Olsen OLSSC-075 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. B [06/2011]

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com

Models

OLSSC

050

OLSSC-075

OLSSC-100

OLSSC-150

OLSSC-200

Summary of Contents for OLSSC-075

Page 1: ...INTENANCE MANUAL An ISO 9001 2008 Certified Company P N 240008852 Rev B 06 2011 H Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13504 4729 web site www ecrinternational com Models O...

Page 2: ...1 1 4 NPT Gas Connection Location J 4 1 2 114mm 4 1 2 114mm Size G 1 2 NPT 3 4 NPT Condensate Drain Connection H 3 4 NPT 3 4 NPT Weight Shipping 111 lb 50 kg 182 lb 83 kg Unit 91 lb 41 kg 157 lb 71 k...

Page 3: ...alve and Air Vent 11 5 4 Trim Piping 12 5 5 System Piping 12 6 Combustion Air And Vent Piping 17 6 2 Removal of Existing Boiler From Common Vent System 17 6 3 Materials 17 6 4 Pipe Installation 18 6 5...

Page 4: ...ly heat potable water Indirect heating is acceptable Heat water with non hydronic heating system chemicals present example swimming pool water Exceed 50 psig 344 kPa system pressure Exceed 195 F 90 5...

Page 5: ...lified agency See glossary for additional information WARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and...

Page 6: ...lation during servicing See section 7 during servicing See section 7 Combustion Air Blower Combustion Air Blower 19 see page 8 Delivers Delivers proper quantity of combustion air receives fuel from pr...

Page 7: ...RELIEF VALVE SAFETY RELIEF VALVE AIR VENT AIR VENT WALL HANGING WALL HANGING BRACKET BRACKET FIGURE 3 2 Lower Jacket Viewed from front of boiler Disconnect connector before removing Lower Jacket Lowe...

Page 8: ...STEM IN SUPPLY WATER TO HEATING SYSTEM OUT OUT LOW VOLTAGE LOW VOLTAGE TERMINAL STRIP TERMINAL STRIP VENT TEMPERATURE SENSOR GAS CONNECTION GAS CONNECTION COMBUSTION COMBUSTION ANALYSIS TEST ANALYSIS...

Page 9: ...solution during boiler service or 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 mate...

Page 10: ...and 4 washers for attaching wall mount bracket to wood studs Field source appropriate fasteners for other wall constructions masonry concrete Attach wall mount bracket level on wall Boiler must engage...

Page 11: ...ther automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Boiler rated at 50 psig 345 kPa maximum allowable working pressure...

Page 12: ...back flow prevention device Single boiler system See figures 5 4 5 5 5 6 5 7 for general guidance Additional considerations Control system designed for single central heating pump Installer responsibl...

Page 13: ...CE Illustrations are meant to show system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction Check Local Codes For Maximum Distance To...

Page 14: ...NED SYSTEM WITH VALVES 5 6 TWO PIPE ZONED SYSTEM WITH 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 10mm Open...

Page 15: ...Heat exchanger ball valve open Heat exchanger ball valves closed 3 8 10mm Open End Wrench 5 7B SINGLE BOILER USING PRIMARY SECONDAY PUMPING CH System Pump 12 305mm Max apart 12 305mm Max apart Existi...

Page 16: ...iple Boiler Guide CH System Pump 12 305mm Max apart System Temperature Sensor Size common piping according to maximum heat capacity of entire system Up to 16 boilers All heat exchanger ball valves clo...

Page 17: ...speed Do not operate summer exhaust fan Close fireplace dampers Turn on appliance being inspected Follow lighting instructions Adjust thermostat so appliances will operate continuously Test for spilla...

Page 18: ...NOT be inter changed with 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...

Page 19: ...n air intake and vent of same appliance 8 21 cm Minimum vertical separation between combustion air intake and vent of different appliances 15 38 cm Maximum horizontal length of vent Maximum vent intak...

Page 20: ...or 3 5 0 or 7 6cm Diameter PVC intake combustion air Elbow field supplied Combustion Air Note Securing strap must be field installed to prevent movement of termination kit in side wall 2 5 0cm Diamete...

