A.O. Smith Upsilon Installation And Service Manual Download Page 1

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0310 351

Innovation has a name.

Commercial Modular High
Efficiency Condensing Boiler

UB - 70/110/140

Upsilon

Installation and Service
Manual

These instructions should be retained by user.

8G.51.91.03/09.13

Changes reserved. E. & O. E.

Summary of Contents for Upsilon

Page 1: ...ovation has a name Commercial Modular High Efficiency Condensing Boiler UB 70 110 140 Upsilon Installation and Service Manual These instructions should be retained by user 8G 51 91 03 09 13 Changes re...

Page 2: ...Installation and Service Manual Upsilon Series 2 Version from sv 4 1 05 2013...

Page 3: ...31 8 1 External controls 33 8 2 Wiring diagram 34 9 Boiler control 36 9 1 Operational status 37 9 2 Operation 37 9 3 Commissioning 38 9 4 Setting the flow temperature with On Off control 40 9 5 Filli...

Page 4: ...ion Separate instructions for use are supplied with the boiler for users of A O Smith central heating boilers A O Smith is not liable for the consequences of mistakes or shortcomings which have found...

Page 5: ...lation pump 15 gas isolation valve in optional boiler connections set 16 service valves flow return in optional boiler connections set 17 fill and drain valve in optional boiler connections set 18 saf...

Page 6: ...e Air supply concentric 3 Gas isolation valve 4 Service valves flow and return 5 Non return valve 6 Flow return header 7 Gas line 8 Low velocity header 9 Safety valve 10 Fill and drain valve 11 Automa...

Page 7: ...the British Standards The Upsilon boiler is a certified appliance and must not be modified or installed in any way contrary to this Installation Manual Manufacturers instructions must not be taken in...

Page 8: ...k search spray The following safety symbols may be encountered in these installation instructions and on the boiler This symbol indicates that the boiler must be stored away from frost This symbol ind...

Page 9: ...nd gaskets 35 mm blind covers for unused boiler connections DN50 or DN65 gas pipe work headers for 2 or 3 boilers with Flanges M12 bolts nuts spring washers and gaskets 1 blind covers for unused boile...

Page 10: ...peratures and water flow temperatures Using this data the control system works out the optimum water flow temperature re quired for the installation Standard connection facilities for external control...

Page 11: ...has to be flat and level and have sufficient deadweight capacity for the complete filled installation The Upsilon cascade can be mounted in 3 ways Wall mounted in line All boilers alongside one anothe...

Page 12: ...gure 5 1 b C Hang the boilers on the suspension brackets Lift the boiler only by the special grips on the bottom panel 1 and support the boiler by its rear panel 2 Refer to figure 5 1 d D Place the ga...

Page 13: ...te use the left hand holes in the column D Fit a mounting frame on the I column using 3 x bolt M8x50mm Refer to figure 5 2 e Attention mounting rail at the top E Fit a mounting frame on the other I co...

Page 14: ...hand holes in the column D Fit a mounting frame on the L column using 3x bolt M8x50mm Refer to figure 5 3 e Attention mounting rail at the top E Fit a mounting frame on the other L column using 3 x b...

Page 15: ...e in the cross union Gas 1 x 28mm gas isolation valve Polluted test water may be released when removing the plastic caps on the boiler flow and return For connections use the supplied gaskets Check al...

Page 16: ...positioned on either the left or right hand side of the pipe work headers 0310290 Temperature sensor T3 T10 fig 6 1 c Every system with 1 or more UB boilers must be provided with a flow temperature s...

Page 17: ...s are not clear or you wish to discuss any deviations Without approval the warranty becomes invalid Installation The use of groundwater demi water and distilled water is prohibited on the next page yo...

Page 18: ...uring operation Max 5 filling water addition annually Corrosion inhibitors Refer to Additives Attachment pH increasing or lowering agents Refer to Additives Attachment Anti freeze additives Refer to A...

Page 19: ...as line may be 1 7 mbar max In the case of an extension this may be 2 5 mbar max This value is to be measured in between the operational gas meter and the CH boilers For correct functioning of the boi...

Page 20: ...tre towards the outlet and take the shortest possible route Support the pipe at least every 50 cm for near horizontal sections and 1 metre for vertical sections External pipework The pipework should b...

Page 21: ...anger of freezing Before putting the boiler into operation fill the syphon with 600 ml of water A Condensate from boiler syphon trap B Sink with internal overflow C 25mm dia Plastic condensate pipe D...

Page 22: ...ents IG UP 10 BS 715 and BS 6644 Ireland Irish standard is 813 section 9 10 1 Furthermore Boiler Class indicated on the boiler s type plate Flue category Locally applicable rules The supplier s instal...

Page 23: ...ion 2 has a diameter of 100mm 7 2 Concentric boiler connection Carry out the following tasks to convert the boiler to a concentric connection Remove the lid 150 3 from the air supply connection of the...

Page 24: ...determined by Favourable position of boilers with regard to outlet area wall or roof Limited space above the boilers Limited number of boilers You may opt for Roof terminal pitched or flat roof Wall t...

