ECR International Olsen OSVB II Series Gebrauchsanweisung

P/N 240009138, Rev. D [10/2014]

An ISO 9001-2008 Certified Company

OSVB SERIES II

Gas-Fired Hot Water

Induced Draft Boilers

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Models

OSVB-2

OSVB-3

OSVB-4

OSVB-5

OSVB-6

OSVB-7

An ISO 9001-2008 Certied Company

C.S.A. Certied

For Natural Gas Or Propane

Tested For 50 psi.

ASME

Working Pressure

Boiler Ratings & Capacities...................... 3

Dimensions ............................................. 4

Installation Procedure............................. 5

Ventilation & Combustion Air .................. 6

Installation System Piping ...................... 7

Vent Installation ................................... 10

Horizontal Venting Instructions .......... 13

Optional Horizontal Venting Instruction 18

Gas supply Piping .................................. 19

Electrical Wiring .................................... 21

Sequence of Operation .......................... 22

Wiring Diagrams ................................... 23

Starting Your Boiler............................... 24

Checking and Adjusting......................... 26

Maintaining Your Boiler ......................... 28

Service Hints ......................................... 29

Equipment & Optional Accessories ........ 30

Appendix A - Control Module ................. 32

A.1 Installation Environment Considerations . 32

A.2 Electrical Connections .......................... 32

A.3 Adjusting Settings ............................... 32

A.4 Display .............................................. 32

A.5 Operation .......................................... 33

A.6 Boiler High Limit Temperature Controller 34

A.7 Troubleshooting .................................. 34

A.8 Troubleshooting Error Codes ................. 34

A.9 Intermittent Pilot ................................ 35

TABLE OF CONTENTS

Safety Symbols & Warnings

The following dened symbols are used throughout this

manual to notify the reader of potential hazards of varying

risk levels.

NOTICE

Used to address practices not related to personal

injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

WARNING

Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors

and liquids.

DO NOT obstruct air openings to the boiler room.

Modication, substitution or elimination of factory

equipped, supplied or specied components may

result in personal injury or loss of life.

TO THE OWNER - Installation and service of this

boiler must be performed by a qualied installer.

TO THE INSTALLER - Leave all instructions with

boiler for future reference.

When this product is installed in the

Commonwealth of Massachusetts the installation

must be performed by a Licensed Plumber or

Licensed Gas Fitter.

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death

or serious injury. Read this manual and understand

all requirements before beginning installation.

New York City MEA Number 484-84-E Vol. IV.

BOILER RATINGS & CAPACITIES

Table 1 - RATINGS NATURAL AND PROPANE GASES

Model

Input

*Mbh

Heating

Capacity

*Mbh

**Net

AHRI

Rating

Water

*Mbh

AFUE

High Altitude

Input *Mbh

Vent Diameter (Inches)

To Chimney

(Category I)

Horizontal Vent

(Category III)

OSVB-2 42 36 31 84.4 38 43

OSVB-3 75 63 55 83.4 67 4 3

OSVB-4 112 94 82 83.0 101 43

OSVB-5 150 125 109 82.7 135 4 3

OSVB-6 187 155 135 82.3 168 4 4

OSVB-7 225 186 162 82.0 202 4 4

* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only.

• U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each

1,000 feet above sea level.

• Canada Only - Boilers may be used at high altitude (2,000-4500 feet/640-1350m) by using a certied

eld conversion kit, resulting in a 10% de-rate. Contact Provincial authority having jurisdiction for installations

above 4500 ft (1350m)above sea level.+ Heating Capacity based on D.O.E. (Department of Energy) test

procedure.

** Net AHRI Water Ratings i

ndicate amount of remaining heat input that can be used to heat the radiation

or terminal units. Net AHRI Ratings shown are based on an allowance of 1.15 Selection of

boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated

heat loss of building.

Manufacturer should be consulted before selecting a boiler for installations having unusual piping

and pickup requirements.

This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing.

These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron boilers Design Certied by C.S.A. (Canadian Standards

Association) for use with Natural and Propane Gases. Constructed and hydrostatically tested for maximum working pressure of 50 psi in

accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.

