1. DL manuals
  2. ECR International
  3. Boiler
  4. UBSSC-050
  5. Installation, operation & maintenance manual

ECR International UBSSC-050 Installation, operation & maintenance manual

Manual is about: WALL MOUNTED GAS BOILER

Summary of UBSSC-050

  • Page 1

    Wall mounted gas boiler installation, operation & maintenance manual an iso 9001-2008 certified company p/n# 240008845, rev. L [03/2014] models ubssc - 050 ubssc-075 ubssc-100 ubssc-150 ubssc-200 ubssc-299 manufactured by: ecr international, inc. 2201 dwyer avenue, utica ny 13501 web site: www.Ecrin...

  • Page 2

    2 verify contents received description item no. Illustration fully assembled boiler 1 metal wall bracket 2 lag bolt, 3/8" x 3" hex (4 ea) 3 *safety relief valve 4 3/4" tee 5 3/4" nipple 6 3/4" x 1/4" elbow 7 air vent 8 **temperature pressure gauge 9 bushing 3/4" x 1/4" 10 3/4" tee (same as no. 11) 1...

  • Page 3

    3 table 1 : physical data models 050/075/100 150/200 299 width (a) 20" (508mm) 23" (584mm) height (b) 30" (762mm) 41" (1041mm) depth (c) 14" (356mm) 16.0" (406mm) 18.3" (465mm) bracket (d) 28" (711mm) 40" (1016mm) height (e) 31" (787mm) 42" (1092mm) water connections size (f) 1-1/4" npt 1-1/4" npt l...

  • Page 4

    4 1 - introduction ......................................................................................................................... 5 2 - important safety information .............................................................................................. 6 3 - component listing ........

  • Page 5

    5 1.1 designated use • hot water heating boiler. • indoor installation. • closet or alcove installation. • direct vent boiler. • for use with natural gas or liquefied petroleum gases (lp/propane). 1.2 the unit must not: • directly heat potable water. Indirect heating is acceptable. • heat water with...

  • Page 6

    6 notice used to address practices not related to personal injury. Caution indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. ! Warning indicates a hazardous situation which, if not avoided, could result in death or serious injury. ! Danger indicates a h...

  • Page 7

    7 3.1 component listing - refer to diagrams on following pages. 1. User interface displays information regarding boiler condition. Allows adjustment of boiler operating parameters. Note: does not replace thermostat used to control central heating space. 2. Combustion air inlet (2"/3") see section 6....

  • Page 8

    8 figure 3-1 boiler components (viewed from back of boiler) (25) vent connector note: see section 5-3 for safety relief valve piping instructions (2) combustion air inlet (23) safety relief valve (28) air vent figure 3-3 jacket latch (viewed from front of boiler) lift jacket up, engage jacket with c...

  • Page 9

    9 figure 3-4 boiler components 50/75/100 mbh (view from front of boiler) as seen on front cover (18) gas shutoff valve (shown in open position) (25) vent connector (19) combustion air blower (20) gas (control) valve (22) low water cutof f (23) safety relief valve (28) air vent (2) combustion air inl...

  • Page 10

    10 figure 3-5 boiler components 299 mbh ( view from front of boiler) (18) gas shutoff valve (shown in open position) (25) vent connector (20) gas (control) valve (22) low water cutoff (21) supply water temperature sensor & high limit switch (23) safety relief valve (28) air vent (2) combustion air i...

  • Page 11

    11 figure 4-1 clearance to combustible materials 4.1 boiler location considerations • ambient room temperature always above 32°f (0°c) to prevent freezing of liquid condensate. • approved for installation in closets. • protect gas ignition system components from water (dripping, spraying, rain, etc....

  • Page 12

    12 figure 4-2 wall mount bracket engaged with bracket on boiler caution boiler weight exceeds 75 pounds (34 kg). Do not lift boiler onto wall without assistance. ! 4 slots for attaching wall mount bracket to studs notice lift boiler using chassis. Using front jacket, vent piping, water or gas fittin...

