UTICA BOILERS 95M-200 Control Manual And Troubleshooting Manual
95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
!
WARNING
Revise boiler control parameters only if you fully un-
derstand the purpose and result of the changes. T am-
pering without understanding the control settings in
this manual will void the warranty and can result in
unreliable operation, with possible severe personal
injury , death, or substantial property damage.
WARNING
!
This document must only be used by a qualied
heating installer or service technician. Read all
instructions, including the Installation Manual
(P/N# 240006103), the Parameter Guide (P/N#
240006105), the User’s Information Manual (P/N#
240006106), and this Control Manual and Operating Instructions before attempting to program
the control, and be sure to perform all steps in
the order specied. Failure to comply could result in severe personal injury, death, or substantial property damage.
Control manual and troubleshooting guide
IMPORTANT: Installation must comply
with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for
Canadian installations.
DO NOT DESTROY THESE INSTRUCTIONS!!
Please read carefully and keep in a safe place
for future reference.
P/N 240006104, Rev. A [05/08]
2
95-200M GAS FIRED DIRECT VENT MODULATING HOT WATER BOILER
Control manual and oPerating instruCtions
Printed in USA • Made In USA
TABLE OF CONTENTS
I - Safety Symbols and Warnings ................................................................................................... 3
II - Operating Information................................................................................................................4
iii - modulating Control Features ....................................................................................................6
iV - Boiler startup ........................................................................................................................... 6
V - Checkout Procedures and Adjustments ....................................................................................9
Vi - detailed sequence of operation ............................................................................................ 12
Vii- service Hints ..........................................................................................................................13
VIII - Troubleshooting ...................................................................................................................14
iX - user interface Quick reference.............................................................................................20
Keep this manual near boiler
and retain for future reference.
I - SAFETY SYMBOLS AND WARNINGS
The following dened symbols are used throughout this manual to notify the reader of
potential hazards of varying risk levels.
!
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, seri-
ous injury or substantial property damage.
WARNING
!
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious in-
jury or substantial property damage.
CAUTION
!
indicates a potential hazardous situation which,
if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
IMPORTANT: read the following instructions
completely before installing!!
3
II - OPERATING INFORMATION
This boiler is controlled by a microprocessor electronic control that senses outlet water temperature, return water tem-
perature, and outdoor temperature (when a factory supplied,
eld installed outdoor sensor is installed). This information
(plus input from external limit and operating controls) is used
to regulate boiler on/off operation and will modulate boiler r-
ing rate to more closely match output to demand.
ELECTRICAL SPECIFICATIONS
Boilers require 120 vac/60 HZ power supply and are not polarity sensitive.
CONTROL SPECIFICATIONS
supply voltage 120 vac/60 hz
Electrical demand 10 va
Prepurge timing 10 seconds
Postpurge timing 15 seconds
Min. off time, space heating 10.2 seconds
Pump on after space htg. 0 minutes
Min. off time, DHW 10.2 seconds
Pump on after DHW 30.6 seconds
line voltage fuse, F1 5 amp fast-blow
low voltage fuse, F3 4 amp slow-blow
BOILER CIRCULATOR
The circulator has sufcient head to handle the boiler pressure
drop plus reasonable pressure drop in the connecting piping.
See the separate Installation Manual (P/N# 240006103) for
piping and ow rate information.
The boiler control’s internal relay contact is suitable for handling only the boiler circulator provided. Do not wire addi-
tional pumps in parallel with the boiler circulator. To operate
a system circulator when the boiler circulator is running, see
the section on “Electrical Wiring” in the Installation Manual for
wiring required.
BOILER TEMPERATURE REGULATION
OPERATING TEMPERATURE (TARGET): The boiler con-
trol senses outlet water temperature and regulates the boiler
ring rate to achieve a target temperature, set by installer
with Parameter 4. Temperature can be set between 120°F
and 194°F.
SPACE HEATING: • Target temperature is xed (equal to
Parameter 4) when outdoor reset is not installed or calculated as described under “Outdoor Reset Operation”
when outdoor sensor is connected.
ExCEPTION: • See explanation of “Supply Temperature
Boost.”
DHW HEATING: • Target temperature is determined by
adding Parameter 1 to Parameter 33 (default 150°F and
30°F). Do not change Parameter 1 from the factory de-
fault setting of 150°F unless the application is specially
engineered for other temperature. DHW heating default
setting is 180°F.
High limit operation: If outlet water temperature exceeds target temperature (or 180°F, whichever is lower), high limit ac-
tion occurs. The control module shuts the burner off showing
“b 9” followed by “26” on the display.
DHW operation (if used): The boiler is factory set to immedi-
ately change target outlet water temperature to 180°F on a
call for heat from the DHW aquastat.
