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• High limit control is mounted in ½” NPT control well

and ¾” X ½” bushing on top of front boiler section at

hot water outlet.

• High limit control is tied in with boiler control and is

factory set at 200°F (94°C) water temperature.

• High limit setpoint is fi eld adjustable and may be set

anywhere between 100°F (38°C) and 200°F (94°C),

with maximum high limit setpoint not exceeding 200°F

(94°C). Field high limit setpoint adjustment for each

installation depends on heating system requirements.

• High limit control automatically resets when boiler water

temperature decreases below high limit setpoint value

by differential setpoint value. (Adjustable differential

from 5°F (2.8°C) to 30°F (16.7°C).

• Boiler operating temperature (temperature curve) is

calculated and set in boiler control parameters.

11.13 Casting Temperature Safety Switch

• Casting temperature safety switch, 230°F (110°C)

setpoint, shuts off power to boiler control in event of

boiler lack of or loss of water.

• Casting temperature safety switch is installed on top of

aluminum boiler section behind supply piping.

• Failure code is displayed on digital readout. Fault

requires manual reset of casting temperature safety

switch to restart boiler. Press reset on user interface

panel also.

• Verify boiler is properly fi lled with water and no air is

trapped in top of casting (check cap on Cam Vent at

heat exchanger) before resetting.

WARNING

Burn and scald hazard. Never run cold water into a

hot, empty boiler. Failure to follow these instructions

could result in death or serious injury

11.14

Circulator Pump

• Circulating pump moves water through closed loop

supply and return piping systems, terminal heating

equipment (fi nned tube radiators, etc.) and back

through boiler for reheating.

• Properly size circulator pump to overcome frictional

losses (usually measured in feet of water, also referred

to as “pump head loss”) of supply and return piping

systems and boiler to provide required hot water fl ow

rates.

• Circulator pump is furnished in carton within boiler

cabinet.

• Locate circulator(s) on downstream (“pumping away”)

side of expansion tank.

11.15 Blocked Vent Safety Assembly

Blocked vent safety assembly incorporates two pressure

switches designed to discontinue operation of boiler if there

is a problem with blower or venting system.
The normally open switch closes upon initiation of blower

and functions as air proving switch.
The normally closed switch opens if there is a blockage in

combustion air intake or exhaust vent pipes.

11.16 Drain Valve

Manual drain valve drains water in heating system,

including boiler, hot water supply and return piping systems

installed above drain valve.
Drain valve is installed in return piping at bottom front of

boiler section. Any piping installed below elevation of drain

valve requires additional drain valves to be installed at low

points in piping system in order to drain entire system.

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per these instructions.

11.17 Safety Relief Valve

• Each boiler must have a properly sized and installed

American Society of Mechanical Engineers (ASME) rated

safety relief valve.

• Furnished safety relief valve automatically opens at 30

psig pressure to relieve strain on boiler and heating

system from increasing pressure.

• Pipe Safety relief valve discharge with same size pipe

as valve discharge opening to open drain, tub or sink,

or other suitable drainage point not subject to freezing.

11.18 External Condensate Pump (optional)

For installations where there is no fl oor drain or other

appropriate drainage receptacle available to receive

condensate from boiler, external fl oat activated condensate

pump with integral sump is required. Condensate pump can

be piped to remote tie in point to sanitary sewer system.

For this application, boiler must be installed so that proper

pitch of piping to external condensate reservoir (sump) can

be accomplished. Use wood frame or concrete blocks to

raise boiler as required for proper installation.

11.19 Concentric Vent/Air Intake Termination

(Optional)

Optional concentric vent/air intake termination utilizes

single opening per each appliance through wall or roof of

structure.

11 - CONTROLS AND ACCESSORIES

Содержание Olsen OQ95M-200

Страница 1: ... HOT WATER BOILER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com P N 240006103B Rev D 03 2013 Model OQ95M 200 ...