  • Page 13

    13 5.1 general • install piping in accordance with authority having jurisdiction. Notice use two (2) wrenches when tightening and fitting to pipe boiler's threaded fittings. Boiler's internal piping can be damaged if subjected to excessive torque. • support system piping and safety relief valve disc...

  • Page 14

    14 • 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. • individual boiler discharge piping shall be independent of other discharge piping. • size and arrange discharge piping to avoid reducin...

  • Page 15

    15 piping legend figure 5-4 system piping notice illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. System return system supply safety relief valve wall mounted only pipe to condensate drain tab...

  • Page 16

    16 figure 5-5 single boiler two-pipe zoned system with zone valves figure 5-6 single boiler two-pipe zoned system with zone pumps heat exchanger ball valve open (as shipped) heat exchanger ball valve open (as shipped) dhw pump ch/system pump dhw pump zone pump 3/8"/10mm open end wrench may be requir...

  • Page 17

    17 heating load heating load heating load ch/system pump 12"(305mm) maximum separation 12"(305mm) maximum separation existing closely spaced tees in primary system loop heating load heating load heating load figure 5-7a single boiler using primary/secondary pumping with closed external primary loop ...

  • Page 18

    18 figure 5-8a multiple boiler two pipe zoned system with zone valves - (see multiple boiler guide) 5 - hydronic piping up to 16 boilers dhw pump (see multiple boiler guide) ch/system pump 12"/305mm maximum separation system temperature sensor size common piping per maximum heat capacity of entire s...

  • Page 19

    19 figure 5-8b multiple boilers using primary/secondary pumping with closed external primary loop 5 - hydronic piping heating load heating load heating load existing closely spaced tees in primary system loop 12"/305mm maximum separation up to 16 boilers ch/system pump 12"/305mm maximum separation s...

  • Page 20

    20 5-8c multiple boilers using primary/secondary pumping with open external primary loop existing closely spaced tees in primary system loop 12"/305mm maximum separation ch/system pump 12"/305mm maximum separation system temperature sensor size common piping per maximum heat capacity of entire syste...

  • Page 21

    21 6.1 general this boiler requires a dedicated direct vent system. Install combustion air and vent piping in accordance with these instructions, authority having jurisdiction, and: • usa - national fuel gas code, ansi 223.1/nfpa 54. Vent connections serving appliances vented by natural draft shall ...

  • Page 22

    22 warning vent extending through exterior wall shall not terminate adjacent to wall or below building extensions such as eaves, balconies, parapets or decks. Failure to comply could result in death or serious injury. ! 6.4 vent pipe installation • minimum and maximum combustion air and vent pipe le...

  • Page 23

    23 6.7 venting configurations various venting configurations can be applied to this boiler. For guidance see venting configuration table 7 and corresponding figures. Flue gas location combustion air location flue gas terminals corresponding figures roof roof two pipe figure 6-1 concentric figure 6-7...

  • Page 24

    24 side wall terminations 3" (80mm) minimum horizontal separation between combustion air intake and vent terminations. 8" (203mm) minimum vertical separation between combustion air intake and vent terminations. 12" (305mm) separation between bottom of combustion air intake and bottom of vent. Multip...

  • Page 25

    25 1"(2.54cm) maximum combustion air vent figure 6-4 side wall concentric terminal figure 6-5 side wall concentric terminal multiple appliances 1" (25.4mm) maximum maintain 12" clearance above highest anticipated snow level or grade * see note below vent combustion air 1" (25mm) maximum roof overhan...

  • Page 26

    26 concentric vent roof terminations glue inner vent pipe to prevent recirculation. Maintain 12" (305mm) us (18"(457mm) canada) minimum clearance above highest anticipated snow level. Maximum of 24"(610mm) above roof. Support must be field installed to secure termination kit to structure. Elbow, roo...

  • Page 27

    27 figure 6-10 flue on sidewall, combustion air on roof figure 6-11 flue on sidewall, inside combustion air combustion air vent 12" (305mm) anticipated snow line 6 - combustion air and vent piping notice configurations of single pipe vent with flue on the sidewall, requires a tee as the vent termina...

