Utica Boilers SVB Series II Operation and Installation Manual

SVB SERIES II

Models

SVB-2

SVB-3 SVB-4 SVB-5 SVB-6

SVB-7

Gas-Fired Hot Water

Induced Draft Boilers

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

C.S.A. Certied for

Natural gas or Propane

An ISO 9001-2008 Certied Company

Tested for 50 psi. ASME

Working Pressure

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240009132, Rev. D [10/2014]

TABLE OF CONTENTS

Boiler Ratings & Capacities...................... 3

Dimensions ............................................. 4

Installation Procedure ............................. 5

Ventilation & Combustion Air .................. 6

Installation System Piping ...................... 7

Vent Installation ................................... 10

Horizontal Venting Instructions .......... 13

Optional Horizontal Venting Instruction 18

Gas supply Piping .................................. 19

Electrical Wiring .................................... 21

Sequence of Operation .......................... 22

Wiring Diagrams ................................... 23

Starting Your Boiler ............................... 24

Checking and Adjusting ......................... 26

Maintaining Your Boiler ......................... 28

Service Hints ......................................... 29

Equipment & Optional Accessories ........ 30

Appendix A - Control Module ................. 32

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

Safety Symbols & Warnings

The following dened symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

A.1 Installation Environment Considerations . 32

A.2 Electrical Connections .......................... 32

A.3 Adjusting Settings ............................... 32

A.4 Display .............................................. 32

A.5 Operation .......................................... 33

A.6 Boiler High Limit Temperature Controller 34

A.7 Troubleshooting .................................. 34

A.8 Troubleshooting Error Codes ................. 34

A.9 Intermittent Pilot ................................ 35

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

WARNING

Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors and liquids.

DO NOT obstruct air openings to the boiler room. Modication, substitution or elimination of factory

equipped, supplied or specied components may result in personal injury or loss of life.

TO THE OWNER - Installation and service of this boiler must be performed by a qualied installer.

TO THE INSTALLER - Leave all instructions with boiler for future reference.

When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter.

BOILER RATINGS & CAPACITIES

Table 1 - RATINGS NATURAL AND PROPANE GASES

Vent Diameter (Inches)

Model

SVB-2 42.5 36 31 84.4 4 3

SVB-3 75.0 63 55 83.4 4 3

SVB-4 112.5 94 82 83.0 4 3

SVB-5 150.0 125 109 82.7 4 3

SVB-6 187.5 155 135 82.3 4 4

SVB-7 225.0 186 162 82.0 4 4

Input *Mbh

Heating

Capacity

*Mbh

* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only. U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above

 sealevel.CanadaOnly-Boilersmaybeusedathighaltitude(2,000-4500feet/640-1350m)byusingacertied  eldconversionkit,resultingina10%de-rate.ContactProvincialauthorityhavingjurisdictionforinstallations

above 4500 ft (1350m)above sea level.+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.

**Net AHRI Water Ratings i

ndicate amount of remaining heat input that can be used to heat the radiation or terminal units. Net AHRI Ratings shown are based on an allowance of 1.15 Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of building.

Manufacturer should be consulted before selecting a boiler for installations having unusual piping

and pickup requirements.

**Net

AHRI Rating Water

*Mbh

AFUE

To Chimney

(Category I)

Horizontal Vent

(Category III)

New York City MEA Number 484-84-E Vol. IV.

This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing. These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron boilers Design Certied by C.S.A. (Canadian

Standards Association) for use with Natural and Propane Gases. Constructed and hydrostatically tested for maximum working pressure of 50 psi in accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.

Boilers must stand on noncombustible oor. If installed on combustible oor, please refer to Repair Parts manual for appropriate Combustible Floor Base part number.

Boilers For Use At High Altitude

Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner orice size. U.S.A. For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above sea level. Consult National Fuel Gas Code (NFPA54/ANSI Z223.1), or manufacturer for correct orice sizing information. High altitude orices are available from boiler manufacturer.

DIMENSIONS

Model Width (A)

SVB-2

SVB-3

SVB-4

SVB-5

SVB-6

SVB-7

14-1/4

17-1/2

20-3/4

27-1/4

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury.

Installation must conform to requirements of authority having jurisdiction or, in absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Where required by authority having jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically red Boilers, ANSI/ASME CSD-1.

Boiler series is classied as Category I. Vent installation shall be in accordance with "Venting of Equipment ," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes.

Boiler has met safe lighting and other performance criteria with gas manifold and control assembly on boiler per latest revision of ANSI Z21.13/CGA 4.9.

Install such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service, (circulator replacement, condensate trap, control replacement, etc.).

Locate boiler on level, solid base as near chimney as possible and centrally located with respect to heat distribution system as practical.

