. STAT CONTINURES TO CALL FOR HEAT PURGE LIGHT GOES OUT HOT SURFACE IGNITER POWERED THRU 5K1 5 2 CONTACTS FOR 20 SEC IGNITER WARMUP BRIGHT YELLOW ORANGE GLOW OF THE HOT SURFACE IGNITER CAN BE OBSERVED THRU THE OBSERVATION PORT IN FRONT OF BOILER SECTION JUST ABOVE IGNITER IGNITOR LIGHT IS ON PURGE LIGHT IS ON AIRFLOW PROVED DRAFT INDUCER RUNS FOR 15 SEC PREPURGE 13 SEQUENCE OF OPERATI ON DI AGNOSTI CS Sequence Of Operation Diagnostics Follow sequence using the diagnostic indicator lamps on Integrated Boiler Control IBC See Controls And Accessories on page 26 for normal sequence of operation Detailed sequence of operation containing potential faults can be found in service hints section DIAGNOSTIC SEQUENCE OPERATION ROCA OR ANDE gt DERE 1 Lamp A is illuminated indicating integrated control is receiving 24 volts and is in standby waiting for thermostat call for heat 2 Thermostat calls for heat energizing system circulator 3 Integrated boiler control performs self check of internal circuitry approximately two seconds energizing draft inducer 4 Draft inducer comes up to speed and establishes combustion airflow causing normally open differential pressure air proving switch contacts to close When combustion airflow is proved Lamp B illuminates indicating 15 second pre purge cycle has begun 5 After pre purge completion Lamp B is extinguished and Lamp C is illumina
30. UB 90 125 200 SERI BII GAS FIRED DIRECT VENT CONDENSING HOT WATER BOILER INSTALLATION OPERATI ON amp MAI NTENANCE MANUAL ENERGY STAR e US H Manufactured by r ECR International Inc 2201 Dwyer Avenue Utica NY 13504 4729 An IS0 9001 2008 Certified Company web site www ecrinternational com P N 240009432 Rev D 09 2013 TABLE OF CONTENTS l Boiler Ratings amp Capacities sa 3 I MPORTANT Read following instructions COMPLETELY 2 Safe Installation And Operation 5 before installing 3 Locating The Boiler 6 4 Near Boiler 8 5 Water Chemistry amp Antifreeze Guidelines 13 Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death 6 Combustion Air vent Requirements 15 or serious injury Read this manual and understand 7 Combustion Air And Vent Pipe 17 all requirements before beginning installation 8 Gas Supply Piping 21 9 Electrical Wiring 22 10 Controls And Accessories 26 enkle dere combustible SO Ua c seu eee 28 materials gasoline and other flammable vapors and 12 Detailed Sequence Of Operation 31 el obstruct air openings to the boiler room a Operation Modificati
31. VPower amp 1 1 4 NPT Connections Vent Connedtign 24 V Thermostat Leads Provided Inside Boiler 2 CPVC Cabinet Combustion Air Intake 32 5 16 201 8 Gas Suppif Fitting 2 PVC B20mn Piles Opening 1 2 NPT 40 1 4 P 6 022mm mm 1 i a Vent Tee Front Right Side Back 2 CPVC Leveling Feet Condensate Drain Fitting 1 2 PVC T CERTIFIED SEA LEVEL RATINGS NATURAL AND PROPANE GASES E TUR org 1 1 MBH 1 000 Btuh British Thermal Units Per Hour AFUE Annual Fuel Utilization Efficiency and Heating Capacity is based on Department of Energy test procedure These low pressure gas fired hot water boilers are design certified by CSA International for use with natural and propane gases Boilers are constructed and hydrostatically tested for maximum working pressure of 50 psi pounds per square inch in accordance with A S M E American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section IV Standards for heating boilers Boilers are certified in accordance with ANSI American National Standards Institute 221 13 standards as gas fired direct vent condensing hot water boilers Heating Capacity indicates amount of heat available after subtracting losses up the stack Most of this heat is available to heat water Small portion is heat loss from jacket and surfaces of boiler it is assumed this heat stays in the structure Net AHRI Rating represents portio
32. amaged by exhaust of flue gas US Installation Requirements Venting system shall terminate at least 3 ft 0 9m above any forced mechanical air inlet located within 10 ft 3m horizontally to any building Venting system shall terminate minimum of 1 ft 0 3m above grade or expected snow level in such a way that it cannot be blocked by snow Termination shall be not less than 7 ft 2 1m above adjacent public walkway paved driveway or sidewalk Vent terminal shall not be installed closer than 3 ft from inside corner of L shaped structure Venting system shall terminate at least 1 ft from any air opening i e window door or non mechanical inlet into any building Vent termination should be kept at least 3 ft away from vegetation Venting system shall terminate at least 4 ft horizontally from and in no case above or below unless 4 ft 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Venting system shall not terminate where hot gases can cause property damage personal injury or where condensate may cause hazardous frost or ice accumulations Every outside wall penetration shall be permanently sealed to prevent entry of combustion products into building Venting that discharges flue gases perpendicular to the adjacent wall shall be located not less than 10 ft 3m horizontally or must be a minimum of 2 ft 0 6m above or must be a minimum of 25 ft 7
33. ator Pump Wiring NOTICE Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing See Figure 16 Page 24 and Figure 17 Page 25 for service switch junction box and circulator pump field wiring connections If the two 120 volt circulator wire terminals inside junction box are not used leave two wire nuts to prevent short circuit 9 ELECTRICAL WIRING Figure 17 Schematic Wiring Connections NOTE If any of the original wire as supplied with this appliance must be replaced it must be replaced with type 150 C Thermoplastic wire or its equivalent INTEGRATED BOILER CONTROL CASTING TEMPERATURE SAFETY SWITCH MANUAL RESET 24 VAC TRANSFORMER DIFFERENTIAL P3 SECONDARY AIR PRESSURE AIR PRESSURE SWITCH N C SWITCH N O SET AT 0 5 WC GAS VALVE RECTIFIER PLUG EAEF 3801 CONTROL TRANSFORMER BK HOT SURFACE IGNITER 24V THERMOSTAT 120 VAC 60 HZ 1 990 aes 120VAC INDICATOR LIGHTS HOT 1 6 POWER R PURGE NEUTRAL L2 IGNITOR GROUND VALVE WIRING CABLAGE INE VOLTAGE BY FACTORY LIGNE DE VOLTAGE PAR L USINE LOW VOLTAGE BY FACTORY BAS VOLTAGE PAR L USINE LINE VOLTAGE BY INSTALLER LIGNE DE VOLTAGE PAR L INSTALLATE LOW VOLTAGE BY INSTALLER BAS VOLTAGE PAR L INSTALLATEUR
34. ck pH and chemistry of boiler solution Consult antifreeze manufacturer for recommendations Take pH reading annually and adjust as necessary Follow antifreeze inhibitor manufacturer s instructions for details on how to adjust pH Antifreeze solutions can break down over time Failure to check antifreeze chemistry on annual basis may result in accelerated corrosion of boiler and other system components Consult with antifreeze manufacturer for recommendations Use of antifreeze in any boiler will reduce heating capacity as much as 10 2096 Take into consideration when sizing heating system pumps and expansion tank Consult antifreeze manufacturer s literature for specific information on reduced capacity Using antifreeze manufacturer s instructions determine freezing temperature needed and use correct amount of antifreeze Never exceed 50 antifreeze by volume Boiler operating pressure must remain below 15 psi for antifreeze solutions that specify maximum of 250 F 121 C Otherwise increase system operating tank pressure to 20 psig Refer to expansion tank manufacturer instructions for adjusting tank pressure 5 WATER CHEMI STRY AND GENERAL ANTI FREEZE GUI DELI NES Table5 Compatible Aluminum Antifreeze amp Inhibitor Suppliers Noburst AL Antifreeze Rhogard Antifreeze amp Pro Tek 922 I nhibitor Noble Company P O Box 350 Grand Haven MI 49417 www noblecompany com Tel 800 878 5788 Fax 231 799 8850 Rho