  • Page 28

    28 doors & windows combustion air and vent termination must be 12" (305mm) from or below doors, windows or gravity inlet. Forced air inlet terminate venting system 3’ (0.9m) above and 10' (3.0m) from any forced air inlet (except boiler’s combustion air inlet). "l" corner vent termination shall not b...

  • Page 29

    29 multiple family dwellings vent shall not terminate directly above paved sidewalk or paved driveway located between two single-family dwellings serving both dwellings. 7' (2.1m) minimum 3' (0.9m) minimum termination stones, balls, etc. Position combustion air and vent termination where it will not...

  • Page 30

    30 6.9 multiple boiler venting installation • multiple boiler application boiler can vent individually or use common vent pipes. • if boilers vent individually follow guidelines as described in figures 6-1 through 6-7. • if boilers vent through common vent pipes, as shown in figure 6-17, choose comm...

  • Page 31

    31 6.10 condensate piping • use materials acceptable to authority having jurisdiction. In absence of such authority: • usa - pvc or cpvc per astm d1785/d2845 cement or primer per asme d2564 or f493. • canada - csa or ulc certified pvc/cpvc pipe, fittings and cement. • attach pvc tee provided with bo...

  • Page 32

    32 7.1 general • use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements: • usa - national fuel gas code, ansi z223.1/nfpa 54 • size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than min...

  • Page 33

    33 figure 7-2 manual main gas shutoff valve outside boiler jacket 7.3 leak check gas piping pressure test boiler and gas connection before placing boiler in operation. • pressure test over 1/2 psig (3.5 kpa). Disconnect boiler and its individual gas shutoff valve from gas supply system. • pressure t...

  • Page 34

    34 8.1 general electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to: • usa- national electrical code, ansi/nfpa 70. 8.2 electric knockouts (figure 8-1) • five knockouts located on bottom of chassis. A. Three knockouts located under junction bo...

  • Page 35

    35 • outdoor sensor, if used. A. Provided with boiler. B. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor. C. Maximum wire length is 100 ft (30m) for 22 ga. Wire, or 150 ft (45m) for 18 ga. Wire. D. Connect wires to outdoor sensor termina...

  • Page 36

    36 9.1 fill boiler with water and purge air notice to maintain boiler efficiency and prevent boiling inside the heat exchanger, flush entire heating system until clean. • flush heating system, including all heating zones. • fill boiler with potable water. • fill boiler and system piping with water (...

  • Page 37

    37 figure 9 -2 user interface 9.3 program boiler control key description - manual lockout reset - enter/exit user menu - go to previous screen - select a menu item - confirm new parameter value - scroll up to next menu item - increase value - scroll down to next menu item - decrease value boiler is ...

  • Page 38

    38 9.4 boiler start-up and operational test 1. Verify air is purged from hydronic piping 2. System test pumps - verify each pump is operational 3. Verify gas piping • confirm pressure test. See section 7.3. • visually inspect piping to determine there are no open fittings or ends, and all valves at ...

  • Page 39

    39 9 - start up procedure gas co 2 co min. Max. Natural gas 9.0 9.5 propane 10.0 11.0 notice contact technical support @ 800-325-5479 for additional information or assistance. Natural gas only** 4. Measure input. Compare to table above. Continue to measure input and co 2 until both measured values a...

  • Page 40

    40 figure 9-5 combustion analyzer port - 050/075/100/150/200 flame flame burner 9.6 perform csd-1 compliance test (see paragraph 2.4 page 6) verify operation of boiler safety control operation with regard to no flow conditions as follows: 1. Turn off boiler using boiler service switch. 2. Disable pr...

  • Page 41

    41 9.7 complete start up procedure 1. Reset control parameters to operating settings if adjusted to allow startup and operation test. 2. Follow instructions to turn off gas to appliance (page 42) if boiler is not being placed into immediate operation. 3. Enter installer information on warranty regis...

