ECR International Olsen Q90 125-200 II Series Installation, Operation & Maintenance Manual
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ECR International Olsen Q90 125-200 II Series Installation, Operation & Maintenance Manual

Gas-fired, direct vent, condensing, hot water boiler
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Models
OQ90-125
OQ90-150
OQ90-175
OQ90-200
An ISO 9001-2008 Certified Company
Q90 125-200 SERIES II
GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com
BOILER
P/N 240009433 Rev. A [03/2012]

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Summary of Contents for ECR International Olsen Q90 125-200 II Series

  • Page 1 Q90 125-200 SERIES II GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER Models OQ90-125 INSTALLATION, OPERATION & OQ90-150 MAINTENANCE MANUAL OQ90-175 OQ90-200 Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com P/N 240009433 Rev. A [03/2012] An ISO 9001-2008 Certified Company...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1 - Boiler Ratings & Capacities ....................3 2 - Safe Installation And Operation ..................5 3 - Locating The Boiler ......................6 5 - Combustion Air/ Vent Requirements ................11 6 - Combustion Air And Vent Pipe ..................13 7 - Gas Supply Piping ......................

  • Page 3: Boiler Ratings & Capacities

    1 -BOILER RATINGS & CAPACITIES Figure 1 - Boiler Jackets Table 1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES) Input Heating Capacity Net AHRI Rating Shipping AFUE Model Flue Diameter (MBH) (MBH) (MBH) Weight (lbs.) (1)(2) 90.0 2” CPVC & 3” PVC 90.0 2”...
  • Page 4 1 - BOILER RATINGS & CAPACITIES Ratings shown are for sea level applications. Boiler automatically derates input as altitude increases. No alterations to boiler are required for altitudes above sea level. Table 2 - NATURAL GAS 200,000 175,000 150,000 125,000 Nominal Input Vent Lengths...

  • Page 5: Safe Installation And Operation

    2 - SAFE INSTALLATION AND OPERATION Installers - Follow local regulations with respect to WARNING installation of CO (Carbon Monoxide) Detectors. Follow Improper installation, adjustment, alteration, service maintenance recommendations in this manual. See or maintenance could result in death or serious “Maintenance And Cleaning”...

  • Page 6: Locating The Boiler

    3 - LOCATING THE BOILER Locating The Boiler Boiler shall be installed such that automatic gas ignition system components are protected from water Select level location, central to piping systems served (dripping, spraying, rain, etc.) during operation and and close to vent and air intake terminals as possible. service (circulator replacement, condensate trap, Accessibility clearances, if more stringent (i.e.
  • Page 7 3 - LOCATING THE BOILER After it has been determined each appliance remaining connected to common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition. Any improper operation of common venting system should be corrected so installation conforms with the National Fuel Code, ANSI Z223.1/NFPA 54, or Natural Gas and Propane Installation Code, CAN/CSA B149.1.
  • Page 8 4 - NEAR BOILER PIPING Do not install copper supply and return piping directly Figure 2 - Diaphragm Type Expansion Tank into aluminum boiler section castings due to galvanic Piping corrosion between dissimilar metals. Use iron, steel bushings or pipe connectors between copper system piping and boiler to make fi...
  • Page 9 4 - NEAR BOILER PIPING Safety Relief Valve / Temperature Pressure Gauge Figure 4 - Single Zone Boiler Piping Boiler is furnished with safety relief valve and temperature pressure gauge. • Install safety relief valve using pipe fi ttings provided with boiler.
  • Page 10 4 - NEAR BOILER PIPING Condensate Drain Requirements • Condensate pump with reservoir (not furnished) may be used to remove condensate to drain line (sanitary Pitch condensate drain line down to fl oor drain line) above boiler if fl oor drain is not available or is at minimum of ¼”...

  • Page 11: Combustion Air/ Vent Requirements

    5 - COMBUSTION AIR/ VENT REQUIREMENTS Combustion Air/Vent Pipe Requirements Figure 9 - Sidewall Vent/Intake Terminations Boiler requires dedicated direct vent system. Direct vent system, all air for combustion is taken directly from outside atmosphere, and all fl ue products are discharged to outside 12"...
  • Page 12 5 - COMBUSTION AIR/ VENT REQUIREMENTS WARNING Figure 12 - Concentric Vent Roof Installation Fire, explosion, asphyxiation hazard. Solvent cements are combustible. Keep away from heat, NOTE: VENT sparks, or open fl ame. Use only in well ventilated SUPPORT MUST BE areas.

  • Page 13: Combustion Air And Vent Pipe

    6 - COMBUSTION AIR AND VENT PIPE Combustion air and vent piping connections on boiler Connections And Termination are 2”, but must increase to 3”. Due to potential for To prevent damage to gas burner and ensure proper fl ue gas temperatures over 155°F, fi rst 5 feet of vent operation of unit, installer must clean and remove all pipe must be CPVC (furnished), remaining vent pipe shavings from interior of all PVC pipe used on air intake.
  • Page 14 6 - COMBUSTION AIR AND VENT PIPE Canada - Terminate vent system at least 6 feet (1.83m) NOTICE horizontally from, and in no case above or below, unless 6 feet (1.83m) horizontal distance is maintained, Exhaust transition from 2” pipe to 3” pipe must be made from electric meters, gas meters, regulators and relief in vertical run.