35. d with indirect water heater insure end switch in relay box controlling indirect water heater is properly connected to Cable 2 This will insure domestic water calls are prioritized If Cable 2 is not used turn Economy Feature OFF No or Insufficient Domestic Hot Water Check for air bound radiators Check thermostat settings including heat anticipator settings common on non digital House Will Not Get or thermostats Stay Warm Check Economy setting Economy feature like outdoor reset controls lowers average boiler temperature and can slow or in some cases prevent the house from coming up to temperature Move to lower setting CAUTION ALWAYS ALLOW BOILER TO COOL BEFORE Burner will not fire until low water condition is satisfied Control is gt Verify system filled with water ensing Low gt Verify sensor is inserted correctly into well Water Note Use of heat conductive grease may interfere with contact between spring clip and copper well tube gt Verify control is tightly clamped to well Is Red LED LOW WATER On Control is I il hoi s Yellow LED Burner will not fire until boiler water has dropped to high TEMP Sensing High limit differential set point 10 below high limit setting Temperature gt Verify high temperature setting is correct When ECONOMY function is active control monitors Boiler Baschad heating demand and establishes Target boil
36. dular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil UTICA BOILERS UTICA 2201 Dwyer Avenue BOILERS C CCC J Utica NY 13501 web site www ecrinternational com
37. e 40 PVC condensate drain piping and pipe fittings must conform to ANSI standards and ASTM D1785 or D2846 e Schedule 40 PVC cement and primer must conform to ASTM D2564 or F493 In Canada use CSA or ULC certified schedule 40 PVC drain pipe and cement Figure 8 Condensate Trap and Vent 1 2 PVC Piping 12 Long To Condensate Drain Field Supplied 1 2 PVC Tee 1 2 PVC Piping 3 3 4 Long gat 1 2 PVC Piping 2 Long e Condensate pump with reservoir not furnished may be used to remove condensate to drain line sanitary line above boiler if floor drain is not available or is inaccessible Filling Condensate Trap With Water Manually fill condensate trap at initial start up with water Following steps are required to fill condensate trap for start up Steps are only required at initial start up or if maintenance requires draining of condensate trap 1 2 Pour about 1 cup of cold tap water into condensate trap vent Excess water will go through condensate drain line Verify proper operation of drain line and external condensate pump if used Chilled Water Piping Install boiler used in connection with refrigeration system so chiller medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerat
38. e 7 Multi Zone Boiler Piping With Zone Valves ZONE SERVICE ZONE VALVE A SUPPLY TO PRESSURE Ag REDUCING VALVE N ZONE SERVICE E e VALVE Q p CIRCULATOR Q gt A GATE VALVE CAN VENT gt Ze 37 ge T REDUCED PRESSURE EXPANSION TANK FEED BACKFLOW PREVENTER SHUT OFF VALVE WATER Q e RETURN FROM e x ZONES 39 PURGE VALVE Q S 3 L ON eS i ZONE SERVICE O A W S ZONE SERVICE VALVE DIELECTRIC UNIONS Supply And Return Lines Packaged boiler receives 1 NPT supply and return piping from top access 11 4 NEAR BOILER PIPING Condensate Drain Requirements Pitch condensate drain line down to floor drain at minimum of 1 4 per foot 21mm m External condensate pump not furnished may be used if floor drain is not available Condensate pump must be designed for flue gas condensate application Condensate trap is proved with boiler 1 Build condensate trap in the field See Figure 7 Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir 115 volt AC receptacle provided on service switch junction box which is located at boiler right side to provide power for external condensate pump if needed Condensate Drain Piping e Condensate trap is to be field installed as shown in Figure 7 e Provided are 1 2 PVC fittings for condensate drain trap assembled in field e he diameter schedul
39. ed air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle To Exhaust Vent 2 CPVC 1 Adapter Male NPT x Socket Weld PVC Piping ad 9 1 3 8 Long p EP CT Boiler Flue Outlet 2 CPVC 2 Male x 2 NPT Male PVC Bushing ET 2 NPT Male PVC Bushing 1 2 PVC Elbow 1 2 PVC Piping 3 3 4 Long 1 2 PVC Elbow 5 WATER CHEMI STRY AND GENERAL ANTI FREEZE GUI DELI NES e his boiler is designed for closed loop hydronic heat system only Boiler is not suitable for natural gravity Fire explosion asphyxiation hazard Inadequate type installations or any other open type system dielectric isolation incorrect water treatment or antifreeze application may cause damage to boilers heat exchanger Improper installation could result in death or serious injury Follow these instructions General Guidelines When Using Antifreeze e Use only antifreeze products recommended for use with completely Boiler Water Quality and Antifreeze Water treatment and antifreeze protection must be applied to all aluminum series high efficiency gas fired boilers using antifreeze protection Clean System First Before connecting boiler to heating system clean and flush system thoroughly Verify system is free of sediment flux and residual boiler water additives Systems having antifreeze not recommended must be completely flushed
40. er operation Use flame of match or candle or smoke from cigarette cigar or pipe 3 LOCATING THE BOILER 6 After it has been determined each appliance remaining connected to common venting system properly vents when tested as outlined above return doors windows exhaust fans and any other gas burning appliance to their previous condition T Any improper operation of common venting system should be corrected so installation conforms with the National Fuel Code ANSI Z223 1 NFPA 54 When re sizing any portion of common venting system common venting system should be re sized to approach minimum size as determined using appropriate tables in chapter 13 of the National Fuel Code ANSI Z223 1 NFPA 54 Placing The Boiler e Place boiler to provide most direct connections to combustion air vent and system piping as possible e Place crated boiler as close to selected location as possible and uncrate boiler e Move uncrated boiler into position with appliance dolly or 2 wheel hand truck e Insert dolly or hand truck under right hand side of boiler It is possible to slide boiler for short distance on smooth floor or surface 4 NEAR BOILER PIPING General I nstructions 1 Packaged boiler is furnished with iron piping in front boiler section for supply and return connections 2 Install all of radiation units panels radiators baseboard or tubing and supply and return mains first when installation of boiler is for
