UTICA BOILERS UB90-200 Gebrauchsanweisung

P/N 240004826U, Rev. B [08/11]

UB90 125-200 GAS-FIRED, DIRECT VENT,

CONDENSING, HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Utica Boilers

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

90 125200 CAST ALUMINUM BOILER

SAFETY SYMBOLS

DANGER

Indicates a hazardous situation which, if not

avoided, will result in death, serious injury.

WARNING

Indicates a hazardous situation which, if not

avoided, may result in death, serious injury.

CAUTION

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate

injury.

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

levels.

KEEP THIS MANUAL NEAR BOILER AND RETAIN FOR FUTURE REFERENCE.

NOTICE

Indicates information which should be

followed to ensure proper installation and

operation.

Safety Symbols........................................................................................................................... 2

Rules For Safe Installation And Operation ....................................................................................... 3

Boiler Ratings & Capacities ........................................................................................................... 4

Before Installing The Boiler........................................................................................................... 5

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

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

Combustion Air And Vent Pipe ......................................................................................................13

Gas Supply Piping.......................................................................................................................15

Electrical Wiring .........................................................................................................................16

Controls And Accessories.............................................................................................................20

Startup .....................................................................................................................................22

Checkout Procedure & Adjustments...............................................................................................25

Maintenance And Cleaning...........................................................................................................28

Detailed Sequence Of Operation ...................................................................................................30

Troubleshooting..........................................................................................................................33

Installation And Check-Out Certiﬁcate ...........................................................................................43

NOTICE

Read and understand the following

instructions completely before installing.

Introduction

This appliance is a gas-ﬁred direct vent cast aluminum

hot water boiler. A revolutionary cast aluminum heat

exchanger means better heat transfer and thermal storage

than similarly sized cast iron boilers, which results in

higher efﬁciency. The heating system water absorbs large

amounts of heat from the cast aluminum heat exchanger,

cooling the ﬂue gases and causing condensation. Sealed

combustion, premix gas burner, and low ﬂame temperature

means drastically reduced CO and NOx emissions, which

contribute to a cleaner and healthier environment.

This appliance has been equipped for residential

installations. If used for commercial applications, any and

all additional code requirements must be adhered to for

installation. This may require additional controls, including

but not limited to a manual reset low water 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 acknowledged in this manual.

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.

Before servicing the boiler, allow it to cool. Always

shut off any electricity and gas supply connected to the

boiler prior to servicing.

Inspect gas line for leaks.

Be certain gas input rate is correct. Over-ﬁring may

result in early failure of the boiler components. This

may cause dangerous operation. Under-ﬁring may

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

poor or loss of combustion.

Never vent the products of combustion from this boiler

to an enclosed space. Always vent to the outdoors.

Never vent to another room or to inside a building.

Be sure there is adequate outdoor air supply to boiler

for complete combustion.

Follow a regular service and maintenance schedule for

efﬁcient and safe operation.

Keep boiler area clean of debris and free from

combustible materials, gasoline and other ﬂammable

vapors and liquids.

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.

This boiler and related hot water heating systems are

10.

not do-it-yourself items. They must be installed and

serviced by qualiﬁed professionals.

RULES FOR SAFE INSTALLATION AND OPERATION

WARNING

Failure to follow these instructions 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.

This appliance, unlike normal residential atmospheric and

induced draft units, takes its combustion air directly from

the outdoors (sealed combustion) 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 inexpensive and readily available PVC and

CPVC vent pipes.

90 125200 CAST ALUMINUM BOILER

TABLE #1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)

Model Input

(MBH)(1) Heating Capacity

(MBH)(1)(2) Net I=B=R Rating

(MBH)(1) Shipping

Weight (lbs.) AFUE

(2) Flue Diameter

125 125 113 98 284 90.0 2” CPVC & 3” PVC

150 150 134 117 284 90.0 2” CPVC & 3” PVC

175 175 158 137 284 90.0 2” CPVC & 3” PVC

200 200 180 157 284 90.0 2” CPVC & 3” PVC

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

(2) AFUE (Annual Fuel Utilization Eciency) and Heating Capacity is based on Department of Energy test procedure.

