UTICA BOILERS DVB-50 Betriebsanleitung

DVB SERIES

Gas Fired Boilers For Forced Hot Water

INSTALLATION, OPERATION &

MAINTANANCE MANUAL

P/N 37615501, Rev. B [02/09]

UTICA BOILERS

P.O. Box 4729

Utica, NY 13504-4729

MEMBER: The Hydronics Institute

An ISO 9001-2000 Certified Company

TABLE OF CONTENTS

KEEP THIS MANUAL NEAR BOILER AND

RETAIN FOR FUTURE REFERENCE.

GAS FIRED BOILERS FOR FORCED HOT WATER

Tested for 100 lbs.

ASME Working Pressure

C.S.A. Certied for

Natural gas or Propane

SAFETY SYMBOLS

IMPORTANT: Read the following instructions

COMPLETELY before installing!

The following dened symbols are used throughout this manual to notify the reader of potential hazards of varying

risk levels.

Indicates an imminently hazardous situation

which, if not avoided, will result in death, serious

injury or substantial property damage.

DANGER

Indicatesapotentiallyhazardoussituationwhich,

if not avoided, could result in death, serious

injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which,

if not avoided, could result in minor or moderate

injury or property damage.

CAUTION

Indicates special instructions on installation,

operation or maintenance which are important

but not related to personal injury hazards.

NOTICE

Introduction..........................................................................................................................................4

Boiler Ratings, Capacities & Dimensions ............................................................................................5

Ventilation & Combustion Air ...............................................................................................................7

Connecting Supply & Return Piping ..................................................................................................10

Applicable Federal Codes .................................................................................................................13

Vent System Modication ..................................................................................................................13

Connecting Gas Service....................................................................................................................14

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

Lighting Instructions...........................................................................................................................17

Sequence of Operations....................................................................................................................18

General Instruction For Seasonal Startup & Maintenance................................................................19

Replacement Parts............................................................................................................................22

NOTES:

• Greater clearances for access should supersede re pro-

tection clearances.

* For installation on combustible ooring Special Base MUST

BE USED. (See Replacement Parts Section)

1. Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors

and liquids.

2. DO NOT obstruct air openings to the boiler

room.

3. Modication, substitution or elimination of factory

equipped, supplied or specied components may

result in property damage, personal injury or the

loss of life.

4. TO THE OWNER: Installation and service of

this boiler must be performed by a qualified

installer.

5. TO THE INSTALLER: Leave all instructions with

the boiler for future reference.

6. When this product is installed in the Com-

monwealth of Massachusetts the installation

must be performed by a Licensed Plumber

or Licensed Gas Fitter.

Improper installation, adjustment, alteration,

service or maintenance can cause injury or

property damage.

INTRODUCTION

The installation must conform to the requirements of

the authority having jurisdiction or, in absence of such

requirements, to the latest revision of the National Fuel

Gas Code, ANSI Z223-1. (Available from the American

Gas Association, Pleasant Valley Road, Cleveland, Ohio

44134.) Reference should also be made to local gas utility

regulations and other codes in effect in the area in which

the installation is to be made.

Where required by the authority having jurisdiction, the

installation must conform to American Society of Me-

chanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME No.

CSD-1.

This boiler is classied as a Category I and III and vent

installation shall be in accordance with the latest revision

of the National Fuel Gas Code, ANSI Z223.1 or applicable

provisions of the local building codes.

LOCATE BOILER on level, solid base as near the outside

wall as possible and centrally located with respect to the

heat distribution system as practicable.

Allow 24 inches at the front and right side for servicing

and cleaning.

When installed in utility room, the door should be wide

enough to allow the largest boiler part to enter, or to

permit replacement of another appliance such as a water

heater.

The boiler shall be installed such that the gas ignition

system components are protected from water, (dripping,

spraying, rain, etc.), during appliance operation and

service, (circulator replacement, condensate trap, control

replacement, etc.).

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS

ONLY. *The boiler must not be installed on carpeting.

Minimum clearances to combustible constructions are:

TOP ...................................................... 18 IN.

FRONT .....................................................6 IN.

