UTICA BOILERS UB90 125 Installation Manual And Operating Instructions

Gas-fired direct vent condensing hot water boiler

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Installation, operation & maintenance manual (44 pages)

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UB90 125-200 GAS-FIRED DIRECT VENT

CONDENSING HOT WATER BOILER

UTICA BOILERS

P.O. Box 4729

Utica, NY 13504-4729

An ISO 9001-2000 Certiﬁed Company

www.uticaboilers.com

P/N 240004826U, Rev. 1.3 [01/06]

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Page 1 UB90 125-200 GAS-FIRED DIRECT VENT CONDENSING HOT WATER BOILER UTICA BOILERS P.O. Box 4729 Utica, NY 13504-4729 An ISO 9001-2000 Certiﬁed Company www.uticaboilers.com P/N 240004826U, Rev. 1.3 [01/06]...
Page 2: Table Of Contents
UB90 125-200 CAST ALUMINUM BOILER INSTALLATION MANUAL AND OPERATING INSTRUCTIONS P/N# 240004826U, Rev. 1.3 [01/06] • Printed in USA • Made In USA TABLE OF CONTENTS forces the resulting ﬂue gases from the boiler unit and provides a positive removal of the ﬂue gases from the building through inexpensive and readily I.
Page 3: Rules For Safe Installation And Operation
III. RULES FOR SAFE INSTALLATION AND OPERATION WARNING This appliance has been equipped for residential installations. If used for commercial applications, any and all additional code requirements must be adhered to for installation. This may require additional controls, including but not limited to a manual reset low water cut off, a manual reset high temperature limit, and wiring and/or piping modiﬁcations.
Page 4: Boiler Ratings And Capacities
IV. BOILER RATINGS & CAPACITIES TABLE 1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES) Input Heating Capacity Net I=B=R Rating Shipping Model AFUE Flue Diameter (MBH) (MBH) (MBH) Weight (lbs.) (1)(2) 112.5 2” CPVC & 3” PVC 2” CPVC & 3” PVC 157.5 2”...
Page 5: Before Installing The Boiler
These low pressure gas-ﬁred hot water boilers are design certiﬁed by CSA International, for use with natural and propane gases. The boilers are constructed and hydrostatically tested for a maximum work- ing pressure of 50 psig (pounds per square inch gauge) in accordance with A.S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code, Section IV Standards for heating boilers.
Page 6 • Connected to a suitable hot water heating the front where passage is required for cleaning or system. servicing, inspection or replacement of any parts that normally may require such attention. Allow at • Supplied with a suitable electrical supply for least 24”...
Page 7 SIDEWALL VENT/INTAKE TERMINATIONS WARNING FAILURE TO FOLLOW THESE WARNINGS OVERHANG COULD RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH. 12" MINIMUM 12" MINIMUM 12" SEPARATION When vent pipe is exposed to temperatures 12" BETWEEN BOTTOM OF MINIMUM COMBUSTION AIR INTAKE below freezing, such as when it passes through AND BOTTOM OF VENT 90°...
Page 8 remaining connected to it. At the time of removal of CONCENTRIC VENT ROOF INSTALLATION an existing boiler, the following steps shall be fol- lowed 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.
Page 9: Placing The Boiler
VI. PLACING THE BOILER The boiler should be placed to provide the most ly or 2-wheel hand truck. The dolly or hand truck direct connections to the combustion air, vent and should be inserted under the right hand side of system piping as possible.
Page 10 but leave an air gap between piping and drain. MULTIZONE BOILER PIPING No shutoff of any description shall be placed be- WITH ZONE VALVES tween safety relief valve and the boiler, or on the discharge pipes between such safety valve and the atmosphere.
Page 11: Combustion Air And Vent Pipe
FILLING CONDENSATE TRAP WITH WATER NOTES ON INITIAL START UP THE CONDENSATE TRAP 1. Condensate trap is to be built in the ﬁeld per Figure 10 MUST BE MANUALLY FILLED WITH WATER. 2. Wood frame or blocks may be used to raise the boiler to maintain drain pitch or to be above external condensate The following are the steps required to initially ﬁll pump reservoir.
Page 12 • D2665 (PVC-DWV) Reduce the maximum vent length 5 feet per each additional elbow. • D2241 (SDR-21 and SDR-26 PVC) 4. Combustion air and vent piping to be pitched • D2661 (ABS-DWV) back to boiler at minimum ¼” per foot from intake and vent terminals so that all moisture in com- •...
