UTICA BOILERS OLSSV-050 Installation, Operation & Maintenance Manual Download

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User Interface Display

Explanation

Installer Menu

iler Status

Control module logs successful and failed ignition attempts.

Information accessed in ‘Ignition Attempts’ Screen as shown.
Ignition attempts are stored in non-volatile memory and are

retained in event of power failure.

Figure A-1 Typical Ignition Cycle

Following control features are implemented to ensure safe and

reliable operation of Combustion System:

False Flame

Detection

If flame is detected 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 following same cycle.

Number of re-ignition attempts limited

to 3 after which lockout occurs.

Intermittent

Operation

Boiler can be firing continuously for 24

hours. Burner switched off and restart

sequence follows.

Flame out too

late

If flame detected after post purge lockout

follows.

Safety relay test

In Safety ON/OFF state correct operation

of safety relay is proved before ignition.

UL3563

High Limit

Temperature

Device

Boiler comes equipped with UL353

approved temperature high limit device.

Gas Valve de-energized when supply

temperature exceeds 203°F lockout

follows.

APPENDIX A - CONTROL MODULE

P/N# 2400010616, Rev. F [10/26/2015]

Summary of Contents for OLSSV-050

Page 1: ...LLATION OPERATION MAINTENANCE MANUAL P N 2400010616 Rev F 10 26 2015 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models OLSSV 050 OLSSV 075 OLSSV 100 OLSSV 150 OLSSV 200 ...

Page 2: ... wire knockouts Stopper Rubber 5 16 2 ea 15 Used for packaging holes on back of boiler Plastic Plug 2 ea 16 Used for packaging holes on back of boiler Outdoor Sensor 17 Used for measuring outside temperature Critical Installation Instruction 18 11 x 17 Page for critical installation issues Document Package 19 Includes essential documents VERIFY CONTENTS RECEIVED 4 2 3 5 6 8 12 11 7 10 Boiler provi...

Page 3: ...on G 2 22 56 4mm 2 51mm Location H 2 33 59mm 3 76mm Condensate Drain Connection Location I 9 32 237mm 11 282mm Location J 1 4 35 6mm 4 6 116 8 Size 3 4 NPT 3 4 NPT Gas Connection Top of Boiler Size K 1 2 NPT 3 4 NPT Weight Shipping 135 lb 61 kg 200 lb 91kg Unit 75 lb 34kg 127 lb 58kg Vent Connector Combustion Air 2 51mm 3 76mm LEFT SIDE OF BOILER D Wall Hanging Bracket D A B Vent Connector Combust...

Page 4: ...ensate 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 Procedure 36 9 6 Perform CSD 1 Compliance Test 40 9 7 Complete Start Up Procedure 41 10 Operating Instructions 42 11 General Maintenance And Cleaning 43 12 Ratings And Capacities 45 13 Trouble Shooting 46 13 Trouble Shooting Temperature Resistance Chart 63 14 W...

Page 5: ...ign temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Connection provided for required field sourced low water cutoff LWCO Outdoor Temperature Reset Integral Multiple Boiler Control Heat exchanger over heat protection Alternate mounting of User Interface Information and specifications outlined in this manual in effect at the time of printing of this manual ECR Internationa...

Page 6: ...allation 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 authority having jurisdiction or in absence of such requirements United States National Fuel Gas Code ANSI Z223 1 NFPA 54 National Electrical Code NFPA 70 Canada Natural Gas and Propane Installation Code CAN CSA B149 1 Can...

Page 7: ...n See page 14 16 Condensate Trap Field Installed Condensate must be piped to appropriate drain See section 6 17 Jacket Panel Latch 18 Supply Water Outlet to Heating System Out Connections supplied for connecting from bottom of boiler See section 5 19 Temperature Pressure Gauge Field Installed 20 High Voltage Junction Box For connection of 120V components See section 8 21 Flue Collector 22 Vent Tem...

Page 8: ...31 WALL MOUNT SUPPORT BRACKET 3 COMPONENT LISTING 050 075 100 150 200 SIZE SHOWN 32 GAS CONNECTION FIGURE 3 2 Jacket Removal Viewed from Bottom of Boiler Jacket Latch Lift latch to dis engage Bottom of Boiler FIGURE 3 3 Jacket Removal Viewed from Left Side of Boiler Disengage latch and lift jacket up and off jacket support Jacket Support Lip Jacket Latch P N 2400010616 Rev F 10 26 2015 ...

