UTICA BOILERS UB90 Installation Manual
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UTICA BOILERS UB90 Installation Manual

Gas-fired, direct vent, condensing, hot water boiler
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GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER BOILER
Utica Boilers
P.O. Box 4729
Utica, NY 13504-4729
An ISO 9001-2000 Certified Company
www.uticaboilers.com
MEMBER: The Hydronics Institute
P/N# 1305011, Rev. A [08/08]

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  • Page 1 GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER Utica Boilers P.O. Box 4729 Utica, NY 13504-4729 An ISO 9001-2000 Certified Company www.uticaboilers.com MEMBER: The Hydronics Institute P/N# 1305011, Rev. A [08/08]...
  • Page 2 UB90-50-100 GAS-FIRED BOILER Model No. UB90-50 UB90-75 UB90-100 These instructions must be affixed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional in- formation consult a qualified installer, service agency, or the gas supplier.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Introduction ................................6 Boiler Ratings & Capacities ........................... 7 Boilers For Use At High Altitude ........................... 8 Rules For Safe Installation And Operation ......................10 Before Installing The Boiler..........................10 A. Codes ......................................10 B. Boiler Sizing ....................................11 C.
  • Page 4 TABLE OF CONTENTS G. Differential Pressure Air Proving Switch/Blocked Vent Safety Shutoff ................. 36 H. Draft Inducer ....................................37 I. Circulator Pump .................................... 37 J. Drain Valve ..................................... 37 K. A.S.M.E. Rated Pressure Relief Valve ............................37 L. Blocked Vent Safety Shutoff ................................ 37 M.

  • Page 5: Introduction

    INTRODUCTION This appliance is a gas-fired direct vent hot water boiler with This appliance, unlike normal residential atmospheric and cast aluminum boiler sections. A revolutionary cast aluminum induced draft units, takes its combustion air directly from heat exchanger means better heat transfer and thermal storage the outdoors (sealed combustion) and does not compete with than similarly sized cast iron boilers, which results in higher building occupants for fresh air.

  • Page 6: Boiler Ratings & Capacities

    BOILER RATINGS & CAPACITIES TABLE #1 – SEA LEVEL RATINGS – NATURAL AND PROPANE GASES Input ++ Heating Capacity Net I=B=R Rating Shipping Model Flue Dia. *(MBH) *(MBH) Weight (lbs.) *(MBH) 90-50 2” CPVC & PVC 90-75 2” CPVC & PVC 90-100 2”...

  • Page 7: Boilers For Use At High Altitude

    BOILERS FOR USE AT HIGH ALTITUDE The boilers (with the exception of the 90-75 LP product) Note that 90-75 LP applications for 5,000 - 10,000 feet above are factory equipped for operation at altitudes ranging from sea level will require an orifice change as well as a gas manifold 0-10,000 feet above sea level.
  • Page 8 BOILERS FOR USE AT HIGH ALTITUDE NOTE: For model 90-75 LP units only at altitudes above 5,000 ft., install 90-75 High Altitude Orifice Kit #550001810*. For all other altitudes use factory installed orifice. TABLE #2: SERIES 90 PROPANE GAS series 90-50 stock Factory Btu Value of lP Gas++ settings...

  • Page 9: Rules For Safe Installation And Operation

    RULES FOR SAFE INSTALLATION AND OPERATION Read the entire installation manual before beginning the Follow a regular service and maintenance schedule for ef- installation. Failure to follow these rules for safe instal- ficient and safe operation. lation and operation and these instructions could cause Keep boiler area clean of debris and free of combustible a malfunction of the boiler and result in death, serious and flammable materials.

  • Page 10: Boiler Sizing

    BEFORE INSTALLING THE BOILER feet above finished grade in the area of the venting, includ- Product-approved vent/air-intake: a product-approved ing but not limited to decks and porches, the following vent terminal must be used and, if applicable, a product- requirements shall be satisfied: approved air intake must be used.

