UTICA BOILERS UBSSC-050 Installation, Operation & Maintanance Manual
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UTICA BOILERS UBSSC-050 Installation, Operation & Maintanance Manual

Wall mounted gas boiler
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Models
-
UBSSC
050
UBSSC-075
UBSSC-100
UBSSC-150
UBSSC-200
An ISO 9001-2008 Certified Company
WALL MOUNTED
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com
GAS BOILER
P/N# 240008845, Rev. C [06/2011]
H

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Summary of Contents for UTICA BOILERS UBSSC-050

  • Page 1 Models WALL MOUNTED UBSSC GAS BOILER UBSSC-075 UBSSC-100 INSTALLATION, OPERATION & UBSSC-150 MAINTENANCE MANUAL UBSSC-200 2201 Dwyer Avenue, Utica NY 13504-4729 An ISO 9001-2008 Certified Company P/N# 240008845, Rev. C [06/2011] web site: www.ecrinternational.com...
  • Page 2 DIMENSIONS FIGURE 1-1 Dimensions Combustion Air Vent Connector Safety Relief Valve Connection (¾ NPT) Wall Hanging Bracket Table 1 : Physical Data Models 050/075/100 150/200 20" 23" Width (A) (508mm) (584mm) 31" 42" Height (B) (787mm) (1092mm) 14" 16.0" Depth (C) Supply Water (E) (356mm) (406mm)

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 - Introduction ..........................4 2 - Important Safety Information ....................5 3 - Component Listing ........................6 4 - Locating Boiler ........................... 9 5 - Hydronic Piping ........................11 5.2 Special Conditions ........................11 5.3 Safety Relief Valve and Air Vent ....................11 5.4 Trim Piping ..........................

  • Page 4: Introduction

    1 - INTRODUCTION 1.1 Designated Use • Hot water heating boiler. • Indoor installation. • Closet or alcove installation. • Direct vent boiler. • For use with natural gas or liquefi ed petroleum gases (LP/propane). 1.2 The unit MUST NOT: •...

  • Page 5: Important Safety Information

    2 - IMPORTANT SAFETY INFORMATION 2.1 General 2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of Boiler installation shall be completed by qualifi ed agency. such requirements: See glossary for additional information. • National Fuel Gas Code, ANSI Z223.1/NFPA 54 WARNING •...

  • Page 6: Component Listing

    3 - COMPONENT LISTING 3.1 Component Listing Gas (Control) Valve Gas (Control) Valve (see page 8) - Delivers - Delivers proper quantity of fuel to Combustion Air Blower. proper quantity of fuel to Combustion Air Blower. See section 7. See section 7. User Interface (see Appendix A) - Displays information regarding boiler condition.
  • Page 7 3 - COMPONENT LISTING FIGURE 3-1 Boiler Components (Viewed from Back of Boiler) NOTE: AIR VENT AIR VENT See Section 5-3 SAFETY RELIEF VALVE SAFETY RELIEF VALVE For Safety Relief Valve Piping VENT CONNECTOR Instructions COMBUSTION AIR INLET WALL HANGING WALL HANGING SUPPORT SUPPORT...
  • Page 8 3 - COMPONENT LISTING 3 - COMPONENT LISTING FIGURE 3-4 Boiler Components (View from Front of Boiler) NOTE: See Section 5 AIR VENT AIR VENT For Piping SAFETY RELIEF VALVE SAFETY RELIEF VALVE Instructions VENT CONNECTOR COMBUSTION AIR INLET HIGH TEMPERATURE SUPPLY SWITCH LOW WATER LOW WATER...

  • Page 9: Locating Boiler

    4 - LOCATING BOILER FIGURE 4-1 Clearance to Combustible Materials Boiler Location Considerations • Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate. • Approved for installation in closets. • Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).
  • Page 10 4 - LOCATING BOILER FIGURE 4-2 Wall Mount Bracket Engaged with 4.2 Prepipe supply and return water connections with Bracket on Boiler factory fi ttings before wall mounting. 4.3 Wall Mounting Mount boiler on wall using wall mounting bracket included Center brackets.

  • Page 11: Hydronic Piping

    5 - HYDRONIC PIPING 5.1 General • Install piping in accordance with authority having jurisdiction. WARNING NOTICE • Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol. Use two (2) wrenches when tightening and fi tting to pipe boiler's threaded fi ttings. Boiler's internal •...