Page 25: ...ndensation may also accumulate on the outside of the air inlet pipe Such conditions must be considered and where necessary insulation of the inlet pipe may be required In cold and or humid weather wat...

Page 26: ...nce length 1 1 UB 140 Maximum straight length 100 150 8 87 bend resistance length 2 6 45 bend resistance length 1 1 Parallel flue system Concentric flue system Maximum flue length for individual flue...

Page 27: ...gas outlet system The air supply may also be supplied collectively but if the boiler room is suitable for that purpose refer to chapter 6 3 it may also be obtained from this area open device Boiler ca...

Page 28: ...10 470 440 932 1 7 600 510 470 440 960 8 600 510 470 440 Assumptions Trega cap on flue outlet cross cap on air intake In case of open outlet or diffuser pressures will be better Tinside Toutside 20C O...

Page 29: ...130 212 1 1 120 130 130 150 240 2 120 130 150 150 272 1 1 1 150 150 180 180 300 1 2 150 180 180 180 332 1 2 180 180 180 180 360 3 180 180 180 180 392 1 1 2 180 180 180 200 424 2 2 200 200 200 220 452...

Page 30: ...efore collective flue gas outlet systems have to be fitted with a condensate drai nage facility Using a plastic siphon the drainage is connected to the sewage system by means of an open connection The...

Page 31: ...ctions 1 High voltage supply 230V 2 Voltage free switches 230V relays 3 Low voltage sensors 4 Communication bus for cascaded Upsilon boilers Front view Side view Terminal 1 Terminal 2 Terminal 3 Termi...

Page 32: ...IP67 11 12 11 12 Blocking contact bridge mounted IP67 13 14 13 14 Low water pressure switch off contact NO function not active IP67 PG glands for cable duct already assembled in the factory For a few...

Page 33: ...erature 2 OpenTherm control An OpenTherm control is a digital controller which is communicating with the boiler ac cording the OpenTherm protocol The controller calculates continuously the desired flo...

Page 34: ...r Cascade Param is released and can be adjusted according to specific requests When P101 is adjusted to 2 the temperature control is set On that moment P215 until P220 in chapter Cascade Param is rele...

Page 35: ...X4 X3 X2 X1 X12 6 3A T 6 3A T A B 25 A2 B2 P1 T2 A20 A23 A4 A5 A6 B4 B5 B6 B8 B9 A8 T1a A11 A9 A10 B10 24 30 30 1 A3 B3 26 A21 T1a HEX4 B11 B23 B22 A22 B7 A7 11 1 20 10 10 1 18 9 8 1 12 1 1 9 1 2 3 11...

Page 36: ...2 15 X3 1 16 C1 13 X1 A en X1 B Earth 1 Conn C2 1 X4 3 2 X4 4 3 X4 5 4 X4 6 5 X4 7 6 X4 8 A21 Cable loom conn terminal LV Conn C3 1 X5 1 2 C3 4 3 X5 2 4 C3 2 6 5 X5 5 6 C3 4 8 7 X5 12 8 C3 6 10 9 X5 1...

Page 37: ...creen Screen explanation 9 10 11 12 13 1 5 2 6 3 7 4 8 1 CH program active 2 DHW program active 3 Clock program active 4 Pump continuously active or pumps active when frost protection is active 5 Boil...

Page 38: ...urement Value increase change Emission measurement Return correction Backward Forward Reset Confirm selection Value decrease change Reset only functions in case of an Error or Message If reset is rapi...

Page 39: ...ke the time and day settings automatically First set the hours using and Press the right arrow button to move to the minutes Set the minutes using and Confirm by OK The display shows DD MM YY setting...

Page 40: ...ascade param is shown 4 Press the OK button again 5 Push the right arrow key until P114 6 Press the OK button 7 Press the key until the total number of boilers in cascade 8 Press the OK button 9 Press...

Page 41: ...C 4 Press the or button to adjust the desired flow temperature and press the OK but ton Setting the maximum flow water temperature without outdoor sensor T4 starting with illuminated display 1 Press...

Page 42: ...ff due to blocking Drain water until approx 1 7 bar Good dd 00 00 variable xx x C P 3 7 Water pressure is good Boiler operates normally again None Message Block dd 00 00 FILL Message Mx24sc14 xx x C P...

Page 43: ...The setting OFF switches the heating off during the whole set period The frost protection is active Setting turns the switch point OFF Switch times can be set in steps of 30 minutes Advice Keep in min...

Page 44: ...urner A Cascade DHW prog Timeprog CH Boiler param Airflush Boiler Pump prg Timeprog DHW Burner A Param Pump speed Burners Timepr CH Burner B Param 3 way valve Other Timep DHW Pump P2 CH temp Pump P3 D...

Page 45: ...te setting day month year Daylight saving Europe Zone for daylight saving Off Eur USA 12 24hrs 0 24h 12 hour AM PM or 24 hour display AM PM 24h Date format DD MM YY Reproduction of date display DD MM...

Page 46: ...rror bit selection 0 2 0 Only errors 1 Errors and blockings 2 Errors blockings and messages P158 0 Error relay selection 0 2 0 Only errors 1 Errors and blockings 2 Errors blockings and messages P170 9...

