ECR International Utica Boilers UB95M-200 Bedienungsanleitung

INSTALLATIONMANUAL

UB95M-200GAS-FIREDDIRECTVENT

MODULATINGHOTWATERBOILER

UTICA BOILERS

PO Box 4729

Utica, NY 13504-4729

www.uticaboilers.com

An ISO 9001-2000 Certiﬁed Company

P/N 240006103U, Rev. 1.1 [04/06]

GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER

INSTALLATION MANUAL

P/N# 240006103U, Rev. 1.1 [04/06] • Printed in USA • Made In USA

TABLE OF CONTENTS

I Introduction.......................................... 3

II Safety Symbols.................................... 4

III Rules for Safe Installation and Operation 4

IV Boiler Ratings and Capacities............. 5

V Before Installing The Boiler.................. 6

VI Placing The Boiler................................ 9

VII Near Boiler Piping................................ 10

VIII Combustion Air and Vent Pipe............. 11

IX Gas Supply Piping............................... 13

X Electrical Wiring................................... 15

XI Controls and Accessories.................... 16

XII Maintenance and Cleaning.................. 18

XIII Boiler Wire Diagram............................ 21

XIV Piping and Wiring Appendix................. 22

Keep this manual near boiler

and retain for future reference.

I - INTRODUCTION

This appliance is a gas-ﬁred direct vent modulat-

ing cast aluminum hot water boiler. A revolutionary

cast aluminum monoblock heat exchanger means

better heat transfer and thermal storage than simi-

larly sized cast iron boilers, which results in higher

efﬁciency. The heating system water absorbs large

amounts of heat from the cast aluminum heat ex-

changer, cooling the ﬂue gases and causing con-

densation. Sealed combustion, premix gas burner,

and low ﬂame temperature means drastically re-

duced CO and NOx emissions, which contribute to

a cleaner and healthier environment.

This appliance, unlike normal residential atmo-

spheric and induced draft units, takes its combus-

tion air directly from the outdoors (sealed combus-

tion) and does not compete with building occupants

for fresh air. Sealed combustion (also known as

“direct vent”) is the safest and best way to obtain

plenty of clean combustion air. The forced draft fan

draws in the outside combustion air to mix with gas,

which ﬂows into the pre-mix burner and combusts.

The fan then forces the resulting ﬂue gases from

the boiler unit and provides a positive removal of

the ﬂue gases from the building through inexpen-

sive and readily available PVC and CPVC pipes.

! !

III. RULES FOR SAFE INSTALLATION AND OPERATION

WARNING

This appliance has been equipped for resi-

dential installations. If used for commercial

applications, any and all additional code re-

quirements must be adhered to for installa-

tion. This may require additional controls,

including but not limited to an external wa-

ter cut off, a manual reset high temperature

limit, and wiring and/or piping modiﬁcations.

The manufacturer is not responsible for any

ﬁeld installation changes made to a boiler

installation which are not described or ac-

knowledged in this manual.

IMPORTANT: Failure to follow these instruc-

tions could cause a malfunction of the boiler

and result in death, serious bodily injury, and/or

property damage. For assistance or additional

information, consult a qualiﬁed installer, service

agency, or the gas supplier.

WARNING

This boiler contains ceramic ﬁber materials.

Use care when handling these materials per

the instructions speciﬁed under “Modulating

Burner” in Section XI of this manual.

1. Check all applicable state and local building

codes and utility company requirements before

installation. This installation must conform with

these requirements in their entirety. In the absence

of these codes, use NFPA installation codes and

good industry practice.

2. Before servicing the boiler, allow it to cool. Al-

ways shut off any electricity and gas supply con-

nected to the boiler prior to servicing.

3. Inspect gas line for leaks.

4. Be certain gas input rate is correct. Overﬁring

may result in early failure of the boiler components.

This may cause dangerous operation. Underﬁring

may result in too much air for the pre-mix burner

causing poor or loss of combustion.

5. Never vent the products of combustion from this

boiler to an enclosed space. Always vent to the out-

doors. Never vent to another room or to inside a

building.

6. Be sure there is adequate outdoor air supply to

boiler for complete combustion.

7. Follow a regular service and maintenance sched-

ule for efﬁcient and safe operation.

8. Keep boiler area clean of debris and free of com-

bustible and ﬂammable materials.

9. Proper through-the-wall or through-the-roof

combustion venting shall be in accordance with the

materials and methods described in this manual.

Installation must comply with local codes.