Страница 2: ...1 DIMENSIONS OPENING FOR SAFETY RELIEF VALVE DISCHARGE PIPE 30 785mm 39 1 1m 18 458mm 2 ...

Страница 3: ...at from the cast aluminum heat exchanger cooling flue gases and causing condensation Sealed combustion premix gas burner and low flame temperature means reduced CO and NOx emissions which contribute to cleaner and healthier environment This appliance takes its combustion air directly from outdoors sealed combustion and does not compete with building occupants for fresh air 2 INTRODUCTION Sealed co...

Страница 4: ...k hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation Keep this manual near boiler Retain for future reference 3 2 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements United States National Fuel Gas Code ANSI Z223 1 NFPA 54 National Electrical C...

Страница 5: ...d above 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 boiler surfaces and it is assumed this heat stays in the structure Net AHRI Rating represents portion of remaining heat that can be applied to heat radiation or terminal units i e finned tube baseboard cast iron ra...

Страница 6: ...rly located thermostat or operating control not included with boiler WARNING Fire hazard Do not install on carpeting Failure to follow these instructions could result in death or serious injury Placed on level surface must NOT be installed on carpeting Pitch condensate drain line down to floor drain or external condensate pump with reservoir at per foot wood frame or blocks may be used to raise bo...

Страница 7: ... are required to venting or combustion air intake piping 6 Install equipment in location which facilitates operation of venting and combustion air intake piping systems as described in this manual 7 Advise owner to keep venting and combustion air intake passages free of obstructions Both venting and combustion air intake piping systems connected to outdoors must permit flow through piping systems ...

Страница 8: ...From Common Vent System When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliance...

Страница 9: ...lder systems obviously discolored murky or dirty water or pH reading outside acceptable range between 7 0 and 8 0 are indications system should be cleaned or treated Thoroughly flush system with clean water to remove any sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flushing with clean water If chemical cleaners are used use only those recommended ...

Страница 10: ... relief valve outlet Install elbow s if used close to safety relief valve outlet and downstream of union if used Terminate pipe with plain end not threaded 7 4 Expansion Tank Make up Water Determine required system fill pressure system design temperature and system water content Boiler contains 2 6 gallons US Size expansion tank accordingly Consult expansion tank manufacturer for proper sizing inf...

Страница 11: ...are steps required to initially fill condensate trap for start up Steps are only required at initial start up or if maintenance requires draining of condensate trap 1 Remove vent drain line from CPVC vent pipe Pour about 1 cup of cold tap water into vent drain line 2 Excess water should go through overflow and out through condensate drain line Verify proper operation of drain line or external cond...

Страница 12: ... installations all plastic venting material must be listed to ULC S636 4 Construction through which vent and air intake pipes may be installed is maximum 24 inches minimum thickness 5 See Table 5 for combustion air and vent pipe fittings approved material and standards 6 Canada construct all combustion air and vent pipes for this unit of ULC S636 listed schedule 40 CPVC schedule 40 PVC PVC DWV or ...

Страница 13: ...ins to boiler Pitch pipes with no sags or low spots where moisture can accumulate and block flow of flue gas 13 Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure F Terminate vent above normal snow line Avoid locations where snow may drift and block vent Ice or snow may cause boiler to sh...

Страница 14: ...Figure 5 Side Wall Vent Intake terminations Less Than 12 Clearance Above Grade 8 COMBUSTION AIR AND VENT PIPE 14 ...

Страница 15: ... 36 915mm Minimum Maintain 12 300mm clearance above highest anticipated snow level or grade 12 300mm Minimum Must be less than 4 102mm or greater than 24 610mm Horizontal distance between end bells of each air intake to prevent flue gas recirculation Figure 6 Roof Vent Intake Terminations Figure 7 Concentric Vent Terminations 15 ...