41. er temperatures below high limit setting to conserve fuel Burner will not fire until boiler temperature drops to Target Temperature Differential Is Yellow LED TARGET On Boiler in Purge Mode and will not fire until temperature drops to Is PURGE LED on 140 F See Purge page 36 NO Both red and yellow LEDs are off and there is call to fire burner there will be 120 VAC in terminals Replace Control Bland B2 120 VAC is not present replace control 39 15 TROUBLESHOOTI NG Initial Service Checks 1 Before Troubleshooting A Verify circuit breaker is on or fuse is OK at electrical panel B Verify service switch is ON e n reset from lockout condition all electrical meter C Verity Gas Is ON at readings at gas control valve 24 vac must be taken e Gas meter within trial for ignition period e f any component dose not function properly make sure it is correctly installed and wired before replacing Fire explosion or shock hazard may cause death or serious injury Do not attempt to modify physical or electrical characteristics of this boiler in any way e Appropriate manual shutoff valves e Gas control valve e Static electricity discharge can damage integrated D Verify thermostat is calling for heat boiler control IBC Touch metal surface to discharge E Verify wire connections at integrated boiler control static electricity before touching IBC IBC and ori
42. et assembly to gas valve using 2 x 1 flexible coupling pressure switch hose to gas valve and air inlet assembly 2 flexible coupling to boiler exhaust port igniter wires and gas valve wires Visually inspect condensate trap Clean out any visible foreign material or debris from condensate lines as described below A Inspect for sediment or blockage B Flush out with water or vacuum C Follow instructions in Near Boiler Piping on page 8 for filling condensate trap with water Inspect flue connector using following steps A Loosen clamp on draft inducer end of 2 flexible coupling connecting vent tee to exhaust port B Inspect interior of vent tee Clean any buildup of sediment on inside surface C Connect 2 flexible coupling to draft inducer outlet IMPORTANT In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRI DE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDI TIONS 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 mo
43. flue gas reading and observe CO2 value B Adjust throttle screw until CO2 value is between 8 5 And 1096 O2 between 5 596 and 296 C Turning throttle screw counter clockwise increases rate and CO2 value D Turning throttle screw clockwise decreases rate and CO2 value E Allow boiler to stabilize for 1 minute after adjusting throttle screw before taking reading with combustion analyzer Ur a I 6 After adjustments are made stop appliance Disconnect pressure gauge Tighten inlet pressure tap on gas valve remove CO2 meter from CPVC pipe T Seal hole in CPVC pipe with appropriate material 8 Return thermostat switch to its original position Installation Final Checkout After any adjustment to boiler observe several complete cycles to ensure all components function correctly 37 15 TROUBLESHOOTI NG High Limit Control and LWCO Figure 21 LED Legend LED Legend and LWCO Test Button e HI TEMP illuminates when boiler water temperature reaches high limit setting Remains lit until water temperature falls 10 F Limit prevents burner operation while this LED is on LWCO ACTIVE Indicates low water cut off function is active When control is installed with Electro well LED is on at all times when control is powered If the control is installed with a well other than Electro well LED will not illuminate indicating the control is not providing low water cutoff functionality e cC 2 e h
44. ginating control are securely plugged e BCcannot be repaired If it malfunctions it must be in or connected replaced F Check hoses are securely connected and are not e Only trained experienced service technicians should plugged or damaged service IBC systems Follow troubleshooting to check out system and sequence of operation for normal light off sequence e Defective control is least likely cause of malfunction 2 Troubleshooting Tools A Voltmeter to verify 120 VAC and 24 VAC B Continuity Tester If you suspect unit has defective control read through C Inclined Manometer or Pressure Gauge with 0 2 0 troubleshooting chart before replacing it range 0 01 scale for measuring suction pressures tis unlikely two consecutive controls are defective If at pressure switch this seems to be the case chances are the controls are D U Tube Manometer or Differential Pressure Gauge not the cause but rather malfunction is due to some with 0 14 range 0 1 scale for measuring inlet other problem such as electrical short burning out and manifold gas pressures transformer 3 System Status A Consult System Status on page 40 B See Figure 19 Page 26 for location of boiler Diagnostic Indicator Lamps 40 15 TROUBLESHOOTI NG Troubleshooting Chart 1 GREEN POWER INDICATOR LIGHT IS NO ILLUMINATED ON THE IBC CHART 2 YES CHECK SYSTEM STATUS IF LOCKED OUT NOTE FAILURE MODE WHICH INDICATOR LIGHT IS BLIN
45. hanger means better heat transfer and thermal storage than similarly sized cast iron boilers which results in higher efficiency Heating system water absorbs large amounts of heat from cast aluminum heat exchanger cooling flue gases and causing condensation Sealed combustion premix gas burner and low flame temperature means drastically reduced CO and NOx emissions which contribute to cleaner and healthier environment Appliance unlike normal residential atmospheric and induced draft units takes its combustion air directly from outdoors sealed combustion and does not compete with building occupants for fresh air Sealed combustion also known as direct vent is safest and best way to obtain plenty of clean combustion air Forced draft fan draws in outside combustion air to mix with gas which flows into pre mix burner and combusts Fan forces resulting flue gases from boiler unit and provides positive removal of flue gases from building through choice of PVC CPVC or PP vent pipes Refer to Table 7 page 18 for material limitations 2 SAFE INSTALLATI ON AND OPERATI ON Improper installation adjustment alteration service or maintenance could result in death or serious injury Boiler is equipped for residential installations If used for commercial applications additional code requirements must be adhered to This may require additional controls including but not limited to manual reset low water cut off manual reset high tem
46. ial Pressure Switches e Diaphragm type differential pressure switches are connected by vinyl tubing to gas valve air inlet connection on negative side and sight glass adapter on positive side Pressure switches monitor air flow by sensing differential pressure measured in inches of water w c e Switch factory settings are 0 5 w c on normally open switch and 3 5 w c for normally closed switch e See pages 31 32 Detailed Sequence of Operation for details Blower Blower provides means for pushing combustion air into and through mixer burner and flue ways of cast aluminum boiler section before being discharged through vent piping to outdoors Circulator Pump e Forced hot water system requires at least one circulating pump e Circulating pump provides energy to move water through closed loop supply return piping systems terminal heating equipment finned tube radiators etc and back through boiler for reheating To provide required hot water flow rates circulator pump must be properly sized to overcome frictional losses usually measured in feet of water also referred to as pump head loss of supply and return piping systems and boiler Circulator pump is furnished in a carton within boiler cabinet Locate circulator s on downstream i e pumping away side of expansion tank Drain Valve Manual drain valve is means of draining water in heating system including boiler hot water supply and return piping