FLUE CONNECTOR ...............................6 IN.

REAR........................................................4 IN.

CONTROL SIDE.......................................9 IN.

OTHER SIDE ...........................................3 IN.

VENT PIPE ..............................................6 IN.

WARNING

ALL INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED

EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL. INSTALL-

ING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR

MATERIALS MAY RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION

FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

BOILER RATINGS, CAPACITIES & DIMENSIONS

BOILER DIMENSIONS

DIMENSIONS FOR NATURAL GAS

Model # Natural

Gas Inlet

Dimensions Pump size

Supply

& Return

Tappings

Number

Burners

AFUE

Ratings

A B C D E

-50 ½" 11¼ 2⅛ 36⅜ 27 1¼" 1 83%

-100 ½" 15⅛ 4⅛ 36⅜ 27 1¼" 2 82%

-125 ½" 19 6 3 6⅜ 27 1¼" 3 82%

-150 ½" 19 6 4 6⅜ 27 1¼" 3 80%

-200 ½" 22⅞ 8 4 7 28 1¼" 4 80%

NOTE: For altitudes above 2,000 ft. ratings should be reduced at the rate of 4% for each 1,000 ft. above sea level.

WARNING

BOILER RATINGS, CAPACITIES & DIMENSIONS

Model # A.G.A.

Input

Btu/Hr.

Heating

Capacity

Btu/Hr.

I=B=R

NetOutput

Btu/Hr

No.

Burners

Water

Content

(Gals.)

AFUE

Ratings

-50 50,000 42,000 37,000 1 2.4 83%

-100 100,000 82,000 71,000 2 4.0 82%

-125 125,000 103,000 90,000 3 5.6 82%

-150 150,000 122,000 106,000 3 5.6 80%

-200 199,999 160,000 139,000 4 7.2 80%

STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, Combination Aquastat Relay, Theraltimeter

Gauge, Circulator, Main Gas Burners, Electric Ignition System, A.S.M.E relief Valve, Drain Valve, Induced Draft

Fan, and Safety Pressure Switch

All boilers are design certied for installation on non-combustible oors. For installation on combustible oors, use

combustible oor kit.

This boiler is a Category III Designed Certied appliance which requires a special horizontal through the wall venting

system. Only HEAT-FAB SAF-T-VENT™, FLEX-L STAR-34™, ProTech™ FasNSeal, and Z-FLEX Z-VENT™ vent

material products shall be used.

Should a chimney installation be required, see venting addendum.

See venting addendum for maximum vent lengths and proper congurations.

MEA number for the boilers is 415-90-E.

Electric service to be 120 Volts, 15 Amps, 60 Hz.

**For equivalent square feet of radiation, divide I=B=R output by 150.

VENTILATION & COMBUSTION AIR

COMBUSTION AIR REQUIREMENTS

(Minimum Square Inch Openings)

MODEL #

*UNCONFINED AREA **CONFINED AREA

OUTSIDE

COMBUSTION AIR

1 SQ. IN/5000 BTU/

HR (SEE Figure #2)

INSIDE

COMBUSTION AIR

1 SQ. IN. /1000

BTU/HR

(SEE Figure #1)

OUTSIDE COMBUSTION AIR

VERTICAL

DUCTS 1 SQ. IN.

/4000 BTU/HR

(SEE Figures #2

& 3)

HORIZONTAL

DUCTS 1 SQ. IN.

/2000 BTU/HR

(SEE Figure #4)

-50 10 100 13 25

-100 20 100 25 50

-125 25 125 32 63

-150 30 150 38 75

-200 40 200 50 100

* Unconned Area: A space whose

volume is not less than 50 cubic feet

per 1000 BTU per hour of all appliances

installed in that space (cubic feet of space

= height x width x length).

** Conned Area: A space whose volume

is less than 50 cubic feet per 1000 BTU

per hour of all appliances installed in that

space(cubicfeetofspace=heightxwidth

x length).

Ventilation of the boiler room must be adequate to

provide sufcient air to properly support combustion

per the latest revision of the National Fuel Gas Code,

ANSI Z223.1.