  • Page 12: Trim Piping

    5 - HYDRONIC PIPING fi gure 5-2. WARNING • Use ¾" or larger pipe. Burn and scald hazard. Safety relief valve could • Use pipe suitable for temperatures of 375°F (191°C) discharge steam or hot water during operation. or greater. Install discharge piping per these instructions.
  • Page 13 5 - HYDRONIC PIPING Piping Legend NOTICE Illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. FIGURE 5-4 System Piping Safety Relief Valve System System Supply Return F L O O R Check Local Codes For Maximum Distance To Floor...
  • Page 14 5 - HYDRONIC PIPING 5-5 TWO-PIPE ZONED SYSTEM WITH VALVES Pump CH/System Pump Heat exchanger ball valve open (as shipped) 3/8"/10mm Open End Wrench 5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS Pump Heat exchanger ball valve open Zone (as shipped) Pump 3/8"/10mm Open End Wrench...
  • Page 15 5 - HYDRONIC PIPING 5-7A SINGLE BOILER USING PRIMARY/SECONDAY PUMPING 12"/305mm Max. apart 12"/305mm Existing closely spaced tees Max. apart in primary system loop CH/System Limit length Pump 5'/1.6 m Heat exchanger ball valves closed 3/8"/10mm Open End Wrench 5-7B SINGLE BOILER USING PRIMARY/SECONDAY PUMPING 12"/305mm Max.
  • Page 16 5 - HYDRONIC PIPING 5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide) Pump System Pump 12"/305mm Max. apart System Size common piping Temperature according to Sensor maximum heat capacity of entire system Up to 16 boilers All heat exchanger ball valves closed 3/8"/10mm Open End Wrench...

  • Page 17: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING • Any improper operation of common venting system 6.1 General should be corrected so installation conforms with National This boiler requires a dedicated direct vent system. Fuel Code, ANSI Z223.1/NFPA 54. When re-sizing any Install combustion air and vent piping in accordance portion of common venting system, common venting with these instructions, authority having jurisdiction,...

  • Page 18: Pipe Installation

    6 - COMBUSTION AIR AND VENT PIPING 6.4 Pipe Installation 6.5 Termination • Minimum and maximum combustion air and vent pipe • Terminate combustion air and vent pipes with fi ttings or lengths listed in Table (3). Pipe length counted from concentric vent kit.
  • Page 19 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 3" (8 cm) Maximum 3" (8 cm) Maximum horizontal separation between combustion air intake and vent of same appliance. 12" (30 cm) 15" (38 cm) 8" (21 cm) Minimum vertical Minimum Maximum Roof Line separation between combustion...
  • Page 20 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 FIGURE 6-5 1" (2.54cm) 1" (2.54cm) Roof overhang Maximum Maximum 1"(2.54cm) Maximum 12" (30cm) Minimum * See Note 36"(0.9m) Minimum Below Maintain 12" Maintain 12"(30cm) clearance above Vent Vent clearance above highest highest anticipated Combustion anticipated snow level or...
  • Page 21 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-6 Glue inner vent pipe to prevent Vent recirculation. Maintain 12"(30cm) Maintain 12" (30 cm) minimum clearance above highest clearance above highest anticipated anticipated snow level snow level. Maximum of 24"(0.61m) 24" above roof Combustion Air above roof.
  • Page 22 6 - COMBUSTION AIR AND VENT PIPING Combustion air and vent termination Doors & must be 12" (300mm) from or below Windows doors, windows or gravity inlet. Termination must Vent gas may condense, forming be 12" (30.5 cm) moisture, may be corrosive. Protect Condensate from or below doors, building materials at vent from exhaust...
  • Page 23 6 - COMBUSTION AIR AND VENT PIPING Keep vent termination 3’ minimum Vegetation, (0.9m) away from vegetation. Position Plants & termination where vent vapors will not damage plants/shrubs or air conditioning Shrubs equipment. Termination Vent termination 4’ (1.2m), horizontally Meters, from, no case above or below, electric Regulators, meters, gas meters, regulators, and...

  • Page 24: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 Condensate Drain 6.6 Condensate Piping • Use materials acceptable to authority having jurisdiction. In absence of such authority: • PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493. •...

  • Page 25: Gas Supply Piping

    7 - GAS SUPPLY PIPING 7-1 Gas Connection CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switches; do not use any phones in your building. • Immediately call your gas supplier from a neighbor’s phone.
  • Page 26 7 - GAS SUPPLY PIPING 7-2 Manual Main Gas Shutoff Valve Outside DANGER Boiler Jacket Fire Hazard. Do not use matches, candles, open fl ames, or other methods providing ignition source. Failure to comply will result in death or serious injury.

