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UTICA BOILERS UB90 125 Installation, Operation & Maintenance Manual Download Page 39

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Troubleshooting Chart 5

TROUBLESHOOTING

Summary of Contents for UB90 125

Page 1: ... 11 UB90 125 200 GAS FIRED DIRECT VENT CONDENSING HOT WATER BOILER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company Utica Boilers 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

Page 2: ...potential hazards of varying risk levels KEEP THIS MANUAL NEAR BOILER AND RETAIN FOR FUTURE REFERENCE NOTICE Indicates information which should be followed to ensure proper installation and operation Safety Symbols 2 Rules For Safe Installation And Operation 3 Boiler Ratings Capacities 4 Before Installing The Boiler 5 Placing The Boiler 9 Near Boiler Piping 10 Combustion Air And Vent Pipe 13 Gas S...

Page 3: ...nents This may cause dangerous operation Under firing may result in too much air for the pre mix burner causing poor or loss of combustion Never vent the products of combustion from this boiler 5 to an enclosed space Always vent to the outdoors Never vent to another room or to inside a building Be sure there is adequate outdoor air supply to boiler 6 for complete combustion Follow a regular servic...

Page 4: ... 196 500 172 400 172 200 147 800 147 400 123 500 123 000 2 000 194 000 193 000 169 800 169 400 145 600 144 800 122 000 121 000 3 000 191 000 189 500 167 200 166 600 143 400 142 200 120 500 119 000 4 000 188 000 186 000 164 600 163 800 141 200 139 600 119 000 117 000 5 000 185 000 182 500 162 000 161 000 139 000 137 000 117 500 115 000 6 000 182 000 179 000 159 400 158 200 136 800 134 400 116 000 1...

Page 5: ...as gas fired direct vent condensing hot water boilers Heating Capacity indicates amount of heat available after subtracting losses up the stack Most of this heat is available to heat water Small portion is heat loss from jacket and surfaces of boiler it is assumed this heat stays in the structure Net I B R Rating represents portion of remaining heat applied to heat radiation or terminal units i e ...

Page 6: ...or external condensate pump with reservoir at per foot 21 mm m wood frame or blocks may be used to raise boiler Locating The Boiler Select location which is level central to piping systems 1 served and as close to vent and air intake terminals as possible Accessibility clearances if more stringent i e larger 2 clearances than required fire protection clearances must be used for boiler installation...

Page 7: ... dripping spraying rain etc during operation and service circulator replacement condensate trap control replacement etc Boiler must be located where ambient temperatures 8 minimum possible room temperatures where boiler is installed assuming boiler is not in operation and therefore contributes no heat to space are always at or above 32 F 0 C to prevent freezing of liquid condensate Combustion Air ...

Page 8: ...lated with 1 2 armaflex or equivalent In extremely cold climate areas use 3 4 armaflex or equivalent Combustion air must be clean outdoor air Combustion air must not be taken from inside structure because that air is frequently contaminated by halogens which include fluorides chlorides phosphates bromides and iodides These elements are found in aerosols detergents bleaches cleaning solvents salts ...

Page 9: ...ate at maximum speed Do not operate a summer exhaust fan Close fire dampers Place in operation the appliance being inspected 4 Follow the lighting instructions Adjust thermostat so appliances will operate continuously Test for spillage at the draft hood relief opening after 5 5 minutes of main burner operation Use the flame of a match or candle or the smoke from a cigarette cigar or pipe After it ...

Page 10: ...ons U S Size expansion tank accordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished as shown in Figure 6 for diaphragm type expansion tank For diaphragm type expansion tanks adjust the tank air pressure to match the system fill pressure Install air vent furnished as shown for diaphragm type expansion tank system only Install...

Page 11: ... Single Zone Boiler Piping Figure 9B Multi Zone Boiler Piping With Zone Valves Figure 9A Multi zone Boiler Piping with Circulators Individual boiler discharge piping shall be independent of other discharge piping Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Run pipe as short and straight as pos...

Page 12: ...a use CSA or ULC certified schedule 40 PVC drain pipe and cement Condensate pump with reservoir not furnished may be used to remove condensate to drain line sanitary line above boiler if floor drain is not available or is inaccessible Filling Condensate Trap With Water NOTICE On initial start up the condensate trap must be manually filled with water Following are steps required to initially fill c...

Page 13: ...is unit of CSA or ULC certified schedule 40 CPVC schedule 40 PVC PVC DWV or ABS DWV pipe and pipe cement SDR pipe is NOT approved in Canada For Canadian installations all plastic venting material must be listed to ULC S636 Combustion air and vent piping connections on boiler 3 are 2 but must increase to 3 Due to potential for flue gas temperatures over 155 F first 5 feet of vent pipe must be CPVC ...