Page 9: ... HEATING SYSTEM OUT 12 LOW VOLTAGE TERMINAL STRIP 22 VENT TEMPERATURE SENSOR 1 GAS CONNECTION SHUT OFF VALVE 23 COMBUSTION ANALYSIS TEST PORT 20 HIGH VOLTAGE JUNCTION BOX 10 HEAT EXCHANGER 9 BOILER CONTROL MODULE Fuse and Holder 4 IGNITER 5 FLAME SENSOR 6 SIGHT GLASS 7 AIR FLUE MIXTURE PRESSURE TEST PORT 15 CONDENSATE DRAIN 8 USER INTERFACE 13 RETURN WATER TEMPERATURE SENSOR 11 ASME PLATE 27 SUPPL...

Page 10: ... FROM HEATING SYSTEM IN 18 SUPPLY WATER TO HEATING SYSTEM OUT 12 LOW VOLTAGE TERMINAL STRIP 1 GAS CONNECTION SHUT OFF VALVE 20 HIGH VOLTAGE JUNCTION BOX 10 HEAT EXCHANGER 9 BOILER CONTROL MODULE Fuse and Holder 5 FLAME SENSOR 15 CONDENSATE DRAIN 8 USER INTERFACE 25 COMBUSTION AIR BLOWER 26 HEAT EXCHANGER SURFACE TEMPERATURE SWITCH 6 SIGHT GLASS 22 VENT TEMPERATURE SENSOR 13 RETURN TEMPERATURE SENS...

Page 11: ...freeze 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 materials and service clearances See Table 2 and figure 4 1 Multiple Boilers can be wall mounted placed side by side or back to back TABLE 2 BOILER CLEARANCES Dimension Combustible Materials 1 Serv...

Page 12: ...e figure 4 2 Boiler includes 4 3 8 x 3 lag screws 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 with wall mount bracket Avoid overhang on sides of wall mount bracket Verify boiler bracket is centered on wall bracket See figure 4 2 WARNING Fire e...

Page 13: ...cycle 5 3 Safety Relief Valve NOTICE Boiler rated at 150 psig 1 03 MPa maximum allowable working pressure Boiler provided with 30 psig 206 kPa safety relief valve Field source safety relief valve for system pressures greater than 25 psig Temperature Pressure Gauge satisfactory for 60 psig operation Field source temperature pressure gauge for system pressures greater than 60 psig Install safety rel...

Page 14: ...ntral heating pumps Boiler control allows domestic hot water prioritization Function could be lost if central heating pump not directly connected to control system Multiple boiler system See figures 5 8A B C for general guidance Additional considerations Control system requires equivalent water temperatures entering each boiler to properly sequence and adjust system supply temperature Install mult...

Page 15: ...and Pipe System Return System Supply No Valves 12 Max Air Vent Safety Relief Valve LWCO Pipe to condensate drain System Supply System Return MINIMUM ACCEPTABLE HEIGHT FOR LWCO PROBE Air Vent LWCO Safety Relief Valve Safety Relief Valve System Supply System Return No Valves 12 Max MINIMUM ACCEPTABLE HEIGHT FOR LWCO PROBE MINIMUM ACCEPTABLE HEIGHT FOR LWCO PROBE MINIMUM ACCEPTABLE HEIGHT FOR LWCO PR...

Page 16: ...ned System With Zone Valves figure 5 8A With Zone Pumps Not Shown Primary Secondary Pumping Without DHW Tank figure 5 8B With DHW Tank figure 5 8C NOTICE Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdiction NOTICE Arrange piping to prevent water dripping onto boiler Primary Loop Equivalent Leng...

Page 17: ...es FIGURE 5 6 Single Boiler Primary Secondary Two Pipe Zoned System With Zone Pumps DHW Pump CH System Pump DHW Pump Zone Pump 5 HYDRONIC PIPING Primary Loop Equivalent Length Calculation Pump Selections may be found on pages 84 thru 87 of this manual P N 2400010616 Rev F 10 26 2015 ...