Page 21: ...e roof Concentric Vent Roof Terminations Glue inner vent pipe to prevent recirculation Maintain 12 30 cm US 18 46 cm Canada minimum clearance above highest anticipated snow level Maximum of 24 0 61m a...

Page 22: ...inimum 12 300 mm above highest anticipated snow level Avoid locations where snow may drift and block vent and combustion air Ice or snow may cause boiler to shut down if vent or combustion air becomes...

Page 23: ...ent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable 6 COMBUSTION AIR AND VENT PIPING Walkw...

Page 24: ...Attach PVC tee provided with boiler and field sourced piping to condensate drain at bottom of boiler See figure 6 1 Slope condensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field...

Page 25: ...onversion Kit Instructions included with Boiler CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediate...

Page 26: ...as shutoff valve See figure 7 3 Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles ope...

Page 27: ...e voltage terminal C strip 120 VAC L N G Central Heating Pump if used Isolate pump from control module if pump FLA Full A Load Amps exceeds 2 amps or 1 amp if external DHW pump is used Connect pump to...

Page 28: ...oiler control does not provide power to DHW temperature control NOTICE IMPORTANT Do not apply power to DHW T T terminals Dry contact only use of isolation relay may be necessary Maximum wire length is...

Page 29: ...ndensate Trap with Water Disconnect collet clip from condensate hose barb See figure 9 1 Disconnect tubing below from hose barb Pour approximately 2 cups 473 ml of water into condensate drain Reconnec...

Page 30: ...F 82 C 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 S...

Page 31: ...or one or more complete revolutions Measure time for 1 2 minutes Calculate input Input MBH 3600 x cu ft seconds Example Gas flow from Meter 2 cu ft Measured time 72 seconds Rate MBH 3600 x 2 cu ft 100...

Page 32: ...t Follow instructions TO TURN OFF GAS TO APPLIANCE 4 if boiler is not being placed into immediate operation Enter installer information on Warranty Registration 5 Card Gather all instructions manuals...

Page 33: ...evice which automatically lights the burner Do not try to light burner by hand Remove upper jacket panel Turn gas shutoff valve clockwise to closed position Handle should be perpendicular to gas pipe...

Page 34: ...erly and are free of blockages or obstructions air vent check venturi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in place return temperatur...

Page 35: ...ction and cleaning Remove gasket and burner Allow burner to clear top lip of chasiss Remove any residual sleeve and or gasket material from removed burner Clean burner using air hose directed into top...

Page 36: ...nsate collector to heat exchanger using 7 16 deep well socket See figure 11 2 Remove condensate collector assembly from heat exchanger and flue pipe Flush collector and condensate trap with water Foll...

Page 37: ...allations above 4500 feet 1350 m above sea level TABLE 12 1 SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net I B R Rating Water MBH 1 3 AFUE 2 Maxi...

Page 38: ...0 Vac available Replace Wire Harness NO YES Replace Power Light YES NO Remove User Interface from base Using Digital Voltmeter check for 25 to 30 Vdc Is voltage present Make sure all wire harness plug...

Page 39: ...6 Go to Page 47 Go to Page 48 Go to Page 48 Go to Page 49 Go to Page 50 Go to Page 50 Go to Page 51 Go to Page 51 Replace Control Module Replace Control Module Replace Gas Valve Replace Control Module...

Page 40: ...as Valve Is harness connected to Control Module J13 NO YES _ P _ _ _ Lockout Alarm A 0 5 GV relay error Replace Control Module Connect harness Disconnect harness from Control Module J13 Measure resist...

Page 41: ...des of the baffle near the coil for blockages Is there any apparent debris or obstruction of the flue way YES NO Reset the boiler by pressing the Reset button When the boiler tries to ignite is there...

Page 42: ...rom Control Module J9 Measure voltage between J9 2 and J9 3 Is voltage 120 Vac 10 Disconnect 3 wire harness from Combustion Air Blower Measure continuity in each wire Continuity in each wire Replace h...