  • Page 42

    42 for your safety read before operating warning if you do not follow these instructions exactly, a fire 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 ...

  • Page 43

    43 11.1 beginning of each heating season • check boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids. • visually inspect combustion air and vent piping for proper operation. Check for and remove any obstruction to flow of combustion air or vent gases. Imm...

  • Page 44

    44 figure 11-3 condensate trap - 050,075,100,150,200 flue pipe temperature sensor hose barb w/cap coupling condensate collector condensate trap connection to condensate collector flexible gas line 11.2 annual shut down procedure • follow instructions “to turn off gas to appliance” unless boiler is a...

  • Page 45

    45 • remove ¼-20 hex flange nuts securing condensate collector to heat exchanger using 7/16" deep well socket. See figures 11-3 & 11-4. • remove condensate collector assembly from heat exchanger and flue pipe. • flush collector and condensate trap with water. • follow burner inspection kit instructi...

  • Page 46

    46 12.1 ratings and capacities • constructed and hydrostatically tested for maximum allowable working pressure of 50 psig (pounds per square inch gauge) (345 kpa) in accordance with asme boiler and pressure vessel code, section iv, rules for construction of heating boilers. • ratings used for elevat...

  • Page 47

    47 13 - trouble shooting.

  • Page 48

    48 screen display explanation go to page for troubleshooting control has blocking error for more than 20 hours in a row. Go to page 50 three unsuccessful ignition attempts in a row go to page 51 open gas valve power circuit. May involve high temperature switch, gas valve, or gas valve relay in contr...

  • Page 49

    49 screen display explanation go to page for troubleshooting low water cutoff sees no water. Go to page 56 flue temperature sensor sees temperature higher than 200°f. Go to page 57 return water temperature sensor sees temperature higher than 200°f. Go to page 58 control board internal error. Power d...

  • Page 50

    50 _ _ _ _ _ lockout alarm a 0 0 blocking too long e rror enter installer menu, boil er status. Scr oll to most recent lockout alarm or blocking error. Di agnose corrective action usi ng appropriate trou blesh ooting tree. Unplug connector on supply sensor . Measure continuit y of high limit sensor ...

  • Page 51

    51 13 - trouble shooting.

  • Page 52

    52 error shows when safet y circuit is open. R emo ve j13 connector from control module. Check for continuit y between two pins connected to two pink wires, is continuit y a vailable? Yes no replace control module boiler fired without enough w ater flow through heat ex changer . Heat ex changer is o...

  • Page 53

    53 13 - trouble shooting.

  • Page 54

    54 disconnect harness f rom high temper ature supply s witch a nd control module j13. Check continuit y of both purple wires. Continuit y a vailable for both purple wires? 13 - trouble shooting.

  • Page 55

    55 in sp ect bu rne r thro ugh sigh t gl as s. Is fla m e pr es en t? No ye s _ p _ _ _ blocking error e 3 5 fals e flame detect replace control module turn ga s sh utoff va lv e clockw ise to cl osed pos ition. Follow instructi ons to turn off g a s to appliance. Rep la ce gas va lv e. Turn of f ma...

  • Page 56

    56 13 - trouble shooting connect ha rness to t ransf ormer . D isconnect harness f rom low w ater cutof f. Is 24 v ac at terminals 1 & 2 (between blue and y ellow wires)? Yes no repair s ystem piping, remo ve an y remaining air in system..

  • Page 57

    57 read flue gas temper ature on user interface. Is temper ature higher than 200°f ? Yes no boiler is o ver fired. W ait for boiler to cool. Fix flow r ate problem if an y, purging all air out of the system. Replace flue gas sensor replace control module use thermal couple to measure flue gas temper...

  • Page 58

    58 yes remo ve all liquid from connector . Check for leaks. Repair all leaks. Replace control module replace r eturn w ater sensor 13 - trouble shooting is correct harness connected to return sensor (2 brown wires)? Yes no correct wiring unplug molex connector on return sensor . Is there moisture or...