Page 18: ...ndary Pumping FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With DHW Tank CH System Pump closely spaced tees in primary system loop Limit length to 5 1 6m 12 305mm Maximum separation Limit length to 5 1 6m 5 HYDRONIC PIPING Primary Loop Equivalent Length Calculation Pump Selections may be found on pages 84 thru 87 of this manual P N 2400010616 Rev F 10 26 2015 ...

Page 19: ...ves See Multiple Boiler Guide 5 HYDRONIC PIPING P N 2400010616 Rev F 10 26 2015 Up to 16 boilers DHW Pump See Multiple Boiler Guide CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system Limit length to 5 1 6m ...

Page 20: ... 5 HYDRONIC PIPING P N 2400010616 Rev F 10 26 2015 Closely spaced tees in primary system loop 12 305mm Maximum Separation Up to 16 boilers CH System Pump System Temperature Sensor Size common piping per maximum heat capacity of entire system Limit length to 5 1 6m ...

Page 21: ...Tank Closely spaced tees in primary system loop CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system Limit length to 5 1 6m 5 HYDRONIC PIPING P N 2400010616 Rev F 10 26 2015 Up to 16 boilers ...

Page 22: ...so appliances will operate continuously Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use flame of match or candle smoke from cigarette cigar or pipe Determine each appliance remaining connected to common venting system properly vents when tested as outlined above Then return doors windows exhaust fans and any other gas burning appliance to their previous ...

Page 23: ...Max 50 ft 15 2 m 100 ft 30 5 m 100 ft 30 5 m Table 5 Combustion Air and Vent Piping Length For Example Boiler can be installed on outside wall and vented with one 90 elbow and 1 ft 0 30 m of vent pipe Table 6 Equivalent Length of Venting Components Equivalent Length of Venting Components Component Feet Meters 90 Elbow 5 1 6 45 Elbow 3 1 1 2 x 4 Adapter 0 0 3 x 4 Adapter 0 0 Concentric Vent Kit 5 1...

Page 24: ...h Air Roof Single Pipe Figure 6 10 Side Wall Two Pipe Figures 6 2 6 3 Concentric Figures 6 4 6 5 6 6 Inside Air Single Pipe Figure 6 11 Table 7A Combustion Air Venting Locations Type Location Terminal Type Corresponding Figures Venting Flue Gas Side Wall S Terminal with 90 elbow Figure 6 2 6 3 S Terminal with 45 elbow Figure 6 12 Concentric Figure 6 4 6 5 6 6 Concentric with accelerator Figure 6 1...

Page 25: ...f different appliances 15 381mm Max horizontal length of vent Min vent intake between different appliances 12 305mm Max allowable total vertical vent length with outside exposure is 10 ft 3 05m Abandoned unused masonry chimney may be used as chaseway for combustion air and vent Both combustion air and vent pipe must exit above top of chimney with clearances as shown in figure 6 1 FIGURE 6 1 Two Pi...

Page 26: ...g strap 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 76 mm Diameter PVC intake combustion air Combustion Air 2 51mm Diameter 41 Length 1 1m 3 77mm Diameter 47 Length 1 2m Note Overall length may be modified by cutting or extending both combustion air and vent pipes 12 305mm is minimum allowable length and 60 ...

Page 27: ...el 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 305mm 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 obstructed Doors Windows Combustion air and v...

Page 28: ...as shown in Fig 6 14 does not have a max separation requirement between flue gas and fresh air FIGURE 6 14 Side Wall Venting Terminal w T Terminal Combustion Air Vent w Accelerator 1 25 4mm Max Separation Vent w T Terminal 12 305mm Min Separation of Combustion Air and Vent shall be maintained No Maximum separation is required when using T Terminal for vent See Snow Ice Page 26 See Snow Ice Page 26...

Page 29: ...ense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas 12 305mm Min Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termination Less than 10 3m Min 3 0 9m Min FIGURE 6 15 FIGURE 6 16 FIGURE 6 17 6 7 Side Venting Terminal Requirements USA National Fuel Gas Code ANSI 223 1 NFPA 54 Canada Natural Gas and Propane Installation ...