Page 43: ...6 to Switch 3 YES NO YES NO Replace wire s YES NO Is High Temperature Supply Switch open no continuity between terminals 1 and 3 YES NO 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resist...

Page 44: ...ction clean and secure NO Replace Flame Sensor or harness Remove Flame Sensor Is rod free of contamination Clean or replace Flame Sensor Replace Control Module Replace Flame Sensor and Burner YES YES...

Page 45: ...45 13 TROUBLE SHOOTING...

Page 46: ...between 950 to 33 000 ohms Is Heat Exchanger Pump oriented properly Pump Arrow pointing down YES NO YES NO Correct wiring Install Heat Exchanger Pump in proper orientation Replace Control Module Repl...

Page 47: ...pply between 59 and 61 Hz NO YES _ P _ _ _ Blocking Error E 4 5 Net frequency error Correct wiring Is power supply circuit breaker loose or faulty Provide frequency stabilized power supply rated at 60...

Page 48: ...ith digital meter Estimate 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 o...

Page 49: ...rn Temperature Sensor 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...

Page 50: ...Replace Vent Temperature Sensor Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Do temperature and resistance fall within ranges shown in chart...

Page 51: ...Replace Return Water Sensor Replace Control Module Disconnect wire harness from Vent Temperature Sensor Measure Sensor resistance Does resistance match estimated flue temperature NO YES _ P _ _ _ Bloc...

Page 52: ...52 14 WIRING DIAGRAM 14 1 Connection Diagram...

Page 53: ...53 14 WIRING DIAGRAM 14 2 Schematic Diagram of Ladder Form...

Page 54: ...mpanied by production 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 compr...

Page 55: ...RELIEF VALVE 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 control...

Page 56: ...nel Indicators and User Interface Display POWER INDICATOR Green 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 B...

Page 57: ...new parameter value Scroll up to next menu item Increase value Scroll down to next menu item Decrease value Key Boiler Status Indicator F Flame Detected P Central Heating System pump On B Combustion A...

Page 58: ...H or DHW pump is turned on based on type of heating demand CH call is illustrated Control Module compares sup ply temperature to set point Boiler proceeds to igni tion if supply temperature is less th...

Page 59: ...ontrol module adjusts firing 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 en...

Page 60: ...submenu used to view runtime parameters See Multiple Boiler Manual Boiler Status Supply Temperature set point displayed If boiler running in CH mode CH set point displayed Note While running in Outdo...

Page 61: ...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 CH Settings submenu S E T T I...

Page 62: ...or diagnosis of common problems Boiler Status S T A T U S F a n S p e e d A c t u a l 4 0 0 0 R P M L o w P o w e r 1 5 6 0 R P M Combustion air Blower provides airflow through Combustion and Vent sys...

Page 63: ...ted at end of pre spark period Ignit_0 than lockout will occur Re ignition If at end of safety period no flame detected control will go to post purge removing unburned gas Re ignition attempt started...

Page 64: ...k I g n i t i o n E r r o r Boiler Confi guration B O I L E R C O N F I G A d d r e s s S e l e c t i o n B o i l e r A d d r e s s 0 Address Selection screen used to set boiler position in multiple...

Page 65: ...the CH System Pump electrical terminal block See page 56 for diagram The DHW pump terminal does not function This is typical of a hydronic system design which utilizes zone valves for all CH zones and...

Page 66: ...et curve See figure A 2 CH Mode 2 CH 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 temperat...

Page 67: ...ther reference temperatures See points A B of Reset Curve below Calculated CH set point always limited between Reset Curve Boiler Minimum Maximum temperatures See points C D of Reset Curve below Figur...

Page 68: ...is value while operating in CH Mode Allowable Range 1 100 Default Setting 100 DHW Settings D H W S E T T I N G S D H W m o d e M O D E 1 D H W s t o r e w i t h s e n s o r Two DHW modes are available...

Page 69: ...H or DHW demand 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 followi...

Page 70: ...70 NOTES...

Page 71: ...71 Date Service Performed Company Name Tech Initials Company Address Phone...

Page 72: ...ECR International Inc 2201 Dwyer Avenue Utica NY 13504 4729 web site www ecrinternational com...

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