ECR International Olsen OLSSC-050 Installation, Operation & Maintenance Manual Download

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WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

P/N# 240008852, Rev. I [07/2013]

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com

Models

OLSSC

050

OLSSC-075

OLSSC-100

OLSSC-150

OLSSC-200

OLSSC-299

050/075/100/150/200

SIZE SHOWN

Summary of Contents for Olsen OLSSC-050

Page 1: ...An ISO 9001 2008 Certified Company P N 240008852 Rev I 07 2013 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models OLSSC 050 OLSSC 075 OLSSC...

Page 2: ...5 16 2 ea 17 Used for packaging holes on back of boiler Plastic Plug 2 ea 18 Used for packaging holes on back of boiler Outdoor Sensor 19 Used for measuring outside temperature Critical Installation I...

Page 3: ...Depth C 14 356mm 16 0 406mm 18 3 465mm Bracket D 28 711mm 40 1016mm Height E 31 787mm 42 1092mm Water Connections Size F 1 1 4 NPT 1 1 4 NPT Location G 2 51mm 2 51mm Location H 5 127mm 3 76mm Locatio...

Page 4: ...ents 28 6 8 Multiple Boiler Venting Installation 30 6 9 Condensate Piping 31 7 Gas Supply Piping 32 8 Electrical Connections 34 8 3 Line Voltage Connections 34 8 4 External Connections 34 9 Start Up P...

Page 5: ...essure Exceed 195 F 90 5 C system design temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Integral Low Water Cutoff with test button Outdoor Temperature Reset Integral Multip...

Page 6: ...d Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation 2 3 Installation shall conform to requirements of authori...

Page 7: ...Gas Shutoff Valve Fuel supply isolation during servicing See section 7 19 Combustion Air Blower Delivers proper quantity of combustion air receives fuel from gas valve mixes air and fuel sending mixt...

Page 8: ...IGURE 3 2 Lower Jacket Viewed from front of boiler Disconnect connector before removing Lower Jacket Lower Jacket Connector to User Indicator Lights FIGURE 3 3 Upper and Lower Jacket Latch Viewed from...

Page 9: ...ROM HEATING SYSTEM IN 14 SUPPLY WATER TO HEATING SYSTEM OUT 4 LOW VOLTAGE TERMINAL STRIP 15 VENT TEMPERATURE SENSOR 26 GAS CONNECTION 33 COMBUSTION ANALYSIS TEST PORT 24 HIGH VOLTAGE JUNCTION BOX 9 HE...

Page 10: ...E COLLECTOR 3 RETURN WATER FROM HEATING SYSTEM IN 14 SUPPLY WATER TO HEATING SYSTEM OUT 4 LOW VOLTAGE TERMINAL STRIP 33 COMBUSTION ANALYSIS TEST PORT 26 GAS CONNECTION 24 HIGH VOLTAGE JUNCTION BOX 9 H...

Page 11: ...from safety relief valve discharge See section 5 Access to system water piping gas supply and electrical service See sections 5 7 and 8 Clearances to combustible materials and service clearances See...

Page 12: ...on hazard Mount boiler vertically or slightly tilted backward to insure proper function of low water cutoff Failure to follow these instructions could result in death or serious injury When mounting b...

Page 13: ...to refrigerated air circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Bo...

Page 14: ...for general guidance Additional considerations Boiler control is designed for single central heating pump Installer responsible for integration of multiple central heating pumps Boiler control allows...

Page 15: ...e to condensate drain Table 3 System Piping Configurations Single Boiler Two Pipe Zoned System With Zone Valves figure 5 5 With Zone Pumps figure 5 6 Primary Secondary Pumping Closed External Primary...

Page 16: ...lves FIGURE 5 6 Single Boiler Two Pipe Zoned System With Zone Pumps Heat exchanger ball valve open as shipped Heat exchanger ball valve open as shipped DHW Pump CH System Pump DHW Pump Zone Pump 3 8 1...