10. This boiler and related hot water heating sys-

tems are not do-it-yourself items. They must be in-

stalled and serviced by qualiﬁed professionals.Rat-

The following deﬁned symbols are used throughout this manual to notify the reader of potential hazards

of varying risk levels.

II - SAFETY SYMBOLS AND WARNINGS

DANGER

Indicates an imminently hazardous situation

which, if not avoided, will result in death or

serious injury.

WARNING

Indicates a potentially hazardous situation

which, if not avoided, could result in death

or serious injury.

! !

CAUTION

Indicates a potentially hazardous situation

which, if not avoided, may result in minor or

moderate injury. It may also be used to alert

against unsafe practices.

IMPORTANT: Read the following instructions

completely before installing!!

IV - BOILER RATINGS AND CAPACITIES

ings above are for sea level applications. The boiler

automatically derates input at a rate of 2% for every

1000 feet above an elevation of 2000 feet (see Table

2). The boiler will also derate relative to the caloriﬁc

value of the gas being used. Use the formula speci-

ﬁed in “Measure The Natural Gas Input Rate” in Sec-

tion VII of the Control Manual and Operating Instruc-

tions (P/N# 240006104) to determine the proper rate

due to derated gas. No alterations to the boiler are

required for altitudes above sea level.

These low pressure gas-ﬁred hot water boilers are

design certiﬁed by CSA International, for use with

natural and propane gases. The boilers are con-

structed and hydrostatically tested for a maximum

working pressure of 50 PSIG (pounds per square

inch gauge) in accordance with ASME (American

Society of Mechanical Engineers) Boiler and Pres-

sure Vessel Code Section IV Standards for heating

boilers.

The Boilers are certiﬁed in accordance with ANSI

(American National Standards Institute) Z21.13

standards as gas-ﬁred, direct vent, condensing,

hot water boilers.

TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES

Boiler Input Rate

(MBH)(1)

Heating Capacity

(MBH)(1)(2)

Net I=B=R Rating

(MBH)(1)

AFUE(2) Flue Diameter Shipping

Wt.

High Fire 200 190 165 95% 2” CPVC & 3” PVC 284 lbs.

Low Fire 80 76 66

(1) 1 MBH = 1,000 Btuh (British Thermal Units Per Hour)

(2) Heating Capacity and AFUE (Annual Fuel Utilization Efﬁciency) are based on DOE (Department of Energy) test procedures.

TABLE 2: 95M-200 HIGH ALTITUDE DERATE CHART

Boiler Input

Rate (MBH)

Altitude (In Feet)

3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

High Fire 196 192 188 184 181 177 174 170

Low Fire 78.4 76.8 75.3 73.8 72.3 70.9 69.5 68.1

The Heating Capacity indicates the amount of heat

available after subtracting the losses up the stack.

Most of this heat is available to heat water. A small

portion is heat loss from the jacket and surfaces of

the boiler, and it is assumed that this heat stays in

the structure. The Net I=B=R Rating represents the

portion of the remaining heat that can be applied

to heat the radiation or terminal units (i.e., ﬁnned

tube baseboard, cast iron radiators, radiant ﬂoor,

etc.) The difference between the Heating Capacity

and the Net I=B=R Rating, called the piping and

pickup allowance, establishes a reserve for heating

the volume of water in the system and offsetting

heat losses from the piping. The Net I=B=R Rat-

ings shown are based on a piping and pickup factor

of 1.15 in accordance with the I=B=R Standard as

published by the Hydronics Institute. The Net I=B=R

Rating of the boiler selected should be greater than

or equal to the calculated peak heating load (heat

loss) for the building or area(s) served by the boiler

and associated hot water heating systems. The

manufacturer should be consulted before selecting

a boiler for installations having unusual piping and

pickup requirements.

V - BEFORE INSTALLING THE BOILER

Review the following before installing the boiler.

CODES

This boiler product is a gas-ﬁred, direct vent, con-

densing boiler and must be installed in accordance

with all applicable federal, state and local building

codes including, but not limited to the following:

United States - Installation shall conform with

National Fuel Gas Code (NFPA-54/ANSI Z223.1-

latest edition)

Canada - Installation shall be in accordance with

CSA-B149.1 and .2 installation codes.

Where required by the authority having jurisdiction,

the installation must conform to the ASME Safety

Code for Controls and Safety Devices for Automati-

cally Fired Boilers, No.CSD-1.

