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ECR International UB90-125 Installation, operation & maintenance manual

Manual is about: UB 90 125-200 SERIES II GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER

Summary of UB90-125

  • Page 1

    P/n 240009432 rev. A [03/2012] ub 90 125-200 series ii gas-fired, direct vent, condensing, hot water boiler installation, operation & maintenance manual an iso 9001-2008 certified company models ub90-125 ub90-150 ub90-175 ub90-200 manufactured by: ecr international, inc. 2201 dwyer avenue, utica ny ...

  • Page 2

    2 1 - boiler ratings & capacities ..............................................................................................3 2 - safe installation and operation .......................................................................................5 3 - locating the boiler ........................

  • Page 3

    3 1 -boiler ratings & capacities - sea level ratings (natural and propane gases) table 1 model input (mbh) (1) heating capacity (mbh) (1)(2) net ahri 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 ...

  • Page 4

    4 1 - boiler ratings & capacities this is gas-fi red direct vent cast aluminum hot water boiler. Cast aluminum heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers, which results in higher effi ciency. Heating system water absorbs large amounts of heat...

  • Page 5

    5 boiler is equipped for residential installations. If used for commercial applications; additional code requirements must be adhered to. This may require additional controls, including but not limited to manual reset low water cut off, manual reset high temperature limit, and wiring and/or piping m...

  • Page 6

    6 locating the boiler select level location, central to piping systems served 1. And close to vent and air intake terminals as possible. Accessibility clearances, if more stringent (i.E. Larger 2. Clearances) than required fi re protection clearances, must be used for boiler installation. Accessibil...

  • Page 7

    7 after it has been determined each appliance remaining 6. Connected to 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. Any improper operation of common venting system 7. Should b...

  • Page 8

    8 do not install copper supply and return piping directly 1. Into aluminum boiler section castings due to galvanic corrosion between dissimilar metals. Use iron, steel bushings or pipe connectors between 2. Copper system piping and boiler to make fi nal connection to boiler. Use of dielectric unions...

  • Page 9

    9 safety relief valve / temperature pressure gauge boiler is furnished with safety relief valve and temperature pressure gauge. Install safety relief valve using pipe fi ttings provided • with boiler. Figure 3, page 8 . Install safety relief valve with spindle in vertical position. • do not install ...

  • Page 10

    10 condensate drain requirements pitch condensate drain line down to fl oor drain at minimum of ¼” per foot (21mm/m). External condensate pump (not furnished) may be used if fl oor drain is not available. Condensate pump must be designed for fl ue gas condensate application. Condensate trap is prove...

  • Page 11

    11 if concentric vent termination is being used, refer to figure 10for proper setup. 5 - combustion air/ vent requirements - roof vent / intake terminations figure 8 - sidewall vent/intake terminations figure 9 - concentric vent terminations figure 10 combustion air/vent pipe requirements boiler req...

  • Page 12

    12 3” diameter pvc vent/exhaust 1½” 4½” dia. 31 ⅞ ” a a b b c c d e f g g 3” diameter pvc intake/combustion air 46¾” dimension 1 ³ ⁄ ΟΤ ” d e f dimension vent combustion air combustion air 1” maximum note: securing strap must be field installed to prevent movement of termination kit in side wall. El...

  • Page 13

    13 connections and termination to prevent damage to gas burner and ensure proper operation of unit, installer must clean and remove all shavings from interior of all pvc pipe used on air intake. Boilers require dedicated direct vent system. All air for combustion is taken directly from outdoors thro...

  • Page 14

    14 installation recommend all pipes be cut, prepared, and pre- 1. Assembled before permanently cementing any joint. Rigid supports cause excess noise in vent piping. 2. Attach combustio 3. N air intake piping to supplied 2” coupling on cvi gas valve. Attach vent piping to furnished 2” cpvc vent tee ...

  • Page 15

    15 check gas supply gas pipe to boiler must be correct size for length of • run and total btuh input of all gas utilization equipment connected to it. See tables 6 and 7 • for proper size. Verify your gas line complies with local codes and gas • company requirements. Connecting gas piping - gas supp...

  • Page 16

    16 warning electrical shock hazard. Turn off electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. ! Notice use copper conductors only. Electrically bond boiler to ground in accordance with requirements of authority h...