Page 30: ...ecirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkways Locate vent termination minimum 7 2 1m above any public walkway with consideration to condensate Meters Regulators deck porch Vent termination US only 4 1 2m Canada 6 1 9m horizontally from no case above or below ele...

Page 31: ...oiler and field sourced piping to condensate drain at bottom of boiler See figure 6 20 Slope condensate 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 authority having jurisdiction or for environmentally friendly condensate disposal FIGURE 6 20 Condensate Drain C...

Page 32: ...cluded 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 Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fire department Gas Supply Pressure MODEL Natural Gas Propane Min Max Min Max 050 3 0 w c 0 7 kPa...

Page 33: ...ncorrosive 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 ignition source Correct leaks immediately and retest Supplied Manual Main Gas Shutoff Valve shown in open position FIGURE 7 3 Gas Shutoff Valve OPEN PARALLEL TO PIPE DANGER Fire Hazard Do not use matches candles open flames o...

Page 34: ...le current draw See Figure 8 3 and Table 9 B Connect pump to line voltage terminal strip DHW PUMP L N G Primary Pump A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figure 8 3 Table 9 B Connect pump to line voltage terminal strip primary pump L N G 8 4 External Connections figure 8 4 User Interface Terminals A Factory wired to USER INTERFACE terminals B Op...

Page 35: ...em control with dry contacts related 0 5 amps 120 VAC Boiler control does not provide 24 VAC power to central heating thermostat B Locate and install thermostat per manufacturer s instructions Maximum wire length is 330 ft 100m for 22 ga wire C Connect wires to CH T T terminals Wires are interchangeable Low Water Cutoff LWCO Connect LWCO switch leads to terminals provided See Figures 14 1 thru 14 ...

Page 36: ...ntil boiler resets Do not open gas shutoff valve until all air is purged from system 9 2 Fill Condensate Trap with Water Remove spring tension clip from clear hose attached to barbed fitting at bottom of boiler chassis See figure 9 1 Disconnect hose from barbed fitting Remove barbed fitting from boiler Attach supplied condensate trap to barbed fitting using pipe tape Fill trap through fitting with...

Page 37: ... Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Required Low Water Cutoff Field Supplied Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminder Days 365 Days 1 999 Days CH Settings CH Mode 1 0 1 2 3 Warm Weather Shutdown 70 F 21 C 35 100 F 2 38 C Reset Curve Design Temperature Boiler 180 F 82 C 60 195 F 40 91 C Reset Curve Design Temperature Outdoor 2...

Page 38: ...eating zones to dissipate heat Set boiler on high fire Use 1 or 2 cu ft dial on gas meter Measure time required for two or more complete revolutions Measure time for one or more minutes Calculate input For Natural Gas Input MBH 3600 x cu ft seconds Example Natural Gas Gas flow from Meter 2 cu ft Measured time 72 seconds Rate MBH 3600 x 2 cu ft 100 MBH 72 seconds For Propane LP Input MBH 9160 x cu ...

Page 39: ...esign Target μA Natural Gas 9 0 9 5 9 5 200ppm 6 5 7 5 Propane 10 0 11 0 11 0 3 Switch to LOW fire in boiler System Test On user interface push Enter HIGH power starts flashing Scroll down to Low Power Push Enter Low Power stops flashing and becomes solid Boiler is now locked in LOW fire Adjust Offset Screw slowly and in small steps no more than 1 8 of a turn each time See Figures 9 3 and 9 4 Perf...

Page 40: ...00 MBH White Plastic Offset Screw Is Located Under The Aluminum Cap 4 See Figure 9 4 for location of Offset Screw on modulating gas valve of various boiler models T40 male Torx bit is necessary for removal of Offset Screw cap and adjustment of Offset Screw 5 Set boiler to High Power using System Test to confirm combustion in High Fire Step 2 6 Combustion setting is now complete A Exit System Test ...

Page 41: ...E Combustion Analyzer Port Shown 50 75 100 Model FIGURE 9 7 Control Module J7 Connector J7 CONNECTOR 9 7 Complete Start Up Procedure 1 Reset control parameters to operating settings if adjusted to allow startup and operation test 2 Follow instructions TO TURN OFF GAS TO APPLIANCE page 42 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration C...

