UTICA BOILERS SVB II Series, Installation, Operation And Maintenance Manual

Page 1: ...Boilers INSTALLATION OPERATION MAINTENANCE MANUAL Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models SVB 2 SVB 3 SVB 4 SVB 5 SVB 6 SVB 7 C S A Certified For Natural Gas Or Propane Tested For 50 psi ASME Working Pressure ...

Page 2: ...Electrical Wiring 22 Sequence of Operation 23 Wiring Diagrams 24 Starting Your Boiler 25 Checking and Adjusting 27 Maintaining Your Boiler 29 Service Hints 30 Equipment Optional Accessories 31 Appendix A Control Module 33 A 1 Installation Environment Considerations 33 A 2 Electrical Connections Connect Module Connectors 33 A 3 Adjusting Settings 33 A 4 Display 33 A 5 Operation 34 A 6 Boiler High L...

Page 3: ...tion or elimination of factory equipped supplied or specified components may result in personal injury or loss of life TO THE OWNER Installation and service of this boiler must be performed by a qualified installer 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 Lice...

Page 4: ...4 P N 240011589 Rev A 08 03 2016 DIMENSIONS Model Width A SVB 2 11 SVB 3 14 1 4 SVB 4 17 1 2 SVB 5 20 3 4 SVB 6 24 SVB 7 27 1 4 ...

Page 5: ...RI Rating Water Mbh AFUE Vent Diameter Inches To Chimney Category I Horizontal Vent Category III SVB 2 42 5 36 31 84 4 4 3 SVB 3 75 0 63 55 83 4 4 3 SVB 4 112 5 94 82 83 0 4 3 SVB 5 150 0 125 109 82 7 4 3 SVB 6 187 5 155 135 82 3 4 4 SVB 7 225 0 186 162 82 0 4 4 MBH 1 000 Btuh British Thermal Unit Per Hour Boilers are equipped for altitudes up to 2 000 feet only U S A Only For altitudes above 2 00...

Page 6: ...ally located with respect to heat distribution system as practical 7 Verify you have the right size boiler before starting installation See rating and capacity table 8 When installed in utility room door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater 9 Boiler installed in building under construction take care to insure...

Page 7: ...ent opening s communicating directly or by ducts with outdoors о о Two Permanent Opening Method Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure Direct communication with outdoors or communicating through vertical ducts Provide minimum free area of 1 in2 per 4 Mbh of total input rating of all appliances in enclosure Communicating...

Page 8: ...ve See Figure 2 x x Use or larger pipe x x Use pipe suitable for temperatures of 375 F 191 C or greater x x Individual boiler discharge piping shall be independent of other discharge piping x x Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate x x Run pipe as short and straight as possible to locati...

Page 9: ...T SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE Figure 3 Forced Hot Water Typical Piping LIMIT SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE Figure 4 Forced Hot Water Typical Piping With Zone Control Valve INSTALLATION SYSTEM PIPING ...

Page 10: ...oiler See Figure 5 x x Boiler connected to heating coils located in air handling units exposed to refrigerated air circulation piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle INSTALLATION SYSTEM PIPING Figure 5 Piping Arrangements For Boiler When Used In Connection With Refrigeration System Low De...

Page 11: ...lining system 6 Vent connector from boiler to chimney should run as directly as possible with as few elbows as possible 7 Where possible it is recommended to common vent water heater and boiler Consult appropriate Vent Sizing Tables in National Fuel Gas Code for specific requirements of multiple appliance venting 8 Boiler is only appliance connected to vent Type B vent pipe is recommended for vent...

Page 12: ...Boiler Water Heater Chimney CHECK YOUR CHIMNEY For boilers for connection to gas vents or chimneys vent installations shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or of the Natural Gas and Propane Installation Code CAN CSA B149 1 or applicable provisions of the local building codes Figure 7 Type B Gas Vent 12 P N 240011589 Rev A 08 03 2016 VENT...

Page 13: ...hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously VENT INSTALLATION 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use flame of a match ...

Page 14: ...or 4 diameter 90 elbow or 3 feet of straight pipe for 3 diameter 90 elbow 2 3 4 5 Section Boilers use 3 vent pipe for 6 7 Section Boilers use 4 vent pipe CHOICE OF VENT PIPE MATERIAL x x U L Listed Z Flex Z Vent Stainless Steel Vent Pipe x x U L Listed Heat Fab Saf T Vent Stainless Steel Vent Pipe x x U L Listed Flex L Star 34 Stainless Steel Vent Pipe x x U L Listed ProTech Systems FasNSeal Stain...