  • Page 15: Gas Supply Piping

    7 - GAS SUPPLY PIPING Check Gas Supply Use ground joint unions. Install sediment trap upstream of gas controls. Table 5 - Gas Supply Pressure Use two pipe wrenches when making connection to Pressure Natural Gas Propane Gas gas valve to keep it from turning. Minimum 4”...

  • Page 16: Electrical Wiring

    8 - ELECTRICAL WIRING WARNING Figure 15 - Field Wiring Connection Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. NOTICE Use copper conductors only. Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction.
  • Page 17 8 - ELECTRICAL WIRING Thermostat Installation AVOID THE FOLLOWING • Follow instructions included with your thermostat. Corners • Locate thermostat fi ve feet above fl oor on inside wall. Dead Spots Alcoves • Mount directly on wall or vertically mount on outlet box. Behind doors Thermostat should sense average room temperature.
  • Page 18 8 - ELECTRICAL WIRING Figure 16 - Schematic Wiring Connections NOTE: 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 19 8 - ELECTRICAL WIRING Figure 17 - Ladder Wiring Diagram NOTE: 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 20: Controls And Accessories

    9 - CONTROLS AND ACCESSORIES See “Troubleshooting” on page 34 for detailed sequences of Figure 19 - Indicator Lights operation and troubleshooting procedures. See separately provided “Repair Parts Manual” for locations of control components and accessories described. Integrated Boiler Control (IBC) •...
  • Page 21 9 - CONTROLS AND ACCESSORIES Differential Pressure Switches • Furnished relief valve automatically opens at 30 psi • Diaphragm type differential pressure switches are to relieve strain on boiler and heating system from connected by vinyl tubing to gas valve, air inlet increasing pressure.

  • Page 22: Startup

    10 - STARTUP Water Treatment And Freeze Protection - See Filling Boiler With Water And Purging Air For Systems Appendix A With Conventional Closed Type Expansion Tanks Refer to diagrams on “Near Boiler Piping” on page 8 and 9 for more information. Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks Close all zone service valves on supply and return...
  • Page 23 10 - STARTUP Operating Instructions WARNING STOP! Read the safety information on this page before If you do not follow these instructions operating this appliance. exactly, a fi re or explosion may result Set the thermostat to the lowest setting. causing property damage, personal injury Turn off all electrical power to the appliance.
  • Page 24 10 - STARTUP If Burner Appears To Pulsate During Ignition: Turn off boiler power. Shut off gas supply to boiler. Take burner assembly apart by removing combustion air blower and gas valve/venturi assembly from boiler. Visually inspect inside of burner. Look for debris (PVC shavings, etc.).
  • Page 25 11 - DETAILED SEQUENCE OF OPERATION DRAFT INDUCER TEMPERATURE SAFETY CASTING TEMPERATURE SAFETY SWITCH SWITCH If burner operates when boiler has no water, If draft inducer temperature reaches temperature aluminum boiler sections heat up rapidly. safety switch set-point, safety switch contacts open immediately, closing gas valve (light goes out) Casting temperature safety switch contacts will...
  • Page 26 11 - DETAILED SEQUENCE OF OPERATION End Of Normal Sequence Of Operation Thermostat ends call for heat. Gas valve and circulator pump are de-energized, valve and fl ame lights go out. Blower runs for 30 seconds post purge, purge light is on. Blower is de-energized after 30 seconds, purge light shuts off.

  • Page 27: Detailed Sequence Of Operation

    11 - DETAILED SEQUENCE OF OPERATION SERVICE HINTS POWER ON STAND BY THERMOSTAT CALLS FOR HEAT IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME LIGHT BLINKS , CIRCULATOR RESET IS REQUIRED. THIS PROBLEM IS A ENERGIZES THRU RESULT OF NOT ESTABLISHING FLAME SIGNAL.

  • Page 28: Sequence Of Operation Diagnostics

    12 - SEQUENCE OF OPERATION DIAGNOSTICS Sequence Of Operation Diagnostics Follow sequence using the diagnostic indicator lamps on Integrated Boiler Control (IBC). See “Controls And Accessories” on page 20 for normal sequence of operation. Detailed sequence of operation containing potential faults can be found in service hints section.

  • Page 29: Checkout Procedure & Adjustments

    13 - CHECKOUT PROCEDURE & ADJUSTMENTS Inspect Venting & Air Intake System - Operate boiler. Test Other Safety Controls Verify all vent/air intake connections are gas-tight and If boiler is equipped with low water cut off, manual reset water-tight. Repair any leaks immediately. high limit, or additional safety controls, test for operation as outlined by control manufacturer.
  • Page 30 13 - CHECKOUT PROCEDURE & ADJUSTMENTS Adjustments And Checkout Set Thermostat To Desired Temperature Set thermostat to desired room temperature and observe Appliance should operate between 8.5 And 10% CO2. several complete cycles to verify proper operation. Verify boiler is operating in this range. Follow steps below. NOTICE Final Review And Sign-Off Under all conditions CO levels should not exceed...