  • Page 17

    17 avoid the following dead spots corners alcoves behind doors cold spots concealed pipes or ducts stairwells - drafts unheated rooms on the other side of the wall hot spots concealed pipes fireplaces tvs or radios lamps direct sunlight kitchens thermostat installation follow instructions included w...

  • Page 18

    18 note: if any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°c thermoplastic wire or its equivalent. 8 - electrical wiring - schematic wiring connections figure 16.

  • Page 19

    19 note: if any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°c thermoplastic wire or its equivalent. 8 - electrical wiring - ladder wiring diagram figure 17.

  • Page 20

    20 see “troubleshooting” on page 34 for detailed sequences of operation and troubleshooting procedures. See separately provided “repair parts manual” for locations of control components and accessories described. Integrated boiler control (ibc) integrated boiler control (ibc) is a microprocessor • b...

  • Page 21

    21 differential pressure switches diaphragm type differential pressure switches are • connected by vinyl tubing to gas valve, air inlet connection on negative side, and sight glass adapter on positive side. Pressure switches monitor air fl ow by sensing differential pressure measured in inches of wa...

  • Page 22

    22 filling boiler with water and purging air for systems with conventional closed type expansion tanks refer to diagrams on “near boiler piping” on page 8 and 9 for more information. Close all zone service valves on supply and return 1. Piping. Close expansion tank service valve. Drain expansion tan...

  • Page 23

    23 warning if you do not follow these instructions exactly, a fi re or explosion may result causing property damage, personal injury or loss of life. This appliance is equipped with an ignition device • which automatically lights burner. Do not try to light this burner by hand. Before operating smel...

  • Page 24

    24 10 - startup if burner appears to pulsate during ignition: turn off boiler power. Shut off gas supply to boiler. 1. Take burner assembly apart by removing combustion 2. Air blower and gas valve/venturi assembly from boiler. Visually inspect inside of burner. Look for debris (pvc shavings, etc.). ...

  • Page 25

    25 draft inducer temperature safety switch draft inducer runs through 30 second post purge and switches off. Circulator runs with thermostat on call for heat. When temperature safety switch contacts connect before end of call for heat, control goes in normal light-off sequence. Loss of combustion ai...

  • Page 26

    26 end of normal sequence of operation thermostat ends call for heat. Gas valve and circulator pump are de-energized, valve and fl ame lights go out. Blower runs for 30 seconds post purge, purge light is on. Blower is de-energized after 30 seconds, purge light shuts off. Boiler stand by for next cal...

  • Page 27

    27 service hints power on stand by thermostat calls for heat circulator energizes thru 2k1 contacts ibc selfcheck of internal circuitry 1-2 sec ibc checks n.O. Air pressure switch contacts false positive proof of airflow. Ibc waits for 45 sec for air pressure switch contacts to open closed closed dr...

  • Page 28

    28 sequence of operation diagnostics follow sequence using the diagnostic indicator lamps on integrated boiler control (ibc). See “controls and accessories” on page 20 for normal sequence of operation. Detailed sequence of operation containing potential faults can be found in service hints section. ...

  • Page 29

    29 inspect venting & air intake system - operate boiler. Verify all vent/air intake connections are gas-tight and water-tight. Repair any leaks immediately. Inspect condensate drain - verify all connections are watertight, and condensate fl ows freely. Repair any leaks immediately. Inspect system pi...

  • Page 30

    30 set thermostat to desired temperature set thermostat to desired room temperature and observe several complete cycles to verify proper operation. Final review and sign-off review all instructions shipped with this boiler with owner or maintenance person. Affi x instructions on or adjacent to boile...

  • Page 31

    31 14 - troubleshooting - high limit control and lwco led legend and lwco test button 1 hi temp illuminates when boiler water temperature reaches high limit setting. Remains lit until water temperature falls 10°f. Limit prevents burner operation while this led is on. 2 lwco active indicates low wate...

  • Page 32

    32 15 - troubleshooting -high limit control and lwco troubleshooting flow chart burner will not fire see flow chart, this page. No or insuffi cient domestic hot water if installed with indirect water heater, insure end switch in relay box controlling indirect water heater is properly connected to ca...

  • Page 33

    33 initial service checks before troubleshooting: 1. Verify circuit breaker is on or fuse is ok at electrical a. Panel. Verify service switch is on. B. Verify gas is on at: c. Gas meter • appropriate manual shutoff valves • gas control valve • verify thermostat is calling for heat. D. Verify wire co...