Page 15: ... you may use either A A 90 elbow pointing down fitted with a minimum 1 4 mesh screen to keep out rodents and birds The elbow shall be of the same material and size as vent pipe The elbow exit should be at least 6 away from exterior wall as shown in Figure 7 Page 11 or B Tjernlund VH 1 Series side wall vent hood For 2 3 4 5 section boilers use VH 1 3 For 6 7 section boilers use VH 1 4 7 Vent Pipe T...

Page 16: ...l distance is maintained from electric meters gas meters regulators and relief equipment See Figure 9 HORIZONTAL VENTING INSTRUCTIONS Figure 9 Horizontal Venting Clearances о о Canada Terminate vent system at least 6 feet 1 83m horizontally from and in no case above or below unless 6 feet 1 83m horizontal distance is maintained from gas and electric meters regulators and relief equipment о о Venti...

Page 17: ...re for 24 hours before operating appliance B For Heat Fab Saf T Vent stainless steel vent pipe use a high temperature silicone sealant rated for 550 F The outside of the male end and inside of the female end of the pipe must be cleaned before applying the silicone bead For 3 vent pipe runs the male end of the vent pipe which goes over the outlet of the boiler s induced draft blower must be crimped...

Page 18: ...downward away from the boiler to prevent collection of condensate throughout the assembly 7 Allow the sealant to cure for 24 hours before operating the appliance D For ProTech Systems FasNSeal stainless steel vent pipe no cleaning fluid is required For 3 vent pipe runs on 2 3 4 and 5 section boilers begin by locating the FasNSeal Ametek Adapter over the boiler s induced draft blower Continue the v...

Page 19: ... for these boilers Table 4 Field Controls Number Of Boiler Sections Field Controls Power Venter 2 3 4 5 SWG 4G 6 7 SWG 5 Some possible reasons for using a power venter for sidewall venting 1 May be preferred by local codes 2 Need for vent piping run beyond 30 9 1m but not more than 50 15 2m 3 Boiler installation site experiences gusting or high winds Power venter helps prevent boiler from short cy...

Page 20: ...s controls x x Use two pipe wrenches when making connection to gas valve to keep it from turning x x Install manual shut off valve in vertical pipe about 5 feet 1 5m above floor See Figure 10 x x Tighten all joints securely x x Propane gas connections should only be made by licensed propane installer x x Two stage regulation should be used by propane installer x x Propane gas piping should be chec...

Page 21: ... Pipe Ft Pipe Capacity BTU Per Hour Input Includes Fittings 1 1 20 92 000 190 000 350 000 625 000 40 63 000 130 000 245 000 445 000 60 50 000 105 000 195 000 365 000 Table 7 PROPANE GAS Length of Pipe Ft Pipe Capacity BTU Per Hour Input Includes Fittings Copper Tubing Iron Pipe 20 131 000 216 000 189 000 393 000 40 90 000 145 000 129 000 267 000 60 72 000 121 000 103 000 217 000 ...

Page 22: ...out four feet above the floor 2 NEVER install a thermostat on an outside wall 3 Do not install a thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures televisions a fireplace or a chimney 4 Check thermostat operation by raising and lowering thermostat setting as required to start and stop the burners 5 Instructions for the final adjustment of the thermostat ar...

Page 23: ...rners 8 If boiler water temperature reaches high limit set point high limit contacts open cutting power to blower and pilot control Burners extinguish and blower stops Circulator pump continues to run as long as the thermostat continues to call for heat When boiler water temperature drops past the high limit set point and through the differential high limit contacts close repeating steps 3 7 9 If ...

Page 24: ...24 P N 240011589 Rev A 08 03 2016 WIRING DIAGRAMS Figure 12 Control Module Damper is not an option ...

Page 25: ...nd repeat this process x x Repeat until you have covered every radiation unit in system End at highest unit in system x x If units have automatic vents manual venting is unnecessary but it will speed up proper filling of system x x If system is closed expansion tank system you may have automatic fill valve Leave it open to refill system automatically as needed x x Check temperature pressure gauge ...

Page 26: ...nob WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life x x This appliance is equipped with an ignition device which automatically lights burner Do NOT try to light this burner by hand x x Before operating smell all around appliance area for gas Be sure to smell next to floor because some gas is heavier than...

Page 27: ...re primary air adjustment and are not equipped with primary air shutters Main burner flames form sharp blue inner cones in softer blue outer mantel with no yellow Puffs of air from blowing on flame or stamping on floor will cause flames to turn orange momentarily This is not unusual Remain still when observing main burner flames See Figure 16 Page 27 If flame appearance is not correct check main b...