  • Page 59

    59 is field wiring loose or fa ulty? Is power su pply betw een 59 and 61 hz? N o ye s _ p _ _ _ blocking error e 4 5 net frequency error correct wiring is p ow er s up pl y c ircu it br ea ke r loose or fa ulty? Prov ide frequency st abilize d power supp ly rated at 60 hz +/- 2% replace control m od...

  • Page 60

    60 13 - trouble shooting is harness p lug ged into sup ply w at er sensor? Is harness p lugg ed into c ontr ol module j 5? _ p _ _ _ blocking error e 5 1 supply sens open inse rt h arne ss r epl ace supply water senso r disco nnect j5 fro m co nt rol mo dule. Using di gi tal m et er me as ur e check...

  • Page 61

    61 13 - trouble shooting is ha rne ss plug ged in to return te m pe ra tu re s en so r? Is h ar ne ss p lu gg ed in to c on tro l module j5? _ p _ _ _ blocking error e 5 2 return sens open replac e re tur n tem pe ra tu re s en so r replace control module check con tin uity of brown wires between re...

  • Page 62

    62 13 - trouble shooting supply w ater t emperature sensor resistance chart disconnect wire harness from high temperature supply switch. Measure resistance across terminals 2 and 4. Does temperature fall within ranges shown in chart?.

  • Page 63

    63 disconn ect ha rne ss from contro l m odule j5. M easure resistan ce b etwee n brown wires at terminals j5 -4 a nd j5 - 12 . Is resistan ce le ss th an 50 oh ms? _ p _ _ _ blocking error e 6 0 return sens shorted disconn ect ha rne ss from re tu rn te mperat ure sensor. M ea su re re si st an ce ...

  • Page 64

    64 14.1 connection diagram - 050/075/100 mbh 14 - wiring diagram external pump relay - limit of 1 amp per pump see section 8.

  • Page 65

    65 14.2 schematic diagram of ladder form - 050/075/100 mbh 14 - wiring diagram j5-2 j5-11 j5-3 j5-12 j5-4 j5-13 j5-5 j5-14 j5-6 j5-15 j5-7 j5-16 j5-8 s4 j18-1 j18-2 j16-1 j16-4 j16-8 j16-7 j16-3 j16-2 j12 j13-2 j9-1 j9-2 j9-6 j9-7 j9-5 j9-4 j9-3 j7-1 j7-4 j7-3 j7-2 j6-1 j6-3 j6-2 j4-1 j4-2 j4-3 j4-4...

  • Page 66

    66 14.3 connection diagram - 150/200/299 mbh 14 - wiring diagram external pump relay - limit of 1 amp per pump see section 8.

  • Page 67

    67 14.4 schematic diagram of ladder form - 150/200/299 mbh 14 - wiring diagram ladder diagram j5-2 j5-11 j5-3 j5-12 j5-4 j5-13 j5-5 j5-14 j5-6 j5-15 j5-7 j5-16 j5-8 s4 j18-1 j18-2 j16-1 j16-4 j16-8 j16-7 j16-3 j16-2 j12 t2 j13-2 j9-1 j9-2 j9-6 j9-7 j9-5 j9-4 j9-3 j13-5 j13-6 j13-3 j13-4 j7-4 j7-2 j7...

  • Page 68

    68 natural gas length of pipe - ft. Pipe capacity - btu per hour input includes fittings 1/2” 3/4” 1” 1 1/4” 20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000 60 50,000 105,000 195,000 365,000 propane gas length of pipe - ft. Pipe capacity - btu per hour input includes fittings cop...

  • Page 69

    69 • qualified agency - any individual, firm, corporation, or company engaged in and responsible for: • installation, testing, or replacement of gas piping, or connection, installation, testing, repair or servicing of appliances and equipment. • experienced in such work. • familiar with all precauti...

  • Page 70

    70 appendix a - control module 1.1 front panel status indicators see control module section for operational states of front panel indicators and user interface display. Power indicator (green) light is lit when boiler power is on. Heat indicator (green) light is lit when boiler is providing heat for...