Boilers must stand on noncombustible oor. If installed on combustible oor, please refer to Repair Parts manual for appropriate

Combustible Floor Base part number.

Boilers For Use At High Altitude

Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level,

input ratings are reduced by change in main burner orice size.

U.S.A. Only - For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above

sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1,

or manufacturer for correct orice sizing information.

Canada Only - For altitudes in the range of 2,000-4,500 feet (610 - 1350m) above sea level, boilers may be eld equipped for use

at high altitude by using a certied eld conversion kit. The change in main burner orice size results in the boiler’s input rating

being reduced by 10%.The conversion shall be carried out by a manufacturer’s authorized representative, in accordance with the

requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in accordance with the requirements of

CSA-B149 Natural Gas and Propane Installation Code. The certied eld conversion kit includes a conversion data plate, which must be

attached to the boiler adjacent to the rating plate, indicating that the boiler has been converted for high altitude use. The conversion

data plate must be lled in with the correct conversion information.

For altitudes over 4500 feet (1350m), contact Provincial authority having jurisdiction.

DIMENSIONS

Model Width (A)

OSVB-2 11

OSVB-3 14-1/4

OSVB-4 17-1/2

OSVB-5 20-3/4

OSVB-6 24

OSVB-7 27-1/4

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

The installation must conform to the requirements of

the authority having jurisdiction or, in the absence

of such requirements, to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane

Installation Code, CAN/CSA B149.1

Where required by authority having jurisdiction,

installation must conform to the Standard for Controls

and Safety Devices for Automatically red Boilers,

ANSI/ASME CSD-1.

This boiler series is classied as a Category I. Vent

installation shall be in accordance with “Venting of

Equipment ,” of the National Fuel Gas Code, ANSI

Z223.1/NFPA 54, or “Venting Systems and Air Supply

for Appliances,” of the Natural Gas and Propane

Installation Code, CAN/CSA B149.1, or applicable

provisions of the local building codes.

Boiler has met safe lighting and other performance

criteria with gas manifold and control assembly on

boiler per latest revision of ANSI Z21.13/CGA 4.9.

Install such that gas ignition system components are

protected from water (dripping, spraying, rain, etc.)

during appliance operation and service, (circulator

replacement, condensate trap, control replacement,

etc.).

Locate boiler on level, solid base as near chimney as

possible and centrally located with respect to heat

distribution system as practical.

Verify you have the right size boiler before starting

installation. See rating and capacity table.

When installed in utility room, door should be wide

enough to allow largest boiler part to enter, or to

permit replacement of another appliance such as water

heater.

Boiler installed in building under construction, take

care to insure clean combustion air supply during

construction process. Airborne particulates such as

from drywall dust and from berglass insulation can

clog burner ports and cause incomplete combustion and

sooting.

NOTICE

Follow local regulations with respect to installation

of CO detectors.

Table 1 - BOILER MINIMUM CLEARANCE TO

COMBUSTIBLES

Unit Minimum

Clearances

Top 6” (152mm)

Rear 6” (152mm)

Control Side 8” (203mm)

Opposite Side 6” (152mm)

Front (Alcove) 18” (457mm)

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1” (24mm)

Set unit on concrete or other noncombustible material base or

oor. DO NOT INSTALL ON CARPETING.

Figure 1 - Minimum Clearances To Combustible

Construction

10.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY - For installation on combustible

ooring special base must be used. (See Replacement

Parts Section.) Do Not Install Boiler on carpeting.

11.

Verify boiler is supplied with correct type of gas, fresh

air for combustion, and suitable electrical supply.

WARNING

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

8”

Boiler

Rear

Front

Control Side

Opposite Side

18”

6”

6” 8”

VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance

with the section “Air for Combustion and Ventilation,” of the

National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation

Code, CAN/CSA B149.1, or applicable provisions of local

building codes.

Provide make-up air where exhaust fans, clothes dryers,

and kitchen ventilation equipment interfere with proper

operation.

National Fuel Gas Code recognizes several methods

of obtaining adequate ventilation and combustion air.

Requirements of the authority having jurisdiction may

override these methods.