47. ined by control manufacturer Burner should be operating and should go off when controls are tested When safety controls are restored burner should re ignite Set Thermostat Heat Anticipator If Used And Verify Thermostat Operation e Set heat anticipator at 0 7 amps for single thermostat connected to yellow thermostat lead wires in furnished field wiring junction box e For other wiring configurations refer to instructions provided by thermostat manufacturer regarding adjustment of heat anticipator e Cycle boiler with thermostat e Raise thermostat to highest setting e Verify boiler goes through normal start up cycle e Lower thermostat to lowest setting and verify boiler shuts off Measure Natural Gas Input Rate Correct input rate is essential for proper and efficient operation of burner and boiler 1 Determine elevation at installation site 2 See Boiler Ratings amp Capacities on page 4 to determine correct approximate input rate for local elevation 3 Obtain yearly average heating value of local gas utility At sea level elevation approximately 1000 BTU per standard cubic foot 4 Operate boiler for 5 minutes 5 Turn off all other gas appliances extinguishing standing pilots where applicable 6 At gas meter measure time in seconds required to use one cubic foot of gas T Calculate input rate Refer to following formula Btuh I nput Rate X Heating Value From St Time In Seconds From Step
48. is i Low water Burn and scald hazard Do not add water until boiler has fully cooled Failure to follow these instructions esult in death or serious injury LWCO LOW WATER Illuminates if boiler is low water condition Control will prevent burner operation during this condition Important System must be checked by qualified service agency prior to resuming operation ECONOMY ACTIVE Indicates that thermal targeting function is active and control reduces boiler temperature to conserve fuel Economy feature is activated using the ECONOMY dial CI ECONOMY TARGET When feature IS active control continually sets target temperatures below high limit setting to maximize fuel efficiency When boiler reaches target temperature LED illuminates and burner shuts down Boiler water continues to circulate and het the house as long as thermostat call continues LED stays lit until boiler temperature drops below differential at which point boiler will be allowed to fire again Note LED illuminates regularly during normal boiler operation Q PURGE Control is purging latent heat from boiler and will not fire until temperature drops to 135 F Qi To Test LWCO Press and hold TEST button Red Low Water light will illuminate and burner circuit will de energize 38 15 TROUBLESHOOTING Troubleshooting Flow Chart High Limit Control And LWCO Burner Will Not Fire See Flow Chart this page If installe
49. ler monitors all safety controls which control operation of combustion air blower circulator pump burner and combination hot surface igniter flame Sensor e Controller is not intended for use with vent damper Controller is mounted on control panel inside boiler Contains five diagnostic indicator lights Gas Control Valve Electronic 24 volt gas control valve contains 1 1 gas air pressure regulator controls gas flow to main burner of appliance Suited for both natural and LP gas and rated in accordance with ANSI Z21 21 latest revision and CGA 6 5 M95 Figure 19 Gas Valve VENTURI VALVE THROTTLE OFFSET PRESSURE PRESSURE TAP TAP LINE AIR PRESSURE CONNECTION OUTLET CAP SCREW MOLEX PIN HEADER CA NOT REMOVE Hot Surface Igniter e 120 volt hot surface igniter heats up 1800 F initiates combustion of gas in burner e gniter is mounted next to burner through gas air mixer e gniter also serves as means for proving main burner flame by flame rectification A In event of lack of flame signal on three consecutive trials for ignition IBC will lock out B Valve and Flame diagnostic indicator lamps blink indicating failure mode as lack of flame signal C Manually reset IBC from lockout by removing and re establishing thermostat s call for heat or turn service switch off then back on See Figure 19 26 Figure 20 Indicator Lights DIAGNOSTIC INDICATOR LAMPS POWER PURGE IGN
50. ll be visible around perimeter of properly made joint Handle pipe joint carefully until cement sets Support combustion air and vent piping minimum of every 5 feet using pre formed metal hanging straps Do not rigidly support pipes Allow for movement due to expansion and contraction Slope combustion air and vent pipes toward boiler minimum of 1 4 per linear foot with no sags between hangers Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or side wall 20 8 GAS SUPPLY PIPING Check Gas Supply Table 8 Gas Supply Pressure Pressure Natural Gas Propane Gas Please check line pressure while unit is running e Gas pipe to boiler must be correct size for length of run and total Btuh input of all gas utilization equipment connected to it e See Tables 9 and 10 for proper size Refer to NFPA54 for additional tables e Verify your gas line complies with local codes and gas company requirements Table 9 Natural Gas Piping Sizes Pipe Capacity BTU Hr Input Pipe Length 127 3 4 1 35 114 92 000 190 000 350 000 625 000 63 000 130 000 245 000 445 000 50 000 105 000 195 000 365 000 Table 10 Propane Gas Piping Sizes Pipe Capacity BTU Hr Input Copper Tubing Iron Pipe ov 72000 121000 103000 217 000 Includes Fittings Outside Diameter Length of pipe or tubing should be measured from gas meter or propane sec
51. mar Water Management Inc P O Box 229 Springfield MO 65801 www rhomarwater com Tel 800 543 5975 Fax 417 862 6410 Pro Tek 922 Inhibitor may be used to adjust the pH level of the hydronic system but on occasion may not resolve the DH issue In these cases flush the system and refill with untreated water and antifreeze suitable for aluminum heat exchangers as listed in this supplement I ntercool NFP 30 40 50 AA I ntercool RPH 15 Hercules cryo tek 100 Al Hydronic Agencies Ltd Fernox North Distributor 15363 117 Avenue Edmonton AB T5M 3X4 Canada www hydronicagencies com Tel 780 452 8661 Fax 780 488 2304 Fernox www fernox com Interstate Chemical 2797 Freedland Road P O Box 1600 Hermitage PA 16148 0600 www interstatechemical com Tel 800 422 2436 Fax 724 981 8383 Hercules Chemical Company Inc 111 South Street Passaic NJ 07055 www herchem com Tel 800 221 9330 Fax 800 333 3456 This product may be used to adjust pH level of hydronic system but on occasion may not resolve pH issue In these cases it is recommended to flush system and refill with untreated water and new boiler manufacturer approved antifreeze suitable for Aluminum heat exchangers 14 6 COMBUSTION AIR VENT REQUIREMENTS Combustion Air Vent Pipe Requirements Boiler requires dedicated direct vent system Direct vent system all air for combustion is taken directly from outside atmosphere and all flue p
52. minum boiler sections heat up rapidly Casting temperature safety switch contacts will open breaking 24 volt power to IBC Power indicator light goes out Requires manual reset to re close contacts HI GH LIMIT CONTROL REFER TO PAGE 37 FOR MORE INFO If boiler water temperature reaches high limit setpoint high limit n c contacts open immediately closing gas valve Valve and flame lights go out Draft inducer continues to run for 30 second post purge and switch OFF Circulator runs as long as thermostat calls for heat When high limit contacts connect before end of call for heat control goes into normal light off sequence CI RCULATOR PUMP Circulator is energized as long as thermostat calls for heat during lockout Recovery from any lockout requires reset which can be accomplished by a Removing and re establishing thermostat s call for heat or turning service switch off and back on Or b Waiting for control to automatically reset after 15 minutes for loss of combustion airflow or one hour for loss of flame 12 DETAILED SEQUENCE OF OPERATI ON End Of Normal Sequence Of Operation Thermostat ends call for heat Gas valve and circulator pump are de energized valve and flame lights go out Blower runs for 30 seconds post purge purge light is on Blower is de energized after 30 seconds purge light shuts off Boiler stand by for next call for heat 32 12 DETAILED SEQUENCE OF
