UTICA BOILERS DVB-100 Installation, Operation & Maintanance Manual Download Page 1

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DVB SERIES

Gas Fired Boilers For Forced Hot Water

INSTALLATION, OPERATION &

MAINTANANCE MANUAL

P/N

37615501

, Rev. B [02/09]

Utica BOiLERS

P.O. Box 4729
Utica, NY 13504-4729

MEMBER: The Hydronics Institute

An ISO 9001-2000 Certified Company

Summary of Contents for DVB-100

Page 1: ...Fired Boilers For Forced Hot Water INSTALLATION OPERATION MAINTANANCE MANUAL P N 37615501 Rev B 02 09 Utica BOILERS P O Box 4729 Utica NY 13504 4729 MEMBER The Hydronics Institute R An ISO 9001 2000 Certified Company ...

Page 2: ...dicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or property damage CAUTION Indicates special instructions on installation operation or maintenance which are important but not related to personal injury h...

Page 3: ... to local gas utility regulations and other codes in effect in the area in which the installation is to be made Where required by the authority having jurisdiction the 2 installation must conform to American Society of Me chanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME No CSD 1 This boiler is classified as a Category I and III and vent 3 ins...

Page 4: ...TION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE Boiler Ratings Capacities Dimensions BOILER dimensions DIMENSIONS FOR NATURAL GAS Model Natural Gas Inlet Dimensions Pump size Supply Return Tappings Number of Burners AFUE Ratings A B C D E 50 11 2 3 6 27 1 1 83 100 15 4 3 6 27 1 2 82 125 19 6 3 6 27 1 3 82 150 19 6 4 6 27 1 3 80 200 22 8 4 7 28 1 4 80 NOTE For alti...

Page 5: ...n Valve Induced Draft Fan and Safety Pressure Switch All boilers are design certified for installation on non combustible floors For installation on combustible floors use combustible floor kit This boiler is a Category III Designed Certified appliance which requires a special horizontal through the wall venting system Only HEAT FAB SAF T VENT FLEX L STAR 34 ProTech FasNSeal and Z FLEX Z VENT vent...

Page 6: ...truction frame masonry or metal building infiltration normally is adequate to provide air for combustion and ventilation However if the equipment is located in a building of tight construction See the National Fuel Gas Code ANSI Z223 1 latest revision the boiler area should be considered as a con fined space In this case air for combustion and ventilation shall be provided according to paragraph 5...

Page 7: ...which they connect The mini mum dimension of rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches When installing two openings one must commence A within 12 inches from the top and the other within 12 inches from the bottom of the enclosure The open ings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely commu nicate with the outdo...

Page 8: ... have a minimum free area of 1 square inch per 3000 Btu per hour of the total input rating of all equipment located in the enclosure The free area must be no less than the sum of the areas of all vent connec tors in the confined space VENTILATION COMBUSTION AIR In calculating free area using louvers grilles or screens 6 for the above consideration shall be given to their block ing effect Screens u...

Page 9: ...r 5 and maintained to a minimum pressure of 12 pounds per square inch Bypass piping is an option which gives the ability to adjust 6 the supply boiler water temperature to fit the system or the condition of the installation This method of piping however is not typically required for baseboard heat ing systems Typical installations where bypass piping is used are as follows This method is used to p...

Page 10: ...op must be same size piping as the supply and return piping Installation using circulators is shown in 7 figure 9 Installation using zone valves is shown in 8 figure 10 For further piping information refer to the I B R Installa 9 tion and Piping Guide CONNECTING SUPPLY RETURN PIPING CIRCULATOR VALVE EXPANSION TANK VALVE RETURN SUPPLY 12 MAX CIRCULATOR FLOW VALVE SYSTEM TEMPERATURE GAUGE B A SYSTEM...