Page 42: ...gas shutoff valve 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 instructions on this page What To Do If You Smell Gas If you do not smell gas go to next step Turn gas shutoff valve to the open position Handle should be parallel to gas pipe Replace upper jacket panel Turn ON electrica...

Page 43: ... operating properly and are free of blockages or obstructions system 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 temperature sensor clip must be securely seated on pipe Check boiler for any sign of leaks Check field sourced low water cutoff according to relief valve manufacturer instructions Check fl...

Page 44: ...rner if it cannot be cleaned or is showing deterioration Clean heat exchanger with low pressure water spray Use flexible handle nylon brush to loosen sediment and oxide on all accessible heating surfaces of heat exchanger Take care not to get brush stuck in heat exchanger Remove any remaining loosened sediment using shop vacuum with snorkel attachment Clean condensate collector if significant debr...

Page 45: ...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 Maximum Minimum 050 50 10 46 40 95 0 075 75 15 69 60 95 0 100 100 20 91 79 95 0 150 150 30 139 121 95 0 200 200 40 185 161 95 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual ...

Page 46: ... in Release plug lock with finger remove and reconnect all 7 plugs Check wiring from User Interface to Low Voltage Terminal Strip including checking continuity of wires Does User Interface Display work Remove User Interface from base Using Digital Voltmeter check for 25 to 30 Vdc Is voltage present Does display show Standby No Demand There is no call for heat or hot water Check thermostat Outdoor ...

Page 47: ... High Temperature opens during normal operation Go to Page 53 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas valve opens Replace Gas Valve Control module internal error Replace Control Module Lost flame signal 3 times during one heat call Go to Page 54 Control Module internal error Replace Control Module Control Module int...

Page 48: ...ge 58 Boiler power supply ground wire is not grounded Go to Page 59 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replace Control Module Supply temperature sensor is open No continuity Go to Page 59 Return water temperature sensor is open No continuity Go to Page 60 Flue temperature sensor is open No continuity Go to Page 61 Supply w...

Page 49: ...alve and J13 connector on Control Module NO YES Disconnect J13 connector on gas valve Measure resistance across top and bottom pins 1 5 Is resistance between 1 0 and 1 2 kΩ NO YES Disconnect harness from Gas Valve Does each wire have continuity between Gas Valve and Control Module NO YES Is supply pipe copper pipe at top of boiler hot NO YES Boiler has been dry fired System has too much air Close ...

Page 50: ...50 13 TROUBLE SHOOTING P N 2400010616 Rev F 10 26 2015 ...

Page 51: ...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 between two pins on sensor two pins connected to two pink wires Is continuity available YES NO Check for loose connections on two pink wires on J13 connector supply sensor and safety temperature switch ...

Page 52: ...52 13 TROUBLE SHOOTING P N 2400010616 Rev F 10 26 2015 ...

Page 53: ...y from J13 6 to Switch 3 continuity of the two purple wires Disconnect harness from High Temperature Supply Switch and Control Module J13 Check continuity of both purple wires Continuity available for both purple wires 13 TROUBLE SHOOTING See Thermistor Resistance Chart Page 63 of this manual P N 2400010616 Rev F 10 26 2015 ...

Page 54: ... 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 operation Enter Installer Menu Boiler Status Flame Signal Is flame signal greater than 3 7µA Boiler may be running at any firing rate YES NO Replace Control Module Replace Flame Sensor and Burner 13 TROUBLE SHOOTING P N 2...

Page 55: ... connector is connected Verify continuity between low voltage terminal strip LWCO connections and J16 1 and J16 4 Continuity Disconnect LWCO from low voltage terminal strip Check for continuity through LWCO safety circuit Continuity Check LWCO per manufacturer s instructions repair or replace NO YES Replace Wire Harness NO YES Replace Control Module P N 2400010616 Rev F 10 26 2015 ...

Page 56: ...ging 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 flue temperature reading on User Interface significantly different YES NO 3 B l o c k i n g E r r o r F l u e G a s E r r o r 13 TROUBLE SHOOTING E 39 P N 2400010616 Rev F 10 26 2015 ...

Page 57: ... water or antifreeze solution NO Is Primary Pump properly oriented YES NO Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 to 33 000 ohms Install Primary Pump in proper orientation YES NO Replace Control Module Verify order of pins on J2 Pin order should be empty black or red white green Measure volts on pins of black wire and white w...

