Olsen OLSSC-050 Installation, Operation & Maintenance Manual Download

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P/N# 240008852, Rev. M [07/2015]

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Models

OLSSC

050

OLSSC-075

OLSSC-100

OLSSC-150

OLSSC-200

OLSSC-299

050/075/100/150/200

SIZE SHOWN

Summary of Contents for OLSSC-050

Page 1: ...LER INSTALLATION OPERATION MAINTENANCE MANUAL Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models OLSSC 050 OLSSC 075 OLSSC 100 OLSSC 150 OL...

Page 2: ...sed for packaging holes on back of boiler Plastic Plug 2 ea 18 Used for packaging holes on back of boiler Outdoor Sensor 19 Used for measuring outside temperature Critical Installation Instruction 20...

Page 3: ...Location I 3 76mm 4 114mm Gas Connection Location J 4 1 2 114mm 4 1 2 114mm 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...

Page 4: ...Requirements 28 6 8 Multiple Boiler Venting Installation 30 6 9 Condensate Piping 31 7 Gas Supply Piping 32 8 Electrical Connections 34 8 3 Line Voltage Connections 34 8 4 External Connections 34 9 S...

Page 5: ...5 F 90 5 C system design temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Integral Low Water Cutoff with test button Outdoor Temperature Reset Integral Multiple Boiler Contro...

Page 6: ...tallation 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 juri...

Page 7: ...alve Fuel supply isolation during servicing See section 7 19 Combustion Air Blower Delivers proper quantity of combustion air receives fuel from gas valve mixes air and fuel sending mixture to burner...

Page 8: ...Lift Jacket up engage jacket with chassis push down 27 WALL MOUNT SUPPORT BRACKET Jacket Latch 3 COMPONENT LISTING 050 075 100 150 200 SIZE SHOWN P N 240008852 Rev M 07 2015 FIGURE 3 2 Lower Jacket V...

Page 9: ...STEM IN 14 SUPPLY WATER TO HEATING SYSTEM OUT 4 LOW VOLTAGE TERMINAL STRIP 15 VENT TEMPERATURE SENSOR 26 GAS CONNECTION 33 COMBUSTION ANALYSIS TEST PORT 24 HIGH VOLTAGE JUNCTION BOX 9 HEAT EXCHANGER 2...

Page 10: ...ECTOR 3 RETURN WATER FROM HEATING SYSTEM IN 14 SUPPLY WATER TO HEATING SYSTEM OUT 4 LOW VOLTAGE TERMINAL STRIP 33 COMBUSTION ANALYSIS TEST PORT 26 GAS CONNECTION 24 HIGH VOLTAGE JUNCTION BOX 9 HEAT EX...

Page 11: ...elief 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 fi...

Page 12: ...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 fas...

Page 13: ...ed air circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Boiler rated at...

Page 14: ...idance Additional considerations Boiler control is designed for single central heating pump Installer responsible for integration of multiple central heating pumps Boiler control allows domestic hot w...

Page 15: ...e drain Table 3 System Piping Configurations Single Boiler Two Pipe Zoned System With Zone Valves figure 5 5 With Zone Pumps figure 5 6 Primary Secondary Pumping Closed External Primary Loop figure 5...

Page 16: ...System With Zone Pumps Heat exchanger ball valve open as shipped Heat exchanger ball valve open as shipped DHW Pump CH System Pump DHW Pump Zone Pump 3 8 10mm Open End Wrench may be required to turn...

Page 17: ...nternal primary loop ball valves closed FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With Open External Primary Loop CH System Pump 12 305mm Maximum separation Existing closely spaced tee...

Page 18: ...oilers 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 All internal primary loop b...

Page 19: ...sely 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 o...

Page 20: ...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...

Page 21: ...stat 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 Det...

Page 22: ...ted pipe fittings Minimum Maximum Vent Lengths 2 Pipe 3 Pipe 4 Pipe Model 050 075 100 050 075 100 150 200 299 299 Min 6 ft 1 8 m 6 ft 1 8 m 6 ft 1 8 m 6 ft 1 8 m 6 ft 1 8 m Max 50 ft 15 2 m 100 ft 30...

Page 23: ...NOTICE Use of vent covers may cause freezing If using vent covers overall vent length must be considered Failure to heed this information may compromise operation of this boiler Type Location Termina...

Page 24: ...t 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 Aba...

Page 25: ...vement of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 or 3 51 or 76mm Diameter PVC intake combustion air Combustion Air 2 51mm Diameter 41 Length 1 1m 3 76mm Diameter...