Страница 16: ...tion depth on pipe 10 After pipes have been cut and pre assembled apply cement primer to pipe fitting socket and end of pipe to insertion mark Quickly apply approved cement to end of pipe and fitting socket over primer Apply cement in light uniform coat on inside of socket to prevent buildup of excess cement Apply second coat 11 While cement is still wet insert pipe into socket with turn twist Be ...

Страница 17: ... from gas supply piping system by closing its manual shutoff valve during any pressure testing of gas supply piping system at test pressures equal to or less than psig 3 5kPa For proper boiler operation line pressure should be within minimum and maximum values in Table 6 Gas line enters boiler through left side panel See page 2 Dimensions and Figure 10 Boiler is equipped with NPT connection on gas...

Страница 18: ...ector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition source Correct leaks immediately and retest 9 GAS SUPPLY PIPING DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious ...

Страница 19: ...ceptable range green light will illuminate on monitor and boiler will restart Line voltage monitor is factory set at 115 VAC It is important that monitor be set to voltage present at installation site by following these directions 1 Using multimeter locate wall outlet nearest to boiler and determine line voltage present on site 2 Disconnect power to boiler 3 Remove boiler cover 4 Locate line volta...

Страница 20: ...or reset operation of the boiler If fixed temperature operation is required do not install outdoor sensor 2 Mount sensor on exterior wall shielded from direct sunlight or flow of heat or cooling from other sources 3 If desired install a summer winter switch across terminals A1 and A2 When the switch is closed the boiler space heating circulator is disabled 4 Route sensor wires through the holes pr...

Страница 21: ... developed for domestic heating appliances with premix burners and automatic direct burner ignition and are suitable for natural and LP gas Gas controls perform all functions required to safely regulate gas flow to main burner of boiler Gas valve is directly connected to gas air mixer 11 7 Gas Air Mixer Venturi design of gas air ensures correct mixture of air and gas 11 8 Modulating Burner Burner ...

Страница 22: ...on downstream pumping away side of expansion tank 11 15 Blocked Vent Safety Assembly Blocked vent safety assembly incorporates two pressure switches designed to discontinue operation of boiler if there is a problem with blower or venting system The normally open switch closes upon initiation of blower and functions as air proving switch The normally closed switch opens if there is a blockage in co...

Страница 23: ...al Closed Type Expansion Tanks A Close all zone service valves on supply and return piping and close expansion tank service valve Drain expansion tank Open feed valve and fill boiler with water Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler then let relief valve snap shut B Open zone service valve on supply pipe for first zone Open purge valve on...

Страница 24: ... supplier 13 OPERATING INSTRUCTIONS Control Valve ON Control Valve OFF Figure 12 Gas Valve 13 1 Lighting Instructions For Your Safety Read Before Operating WARNING If 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 li...

Страница 25: ...top panels check for piping leaks around safety relief valve and other fittings and repair if found Do not use stop leak compounds 2 Verify boiler area is free from combustible materials gasoline and other flammable vapors and liquids 3 Circulator pump and blower fan motor furnished with boiler are permanently lubricated from factory and require no further lubrication Additional or non factory sup...

Страница 26: ...ough condensate drain Be wary of drain lines getting clogged and causing water to back up in the bottom of casting H Use flexible handle nylon brush to loosen sediment and aluminum oxide on all accessible heating surfaces of boiler Take care not to get brush stuck in heat exchanger I After brushing and rinsing remove any remaining loosened sediment using shop vacuum with snorkel attachment J Inspe...

Страница 27: ...APPENDIX A BOILER PIPING AND WIRING Electrical Wiring Diagram 27 ...

Страница 28: ...OOR AIR SENSOR BOILER CONTROL PANEL DHW CIRC L1 120 VAC L2 CH CIRC Note CH DHW Circulator connections on boiler only support pump with 1 amp rating or less Boiler Control Wiring Diagram Single Zone System With Domestic Hot Water Priority APPENDIX A BOILER PIPING AND WIRING 28 ...