TABLE #2 - NATURAL GAS

Nominal Input 200,000 175,000 150,000 125,000

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude Min Max Min. Max Min. Max Min. Max

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000

2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000 121,000

3,000 191,000 189,500 167,200 166,600 143,400 142,200 120,500 119,000

4,000 188,000 186,000 164,600 163,800 141,200 139,600 119,000 117,000

5,000 185,000 182,500 162,000 161,000 139,000 137,000 117,500 115,000

6,000 182,000 179,000 159,400 158,200 136,800 134,400 116,000 113,000

7,000 179,000 175,500 156,800 155,400 134,600 131,800 114,500 111,000

8,000 176,000 172,000 154,200 152,600 132,400 129,200 113,000 109,000

9,000 173,000 168,500 151,600 149,800 130,200 126,600 111,500 107,000

10,000 170,000 165,000 149,000 147,000 128,000 124,000 110,000 105,000

Ratings shown are for sea level applications. The boiler automatically de-rates input as

altitude increases. No alterations to boiler are required for altitudes above sea level.

BOILER RATINGS & CAPACITIES

Figure 1 -Boiler Jackets

TABLE #3 - LP GAS

Nominal Input 200,000 175,000 150,000 125,000

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude Min. Max Min. Max Min. Max Min. Max

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 195,900 195,750 171,900 171,200 146,900 146,700 123,050 122,250

2,000 191,800 191,500 168,800 167,400 143,800 143,400 121,100 119,500

3,000 187,700 187,250 165,700 163,600 140,700 140,100 119,150 116,750

4,000 183,600 183,000 162,600 159,800 137,600 136,800 117,200 114,000

5,000 179,500 178,750 159,500 156,000 134,500 133,500 115,250 111,250

6,000 175,400 174,500 156,400 152,200 131,400 130,200 113,300 108,500

7,000 171,300 170,250 153,300 148,400 128,300 126,900 111,350 105,750

8,000 167,200 166,000 150,200 144,600 125,200 123,600 109,400 103,000

9,000 163,100 161,750 147,100 140,800 122,100 120,300 107,450 100,250

10,000 159,000 157,500 144,000 137,000 119,000 117,000 105,500 97,500

These low pressure gas-ﬁred hot water boilers are design

certiﬁed by CSA International, for use with natural

and propane gases. The boilers are constructed and

hydrostatically tested for a maximum working pressure of

50 psig (pounds per square inch gauge) in accordance with

A.S.M.E. (American Society of Mechanical Engineers) Boiler

and Pressure Vessel Code, Section IV Standards for heating

boilers.

Boilers are certiﬁed in accordance with ANSI (American

National Standards Institute) Z21.13 standards as gas-

ﬁred, direct vent, condensing, hot water boilers.

Heating Capacity indicates amount of heat available

after subtracting losses up the stack. Most of this heat is

available to heat water. Small portion is heat loss from

jacket and surfaces of boiler, it is assumed this heat stays

in the structure. Net I=B=R Rating represents portion

of remaining heat applied to heat radiation or terminal

units (i.e. Finned tube baseboard, cast iron radiators,

radiant ﬂoor, etc.). Difference between Heating Capacity

and Net I=B=R Rating, called piping and pickup allowance,

establishes reserve for heating volume of water in the

system and offsetting heat losses from piping. Net I=B=R

Ratings shown are based on piping and pickup factor of

1.15. Net I=B=R Rating of boiler selected should be greater

than or equal to calculated peak heating load (heat loss)

for building or area(s) served by boiler and associated hot

water heating systems. Manufacturer should be consulted

before selecting boiler for installations having unusual

piping and pickup requirements.

Complete the following prior to installing boiler.

Codes

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

boiler. Installation must conform to the requirements of

authority having jurisdiction or, in the absence of such

requirements:

United States

•

National Fuel Gas Code, NFPA 54/

ANSI Z223.1

Canada

•

-Natural Gas Propane Installation Code,

CAN/CSA B149.1

Where required by the authority having jurisdiction,

installation must conform to the Standard for Controls and

Safety Devices for Automatically Fired Boilers, ANSI/ASME

CSD-1.

BOILER RATINGS & CAPACITIES

BEFORE INSTALLING THE BOILER

In the State of Massachusetts:

This product must be installed by a licensed plumber• or gas ﬁtter.

When ﬂexible connectors are used, the maximum• length shall not exceed 36 inches.