  • Page 27: Electrical Connections

    8 - ELECTRICAL CONNECTIONS 8.1 General WARNING Electrically bond boiler to ground in accordance with Electrical shock hazard. Turn OFF electrical power requirements of authority having jurisdiction. Refer to supply at service panel before making electrical National Electrical Code, ANSI/NFPA 70. connections.
  • Page 28 8 - ELECTRICAL CONNECTIONS • Argus Link (Multiple boiler applications only) 8-3 EXTERNAL CONNECTIONS • Outdoor Sensor, if used. (Do not apply voltage to external terminals.) Provided with boiler. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor.

  • Page 29: Start Up Procedure

    9 - START UP PROCEDURE 9.1 Fill boiler with water and purge air NOTICE • Fill boiler with potable water. IMPORTANT: Condensate trap must be manually • Fill boiler and system piping with water (or antifreeze- fi lled with water at initial start up. water solution, if used).
  • Page 30 9 - START UP PROCEDURE 9 -2 User Interface -2 User Interface 9.3 Program Boiler Control Description - Manual Lockout Reset - Enter/Exit user menu - Go to previous screen - Select a menu item - Confi rm new parameter value - Scroll up to next menu item - Increase value - Scroll down to next menu item...
  • Page 31 9 - START UP PROCEDURE 9.4 Boiler Start-up and Operational Test if needed using fi gure 9-3 below. Verify air is purged from hydronic piping Size Minimum Maximum System test pumps - verify each pump is opera- tional Verify gas piping •...

  • Page 32: Csd-1 Compliance Test

    9 - START UP PROCEDURE Verify Burner, Proper Operation WARNING Inspect burner fl ame through Sight Glass. See Asphyxiation hazard. Carbon monoxide is odorless, fi gure 9-5. tasteless, clear colorless gas, which is highly toxic. Operate boiler through several heating cycles, Verify cap is fi...
  • Page 33 9 - START UP PROCEDURE 9-6 Control Module J7 Connector 9.7 Complete Start Up Procedure Reset control parameters to operating settings if adjusted to allow startup and operation test. Follow instructions TO TURN OFF GAS TO APPLIANCE if boiler is not being placed into immediate operation.

  • Page 34: Operating Instructions

    10 - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WARNING WHAT TO DO IF YOU SMELL GAS If you do not follow these instructions • Do not try to light any appliance. exactly, a fi re or explosion may result •...

  • Page 35: General Maintenance And Cleaning

    11 - GENERAL MAINTENANCE AND CLEANING 11.1 Beginning of Each Heating Season DANGER • Check boiler area is free from combustible materials, Before servicing, turn off electrical power to boiler gasoline, and other fl ammable vapors and liquids. at service switch. Close manual gas valve to turn •...
  • Page 36 11 - GENERAL MAINTENANCE AND CLEANING Figure 11-2 Condensate Trap 11.2 Annual Shut Down Procedure • Follow instructions “To Turn Off Gas To Appliance” unless boiler is also used to supply domestic hot water. See section 10. • Drain system completely if system does not have antifreeze when heating system is to remain out of service during freezing weather.
  • Page 37 11 - GENERAL MAINTENANCE AND CLEANING • Remove ¼-20 hex fl ange nuts securing condensate collector to heat exchanger using 7/16" deep well socket. See fi gure 11-2. • Remove condensate collector assembly from heat exchanger and fl ue pipe. •...

  • Page 38: Ratings And Capacities

    12 - RATINGS AND CAPACITIES TABLE 12-1: SEA LEVEL RATINGS NATURAL AND PROPANE GASES Net I=B=R Rating, Boiler Input Rate (MBH) Heating Capacity Size Water (MBH) (1)(3) AFUE (MBH) (1)(2) Maximum Minimum 96.0 96.0 96.0 96.0 96.0 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Effi...

  • Page 39: Troubleshooting

    13 - TROUBLE SHOOTING GO TO NEXT PAGE...

  • Page 40: Trouble Shooting

    13 - TROUBLE SHOOTING Go to Page 45 Go to Page 41 Go to Page 46 Go to Page 42 Go to Page 41 Go to Page 47 Replace Control Replace Control Module Module Go to Page 47 Go to Page 43 Replace Control Go to Page 48 Module...
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  • Page 53: Wiring Diagram

    14 - WIRING DIAGRAM 14.1 Connection Diagram...
  • Page 54 14 - WIRING DIAGRAM 14.2 Schematic Diagram of Ladder Form...

  • Page 55: Glossary

    15 - GLOSSARY • ANSI - American National Standards Institute, Inc. oversees creation and maintenance of voluntary consensus standards, including ANSI Z21.13/CSA 4.9: NATURAL GAS Gas-Fired Low Pressure Steam and Hot Water Boilers. Pipe Capacity - BTU Per Hour Input Includes Fittings Length of Pipe - Ft.
  • Page 56 15 - GLOSSARY • QUALIFIED AGENCY - Any individual, fi rm, corporation, or company engaged in and responsible for: • Installation, testing, or replacement of gas piping, or connection, installation, testing, repair or servicing of appliances and equipment. • Experienced in such work. •...