The installation must conform to the requirements

of the authority having jurisdiction or, in the ab-

sence of such requirements, to the National Fuel

Gas Code, ANSI Z223.1 - latest revision.

Installers - Follow local regulations with respect

to installation of Carbon Monoxide Detectors.

Follow maintenance recommendations in this

manual.

BOILER SIZING

Check to be sure you have selected the

boiler with the proper capacity before con-

tinuing the installation. The I=B=R Rating of

the boiler selected should be greater than

or equal to the calculated peak heating load

(heat loss) for the building or area(s) served

by the boiler and associated hot water heat-

ing systems. See “Table 1: Sea Level Rat-

ings - Natural and Propane Gases” in Sec-

tion IV of this manual.

Heat loss calculations should be based on

approved industry methods.

CONSIDERATIONS FOR BOILER LOCATION

Before selecting a location for the boiler, the follow-

ing should be considered. Each boiler considered

for installation must be:

Supplied with the correct type of gas (natural

gas or propane).

Connected to a suitable combustion air in-

take piping system to supply the correct

amounts of fresh (outdoor) air for combustion

(15’ minimum length/60’ maximum length).

Connected to a suitable venting system to

remove the hazardous products of gas com-

bustion (15’ minimum length/60’ maximum

length).

Connected to a suitable hot water heating

system.

Supplied with a suitable electrical supply for

all boiler motors and controls.

Connected to a properly located thermostat or

operating control (not included with boiler).

Placed on level surface (must NOT be in-

stalled on carpeting).

Condensate drain line must be pitched down

to ﬂoor drain or external condensate pump

with reservoir at ¼” per foot (wood frame or

blocks may be used to raise boiler).

•

LOCATING THE BOILER

1. Select a location which is level, central to the pip-

ing systems served and as close to the vent and air

intake terminals as possible.

2. Accessibility clearances, if more stringent (i.e.

larger clearances) than required ﬁre protection

clearances, must be used for the boiler installation.

Accessibility clearances may be achieved with the

use of removable walls or partitions.

3. The boiler is approved for installation in closets

and on combustible ﬂoors. This boiler shall NOT be

installed on carpeting.

4. The clearances shown in Table 3 below indicate

required clearances per CSA listing.

A minimum 1” clearance must be maintained be-

tween combustible construction and each of the

right, top and back surfaces of the boiler. Allow at

least 24” at the front and left side and 8”at the top

for servicing. No combustible clearances are re-

quired to venting or combustion air intake piping.

5. Equipment shall be installed in a location which fa-

cilitates the operation of venting and combustion air

intake piping systems as described in this manual.

6. Advise owner of boiler to keep venting and com-

bustion air intake passages free of obstructions.

Both the venting and combustion air intake piping

systems connected to the outdoors must permit

ﬂow through the piping systems without restrictions

for the boiler to operate.

7. The boiler shall be installed such that the auto-

matic gas ignition system components are protect-

ed from water (dripping, spraying, rain, etc.) during

TABLE 3: BOILER CLEARANCES*

Dimension Combustible

Construction

Accessibility/

Cleaning Service

Top 1” 8” 8”

Left Side 1” 24” 24”

Right Side 1” - -

Base 1” - -

Front 0 24” 24”

Back 6” - -

Intake/Vent Piping 0 - -

Near Boiler Hot

Water Piping 1” - -

* All distances measured from the cabinet of the boiler.

! !

operation and service (circulator replacement, con-

trol replacement, etc.).

8. The boiler must be located where ambient room

temperatures (minimum possible temperatures

where boiler is installed assuming boiler is not in

operation and therefore contributes no heat to the

space) are always at or above 32°F to prevent

freezing of liquid condensate.

COMBUSTION AIR AND

VENT PIPE REQUIREMENTS

8" MINIMUM

VERTICAL SEPARATION

BETWEEN COMBUSTION

AIR INTAKE AND VENT

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL

3'' MAXIMUM

SEPARATION

15'' MAXIMUM

COMBUSTION

AIR

12''

MIMIMUM

Figure 1 - Roof Vent/Intake Terminations

Figure 2 - Sidewall Vent/Intake Terminations

OVERHANG

12" MINIMUM

90°

VENT

12" SEPARATION

BETWEEN BOTTOM OF

COMBUSTION AIR INTAKE

AND BOTTOM OF VENT

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL OR

GRADE

MAXIMUM

SEPARATION

18"

MAXIMUM

15"

MAXIMUM

LESS THAN 12" CLEARANCE

12"

MINIMUM

12"

MINIMUM

12" OR MORE CLEARANCE

90°

BRACKET

VENT

18"

MAXIMUM

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL OR

GRADE

12" SEPARATION

BETWEEN BOTTOM OF

COMBUSTION AIR INTAKE

AND BOTTOM OF VENT

12" MINIMUM

OVERHANG

MAXIMUM

SEPARATION

12"

MINIMUM

12"

MINIMUM

This boiler requires a dedicated direct vent system.