When lever type gas shut-offs are used, they shall• be T-handle type.

Installers

-Follow local regulations with respect to

installation of CO (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 continuing 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 heating systems.

See “Boiler Ratings and Capacities,” (page 4) for more

information.

Heat loss calculations should be based on approved• industry methods.

Considerations For Boiler Location

Before selecting a location for the boiler, the following

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 intake piping• system to supply the correct amounts of fresh

(outdoor) air for combustion (max. length 60’).

Connected to a suitable venting system to remove• the hazardous products of gas combustion (max.

length 60’).

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 installed on• carpeting)

Condensate drain line must be pitched down to ﬂoor• drain or external condensate pump with reservoir at

¼” per foot (21 mm/m) (wood frame or blocks may

be used to raise boiler).

Locating The Boiler

Select location which is level, central to piping systems

served and as close to vent and air intake terminals as

possible.

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

clearances) than required ﬁre protection clearances,

must be used for boiler installation. Accessibility

clearances may be achieved with use of removable

walls or partitions.

Boiler is approved for installation in closets and on

combustible ﬂoors. Boiler shall NOT be installed on

carpeting.

Clearances shown in Table 4 indicate required

clearances per CSA listing. Minimum 1” (25 mm)

clearance must be maintained between combustible

construction and each of the right, top and back

surfaces of boiler. Minimum 8” (203 mm) clearance is

required on left side, to allow room for inlet air pipe.

18” (457 mm) clearance must be maintained at front

where passage is required for cleaning or servicing,

inspection or replacement of any parts that normally

may require such attention. Allow at least 24” (610

mm) at front and left side and 8” (203 mm) at top for

servicing. No combustible clearances are required to

venting or combustion air intake piping.

TABLE #4 - BOILER CLEARANCES

Unit Combustible

Clearance Accessibility, Cleaning,

and Servicing

Top 1” (25 mm) 8” (203 mm)

Left Side 8” (203 mm) 24” (610 mm)

Right Side 1” (25 mm) -

Base 1” (25 mm) -

Front 0” (0 mm) 24” (610 mm)

Back 1” (25 mm) -

Intake/Vent

Piping 0” (0 mm) -

Near Boiler Hot

Water Piping 1” (25 mm) -

All distances measured from the cabinet of the boiler.

CAUTION

Keep boiler area clean of debris and free of

ﬂammable and combustible materials, liquids

and vapors.

Equipment shall be installed in location which facilitates

operation of venting and combustion air intake piping

systems as described in this manual.

BEFORE INSTALLING THE BOILER

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

Advise owner of boiler to keep venting and combustion

air intake passages free of obstructions. Both venting

and combustion air intake piping systems connected

to outdoors must permit ﬂow through piping systems

without restrictions for boiler to operate.

Boiler shall be installed such that automatic gas

ignition system components are protected from water

(dripping, spraying, rain, etc.) during operation and

service (circulator replacement, condensate trap,

control replacement, etc.).

Boiler must be located where ambient temperatures

(minimum possible room temperatures where boiler

is installed assuming boiler is not in operation and

therefore contributes no heat to space) are always

at or above 32°F (0°C) to prevent freezing of liquid

condensate.

Combustion Air/Vent Pipe Requirements

Boiler requires dedicated direct vent system. In 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 same atmospheric pressure zone, either

through roof or sidewall (roof termination preferred).

See

Figures #1 and #2

for required clearances.

If concentric vent termination is being used, refer to

Figure #3

for proper setup.

Less Than 12” Clearance

12” or More Clearance

BEFORE INSTALLING THE BOILER

Figure 1 - Roof Vent / Intake Terminations

Figure 2 - Sidewall Vent/Intake Terminations

Figure 3 - Concentric Vent Terminations

3” Diameter PVC

Vent/Exhaust

1½” 4½” Dia.

31⅞”

3” Diameter PVC

Intake/Combustion Air

46¾”

Dimension 1³⁄16”

Dimension

Combustion Air/Vent Pipe Requirements Continued

VENT

COMBUSTION AIR

COMBUSTION

AIR

1” MAXIMUM

NOTE:

SECURING STRAP MUST BE FIELD INSTALLED TO

PREVENT MOVEMENT OF TERMINATION KIT IN SIDE

WALL.