Page 13: Gas Supply Piping
above grade. Termination of the vent shall be 6. Check dry ﬁt of pipe and mark insertion depth not less than 7 feet above an adjacent public on pipe. walkway. The vent terminal shall not be installed closer than 3 feet from the inside corner of an L NOTE: It is recommended that all pipes be cut, prepared, and shaped structure.
Page 14 requirements, by the National Fuel Gas Code, TABLE 6 - NATURAL GAS PIPING SIZES ANSI Z223.1- latest revision. In Canada, follow Pipe Capacity - BTU/Hr. Input Pipe the CAN/CGA B149.1 and .2 Installation Codes Length ½” ¾” 1” 1¼” for Gas Burning Appliances and Equipment. 20’...
Page 15: Electrical Wiring
X. ELECTRICAL WIRING WARNING The boiler, when installed, must be electrically grounded in accordance with the requirements of Turn off electrical power at fuse box before the authority having jurisdiction or, in the absence making any line voltage connections. Follow of such requirements, with the National Electrical local electrical codes.
Page 16 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. LADDER WIRING DIAGRAM Figure 14...
Page 17: Controls And Accessories
XI. CONTROLS AND ACCESSORIES This section provides a brief description of the key as a lack of ﬂame signal. The IBC is manually reset controls and accessories found in this boiler. from lockout by either removing and reestablishing the thermostat’s call for heat, or by turning the ser- See Section XVII, “Troubleshooting,”...
Page 18 as it is heated by the burner/boiler sections. If there WARNING is no place for the water to expand its volume, (i.e., a properly sized and functioning expansion tank) pres- Never run cold water into a hot, empty boiler. sure on the inside of the boiler and heating system will increase.
Page 19: Startup
sate from the boiler, an external ﬂoat activated con- that proper pitch of piping to the external condensate reservoir (sump) can be accomplished. Use wood densate pump with integral sump (supplied by oth- frame or blocks (not factory supplied) to raise boiler ers) is required.
Page 20 faces and greatly reduce capacity and efﬁ- FILLING BOILER WITH WATER ciency. AND PURGING AIR FOR SYSTEMS WITH CONVENTIONAL f. Use of antifreeze in any boiler will reduce CLOSED TYPE EXPANSION TANKS heating capacity by as much as 10-20% due to differing heat transfer and pumping char- Refer to the appropriate diagrams in Section VII, acteristics.
Page 21 2. Before operating smell all around the appli- 5. Remove the front jacket panel. ance area for gas. Be sure to smell next to the ﬂoor because some gas is heavier than air and 6. Turn off the gas shut off valve. Valve handle will settle to the ﬂoor.
Page 22 IF BURNER APPEARS TO PULSATE DURING IGNITION: 1. Turn off boiler power and shut off gas supply to the boiler. 2. Take the burner assembly apart by removing the com- bustion air blower and gas valve/venturi assembly from the boiler and visually inspect the inside of the burner. Look for any debris (PVC shavings, etc.) and, if anything is present, remove it.
Page 23: Checkout Procedures And Adjustments
XIII. CHECKOUT PROCEDURE & ADJUSTMENTS VERIFY PROPER SEQUENCE OF OPERATION The sequence can be followed via the diagnostic indicator lamps on the Integrated Boiler Control in Figure 16 (Section XI). This is the normal sequence of operation. A more detailed sequence of opera- tion containing potential faults can be found in the service hints section.
Page 24 test for operation as outlined by the control manu- INSPECT VENTING & AIR INTAKE SYSTEM facturer. Burner should be operating and should go Operate the boiler and verify that all vent/air intake off when controls are tested. When safety controls connections are gastight and watertight.
Page 25 ADJUSTMENTS AND CHECKOUT It is important that this appliance operate between 8.5 and 10% CO . To verify that the appliance is operating in this range, follow the steps below. 1. Check incoming gas pressure to the appliance using a pressure gauge with a resolution of 0.1”...
Page 26: Maintenance And Cleaning
XIV. MAINTENANCE AND CLEANING Maintenance as outlined below can be performed tings. Repair, if found. DO NOT use stop leak by the owner unless otherwise noted. compounds. The acidic nature of ﬂue gasses condensing on the 2. Check that boiler area is free from combustible aluminum boiler sections will cause the formation materials, gasoline, and other ﬂammable vapors of aluminum oxide.