  • Page 11: Locating The Boiler

    BEFORE INSTALLING THE BOILER Equipment shall be installed in a location which facilitates the operation of venting and combustion air intake piping D. Locating The Boiler systems as described in this manual. Select a location which is level, central to the piping sys- Advise owner of boiler to keep venting and combustion tems served and as close to the vent and air intake termi- air intake passages free of obstructions.

  • Page 12: Condensate Drain Requirements

    BEFORE INSTALLING THE BOILER CAUTION F. Condensate Drain Requirements Keep boiler area clean of debris and free of flamable and Condensate drain line to be pitched down to floor drain at a combustible materials, vapors and liquids. minimum of ¼” per foot. An external condensate pump (not furnished) may be used if floor drain is not available.

  • Page 13: Foundation Requirements

    BEFORE INSTALLING THE BOILER on clothes dryer and any appliance not connected to the common venting system. Turn on any exhaust fans, such G. Foundation Requirements as range hoods and bathroom exhaust, so they will operate Boiler must be placed on level surface. Boiler is NOT to be at maximum speed.

  • Page 14: Placing The Boiler

    PLACING THE BOILER The boiler should be placed to provide the most direct connec- tions to the combustion air, vent and system piping as possible. Place crated boiler as close to selected location as possible and uncrate boiler. The uncrated boiler may be moved into position with an appliance dolly or 2-wheel hand truck.
  • Page 15 NEAR BOILER PIPING Figure 2 - Single Zone Boiler Piping...
  • Page 16 NEAR BOILER PIPING Figure 3 - Multi-zone Boiler Piping With Zone Valves...
  • Page 17 NEAR BOILER PIPING Figure 4 - Multi-Zone Boiler Piping With Circulators NOTE: When zoning with circulators, the furnished circulator pump should be used as one of the zone pumps. Each stripped end of the electrical wires for the circulator pump inside the junction box should be taped or wire nutted to prevent short circuits.

  • Page 18: Pressure Relief Valve

    NEAR BOILER PIPING Figure 5 - Single Zone Boiler Piping B. Pressure Relief Valve C. Expansion Tank And Make-Up Water The boiler is furnished with a factory installed relief valve in Determine required system fill pressure, system design tem- the top of the boiler. Provide ¾” piping from the supplied perature, and system water content.
  • Page 19 NEAR BOILER PIPING Figure 6 - Diaphragm Type Expansion Tank Piping...
  • Page 20 NEAR BOILER PIPING Figure 7 - Conventional (closed type) Expansion Tank Piping...

  • Page 21: Condensate Drain Piping

    NEAR BOILER PIPING Figure 8 - Condensate Drain Piping The ½” diameter schedule 40 PVC or CPVC condensate drain D. Condensate Drain Piping and pipe fittings must conform to ANSI standards and ASTM The condensate trap is built into the boiler, an external trap is D 1785 or D2846.

  • Page 22: Filling Condensate Trap With Water

    NEAR BOILER PIPING E. Filling Condensate Trap With Water F. Chilled Water Piping On The Initial Start Up The Condensate Trap Must Be Manu- The boiler, when used in connection with a refrigeration sys- ally Filled With Water. tem, must be installed so the chiller medium is piped in paral- lel with the boiler with appropriate valves to prevent the chilled The following are the steps required to initially fill the conden- medium from entering the boiler.
  • Page 23 COMBUSTION AIR AND VENT PIPE Combustion air and vent piping connections on boiler are sized for 2” pipe. Any pipe size change (to 3”) must be made outside of the boiler casing in a vertical run of pipe to allow for proper drainage of vent condensate. Due to NOTE: The transition from 2”...
  • Page 24 COMBUSTION AIR AND VENT PIPE Combustion air and vent piping lengths: coMBUstioN air aND VeNt PiPiNG leNGtHs Boiler 2” PIPE MINIMUM 2” PIPE MAXIMUM 3” PIPE MINIMUM 3” PIPE MAXIMUM siZe VENTING VENTING” VENTING VENTING” 8 FEET 21 FEET 27 FEET 92 FEET 75 &...
  • Page 25 COMBUSTION AIR AND VENT PIPE snow may cause the boiler to shut down if the vent be- Consideration for the following should be used when comes obstructed. determining an appropriate location for termination of combustion air and vent piping. • Under certain conditions, flue gas will condense, form- ing moisture, and may be corrosive.
  • Page 26 COMBUSTION AIR AND VENT PIPE Figure 10 - Side Wall Vent / Intake terminations Less Than 12” Clearance 12” Or More Clearance...
  • Page 27 COMBUSTION AIR AND VENT PIPE Figure 11 - Combustion Air and Vent Piping...

