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UTICA BOILERS UHSW Series, Installation, Operation & Maintenance Manual

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UHSW

Gas-Fired Hot Water 

Induced Draft Boilers

INSTALLATION, OPERATION & 

MAINTENANCE MANUAL

Tested for 50 psi. 

ASME Working 

Pressure

C.S.A. Certified for 

Natural gas or 

Propane

Models

 

UHSW42

UHSW75

UHSW112

UHSW150

UHSW188

UHSW225

Manufactured by: 

ECR International Inc.   

2201 Dwyer Avenue, Utica, NY 13501 

 Tel. 800 253 7900  

www.ecrinternational.com  

PN 240012689 REV. A [05/15/2019]

Summary of Contents for UHSW Series

Page 1: ...ANUAL Tested for 50 psi ASME Working Pressure C S A Certified for Natural gas or Propane Models UHSW42 UHSW75 UHSW112 UHSW150 UHSW188 UHSW225 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240012689 REV A 05 15 2019 ...

Page 2: ...nd service of this boiler must be performed by a qualified installer TO THE INSTALLER Leave all instructions with boiler for future reference When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter WARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or...

Page 3: ...size should be based upon Net AHRI Rating being equal to or greater than calculated heat loss of building Manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements This boiler cannot be used with all types of chimneys Read these instructions carefully before installing These Gas Fired Hot Water Boilers are low pressure sectional cast...

Page 4: ...4 PN 240012689 Rev A 05 15 2019 DIMENSIONS Model Width A UHSW42 11 UHSW75 14 1 4 UHSW112 17 1 2 UHSW150 20 3 4 UHSW188 24 UHSW225 27 1 4 ...

Page 5: ...ion See rating and capacity table 8 When installed in utility room door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater 9 Boiler installed in building under construction take care to insure clean combustion air supply during construction process Airborne particulates such as from drywall dust and from fiberglass insulat...

Page 6: ...directly or by ducts with outdoors о о Two Permanent Opening Method Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure Direct communication with outdoors or communicating through vertical ducts Provide minimum free area of 1 in2 per 4 Mbh of total input rating of all appliances in enclosure Communicating through horizontal ducts Pr...

Page 7: ... 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 scalding an...

Page 8: ...ENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE Figure 3 Forced Hot Water Typical Piping LIMIT SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE Figure 4 Forced Hot Water Typical Piping With Zone Control Valve PN 240012689 Rev A 05 15 2019 ...

Page 9: ...cted to heating coils located in air handling units exposed to refrigerated air circulation piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle INSTALLATION SYSTEM PIPING Figure 5 Piping Arrangements For Boiler When Used In Connection With Refrigeration System Low Design Water Temperature Systems Belo...

Page 10: ... possible with as few elbows as possible 7 Where possible it is recommended to common vent water heater and boiler Consult appropriate Vent Sizing Tables in National Fuel Gas Code for specific requirements of multiple appliance venting 8 Boiler is only appliance connected to vent Type B vent pipe is recommended for vent connector 9 Slope pipe up from boiler to chimney not less than 1 4 per foot 21...

Page 11: ...hin a 10 ft 3m radius of the apex Boiler Water Heater Chimney CHECK YOUR CHIMNEY For boilers for connection to gas vents or chimneys vent installations shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable provisions of the local building codes Figure 7 Type B Gas Vent 11 VENT INSTALLATION PN 240012689 Rev A 05 15 2019 ...

Page 12: ...n on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously VENT INSTALLATION 5 Test for spillage at the draft hood relief opening after 5 minutes of main bu...

Page 13: ... or 3 feet of straight pipe for 3 diameter 90 elbow 2 3 4 5 Section Boilers use 3 vent pipe for 6 7 Section Boilers use 4 vent pipe CHOICE OF VENT PIPE MATERIAL U L Listed Z Flex Z Vent Stainless Steel Vent Pipe U L Listed Heat Fab Saf T Vent Stainless Steel Vent Pipe U L Listed Flex L Star 34 Stainless Steel Vent Pipe U L Listed ProTech Systems FasNSeal Stainless Steel Vent Pipe INDUCED DRAFT HIG...