When a boiler is located in an unconned space in a

building or conventional construction frame, masonry

or metal building, inltration normally is adequate to

provide air for combustion and ventilation. However, if

the equipment is located in a building of tight construction

(See the National Fuel Gas Code, ANSI Z223.1 latest

revision), the boiler area should be considered as a con-

ned space. In this case air for combustion and ventilation

shall be provided according to paragraph #5. If there is

any doubt, install air supply provisions in accordance with

the latest revision of the National Fuel Gas Code.

When a boiler is installed in an unconned space, in a

building of unusually tight construction, air for combus-

tion and ventilation must be obtained from outdoors or

from spaces freely communicating with the outdoors.

A permanent opening or openings having a total free

area of not less than 1 square inch per 5,000 BTU per

hour of total input rating of all appliances shall be pro-

vided. Ducts may be used to convey makeup air from

the outdoors and shall have the same cross-sectional

area of the openings to which they are connected.

When air for combustion and ventilation is from inside

WARNING

AIROPENINGSTOCOMBUSTIONAREAMUSTNOTBEOBSTRUCTED.

BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE

COMBUSTION AIR CAN BE MAINTAINED.

VENTILATION & COMBUSTION AIR

buildings, the conned space shall be provided with

two permanent openings, one starting 12 inches from the

top and one 12 inches from the bottom of the enclosed

space. Each opening shall have a minimum free area

of 1 square inch per one thousand (1000) BTU per hour

of the total input rating of all appliances in the enclosed

space, but must not be less than one hundred (100)

square inches. These openings must freely communicate

directly with other spaces of sufcient volume so that the

combined volume of all spaces meets the criteria for an

unconned space. See

Figure #1.

VENT PIPE

BASEBOARD

VENTS

BOILER

12"

Figure #1

When the boiler is installed in a conned space and all air

is provided from the outdoors the conned space shall be

provided with one or two permanent openings according

to methods A or B. When ducts are used, they shall be

of the same cross sectional area as the free area of the

area of the openings to which they connect. The mini-

mum dimension of rectangular air ducts shall be not less

than 3 x 3 inches or 9 square inches.

When installing two openings, one must commence A.

within 12 inches from the top and the other within 12

inches from the bottom of the enclosure. The open-

ings shall communicate directly, or by ducts, with the

outdoors or spaces (crawl or attic) that freely commu-

nicate with the outdoors. One of the following methods

must be used to provide adequate air for ventilation

and combustion.

When directly communicating with the outdoors, each I.

opening shall have a minimum free area of 1 square

inch per 4,000 BTU per hour of total input rating of all

equipment in the enclosure. See

Figure #2

OUTLET

AIR

VENTILATION LOUVERS

(EACH END OFATTIC)

INLET

AIR

VENTILATION

LOUVRES FOR

UNHEATED

CRAWLSPACE

Figure #2

When communicating with the outdoors by means of II.

vertical ducts, each opening shall have a minimum

free area 1 square inch per 4,000 BTU per hour of

total input rating of all appliances in the enclosed

space. See

gure #3

BOILER

OUTLET

AIR

VENTILATION LOUVERS

(EACH END OFATTIC)

-- SLAB --

INLETAIR DUCT

12"

(DUCT ENDS 1 FT.

ABOVE THE FLOOR)

Figure #3

If horizontal ducts are used, each opening and duct III.

shall have a minimum free area 1 square inch per

2,000 BTU per hour of total input rating of all appli-

ances in the enclosed space. See

gure #4

BOILER

-- SLAB --

INLETAIR DUCT

12"

INLETAIR DUCT

12"

Figure #4

One permanent opening, commencing within 12 inches B.

of the top of the enclosure, shall be permitted where the

equipment has clearances of at least 1 inch from the

sides, 1 inch from the back, and 6 inches from the front

of the boiler. The opening shall directly communicate

with the outdoors or shall communicate through a verti-

cal or horizontal duct to the outdoors or spaces (crawl

or attic) that freely communicate with the outdoors. The

openings must have a minimum free area of 1 square

inch per 3000 Btu per hour of the total input rating of all

equipment located in the enclosure. The free area must

be no less than the sum of the areas of all vent connec-

tors in the conned space.

