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UTICA BOILERS UH15B-060K, Installation, Operation & Maintenance Manual

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UTICA BOILERS UH15B-060K Installation, Operation & Maintenance Manual Download Page 15

15

4 - CONNECTING SUPPLY & RETURN PIPING

Figure 4-6 - Bypass Piping - Fixed Low Temp Only With Zone Valve

Piping legend:

ASME 

Relief 

Valve

*

*

*

Manually adjust until proper system 

temperature is reached.

Drain 

Valve

Drain 
Valve

 PN 240012809, Rev. D [08/15/2021]

Summary of Contents for UH15B-060K

Page 1: ...ilers For Forced Hot Water With Resideo Control INSTALLATION OPERATION MAINTENANCE MANUAL Tested For 50 psi ASME Working Pressure C S A Certified For Natural Gas Or Propane Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com PN 240012809 REV D 08 15 2020 ...

Page 2: ...Diagrams Document Package Junction Box Circulator Harness Items found in parts box included with your boiler Information and specifications outlined in this manual in effect at the time of printing of this manual Manufacturer reserves the right to discontinue change specifications or system design at any time without notice and without incurring any obligation whatsoever For Parts lists see manual...

Page 3: ... Piping 24 10 Electrical 25 10 1 Electrical Wiring 25 10 2 Thermostat Installation 25 11 Wiring Diagram 26 12 Lighting Instructions 28 12 1 Lighting Procedure For Boiler With Intermittent Pilot System 28 12 2 Operating Instructions For Intermittent Pilot System 28 12 3 To Turn Off Gas To The Appliance 28 13 Normal Sequence Of Operation 29 14 General Maintenance And Care Instructions 30 14 1 Season...

Page 4: ... 8 24 1 8 24 1 8 24 1 8 24 1 8 613 mm 613 mm 613 mm 613 mm 613 mm 613 mm 613 mm H Flue Diameter 4 5 6 6 7 7 7 102 mm 127 mm 153 mm 153 mm 178 mm 178 mm 178 mm Supply Return Tappings 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT Natural Gas Inlet 1 2 NPT 1 2 NPT 1 2 NPT 1 2 NPT 1 2 NPT 3 4 NPT 3 4 NPT Relief Valve NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT 3 4 NPT D...

Page 5: ...tand all requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never leave them unattended in bathtub or shower...

Page 6: ...rbon monoxide detector located on each floor of your home Follow your detector s located on each floor of your home Follow your detector s instructions for operation and verification Some instructions for operation and verification Some jurisdictions may by law require jurisdictions may by law require WARNING Fire Explosion Asphyxiation Electrical shock hazard Flooding will result in damages such ...

Page 7: ... level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical 6 Horizontal vent run to chimney shall be as short as practicable Refer to NFPA 54 to determine maximum permissible horizontal run for chimney type and height 7 Verify floor will support weight of boiler water and equipment 8 May be installed on combustible floor Do not install...

Page 8: ...ine etc Cleaning Solvents Hydrochloric acid muriatic acid Cements adhesives and glues Photo processing plants Garages with workshops Furniture refinishing areas and establishments Laundry Chemicals Laundry detergents bleaches fabric softeners etc Antistatic fabric softeners dryer sheets Dry cleaning laundry areas and establishments Other Permanent wave solutions Refrigerants Freon etc only where t...

Page 9: ...ping See Figure 4 1 ASME relief valve may be located off unused supply tapping IN UPRIGHT POSITION ONLY Drain valve may as an option be located on the return line using a contractor supplied tee piped right or left See Figure 4 3 Unused supply and return tappings may be capped as desired Relief valve and drain valve may be located on near boiler piping using contractor supplied tees with no valves...

Page 10: ...ly supported and securely anchored to avoid applied stress on the relief valve G be as short and straight as possible H terminate with plain end not threaded I be constructed of material suitable for exposure to temperatures of 375 F 191 C or greater Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements Alternate Location Piped in Supply...

Page 11: ...s a possibility install appropriate safeguards and alarms on the heating system to prevent property damage due to frozen and burst pipes should the boiler heating system become inoperative due to a power outage safety lockout or component failure 4 4 Water Treatment Manufacturer recommends a water analysis be done on water used to fill the system Treatment may be required based on the analysis res...

Page 12: ...ng cycle Do not expose boiler and piping to freezing temperatures Note WARNING Asphyxiation hazard Gradual flueway blocking resulting from condensate induced corrosion may block boiler passages resulting in carbon monoxide and or flame rollout Install bypass piping if return temperature is under 130 F Failure to follow these instructions could result in death or serious injury 4 Boiler connected t...

Page 13: ...closed water heating system Do not use automotive or ethylene glycol Boiler installed above radiation level or as required by authority having jurisdiction Integral low water switch is provided in boiler Do not expose boiler and piping to freezing temperatures Note Boiler used in connection with refrigeration system Install piping in parallel with boiler with appropriate valves to prevent chilled ...