Page 58: ...t 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 blower motor system Check wire connector to blower Check connector J9 on control board Is any connection loose YES NO Replace blower motor Does this correct the problem YES NO Boiler is operating properly Replace Co...

Page 59: ...K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Supply Water Sensor Resistance Chart Disconnect field wiring Is continuity between field wiring neutral and ground less than 10 ohms Is field grounding conductor connected to High Voltage Terminal Strip 120 VAC G NO YES _ P _ _ _ Blocking Error E 4 6 Faulty ground Connect ground conductor YES NO Correct faulty ground conductor Replace Control M...

Page 60: ...th digital meter Estimate Sensor temperature Do temperature and resistance fall within ranges shown in 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 to 9K ohms 54 to 66 32 to 54 66 to 94 Return Temperature Sensor Resistance Chart YES NO Insert Harness YES NO YES NO Measure Return Temperature Sensor resistance with...

Page 61: ...esistance Chart Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Does temperature fall within ranges shown in chart See Thermistor Resistance Chart Page 63 of this manual P N 2400010616 Rev F 10 26 2015 ...

Page 62: ...l 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 Flue Sens Shorted Replace Vent Temperature Sensor 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 to 9K ohms 54 to 66 32 to 54 66 to 94 Vent Temperature Sensor Re...

Page 63: ...10 50 22790 15 59 18290 20 68 14770 25 77 12000 30 86 9805 35 95 8055 40 104 6653 45 113 5524 50 122 4809 55 131 3863 60 140 3253 65 149 2752 70 158 2337 75 167 1994 80 176 1707 85 185 1467 90 194 1265 95 203 1095 100 212 952 Thermistor Resistance Chart P N 2400010616 Rev F 10 26 2015 ...

Page 64: ...64 14 1 Connection Diagram 050 075 100 MBH 14 WIRING DIAGRAM P N 2400010616 Rev F 10 26 2015 ...

Page 65: ...65 14 2 Schematic Diagram of Ladder Form 050 075 100 MBH 14 WIRING DIAGRAM P N 2400010616 Rev F 10 26 2015 ...

Page 66: ...66 14 3 Connection Diagram 150 200 MBH 14 WIRING DIAGRAM P N 2400010616 Rev F 10 26 2015 ...

Page 67: ...67 14 4 Schematic Diagram of Ladder Form 150 200 MBH 14 WIRING DIAGRAM P N 2400010616 Rev F 10 26 2015 ...

Page 68: ...eat 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 plant fibers or other materials capable of being ignited and burned Such material shall be considered combustible even though flame proofed fire retardant treated or plastered CONDENSATE Liquid separated from flue ...

Page 69: ...d 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 in event source of ignition fails SEDIMENT TRAP Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve VENT Passageway used to convey flue gases from appliance vent conne...

Page 70: ...ue 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 Open D DHW Pump On Service Reminder Indicator Boiler in Standby Mode Boiler Supply Water Temperature Indicator Boiler Running in Central Heat mode Combustion Air Blower Speed Indicator Boiler Running in DHW mode Lockou...

Page 71: ...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 Blower speed modulates to pre purge setting for 15 seconds Sparking initiated sequence Heat Demand DHW CH Pump on Supply Temperature Setpoint 15 Second Prepurge Ignition Sparking No Yes No Yes After 2 seconds APPENDIX A CONTRO...

Page 72: ...g 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 Priority mode limits amount of time boiler can run in DHW mode to meet CH demand Max DHW Priority Time setting determines maximum time allowed for DHW heating mode Please refer to section Appendix A section 1 5 for more ...

Page 73: ...iple boiler installation submenu used to view runtime parameters See Multiple Boiler Manual This line is not shown if boiler is not in cascade system Boiler Status Supply Temperature set point displayed If boiler running in CH mode CH set point displayed Note While running in Outdoor Reset mode this value may change in proportion with the outdoor temperature If the boiler is running in DHW mode th...

Page 74: ...point 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 in Installer Menu Setting Range 104 F to 195 F 40 C to 91 C Default Value 180 F 82 C DHW set point determines supply water temperature set point while operating in DHW mode User interface temperature unit...