53. mum 14 and maximum 24 thickness Combustion air and vent pipe fittings must conform to one of the following American National Standards Institute ANSI and American Society for Testing and Materials ASTM standards Combustion air and vent piping connections on boiler are 2 but must increase to 3 Due to potential for flue gas temperatures over 155 F first 5 feet of vent pipe must be CPVC furnished remaining vent pipe can be PVC This requirement is not required when using PP If any elbows are employed within first 21 of vent they must be CPVC Two 30 pieces of 2 CPVC pipe and one 2 CPVC coupling are furnished with boiler See Figure 13 Length of pipe is counted from boiler jacket air intake pipe or from vent tee vent pipe First five feet of Total Equivalent Length of vent pipe must be CPVC This requirement is required when using PP Reduce maximum vent length 5 feet per each additional elbow 4 Pitch horizontal combustion air and vent piping back to boiler at minimum 1 4 per foot 21mm m from intake and vent terminals so all moisture in combustion air and vent piping drains to boiler Pitch pipes continuously with no sags or low spots where moisture can accumulate and block flow of air or flue gas This blockage may cause combustion instability noise and lead to nuisance control lockouts Combustion air and vent pipes must be airtight watertight and tested for leaks 17 Use of cellular core
54. n of remaining heat applied to heat radiation or terminal units i e Finned tube baseboard cast iron radiators radiant floor etc Difference between Heating Capacity and Net AHRI Rating called piping and pickup allowance establishes reserve for heating volume of water in the system and offsetting heat losses from piping Net AHRI Ratings shown are based on piping and pickup factor of 1 15 Net AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load heat loss for building or area s served by boiler and associated hot water heating systems Manufacturer should be consulted before selecting boiler for installations having unusual piping and pickup requirements 1 BOILER RATINGS amp CAPACITIES Ratings shown are for sea level applications Boiler automatically derates input as altitude increases No alterations to boiler are required for altitudes above sea level Table 2 NATURAL GAS Nominal 2000000 175 000 150000 125000 input Altitude Min Max Min Max Min Max Min Max 0 200 000 200 000 175 000 175 000 150 000 150 000 125 000 125 000 Table 3 LP GAS Nominal 200 000 175000 150000 125000 Input Altitude Min Max Min Max Min Max Min Max 0 00 00 200 000 175 000 175 000 150 000 150 000 125 000 125 000 This is gas fired direct vent cast aluminum hot water boiler Cast aluminum heat exc
55. new heating system 3 After installation of all heating system piping and components make final connection of system piping to boiler 4 Hot water boiler installed above radiation level or as required by authority having jurisdiction must be equipped with low water cut off device included with boiler 5 Periodic inspection is necessary as is flushing of float type devices per low water cut off manufacturers specific instructions 6 Proper water flow through any boiler is essential to proper operation and long life Simple single or two zone systems with adequate flow do not require primary secondary piping Systems with more zones or low flow require primary secondary piping Dielectric I solation 1 Two 2 1 1 4 X 1 1 4 female to female dielectric isolation unions are supplied Install dielectric isolation unions at boiler supply line and return line Install isolation fittings nearest boiler prior to system piping connections 2 Water contaminants that cause low or high pH makes corrosion more likely 3 Do not install copper supply and return piping directly into aluminum boiler section castings due to galvanic corrosion between dissimilar metals 4 Use iron steel bushings or pipe connectors between copper system piping and boiler to make final connection to boiler 5 Use of dielectric unions is required supplied with boiler the purpose is to electrically insulate aluminum boiler from remainder of the s
56. o switch e Blockage in air intake or vent pipes e Undersized air intake or vent pipes e loose blower wheel on motor shaft e ncorrect pressure switch or pressure switch set point e Gas valve out of adjustment 6 When pressure reading corresponds to Table 11 and pressure switch is operating properly remove testing lines and reinstall vinyl caps to tee and 3 way connector Boiler Status Not Running minimum vent 47 Figure 22 Locations Of Connection Points Required To Check Differential Air Pressure DIFFERENTIAL AIR PRESSURE SWITCHES N TRANSPARENT WHITE _ SILICONE HOSE A SIGHT GLASS amp ADAPTER TESTING LINES Table 11 Correct Manometer Readings Differential Pressure Switch Contacts Qu Closed Open 0 5 Closed 3 9 0 97 1 00 for Model 125 1 50 for Model 150 1 50 for Model 175 Running Without Blockage Approximate 2 00 for Model 200 Greater Than or Equal 3 5 Open To Setpoints 0 5 Closed lengths Running With Blockage 16 MAINTENANCE AND CLEANI NG Acidic nature of flue gasses condensing on aluminum boiler sections cause formation of aluminum oxide This oxide formation is normal is generally uniform throughout boiler sections and represents negligible mass of aluminum that is consumed by oxidation during life of boiler If left unchecked this buildup may eventually cause blockage of flue gas passages
57. on substitution or elimination of factory 14 Checkout Procedure amp Adjustments 36 equipped supplied or specified components may 15 Troubleshooting 38 result in personal injury or loss of life TO THE OWNER Installation and service of this 16 Maintenance And Cleaning 48 boiler must be performed by a qualified installer KEEP THI S MANUAL NEAR BOILER RETAI N FOR FUTURE REFERENCE Safety Symbols amp Warnings The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels A DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTI CE Used to address practices not related to personal injury TO THE INSTALLER Leave all instructions with boiler for future reference When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter 1 BOI LER RATINGS amp CAPACITIES Figure 1 Boiler J ackets Opening for Air Vent and Expansion Tank Connection Opening for Relief Valve Discharge Pipe Standard Supply amp Return Openings Junction Box for 120
58. on Air b If concentric vent termination is being used refer to Figure 10 for proper setup a Multiple Boiler Application SS eet 12 305mm Minimum J See Note 777 36 0 9m Minimum oo im lt er w ji p Must be less than 4 or greater than 24 Horizontal distance between end bells of each air intake to prevent flue gas recirculation 6 COMBUSTION AI R VENT REQUIREMENTS Fire explosion asphyxiation hazard Solvent cements are combustible Keep away from heat sparks or open flame Use only in well ventilated areas Avoid breathing in vapor or allowing contact with skin or eyes Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation Fire asphyxiation hazard Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited Improper installation could result in death or serious injury e Combustion air must be clean outdoor air Do not take combustion air from inside structure because that air is frequently contaminated by halogens which includes fluorides chlorides phosphates bromides and iodides These elements are found in aerosols detergents bleaches cleaning solvents salts air fresheners paints adhesives and other household products Typical areas of contamination include dry cleaning facilities s