  • Page 71

    71 1.1 introduction boiler is equipped with programmable electronic control and user interface module. 1.2 operation • display: 4 x 20 character lcd screen to show boiler status. • function keys operation with lcd character display module 1.3 status indication the following status screens can be dis...

  • Page 72

    72 1.4 sequence of operation operational state front panel indicators user interface display explanation boiler operates in standby mode until demand for central heat (ch) or domestic hot water (dhw) is detected. Ch or dhw pump is turned on based on type of heating demand. (ch call is illustrated) c...

  • Page 73

    73 1.4 sequence of operation operational state user interface display explanation if flame detected before gas valve opens during ignition boiler will lockout. Please refer to troubleshooting guide. Gas valve energized to deliver air/ fuel to burner. If flame undetected after 3 sec - onds boiler wil...

  • Page 74

    74 1.5 user menu user interface display explanation standby boiler operates in standby mode until demand for central heat (ch) or domestic hot water (dhw) is detected. User menu (press menu button on user interface to access user menu) user menu user menu structure includes: • ‘boiler status’ submen...

  • Page 75

    75 user interface display explanation sett ings setting range: 104° f to 195° f (40° c to 91° c) default value: 140° f (60° c) adjust ch set point to hydronic system design while in operating in ch mode = 0 (ch with thermostat) or 3 (permanent demand). In ch mode = 1 (ch with thermostat and outdoor ...

  • Page 76

    75 user interface display explanation installer menu inst aller menu installer menu structure includes: • user 'menu' can be accessed by pressing 'menu' key on user interface. • installer 'menu' can be accessed by first pressing and holding the 'enter' key continue to hold and at the same time press...

  • Page 77

    77 user interface display explanation installer menu bo iler status control module logs successful and failed ignition attempts. Information accessed in ‘ignition attempts’ screen as shown. Ignition attempts are stored in non-volatile memory and are retained in event of power failure. Figure a-1 typ...

  • Page 78

    78 user interface display explanation bo iler status boiler stores information regarding total ch and dhw run time in hours. Data stored in non-volatile memory and retained in event of power failure. Boiler logs last 16 blocking errors and 16 lockout errors in non-volatile memory. Information retain...

  • Page 79

    79 user interface display explanation bo iler co nfiguratio n two pump modes are available: 1. Pump mode = 0 ‘ch or ch&dhw’ • in this mode either ch or dhw pump terminal is energized depending on type of demand (ch or dhw). • ch and dhw pumps are never energized at the same time. • in the case of si...

  • Page 80

    80 user interface display explanation ch settings 4. Central heating (ch) modes available: • ch mode = 0 ‘ch with thermostat’ • boiler will attempt to satisfy ch demand while ch thermostat input is closed. • boiler will modulate its firing rate to maintain ch set point and match system heat load. • ...

  • Page 81

    81 b allowed boiler range: 35°f to 120 f (2°c to 49°c) default boiler setting: 100°f (37°c) allowed outdoor range: 35°f to 85°f (2°c to 29°c) default outdoor setting: 70°f (21°c) 1 0 0 a c d appendix a - control module user interface display explanation ch set tings allowed range: 35°f to 100°f (2°c...

  • Page 82

    82 user interface display explanation ch settings outdoor reset boost function increases ch set point by increment (‘temp’) if ch demand continues beyond pre-set time limit (‘time’). Ch set point will continue to increase until set point reaches 195°f / 91°c allowable temperature increment: 0..36 °f...

  • Page 83

    83 user interface display explanation dhw sett ings allowed range: 1 to 60 minutes default setting: 30 minutes maximum time boiler operates in dhw mode limited by dhw maximum priority time setting. Priority timer starts when both ch and dhw demand is present. Boiler will switch from dhw back to ch o...

  • Page 84: Important

    Ecr international, inc 2201 dwyer avenue, utica ny 13501 web site: www.Ecrinternational.Com important in accordance with section 325 (f) (3) of the energy policy and conservation act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating loa...