Page 14: ...ng down fitted with a minimum 1 4 mesh screen to keep out rodents and birds The elbow shall be of the same material and size as vent pipe The elbow exit should be at least 6 away from exterior wall as shown in Figure 8 or B Tjernlund VH 1 Series side wall vent hood For 2 3 4 5 section boilers use VH 1 3 For 6 7 section boilers use VH 1 4 7 Vent Pipe Termination Location See Figure 9 A When venting...

Page 15: ...relief equipment See Figure 9 United States Terminate vent system at least 4 feet 1 22m horizontally from and in no case above or below unless a 4 feet 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment HORIZONTAL VENTING INSTRUCTIONS Figure 9 Horizontal Venting Clearances A The venting system shall terminate at least 4 feet below any eave soffi...

Page 16: ...ng appliance B For Heat Fab Saf T Vent stainless steel vent pipe use a high temperature silicone sealant rated for 550 F The outside of the male end and inside of the female end of the pipe must be cleaned before applying the silicone bead For 3 vent pipe runs the male end of the vent pipe which goes over the outlet of the boiler s induced draft blower must be crimped The vent pipe should be crimp...

Page 17: ...vent collection of condensate throughout the assembly 7 Allow the sealant to cure for 24 hours before operating the appliance D For ProTech Systems FasNSeal stainless steel vent pipe no cleaning fluid is required For 3 vent pipe runs on 2 3 4 and 5 section boilers begin by locating the FasNSeal Ametek Adapter over the boiler s induced draft blower Continue the vent pipe run with 3 FasNSeal vent pi...

Page 18: ... Sections Field Controls Power Venter 2 3 4 5 SWG 46 6 7 SWG 5 SWG 5 requires purchase of CK 43F control kit Reasons for the use of a power venter for sidewall venting 1 Preferred by some local codes 2 Installation requires a vent piping run more than 30 9 1m less than 50 15 2m 3 Boiler installation site experiences gusting or high winds Power venter can prevent boiler from short cycling due to gu...

Page 19: ...l joints securely Propane gas connections should only be made by licensed propane installer Two stage regulation should be used by propane installer Propane gas piping should be check by propane installer Check Gas Supply Gas pipe must be correct size for length of run and for total BTU per hour input of all gas utilization equipment connected to it See Gas Table 6 7 Page 20 for proper size Be sur...

Page 20: ... Hour Input Includes Fittings 1 1 20 92 000 190 000 350 000 625 000 40 63 000 130 000 245 000 445 000 60 50 000 105 000 195 000 365 000 Table 6 PROPANE GAS Length of Pipe Ft Pipe Capacity BTU Per Hour Input Includes Fittings Copper Tubing Iron Pipe 20 131 000 216 000 189 000 393 000 40 90 000 145 000 129 000 267 000 60 72 000 121 000 103 000 217 000 PN 240012689 Rev A 05 15 2019 ...

Page 21: ...ed by drafts hot or cold pipes sunlight lighting fixtures televisions a fireplace or a chimney 4 Check thermostat operation by raising and lowering thermostat setting as required to start and stop the burners 5 Instructions for the final adjustment of the thermostat are packaged with the thermostat adjusting heating anticipator calibration etc 6 Set heat anticipator at 2 amps 24 volt thermostat co...

Page 22: ...rature reaches high limit set point high limit contacts open cutting power to blower and pilot control Burners extinguish and blower stops Circulator pump continues to run as long as the thermostat continues to call for heat When boiler water temperature drops past the high limit set point and through the differential high limit contacts close repeating steps 3 7 9 If venting system becomes blocke...

Page 23: ...23 WIRING DIAGRAMS Figure 12 Control Module Damper is not an option PN 240012689 Rev A 05 15 2019 ...

Page 24: ... you have covered every radiation unit in system End at highest unit in system If units have automatic vents manual venting is unnecessary but it will speed up proper filling of system If system is closed expansion tank system you may have automatic fill valve Leave it open to refill system automatically as needed Check temperature pressure gauge Note position of hand indicating pressure This shou...