Page 28: ...it shuts off gas supply to burners 3 Turn your thermostat up to call for heat and let your boiler run until temperature of water reaches limit setting Gas valve shuts off and circulator keeps running until thermostat is satisfied or water cools enough to restart burners through limit control 4 To check operation of contacts in pressure switch disconnect rubber tubing located between blower and pre...

Page 29: ... to freeze will crack pipes and or boiler Cleaning Your Boiler And Burners Flue passages between sections should be examined yearly and cleaned if necessary To clean x x Remove burners pilot and vent pipe x x Remove top and front jacket panels x x Remove two screws attaching intermediate front panel to left and right side jacket panels x x Remove control panel as a unit x x Remove draft diverter a...

Page 30: ...Poor electrical contact Check all control terminals and wire joints Chimney flue is blocked Pressure switch will not close and pilot spark will not operate to start pilot Have your service technician check and correct if necessary Rollout switch blown Have your service technician check heat exchanger for blockage Replace rollout switch with exact replacement IF BURNER IS NOISY POSSIBLE CAUSE WHAT ...

Page 31: ...system to expand as temperature changes Diaphragm type tank can be mounted on air purger fitting or at any convenient place in supply or return line AIR ELIMINATING FITTING AIR PURGER Air purger is used to remove excess air from system It is installed in supply line It will eliminate air from water before it reaches radiators and bleed off this air MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM ...

Page 32: ... system is blocked Factory Pressure Switch Set point 0 4 wc for 2 5 section boilers 0 5 w c for 6 7 section boilers ROLLOUT SWITCH FLAME ROLLOUT SAFETY SHUTOFF Rollout switch is temperature sensitive fuse link device Located on boiler base just outside fire box In event of heat exchanger flueway blockage causing flame to roll out of fire box fuse does not change in appearance when blown If rollout...

Page 33: ...ellow wires marked TT using wire nuts x x Ensure remaining Molex plug connectors have not worked loose during transit x x Check sensing bulb is fully inserted in well and is not loose A 3 Adjusting Settings To discourage unauthorized changing of settings procedure to enter adjustment mode is required To enter adjustment mode press UP DOWN and I buttons see Figure 1 simultaneously for three seconds...

Page 34: ...iler water temperature to determine whether thermostat can be satisfied without firing burners 2 Control determines burner operation is required module proceeds to start burner see state codes list and heats water in boiler until setpoint temperature is achieved or thermostat is satisfied 3 Burner is de activated ignition module completes heating cycle returns to idle and waits for temperature to ...

Page 35: ...r AC frequency is incorrect or noisy 1 Some electric or electronic devices may generate electromagnetic interference Verify none is present 2 Check thermostat connection 59 Line voltage error Line voltage or possibly thermostat is either too high or too low Source problem is likely in electrical external to boiler Control will clear itself and resume normal operation once the situation is resolved...

Page 36: ...ill continue as long as thermostat requires During this period control will monitor pilot signal boiler temperature damper and limit switches to assure safe operation j 9 Post purge Inducer motor is purging gases after heat cycle k 1 Post operation Circulator pumps will continue for short time to deliver stored heat to house before it has a chance to escape during coming off period 2 Other possibl...

Page 37: ... module shuts off lockout models must be reset through key buttons and display On retry models wait for retry or reset at thermostat x x Check for correct installation and wiring before replacing any component x x Control module cannot be repaired If it malfunctions it must be replaced x x Use only qualified service agent to service ignition systems 1 Perform checkout as first step in troubleshoot...

Page 38: ...ectrical connections Failure to do so could result in death or serious injury Energize module and listen for audible sparking noise When operating normally there should be buzzing noise turns on and off twice per second for duration of 1 7 seconds depending on model STEP 4 Verify pilot and main burner light off x x Initiate call for heat Turn thermostat above room temperature Ignition sequence may...

Page 39: ...rature Verify ignition sequence at burner If spark does not stop after pilot lights replace module If main burner does not light or if main burner lights and system locks out check module ground wire and gas control as described in troubleshooting table See Table 9 Page 35 Figure 19 Pilot Flame Correct Pilot Flame 3 8 to 1 2 inch in flame See Figure 15 Page 27 ...

Page 40: ...which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE x x An external energy management system is installed that reduces the boiler water temperature as the heating load decreases x x This boiler is not used for any space heating x x This boiler is pa...