• Engineered Installations. Must be approved by

authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35

cfm per Mbh for all appliances located within space.

Additional requirements where exhaust fans installed.

Interlock each appliance to mechanical air supply

system to prevent main burner operation when

mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all

appliances in space. Use a different method if

minimum volume not available.

оStandard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per

hour. See Table 3 for space with boiler only. Use

equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

оKnown Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inltration rate

(ACH) greater than 0.60.

Volume ≥ 15 ft3/ACH x Total Input [Mbh]

оRefer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

• All Outdoor Air. Provide permanent opening(s)

communicating directly or by ducts with outdoors.

оTwo Permanent Opening Method. Provide opening

commencing within 12 inches of top and second

opening commencing within 12 inches of bottom

enclosure.

Direct communication with outdoors or

communicating through vertical ducts. Provide

minimum free area of 1 in2 per 4 Mbh of total

input rating of all appliances in enclosure.

Communicating through horizontal ducts.

Provide minimum free area of 1 in2 per 2

Mbh of total input rating of all appliances in

enclosure.

оOne Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.

Provide minimum clearance of 1 inch on sides

and back and 6 inches on front of boiler (does not

supersede clearance to combustible materials).

оCombination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements

for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for application information.

National Gas and Propane Installation Code Requires

providing air supply in accordance with:

• Section 8.2 and 8.3 when combination of appliances

has a total input of up to and including 400 Mbh (120

kW).

оDoes not have draft control device.

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code

for specic air supply requirements for enclosure

or structure where boiler is installed, including air

supply openings and ducts.

Table 2 - Air Inltration Rate

Input Mbh Standard

Method

Known Air Inltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

42.5 2125 6375 3188 2125 1594 1275 1063

75 3750 11250 5625 3750 2813 2250 1875

112.5 5625 16875 8438 5625 4219 3375 2813

150 7500 22500 11250 7500 5625 4500 3750

187.5 9375 28125 14063 9375 7031 5625 4688

225 11250 33750 16875 11250 8438 6750 5625

INSTALLATION SYSTEM PIPING

Check local codes

for maximum

distance from

oor or other

allowable safe

point of discharge

RELIEF VALVE

DISCHARGE

PIPING

Figure 2 - Safety Relief Valve Discharge Piping

Refer to local codes and appropriate ASME Boiler and

Pressure Vessel Code for additional installation require-

ments. Install safety relief valve using pipe ttings

provided with boiler. See Figure 2

Install safety relief valve with spindle in vertical posi-

tion.

Do not install shutoff valve between boiler and safety

relief valve.

Install discharge piping from safety relief valve. See

Figure 2.

• Use ¾” or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C)

or greater.

• Individual boiler discharge piping shall be independent

of other discharge piping.

• Size and arrange discharge piping to avoid reducing

safety relief valve relieving capacity below minimum

relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to loca-

tion protecting user from scalding and properly drain

piping.

• Install union, if used, close to safety 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).

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per these instructions.

LIMIT SENSOR

MINIMUM HEIGHT FOR

LOW WATER CUTOFF

PROBE

Figure 3 -

Forced Hot Water Typical Piping

LIMIT SENSOR

MINIMUM HEIGHT

FOR LOW WATER

CUTOFF PROBE

Figure 4 - Forced Hot Water Typical Piping

With Zone Control Valve

INSTALLATION SYSTEM PIPING

• Install radiation units (panels, radiators or cabinets) and

supply and return mains rst then make connections at

boiler.

• Verify clean water supply is available when connecting

cold water supply to water valve. Install sand strainer at

pump when water supply is from well or pump.

• Provide low water cutoff device when boiler is installed

above radiation level or as required by the Authority

having jurisdiction, either provide as part of boiler or at

time of boiler installation. Periodic inspection is neces-

sary, as is ushing of oat type devices, per manufac-

turers specic instructions. Refer to Figures 3 & 4 for

minimum height for installation of LWCO. Use kit #

550002998 and follow instructions included with kit.

When using LWCO other than kit listed follow specic

LWCO manufacturer instructions.