Page 25: ... you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which automatically lights burner Do NOT try to light this burner by hand Before operating smell all around appliance area for gas Be sure to smell next to floor because some gas is heavier than air and will settle t...

Page 26: ... air adjustment and are not equipped with primary air shutters Main burner flames form sharp blue inner cones in softer blue outer mantel with no yellow Puffs of air from blowing on flame or stamping on floor will cause flames to turn orange momentarily This is not unusual Remain still when observing main burner flames See Figure 16 Page 27 If flame appearance is not correct check main burner orif...

Page 27: ...ers 3 Turn your thermostat up to call for heat and let your boiler run until temperature of water reaches limit setting Gas valve shuts off and circulator keeps running until thermostat is satisfied or water cools enough to restart burners through limit control 4 To check operation of contacts in pressure switch disconnect rubber tubing located between blower and pressure switch from pressure swit...

Page 28: ...to freeze will crack pipes and or boiler Cleaning Your Boiler And Burners Flue passages between sections should be examined yearly and cleaned if necessary To clean Remove burners pilot and vent pipe Remove top and front jacket panels Remove two screws attaching intermediate front panel to left and right side jacket panels Remove control panel as a unit Remove draft diverter and intermediate front...

Page 29: ... Check all control terminals and wire joints Chimney flue is blocked Pressure switch will not close and pilot spark will not operate to start pilot Have your service technician check and correct if necessary Rollout switch blown Have your service technician check heat exchanger for blockage Replace rollout switch with exact replacement IF BURNER IS NOISY POSSIBLE CAUSE WHAT TO DO Gas input amount ...

Page 30: ...mperature changes Diaphragm type tank can be mounted on air purger fitting or at any convenient place in supply or return line AIR ELIMINATING FITTING AIR PURGER Air purger is used to remove excess air from system It is installed in supply line It will eliminate air from water before it reaches radiators and bleed off this air MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM TYPE EXPANSION TANK Be...

Page 31: ...ssure Switch Set point 0 4 wc for 2 5 section boilers 0 5 w c for 6 7 section boilers Rollout Switch FLAME ROLLOUT SAFETY SHUTOFF Rollout switch is temperature sensitive fuse link device Located on boiler base just outside fire box In event of heat exchanger flueway blockage causing flame to roll out of fire box fuse does not change in appearance when blown If rollout switch blows it must be repla...

Page 32: ...nsure remaining Molex plug connectors have not worked loose during transit Check sensing bulb is fully inserted in well and is not loose 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 see Figure 1 simultaneously for three seconds Press and release I button until parameter req...

Page 33: ...etected and delay is called before retry Recycle delay Flame signal was lost and delay is called before retry 11 Wait for pressure switch to open failed to close Inducer is still off Pressure switch has not opened at beginning of heat cycle Alarm is sent but no lockout occurs 12 Wait for pressure switch to close failed to open Inducer is on Pressure switch has not closed at beginning of heat cycle...

Page 34: ...t be reset through key buttons and display 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 2 Check troubleshooting guide to pinpoint ca...

Page 35: ...t is reset after one hour if alarm reason disappears 63 Soft lockout maximum number of recycles exceeded Soft lockout 64 Soft Lockout electronics failure On board self diagnostics detected error Soft lockout 65 Over temperature error Sensor measured temperature in excess of maximum allowable limit Soft lockout Note Soft lockout time is 1 hour or manual reset Hard lockout requires manual reset A 9 ...

Page 36: ...k for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary At gas valve disconnect main valve wire from MV terminal Turn on power and set thermostat to call for heat Pilot should light main burner will remain off because main valve actuator is disconnected Check pilot flame Verify it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of flame rod Fig...

Page 37: ...37 NOTES ...

Page 38: ...NOTES ...

Page 39: ...TU HR input____________ 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 ...

Page 40: ...es This feature is equipped with an override which is provided primarily to per mit 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 x x An external energy management system is installed that reduces the boiler water temperature as the heating load decreases x x This boiler is not us...

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