59. onals are required Installers Follow local regulations with respect to installation of CO Carbon Monoxide Detectors Follow maintenance recommendations in this manual See Maintenance And Cleaning on page 48 Boiler Sizing e Verify you have selected the boiler with proper capacity before continuing installation AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load heat loss for building or area s served by boiler and associated hot water heating systems See Boiler Ratings amp Capacities on page 3 e Heat loss calculations should be based on approved industry methods Considerations For Boiler Location Before selecting boiler location consider following e Supplied with correct type of gas natural gas or propane e Connected to suitable combustion air intake piping system to supply correct amount of fresh outdoor air for combustion See Combustion Air And Vent Pipe on page 15 e Connected to suitable venting system to remove hazardous products of gas combustion See Combustion Air And Vent Pipe on page 15 e Connected to suitable hot water heating system e Supplied with suitable electrical supply for all boiler motors and controls e Connected to properly located thermostat or operating control Not included with boiler Fire hazard Do not install boiler on carpeting Failure to follow these instructions could result in death or serious injury
60. ond stage regulator Connecting Gas Piping Refer to Figure 14 for general layout at boller Gas line enters boiler through left side panel Boiler is equipped with 1 NPT connection on gas valve for supply piping and 1 2 NPT ball valve for manual shut off Following rules apply 1 Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction or in the absence of such requirements National Fuel Gas Code ANSI Z223 1 NFPA 54 2 Use pipe joint compound suitable for liquefied petroleum gas on male threads only 3 Use ground joint unions 21 4 Install sediment trap upstream of gas controls 5 Usetwo pipe wrenches when making connection to gas valve to keep it from turning 6 Install manual main shutoff valve in vertical pipe about 5 feet 1 5m above floor outside boiler jacket T Tighten all joints securely 8 Propane gas connections made by licensed propane installer 9 Two stage regulation used by licensed propane installer 10 Propane installer to verify Propane gas piping 11 Recommend use union suitable for natural and propane gas after ball valve to facilitate service on unit Leak Check Gas Piping Pressure test boiler and gas connection before placing boiler in operation Figure 15 Gas Piping GAS CONNECTION e Pressure test over 1 2 psig 3 5 kPa Disconnect boiler and its individual gas shutoff valve from gas supply system e
61. or deck is fully open on minimum of two sides beneath floor and b The distance between top of vent termination and the underside of the veranda porch or deck is greater than 1 ft 0 3 m 7 COMBUSTION AIR AND VENT PIPE Installation 1 2 3 10 11 12 13 14 15 16 Recommend all pipes be cut prepared and pre assembled before permanently cementing any joint Rigid Supports cause excess noise in vent piping Attach combustion air intake piping to supplied 2 coupling on CVI gas valve Attach vent piping to furnished 2 CPVC vent tee on draft inducer outlet All pipe joints are to be water tight Working from boiler to outside cut pipe to required length s Deburr inside and outside of pipe Remove all chips and Shavings Chamfer outside edge of pipe for better distribution of primer and cement Clean and dry all surfaces to be joined Check dry fit of pipe and mark insertion depth on pipe After pipes have been cut and pre assembled apply cement primer to pipe fitting socket and end of pipe to insertion mark Quickly apply approved cement to end of pipe and fitting socket over primer Apply cement in light uniform coat on inside of socket to prevent buildup of excess cement Apply second coat While cement is still wet insert pipe into socket with 1 4 turn twist Be sure pipe is fully inserted into fitting socket Wipe excess cement from joint Continuous bead of cement wi
62. pection of low water cutoff is necessary including flushing of float type devices Refer to low water cut off manufacturer s specific instructions 16 MAINTENANCE AND CLEANI NG A DANGER Before servicing turn off electrical power to boiler at service switch Close manual gas valve to turn gas supply OFF to boiler Failure to comply will result in death or serious injury Following service procedures must be performed by qualified service agent Boiler owner shall not attempt these steps Failure to do so could result in death or serious injury NOTI CE Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe trouble free operation and maximum efficiency NOTICE Verify proper operation after servicing Annual Shut Down Procedure End Of Each Heating Season 1 Follow the instructions in WHAT TO DO IF YOU SMELL GAS on page 29 2 f heating system is to remain out of service during freezing weather and does not contain antifreeze drain system completely If boiler will be exposed to freezing temperatures drain condensate lines Otherwise do not drain system or boiler Annual Examination And Cleaning Of Boiler Components 1 Examine flue passages Remove blower assembly from casting Follow procedure for examining and cleaning burner is described below Any buildup of sediment or aluminum oxide white powdery or flaky substance in flue passages mu
63. perature limit and wiring and or piping modifications 1 Installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 2 Where required by authority having jurisdiction installation must conform to the Standard for Controls and Safety Devices for Automatically fired Boilers ANSI ASME CSD 1 3 Becertain gas input rate is correct Over firing may result in early failure of boiler components this may cause dangerous operation Under firing may result in too much air for pre mix burner causing poor or loss of combustion 4 Never vent products of combustion from this boiler to enclosed space Always vent to outdoors Never vent to another room or to inside building 5 Verify adequate outdoor air supply to boiler for complete combustion 6 Follow regular service and maintenance schedule for efficient and safe operation T Keep boiler area clean of debris and free from combustible materials gasoline and other flammable vapors and liquids 8 Proper through the wall or through the roof combustion venting shall be in accordance with materials and methods described in this manual Installation must comply with local codes 9 Boiler and related hot water heating systems are not do it yourself items Installation and service by qualified professi