Page 14: ...ere vent vapors will not damage plants shrubs air conditioning equipment or siding on the house Termination should be positioned so that it will not be effected by wind eddy air born leaves snow or recirculated flue gases Termination should be positioned where it will not be subjected to potential damage by foreign objects such as stones balls etc Termination should be positioned where vent vapors...

Page 15: ...ty having jurisdiction or in the absence of such requirements United States National Fuel Gas Code ANSI Z223 1 NFPA 54 Canada Natural Gas and Propane Installation Code CAN CSA B149 1 Use pipe joint compound suitable for liquefied 2 petroleum gas on male threads only Use ground joint unions 3 Install sediment trap upstream of gas controls 4 Use two pipe wrenches when making connection to 5 gas valv...

Page 16: ...located on exterior boiler jacket See Figure 13 for diagram showing location of service switch junction box and power supply connection points Connect black hot lead from power supply to either of unused brass screws on service switch Connect white neutral lead from power supply to white screw on service switch Connect green ground lead from power supply to ground green screw on service switch Rec...

Page 17: ...ctions If the two 120 volt circulator wire terminals inside the junction box are not used please leave the two wire nuts to prevent the short circuit CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Run 14 gauge or heavier copper wire from boiler to grounded connection in service ...

Page 18: ...6 BLOWER G 2 4 3 1 P5 W BK CASTING TEMPERATURE SAFETY SWITCH MANUAL RESET BR BL W V BR SET AT 3 5 WC SWITCH N C AIR PRESSURE DIFFERENTIAL CONTROL HI LIMIT AQUASTAT SET AT 0 5 WC BL BR AIR PRESSURE DIFFERENTIAL SWITCH N O V CIRCULATOR 2 4 3 1 P4 9 3 6 Y 24 VAC SECONDARY TRANSFORMER 1 4 7 8 5 2 BR CONTROL P3 1 2 V 1 3 P2 Y 2 Y 1 1013 10 INTEGRATED BOILER CONTROL W BK NOTE USE COPPER CONDUCTORS ONLY ...

Page 19: ... 3K 5K GAS VALVE 4K1 3K1 P3 5 24 VAC 4 5 P2 2 P3 2 BLOWER P5 1 1K1 P10 1 2K1 P7 1 P4 1 TRANSFORMER P1 1 120 VAC 3 P1 3 1 HOT SURFACE IGNITER P12 1 P6 1 5K1 P12 2 5K2 P6 2 P10 3 CIRCULATOR FIELD WIRED P5 3 P10 2 P7 3 P4 3 P7 2 NOTE USE COPPER CONDUCTORS ONLY ON OFF BLK HOT L1 WHT L2 SWITCH 120 VOLT POWER SUPPLY NOTE If any of the original wire as supplied with this appliance must be replaced it mus...

Page 20: ...igure 16 will blink indicating the failure mode as a lack of flame signal The IBC is manually reset from lockout by either removing and reestablishing the thermostat s call for heat or by turning the service switch off then back on High Limit Aquastat Control The high limit aquastat control determines the maximum boiler water temperature and also provides a means for protecting the boiler and heat...

Page 21: ... valve discharge must be piped with the same size as the valve discharge opening to an open drain tub or sink or other suitable drainage point not subject to freezing in accordance with A S M E specifications Failure to provide the pressure relief valve with piping as herein described may cause water damage and or serious bodily injury The boiler manufacturer is not responsible for any water damag...

Page 22: ... type 356 T6 aluminum Use of incompatible antifreeze could damage the heat exchanger and will void the product warranty Antifreeze must be maintained per specifications of manufacturer Failure to do so will result in warranty being voided Follow antifreeze manufacturer s instructions on determining proper ratio of antifreeze to water for expected low temperature conditions and for maintaining anti...

Page 23: ...t turn by hand do not try to repair it call a qualified service technician Force or attempted repair may cause fire or explosion Do not use this appliance if any part has been under 4 water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Operating Instructions STOP 1 Read the safet...

Page 24: ...y piping section in this manual Check for orifice in negative pressure hose at gas valve and 2 air intake pipe upstream of 3 gas valve Relight boiler 4 If boiler still does not light the air inlet pipe may need to be disconnected to allow the 5 boiler to start in order to verify the boiler firing rate and combustion properties The inlet air pipe can be disconnected by removing the pvc inlet air pi...

Page 25: ...on port on the boiler A z B C z D E 6 After the igniter warm up period the integrated boiler control energizes the gas valve initiating a 6 second trial for ignition mode which is indicated by the illumination of Lamp D Two seconds later Lamp C will extinguish when the integrated boiler control stops sending power to the hot surface igniter A z B C z D z E 7 A low level illumination of Lamp E indi...

Page 26: ... manual reset high limit or additional safety controls test for operation as outlined by the control manufacturer Burner should be operating and should go off when controls are tested When safety controls are restored burner should reignite Set Thermostat Heat Anticipator If Used And Verify Thermostat Operation For a single thermostat connected to the yellow thermostat lead wires in the furnished ...

