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

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• ANSI

- American National Standards Institute,

Inc. oversees creation and maintenance of voluntary

consensus standards, including ANSI Z21.13/CSA 4.9: Gas-

Fired Low Pressure Steam and Hot Water Boilers.

• ASTM

- American Society for Testing and Materials.

ASTM International is one of largest voluntary standards

development organizations in world trusted source for

technical standards for materials, products, systems, and

services. Known for their high technical quality and market

relevancy, ASTM International standards have important

role in information infrastructure that guides design,

manufacturing and trade in the global economy.

• AUTHORITY HAVING JURISDICTION

Individual or

organization adopting and enforcing codes, rules, and by-

laws governing various concerns of community. Commonly

referred to as "final authority" for any matters relating

to LIFE SAFETY and BUILDING CONSTRUCTION within a

community.

• Btu

- Abbreviation for British Thermal Unit. Quantity of heat

required to raise temperature of 1 pound of water 1°F.

• BURNER

- Device for final conveyance of gas or mixture of

gas and air, to combustion zone.

• COMBUSTION

- Rapid oxidation of fuel gases accompanied

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, 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 gas due to

reduction in temperature.

• DIRECT VENT BOILER

- Boiler constructed and installed so

all combustion air is derived directly from outdoors and all

vent gases are discharged to outdoors.

• DRAFT

- Pressure difference causes gases or air to flow

through a chimney, vent, flue or appliance.

• FLA

- Full load amps.

• FLUE GASES

- Products of combustion plus excess air in

appliance flues or heat exchanger.

15 - GLOSSARY

• HIGH-VOLTAGE

- Circuit involving potential of not more

than 600 volts and having circuit characteristics in excess of

those of low-voltage circuit.

• IGNITER

- Device utilizing electrical energy to ignite gas at

main burner.

• LEAK CHECK

- Operation performed on gas piping system

to verify system does not leak.

• LOW WATER CUTOFF

- Device constructed to automatically

cut off fuel supply when surface of water in boiler falls to

lowest safe water level.

• LOW-VOLTAGE

- Circuit involving potential of not more

than 30 volts.

• METRIC GAS METERS
Natural Gas

MBH

127,116 x cu meters
Seconds

For example: Gas Meter measures 0.1 cubic Meters in 100

seconds

MBH

127,116 x 0.1

= 127 MBH

100

Propane Gas (LP)

MBH

383,482 x cu meters
Seconds

• PRESSURE TEST

- Operation performed to verify gas

tight integrity of gas piping following its installation or

modification.

PN 240011320 Rev. G 10/01/2021]

Summary of Contents for UBSSC-050

Page 1: ...AINTENANCE MANUAL Models UBSSC 050 UBSSC 075 UBSSC 100 UBSSC 150 UBSSC 200 UBSSC 299 050 075 100 SIZE SHOWN Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com PN 240011320 REV G 10 01 2021 ...

Page 2: ... 4 ea Safety Relief Valve w 3 4 Tee 3 4 Nipple 3 4 x 1 4 Elbow and Air Vent Temperature Pressure Gauge w 3 4 x 1 4 Bushing 3 4 Nipple 1 x 5 4 Tee Used for electrical wire knockouts Used for packaging holes on back of boiler Used for packaging holes on back of boiler Drain Valve 3 4 3 4 Tee 3 4 Tee Bushing 7 8 OD Heyco 2 ea Stopper Rubber 5 16 2 ea Plastic Plug 2 ea Used for measuring outside tempe...

Page 3: ...e Venting Terminal Requirements 30 6 8 Multiple Boiler Venting Installation 32 6 9 Condensate Piping 33 7 Gas Supply Piping 34 8 Electrical Connections 36 8 3 Line Voltage Connections 36 8 4 External Connections 36 9 Start Up Procedure 38 9 6 Perform CSD 1 Compliance Test 40 9 7 Complete Start Up Procedure 41 10 Operating Instructions 45 11 General Maintenance And Cleaning 46 12 Ratings And Capaci...

Page 4: ...nections Size F 1 1 4 NPT 1 1 4 NPT Location G 2 51mm 2 51mm 3 51mm Location H 5 127mm 3 76mm 2 6 66mm Location I 3 89mm 4 112mm 4 114mm Gas Connection Location J 4 124mm 7 197mm Size K 1 2 NPT 3 4 NPT Condensate Drain Connection L 3 4 NPT 3 4 NPT Weight Shipping 111 lb 50 kg 182 lb 83 kg 225 lb 102 kg Unit 91 lb 41 kg 157 lb 71kg 195 lb 89 kg Vent Connector 2 51mm 3 76mm PHYSICAL DATA PN 24001132...

