UTICA BOILERS UB95M-200 (01) PDF Document

The dimensions for the UTICA BOILERS UB95M-200 are as follows:

Front Width: 18″ (458mm)

Side Depth: 30 7/8″ (785mm)

Back Height: 39 3/8″ (1.1m)

The connection points are located on various sides of the boiler:

Left Side (Optional):

Air Vent Intake Opening: 2″ PVC

Gas Supply Opening: 1/2 NPT

Water Return Opening: 1 1/4 NPT Connection

Top:

Opening for Vent Tee Exhaust: 2″ CVPC

Standard Supply Opening: 1 1/4 NPT connections are provided inside the boiler cabinet.

Right Side (Optional):

Gas Supply Opening: 1/2 NPT

Electrical Connection for 120V power & 24V thermostat leads

Water Return Opening: 1 1/4 NPT Connection

Back:

Opening for Safety Relief Valve Discharge Pipe

Air Vent Intake Opening: 2″ PVC (Optional)

Condensate Drain Opening: 1/2″ PVC

You should become familiar with the following symbols that identify potential hazards for your UTICA BOILERS UB95M-200:

Safety Alert Symbol: This symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

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.

If you smell gas near your UTICA BOILERS UB95M-200, follow these steps immediately:

1. Do not try to light any appliance.

2. Do not touch any electrical switch; do not use any phone in your building.

3. Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

4. If you cannot reach your gas supplier, call the fire department.

The sea level ratings for the UTICA BOILERS UB95M-200 for both natural and propane gases are as follows:

Notes:

1 MBH = 1,000 BTUH (British Thermal Units Per Hour).

Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.

The input of the UTICA BOILERS UB95M-200 must be derated for high altitude installations. The following table shows the derated input values (in MBH) at various altitudes:

Notes:

1. Boiler Input Rate is determined at minimum vent length. The rate will decrease as vent length increases.

2. Parameter 17 is set to 2,250 at elevations of 2,000 feet and below.

3. Parameter 17 must be raised to 3,200 at altitudes or elevations of 2,000 feet and above.

Before installing your UTICA BOILERS UB95M-200, ensure the following:

1. The boiler is equipped for residential installations. If used for commercial applications, additional code requirements must be followed.

2. Never vent products of combustion from this boiler to an enclosed space. Always vent to the outdoors.

3. Keep the boiler area clean of debris and free of combustible and flammable materials.

4. Proper through-wall or through-roof combustion venting must be in accordance with the methods described in the manual and comply with local codes.

Before selecting a location for your UTICA BOILERS UB95M-200, consider the following points:

• The location must be supplied with the correct type of gas (natural or propane).

• It must be connected to a suitable combustion air intake piping system to supply correct amounts of fresh outdoor air for combustion (15′ minimum to 100′ maximum equivalent length).

• It must be connected to a suitable venting system (15′ minimum to 100′ maximum equivalent length).

• It must be connected to a suitable hot water heating system.

• The location must have a suitable electrical supply for all boiler motors and controls.

• It must be connected to a properly located thermostat or operating control (not included with the boiler).

• The boiler must be placed on a level surface and must NOT be installed on carpeting.

• The condensate drain line must be pitched down to a floor drain or external condensate pump at 1/4″ per foot.

The required clearances for the UTICA BOILERS UB95M-200 are detailed in the table below. If accessibility clearances are larger than fire protection clearances, the larger dimension must be used.

Additionally, locate the boiler where ambient room temperatures are always at or above 32°F (0°C) to prevent freezing of liquid condensate.

The UTICA BOILERS UB95M-200 has the following condensate drain requirements:

• A condensate trap is provided with the boiler; an additional trap is not required.

• Pitch the condensate drain line down to a floor drain at a minimum of 1/4″ per foot. An external condensate pump (not furnished) can be used if a floor drain is not available.

• The condensate pump must be designed for flue gas condensate application.

• Wood frames or blocks may be used to raise the boiler to maintain drain pitch or to be above an external condensate pump reservoir.

• The boiler must be level for the condensate drain lines to function properly. Adjustable feet are provided to compensate for minor surface irregularities.

• A 115-volt AC receptacle is provided on the control panel to power an external condensate pump if used.

When an existing boiler is removed from a common venting system, the system is likely to be too large for the remaining appliances. The UTICA BOILERS UB95M-200 requires a dedicated direct vent system and cannot use a common vent. Before installing the new boiler, you must assess the common vent for the remaining appliances by following these steps:

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and check for any blockage, restrictions, leakage, corrosion, or other deficiencies that could cause an unsafe condition.

3. Close all building doors and windows. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on exhaust fans (e.g., range hoods, bathroom exhausts) to operate at maximum speed. Do not operate a summer exhaust fan. Close fire dampers.