Additional Thermal Overrun Protection: High limit operation
shuts down the burner when the outlet water temperature ex-
ceeds the target temperature. However, adverse conditions
could cause the water temperature to rise too quickly and
overshoot this temperature. The boiler control’s advanced
technology provides protection in the event of thermal over-
run. using its electronics, the control provides two additional
levels of overrun protection:
LEVEL 1:• Indication would occur if supply water tem-
perature reached 183°F. The control would display a
soft lockout code (“b 9” followed by “18” if on the supply
or “19” if on the return). The control would not operate
the burner again until the water temperature dropped
9°F below target temperature.
LEVEL 2:•
Lockout would occur if supply water tempera-
ture reached 200°F or if the return water reached 193°F.
the control would enter hard lockout and display an error
code (“E” followed by “18” if on the supply or “19” if on
the return).
NOTE: Hard lockout requires manually pressing the display
panel reset button to restart operation. Service technician must
troubleshoot the cause of the problem and correct it before placing
the boiler back in operation.
LOW WATER PROTECTION
This boiler comes factory equipped with a manual reset
1.
low water cutoff. In addition, the boiler control uses tem-
peratures sensed at both supply and return areas of the
heat exchanger. If the ow rate is too low (temperature
difference too high) or either temperature is too high, the
control shuts the boiler down. This ensures boiler shut-
down in the event of low water or low ow conditions.
2.
Some codes and jurisdictions may accept these integral
features of the control in lieu of requiring an additional limit
control or low water cutoff. Consult your local jurisdiction
for more information on low water cutoff requirements.
4
Target Outlet Temperature, °F
Outside Temperature, °F
Outdoor Reset Target Temperature
210
50
70
60 50 40
30
20
10 0
-10
-20
70
90
110
130
150
170
160
190
120
Parameter 4 = 190°F
Parameter 4 = 150°F
Parameter 4 = 170°F
Reset Curve Calculations
Target Outlet Temperature, °F
Outside Temperature, °F
Default Reset Curve
Outdoor Reset Target Temperature
210
50
70
60 50 40
30
20
10 0
-10
-20
70
90
110
130
150
170
160
190
180
120
Parameter 7 = 60°F
Parameter 4 = 180°F
Parameter 6 = 0°F
II - OPERATING INFORMATION
FREEZE PROTECTION
Do not install the boiler in a room likely to freeze.
NOTE: The following integral feature of the boiler control pro-
vides some protection for the boiler only, not for the system.
The control module provides freeze-up protection as follows
when the boiler water temperature drops below 45° F:
•
Below 45° F, the boiler circulator operates constantly.
Below 37° F, the boiler turns on at low re.•
Boiler and circulator turn off if boiler water temperature •
rises above 50° F.
CAUTION
!
This feature of the boiler control does not eliminate the
possibility of freezing. The installation must still use rec-
ognized design, installation and maintenance practice to
prevent freeze potential for the boiler and system.
SUPPLY TEMPERATURE BOOST
In outdoor reset operation (factory supplied, eld installed
outdoor sensor connected), the boiler control automatically
increases the target outlet water temperature if a call for heat
exceeds 10 minutes. At each 10 minutes of a continuous call
for heat, the control module increases the target temperature
by 18°F. The module will continue increasing target tempera-
ture until it reaches the value set in Parameter 4.
Reset cuRve: The graph below shows how the boiler con-
trol calculates target temperature.
•
For outdoor temperature at or below 0°F, the target tem-
perature equals Parameter 4 and never higher.
•
For outdoor temperature above 0°F, the target tempera-
ture is reduced on a curve that would result in 60°F supply
temperature at 70°F outdoor temperature.
Summer/winter switch option: Install a summer/winter switch, if
desired, to disable the boiler (space heating) circulator during
non-heating months. Connect switch across the outdoor sensor
terminals. When switch closes, the boiler circulator is disabled
and the boiler operates only on call for DHW heating.
When the call for heat ends while target temperature is
“boosted,” the target temperature drops about 2°F for each
minute the thermostat is open.
Purpose of “boosting”
: If the target temperature happens
to be too low, the control “boosts” the target temperature until
the supply water meets the system’s needs.
OUTDOOR RESET OPERATION (IF USED)
Target temperature with outdoor reset:
shipped with an outdoor temperature sensor. When this sen-
sor is installed (low voltage terminal strip terminals A1 and
A2), the boiler control regulates target outlet water temper-
ature based on outside temperature. Set the temperature
curve by setting Parameter 4 to:
•
ODT (outdoor design temperature for the area).
For ODT of 0°F or lower, set Parameter 4 to the desired •
supply temperature at the ODT.
•
For ODT above 0°F, set Parameter 4 to the desired sys-
tem temperature when outdoor temperature is 0°F.