Page 47: ...nsation and flue length 0 15 BurnerA param Burner A parameters When the boiler has 2 heat exchangers Burner B will follow with the same parameters When the boiler has 2 heat exchangers Burner B will f...

Page 48: ...B off Status relay external heating source on off Boiler Information of the boiler T1 ave xx x C Actual average flow temperature of the boiler in C T2 ave xx x C Actual average return temperature of...

Page 49: ...Put out of operation In some cases it might be necessary to put the complete boiler out of operation The boiler is put out of operation by switching off the three functions and or Proceed as follows F...

Page 50: ...me tasks are described in these maintenance instruc tions For complete inspection and maintenance instructions please contact A O Smith When carrying out maintenance on the boiler the gas tap has to b...

Page 51: ...B Open the top test nipple fig 13 2 1 a Connect the hose of the digital pressure meter to the top test nipple of the gas unit Measuring is only allowed using the top test nipple refer to arrow Press...

Page 52: ...ropane O2 percentage at full load 4 7 1 2 0 8 5 1 1 2 0 7 CO2 percentage at full load 9 0 0 4 0 6 10 3 0 4 0 8 If required you may turn the setting screw to set the correct O2 percentage refer to fig...

Page 53: ...adapter F hanging on the bottom plate Slide the slider G in the upper part of the flue gas pipe upward Pull the flue gas pipe E forward both exchangers simultaneously Ventilation unit and burner cass...

Page 54: ...valve if the entire circumference closes seals completely If the valve seals fully replace the non return valve back into the upper casing transparent part inside Replace the non return valve if the v...

Page 55: ...ignition electrode Push the clips on either side of the electrode to the outside and remove the electrode Remove and replace the gasket Assembly is done in reverse order Condensate container refer to...

Page 56: ...d number of running hours is set for service interval The number of running hours can not be changed After expiring of the number of running hours the message Service is displayed on the screen If the...

Page 57: ...d Bx12sc03 Water pressure lower than 0 7bar Top up Bx12sc04 Water pressure too high Decrease pressure Bx12sc05 No pressure increase on pump start Bx13sc01 DT between T1 and T2 too high Bx15sc01 Commun...

Page 58: ...in articles 1 and 2 will apply solely under the following conditions a The central heating boiler is installed under strict adherence to A O Smith Water Heaters installation instructions for the spec...

Page 59: ...Shipping labor installation and any other costs associated with the replacement will not be accepted by A O Smith Water Heaters Replaced parts can only be claimed atA O Smith Water Heaters if they are...

Page 60: ...otection acc EN 60529 Weight empty kg 65 83 87 Mounting weight kg 54 72 76 Width mm 660 660 660 Height mm 1065 1065 1065 Depth mm 460 460 460 Mounting height excl flue connection mm 1715 1715 1715 Wat...

Page 61: ...ess 100 litres CH water content Preventing corrosion and scale forming Anti freeze Kalsbeek Monopropyleneglycol propane 1 2 diol inhibitors AKWA Colpro KIWA ATA Nr 2104 1 50 w w Anti freeze Tyfocor L...

Page 62: ...ystem mm 2x 100 2x 100 2x 100 Gas pipe g 1 1 4 1 1 4 1 1 4 Flow pipe CH a 1 1 2 1 1 2 1 1 2 Return pipe CH r 1 1 2 1 1 2 1 1 2 Condensate drain pipe c mm 26 26 26 Upsilon 465 315 150 100 165 100 345 1...

Page 63: ...0 460 1715 1000 1070 460 1715 540 2830 660 5630 660 1070 460 1715 540 1070 460 1715 540 1430 660 2 Upsilon boilers free standing in line 3 Upsilon boilers free standing back to back 4 Upsilon boilers...

Page 64: ...Installation and Service Manual Upsilon Series 64 1430 660 1070 460 1715 1000 700 195 195 700 700 270 30 700 315 150 120 770 410 180 180 Dimensions flue connections...

Page 65: ...8mm DN65 DN100 L 3 6 places 2098mm DN65 DN100 140 73 228 441 680 330 175 30 220 110 G1 2 G3 8 DN65 DN65 DN65 DN65 G1 250 80 349 709 910 560 175 30 220 110 DN100 DN100 DN100 DN100 G1 G1 2 G3 8 Dimensio...

Page 66: ...265 L shape frame for back to back alignment 2 2 0310266 I shape frame for line alignment 1 0310267 Boiler frame 1 2 0310335 Low velocity header for 1 or 2 boilers max 200kW 1 1 1 1 0310286 Boiler con...

Page 67: ...d standards Gas Appliance Directive 2009 142 EC EN483 2005 EN15420 2010 EN15417 2007 EN60335 2 12 2006 EN60335 1 partly 2002 Efficiency Directive 92 42 EEC EN677 1998 EN15417 2007 Low Voltage Directiv...

Page 68: ...A O Smith UK Unit B8 Amstrong Mall Southwood Business Park Farnborough Hampshire GU14 0NR www aosmith co uk A O Smith Water Heaters is a trading name of Advance Services Sales Ltd Reg your installer...

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