  • Page 28: Installation

    COMBUSTION AIR AND VENT PIPE B. Installation While cement is still wet, insert pipe into socket with ¼ Attach combustion air intake piping to supplied Fernco turn twist. Be sure pipe is fully inserted into fitting socket. 2” coupling on mixer. Attach vent piping to furnished 2” CPVC vent tee on draft inducer outlet.

  • Page 29: Connecting The Gas Piping

    GAS SUPPLy PIPING B. Connecting The Gas Piping 8. Propane gas connections should only be made by a Refer to Figure #12 (on following page) for the general lay- licensed propane installer. out at the boiler. It shows the basic fittings you will need. The 9.

  • Page 30: Electrical Wiring

    GAS SUPPLy PIPING Figure 12 - Gas Piping ELECTRICAL WIRING box and power supply connection points. Connect black WARNING (hot) lead from the power supply to either of the unused brass screws on the service switch. Connect the white Turn off electrical power at fuse box before making any line (neutral) lead from the power supply to the white screw on voltage connections.

  • Page 31: Install Your Thermostat

    ELECTRICAL WIRING B. Install your Thermostat The thermostat location has an important effect on the op- CAUTION eration of your boiler system. BE SURE TO FOLLOW THE LABEL ALL WIRES PRIOR TO DISCONNECTION INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT. WHEN SERVICING CONTROLS. WIRING ERRORS Locate the thermostat about five feet above the floor on an CAN CAUSE IMPROPER AND DANGEROUS OPERA- inside wall.
  • Page 32 ELECTRICAL WIRING Figure 13 - Field Wiring Connections...
  • Page 33 ELECTRICAL WIRING Figure 14 - D - Schematic Wiring Diagram If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent...
  • Page 34 ELECTRICAL WIRING Figure 15 - E - Ladder Wiring Diagram 120 VOLT POWER SUPPLY ON/OFF SWITCH P7-2 P7-1 P7-3 P4-3 P4-1 P10-1 CIRCULATOR MOTOR P5-3 P5-1 P10-2 DRAFT INDUCER HOT SURFACE IGNITER P6-1 P12-1 P12-2 P6-2 P1-3 P1-1 TRANSFORMER P2-1 P2-2 CASTING TEMPERATURE SAFETY SWITCH...

  • Page 35: Controls And Accessories

    CONTROLS AND ACCESSORIES and may be set anywhere between 100 °F and 200 °F. The field This section provides a brief description of the key controls setpoint adjustment for each installation depends on heating and accessories found in this boiler. system requirements.

  • Page 36: Draft Inducer

    CONTROLS AND ACCESSORIES adequate combustion air flow or flue gas flow. The IBC will be K. A.S.M.E. Rated Pressure Relief Valve automatically reset after fifteen (15) minutes or can be manu- Each boiler must have a properly sized and installed American ally reset from lockout by (a) removing and reestablishing the Society of Mechanical Engineers rated pressure relief valve.

  • Page 37: Water Treatment & Freeze Protection

    WATER TREATMENT & FREEZE PROTECTION When filling the boiler water is the preferred heating solution. Piping Recommendations Most potable water supplies may be used to charge and re-fill System leaks may not always be visible. An unseen system leak provided the chlorine and chloride ions levels are less than 100 will become obvious if boiler pressure decreases when make up ppm.