In a direct vent system, all air for combustion is

taken directly from outside atmosphere, and all ﬂue

products are discharged to outside atmosphere.

Combustion air and vent pipe connections must

terminate together in the same atmospheric pres-

sure zone, either through the roof or sidewall (roof

termination preferred). See Figures 1 and 2 for re-

quired clearances.

If the concentric vent termination is being used, re-

fer to Figure 3 for proper setup.

CAUTION

Keep boiler area clean of debris and free of

ﬂammable and combustible materials, va-

pors, and liquids.

WARNING

Failure to follow these warnings could result

in ﬁre, property damage, personal injury, or

death.

When vent pipe is exposed to tempera-

tures below freezing, such as when it pass-

es through an unheated space or when a

chimney is used as a chaseway, vent pipe

must be insulated with ½”Armaﬂex or

equivalent. In extremely cold climate ar-

eas, use ¾”Armaﬂex or equivalent.

Combustion air must be clean outdoor

air. Combustion air must not be taken

from inside the structure because that air

is frequently contaminated by halogens,

which include ﬂuorides, chlorides, phos-

•

ROOF

OVERHANG

12" MINIMUM

VENT MAINTAIN 12" IN. CLEARANCE

ABOVE HIGHEST ANTICIPATED

SNOW LEVEL OR GRADE

COMBUSTION AIR

1" MAXIMUM

12" MINIMUM

Figure 3 - Concentric Vent Terminations

(Continued on next page)

Figure 4 - Concentric Vent w/Dimensions

! !

WARNING

(Continued from previous page)

phates, bromides and iodides. These ele-

ments are found in aerosols, detergents,

bleaches, cleaning solvents, salts, air

fresheners, paints, adhesives, and other

household products.

Locate combustion air inlet as far away as

possible from swimming pool and swim-

ming pool pump house. All combustion

air and vent pipes must be airtight and

watertight. Combustion air and vent pip-

ing must also terminate exactly as shown

in Figures 1 and 2. If a concentric vent

termination is being used, refer to Fig-

ures 3 through 5 for proper setup.

Vent connections serving appliances

vented by natural draft shall not be con-

nected into any portion of mechanical

draft systems operating under positive

pressure.

Solvent cements are combustible. Keep

away from heat, sparks, or open ﬂame.

Use only in well ventilated areas. Avoid

breathing in vapor or allowing contact

with skin or eyes.

•

Figure 5 - Concentric Vent Roof Installation

CONDENSATE DRAIN REQUIREMENTS

At the rear of the unit a ½” PVC pipe nipple with

NPT threads is provided for the attachment of the

condensate drain line. Attach the ½” PVC tee in

the parts bag to act as a vent as shown. Attach ½”

PVC from this point to either a drain or an exter-

nal condensate pump (not furnished). If the drain

level is above the condensate trap, a condensate

pump must be used. The condensate pump must

be designed for a ﬂue gas condensate application.

The condensate drain line must be pitched down to

the ﬂoor at a minimum of ¼” per foot and must be

routed within the conditioned space to avoid freez-

ing of condensate and blockage of the drain line. If

the unit will be started immediately upon comple-

tion of installation, prime trap by ﬁlling with water

until water is seen at the vent.

NOTES:

Condensate trap is integral to the boiler.

Wood frame or blocks may be used to raise the boiler to

maintain drain pitch or to be above external condensate

pump reservoir.

There is a 115 volt AC receptacle provided on the con-

trol panel to provide power for an external condensate

pump (if needed).

! !

in which the appliances remaining connected

to the common venting system are located and

other spaces of the building. Turn on clothes

dryer and any appliance not connected to the

common venting system. Turn on any exhaust

fans, such as range hoods and bathroom ex-

haust, so they will operate at maximum speed.

Do not operate a summer exhaust fan. Close

ﬁre dampers.

4. Place in operation the appliance being inspect-

ed. Follow the lighting instructions. Adjust ther-

mostat so appliances will operate continuously.