4. Place the appliance being inspected into operation. Adjust the thermostat so it operates continuously.

5. After 5 minutes of main burner operation, test for spillage at the draft hood relief opening using the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

6. After confirming that each remaining appliance vents properly, return all doors, windows, exhaust fans, and dampers to their previous condition.

7. Any improper operation of the common venting system must be corrected so the installation conforms with the National Fuel Code, NFPA-54/ANSI-Z223.1 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. If re-sizing is needed, the common venting system should be re-sized to approach the minimum size as determined by the appropriate code tables.

To install the supplied safety relief valve on your UTICA BOILERS UB95M-200, follow these instructions:

• Install the furnished safety relief valve using the 3/4″ pipe fittings provided with the boiler.

• Install the safety relief valve with the spindle in a vertical position.

• Do not install a shutoff valve between the boiler and the safety relief valve.

• Install discharge piping from the safety relief valve using 3/4″ or larger pipe suitable for temperatures of 375°F (191°C) or greater.

• The discharge piping for this boiler must be independent of other discharge piping.

• Run the pipe as short and straight as possible to a location that protects users from scalding.

• If a union is used, install it close to the safety relief valve outlet.

• If elbows are used, install them close to the safety relief valve outlet and downstream of the union (if used).

• Terminate the pipe with a plain end (not threaded). Check local codes for maximum distance from the floor.

On initial start-up, you must manually fill the condensate trap with water. This is also required if maintenance involves draining the trap. Follow these steps:

1. Remove the vent drain line from the CPVC vent pipe.

2. Pour about 1 cup of cold tap water into the vent drain line.

3. Excess water should go through the overflow and out through the condensate drain line. Verify the proper operation of the drain line (or external condensate pump, if used).

4. Reinstall the vent drain line.

The UTICA BOILERS UB95M-200 requires a dedicated direct vent system. All combustion air is taken from outdoors and all flue products are discharged outdoors. Key requirements are:

• Due to potential for flue gas temperatures above 155°F, the first 30″ of supplied vent pipe must be CPVC. The remaining vent pipe can be PVC. Any replacement of the first 30″ must be made with CPVC.

• The boiler’s combustion air and vent pipe connections are 2″ but must be increased to 3″. This transition from 2″ to 3″ pipe must be made in a vertical run.

• All field installed vent pipe must be 3″.

• For Canadian installations, all plastic venting material must be listed to ULC S636.

• Covering non-metallic vent pipe and fittings with thermal insulation is prohibited.

• Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (Polyphenolsulfone) in venting systems is prohibited.

Approved Materials and Standards:

The allowable length for 3″ vent and air intake pipes is 15 ft. minimum equivalent length to 100 ft. maximum equivalent length. Reduce the maximum length by 5 feet for each 90° elbow. When locating the termination point, consider the following:

• Position where vapors will not damage plants, siding, or air conditioning equipment.

• Position so it will not be affected by wind eddy, airborne leaves, snow, or recirculated flue gases.

• Position where it will not be subject to potential damage from foreign objects (stones, balls, etc.).

• Position where vent vapors are not objectionable.

• Terminate the vent above the normal snow-line. Avoid locations where snow may drift and block the vent.

• United States: Terminate the vent system at least 4 feet (1.22 m) horizontally from electric meters, gas meters, regulators, and relief equipment.

• Canada: Terminate the vent system at least 6 feet (1.83m) horizontally from electric meters, gas meters, regulators, and relief equipment.

• Terminate at least 3 feet (0.3m) above any forced air inlet (except the boiler’s own) within 10 feet (3m).

• Terminate at least 12 inches (300mm) from any air opening into any building.

• Locate the bottom of the vent at least 12 inches (300mm) above grade.

• Do not terminate less than 7 feet (2.1m) above an adjacent public walkway.

• Do not install the vent terminal closer than 3 feet (0.9m) from the inside corner of an L-shaped structure.

• Keep the termination at least 3 feet (0.9m) away from vegetation.

Follow these steps to install the combustion air and vent piping:

1. It is recommended to cut, prepare, and pre-assemble all pipes before permanently cementing any joint.

2. Attach combustion air intake piping to the supplied 2″ piping on the CVI gas valve. Attach vent piping to the furnished 2″ CPVC preformed exhaust pipe. Use a 2″ x 3″ adapter in a vertical position on both the air intake and vent pipe.

3. Working from the boiler to the outside, cut the pipe to the required length(s).

4. Deburr the inside and outside of the pipe, removing all chips and shavings.

5. Chamfer the outside edge of the pipe for better distribution of primer and cement.

6. Clean and dry all surfaces to be joined.

7. Check the dry fit of the pipe and mark the insertion depth.

8. Apply cement primer to the pipe fitting socket and the end of the pipe up to the insertion mark.

9. Quickly apply approved cement to the end of the pipe and the fitting socket (over the primer). Apply cement in a light, uniform coat on the inside of the socket to prevent buildup.