Verify you have the right size boiler before starting installation. See rating and capacity table.

When installed in utility room, door should be wide enough to allow largest boiler part to enter, or to permit replacement of another appliance such as water heater.

Boiler installed in building under construction, take care to insure clean combustion air supply during construction process. Airborne particulates such as from drywall dust and from berglass insulation can clog burner ports and cause incomplete combustion and sooting.

WARNING

Fire hazard. Do not install boiler on combustible ooring or carpeting. Failure to follow these instructions could result in death or serious injury.

10.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY - For installation on combustible

ooring special base must be used. (See Replacement Parts Section.) Do Not Install Boiler on carpeting.

11.

Verify boiler is supplied with correct type of gas, fresh air for combustion, and suitable electrical supply.

NOTICE

Follow local regulations with respect to installation of CO detectors.

Figure 1 - Minimum Clearances To Combustible

Construction

6”

8”

Rear

Opposite Side

6”

Boiler

Front

18”

Table 1 - BOILER MINIMUM CLEARANCE TO

COMBUSTIBLES

Unit

Top 6” (152mm)

Rear 6” (152mm)

Control Side 8” (203mm)

Opposite Side 6” (152mm)

Front (Alcove) 18” (457mm)

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1” (24mm)

Set unit on concrete or other noncombustible material

base or oor. DO NOT INSTALL ON CARPETING.

Control Side

8”

Minimum

Clearances

VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.

Provide make-up air where exhaust fans, clothes dryers, and kitchen ventilation equipment interfere with proper operation.

National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air. Requirements of the authority having jurisdiction may override these methods.

• Engineered Installations. Must be approved by authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35 cfm per Mbh for all appliances located within space. Additional requirements where exhaust fans installed. Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all appliances in space. Use a different method if minimum volume not available.

о Standard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per hour. See Table 3 for space with boiler only. Use equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

о Known Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple appliances. Do not use an air inltration rate (ACH) greater than 0.60.

Volume ≥ 15 ft3/ACH x Total Input [Mbh]

о Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

National Gas and Propane Installation Code Requires providing air supply in accordance with:

• All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors.

о Two Permanent Opening Method. Provide opening

commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure.

 Direct communication with outdoors or

communicating through vertical ducts. Provide minimum free area of 1 in2 per 4 Mbh of total input rating of all appliances in enclosure.

 Communicating through horizontal ducts.

Provide minimum free area of 1 in2 per 2 Mbh of total input rating of all appliances in enclosure.

о One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure. Provide minimum clearance of 1 inch on sides and back and 6 inches on front of boiler (does not supersede clearance to combustible materials).

о Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to National Fuel Gas Code for application information.

• Section 8.2 and 8.3 when combination of appliances has a total input of up to and including 400 Mbh (120 kW).

о Does not have draft control device.

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code for specic air supply requirements for enclosure or structure where boiler is installed, including air supply openings and ducts.

Table 2 - Air Inltration

Input Mbh

42.5 2125 6375 3188 2125 1594 1275 1063

75 3750 11250 5625 3750 2813 2250 1875

112.5 5625 16875 8438 5625 4219 3375 2813

150 7500 22500 11250 7500 5625 4500 3750

187.5 9375 28125 14063 9375 7031 5625 4688

225 11250 33750 16875 11250 8438 6750 5625

Standard

Method

Known Air Inltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

INSTALLATION SYSTEM PIPING

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements. Install safety relief valve using pipe ttings provided with boiler. See Figure 2

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 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 reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

Figure 2 - Safety Relief Valve Discharge Piping

RELIEF VALVE

DISCHARGE

PIPING

Check local codes

for maximum

distance from

oor or other

allowable safe

point of discharge

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve

outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

INSTALLATION SYSTEM PIPING

LIMIT SENSOR

MINIMUM HEIGHT FOR

LOW WATER CUTOFF

PROBE

LIMIT SENSOR

MINIMUM HEIGHT

FOR LOW WATER

CUTOFF PROBE

Figure 3 -

Forced Hot Water Typical Piping

Figure 4 - Forced Hot Water Typical Piping

With Zone Control Valve

INSTALLATION SYSTEM PIPING

Adjust two throttling valves to maintain at least 120° F (49°C) in boiler return.

• Install radiation units (panels, radiators or cabinets) and supply and return mains rst then make connections at

Low Design Water Temperature Systems (Below 140°F) And Large Water Content Systems

boiler.

• Verify clean water supply is available when connecting cold water supply to water valve. Install sand strainer at pump when water supply is from well or pump.

Condensation is corrosive and can eventually cause severe damage to boiler and venting system.