  • Page 38: Cleaning The Hydronic System

    WATER TREATMENT & FREEZE PROTECTION Cleaning the Hydronic System Freeze Protection IMPORTANT: Do not mix different manufacturers’ products. Aluminum Safe Antifreeze, Treatments and Additive Guidelines: Doing so will void the warranty of the boiler. Consideration MUST be given to cleaning the heating system, Antifreeze, if required, must be one of the antifreeze manufac- particularly in retrofit situations where a new boiler with an turers listed in this manual.
  • Page 39 XII - WATER TREATMENT & FREEZE PROTECTION Recommended Aluminum Antifreeze Recommended Products & Inhibitor Suppliers Interstate Chemical 2797 Freedland Road Intercool NFP-30,40,50 AA P.O. Box 1600 Hermitage, PA 16148-0600 Intercool RPH-15* www.interstatechemical.com Tel: 800-422-2436 Fax: 724-981-8383 Noble Company PO Box 350 Grand Haven, MI 49417 Noburst AL Antifreeze www.noblecompany.com Tel: 800-878-5788 Fax: 800-272-1519...

  • Page 40: Start Up

    START UP zone. Open the purge valve on the first zone. Feed water A – Filling Boiler With Water And Purging Air For will fill the zone, pushing air out the purge valve. Close the Systems With Diaphragm Type Expansion Tanks purge valve when the water runs air free.

  • Page 41: C - Placing Boiler In Operation

    START UP C - Placing Boiler In Operation 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 •...

  • Page 42: Check Out Procedure And Adjustment

    CHECK OUT PROCEDURE AND ADJUSTMENT Figure 16 - Indicator Lamps A. Verify Proper Sequence Of “DiaGNostic Operation seQUeNce oF oPeratioN iNDicator laMPs” The sequence can be followed via the A.  diagnostic indicator lamps on the Hon- B.  “Power ON, boiler standing by. Lamp A is illuminated eywell S9301A integrated boiler control C.

  • Page 43: Inspect Venting And Air Intake System

    CHECK OUT PROCEDURE AND ADJUSTMENT seQUeNce oF oPeratioN “DiaGNostic iNDicator laMPs” A.  After pre purge, Lamp B goes out and Lamp C illuminates, in- B.  dicating the hot surface igniter is powered for the 20 second C.  igniter warm-up period.

  • Page 44: Test High Limit Control And Adjust

    CHECK OUT PROCEDURE AND ADJUSTMENT Turn off all other gas appliances, extinguishing standing F. Test High Limit Control And Adjust pilots where applicable. While burner is operating, move indicator on high limit control below actual boiler water temperature. Burner should At gas meter, measure time in seconds required to use one cubic foot of gas.

  • Page 45: Set Thermostat To Desired Room Temperature

    CHECK OUT PROCEDURE AND ADJUSTMENT Measure new input rate (cover screw must be installed). Repeat steps I.-IV until the input rate is within +/-2% of the nameplate input rating. If the actual input rate can not be set to within 2% of the correct input rating by adjusting manifold pressure, a change in gas orifice size is required.
  • Page 46 CHECK OUT PROCEDURE AND ADJUSTMENT Figure 17 - Manifold Pressure Measurement Detail The following steps and diagram indicate the location of the connection points required to measure the manifold pressure. The manifold pressure may be measured using a U-Tube Ma- nometer or a Differential Pressure Gauge.
  • Page 47 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model serial # Date installed___________ Measured BtU/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...

  • Page 48: Maintanance And Cleaning

    MAINTANANCE AND CLEANING Maintenance as outlined below can be performed by the Insure that there are no leaks. Use RTV silicone rubber owner unless otherwise noted. adhesive sealant (available in caulking gun tubes) rated for at least 400° F to replace or repair seals in locations The acidic nature of flue gasses condensing on the aluminum where original seals have deteriorated.