5. Test for spillage at the draft hood relief open-

ing after 5 minutes of main burner operation. Use

the ﬂame of a match or candle, or the smoke

from a cigarette, cigar or pipe.

6. After it has been determined that each ap-

pliance remaining connected to the 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 of use.

7. Any improper operation of the common vent-

ing system should be corrected so the instal-

lation conforms with the National Fuel Code,

NFPA-54/ANSI -Z223.1-latest revision, or sec-

tion 5 of CSA-B149 for Canadian standards.

When resizing any portion of the common vent-

ing system, the common venting system should

be resized to approach the minimum size as de-

termined using the appropriate tables in part 11

in the National Fuel Gas Code, NFPA-54/ANSI-

Z223.1-latest revision, or section 5 of CSA-B149

for Canadian standards.

VI - PLACING THE BOILER

WARNING

The boiler must be located on a surface that

can support the weight of the installed boiler.

The boiler should be placed to provide the most

direct connections 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 dol-

ly or 2-wheel hand truck. The dolly or hand truck

should be inserted under the right hand side of the

boiler. It is possible to slide the boiler for a short

distance on a smooth ﬂoor or surface.

NOTE: Refer to “Locating The Boiler” in Section V of this

manual for required clearances for servicing and mainte-

nance.

FOUNDATION REQUIREMENTS

Boiler must be placed on level surface. Boiler is

NOT to be installed on carpeting.

NOTES:

If boiler is not level condensate drain lines will not func-

tion properly. Adjustable feet are located on the boiler to

make up for minor surface irregularities or tilt.

Wood frame or blocks may be used to raise boiler to

maintain drain pitch or to be above external condensate

pump reservoir.

REMOVAL OF EXISTING BOILER

FROM COMMON VENT SYSTEM

When an existing boiler is removed from a com-

mon 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 appliances remaining

connected to the common venting system are not

in operation.

1. Seal any unused openings in the common

venting system.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is

no blockage or restrictions, leakage, corrosion

and other deﬁciencies which could cause an un-

safe condition.

3. When it is practical, close all building doors

and windows and all doors between the space

! !

VII - NEAR BOILER PIPING

CAUTION

Copper supply and return piping must NOT be

installed directly into aluminum boiler section

castings due to galvanic corrosion between

dissimilar metals. Iron or steel bushings or

pipe nipples should be used between copper

system piping and boiler to make ﬁnal con-

nection to boiler. Also, the use of dielectric

unions is acceptable. The packaged boiler is

furnished with iron piping where necessary

for the supply and return connections.

When the installation of the boiler is for a new

heating system, ﬁrst install all of the radiation units

(panels, radiators, baseboard, or tubing) and the

supply and return mains. After all heating system

piping and components have been installed, make

ﬁnal connection of the system piping to the boiler.

A hot water boiler installed above radiation level

must be equipped with a low water cut off device.

A periodic inspection is necessary, as is ﬂushing

of ﬂoat type devices, per low water cut off manu-

facturers speciﬁc instructions. This boiler is factory

equipped with a manual reset probe-type low water

cut off.

EXPANSION TANK AND MAKE-UP WATER

CAUTION

Non-potable water only piped directly to

boiler.

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 manufac-

turer for proper sizing information. Connect prop-

erly sized expansion tank (not furnished) as shown

in Figure 6 for diaphragm type expansion tank. For

diaphragm type expansion tanks, adjust the tank

air pressure to match the system ﬁll pressure. In-

stall air vent (furnished) as shown for diaphragm

type expansion tank system only. Install make-up

water connections as shown and per local codes.

If a pressure reducing valve is used, adjust to

match the system ﬁll pressure. In connecting the

cold make-up water supply to the boiler, make sure

that clean water supply is available. When the wa-

ter supply is from a well or pump, a sand strainer

should be installed at the pump.

PRESSURE RELIEF VALVE /

TEMPERATURE PRESSURE GAUGE

The boiler is furnished with a relief valve in the

boiler parts bag. Provide ¾” piping from the sup-

plied relief valve to a local ﬂoor drain, but leave

an air gap between piping and drain. No shutoff of

any description shall be placed between safety re-

lief valve and the boiler, or on the discharge pipes

IMPORTANT: For piping examples using the Gas-Fired Direct Vent Modulating Hot Water Boiler,

see the Piping Appendix in Section XIV of this manual.

Figure 6 - Diaphragm Type

Expansion Tank Piping

Figure 7 - Relief Valve Discharge Piping

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