Page 26: ...pated snow level 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 12 300 mm above highest...

Page 27: ...uirement 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 Combustion Air Vent w T Terminal 12 305mm Min Sepa...

Page 28: ...ense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas Termination must be min 12 305mm from or below doors windows or gravity inlet If boiler uses inside a...

Page 29: ...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 ter...

Page 30: ...rule as single boiler venting as described in Section 6 6 and 6 7 Locate combustion air and vent terminals as required by authority having jurisdiction FIGURE 6 20 Mulitple Boilers With Common Venting...

Page 31: ...nce of such authority USA PVC or CPVC per ASTM D1785 D2845 Cement or primer per ASME D2564 or F493 Canada CSA or ULC certified PVC CPVC pipe fittings and cement Attach PVC tee provided with boiler and...

Page 32: ...ll manual main shutoff valve outside of jacket See figure 7 2 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to...

Page 33: ...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...

Page 34: ...B Connect pump to line voltage terminal strip CH PUMP L N G Domestic Hot Water Pump if used A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figure 8 3 and Tab...

Page 35: ...ct wires interchangeable to DHW T T terminals Wires are interchangeable Central Heating Thermostat A Use thermostat or boiler system control with dry contacts related 0 5 amps 120 VAC Boiler control d...

Page 36: ...W calls if available Close manual gas shut off valve Let system run for 30 minutes When boiler goes into lockout reset boiler by pressing Reset button until boiler resets Do not open gas shutoff valve...

Page 37: ...1 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Enabled Enable Disabled Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminder Days 3...

Page 38: ...tivate some 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 C...

Page 39: ...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...

Page 40: ...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 Hig...

Page 41: ...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...

Page 42: ...tion test 2 Follow instructions TO TURN OFF GAS TO APPLIANCE page 43 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all ins...

Page 43: ...ff valve clockwise 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 thi...

Page 44: ...nturi 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 a...

Page 45: ...er for foreign matter in flame ports or inside burner Remove foreign matter by blowing with compressed air or vacuuming Replace burner if it cannot be cleaned or is showing deterioration Clean heat ex...

Page 46: ...tions 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...

Page 47: ...47 13 TROUBLE SHOOTING P N 240008852 Rev M 07 2015...

Page 48: ...e High Temperature opens during normal operation Go to Page 54 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas valve opens Re...

Page 49: ...age 59 Boiler power supply ground wire is not grounded Go to Page 60 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replace Control Modu...

Page 50: ...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 k NO YES Disco...

Page 51: ...51 13 TROUBLE SHOOTING P N 240008852 Rev M 07 2015...

Page 52: ...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 b...

Page 53: ...53 13 TROUBLE SHOOTING P N 240008852 Rev M 07 2015...

Page 54: ...m 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 w...

Page 55: ...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 Inst...

Page 56: ...G Connect harness to Transformer Disconnect harness from Low Water Cutoff Is 24 vac at terminals 1 2 Between blue and yellow wires YES NO Repair System Piping remove any remaining air in system P N 24...

Page 57: ...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...

Page 58: ...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...

Page 59: ...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 s...

Page 60: ...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 les...

Page 61: ...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...

Page 62: ...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...

Page 63: ...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...

Page 64: ...64 14 1 Connection Diagram 050 075 100 MBH 14 WIRING DIAGRAM P N 240008852 Rev M 07 2015 EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8...

Page 65: ...65 14 2 Schematic Diagram of Ladder Form 050 075 100 MBH 14 WIRING DIAGRAM P N 240008852 Rev M 07 2015...

Page 66: ...66 14 3 Connection Diagram 299 MBH 14 WIRING DIAGRAM P N 240008852 Rev M 07 2015 EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8...

Page 67: ...HALL GND DC 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 OUT...

Page 68: ...ccompanied 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 co...

Page 69: ...rity 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...

Page 70: ...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 O...

Page 71: ...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 1 1 Front Panel Statu...

Page 72: ...information Control module adjusts firing rate according to heating demand When Boiler detects demand met will enter post purge mode then standby mode If simultaneous demand for Central Heat and DHW b...

Page 73: ...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 displa...

Page 74: ...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...

Page 75: ...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...

Page 76: ...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 lockou...

Page 77: ...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 sing...

Page 78: ...ystem 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...

Page 79: ...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...

Page 80: ...t 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 temper...

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 r...

Page 82: ...resent 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...

Page 83: ...83 P N 240008852 Rev M 07 2015 NOTES...

Page 84: ...quipped with 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 F...

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