UTICA BOILERS UB90-100 Manuel d'installation

1Kit ContentsBoiler MBH 50 MBH 75MBH 75 MBH 100 MBH S3 100 MBH S2Fuel NAT/LP NAT LP NAT/LP NAT/LPKit Number 550002825 550002826 550002828 550002827 55

10Natural Gas LPMBH CO2CO MBH CO2CO50 8.7- 9.7 < 100 50 10.0 - 11.1 < 10075 8.7- 9.7 < 100 75 10.0 - 11.1 < 100100 8.7- 9.7 < 100 100 1

11NOTESPrior to leaving job site review supplied instructions for :1. Proper Venting Material2. Proper Venting Size3. Proper Venting Installation4. R

12Company Address & Phone #Company Name & Tech InitialsService PerformedDateSERVICE RECORD

2DIMENSIONS2Figure 1 - Boiler DimensionsNOTICEDraft inducer (blower) may be rotated 90° or 180° to orient vent connection towards right side or rear.

3INTRODUCTIONIntroduction• This appliance is a gas-fi red direct vent hot water boiler with cast aluminum boiler sections. • The heating system water a

4Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:• United States • National Fuel Gas C

5Table 1 - SEA LEVEL RATINGS – NATURAL AND PROPANE GASESModelInput *(MBH)++ Heating Capacity*(MBH)Net AHRI Rating*(MBH)ShippingWeight (lbs.)AFUE90-50

6Table 2 - NATURAL GASMODEL 90-50 Stock Factory Btu Value of Natural Gas++Settings 750 850 950 1000 1050Altitude in Ft. 0-5,000 5,000-10,000Normal In

7Table 3 - PROPANE GASMODEL 90-50 Stock Factory Btu Value of Propane Gas++Settings 2300 2350 2400 2450 2500Altitude in Ft. 0-5,000 5,000-10,000Normal

8Boiler Sizing Check to be sure you have selected boiler with proper capacity before starting installation. AHRI Rating of boiler selected should be g

P/N 240010144, Rev. A [05/2013]DSI Removal:1. Follow instructions to TURN OFF GAS TO APPLIANCE found on Operating Instructions label on boiler or in

9Table 4 - Required ClearancesUnitCombustible ClearanceAccessibility, Cleaning, and Servicing Top 1” (26mm) 8” (204mm)Left Side 1 “ (26mm) -Right

10Condensate Drain Requirements• Pitch condensate drain line down to fl oor drain at minimum of ¼” per foot. External condensate pump (not furnished) m

11Near Boiler Piping• When boiler installation is for new heating system, install all of radiation units (panels, radiators, baseboard, or tubing) and

12NEAR BOILER PIPINGFigure 2 - Single Zone Boiler PipingSAFETY RELIEF VALVE - SEE PAGE 18 FOR REQUIREMENTS

13Figure 3 - Two Zone Boiler Piping With Zone ValvesNEAR BOILER PIPINGMulti-Zone SystemsMulti-zone systems with two zones are typically piped as sho

14Figure 4 - Two Zone Boiler Piping With CirculatorsNEAR BOILER PIPINGSAFETY RELIEF VALVE - SEE PAGE 18 FOR REQUIREMENTS

15NEAR BOILER PIPINGFigure 5 - Primary/Secondary Piping With Circulators And Domestic Hot Water

16NEAR BOILER PIPINGFigure 6 - Piping Primary/Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water (With Zone Valve)

17NEAR BOILER PIPINGFigure 7 - Piping Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator)

18Safety Relief ValveInstallation of safety relief valve shall conform to ANSI/ASME Boiler and Pressure Vessel Code, Section IV. • Install furnished

35. Remove temperature sensor from thermo well, save clip. See fi gure 3.6. Locate wire bundle going to external junction box. Cut the wire bundle. See

19Figure 9 - Diaphragm Type Expansion Tank PipingNEAR BOILER PIPINGSAFETY RELIEF VALVE - SEE PAGE 18 FOR REQUIREMENTS