VENTILATION & COMBUSTION AIR

In calculating free area using louvers, grilles or screens

for the above, consideration shall be given to their block-

ing effect. Screens used shall not be smaller than 1/4 inch

mesh. If the free area through a design of louver or grill is

known, it should be used in calculating the size opening

required to provide the free area specied. If the design

and free area is not known, it may be assumed that wood

louvers will have 20-25% free area and metal louvers and

grilles will have 60-75% free area. Louvers and grilles

should be xed in the open position or interlocked with the

boiler so they are opened automatically during the boiler

operation.

CONNECTING SUPPLY & RETURN PIPING

Connect supply and return piping as suggested in

1. gure

, when the boiler is used in connection with refriger-

ated systems.

The chilled medium MUST BE PIPED IN PARALLEL A. with the boiler.

Use appropriate valves to prevent the chilled medium B.

from entering the heating boiler.

During heating cycle open valves A and B, close I. valves C and D.

During cooling cycle, open valves C and D, close II. valves A and B.

C. Maintain a minimum clearance of one inch to hot C. water pipes.

When the boiler is connected to heating coils located in

air handling units where they may be exposed to refrig-

erated air circulation, the boiler piping system MUST

BE supplied with ow control valves or other automatic

means to prevent gravity circulation of the boiler water

during the cooling cycle.

Hot water boilers installed above radiation level must be

provided with a low water cut-off device.

When a boiler is connected to a heating system that

utilizes multiple zoned circulators, each circulator must

be supplied with a ow control valve to prevent gravity

circulation.

Hot water boilers and system must be lled with water

and maintained to a minimum pressure of 12 pounds per

square inch.

Bypass piping is an option which gives the ability to adjust

the supply boiler water temperature to t the system or

the condition of the installation. This method of piping,

however, is not typically required for baseboard heat-

ing systems. Typical installations where bypass piping is

used are as follows:

This method is used to protect boilers from conden-A.

sation forming due to low temperature return water.

Generally noticed in large converted gravity systems or

other large water volume systems. See

gure #6

This method is used to protect systems using radiant B.

panels and the material they are encased in from high

temperature supply water from the boiler. And protect

the boiler from condensate. See

gure #7

and

IMPORTANT: Circulators in the following

illustrations are mounted on the system supply

side, but mounting on the system return side is

also acceptable practice.

CIRCULATOR

VALVE

EXPANSION

TANK

VALVE

RETURN

SUPPLY

12"

MAX.

CIRCULATOR

FLOW

VALVE

SYSTEM

TEMPERATURE

GAUGE

"B"

"A"

SYSTEM

PRIMARY

FEED

WATER

Figure #5

ZONE

CIR.

VALVE

FLOW

VALVE

EXPANSION

TANK

VALVE

SYSTEM

TEMPERATURE

GAUGE

RETURN

SUPPLY

"A"

"B"

FEED

WATER

BYPASS PIPING

Figure #6

EXPANSION

TANK

TEMPERATURE

SYSTEM

GAUGE

SUPPLY

RETURN

4 WAY MIXING

VALVE

ZONE

CIR.

WATER

FEED

MIXING VALVE PIPING

Figure #7

This method is used to protect boilers from condensate C.

forming as well as protecting the heating system from

high water temperatures, see

gure #8

NOTE #1: When using bypass piping, adjust

valves A and B until desired system temperature

is obtained.

NOTE #2: Bypass loop must be same size piping

as the supply and return piping.

Installation using circulators is shown in

7. gure #9

Installation using zone valves is shown in

8. gure #10

For further piping information refer to the I=B=R Installa-

tion and Piping Guide.

CONNECTING SUPPLY & RETURN PIPING

CIRCULATOR

VALVE

EXPANSION

TANK

VALVE

RETURN

SUPPLY

12"

MAX.

CIRCULATOR

FLOW

VALVE

SYSTEM

TEMPERATURE

GAUGE

"B"

"A"

SYSTEM

PRIMARY

FEED

WATER

PRIMARY SECONDARY PIPING WITH BYPASS

Figure #8

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