64. pplied is required May pipe condensate pump to remote tie in point to sanitary sewer system For this application boiler must be installed so proper pitch of piping to external condensate reservoir sump can be accomplished Use wood frame or blocks to raise boiler as required for proper installation 11 STARTUP Water Treatment And Freeze Protection Filling Boiler With Water And Purging Air For Systems With Conventional Closed Type Expansion Tanks Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on 1 Close all zone service valves on supply and return pages 10 and 11 piping Close expansion tank service valve Drain 1 Close all zone service valves on supply and retur ore a are i i piping anon One i for five seconds to rapidl bleed air from boiler let air vent is open Hold relief valve open until water runs Fels value Sn Sea y air free for five seconds to rapidly bleed air from boiler let relief valve snap shut 2 Open zone service valve on supply pipe for first zone 2 Open zone service valve on supply pipe for first zone Open E vane ea ie water will u Open purge valve on first zone Feed water fills zone ee ee a aoe purge pushing air out purge valve Close purge valve when when water runs air Close zone service valve water runs air free Close zone service valve 3 Repeat step 2 fo
65. r and gas valve venturi assembly from boiler Visually inspect inside of burner Look for debris PVC shavings etc Remove debris if present 3 Reassemble burner assembly turn gas supply and boiler power back on relight boiler If Burner Continues To Pulsates Or Fails To Light 1 Check for proper vent intake pipe sizing proper vent lengths and vent configuration Refer to Safe Installation And Operation on page 6 and Combustion Air Vent Requirements on page 16 2 Check for proper gas supply pressure and proper gas line sizing to boiler Refer to Check Gas Supply on page 22 3 Check for orifice in negative pressure hose at gas valve and 2 air intake pipe upstream of gas valve 4 Relight boiler 5 If boiler still does not light A Disconnect air inlet pipe Allow boiler to start verify boiler firing rate and combustion properties B Disconnect inlet air pipe by removing PVC inlet air piping from coupler located on air inlet of gas valve venturi assembly C Relight boiler 6 Verify firing rate and combustion when boiler lights Refer to Adjustments And Checkout on page 35 If air inlet piping was disconnected in step 4 above leave it disconnected and make first adjustment Reconnect air inlet piping then verify combustion CO adjust again if necessary T f burner pulsation continues or boiler fails to light after performing above procedures contact technical service for assistance 30
66. r remaining zones 3 Repeat step 2 for all remaining zones 4 Open expansion tank service valve and tank 4 Open all service valves Any air remaining trapped ulis ipii P ope od os e in return lines between service valves and boiler ipiius ande dei Seen s scrisse velis are pushed towards air vent when boiler is placed in asd 9 Open all service valves Any air remaining trapped EE nd Svetem Bana ony jamaa akal in return lines between service valves and boiler will y push towards expansion tank when boiler is placed in NOTICE operation Do not use stop leak compounds or other chemicals 6 Inspect piping system Repair any leaks immediately not listed in this manual Repair leaks in threaded connections of aluminum boiler sections Aluminum threads do not seal themselves Systems with automatic fill valves and leaks will cause excessive fill water This water contains oxygen Excessive oxygen will cause the aluminum boiler to corrode over time All system leaks should be repaired immediately 28 Refer to diagrams on Near Boiler Piping on pages 9 and 10 for more information 11 STARTUP If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life e This appliance is equipped with an ignition device which automatically lights burner Do NOT try to light this burner by hand
67. rainage Removal Of Existing Boiler From Common Vent System When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 In so far as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryer and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will operate at maximum speed Do not operate a summer exhaust fan Close fire dampers 4 Place in operation appliance being inspected Follow lighting instructions Adjust thermostat so appliances operate continuously 5 Test for spillage at draft hood relief opening after 5 minutes of main burn
68. roducts are discharged to outside atmosphere Combustion air and vent pipe connections must terminate together in same atmospheric pressure zone either through roof or sidewall roof termination preferred See Figures 8 and 9 for required clearances Venting must be as direct as possible and properly supported Figure9 Multiple Boiler Roof Vent Intake Terminations 3 76mm Minimum 12 305mm 15 381mm Minimum Maximum 8 203mm Minimum 3 r F 12 305mm Minimum Above Anticipated Snow Line Combustion Air Vent Figure 11 Concentric Vent Terminations Single Boiler Application 1 26mm Maximum ET a m Maintain 12 305mm 1 Clearance Above Highest or Grade Anticipated Snow Level Y Canada see page 19 Combustion Air Figure 10 Sidewall Vent I ntake Terminations Single Boiler Application M MEM w 12 305mm Minimum From Overhang 3 76mm Minimum Separation 12 305mm Separation Between Bottom of Combustion Air Intake And Bottom of Vent See Snow amp Ice 19 Combustion Air Multiple Boiler Application eAvoid locations where snow may drift and block vent and combustion air 12 305mm Minimum Separation e ce or snow may cause boiler to shut down if vent or combustion air becomes obstructed 1 eo Combusti
69. st be cleaned as follows A Remove jacket front and top panels B Confirm manual gas valve is closed and disconnect gas line to gas valve at union C Disconnect wires to gas valve and igniter Remove air inlet assembly from gas valve E Loosen do not remove five nuts attaching blower adapter assembly to boiler F Remove two igniter screws Carefully remove igniter Do not touch igniter element with your fingers or hands as oils or debris will cause premature failure G Remove five nuts and blower adapter assembly Remove burner and gaskets H Aluminum oxide deposits are water soluble and may be rinsed away with spraying or running water Use flexible handle nylon brush to loosen sediment and aluminum oxide on all exposed heating surfaces of boiler Take care brush does not get stuck in heat exchanger J After brushing and rinsing remove any remaining loosened sediment using vacuum with snorkel attachment K Inspect burner for foreign matter in flame ports or inside burner Remove any foreign matter by blowing with compressed air or vacuuming L Install burner and gaskets Position blower adapter assembly over studs Install five nuts do not tighten Install igniter and igniter gasket and fasten with two screws Do not touch igniter element with your fingers or hands as oils or debris will cause premature failure Tighten five nuts holding blower adapter assembly M Connect gas line to gas valve air inl
70. ted indicating power is being delivered to hot surface igniter for 20 second igniter warm up period Observe bright yellow orange glow of hot surface igniter through observation port on boiler 6 After igniter warm up period integrated boiler control energizes gas valve initiating 6 second trial for ignition mode indicated by illumination of Lamp D Lamp C extinguishes after 2 second delay Integrated boiler control stops sending power to hot surface igniter 7 Low level illumination of Lamp E indicates initiation of flame proving During last 2 seconds of trial for ignition mode main burner flame is proven by flame rectification through hot surface igniter providing flame signal is relayed to integrated boiler control fully illuminating Lamp E 8 Thermostat ends its call for heat Integrated boiler control de energizes gas valve and system circulator Lamp D is extinguished while unit enters 30 second post purge mode indicated by illumination of Lamp B Lamp E will remains illuminated as remainder of gas in blower is burned off approximately 2 seconds During post purge blower remains powered and clears out any residual products of combustion 9 After post purge mode draft inducer is de energized Unit goes into standby mode until next call for heat from thermostat mocoop rmoom imoom Pmoomw imoompm rmcoom meoosq NOTE First one or two cold starts may be rough due to gas line not being completely purged of air