Page 11: ... PUMP CONTROL WIRING FOR THERMOSTAT SYSTEM RETURN PIPING INLET COLD WATER VALVE TANK ZONE 6 6 PRESSURE REDUCING VALVE BACKFLOW PREVENTER REDUCED PRESSURE GATE VALVE Figure 10 ALL INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE INSTALLATION MANUAL INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR ...

Page 12: ...d any other gas burning appliances to their previous condition of use Any improper operation of the common venting system 7 should be corrected so the installation conforms with the latest revision of the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the ap propr...

Page 13: ...n gas control valve See chart below Maximum Capacity of Pipe in Cubic Feet of Gas Per Hour Gas pressure 0 5 psig or less pre sure drop 5 in w c Nomi nal Iron Pipe Size Length of Pipe Feet 10 20 30 40 60 80 100 175 120 97 82 66 57 50 360 250 200 170 138 118 103 1 680 465 375 320 260 220 195 1 1400 950 770 660 530 460 400 For additional information refer to the National Fuel Gas Code Handbook Latest...

Page 14: ...on Hot water control and intermittent ignition wiring for boilers with fail safe relay See figure 12 WIRING CODE Key LINE VOLTAGE BY FACTORY LOW VOLTAGE BY FACTORY LINE VOLTAGE BY INSTALLER LOW VOLTAGE BY INSTALLER COMPONENT Key CODING Thermostat millivolt TH 1 Thermostat 24 Volt TH 2 Thermostat Line Voltage TH 3 Transformer 120V 24V 40VA TR 1 Transformer 120V 24V 50VA TR 2 24 Volt Gas Valve LGV 2...

Page 15: ...15 HOT WATER CONTROL AND INTERMITTENT IGNITION WIRING PILOT PILOT Electrical Wiring Figure 12 ...

Page 16: ...utomatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appli B ance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch D o not use any phone or mobile electronics in your building Immediate...

Page 17: ... the limit 3 If limit circuit is closed the venter motor and TF 2 trans former are energized The venter motor starts and develops static pressure 4 When the static pressure is reached the pressure switch 5 pulls in completing the circuit between TF 2 and the inter mittent ignition control The intermittent ignition control opens the pilot valve 6 and ignites pilot After pilot is proven the main bur...

Page 18: ...er for signs of deteriora tion and sagging joints Repair if necessary Remove the vent pipe from the boiler and check for obstructions Clean condensate tee trap Periodic cleaning of the 5 condensate collection system is required When a con densate collection system is installed in a venting system it is recommended that the cleaning become a part of the annual servicing VENT PIPE ELBOW VENT SYSTEM ...

Page 19: ...ly inspect the venter assembly for any unusual G wear or dirt build up Clean with vacuum if necessary Place a sheet of heavy paper or similar material over H the bottom of the combustion chamber and brush down the flue passageways The soot and scale will collect on the paper and is easily removed with the paper Vacuum out base and flueways and reassemble the I boiler in reverse order Seal flue col...

Page 20: ...d the pilot burner should be D checked for signs of corrosion or scale build up Clean main burners and pilot burner with a steel bristle E brush CHECK GAS INPUT RATE TO BOILER Maximum permissible gas supply pressure must not be 1 higher and minimum supply pressure must not be lower than what is specified on the rating plate To check for proper flow of natural gas to boiler using the 2 gas meter pr...

Page 21: ...ut switch is located on the base NOTE The quantities above are for each switch Replacement Parts PILOT 2 5 1 4 3 SPARK PILOT Item Part No Description Qty 1 109007296 PILOT BRACKET ASSEMBLY 1 2 HW 005 01 BRACKET SCREW 2 3 240007093 SPARK CABLE 1 4 14615005 PILOT TUBING 1 8 x 24 1 5 PB 001 02 Natural Gas Q345A PILOT 1 240007096 LP Q345A Pilot Included with 3 Pilot Tube Assembly Kit above ...