  • Page 57: Appendix A - Control Module

    APPENDIX A - CONTROL MODULE 1.1 Front Panel Status Indicators See Control Module Section for opertional states of Front Panel Indicators and User Interface Display. POWER INDICATOR (Green) Light is lit when boiler power is ON. Light is lit when boiler is providing heat for CH or HEAT INDICATOR (Green) DHW.

  • Page 58: Introduction

    APPENDIX A - CONTROL MODULE 2.1 Introduction Operation with LCD character display module Operation with LCD character display module Boiler is equipped with programmable electronic control and user interface module. 2.2 Operation • Display: 4x20 character LCD screen to show boiler status.

  • Page 59: Sequence Of Operation

    APPENDIX A - CONTROL MODULE 2.4 Sequence of Operation Front Panel Operational State User Interface Display Explanation dica- tors Boiler operates in standby mode until demand for Central Heat (CH) or Domestic Hot Water (DHW) is Heat detected. Demand? CH or DHW pump is turned on based on type of heating demand.
  • Page 60 APPENDIX A - CONTROL MODULE 2.4 Sequence of Operation Operational State User Interface Display Explanation If fl ame detected before Gas Valve After 2 seconds opens during ignition boiler will lockout. Lockout Flame Error A21 Detected? Please refer to troubleshooting guide.

  • Page 61: Theory Of Operation

    APPENDIX A - CONTROL MODULE 2.5 Theory of Operation Explanation User Interface Display Boiler operates in standby mode until demand for Central Heat (CH) or Domestic Hot Water (DHW) is detected. User Menu can be accessed by pressing ‘Menu’ key on user interface.
  • Page 62 APPENDIX A - CONTROL MODULE Explanation User Interface Display Adjust CH set point to hydronic system design while in Operating in CH Mode = 0 (CH with Thermostat) or 3 (Permanent Demand). In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2 (CH with Full Outdoor Reset).
  • Page 63 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu The Installer Menu structure includes: • ‘Boiler Status’ submenu – User monitors detailed boiler status parameters such as fl ame signal, fan speeds and stored error codes. • ‘Boiler Confi g’ submenu – Modifi es general boiler settings.
  • Page 64 APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu Control module logs successful and failed ignition attempts. Information accessed in ‘Ignition Attempts’ Screen as shown. Ignition attempts are stored in non-volatile memory and are retained in event of power failure. Figure A-1 Typical Ignition Cycle ▲...
  • Page 65 APPENDIX A - CONTROL MODULE Explanation User Interface Display Boiler stores information regarding total CH and DHW run time ▲ S T A T U S in hours. B o i l e r R u n T i m e 3 2 0 H R Data stored in non-volatile memory and retained in event of power failure.
  • Page 66 APPENDIX A - CONTROL MODULE Explanation User Interface Display Two pump modes are available: Pump Mode = 0 ‘CH or CH&DHW’ • In this mode either the CH or DHW pump terminal is energized depending on the type of demand (CH or DHW). •...
  • Page 67 APPENDIX A - CONTROL MODULE Explanation User Interface Display 4. Central Heating (CH) modes available: • CH Mode = 0 ‘CH with Thermostat’ • Boiler will attempt to satisfy CH demand while CH thermostat input is closed. • Boiler will modulate its fi ring rate to maintain CH set point and match system heat load.
  • Page 68 APPENDIX A - CONTROL MODULE Explanation User Interface Display ▲ S E T T I N G S If outdoor temperature is greater than Warm Weather W a r m W e a t h e r Shutdown Temperature, demand for CH blocked and pumps S h u t d o w n T e m p stopped.
  • Page 69 APPENDIX A - CONTROL MODULE Explanation User Interface Display Outdoor reset boost function increases CH set point by increment (‘Temp’) if CH demand continues beyond pre-set time limit (‘Time’). ▲ S E T T I N G S CH set point will continue to increase until set point reaches B o o s t F u n c t i o n 195°F / 91°C...
  • Page 70 APPENDIX A - CONTROL MODULE Explanation User Interface Display Maximum time boiler operates in DHW mode limited by DHW Maximum Priority Time Setting. Priority timer starts when both CH and DHW demand is present. Boiler will switch from DHW back to CH operation after ▲...
  • Page 72 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com...

This manual is also suitable for:

Ubssc-075Ubssc-100Ubssc-150Ubssc-200

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