Page 17: ...Heating system with existing primary loop Internal primary loop ball valves closed 3 8 10mm Open End Wrench FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With Open External Primary Loop C...

Page 18: ...5 HYDRONIC PIPING Up to 16 boilers 3 8 10mm Open End Wrench DHW Pump See Multiple Boiler Guide CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat...

Page 19: ...oad Heating Load Existing closely spaced tees in primary system loop 12 305mm Maximum Separation Up to 16 boilers 3 8 10mm Open End Wrench CH System Pump 12 305mm Maximum Separation System Temperature...

Page 20: ...tees in primary system loop 12 305mm Maximum Separation 3 8 10mm Open End Wrench CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of e...

Page 21: ...nce being inspected Follow lighting instructions Adjust thermostat so appliances will operate continuously Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use f...

Page 22: ...ith other vent systems or unlisted pipe fittings Canadian installations only All venting material primer and glue must be listed to ULC S636 Canadian installations only First 3 ft 0 9 m of plastic ven...

Page 23: ...1 Concentric figure 6 7 Side Wall Single Pipe figure 6 8 Inside Air Single Pipe figure 6 9 Side Wall Roof Single Pipe figure 6 10 Side Wall Two Pipe figures 6 2 6 3 Concentric figures 6 4 6 5 6 6 Ins...

Page 24: ...ween combustion air intake and vent of different appliances 15 381mm Maximum horizontal length of vent Minimum vent intake between different appliances 12 305mm Maximum allowable total vertical vent l...

Page 25: ...must be field installed to prevent movement of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 or 3 51 or 77 mm Diameter PVC intake combustion air Combustion Air 2 51mm D...

Page 26: ...ghest anticipated snow level 24 610mm above roof FIGURE 6 8 Flue on Roof Air Intake on Side Wall FIGURE 6 9 Flue on Roof Combustion Air Grade Snow Ice Terminate vent system bottom minimum 12 300 mm ab...

Page 27: ...w Line 6 COMBUSTION AIR AND VENT PIPING NOTICE Configurations of single pipe vent with flue on the sidewall requires a tee as the vent terminal See figures 6 10 and 6 11 Maintain 12 305mm US 18 457mm...

Page 28: ...may condense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas Termination must be 12 305mm from or below doors windows or gravity inlet 12 305mm Minimum Te...

Page 29: ...rn leaves snow or recirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkwa...

Page 30: ...revent flue gas back flow External terminals follow same rule as single boiler venting as described in Section 6 6 and 6 7 FIGURE 6 17 Mulitple Boilers With Common Venting Pipe Model Minimum Diameter...

Page 31: ...ondensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by author...

Page 32: ...as valve Install manual main shutoff valve outside of jacket See figure 7 2 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler Table 10 Gas Supply Pressure CAUTIO...

Page 33: ...e 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 that can provide ig...

Page 34: ...and Table 11 B Connect pump to line voltage terminal strip CH PUMP L N G Domestic Hot Water Pump if used A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figu...

Page 35: ...e wire C Connect wires interchangeable to DHW T T terminals Wires are interchangeable Central Heating Thermostat A Use thermostat or boiler system control with dry contacts related 0 5 amps 120 VAC Bo...

Page 36: ...manual gas shut off valve Let system run for 30 minutes When boiler goes into lockout reset boiler by pressing Reset button until boiler resets Do not open gas shutoff valve until all air is purged fr...

Page 37: ...104 195 F 40 91 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Enabled Enable Disabled Pump Mode 0 0 4 Service Reminder Status On ON OFF Service R...

Page 38: ...dequately and is disposed properly 8 Check control module operation 9 Check field sourced limits low water cutoffs etc per manufacturer s instructions 9 5 Check Combustion Natural Gas 1 Measure input...

Page 39: ...If CO2 is high decrease gas flow following figure 9 3 9 4 FIGURE 9 3 Gas Valve Models 050 075 100 150 200 MBH To increase gas flow turn throttle left or counter clockwise To decrease gas flow turn thr...