Page 22: ...6 2 1 03 MANIFOLD 200 356 2 1 04 Item Description Part Qty 5 SCREW 3 8 HEX HW005 01 4 6 GAS VALVE VR8204H 1006 50 150 SPARK NAT VG01101 1 GAS VALVE VR8304H 4206 200 SPARK NAT VG01103 GAS VALVE VR83043216 50 200 LP VG01104 7 ORIFICE3 2mm 50 100 150 200 240007406 ORIFICE 2 9mm 125 240007404 ORIFICE 47 LP 50 100 150 200 240007403 ORIFICE 49 LP 125 240007402 NOT SHOWN Combustible Base Flooring 50 325 ...

Page 23: ... PANEL FRONT 125 150 315 2 19 03 PANEL FRONT 200 315 2 19 04 3 PANEL BASE 50 315 2 12 01 1 PANEL BASE 100 315 2 12 02 PANEL BASE 125 150 315 2 12 03 PANEL BASE 200 315 2 12 04 4 PANEL RIGHT 50 200 3162701 1 5 PANEL SEPARATOR 50 31522401 1 PANEL SEPARATOR 100 31522402 PANEL SEPARATOR 125 150 31522403 PANEL SEPARATOR 200 31522404 REPLACEMENT PARTS ...

Page 24: ... 1 2 NPT 1310002 1 6 PUSH NIPPLE 2 MACH 50 43300976 2 PUSH NIPPLE 2 MACH 100 4 PUSH NIPPLE 2 MACH 125 150 6 PUSH NIPPLE 2 MACH 200 8 9 BAFFLE 50 2 per Flueway 3461601 2 BAFFLE 100 2 per Flueway 3472301 4 BAFFLE 125 150 2 per Flueway 6 BAFFLE 200 2 per Flueway 8 7 WASH 5 16 FLAT STL ZP HW 008 01 4 8 NUT 1 4 20 HEX STL ZP HW 003 02 2 HEAT EXCHANGER 1 2 3 5 4 7 8 6 9 COMPLETE HEAT EXCHANGER ASSEMBLY ...

Page 25: ... X 4 NPT 1 1310002 1 4 DRAIN SHORT HW 016 03 1 5 PIPE TEE 1 X X 1 1510001 1 6 HARNESS CONTROL LIMIT 38 37518901 1 7 GAUGE THERALTIMETER 1260006 1 8 CONTROL L4080B AQ02201 1 9 WELL X 3 AQ 020 01 1 10 RELIEF VALVE 30 VR 001 01 1 11 PIPE ELBOW 90 1190001 1 12 PIPE NPL X 4 1310001 1 3 4 5 7 8 9 10 11 12 6 2 1 REPLACEMENT PARTS ...

Page 26: ...2C 1008 RELAY 1410001 1 6 9 TERM STRIP EF04001 1 7 SCREW 10 32X5 16 GREEN GROUND HW09001 1 8 PRESSURE SWITCH FS6205A 2413 50B 150B SS00801 1 PRESSURE SWITCH FS6273A 3065 200B ONLY SS00802 1 9 HW TUBE SIL ORANGE 1 8ID HW09701 1 FULLY ASSEMBLED CONTROL BRACKET CONTROL BRACKET SUB ASSY 50B 150B 31522901 CONTROL BRACKET SUB ASSY 200B 31522902 P N 31522901 31522902 INCLUDE PART 1 8 ALL WIRING REPLACEME...

Page 27: ...ECTOR 100 34524804 FLUE COLLECTOR 125 34524805 FLUE COLLECTOR 150 34524806 FLUE COLLECTOR 200 34524808 2 VENT ADAPTER 50 100 125 345 2 7 01 1 VENT ADAPTER 150 200 345 2 7 02 3 VENTER MOUNTING PLATE 50 ONLY 34524902 1 4 HW SCR 20x HW 005 01 5 5 VENTER 50 200 DC00402 1 6 BOLT 5 16 18 x 1 14695039 2 REPLACEMENT PARTS ...

Page 28: ...P O Box 4729 Utica NY 13504 4729 ...

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