All boilers are
5
II - OPERATING INFORMATION
DHW OPERATION (IF USED)
The boiler control allows connection of a DHW aquastat to
low voltage terminal strip terminals DHW T1 and DHW T2.
When the DHW aquastat calls for heat, the module shuts
down the boiler circulator activated the DHW circulator and
III - MODULATING CONTROL FEATURES
BOILER CONTROL DESIGN
The integrated modulating boiler control is designed for cen-
tral heating (CH) hot water boilers with modulating fan and
gas-air control. Options for domestic hot water (DHW) and
outdoor reset are available. Modulation is based upon data
relayed to the control by specic temperature sensors. To ig-
nite the burner, a direct spark igniter (DSI) is used.
The modulating boiler control is intended for use in combina-
tion with a display/user interface unit for both information and
operation purposes. the control is designed for installation
with a conventional on/off dry contact room thermostat. The
control is able to provide hot water and outdoor reset func-
tions.
MAIN CONTROLLER FUNCTIONS
Central Heat (CH):
water, return water and outside air to determine the heat load
of the heating system. This results in the boiler supplying just
enough heat to satisfy the demand which results in fewer
the control uses sensors on the supply
immediately sets target outlet water temperature to 180°F.
This provides automatic priority heat allocation to the indi-
rect water heater for maximum response and recovery. The
DHW circulator continues for 30.6 seconds after the heating
cycle to deliver the most possible heat.
overshoots and less short cycling than a conventional on/off
boiler.
Domestic Hot Water (DHW):
with an indirect hot water heater this boiler has the capability
to provide domestic hot water. An on/off dry contact aquastat
is used to activate the call for domestic hot water.
Outdoor Reset:
air temperature using a factory supplied, eld installed sensor. the controller detects the presence of the sensor and
acts according to the parameters programmed into the controller.
This control has the ability to sense outside
When used in conjunction
DISPLAY/USER INTERFACE
By means of the display/user interface, the installer and home
owner can scroll through the control settings and customize
the boiler to the heat delivery system used in the location
of installation. See the “User Interface Quick Reference” in
Section X of this manual for more information on using and
programming the boiler control.
IV - BOILER STARTUP
STARTUP
NOTE: Instructions in this manual are based on factory
default parameter settings.
Start the boiler only after completing all instructions 1.
in the installation manual.
To start the boiler, follow the 2. “Operating Instructions”
in this manual.
3.
Once the boiler has started and is operating,
continue the startup procedure by performing all of
the following steps to set and verify operation of the
controls.
SET SPACE HEATING OPERATION
VERIFY SPACE HEATING MODE
1.
Press the “Mode” button until the display shows a.
[PARA]. This is the parameter mode.
Press the “Step” button until the rst digit of the dis-
B.
play shows “3.”
C.
The last digit must show a “1.” If any other number
displays, press the “+” button until a “1” shows in the
right-hand digit, then press the “Store” button to save
this setting.
SET SPACE HEATING TARGET TEMPERATURE
2.
Press the “Step” button until the rst digit of the dis-a.
play shows “4.” The last three digits will show the out-
let water temperature setting.
B.
Press the “+” or “-” buttons to change the setting to
the desired outlet water temperature. The factory de-
fault setting is 180°F.
OUTDOOR SENSOR INSTALLED:• setting is the
target temperature for outdoor temperature at or
below the factory setting (32°F). At higher outside
temperatures, the control module calculates the
target temperature.
6
IV - BOILER STARTUP
When a summer/winter switch is used, closing the •
switch will disable the boiler (space heating) circu-
lator during summer operation.
OUTDOOR SENSOR NOT INSTALLED: • setting
is the target temperature at all times.
C.
Press the “Store” button to save the setting.
CHECK DHW OPERATION SETUP
NOTE: If the control is already in parameter mode , skip
step 1 (below) and proceed to step 2.
Press the “Mode” button until the display shows
1.
(parameter mode).
2.
Press the “Step” button until the rst digit of the display
shows a “2.”
3.
The last digit must show a “1.” If any other number dis-
plays, press the “+” button until a “1” shows in the right-
hand digit, then press the “Store” button to save this set-
ting.
4.
The control module turns on the DHW circulator when
the indirect water heater operating control closes. the
control module shuts off the boiler circulator (stops space
heating) during calls for DHW heating.
VERIFY OPERATION – SPACE HEATING
[PARA]
[2180]• Ignition. After prepurge, the control module
opens the gas valve and starts ignition spark.
•
If burner ame proves within 4.5 seconds, burner con-
tinues to re. Burner will re at startup rate for about
10 seconds to allow ame to stabilize.
•
If burner ame does not prove within 4.5 seconds, con-
trol module attempts ignition sequence again. Flame
must prove within 6 attempts or control will lockout
(display will show [E 02]).