Page 40: ...drops below limit boiler will automatically refire then Lockout A 06 requiring manual reset of control module Press Reset button on User Interface OR C Shut off burner E39 Flue Temperature Sensor Thi...

Page 41: ...E page 42 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all instructions manuals wiring diagrams warranty registration car...

Page 42: ...Turn gas shutoff valve clockwise to closed position Handle should be perpendicular to gas pipe Wait 5 minutes for any gas to clear Smell for gas including near floor If you smell gas STOP Follow instr...

Page 43: ...vent check venturi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in place return temperature sensor clip must be securely seated on pipe Chec...

Page 44: ...y residual sleeve and or gasket material from removed burner Clean burner using air hose directed into top of burner opening to dislodge any debris in burner ports Inspect burner for foreign matter in...

Page 45: ...7 16 deep well socket See figures 11 3 11 4 Remove condensate collector assembly from heat exchanger and flue pipe Flush collector and condensate trap with water Follow Burner Inspection Kit instruct...

Page 46: ...n for installations above 4500 feet 1350 m above sea level SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net AHRI Rating Water MBH 1 3 AFUE 2 Maximu...

Page 47: ...47 13 TROUBLE SHOOTING...

Page 48: ...Control Module High Temperature opens during normal operation Go to Page 54 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas...

Page 49: ...61 Hz Go to Page 59 Boiler power supply ground wire is not grounded Go to Page 60 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replac...

Page 50: ...connector on Control Module NO YES Disconnect J13 connector on Control Module Measure resistance across third connected to blue wire and fourth connected to brown wire terminals Is resistance between...

Page 51: ...51 13 TROUBLE SHOOTING...

Page 52: ...ystem if water is dirty Is boiler supply pipe above heat exchanger hot Wait for boiler to cool down YES NO Replace Broken Switch Unplug molex connector on supply temperature sensor Check continuity be...

Page 53: ...53 13 TROUBLE SHOOTING...

Page 54: ...y from J13 5 to Switch 1 Continuity from J13 6 to Switch 3 continuity of the two purple wires Disconnect harness from High Temperature Supply Switch and Control Module J13 Continuity from J13 5 to Swi...

Page 55: ...TURN OFF GAS TO APPLIANCE Replace Gas Valve Turn off manual gas shutoff valve Follow instructions TO TURN OFF GAS TO APPLIANCE Replace Gas Valve Follow Operating Instructions to initiate boiler operat...

Page 56: ...ect harness to Transformer Disconnect harness from Low Water Cutoff Is 24 vac at terminals 1 2 Between blue and yellow wires YES NO Repair System Piping remove any remaining air in system 13 TROUBLE S...

Page 57: ...blem if any purging all air out of the system Replace Flue Gas Sensor Replace Control Module Use thermal couple to measure flue gas temperature through sampling port Is the measured temperature and fl...

Page 58: ...connector on return sensor Is there moisture or liquid on metal pins Liquid might be water or antifreeze solution NO Is Heat Exchanger Pump properly oriented Pump arrow pointing down YES NO Disconnec...

Page 59: ...supply rated at 60 Hz 2 Replace Control Module YES YES NO NO Replace circuit breaker 13 TROUBLE SHOOTING Fix the connection These error messages are displayed when the control board detects fault in...

Page 60: ...timate Sensor temperature Does it fall in the range of the Resistance Chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K...

Page 61: ...r and Control Module J5 4 and J5 12 Continuity Measure Return Temperature Sensor resistance with digital meter Estimate Sensor temperature Do temperature and resistance fall within ranges shown in cha...

Page 62: ...62 Supply Water Temperature Sensor Resistance Chart 13 TROUBLE SHOOTING...

Page 63: ...Sensor Replace Control Module Disconnect wire harness from Vent Temperature Sensor Measure Sensor resistance Does resistance match estimated flue temperature NO YES _ P _ _ _ Blocking Error E 6 5 Flu...