Страница 29: ...r thermostat Boiler Control Panel DHW CIRC L1 HOT L2 N 120V AC NO L2 VAC 120 4 4 NC AR822 II TORQUE TERMINAL 6 TO 7 INCH LBS ELECTRONIC FUSE CIRCUIT ON AR822 TT R T TT NO 24V W C T 5 SCREWS NC 6 6 CH CIRC Piping Diagram 1 Single Zone System With Domestic Hot Water Priority Wiring Diagram 1 Single Zone System With Domestic Hot Water Priority APPENDIX A BOILER PIPING AND WIRING 29 ...

Страница 30: ...NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 2 Multizone Piping With Zone Valves And Domestic Hot Water Priority With Zone Valve APPENDIX A BOILER PIPING AND WIRING 30 ...

Страница 31: ...ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 SWITCH LEGEND OFF ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANSFORMER 24VAC 40 VA L LINE IN N Black White 24VAC N L Yellow Yellow AZ 4CP Boiler Control Panel DHW C1 DHW C2 CH C2 L2 L1 CH C1 CH DHW ...

Страница 32: ...NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 3 Multizone System With Zone Valves And Domestic Hot Water Priority With Circulator APPENDIX A BOILER PIPING AND WIRING 32 ...

Страница 33: ...UMP PRIORITY ON ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 SWITCH LEGEND OFF ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANSFORMER 24VAC 40 VA L LINE IN N Black White 24VAC N L Yellow Yellow AZ 4CP Boiler Control Panel DHW C1 DHW C2 CH C2 ...

Страница 34: ...NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 4 Multizone System With Circulators And Domestic Hot Water Priority APPENDIX A BOILER PIPING AND WIRING 34 ...

Страница 35: ... 3 R ZONE 4 W T 4 R T DHW CIRC L2 CH C2 DHW C2 DHW C1 DHW T2 A2 A1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR aquastat or thermostat Boiler Control Panel 115 V COIL ISOLATION RELAY NORMALY OPEN NOTE IN PLACE OF 115 VOLT ISOLATION RELAY OPTIONAL CONTROL ARGO AR822II TERMINAL 5 6 N O TO DHW T1 DHW T2 L1 L2 TO ARM L N ON PRIORITY ZONE ELECTRONIC FUSE VAC CIRCUIT ON 120 L2 NO 4 NC 4 AR822 TT SCREWS TORQUE ...

Страница 36: ... NOTE NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS Piping Diagram 5 Primary Secondary Piping With Circulators And Domestic Hot Water Piping Diagram 5 Piping Diagram 5 APPENDIX A BOILER PIPING AND WIRING 36 ...

Страница 37: ... N 2 L N 3 L ZONE 3 ZONE 2 120 VAC 4 N L N PRIORITY ON INDIRECT HOT WATER HEATER AQUASTAT OR THERMOSTAT W T STAT DATA PORT X X ZR ZC W T PRIORITY T 1 ZONE T R ZONE 4 THERMOSTATS ZONE 3 T ZONE 2 2 W T R 3 T TW R TO EXTRA ZONE MODULE T 4 R 1VA 24 VAC COMMON T STAT T STAT 15 VA 2 7K SILKSCREEN 1 2K L1 L2 TO ARM L N ON PRIORITY ZONE ELECTRONIC FUSE VAC CIRCUIT ON 120 L2 NO 4 NC 4 SCREWS TORQUE TERMINA...

Страница 38: ...E RECOMMENDED FOR ANTIFREEZE APPLICATIONS SEE NOTE Piping Diagram 6 Primary Secondary Multizone System Piping With Zone Valves And Domestic Hot Water With Zone Valve APPENDIX A BOILER PIPING AND WIRING 38 ...

Страница 39: ... CIRCUIT ON 120 L2 N O 4 N C 4 AR822 TT TT T T R W 24V C 5 6 6 RELAY TRANSFORMER N O N C 24VAC 15 VA 24VAC L1 3 FACTORY INSTALLED JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOI...