Page 5: ...s 50 100 MBH Bottom View Connection Identification 150 299 MBH Supply Water F I H G C J PHYSICAL DATA Condensate Drain Connection L Return Water F Gas Connection K Bottom View Connection Identification 50 100 MBH Supply Water F Bottom View Dimensions 150 200 MBH I H C J Vent Connector Combustion Air Safety Relief Valve Connection NPT Top View 299 Bottom View Dimensions 299 MBH I C G J G H PN 24001...

Page 6: ...or serious injury Read this manual and understand all requirements before beginning installation 1 SAFETY INFORMATION 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 th...

Page 7: ...sign temperature 2 6 Operational Features Modulating 20 100 Integral Dual Limit Integral Low Water Cutoff with test button Outdoor Temperature Reset Integral Multiple Boiler Control Heat exchanger over heat protection 2 INTRODUCTION 2 1 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements United States National Fuel Gas Code ANSI Z223 1 NFP...

Page 8: ...ity of Delivers proper quantity of combustion air receives fuel from gas valve mixes air combustion air receives fuel from gas valve mixes air and fuel sending mixture to burner for combustion and fuel sending mixture to burner for combustion 20 Gas Control Valve Gas Control Valve Delivers Delivers proper quantity of fuel to proper quantity of fuel to Combustion Air Blower See section 7 Combustion...

Page 9: ... Jacket Removal Viewed from Bottom of Boiler 50 100 MBH shown Jacket Latch Jacket Latch Lift latch to dis engage Lift latch to dis engage Bottom of Boiler FIGURE 3 3 Jacket Removal Viewed from Left Side of Boiler 50 100 MBH shown Dis engage latch lift Dis engage latch lift jacket up and off jacket up and off jacket support jacket support Jacket Support Lip Jacket Support Lip Jacket Latch Jacket La...

Page 10: ...r To Heating System Out System Out Low Voltage Terminal Strip Low Voltage Terminal Strip Vent Temperature Sensor Gas Connection Gas Connection Combustion Analysis Test Port Combustion Analysis Test Port High Voltage Junction Box High Voltage Junction Box Heat Exchanger Heat Exchanger Boiler Control Module Fuse And Holder Igniter Igniter Flame Sensor Sight Glass Sight Glass Flue Air Mixture Pressur...

Page 11: ... Analysis Test Port Port Gas Connection Gas Connection High Voltage Junction High Voltage Junction Box Box Heat Exchanger Heat Exchanger Boiler Control Module Boiler Control Module Fuse and Holder Fuse and Holder Flame Sensor Flame Sensor Condensate Drain Condensate Drain Transformer Transformer User Interface User Interface Internal Primary Loop Internal Primary Loop Ball Valve Ball Valve Behind ...

Page 12: ...m 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 Service 1 2 Model 050 075 100 150 200 299 Top A ...

Page 13: ...wing mounting on two 2 wall studs spaced at 11 to 16 on center See 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 ...

Page 14: ...ng unit exposed to refrigerated air circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle FIGURE 5 1 Safety Relief Valve Air Vent Viewed from front of boiler Safety Relief Safety Relief Valve Valve 3 4 x 4 NPT 3 4 x 4 NPT Nipple Nipple 3 4 x 1 4 3 4 x 1 4 NPT 90 NPT 90 Elbow Elbow 3 4 F x M x 3 4 F x M x F NPT Tee F NPT...

Page 15: ... 5 2 Use or larger pipe Use pipe suitable for temperatures of 375 F 191 C or greater 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 possible to location protecting user from scaldin...

Page 16: ...ritization Function could be lost if central heating pump not directly connected to control system Multiple boiler system See figure 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 multi boiler sensor kit See Parts Kits Optional Accessories manual for...

Page 17: ...5 7A Open External Primary Loop figure 5 7B Multiple Boilers Two Pipe Zoned System With Zone Valves figure 5 8A With Zone Pumps Not Shown Primary Secondary Pumping Closed External Primary Loop figure 5 8B Open External Primary Loop figure 5 8C 5 HYDRONIC PIPING Note Illustrations are meant to show system piping concept only Installer responsible for all equipment and detailing required by authorit...

Page 18: ... System With Zone Pumps DHW Pump 5 HYDRONIC PIPING 3 8 10mm Open End Wrench may be required to turn valve Heat exchanger ball valve open as shipped CH System Pump Heat exchanger ball valve open as shipped DHW Pump Zone Pump 3 8 10mm Open End Wrench may be required to turn valve PN 240011320 Rev G 10 01 2021 ...