• Boiler used in connection with refrigeration systems shall

be installed so chilled medium is piped in parallel with

heating boiler with appropriate valves to prevent chilled

medium from entering heating boiler. See

Figure 5

• Boiler connected to heating coils located in air handling

units exposed to refrigerated air circulation, piping

system shall be equipped with ow control valves or

other automatic means to prevent gravity circulation of

boiler water during cooling cycle.

INSTALLATION SYSTEM PIPING

Figure 5

- Piping Arrangements For Boiler When

Used In Connection With Refrigeration

System

Low Design Water Temperature Systems (Below

140°F) And Large Water Content Systems

Condensation is corrosive and can eventually cause severe

damage to boiler and venting system.

• Minimum design return water temperature to prevent

condensation in boiler and venting is 120°F. Minimum

high limit setting is 140°F.

• Boiler used in heating systems where design water

temperatures below 140°F are desired (e.g. radiant oor

heating), a 3-way or 4-way mixing valve or suitable

alternative is required to prevent low temperature return

water from entering boiler. When using mixing valve,

follow manufacturer’s installation instructions.

• Boiler connected to system having large water content

(such as former gravity system), suggest use of bypass

piping. See

Figure 6

Adjust two throttling valves to maintain at

least 120° F (49°C) in boiler return.

Figure 6

- Bypass Piping

Check Your Chimney

Chimney must be clean, right size, properly constructed

and in GOOD CONDITION.

Installation must conform to requirements of the

authority having jurisdiction or, in absence of such

requirements, to the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 or of the Natural Gas and Propane

Installation Code, CAN/CSA B149.1, or applicable

provisions of the local building codes..

Boiler’s induced draft blower has 3” outlet. 3” X

4” increaser tting is included in parts bag. Locate

increaser tting on outlet of induced draft blower, and

secure gas-tight with bead of furnished silicone sealant.

Increaser tting is required on this boiler for Category I

venting, and 4” is minimum permissible vent diameter.

This does not imply vent connector is intended to be 4”

diameter pipe. Vent connector shall be sized according

to appropriate venting tables in the National Fuel

Gas Code and may be required to be larger than 4”

diameter.

NOTICE

Boiler installation for chimney venting is not complete

unless increaser tting is located and secured.

These are high efciency boilers with low stack or

exhaust temperature.

Venting into masonry chimney without liner, line

chimney from top to bottom with either:

A. Listed Type B vent pipe

B. Listed exible vent liner

C. Poured ceramic liner.

Outside chimneys should not be used unless they are

(choose one of the following):

A. Enclosed in a chase

B. Lined with Type B vent pipe

C. Use listed exible vent liner

D. Use certied chimney lining system

Vent connector from boiler to chimney should run as

directly as possible with as few elbows as possible.

Where possible, it is recommended to common vent

water heater and boiler. Consult appropriate Vent

Sizing Tables in National Fuel Gas Code for specic

requirements of multiple appliance venting.

Boiler is only appliance connected to vent, Type B vent

pipe is recommended for vent connector.

Slope pipe up from boiler to chimney not less than 1/4”

per foot (21mm/m).

10.

End of vent pipe must be ush with inside face of

chimney ue. Use sealed-in thimble for chimney

connection.

11.

Fasten sections of vent pipe with sheet metal screws to

make piping rigid. Use stovepipe wires to support pipe

from above.

12.

Do not connect to replace ue.

13.

Do not install damper on this boiler.

Minimum Vent Pipe Clearance

• Use Type B vent pipe through crawl space. Where vent

pipe passes through combustible wall or partition, use

ventilated metal thimble. Thimble should be 4 inches

larger in diameter than vent pipe.

• Boiler installed with single wall vent, must have 6”

clearance between its surface and any combustible

material. New Type B gas vent or exible liner must be

installed in accordance with instructions furnished with

vent. Maintain clearances as specied for vent pipe.

• Verify vent pipe is re-stopped where it goes through

oor or ceiling. It should have approved vent cap with

clearances from roof. If clearances are less than shown

in have vent checked by local authorities. See Figure 7,

Page 11.

• Vent connectors serving appliances vented by natural

draft shall not be connected into any portion of

mechanical draft systems operating under positive

pressure.

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