Страница 40: ...NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS SEE NOTE Piping Diagram 7 Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator APPENDIX A BOILER PIPING AND WIRING 40 ...

Страница 41: ...N 120 L2 N O 4 N C 4 AR822 II T T R W 24V C 5 6 6 RELAY TRANSFORMER N O N C 24VAC 15 VA 24VAC L1 3 FACTORY INSTALLED JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANS...

Страница 42: ...M EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION TO SYSTEM FROM SYSTEM V2 V1 EXPANSION TANK WATER INLET SYSTEM CIRCULATOR Piping Diagram 8 Bypass Piping Automatic Mixing Valve Piping Diagram 9 Bypass Piping Fixed Low Temp Only APPENDIX A BOILER PIPING AND WIRING 42 ...

Страница 43: ...X 12 MAX TO SYSTEM FROM SYSTEM ALTERNATE CIRCULATOR LOCATION ALTERNATE CIRCULATOR LOCATION BOILER 1 BOILER 2 EXPANSION TANK WATER INLET Piping Diagram 10 Bypass Piping 4 Way Valve Option With Circulator On Supply Piping Diagram 11 Multiple Boiler Piping APPENDIX A BOILER PIPING AND WIRING 43 ...

Страница 44: ...INALS 1 2 TRANSFORMER 24VAC 40 VA Black White Yellow Yellow DHW C1 DHW C2 CH C2 CH C1 A2 DWH T1 DHW T2 A1 BOILER CONTROL PANEL CH T1 CH T2 L1 L2 120 V WHITE BLACK BOILER 1 CIRC DHW C1 DHW C2 CH C2 CH C1 A2 DWH T1 DHW T2 A1 BOILER CONTROL PANEL CH T1 CH T2 L1 L2 BOILER 2 CIRC AMB 8 BOILER 1 BOILER 2 IF USING REQ ACK CONNECT HERE TT THERMOSTAT DRY CONTACT IF USING EXTERNAL DAY NIGHT FEATURE CONNECT ...

Страница 45: ...acement etc DIELECTRIC ISOLATION Two 2 1 1 4 X 1 1 4 Female to female dielectric isolation unions are shipped loose in boiler parts bag Install Dielectric Isolation unions at boiler supply line and return line Install isolation fittings nearest boiler prior to system piping connections WATER TREATMENT and ANTIFREEZE PROTECTION MUST be applied for ALL aluminum series high efficiency gas fired boile...

Страница 46: ... System fluid pH maintained between 7 0 and 8 0 Maintain water hardness below 7 grains hardness Filling with chlorinated potable water is acceptable DO NOT fill boiler with water containing chlorine in excess of 100 ppm DO NOT use inhibitors or other additives that are not listed at end in this addendum Consult local water treatment specialist for recommendations if any of above requirements is ou...

Страница 47: ...commended level Follow antifreeze manufacturer s instructions to adjust pH If system has leaked water and antifreeze chemistry will need to be adjusted To avoid damage to boiler check pH and chemistry of boiler solution and consult the antifreeze manufacturer for recommendations It is recommended that pH reading be taken annually and adjusted as necessary Follow antifreeze inhibitor manufacturer s...

Страница 48: ...onton AB T5M 3X4 Canada www hydronicagencies com Tel 780 452 8661 Fax 780 488 2304 Fernox www fernox com Intercool NFP 30 40 50 AA Intercool RPH 15 Interstate Chemical 2797 Freedland Road P O Box 1600 Hermitage PA 16148 0600 www interstatechemical com Tel 800 422 2436 Fax 724 981 8383 Hercules cryo tek 100 Al Hercules Chemical Company Inc 111 South Street Passaic NJ 07055 www herchem com Tel 800 2...

Страница 49: ...49 NOTES ...

Страница 50: ...50 NOTES ...

Страница 51: ...51 Company Address Phone Company Name Tech Initials Service Performed Date SERVICE RECORD ...

Страница 52: ...ECR International 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

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