  • Page 34

    34 system status indicator lights track operating sequence. If system locks out, lights indicate point in sequence of operation were lockout occurs. Refer to following pages for detailed troubleshooting procedures. Light status indicates power on ibc is energized through 24 volt transformer. Off ibc...

  • Page 35

    35 troubleshooting chart 1 15 - troubleshooting.

  • Page 36

    36 troubleshooting chart 2 !" # " " " "!" " # !" # !# # # !# !" # "! "# "! " " #" # #" #" " !" # ! " # 15 - troubleshooting.

  • Page 37

    37 troubleshooting chart 3 check for vac between terminals 1 and 3 at connector cn4 on ibc no no blower starts replace ibc chart 1 open purge light on? No yes ibc waits up to 5 minutes for normally open air pressure switch contacts to close, indicating blower suction is present yes check for 120 vac...

  • Page 38

    38 troubleshooting chart 4 igniter/sensor warms up and glows yellow/orange during 20 second warm up chart 3 yes no check for 120 vac between terminals 1 and 2 at connector cn1 on ibc (during igniter warm up) no replace ibc yes check for 120 vac at igniter/sensor leads on wiring harness (during ignit...

  • Page 39

    39 ! $$*)%% $$ ($%# $ '' # #$$# $$'%'' ##%$+ $#!#!#%$# #!$$ $% &$ ##%$'%''$+ *$ ! $$*%% # &!$$$ #!# % # &!$$$ # #&!$$$!#% $%#&% $ #% *$ *$ )## # !#% $%#&% $ ## !$$$)## )##!#% $%#&% $ # #%#% # ##%$+ $#!#!#%$ # $ # ##%$+ #!# #% *$ $# #&&% # %$ # %"&$%% %%$ ! #&$$ %* # &% $ $%$&%$ %$! #$ %#$$ # ! $% %!...

  • Page 40

    40 troubleshooting chart 6 runs for 25-50 seconds, then turns off. Check firing rate of unit. Is unit firing at the correct rate? No does the unit use lp gas. Yes no check gas orficice size. Is gas orifice size correct. Check repair parts list for correct size. Is gas orifice clear of blockage. Adju...

  • Page 41

    41 differential air pressure switch is safety device which prevents boiler from fi ring if there is air intake, boiler heat exchanger or vent blockage. Following steps and diagram indicate location of connection points required to measure offset pressure using inclined manometer or differential pres...

  • Page 42

    42 acidic nature of fl ue gasses condensing on aluminum boiler sections cause formation of aluminum oxide. This oxide formation is normal, is generally uniform throughout boiler sections, and represents negligible mass of aluminum that is consumed by oxidation during life of boiler. If left unchecke...

  • Page 43

    43 annual shut down procedure (end of each heating season) follow the instructions in “what to do if you smell 1. Gas” on page 23. If heating system is to remain out of service during 2. Freezing weather, and does not contain antifreeze, drain system completely. If boiler will be exposed to freezing...

  • Page 44: Aluminum Series

    44 p/n# 240006888, rev. E [06/2011] aluminum series high effi ciency gas-fired boiler dielectric isolation & antifreeze protection addendum appendix a - dielectric isolation & antifreeze protection warning you must follow these instructions to prevent damage to boiler’s heat exchanger caused by inad...

  • Page 45

    45 system and operating precautions applies to all aluminum high effi ciency gas-fired water boilers eliminate system leaks continuous addition of make-up water will constantly add oxygen to system. Eliminate all system leaks. All system leaks must be repaired immediately. Verify expansion tank is o...

  • Page 46

    46 system and operating precautions applies to all aluminum high effi ciency gas-fired water boilers general guidelines when using antifreeze use only antifreeze products • recommended for use with aluminum boilers, as listed in this addendum. See table 1. Continuous addition of make-up water will •...

  • Page 47

    47 compatible aluminum antifreeze & inhibitor suppliers noburst al antifreeze noble company p. O. Box 350 grand haven, mi 49417 www.Noblecompany.Com tel: 800-878-5788 fax: 231-799-8850 rhogard antifreeze & pro-tek 922 inhibitor* rhomar water management, inc. P. O. Box 229 springfi eld, mo 65801 www....

  • Page 48

    Ecr international 2201 dwyer avenue, utica ny 13501 web site: www.Ecrinternational.Com.