Page 14: ...4 CONNECTING SUPPLY RETURN PIPING Figure 4 5 Bypass Piping With Automatic Mixing Valve BACK FLOW VALVE Piping legend PURGE VALVE DRAIN VALVE ASME Relief Valve Back Flow Valve PN 240012809 Rev D 08 15 2021 ...

Page 15: ...N PIPING Figure 4 6 Bypass Piping Fixed Low Temp Only With Zone Valve BACK FLOW VALVE Piping legend ASME Relief Valve Manually adjust until proper system temperature is reached Drain Valve Drain Valve PN 240012809 Rev D 08 15 2021 ...

Page 16: ...CTING SUPPLY AND RETURN PIPING Figure 4 7 Bypass Piping 4 Way Valve Option With Circulator On Supply side BACK FLOW VALVE Piping legend ASME Relief Valve Back Flow Valve Drain Valve PN 240012809 Rev D 08 15 2021 ...

Page 17: ... Figure 4 8 Single Zone System With DHW Priority BACK FLOW VALVE Piping legend 4 CONNECTING SUPPLY AND RETURN PIPING ASME Relief Valve Back Flow Valve Drain Valve Purge Valve PN 240012809 Rev D 08 15 2021 ...

Page 18: ...quires all domestic hot water DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Refer to pump manufacturer literature for proper pump sizing 1 4 CONNECTING SUPPLY AND RETURN PIPING BACK FLOW VALVE Piping legend Figure 4 9 Multi Zone System With Zone V...

Page 19: ...Air Infiltration Rate See Table 5 1 for space with boiler only Use equation for multiple appliances Do not use an air infiltration rate ACH greater than 0 60 Volume 21 ft3 ACH x Total Input BTU HR 1 000 C Refer to National Fuel Gas Code for opening requirements between connected indoor spaces All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors A Two Permane...

Page 20: ... exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 Minimum draft should be 02 w c 7 After it has been ...

Page 21: ...n must conform to requirements of the authority having jurisdiction or in absence of such requirements to The National Fuel Gas Code ANSI Z223 1 NFPA 54 7 4 Vent Pipe Connect draft hood to boiler using 2 screws provided onto flue collector Connect two safety circuit wires attached to vent damper harness to blocked vent switch See Figure 13 1 Fasten sections of vent pipe with 3 sheet metal screws a...

Page 22: ...ate damper so it is accessible for servicing See Figure 8 2 4 Damper must be in the open position when appliance main burners are operating 5 Boiler is equipped with factory wired harness that plugs into vent damper 6 Slope pipe up from boiler to chimney not less than 1 4 per foot 7 Run pipe as directly as possible with as few elbows as possible 8 Do not connect to fireplace flue 9 End of vent pip...

Page 23: ...23 Figure 8 2 Vent Damper Placement Figure 8 3 Vent Damper Position Indicator 8 VENT DAMPER INSTALLATION INSTRUCTIONS PN 240012809 Rev D 08 15 2021 ...

Page 24: ...GER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury WARNING Fire explosion asphyxiation and burn hazard Boiler piping and gas connections shall be leak tested before placing boiler in operation Failure to follow these instructions and or improper installation could result in death or serious inju...

Page 25: ...iler 10 2 Thermostat Installation 1 Use a thermostat with dry contacts which does not pull any load from the control Use a separate transformer for zone valve wiring 2 Thermostat should be installed on inside wall about four feet above floor 3 NEVER install thermostat on outside wall 4 Do not install thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures televi...

Page 26: ...Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life Figure 11 1 Integrated High Limit Electronic Ignition Control PN 240012809 Rev D 08 15 2021 ...

Page 27: ...27 11 WIRING DIAGRAM Figure 11 2 Integrated High Limit Electronic Ignition Control PN 240012809 Rev D 08 15 2021 ...

Page 28: ...shutoff valve Never use tools If valve will not turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water NOTI...

Page 29: ...flow of combustion products through boiler venting system becomes blocked A Blocked vent safety switch shuts main burner gas off B If boiler flue way becomes blocked flame rollout safety switch shuts main burner gas off See Figure 13 1 If either of these conditions A or B exist Do not attempt to place boiler back into operation Contact certified service agency Do not jumper safety switch s For det...

Page 30: ...e lamp in flue collector through draft relief opening or flue inspection cover With mirror positioned above burners flue gas passageways can be checked for soot or scale Follow this procedure to clean flue gas passageways 1 Remove burner tray from heat exchanger by disconnecting gas valve remove two 2 nuts and pull out the assembly See Figure 14 1 page 31 2 Remove top jacket panel 3 Remove flue in...

Page 31: ...buildup Area around boiler shall be clear and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler room shall not be restricted or blocked Inspect factory supplied and field sourced low water cutoffs annually or as recommended by low water cutoff manufacturer Flush float type low water cutoffs per manufacture...

Page 32: ...r column from specified pressure listed on boiler rating plate 7 Primary air adjustment is not necessary therefore air shutters are not furnished CHECK SAFETY CONTROL CIRCUIT Test ignition system safety shutoff device after placing boiler in operation Test ignition system safety shutoff device after placing boiler in operation Blocked vent switch and rollout switch can be tested by removing one of...

