UTICA BOILERS UB125, Installation, Operation And Maintanance Manual

Page 1: ...ance MANUAL An ISO 9001 2000 Certified Company MEMBER The Hydronics Institute UB90 125 200 GAS FIRED DIRECT VENT CONDENSING HOT WATER Boiler Utica Boilers P O Box 4729 Utica NY 13504 4729 www uticaboilers com P N 240004826U Rev A 10 08 ...

Page 2: ...duced CO and NOx emissions which contribute to a cleaner and healthier environment This appliance unlike normal residential atmospheric and induced draft units takes its combustion air directly from the outdoors sealed combustion and does not compete with building occupants for fresh air Sealed combustion also known as direct vent is the safest and best way to obtain plenty of clean combustion air...

Page 3: ... correct Overfiring may result in early failure of the boiler components This may cause dangerous operation Underfiring may result in too much air for the pre mix burner causing poor or loss of combustion 5 Neverventtheproductsofcombustionfromthisboiler to an enclosed space Always vent to the outdoors Never vent to another room or to inside a building 6 Be sure there is adequate outdoor air supply...

Page 4: ...ncy and Heating Capacity is based on Department of Energy test procedure TABLE 2 NATURAL GAS Nominal Input 200 000 175 000 150 000 125 000 Vent Lengths Vent Lengths Vent Lengths Vent Lengths 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 1 000 197 000 196 500 172 400 172 200 147 800 147 400 123 500 123 000 2 000 194 000 193 000 169 800 16...

Page 5: ... up the stack Most of this heat is available to heat water A small portion is heat loss from the jacket and surfaces of the boiler and it is assumed that this heat stays in the structure The Net I B R Rating represents the portion of the remaining heat that can be applied to heat the radiation or terminal units i e Finned tube baseboard cast iron radiators radiant floor etc The difference between ...

Page 6: ... motors and controls Connected to a properly located thermostat or op erating control Not included with boiler Placed on level surface must NOT be installed on carpeting Condensate drain line must be pitched down to floor drain or external condensate pump with res ervoir at per foot wood frame or blocks may be used to raise boiler LOCATING THE BOILER 1 Select a location which is level central to t...

Page 7: ...ys at or above 32 F to prevent freezing of liquid condensate COMBUSTION AIR VENT PIPE REQUIREMENTS This boiler requires a dedicated direct vent system In a direct vent system all air for combustion is taken directly from outside atmosphere and all flue products are discharged to outside atmosphere Combustion air and vent pipe connections must termi nate together in the same atmospheric pressure zo...

Page 8: ...hes cleaningsolvents salts airfresheners paints adhesives and other household products 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 Combustion air and vent piping must also terminate exactly as shown in Figures 1 2 If a concentricventterminationisbeingused refertoFigures 3 5 for...

Page 9: ...t so they will operate at maximum speed Do not operate a summer ex haust fan Close fire dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliances will operate continuously 5 Test for spillage at the draft hood relief opening af ter 5 minutes of main burner operation Use the flame of a match or candle or the smoke from a cigarette ci...

Page 10: ...Consult expansion tank manufacturer for proper sizing information Connect properly sized ex pansion tank not furnished as shown in Figure 6 for diaphragm type expansion tank For diaphragm type expansion tanks adjust the tank air pressure to match the system fill pressure Install air vent furnished as shown for diaphragm type expansion tank system only Install make up water connections as shown and...

Page 11: ...ump inside the junction box should be taped or wire nutted to prevent short circuits Unplug the circulator pump wiring at the integrated boiler control MULTI ZONE BOILER PIPING WITH ZONE VALVES Figure 9b SUPPLY AND RETURN LINES The packaged boiler unit is set up to receive 1 NPT supply and return piping from top access NOTE The circulator pump and isolation valves are furnished within a carton ins...

Page 12: ...onform to ASTM D2564 or F493 In Canada use CSA or ULC certified schedule 40 PVC drain pipe and cement A condensate pump with a reservoir not furnished may be used to remove condensate to a drain line sanitary line above boiler if a floor drain is not avail able or is inaccessible FILLING CONDENSATE TRAP WITH WATER On initial start up the CONDENSATE TRAP must be manually filled with water The follo...

Page 13: ...imum 24 thickness 2 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 D1784 schedule 40 CPVC D1785 schedule 40 PVC D2665 PVC DWV D2241 SDR 21 and SDR 26 PVC D2661 ABS DWV F628 schedule 40 ABS Pipe cement and primer must conform to ASTM stan dards D2564 PVC or D2235 ABS ...

Page 14: ...y building The bottom of the vent shall be located at least 12 inches above grade Termination of the vent shall be not less than 7 feet above an adjacent public walkway The vent termi nal shall not be installed closer than 3 feet from the inside corner of an L shaped structure Termination of the vent should be kept at least 3 feet away from VIII COMBUSTION AIR AND VENT PIPE vegetation The venting ...