20Figure 10 - Conventional (Closed Type) Expansion Tank PipingNEAR BOILER PIPINGSAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS

21Condensate Drain PipingBoiler is factory equipped with a condensate trap. An additional trap is not required and should NOT be used.1. Provide ½” PV

22Connections And TerminationProvisions for combustion and ventilation air must be in accordance with section, Air For Combustion and Ventilation, of

235. See Figure 12 thru Figure 17, Pages 24 thru 26 for combustion air and vent pipe roof and sidewall termination. Roof termination is preferred. C

24Figure 12 - Roof Vent / Intake TerminationsInstallation1. Attach combustion air intake piping using fi eld supplied 2” fl exible coupling. Attach ve

25Figure 13 - Side Wall Vent / Intake terminations - Less Than 12” Clearance Above GradeFigure 14 - Side Wall Vent/Intake Terminations - 12” Or Mo

26Figure 15 - Concentric Vent TerminationsCombustion AirVent1" (25.4mm) MaximumMaintain 12" clearance above highest anticipated snow leve

27Figure 18 - Combustion Air and Vent Piping - Boiler ConnectionsCOMBUSTION AIR AND VENT PIPE2” (50.8mm) Diameter Vent And Combustion Air Intake Pip

28Check Gas SupplyGas pipe to your boiler must be correct size for length of run and for total Btu per hour input of all gas utilization equipment con

4Figure 6 - Remove Existing Control Panel AsemblyFigure 7 - Remove Existing Igniter8. Lift, twist and remove control panel assembly. See fi gure 6.9. R

29Table 7 – Gas Pipe Sizes NATURAL GASLength of Pipe - Ft.Pipe Capacity - BTU Per Hour Input Includes Fittings1/2” 3/4” 1” 1 1/4”20 92,000 190,000 35

30Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to:• USA- National Electrical Code

31Figure 20 - Field Wiring ConnectionsELECTRICAL WIRINGSAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS

32ELECTRICAL WIRINGFigure 21 - Wiring SchematicNOTICEIf any of original wire as supplied with this appliance must be replaced, it must be replaced w

33Figure 22 - Ladder Diagram for Figure 22ELECTRICAL WIRING

341 - Integrated Boiler Control (IBC)• Integrated Boiler Control (IBC) is a microprocessor based controller for high effi ciency gas boilers. • Control

35SETTINGOFFDisables economy function. Will allow boiler to fi re until hi-limit temp is reached and re-fi re with a 10° subtractive differential.LOProv

36Water Quality, Water Treatment and Freeze Protection - see Appendix AFilling Boiler With Water And Purging Air For Systems With Diaphragm Type Expan

37Stop! Read Safety information above.1. Set thermostat to lowest setting.2. Turn off all electric power to the appliance.3. This appliance is equippe

38DETAILED SEQUENCE OF OPERATION SERVICE HINTSPOWER ON STAND BYTHERMOSTATCALLS FOR HEATCIRCULATORENERGIZES THRU2K1 CONTACTSIBC SELFCHECK OF INTERNAL C

5DSI Removal Conti.11. Remove mixing valve body and fi rst gasket. See fi gure 9.12. Remove existing burner plate. 13. Disconnect all wires connected in

39DETAILED SEQUENCE OF OPERATION End Of Normal Sequence Of OperationThermostat ends call for heat.Gas valve and circulator pump are de-energized, valv

40 Sequence Of Operation DiagnosticsFollow sequence using the diagnostic indicator lamps on Integrated Boiler Control (IBC). See “Controls And Access

41DRAFT INDUCER TEMPERATURE SAFETY SWITCHDraft inducer runs through 30 second post purge and switches OFF.Circulator runs with thermostat on call for

42First couple of cold starts may be rough due to gas line not being completely purged of air, causing low fi ring rate and high excess air levels.Insp

43 VERIFICATION PROCEDURE AND ADJUSTMENTIV. Measure new input rate (cover screw must be installed). Repeat steps I.-IV until the input rate is within