  • Page 49: Monthly During Heating Season

    MAINTANANCE AND CLEANING Monthly During Heating Season Annual Examination And Cleaning Of Boiler Components 1. Remove jacket front and top panels and check for pip- ing leaks around relief valve and other fittings. If found, contact a qualified service agency to repair. DO NOT use The following service procedures must be performed only stop leak compounds.
  • Page 50 MAINTANANCE AND CLEANING Remove the condensate trap and run cold water through After rinsing, remove any remaining loosened sediment the condensate lines to thoroughly flush out any sedi- using a shop vacuum with a snorkel attachment. ment or debris in the lines. Inspect burner for any foreign matter in the flame ports Reinstall and connect the condensate trap, using the hose or inside the burner.

  • Page 51: Detailed Sequence Of Operation

    DETAILED SEqUENCE OF OPERATION Service Hints POWER ON STAND BY THERMOSTAT CALLS FOR HEAT IF MAIN BURNER DOES NOT PROVE FLAME IN CIRCULATOR ENERGIZES THRU 3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME 2K1 CONTACTS LIGHT BLINKS. MANUAL RESET IS REQUIRED OR CONTROL WILL AUTOMATICALLY RESET AFTER 1 HOUR.
  • Page 52 DETAILED SEqUENCE OF OPERATION DraFt iNDUcer teMPeratUre saFety switcH castiNG teMPeratUre saFety switcH IF DRAFT INDUCER TEMPERATURE REACHES IF BURNER OPERATES WHEN BOILER HAS NO TEMPERATURE SAFETY SWITCH SETPOINT, WATER, ALUMINUM BOILER SECTIONS HEAT UP SAFETY SWITCH CONTACTS OPEN IMMEDIATELY RAPIDLY.
  • Page 53 DETAILED SEqUENCE OF OPERATION...

  • Page 54: Troubleshooting

    TROUBLESHOOTING WARNING Fire, explosion or shock hazard may cause property dam- age, severe injury or death. Do not attempt to modify the physical or electrical characteristics of this boiler in any way. Important n a reset from lockout condition, all electrical meter readings at the gas control valve (24 vac) must be taken within the trial for ignition period.
  • Page 55 TROUBLESHOOTING System Status THE INDICATOR LIGHTS TRACk THE OPERATING SEqUENCE. IF THE SYSTEM LOCkS OUT, THE LIGHTS INDICATE THE POINT IN THE SEqUENCE OF OPERATION WHERE LOCkOUT OCCURS. IF THIS TABLE DOES NOT READILY PROVIDE THE REASON FOR BOILER MALFUNCTION OR NON-OPERATION, REFER LIGHT STATUS INDICATES...
  • Page 56 TROUBLESHOOTING TROUBLESHOOTING CHART 1 WARNING ELECTRICAL SHOCK HAZARD MAY CAUSE SERIOUS INJURY OR DEATH. The following procedures may expose you to dangerous line voltage. Use caution to avoid touching live electrical con- tacts. Service must be performed by a trained, experienced service technician.
  • Page 57 TROUBLESHOOTING TROUBLESHOOTING CHART 2...
  • Page 58 TROUBLESHOOTING TROUBLESHOOTING CHART 3...
  • Page 59 TROUBLESHOOTING TROUBLESHOOTING CHART 4 CHART 3 CHECk FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS 1 UP AND GLOWS AND 2 AT CONNECTOR REPLACE IBC YELLOW/ORANGE CN1 ON IBC (DURING DURING 20 SECOND IGNITER WARM UP) WARM UP CHECk FOR 120 VAC AT IGNITER/SENSOR LEADS REPAIR/REPLACE WIRING ON WIRING HARNESS...
  • Page 60 TROUBLESHOOTING TROUBLESHOOTING CHART 5...
  • Page 61 TROUBLESHOOTING TROUBLESHOOTING CHART 6 CHART 5 CHART 5 CHART 5 REPLACE GAS CONTROL. NO #3 NO #2 CHECk GAS ORFICICE SIzE. IS GAS ORIFICE SIzE CORRECT. CHECk REPAIR PARTS LIST FOR CORRECT SIzE. IS GAS ORIFICE CLEAR OF BLOCkAGE. RUNS FOR 25-50 SECONDS, THEN TURNS OFF.