Page 75: ...omestic hot Water control settings such as DHW priority time Cascade Settings 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 Vent systems Fan speed status screen indicates actual and operational fan speeds in RPM high low and ignition power speed settings ...

Page 76: ... 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 3 after which lockout occurs Intermittent Operation Boiler can be firing continuously for 24 hours Burner switched off and restart sequence follows Flame out too late If flame detected after post purge lockout follows Saf...

Page 77: ...on 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 operating in single boiler mode Boiler incorporates integrated Low Water Cutoff device LWCO that disables boiler when low water condition exists LWCO device located at high point of internal Heat Exchanger loop to dete...

Page 78: ...stem 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 DHW indirect tank Note Pump Mode selection depends on electrical and hydronic system design Please refer to sections 5 and 8 for recommended hydronic piping and electrical configurations Internal heat exchanger pum...

Page 79: ...r Shutdown temperature Boiler will permanently attempt to satisfy CH demand when CH demand is available CH thermostat input is ignored CH set point calculated as function of outdoor temperature using outdoor reset curve See figure A 2 CH Mode 3 CH with Permanent Demand CH demand is permanently on Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point is ad...

Page 80: ... Curve below Calculated CH set point always limited between Reset Curve Boiler Minimum Maximum temperatures See points C D of Reset Curve below Figure A 2 Outdoor Reset Curve Calculated supply temperature follows thick black line in graph below based on outdoor temperature Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor detected CH set point equal to Boile...

Page 81: ...tting 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 Thermostat Boiler reacts to DHW demand when DHW thermostat input closes Boiler modulates to meet DHW demand similar to CH Mode except DHW set point is used DHW set point set in Settings submenu found in User Menu Simult...

Page 82: ...esent 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 are available Disabled Low power Burner starts After ignition period has finished the burner stays at low power Ignition power Burner starts Stays at ignition power High power Burner starts After ignition period has...

Page 83: ...ie This harness will not be required when mounting user interface outside of boiler 7 Before installing user interface in new location route new two conductor wire through hole in back of user interface base Connect the wires to terminal block This connection is not polarity sensitive 8 Install user interface base in new location using appropriate field sourced screws 9 Install user interface on t...

Page 84: ... The figures below are based on industry average Consult valve fitting manufaturer for exact equivalent length or for fittings not shown below Chart 1 A B C Pipe Diameter Fitting Enter Number Of Fittings Multiply By Equivalent Length A x B 3 4 90 Elbow 1 875 45 Elbow 1 Tee branch 3 75 Tee through 1 25 Swing check valve 6 25 Lift check valve 37 5 Enter Total 3 4 straight pipe length in feet Add up ...

Page 85: ...ter Total 1 straight pipe length in feet Add up numbers in column C Total equivalent length of Primary Multiply Total of Column C in Chart 3 by 0 088 Pump Factor Chart 4 Total Equivalent Length of 3 4 Pipe Loop L ft Pump options Minimum From To Grundfos Taco B G 0 15 UP 15 42 Taco 008 NRF 22 16 40 UP 26 64 Taco 0014 NRF 45 speed 3 41 80 UP 26 99 Taco 0013 NRF 36 speed 3 Note If the heating system ...

Page 86: ...re based on industry average Consult valve fitting manufaturer for exact equivalent length or for fittings not shown below Chart 1 A B C Pipe Diameter Fitting Enter Number of Fittings Multiply By Equivalent Length A x B 1 90 Elbow 2 5 45 Elbow 1 3 Tee branch 5 0 Tee through 1 7 Swing check valve 8 3 Lift check valve 50 0 Enter Total 1 straight pipe length in feet Add up numbers in column C Total e...

Page 87: ...ft check valve 75 0 Enter Total 1 straight pipe length in feet Add up numbers in column C Total equivalent length of Primary Multiply Total of Column C in Chart 3 by 0 15 Pump Factor Chart 4 Total Equivalent Length of Primary Pump options Minimum From To Grundfos Taco B G 0 20 UP 26 99 Taco 0013 NRF 36 speed 3 21 35 UP 26 116 Taco 2400 20 PL 36 Note If the heating system uses antifreeze solution 3...

Page 88: ...an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is pa...

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