Page 27 i. Use a ﬂexible handle nylon brush to loosen ANNUAL SHUT DOWN PROCEDURE sediment and aluminum oxide on all exposed (END OF EACH HEATING SEASON) heating surfaces of boiler (see “Repair Parts 1. Follow the instructions in “To Turn Off Gas To Ap- Manual”...
Page 28: Detailed Sequence Of Operation
XV. DETAILED SEQUENCE OF OPERATION POWER ON STAND BY THERMOSTAT CALLS FOR HEAT IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME LIGHT BLINKS. MANUAL RESET IS REQUIRED OR CONTROL CIRCULATOR WILL AUTOMATICALLY RESET AFTER 1 HOUR. ENERGIZES THRU THIS PROBLEM IS A RESULT OF NOT 2K1 CONTACTS...
Page 29 DETAILED SEQUENCE OF OPERATION SAFETY SEQUENCES DURING OPERATION DRAFT INDUCER TEMPERATURE SAFETY SWITCH CASTING TEMPERATURE SAFETY SWITCH IF BURNER OPERATES WHEN BOILER HAS NO WA- IF DRAFT INDUCER TEMPERATURE REACHES TER, ALUMINUM BOILER SECTIONS HEAT UP RAPIDLY. TEMPERATURE SAFETY SWITCH SETPOINT, SAFETY SWITCH CONTACTS OPEN IMMEDIATELY, CLOSING GAS VALVE (LIGHT GOES OUT).
Page 30 DETAILED SEQUENCE OF OPERATION END OF NORMAL SEQUENCE OF OPERATION THERMOSTAT ENDS CALL FOR HEAT. GAS VALVE AND CIRCULATOR PUMP ARE DE-ENER- GIZED, 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.
Page 31 DETAILED SEQUENCE OF OPERATION SERVICE HINTS WARNING Fire, explosion, or shock hazard. May cause property damage, severe injury, or death. Do not attempt to modify the physical or electrical characteristics of this boiler in any way. IMPORTANT c. Make sure that gas is on at the gas me- ter, at all appropriate manual shutoff valves, 1.
Page 32 DETAILED SEQUENCE OF OPERATION SERVICE HINTS The differential air pressure switch is a This diagram indicates the locations of the connection safety device which will prevent the boiler points required to check the differential air pressure. from ﬁring if there is an air intake, boiler heat exchanger or vent blockage.
Page 33: Troubleshooting
XVI. TROUBLESHOOTING SYSTEM STATUS The indicator lights track the operating sequence. If the system locks out, the lights indicate the point in the sequence of operation were lockout occurs. If this table does not readily provide the reason for boiler malfunction or non-operation, refer to the following pages for more detailed troubleshooting procedures.
Page 34 TROUBLESHOOTING TROUBLESHOOTING CHART #1 �� ...
Page 35 TROUBLESHOOTING TROUBLESHOOTING CHART #2 �� ...
Page 36 TROUBLESHOOTING TROUBLESHOOTING CHART #3 CHART 1 OPEN CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND 3 REPLACE IBC AT CONNECTOR CN4 ON IBC CHECK FOR 120 VAC AT REPAIR/REPLACE BLOWER LEADS ON WIRING WIRING FROM IBC HARNESS TO BLOWER REPAIR/REPLACE BLOWER PRESSURE SWITCH...
Page 37 TROUBLESHOOTING TROUBLESHOOTING CHART #4 CHART 3 CHECK FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS 1 UP AND GLOWS AND 2 AT CONNECTOR YELLOW/ORANGE REPLACE IBC CN1 ON IBC (DURING DURING 20 SECOND IGNITER WARM UP) WARM UP CHECK FOR 120 VAC AT IGNITER/SENSOR LEADS REPAIR/REPLACE WIRING ON WIRING HARNESS...
Page 38 TROUBLESHOOTING TROUBLESHOOTING CHART #5 �� ...
Page 39 TROUBLESHOOTING TROUBLESHOOTING CHART #6 CHART 5 CHART 5 CHART 5 REPLACE GAS CONTROL. NO #3 NO #2 CHECK GAS ORFICICE SIZE. IS GAS ORIFICE SIZE CORRECT. CHECK REPAIR PARTS LIST FOR CORRECT SIZE. IS GAS ORIFICE CLEAR OF BLOCKAGE. RUNS FOR 25-50 SECONDS, THEN TURNS OFF.
Page 40: Installation And Checkout Certiﬁcate
XVII. INSTALLATION & CHECKOUT CERTIFICATE Boiler Model___________________Serial #___________________Date Installed_____________ Measured BTU/HR Input___________________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/ maintenance person Installation booklet afﬁxed on or adjacent to boiler Installer (Company) __________________________________________________________ Address ___________________________________________________________________ Phone _____________________________________________________________________ Installer’s Name _____________________________________________________________...

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UTICA BOILERS UB90 125 Installation Manual And Operating Instructions

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