Page 15: ... 267 000 60 72 000 121 000 103 000 217 000 1 Includes Fittings 2 Outside Diameter 12 Slope combustion air and vent pipes toward boiler a minimum of per linear foot with no sags be tween hangers 13 Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or side wall NOTE Rigid supports will cause excess noise in vent piping The boiler and its individual shutof...

Page 16: ... to each joint Bubbles forming indicate leak CORRECT EVEN THE SMALLEST LEAK AT ONCE x ELECTRICAL WIRING Turn off electrical power at fuse box before making any line voltage connections Follow local electrical codes All electrical work must conform to local codes as well as the National Electrical Code ANSI NFPA 70 latest revision In Canada electrical wiring shall comply with the Canadian Electrica...

Page 17: ...please leave the two wire nuts to prevent the short circuit power supply to the ground green screw on the ser vice switch The receptacle on the service switch is always powered regardless of whether the switch is on or off and could be used as a power supply for an external condensate pump if one is used The boiler when installed must be electrically ground ed in accordance with the requirements o...

Page 18: ...RY R R 3 2 P1 1 1 P6 BLOWER G 2 4 3 1 P5 W BK CASTING TEMPERATURE SAFETY SWITCH MANUAL RESET BR BL W V BR SET AT 3 5 WC SWITCH N C AIR PRESSURE DIFFERENTIAL CONTROL HI LIMIT AQUASTAT SET AT 0 5 WC BL BR AIR PRESSURE DIFFERENTIAL SWITCH N O V CIRCULATOR 2 4 3 1 P4 9 3 6 Y 24 VAC SECONDARY TRANSFORMER 1 4 7 8 5 2 BR CONTROL P3 1 2 V 1 3 P2 Y 2 Y 1 1013 10 INTEGRATED BOILER CONTROL W BK NOTE USE COPP...

Page 19: ...TRONIC MICROPROCESSOR 4K 2K 1K 3K 5K GAS VALVE 4K1 3K1 P3 5 24 VAC 4 5 P2 2 P3 2 BLOWER P5 1 1K1 P10 1 2K1 P7 1 P4 1 TRANSFORMER P1 1 120 VAC 3 P1 3 1 HOT SURFACE IGNITER P12 1 P6 1 5K1 P12 2 5K2 P6 2 P10 3 CIRCULATOR FIELD WIRED P5 3 P10 2 P7 3 P4 3 P7 2 NOTE USE COPPER CONDUCTORS ONLY ON OFF BLK HOT L1 WHT L2 SWITCH 120 VOLT POWER SUPPLY LADDER WIRING DIAGRAM NOTE If any of the original wire as ...

Page 20: ...r is mounted next to the burner through the gas air mix er The igniter also serves as a means for proving the main burner flame by flame rectification In the event of GAS VALVE Figure 15 a lack of flame signal on three consecutive trials for ig nition the IBC will lock out The Valve and Flame di agnostic indicator lamps see Figure 16 will blink in dicating the failure mode as a lack of flame signa...

Page 21: ...l drain valve provides a means of draining the water in the heating system including the boiler and hot water supply and return piping systems installed above the drain valve This drain valve is installed in the tapping at the bottom of the boiler Any piping in stalled below the elevation of this drain valve will require additional drain valves to be installed at low points in the piping systems i...

Page 22: ...boiler may lead to premature failure of the boiler sections 2 Use clean fresh tap water for initial fill and periodic make up of boiler a A sand filter must be used if fill and make up water from a well is to be used b Consideration should be given to cleaning the heating system particularly in retrofit sit uations where a new boiler is being installed in an older piping system c In older systems ...

Page 23: ...sure air vent is open Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the zone service ...

Page 24: ...TIONS 1 STOP Read the safety information above before operating this appliance 2 Set the 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 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 h...

Page 25: ...Piping sec tion in this manual 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 the air inlet pipe may need to be disconnected to allow the boiler to start in order to verify the boiler firing rate and combustion properties The inlet air pipe can be disconnected by removing the PVC inlet air pip...

Page 26: ... observed through the observation port on the boiler A B C D E 6 After the igniter warm up period the integrated boiler control energizes the gas valve initiating a 6 second trial for ignition mode which is indicated by the illumination of Lamp D Two seconds later Lamp C will extinguish when the integrated boiler control stops sending power to the hot surface igniter A B C D E 7 A low level illumi...

Page 27: ... cut off a manual reset high limit or additional safety controls test for operation as outlined by the control manufac turer Burner should be operating and should go off when controls are tested When safety controls are restored burner should reignite Set thermostat heat anticipator if used and verify thermostat operation For a single thermostat connected to the yellow ther mostat lead wires in th...