Page 27: ...re should read between 4 and 10 w C For natural gas and between 10 and 14 w c For propane gas Drill a hole in the plastic CPVC combustion analyzer 2 Turn the thermostat to the closed position so the appliance is activated 3 Allow the appliance to run for approximately 5 minutes 4 Insert the sample probe of your combustion analyzer into the hole you drilled in step 2 above about 5 halfway into the ...

Page 28: ...eakage and tighten G bolts or replace gaskets if necessary Remove jacket front and top panels and check for H piping leaks around relief valve and other fittings Repair if found DO NOT use stop leak compounds Check that boiler area is free from combustible 2 materials gasoline and other flammable vapors and liquids Circulator pump and blower motor furnished with 3 boiler are permanently lubricated...

Page 29: ...praying or running water Use a flexible handle nylon brush to loosen I sediment and aluminum oxide on all exposed heating surfaces of boiler see Repair Parts Manual for diagram Be sure that brush does not get stuck in heat exchanger After brushing and rinsing remove any remaining J loosened sediment using a shop vacuum with a snorkel attachment Inspect burner for any foreign matter in the flame K ...

Page 30: ...30 SERVICE HINTS DETAILED SEQUENCE OF OPERATION ...

Page 31: ...ontrol will attempt to relight boiler 3 times if flame is not proven control lockout problem establishing a flame signal Valve light is blinking Control will automatically reset after 1 hour HIGH LIMIT CONTROL if boiler water temperature reaches high limit aquastat setpoint high limit n c contacts open immediately closing gas valve Valve and flame lights go out Draft inducer continues to run for 3...

Page 32: ...at Gas valve and circulator pump are de energized valve and flame lights go out Blower runs for 30 seconds post purge purge light is on Blower is de energized after 30 seconds purge light shuts off Boiler stand by for next call for heat DETAILED SEQUENCE OF OPERATION ...

Page 33: ...evere injury or death Do not attempt to modify the physical or electrical characteristics of this boiler in any way NOTICE In a reset from lockout condition all electrical meter readings at the gas control valve 24 vac must be taken within the trial for ignition period If any component dose not function properly make sure it is correctly installed and wired before replacing it Static electricity d...

Page 34: ...FF Off during purge cycle draft inducer is not powered on or air flow is not proven Off during igniter and run cycle normal operation purge cycle complete Blinking IBC is locked out Problem could indicate false positive proof of air flow Blocked vent intake air pipe flue way or orifice in negative pressure hose IGNITER ON IBC is energizing igniter OFF Igniter is not energized VALVE ON IBC is energ...

Page 35: ...the gas supplier s instructions If you can not contact your gas supplier call the fire department Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas at a location external to the appliance Do not use the boiler if any part of the gas control system has been under water A qualified service technician s...

Page 36: ...36 Troubleshooting Chart 2 TROUBLESHOOTING ...

Page 37: ...R SAGS OR LOW SPOTS WHERE CONDENSATE MAY PUDDLE AND BLOCK THE VENT YES CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY NO CLEAN OUT SAMPLING LINES OR REPLACE DEFECTIVE SWITCH YES CHECK FLUE PASSAGES IN BOILER PER MAINTENACE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN NO CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCT...

Page 38: ...ER LIGHT CHECK FOR 24 VAC ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON NO NO CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT NO REPLACE IBC YES REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL YES CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER RESTORE IGNITER SENSOR TO CORRECT POSITION DO NOT ...

Page 39: ...39 Troubleshooting Chart 5 TROUBLESHOOTING ...

Page 40: ...FIC INSTRUCTIONS REQUIRES SPECIFIC TOOLS NO YES REPLACE BURNER REPLACE IBC BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT AQUASTAT CONTACTS CLOSED NO BOILER OFF ON HIGH LIMIT IS ACTUAL BOILER WATER TEMP GREATER THAN HI LIMIT SET POINT MINUS 30 F CONTROL DIFFERENTIAL NO NO REPLACE AQUASTAT OK YES SEE TROUBLESHOOTING PATH 2 ABOVE CHART 5 NO 3 CHART 5 YES SET THERMOSTAT BELOW ROOM TEMPERAT...

Page 41: ...es Blockage or moisture in suction lines to switch Blockage or moisture in orifice installed in suction lines to switch Blockage in air intake or vent pipes Undersized air intake or vent pipes Loose blower wheel on motor shaft Incorrect pressure switch or pressure switch set point Gas valve out of adjustment When the pressure reading corresponds to the chart 6 at right and the pressure switch is o...

Page 42: ...42 This Page Intentionally Left Blank ...

Page 43: ...nd Service issues reviewed with owner maintenance person Installation booklet affixed on or adjacent to boiler Installer Company __________________________________________ Address ___________________________________________________ Phone _____________________________________________________ Installer s Name _____________________________________________ Signature ___________________________________...

Page 44: ...UTICA BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

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