Page 64: ...64 14 1 Connection Diagram 050 075 100 150 200 MBH 14 WIRING DIAGRAM EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8...

Page 65: ...NK MULTI BOILER OPTIONAL ARGUS LINK POWER ON OFF SUPPLY SENSOR RETURN SENSOR DHW THERMOSTAT FLUE SENSOR OUTDOOR SENSOR SYSTEM SENSOR OPTIONAL L L N G N G ARGUS CONTROL J5 9 J5 1 J5 10 J16 5 J16 6 120V...

Page 66: ...66 14 3 Connection Diagram 299 MBH 14 WIRING DIAGRAM EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8...

Page 67: ...ALL GND DC N GROUND FLAME SENSOR IGNITION LWCO CH THERMOSTAT USER INTERFACE DISPLAY ARGUS LINK MULTI BOILER OPTIONAL ARGUS LINK POWER ON OFF SUPPLY SENSOR RETURN SENSOR DHW THERMOSTAT FLUE SENSOR OUTD...

Page 68: ...roduction of heat or heat and light Complete combustion of fuel is possible only in presence of adequate supply of oxygen COMBUSTIBLE MATERIAL Materials made of or surfaced with wood compressed paper...

Page 69: ...E Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner i...

Page 70: ...een Light is lit when boiler power is ON HEAT INDICATOR Green Light is lit when boiler is providing heat for CH or DHW RESET INDICATOR Red Boiler fault has been detected Normal Operation is suspended...

Page 71: ...em Increase value Scroll down to next menu item Decrease value Boiler Status Indicator F Flame Detected P Central Heating System pump On B Combustion Air Blower On S Safety Relay Check G Gas Valve Ope...

Page 72: ...n based on type of heating demand CH call is illustrated Control Module compares supply Temperature to set point Boiler proceeds to ignition if supply temperature is less than set point Combustion Air...

Page 73: ...ng rate according to heating demand When Boiler detects demand met will enter post purge mode then standby mode If simultaneous demand for Central Heat and DHW boiler will enter DHW Priority Mode Prio...

Page 74: ...ction as part of multiple boiler installation submenu used to view runtime parameters See Multiple Boiler Manual Boiler Status Supply Temperature set point displayed If boiler running in CH mode CH se...

Page 75: ...l change to OD Reset Setpoint and cannot be changed Controller calculates set point based on outdoor temperature Note For explanation of available CH heating modes refer to CH Mode section located in...

Page 76: ...ettings Refer to Multiple Boiler Manual System Test Tool aids setup of boiler installation or diagnosis of common problems Boiler Status Combustion air Blower provides airflow through Combustion and V...

Page 77: ...tion If at end of safety period no flame detected control will go to post purge removing unburned gas Re ignition attempt started following same cycle Number of re ignition attempts limited to 4 after...

Page 78: ...ler Configuration Address Selection screen used to set boiler position in multiple boiler cascade installation Refer to Multiple Boiler Installation Manual Default setting of 0 indicates boiler is ope...

Page 79: ...s pump to CH System Pump electrical terminal block See page 35 for diagram DHW pump terminal does not function This is typical of hydronic system design which utilizes zone valves for all CH zones and...

Page 80: ...with Full Outdoor Reset Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point calculated as function of outdoor temperature using outdoor reset curve See fig...

Page 81: ...door Reset Curve Calculated supply temperature follows thick black line in graph above based on outdoor temperature 25 F 170 F 20 180 200 160 140 120 100 80 60 40 60 100 70 F A D C B Reset Curve Boile...

Page 82: ...100 Default Setting 100 DHW Settings Two DHW modes are available DHW Mode 0 No DHW DHW Mode is disabled The DHW thermostat input is ignored and the DHW pump is not used DHW Mode 2 DHW Store with Therm...

Page 83: ...mand being present System Test has priority over any system demand while test mode activated System test mode automatically ends after 30 minutes boiler resumes normal operation The following modes ar...

Page 84: ...ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com...

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