Page 19: ...ng primary loop Internal primary loop ball valves closed Existing closely spaced tees in primary system loop Limit length to 5 1 6m 3 8 10mm Open End Wrench may be required to turn valve 12 305mm Maximum separation 12 305mm Maximum separation Existing closely spaced tees in primary system loop Limit length to 5 1 6m 3 8 10mm Open End Wrench may be required to turn valve CH System Pump Internal pri...

Page 20: ...ndary Two Pipe Zoned System With Zone Valves Up to 16 boilers DHW Pump CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system All internal primary loop ball valves closed Limit length to 5 1 6m 3 8 10mm Open End Wrench may be required to turn valve ...

Page 21: ...xisting closely spaced tees in primary system loop 12 305mm Maximum Separation Up to 16 boilers CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system All internal primary loop ball valves closed Limit length to 5 1 6m 3 8 10mm Open End Wrench may be required to turn valve ...

Page 22: ...em loop 12 305mm Maximum Separation CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system Heat exchanger ball valve open as shipped Limit length to 5 1 6m 5 HYDRONIC PIPING 3 8 10mm Open End Wrench may be required to turn valve PN 240011320 Rev G 10 01 2021 ...

Page 23: ...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 condition of use Any improp...

Page 24: ...rtified vent system components must NOT be interchanged with other vent systems or unlisted pipe fittings 6 5 Vent Termination Terminate combustion air and vent pipes with fittings or concentric vent kit A See Parts Kits and Optional Accessories manual for concentric vent kit part numbers B Use horizontal pipe for vent and 90 elbow for combustion air termination when using fittings Separate vent t...

Page 25: ...ions 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 13 T Terminal Figure 6 10 6 11 6 14 Roof Straight Terminal Figure 6 1 6 8 6 9 Concentric Figure 6 7 Combustion Air Fresh Air Side Wall Raised 90 down elbow Figure 6 2 90 down...

Page 26: ...of 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 P...

Page 27: ...in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 51mm 3 76mm or 4 102mm Diameter Intake combustion air Combustion Air 2 51mm Diameter 41 Length 1 1m 3 76mm Diameter 47 Length 1 2m 4 102mm diameter 36 Length 0 9m Overall length may be modified by cutting or extending both combustion air and vent pipes 12 305mm is minimum allowable length and 60 1 2m is maximum allowable length for this ...

Page 28: ...oors Windows Combustion air and vent termination must be 12 305mm from or below doors windows or gravity inlet See Tables 4 5 Combustion air and Vent Piping Length Page 24 6 COMBUSTION AIR AND VENT PIPING Combustion Air Roof boot flashing field supplied Support field supplied Combustion Air Vent Note Support must be field installed to secure termination kit to structure Vent Maintain 12 305mm US 1...

Page 29: ...g T Terminal for vent See Snow Ice Page 26 See Snow Ice Page 26 FIGURE 6 12 Two Pipe Side Wall with 45 Vent Vent 45 Elbow Upward 3 76mm Min 24 610mm Max Separation See Snow Ice Page 26 Combustion Air 90 Elbow Downward 12 205mm Min 24 610mm Max Separation Opening Separation 24 Min Note Configurations of single pipe vent with flue on the sidewall requires a tee as the vent terminal See figures 6 10 ...

Page 30: ...t be min 12 305mm from or below doors windows or gravity inlet If boiler uses inside air min 4 1219 mm 12 305mm Min Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termination Less Than 10 3m Minimum 3 914mm Minimum FIGURE 6 15 FIGURE 6 16 FIGURE 6 17 6 7 Side Venting Terminal Requirements of USA National Fuel Gas Code ANSI Z223 1 NFPA 54 Venting terminal from doors...

Page 31: ... 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 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 belo...

Page 32: ...individually follow guidelines as described in figures 6 1 through 6 7 If boilers vent through common vent pipes as shown in Figure 6 17 choose common vent pipe per Table 8 Choose size from Table 9 for pipes between boiler and common vent pipes Longest individual vent lengths and common vent length together must be shorter than 100 ft 30m H L 100 ft 30m See Table 9 Each boiler must have flow check...

Page 33: ...nimum 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 18 Condensate Drain 150 299 MBH shown 6 COMBUSTION AIR AND VENT PIPING Condensate Tee field installed on condensate drain pipe Do not glue...

Page 34: ...tside of jacket See figure 7 2 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler Table 10 Gas Supply Pressure 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 ...

Page 35: ...tector 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 ignition source Correct leaks immediately and retest Manual Main Gas Shutoff Valve FIGURE 7 3 Gas Shutoff Valve 050 075 100 150 200 DANGER Fire Hazard Do not use matches candles open flames or other methods providing...