  • Page 62: Differential Air Pressure Switch Check

    DIFFERENTIAL AIR PRESSURE SWITCH CHECK What Is System Status? The following steps and diagram indicate the locations of the connection points required to check the differential air pressure. The differential air pressure switch is a safety device which will prevent the boiler from firing if there is an air intake, boiler heat exchanger or vent blockage.
  • Page 63 UB90-50-100 GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER Model No. UB90-50 UB90-75 UB90-100...

  • Page 64: Repair Parts

    REPAIR PARTS A. Jacket and Base Assembly TYP OF 4...
  • Page 65 REPAIR PARTS Jacket aND Base asseMBly iteM key # DescriPtioN QUaNtity NUMBer FRONT PANEL 750001020 RIGHT PANEL 750001021 LEFT PANEL 750001022 BACk PANEL 750001023 TOP PANEL 750001024 BASE 750001025 CONTROL PANEL 650001026 AT140B1016 TRANSFORMER 24 VAC 550001339 - - - - - - - - - - - - UT 1013-10 INTEGRATED BOILER CONTROL...
  • Page 66 REPAIR PARTS B. Condensate Drain Trap Assembly Connect to the drain port at the bottom of boiler Connect to the drain port at the exhauster KEY # DESCRIPTION QUANTITY ITEM NUMBER 59019 ½”IDx1/8” THk VINYL TUBING AS REqUIRED 14631035 57134 ¾” SNAP GRIP CLAMP 14631141 62067 ½”ID HOSE TEE 14631320...
  • Page 67 REPAIR PARTS C. Flue Adapter and Exhaust Assembly KEY # DESCRIPTION QUANTITY ITEM NUMBER EXHAUST TEE ASSEMBLY - 1-A,B,C,D,E & F 43800001 62017 1/2”NPTx1/2”ID TUBE STRAIGHT 14631101 PVC 1 1/2” MALE SLIP x 1/2” FEMALE NPT 14631013 PVC SCH 40 2”x1-1/2” REDUCER S636 240006817 3/4’’...
  • Page 68 REPAIR PARTS D. Boiler Block and Piping Assembly TYP OF 5 TYP OF 5 TYP OF 8 TYP OF 4 TYP OF 4 TYP OF 4...
  • Page 69 REPAIR PARTS Boiler Block aND PiPiNG asseMBly key # iteM NUMBer DescriPtioN QUaNtity 41800650 kIT BLOCk REPL q90-100 (INCLUDES #2 THRU #19) 14607044 NPL,1-1/4X2-1/2,BI,STD 14607201 NPL,3/4X2,BI,STD 14619002 OBSERVATION GLASS, 3/4” 14631000 SWITCH CASTING TEMP q90 36T26-42930 300 14631004 ADAPTER, SIGHT GLASS 14631005 FITTING, 125HBL-4-2 1/8”X1/4”BR.B+ 14631101...
  • Page 70 REPAIR PARTS E. Mixer and Air Pressure Switch Assembly To Sight Glass Adapter...
  • Page 71 REPAIR PARTS Mixer aND air PressUre switcH asseMBly key # DescriPtioN QUaNtity iteM NUMBer BURNER GASkET 14631023 BURNER kIT, 50 &100 NAT/LP, 0’-10,000’ (Contains: 1, 2, 3, 7, 10, 11, 12 & 29) 550001811 BURNER kIT, 75 NAT, 0’-10,000’ (Contains: 1, 2, 3, 7, 10, 11, 12 & 29) 550001811 BURNER kIT, 75 LP, 0’- 5,000’...
  • Page 72 P.O. Box 4729 Utica, NY 13504-4729...

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