Page 28: ...or natural gas and between 10 and 14 w c for propane gas 2 Drill a hole in the plastic CPVC vent pipe or exhaust tee just large enough to allow access for the sample probe of your combustion analyzer 3 Turn the thermostat to the closed position so the appliance is activated 4 Allow the appliance to run for approximately 5 minutes 5 Insert the sample probe of your combustion analyzer into the hole ...

Page 29: ...s for leakage and tight en bolts or replace gaskets if necessary h 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 XIV maintenance and cleaning 2 Check that boiler area is free from combustible ma terials gasoline and other flammable vapors and liquids 3 Circulator pump and blower motor furnished wi...

Page 30: ...may be rinsed away with spraying or run ning water i Use a flexible handle nylon brush to loosen sediment and aluminum oxide on all exposed heating surfaces of boiler see Repair Parts Manual for diagram Be sure that brush does not get stuck in heat exchanger j After brushing and rinsing remove any re maining loosened sediment using a shop vacuum with a snorkel attachment k Inspect burner for any f...

Page 31: ...GAS VALVE ENERGIZED THRU 3K1 AND 4K1 CONTACTS VALVE LIGHT IS ON GAS VALVE OPENS FOR 5 SEC TRIAL FOR IGNITION BLUE ORANGE GLOW OF THE BURNER CAN BE SEEN THRU OBSERVATION PORT 2 SEC INTO THE 5 SEC IGNITION TRIAL POWER IS TURNED OFF TO THE HOT SURFACE IGNITER IGNITER LIGHT IS OFF DURING THE LAST 2 SEC OF THE 5 SEC IGNITION TRIAL MAIN BURNER FLAME IS PROVED BY FLAME RECTIFICATION A FLAME SIGNAL TO IBC...

Page 32: ...raft inducer runs through 30 second post purge Control will attempt to relight boiler 3 times if flame is not proven control lockout problem establishing a flame signal Valve light is blinking Control will automatically reset after 1 hour High limit control if boiler water temperature reaches high limit aquastat setpoint high limit n c contacts open immediately closing gas valve Valve and flame li...

Page 33: ...ION 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 ...

Page 34: ...hart before replacing it 7 It is extremely unlikely that two consecutive controls are defective If this seems to be the case chances are that the controls are not the cause but rather the malfunction is due to some other problem such as an electrical short burning out a transformer INITIAL SERVICE CHECKS 1 Before Troubleshooting A Make sure that the circuit breaker is on or fuse is OK at the elect...

Page 35: ...flow is proven Off 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 Blinking 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 IGNITER On IBC is energizing igniter Off Igniter is not energized VALVE...

Page 36: ...supplier s instructions If you can not contact your gas supplier call the fire department Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas at a location external to the appliance Do not use the boiler if any part of the gas con trol system has been under water A qualified service technician should i...

Page 37: ...37 TROUBLESHOOTING TROUBLESHOOTING CHART 2 ...

Page 38: ...R SAGS OR LOW SPOTS WHERE CONDENSATE MAY PUDDLE AND BLOCK THE VENT YES CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY NO CLEAN OUT SAMPLING LINES OR REPLACE DEFECTIVE SWITCH YES CHECK FLUE PASSAGES IN BOILER PER MAINTENACE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN NO CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCT...

Page 39: ...ER LIGHT CHECK FOR 24 VAC ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON NO NO CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT NO REPLACE IBC YES REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL YES CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER RESTORE IGNITER SENSOR TO CORRECT POSITION DO NOT ...

Page 40: ...40 TROUBLESHOOTING CHART 5 TROUBLESHOOTING ...

Page 41: ...FIC INSTRUCTIONS REQUIRES SPECIFIC TOOLS NO YES REPLACE BURNER REPLACE IBC BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT AQUASTAT CONTACTS CLOSED NO BOILER OFF ON HIGH LIMIT IS ACTUAL BOILER WATER TEMP GREATER THAN HI LIMIT SET POINT MINUS 30 F CONTROL DIFFERENTIAL NO NO REPLACE AQUASTAT OK YES SEE TROUBLESHOOTING PATH 2 ABOVE CHART 5 NO 3 CHART 5 YES SET THERMOSTAT BELOW ROOM TEMPERAT...

Page 42: ...ble causes Blockage or moisture in suction lines to switch Blockage or moisture in orifice installed in suction lines to switch Blockage in air intake or vent pipes Undersized air intake or vent pipes Loose blower wheel on motor shaft Incorrect pressure switch or pressure switch setpoint Gas valve out of adjustment 6 When the pressure reading corresponds to the chart at right and the pressure swit...

Page 43: ...ormed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed on or adjacent to boiler Installer Company __________________________________________ Address ___________________________________________________ Phone _____________________________________________________ Installer s Name _____________________________________________ Signature ________________...

Page 44: ...P O Box 4729 Utica NY 13504 4729 ...