44Following steps and diagram indicate location of the connection points required to measure manifold pressure.Manifold pressure may be measured using

45• Following steps and diagram indicate locations of connection points required to check differential air pressure.• Differential air pressure switch

46NEGATIVE PRESSURE SWITCH CHECKBOILER STATUSNEGATIVE PRESSURE (W.C.)PRESSURE SWITCH CONNECTSNot Running 0”Normally ClosedSetpoint-0.50” for Models 10

47Maintenance As Outlined Below Can Be Performed By Owner Unless Otherwise Noted.• The acidic nature of fl ue gasses condensing on aluminum boiler sect

48K. Reinstall burner and mixer gasket and position mixer assembly over studs. Install fi ve (5) nuts but do not tighten. Reinstall igniter and ignite

6Figure 13 - Install Replacement Junction BoxFigure 14 - Install Supplied Replacement Control Panel Assembly19. Kit 550002829 (100 MBH ONLY) :A. Remo

49Important1. In reset from lockout condition, all electrical meter readings at the gas control valve (24 vac) must be taken within trial for ignitio

50TROUBLESHOOTING - HIGH LIMIT CONTROL AND LWCO LED Legend and LWCO Test Button1 HI TEMP illuminates when boiler water temperature reaches high limit

51TROUBLESHOOTING -HYDROSTAT HIGH LIMIT CONTROL AND LWCO Troubleshooting Flow ChartBurner Will Not Fire See Flow Chart, this page.No or Insuffi cient D

52

53 Troubleshooting Chart 2  !"

54 Troubleshooting Chart 3CHECK FOR VAC BETWEEN TERMINALS 1 AND 3 AT CONNECTOR CN4 ON IBCNO NOBLOWER STARTSREPLACE IBCCHART 1OPENIBC PURGE LIGHT ON?NO

55 Troubleshooting Chart 4IGNITER/SENSOR WARMSUP AND GLOWS YELLOW/ORANGEDURING 20 SECOND WARM UPCHART 3YESNOCHECK FOR 120 VAC BETWEEN TERMINALS 1 AND

56POSSIBLY MIXTURE TOO LEAN!CHECK GAS LINES DOWNSTREAM OF GAS VALVE FOR BLOCKAGE.ARE GAS LINES CLEAR?IS GAS/VENTURI VALVE CORRECT SIZE? SEE REPAIR PAR

57 Troubleshooting Chart 6RUNS FOR 25-50 SECONDS, THEN TURNS OFF.CHECK FIRING RATE OF UNIT.IS UNIT FIRING AT THE CORRECT RATE?NODOES THE UNIT USE LP G

58Aluminum SeriesHigh Effi ciency Gas-Fired BoilerDIELECTRIC ISOLATION & ANTIFREEZE PROTECTIONAPPENDIX A - WATER QUALITY, WATER TREATMENT AND FREEZ

Figure 17 Install Hot Surface IgniterFigure 18 Connect to Casting Temperature Switch, Inducer, Gas Valve, Igniter Ground and Ground WireHSI Installa

59System and Operating PrecautionsApplies to ALL Aluminum High Effi ciency Gas-Fired Water BoilersEliminate System LeaksContinuous addition of make-up

60System and Operating PrecautionsApplies to ALL Aluminum High Effi ciency Gas-Fired Water BoilersGeneral Guidelines When Using Antifreeze• Use only a

61Compatible Aluminum Antifreeze & Inhibitor SuppliersNoburst AL AntifreezeNoble CompanyP. O. Box 350Grand Haven, MI 49417www.noblecompany.comTel:

8Figure 19 Connect Thermostat and Power WiresFigure 20 Insert Sensor and Install Sensor ClipHSI Installation9. Run wire bundle with power wires to

9HSI InstallationFigure 21 Pressure Tube Routing12. Connect pressure tubes: See fi gure 21.A. Site glass - run tube over gas valve assembly and/or pi