Page 36: ...Hot Water Pump if used A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figure 8 3 and Table 11 B Connect pump to line voltage terminal strip DHW PUMP L N G 8 4 External Connections figure 8 4 User Interface Terminals A Factory wired to USER INTERFACE terminals B Optional Remote mount user interface for improved access Use low voltage knockout C Maximum wir...

Page 37: ...A Use thermostat or boiler system 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 FIGURE 8 4 External Connections Do not apply external voltage to...

Page 38: ...g Reset button until boiler resets Do not open gas shutoff valve until all air is purged from system 9 2 Fill Condensate Trap with Water Disconnect spring tension 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 Reconnect tubing to hose barb with spring tension clip See figure 9 1 FIGURE 9 1 Condens...

Page 39: ...t Curve Design Temperature Outdoor 25 F 4 C 60 32 F 51 25 C Reset Curve Mild Weather Temperature Boiler 100 F 37 C 35 120 F 2 49 C Reset Curve Mild Weather Temperature Outdoor 70 F 21 C 35 85 F 2 29 C Reset Curve Boiler Minimum Temperature 70 F 21 C 40 180 F 4 82 C Reset Curve Boiler Maximum Temperature 180 82 C 80 195 F 27 91 C Boost Function Temperature 0 F 0 C 0 36 F 0 20 C Boost Function Time ...

Page 40: ...ome heating 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 Input Rate MBH 3600 x 2 cu ft 100 MBH 72 seconds 9 START UP PROCEDURE For...

Page 41: ...ower 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 5 and 9 6 Perform combustion test on LOW fire using calibrated combustion analyzer Adjust CO2 to within specifications by turning Offset Screw clockwise to increase CO2 l...

Page 42: ...p 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 mode by pushing Enter High Power will start flashing B Scroll down to OFF Push Enter button OFF stops flashing C Push Menu button twice to escape Installer Manual Boiler returns to CH mode or DHW mode depending on type of ca...

Page 43: ...to system 4 Establish call for heat Jump CHW T T terminals on low voltage terminal block Turn on boiler using boiler service switch 5 Boiler will fire Based on natural convection within boiler boiler will either A Lockout A 06 Safety Relay Error Requires manual reset of control module Press reset button on User interface See 9 3 Program Boiler Control OR B Shut off burner E40 Return Water Temp Thi...

Page 44: ...w instructions TO TURN OFF GAS TO APPLIANCE page 45 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 card and other supporting information Review with user and or affix in conspicuous location adjacent to boiler 9 START UP PROCEDURE PN 240011320 Rev G 10 01 2021...

Page 45: ...pendicular 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 counter clockwise to the open position Handle should be parallel to gas pipe Replace upper jacket panel Turn ON electrical power to appliance Set thermostat to ...

Page 46: ...ith relief valve Examine flue passages in heat exchanger burner condensate lines and cleaning if necessary by following instructions in Annual Examination and Cleaning of Boiler Components in this section CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation FIGURE 11 1 Sight Glass 050 075 100 150 200 MBH DANGER Before servi...

Page 47: ...ning loosened sediment using shop vacuum with snorkel attachment Clean condensate collector if significant debris found in heat exchanger 1 Expand upper spring tension clip of condensate trap using hose clamp pliers Disconnect condensate trap from condensate collector See figure 9 1 2 Disconnect wire harness from vent temperature sensor See figures 3 4 3 5 3 Loosen upper hose clamp securing conden...

Page 48: ...o heat exchanger using 7 16 deep well socket See figures 3 5 3 6 5 Remove condensate collector assembly from heat exchanger and flue pipe 6 Flush collector and condensate trap with water Follow Burner Inspection Kit instructions to reassemble boiler and resume operation PN 240011320 Rev G 10 01 2021 ...

Page 49: ...t TABLE 14 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 0 299 299 60 273 237 95 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Effic...

Page 50: ...50 Is there power to the Boiler User Interface Lit Turn ON Power to Boiler Is User Interface Lit 13 TROUBLE SHOOTING PN 240011320 Rev G 10 01 2021 ...

Page 51: ...e High Temperature opens during normal operation Go to Page 57 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 58 Control Module internal error Replace Control Module Control Module in...

Page 52: ...2 Boiler power supply ground wire is not grounded Go to Page 63 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 63 Return water temperature sensor is open No continuity Go to Page 64 Flue temperature sensor is open No continuity Note If L indicator appear...