• Minimum design return water temperature to prevent

• Provide low water cutoff device when boiler is installed

above radiation level or as required by the Authority having jurisdiction, either provide as part of boiler or at time of boiler installation. Periodic inspection

• Boiler used in heating systems where design water

is necessary, as is ushing of oat type devices, per manufacturers specic instructions. Refer to Figures 3 & 4 for minimum height for installation of LWCO. Use kit # 550002998 and follow instructions included with kit. When using LWCO other than kit listed follow specic LWCO manufacturer instructions.

• Boiler connected to system having large water content

• Boiler used in connection with refrigeration systems

shall be installed so chilled medium is piped in parallel with heating boiler with appropriate valves to prevent chilled medium from entering heating boiler. See 5

Figure

• Boiler connected to heating coils located in air handling units exposed to refrigerated air circulation, piping system shall be equipped with ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

condensation in boiler and venting is 120°F. Minimum high limit setting is 140°F.

temperatures below 140°F are desired (e.g. radiant oor heating), a 3-way or 4-way mixing valve or suitable alternative is required to prevent low temperature return water from entering boiler. When using mixing valve, follow manufacturer’s installation instructions.

(such as former gravity system), suggest use of bypass piping. See

Figure 6

Figure 5

- Piping Arrangements For Boiler When Used In Connection With Refrigeration System

Figure 6

- Bypass Piping

VENT INSTALLATION

Check Your Chimney

Chimney must be clean, right size, properly constructed and in GOOD CONDITION.

Installation must conform to requirements of the authority having jurisdiction or, in absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

Boiler’s induced draft blower has 3” outlet. 3” X 4” increaser tting is included in parts bag. Locate increaser tting on outlet of induced draft blower, and secure gas-tight with bead of furnished silicone sealant. Increaser tting is required on this boiler for Category I venting, and 4” is minimum permissible vent diameter. This does not imply vent connector is intended to be 4” diameter pipe. Vent connector shall be sized according to appropriate venting tables in the National Fuel Gas Code and may be required to be larger than 4” diameter.

NOTICE

Boiler installation for chimney venting is not complete unless increaser tting is located and secured.

These are high efciency boilers with low stack or exhaust temperature.

Venting into masonry chimney without liner, line chimney from top to bottom with either:

A. Listed Type B vent pipe B. Listed exible vent liner C. Poured ceramic liner.

11.

Fasten sections of vent pipe with sheet metal screws to make piping rigid. Use stovepipe wires to support pipe from above.

12.

Do not connect to replace ue.

13.

Do not install damper on this boiler.

Minimum Vent Pipe Clearance

• Use Type B vent pipe through crawl space. Where vent pipe passes through combustible wall or partition, use ventilated metal thimble. Thimble should be 4 inches larger in diameter than vent pipe.

• Boiler installed with single wall vent, must have 6” clearance between its surface and any combustible material. New Type B gas vent or exible liner must be installed in accordance with instructions furnished with vent. Maintain clearances as specied for vent pipe.

• Verify vent pipe is re-stopped where it goes through oor or ceiling. It should have approved vent cap with clearances from roof. If clearances are less than shown, have vent checked by local authorities. Figure 7, Page 11.

• Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

Outside chimneys should not be used unless they are (choose one of the following):

A. Enclosed in a chase B. Lined with Type B vent pipe C. Use listed exible vent liner D. Use certied chimney lining system

Vent connector from boiler to chimney should run as directly as possible with as few elbows as possible.

Where possible, it is recommended to common vent water heater and boiler. Consult appropriate Vent Sizing Tables in National Fuel Gas Code for specic requirements of multiple appliance venting.

Boiler is only appliance connected to vent, Type B vent pipe is recommended for vent connector.

Slope pipe up from boiler to chimney not less than 1/4” per foot (21mm/m).

10.

End of vent pipe must be ush with inside face of chimney ue. Use sealed-in thimble for chimney connection.

Liner

Chimney

Thimble

Vent System

Cleanout

Boiler

Vent pipe must be: At lease 2 ft. (610mm) higher than any part of the roof, but not less than 3 ft. (915mm) tall, and within a 10 ft.

within a 10 ft. (3m) radius of the apex.

Boiler

Water Heater

Chimney

Figure 7 - Type B Gas Vent

VENT INSTALLATION

CHECK YOUR CHIMNEY

For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.

VENT INSTALLATION

Removing Existing Boiler From Common Venting 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 appliance 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 and other deciencies which could cause an unsafe condition.

Insofar 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 dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close replace dampers.

Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use ame of a match or candle, or 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, replace dampers and any other gas-burning appliance to their previous conditions of use.

Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

It is recommended that existing gas vents be checked to be sure they meet local codes.

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