71. tible materials gasoline and other flammable vapors and liquids Circulator pump and blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication Lubricate additional or non factory supplied pumps and or motors according to manufacturer s instruction AS Daily During Heating Season 1 Check for and remove any obstruction to flow of combustion air or venting of flue gases 2 Check boiler area is free from combustible materials gasoline and other flammable vapors and liquids Monthly During Heating Season 1 Remove jacket front and top panels Check for piping leaks around relief valve and other fittings If found contact qualified service agency to repair DO NOT use stop leak compounds Test relief valve Refer to valve manufacturer s instructions packaged with relief valve Visually inspect venting and air intake system for proper function If vent or air intake show any signs of deterioration or leakage contact qualified service agency to repair or replace immediately and ensure proper reassembly and resealing of vent and air intake system Visually inspect PVC condensate drain pipe for proper operation If drain pipe shows any signs of blockage leakage or deterioration contact qualified service agency to clean repair or replace immediately Check air vent s for leakage Periodically During Heating Season Where low water cutoffs are used periodic ins
72. to ensure no old antifreeze remains In older systems obviously discolored murky or dirty water or pH reading outside acceptable range between 7 0 and 8 0 are indications system should be cleaned or treated Thoroughly flush system with clean water to remove sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flush with clean water If chemical cleaners are used use only those recommended for use with aluminum boilers Follow chemical cleaner manufacturer s instructions completely DO NOT mix different manufacturer s products Fill Water and Chemistry Verify water used to fill system meets these requirements System fluid pH maintained between 7 0 and 8 0 Maintain water hardness below 7 grains hardness Filling with chlorinated potable water is acceptable DO NOT fill boiler with water containing chlorine in excess of 100 ppm DO NOT use inhibitors or other additives that are not listed Consult local water treatment specialist for recommendations if any of above requirements is outside stated ranges Eliminate System Leaks Continuous addition of make up water will constantly add oxygen to system Eliminate all system leaks All system leaks must be repaired immediately Verify expansion tank is operational and properly sized Undersized expansion tanks cause relief valve weeping and substantial make up water addition Operation of this boiler in a system containing significant amo
73. unts of dissolved oxygen can cause severe heat exchanger corrosion damage e his boiler is not designed for use in systems containing regular additions of make up water Regular additions of make up water may cause severe heat exchanger damage System leaks may not always be visible Unseen system leak will become obvious if boiler pressure decreases when make up valve is closed 13 aluminum boilers See Table 5 page 14 Continuous addition of make up water will dilute power of antifreeze and change buffers ability to maintain pH Flush old antifreeze from system Flush boiler and system separately Do not use antifreeze unless required Antifreeze must be of type as listed in this manual due to their operational characteristics of type 356 T6 aluminum at operating temperatures between 20 F 6 7 C and 250 F 121 C Always clean system prior to using antifreeze Follow antifreeze manufacturer s instructions for use safe handling and storage Refer to MSDS Material Safety Data Sheets provided by antifreeze manufacturer for potential hazards and first aid procedures for exposure or ingestion Antifreeze will raise pH of hydronic solution in heating system above recommended level due to corrosion inhibitors Solution must be treated to maintain pH within recommended level Follow antifreeze manufacturer s instructions to adjust pH If system leaked adjust water and antifreeze chemistry To avoid damage to boiler che
74. wimming pools beauty shops new building construction air conditioning equipment For example combustion air intake near swimming pool chemicals will damage any condensing boiler Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump house All combustion air and vent pipes must be airtight and watertight Follow instructions in this manual for combustion air and vent piping termination Use of concentric vent termination refer to Figures 10 11 and 12 for proper setup Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure Fully support all vent piping Use hangers at intervals to prevent pipe from sagging Figure 12 Concentric Vent COMBUSTION AIR A STRAP FIELD SUPPLIED ELBOW FIELD SUPPLIED C 1 26mm Max SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT IN SIDE WALL 16 Figure 13 Concentric Vent Roof I nstallation NOTE VENT SUPPORT MUST BE FIELD INSTALLED TO D SECURE TERMINATION A KIT TO STRUCTURE L gt COMBUSTION AIR Y Oc le 5 e e lt gt C JI E a Roof Boot Flashing Field Supplied B Elbow Field Supplied Support Field Supplied a COMBUSTION AIR lt rn Level Maintain 12 305mm 18
75. ystem Figure2 General Primary Secondary Configuration ZONE 4 r G 1 C ZONE 1 PRIORITY ZONE Ram WATER INLET coc gt Lj i EXPANSION TANK BOILER FLOW CONTROL VALVE CIRCULATOR PUMP SHUT OFF gt E VALVE PRESSURE REDUCER VALVE ZONE VALVE CHECK VALVE BOILER PUMP BALL VALVE AIR SEPARATOR If HOSE BIB 4 NEAR BOILER PIPING Expansion Tank And Make Up Water Determine required system fill pressure design temperature and water content Figure Relief Valve Discharge Piping Boiler contains 2 6 gallons U S Size expansion tank accordingly Consult expansion tank manufacturer for RELIEF VALVE proper sizing information e Connect properly sized expansion tank not furnished DI SCHARGE See Figure 3 for diaphragm type expansion tank PIPING For diaphragm type expansion tanks adjust tank air pressure to match system fill pressure Install air vent furnished as shown for diaphragm type expansion tank system only Check local codes Install make up water connections as shown and per S Dmm BOILER 8 distance from e f pressure reducing valve is used adjust to match floor or other system fill pressure Verify clean water supply is allowable safe available when connecting cold make up water supply point of discharge to boiler When water supply is from well or pump install sand strainer at pump Burn and scald

Download Pdf Manuals

Related Search

Related Contents

JVC AV-20F475 User's Manual  取扱説明書 - ノイズ研究所  Control Systems Security Toolkit  Easypix DVX1035 Premium  Bedienungsanleitung      4サイクルエンジン取扱説明書  MODÈLE - General & General International  Compteur d`énergie thermique Guide de montage à  

Copyright © All rights reserved. Failed to retrieve file