ELBOW

(FIELD SUPPLIED)

STRAP

(FIELD SUPPLIED)

VENT

COM

AIR

COMBUSTION AIR

ROOF BOOT/FLASHING

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

SUPPORT

(FIELD SUPPLIED)

MAINTANIN 12 IN.

(18IN. FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF

NOTE:

SUPPORT MUST BE

FIELD INSTALLED TO

SECURE TERMINATION

KIT TO STRUCTURE.

BEFORE INSTALLING THE BOILER

WARNING

Failure to follow these warnings could result

in ﬁre, property damage, personal injury, or

death.

When vent pipe is exposed to temperatures

below freezing, such as when it passes through

unheated space or when chimney is used as

chaseway, vent pipe must be insulated with

1/2”armaﬂex or equivalent. In extremely cold

climate areas, use 3/4”armaﬂex or equivalent.

Combustion air must be clean outdoor air.

Combustion air must not be taken from

inside structure because that air is frequently

contaminated by halogens, which include

ﬂuorides, chlorides, phosphates, bromides and

iodides. These elements 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 swimming

pool pump house. All combustion air and

vent pipes must be airtight and watertight.

Combustion air and vent piping must also

terminate exactly as shown in ﬁgures #1 – #2.

If a concentric vent termination is being used,

refer to ﬁgures #3 – #5 for proper setup.

Vent connections serving appliances vented by

natural draft shall not be connected 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 4 - Concentric Vent

Figure 5 - Concentric Vent Roof Installation

Foundation Requirements

Boiler must be placed on level surface. Boiler is NOT to be

installed on carpeting.

NOTICE

If boiler is not level condensate drain lines

will not function 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 common

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.

Seal any unused openings in the common venting

system.

Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage

or restriction, leakage, corrosion or other deﬁciencies

which could cause an unsafe condition.

In so far as is practical, close all building doors and

windows and all doors between the space 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 exhaust, so

they will operate at maximum speed. Do not operate a

summer exhaust fan. Close ﬁre dampers.

Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so

appliances will operate continuously.

Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the ﬂame of a

match or candle, or the smoke from a cigarette, cigar

or pipe.

After it has been determined that each appliance

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.

Any improper operation of the common venting system

should be corrected so the installation conforms with

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

Natural Gas and Propane Installation Code, CAN/CSA

B149.1. When resizing any portion of the common

venting system, the common venting system should be

resized to approach the minimum size as determined

using the appropriate tables in chapter 13 of the

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

Gas and Propane Installation Code, CAN/CSA B149.1.

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 dolly 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.

BEFORE INSTALLING THE BOILER

PLACING THE BOILER

NOTICE

Refer to “locating the boiler” for required

clearances for servicing and maintenance.

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

connection to boiler. Use of dielectric unions is

acceptable. Packaged boiler is furnished with

iron piping in front boiler section for supply

and return connections.

When installation of boiler is for new heating system, ﬁrst

install all of radiation units (panels, radiators, baseboard,

or tubing) and supply and return mains. After all heating

system piping and components have been installed, make

ﬁnal connection of system piping to boiler.

Hot water boiler installed above radiation level or as

required by authority having jurisdiction must be equipped

with low water cut off device (included with boiler). A

periodic inspection is necessary, as is ﬂushing of ﬂoat

type devices, per low water cut off manufacturers speciﬁc

instructions.

Expansion Tank And Make-Up Water

Determine required system ﬁll pressure, system design

temperature, and system water content. Boiler contains

2.6 gallons (U.S.). Size expansion tank accordingly. Consult

expansion tank manufacturer for proper sizing information.

Connect properly 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. Install 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 water 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 and temperature

pressure gauge in the boiler parts bag.

Install safety relief valve and air vent using pipe• ﬁttings provided with boiler. See ﬁgure 7.

Install safety relief valve with spindle in vertical• position.

Do not install shutoff valve between boiler and safety• relief valve.

Install discharge piping from safety relief valve. See• ﬁgure 5-2.

Use ¾” or larger pipe.• Use pipe suitable for temperatures of 375°F• (191°C) or greater.

NEAR BOILER PIPING

Figure 6 - Diaphragm Type Expansion Tank Piping Figure 7 - Relief Valve Discharge Piping

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