Page 33: ...Volts 15 Amps 60 Hz The MEA number for the this boiler is 19 79 E 1 Input rating for sea level to 2 000 ft 610m above sea level United States over 2000 ft 610m above sea level Reduce input rate 4 for every 1 000 ft 304m above sea level 2 Net AHRI Water Ratings shown based on piping and pickup allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and...

Page 34: ...nd gas control Do not use corrosive chemicals around or on module or gas control A 3 Adjusting Settings To discourage unauthorized changing of settings procedure to enter adjustment mode is required To enter adjustment mode press UP DOWN and I buttons simultaneously for three seconds Press and release I button until parameter requiring adjustment is displayed See Figure A 1 page 35 о HL_ LIMIT 180...

Page 35: ...the automatic means otH ODR maximal temp F or C 55 40 to 70 F Maximal outdoor temperature Use With Outdoor Reset otL ODR minimal Temp F or C 0 40 to 40 F Minimal outdoor temperature Use With Outdoor Reset btL minimal water temp F or C 140 130 to 150 F Minimal boiler temperature Use With Outdoor Reset tPL minimal boiler temp F or C 140 OFF 120 to 160 F Thermal purging minimal temperature DO NOT CHA...

Page 36: ...per must confirm it is open a switch closes to do this The control is waiting for this to occur This may last up to one minute If the vent damper switch has not closed after one minute ERR 55 will be displayed e 17 Diagnostics Another diagnostic check The control will also check the safety switches rollout and vent are closed This will be so quick the control may move on before the STA code is fla...

Page 37: ... 2 hard lockouts on this model m 15 Wait for limit to close One of the safety limits rollout vent spill or low water cutoff has been activated Control will resume normal operation once limit is reset Underlying cause why the limit switch opened MUST be investigated n 16 Flame out of sequence Flame signal sensed before trial ignition Appropriate alarm is sent OR Flame signal sensed out of sequence ...

Page 38: ...isplay On retry models wait for retry or reset at thermostat Check for correct installation and wiring before replacing any component Control module cannot be repaired If it malfunctions it must be replaced Use only qualified service agent to service ignition systems 1 Perform checkout as first step in troubleshooting Check troubleshooting guide to pinpoint cause of problem See Table A2 2 If troub...

Page 39: ...cted reading 1 Check sensor is plugged into control board 2 Check sensor wiring is not damaged 3 Scroll display reading to bt and hold sensor bulb securely in you hand It should read a temperature close to body temperature If not replace sensor 55 Damper end switch failed to close Vent damper must confirm it is open switch closes to do this Control did not receive this signal after waiting one min...

Page 40: ...gas supply 2 Check all electrical connections are tight 3 Check pilot rod is clean 4 Check for adequate draft 5 Check for adequate combustion air 64 Soft Lockout Internal failure Control is sensing something wrong with electrical circuitry 1 Check all wiring is correct Refer to wiring diagram 2 Check there is a good ground to pilot bracket 65 Hard Lockout Temperature above limit Soft Lockout on S9...

Page 41: ...k for good metal to metal contact between pilot burner bracket and the main burner Check ground lead from GND BURNER terminal on module to pilot burner Verify connections are clean and tight If wire is damaged or deteriorated replace with No 14 18 gauge moisture resistant thermoplastic insulated wire with 105 C 221 F minimum rating Check ceramic flame rod insulator for cracks or evidence of exposu...

Page 42: ...djustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Figure 12 1 page 28 3 If pilot does not stay lit ensure adequate flame current as follows Turn off boiler at circuit breaker or fuse box Clean flame rod with emery cloth Verify electrical connections are clean and tight Replace damaged wire Check for cracked ceramic insulator which can c...

Page 43: ...returns to closed position 4 Return thermostat to desired position 5 Place vent damper in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller 6 Thermostat controls burner firing as before while damper remains open 7 DO NOT turn damper open manually motor damage will result 8 Set switch to AUTOMATIC OPERATION to close vent damper during burner off ...

Page 44: ...to step v v Place jumper wire across orange and yellow wires in Molex plug see Figure 4 This will create bypass of the damper boiler should then ignite If boiler ignites Go to section B 4 Vent Damper Troubleshooting Guide If boiler does not ignite Problem is not the damper Go to Damper harness Molex on Aquastat Step C NOTE Prior to replacing the damper be sure the problem is not with wire connecti...

Page 45: ...2 POWER Between 4 1 When calling for heat 1 Thermostat not calling for heat 2 Burned out heat anticipator 3 Loose or broken connections 4 Off On operating limit pressure control or low water cut off 5 Off On blocked vent switch or flame roll out 1 Turn thermostat up to call for heat 2 Replace thermostat 3 Tighten repair or replace connection 4 Turn operating limit pressure control or low water cut...

Page 46: ...46 NOTES PN 240012809 Rev D 08 15 2021 ...

Page 47: ...__________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed on or adjacent to boiler Installer Company Address Phone Installer s Name Signature PN 240012809 Rev D 08 15 2021 ...

Page 48: ...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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