  • Page 31: Troubleshooting - High Limit Control And Lwco

    14 - TROUBLESHOOTING - HIGH LIMIT CONTROL AND LWCO LED Legend and LWCO Test Button Figure 20 - LED Legend HI TEMP illuminates when boiler water temperature reaches high limit setting. Remains lit until water temperature falls 10°F. Limit prevents burner operation while this LED is on.
  • Page 32 15 - TROUBLESHOOTING -HIGH LIMIT CONTROL AND LWCO Troubleshooting Flow Chart Burner Will Not Fire See Flow Chart, this page. If installed with indirect water heater, insure end switch in relay box controlling indirect water No or Insuffi cient heater is properly connected to Cable 2. This will insure domestic water calls are prioritized. If Domestic Hot Water Cable 2 is not used, turn Economy Feature OFF.

  • Page 33: Troubleshooting

    15 - TROUBLESHOOTING Initial Service Checks WARNING Before Troubleshooting: Fire, explosion or shock hazard may cause death or Verify circuit breaker is on or fuse is OK at electrical serious injury. Do not attempt to modify physical or panel. electrical characteristics of this boiler in any way. Verify service switch is ON.
  • Page 34 15 - TROUBLESHOOTING System Status Indicator lights track operating sequence. If system locks out, lights indicate point in sequence of operation were lockout occurs. Refer to following pages for detailed troubleshooting procedures. LIGHT STATUS INDICATES IBC is energized through 24 volt transformer. POWER IBC is not energized.
  • Page 35 15 - TROUBLESHOOTING Troubleshooting Chart 1...
  • Page 36 15 - TROUBLESHOOTING Troubleshooting Chart 2...
  • Page 37 15 - TROUBLESHOOTING Troubleshooting Chart 3 CHART 1 OPEN CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND 3 REPLACE IBC AT CONNECTOR CN4 ON IBC CHECK FOR 120 VAC AT REPAIR/REPLCE BLOWER LEADS ON WIRING WIRING FROM IBC HARNESS TO BLOWER REPAIR/REPLACE BLOWER...
  • Page 38 15 - 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 39 15 - TROUBLESHOOTING Troubleshooting Chart 5...
  • Page 40 15 - 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 41 15 - TROUBLESHOOTING Differential Air Pressure Switch Check Figure 21 - Locations Of Connection Points Required To Check Differential Air Differential air pressure switch is safety device which Pressure prevents boiler from fi ring if there is air intake, boiler heat exchanger or vent blockage.

  • Page 42: Maintenance And Cleaning

    16 - MAINTENANCE AND CLEANING Acidic nature of fl ue gasses condensing on aluminum boiler Daily During Heating Season sections cause formation of aluminum oxide. This oxide Check for and remove any obstruction to fl ow of formation is normal, is generally uniform throughout boiler combustion air or venting of fl...
  • Page 43 16 - MAINTENANCE AND CLEANING Aluminum oxide deposits are water soluble and DANGER may be rinsed away with spraying or running Before servicing, turn off electrical power to boiler at water. service switch. Close manual gas valve to turn gas supply Use fl...

  • Page 44: Appendix A - Dielectric Isolation & Antifreeze Protection

    APPENDIX A - DIELECTRIC ISOLATION & ANTIFREEZE PROTECTION Aluminum Series High Effi ciency Gas-Fired Boiler DIELECTRIC ISOLATION & ANTIFREEZE PROTECTION ADDENDUM WARNING WARNING You MUST follow these instructions to prevent Install boiler so gas ignition system components are damage to boiler’s heat exchanger caused by protected from water (dripping, spraying, rain, etc) inadequate dielectric isolation, incorrect water during appliance operation and service (circulator...
  • Page 45 System and Operating Precautions Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers Clean the System First Eliminate System Leaks BEFORE connecting boiler to heating system, clean Continuous addition of make-up water will constantly add and fl ush system thoroughly. Verify system is free of oxygen to system.
  • Page 46 System and Operating Precautions Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers General Guidelines When Using Antifreeze • Use only antifreeze products • It is recommended that pH reading be recommended for use with aluminum taken annually, and adjusted as necessary. boilers, as listed in this addendum.
  • Page 47 System and Operating Precautions Applies to ALL Aluminum High Effi ciency Gas-Fired Water Boilers Antifreeze Products Table 9 Compatible Aluminum Antifreeze & Inhibitor Suppliers Noble Company P. O. Box 350 Grand Haven, MI 49417 Noburst AL Antifreeze www.noblecompany.com Tel: 800-878-5788 Fax: 231-799-8850 Rhomar Water Management, Inc.
  • Page 48 ECR International  2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...

This manual is also suitable for:

Olsen oq90-125Olsen oq90-150Olsen oq90-175Olsen oq90-200Olsen oq90 ii series

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