Page 53: ...h Gas Valve and J13 connector on Control Module NO YES Disconnect J13 connector on Control Module Measure resistance across third blue wire and fourth brown wire terminals 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 ...

Page 54: ...iler ignite and stay running pressing the Reset button When the boiler tries to ignite is there a strong consistent spark evident throught the sight glass Disconnect the gas valve electrical harness and close the gas shutoff valve YES YES Remove the flame 14 sensor and igniter and inspect Is there any indication of damage or debris baked on YES Replace clean flame sensor or igniter With the igniti...

Page 55: ...system piping Flush system 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 safet...

Page 56: ...56 13 TROUBLE SHOOTING PN 240011320 Rev G 10 01 2021 ...

Page 57: ...e J13 Continuity 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 Check continuity of both purple wires Continuity available for both purple wires PN 240011320 Rev G 10 01 2021 ...

Page 58: ...O 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 PN 2...

Page 59: ...G Repair System Piping remove any remaining air in system Connect harness to Transformer Disconnect harness from Low Water Cutoff Is 24 vac at terminals 1 2 Between blue and yellow wires YES NO PN 240011320 Rev G 10 01 2021 ...

Page 60: ...rging 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 PN 240011320 Rev G 10 01 2021 ...

Page 61: ...e solution NO Is Heat Exchanger Pump properly oriented Pump arrow pointing down YES NO Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 to 33 000 ohms Install Heat Exchanger 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 bl...

Page 62: ...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 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 C...

Page 63: ...e 130 to 150 2K to 1K ohms 2K 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...

Page 64: ...erature Sensor resistance with 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 Temper...

Page 65: ...ly Water Temperature Sensor Resistance Chart Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Does temperature fall within ranges shown in chart PN 240011320 Rev G 10 01 2021 ...

Page 66: ...e 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 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 S...

Page 67: ...67 14 WIRING DIAGRAM 14 1 Connection Diagram 050 075 100 MBH EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8 PN 240011320 Rev G 10 01 2021 ...

Page 68: ...OUND 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 OUTDOOR SENSOR SYSTEM SENSOR OPTIONAL L L N G N G ARGUS CONTROL J5 9 J5 1 J5 10 J16 5 J16 6 120V 24V 15VA TRANSFORMER LWCO 24 VAC 1 2 4 3 4 2 BURNER G LADDER DIAGRAM J13 5 J13 6 J13 3 J13 4 J13 1 GAS VALVE LIMIT 1 3 HEA...

Page 69: ...69 14 WIRING DIAGRAM 14 3 Connection Diagram 150 200 299 MBH PN 240011320 Rev G 10 01 2021 ...

Page 70: ... 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 OUTDOOR SENSOR SYSTEM SENSOR OPTIONAL L L N G N G ARGUS CONTROL J5 9 J5 1 J5 10 J16 5 J16 6 LIMIT 120V 24V 15VA TRANSFORMER LWCO 24 VAC 1 2 4 3 4 2 1 3 BURNER G HEAT EXCHANGER TEMPERATURE SWITCH PRIMARY PUMP RELAY ...

Page 71: ... 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 gas due to reduction in temperature DIRECT VENT BOILER Boiler constructed and installed so all combustion air is derived directly from outdoors an...

Page 72: ...es with all requirements of authority having jurisdiction SAFETY 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 controlled burner in event source of ignition fails SEDIMENT TRAP Gas piping arrangement designed to collect any liquid or solid contaminant be...

Page 73: ...lue 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 Locko...

Page 74: ... 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 S t a n d b y N o D e m a n d Heat Demand DHW CH Pump on Supply Temperature Setpoint 15 Second Prepurge Ignition Sparking No Yes No Yes After 2 seconds A...

Page 75: ...ng 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 76: ...tiple 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 t...

Page 77: ...tpoint 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 uni...

Page 78: ...W Settings Modifies Domestic 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 ...

Page 79: ...d 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 Sa...

Page 80: ...ion 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 det...

Page 81: ...o 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 an 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 Interna...

Page 82: ...er 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 prermanently on Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point is ...

Page 83: ...ure 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 Boiler Reset Curve Design temperature Outdoor temperature used for CH set point calculation measured once a minute and averaged with previous measurement to compensate for rapid outdoor temperature variatio...

Page 84: ...etting 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 Simul...

Page 85: ...e 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 finished burner stays at high power Note Before running System Test modes check if hydronic sy...

Page 86: ...86 NOTES PN 240011320 Rev G 10 01 2021 ...

Page 87: ...87 Company Address Phone Company Name Tech Initials Service Performed Date SERVICE RECORD PN 240011320 Rev G 10 01 2021 ...

Page 88: ...ction 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 part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a...

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