•
Verify ame failure operation by closing boiler manual
gas cock to prevent gas ow. Open manual gas valve
after testing.
• Burner on, space heating. Once ame is prov-
[3180]
en and stable, the burner turns down to low re for
approximately 2 minutes.
•
After this low re period, the burner is allowed to modulate. Firing rate depends on actual outlet water tem-
perature versus target temperature.
5.
Allow boiler to bring water temperature to target temperature.
• Target temperature reached. The burner will
[6180]
shut down. The blower will run in postpurge (see be-
low), then turn off. Boiler circulator continues to run as
long as there is a call for heat.
NOTE: Information below presented in brackets “[ ]”
represents the actual display on the boiler control panel
with the first digit indicating boiler status and the last three
digits showing the measured boiler water temperature.
(Ex.- [A180] indicates a status of “A” and a boiler water
temperature of 180°F.)
Turn down DHW aquastat on DHW tank (if used). If
1.
necessary, turn off power and remove one of the DHW
aquastat wires to ensure boiler will not receive a DHW
heat call.
2.
Turn off power to boiler at service switch.
Wait a few seconds, then turn on power to boiler.
3.
[180]• self-check on power-up for a few seconds.
[0180]• no call for heat.
Raise room thermostat to call for heat.
4.
[5180] • Blower/boiler circulator on. Blower and boiler
circulator energize and control checks for air ow.
• Prepurge. Blower speed will increase to igni-
[1180]
tion speed. The blower will run in prepurge for 10 seconds.
6.
Lower room thermostat to stop call for heat.
[1180]• Postpurge. When room thermostat is satised
(call for heat ended), burner turns off. Blower will con-
tinue for 15-second postpurge, then turn off. If another
call for heat occurs, boiler will remain off for ten seconds
before starting again, and the display will show [6180].
[0180]
• No call for heat. Boiler is now in standby mode
(waiting for heat call).
7.
Repeat steps 1-6 several times to verify operation.
Return the room thermostat to normal setting.
8.
VERIFY OPERATION – DHW
If necessary, reconnect DHW aquastat wiring to boiler.
1.
Turn off power to boiler at service switch.
2.
Wait a few seconds, then turn on power to boiler.
3.
[A150] self-check on power-up for a few
seconds.
[0150]
no call for heat.
7
IV - BOILER STARTUP
Raise DHW aquastat above tank temperature to call for heat.
4.
[5150] • Blower/DHW circulator on. Blower and DHW cir-
culator energize and control checks for air ow.
• Prepurge. Blower speed will increase to ignition
[1150]
speed. The blower will run in prepurge for 10 seconds.
• ignition. After prepurge, the control module
[2150]
opens the gas valve and starts ignition spark.
•
If burner ame proves within 4.5 seconds, burner con-
tinues to re. Burner will re at startup rate for about
10 seconds to allow ame to stabilize.
•
If burner ame does not prove within 4.5 seconds, con-
trol module attempts ignition sequence again. Flame
must prove within 6 attempts or control will lockout (display will show [E 02]).
•
Verify ame failure operation by closing boiler manual
gas valve to prevent gas ow. Open gas valve after
testing.
• Burner on, DHW. Once ame is proven and
[4150]
stable, the burner is allowed to modulate. Firing rate
depends on actual outlet water temperature versus
target temperature.
5.
Allow boiler to bring water temperature to target temperature.
• Target temperature reached. The burner will
[6150]
shut down. The blower will run in postpurge (see be-
low), then turn off. DHW circulator continues to run as
long as there is a call for DHW heating.
Lower DHW aquastat to stop call for heat.
6.
[1150] • Postpurge. When room thermostat is satised
(call for heat ended), burner turns off. Blower will con-
tinue for 15 second postpurge, then turn off. If another
DHW heat call occurs, boiler will begin heating cycle
after 30 second delay.
• DHW circulator run-on. The DHW circulator
[8150]
continues to run for 30 seconds.
• No call for heat. Boiler is now in standby mode
[0150]
(waiting for heat call).
7.
Repeat steps 1-6 several times to verify operation.
Return the DHW aquastat to normal setting.
8.
OPERATING INFORMATION
To check operating conditions (Ex.- actual or target tem-
1.
perature), see “User Interface Quick Reference” in sec-
tion X of this manual for an explanation of the boiler
control’s “Information” mode.
2.
During normal operation (no shutdown or lockout), the
right 3 display digits show actual boiler outlet water tem-
perature.
PERFORM CHECK-OUT PROCEDURES
Complete the “Checkout Procedures and Adjustments” as in-
dicated in Section VI of this manual.
WARNING
!
Replace boiler front jacket panel after
performing any service to the boiler.
8
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