10. While the cement is still wet, insert the pipe into the socket with a 1/4 turn twist. Ensure the pipe is fully inserted.

11. Wipe any excess cement from the joint. A continuous bead of cement should be visible around the perimeter.

12. Handle the joint carefully until the cement sets.

13. Support the combustion air and vent piping at a minimum of every 5 feet using pre-formed metal hanging straps. Do not rigidly support pipes to allow for movement.

14. Slope the pipes toward the boiler at a minimum of 1/4″ per linear foot with no sags between hangers.

15. Use appropriate methods to seal openings where pipes pass through a roof or side wall.

The gas supply pressure for the UTICA BOILERS UB95M-200 must be within the following ranges when the unit is running in high fire mode:

The gas pipe must be correctly sized for the length of the run and the total Btuh input of all gas equipment connected to it. Refer to the appropriate gas piping size tables in your manual. When connecting the gas piping:

• Use only approved piping materials and joining methods.

• Use pipe joint compound suitable for liquefied petroleum gas on male threads only.

• The gas line enters the boiler through the right side but can be routed through the rear or left side panel.

• Use ground joint unions and install a sediment trap upstream of the gas controls.

• Use two pipe wrenches when making connections to the gas valve to prevent it from turning.

After making gas connections, open the manual shutoff valve(s) and check all gas connections for leaks before placing the boiler in operation. Locate leakage using a gas detector, noncorrosive detection fluid, or another leak detection method acceptable to the authority having jurisdiction. Do not use matches, candles, open flames, or other methods that provide an ignition source. Correct any leaks immediately and retest.

The UTICA BOILERS UB95M-200 is factory equipped with a line voltage monitor set at 115 VAC. It is important that this monitor be set to the voltage present at the installation site. Follow these steps:

1. Using a multimeter, locate the wall outlet nearest to the boiler and determine the line voltage present on site.

2. Disconnect power to the boiler.

3. Remove the boiler cover.

4. Locate the line voltage monitor mounted to the display panel.

5. Remove the line monitor’s protective cover.

6. Using a small screwdriver, turn the left dial until the arrow points at the input voltage you measured in step 1.

7. Set the right dial to 0.1 minute (this is the factory setting).

8. Reinstall the line monitor’s protective cover.

9. Replace the boiler cover and reconnect power to the unit.

The monitor will flash if the incoming voltage is greater than 12% or less than 8% of the nominal voltage setting. It will restart the boiler 6 seconds after the voltage returns to the acceptable range.

To ensure proper operation of your UTICA BOILERS UB95M-200, install the thermostat on an inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sun rays, or fireplaces. Specifically, avoid the following locations:

The procedure for filling and purging air from your UTICA BOILERS UB95M-200 depends on the type of expansion tank in your system.

For Systems With Diaphragm Type Expansion Tanks:

A. Close all zone service valves on the supply and return piping. Open the feed valve and fill the boiler with water. Verify the air vent is open. Hold the relief valve open until water runs air-free for five seconds to rapidly bleed air from the boiler, then let the relief valve snap shut.

B. Open the zone service valve on the supply pipe for the first zone. Open the purge valve on the first zone. Feed water will fill the zone, pushing air out of the purge valve. Close the purge valve when water runs air-free. Close the zone service valve.

C. Repeat step B for all remaining zones.

D. Open all service valves. Any air remaining trapped in the return lines will be pushed towards the air vent when the boiler is placed in operation.

E. Inspect the piping system and repair any leaks immediately.

For Systems With Conventional Closed Type Expansion Tanks:

A. Close all zone service valves and the expansion tank service valve. Drain the expansion tank. Open the feed valve and fill the boiler with water. Hold the relief valve open until water runs air-free for five seconds, then let it snap shut.

B. Open the supply zone service valve and purge valve for the first zone. Fill the zone until water runs air-free, then close the purge valve and the zone service valve.

C. Repeat step B for all remaining zones.

D. Open the expansion tank service valve and tank vent. Fill the tank to the proper level and close the tank vent. Remove the handle from the expansion tank service valve so it is not accidentally closed.

E. Open all service valves. Any remaining air will be pushed towards the expansion tank when the boiler is placed in operation.

F. Inspect the piping system and repair any leaks immediately.

NOTICE: Do not use stop leak compounds. Repair leaks in threaded connections of aluminum boiler sections. Aluminum threads do not seal themselves.

To operate your UTICA BOILERS UB95M-200, please follow these instructions carefully. The boiler is equipped with an automatic ignition device and does not have a pilot.

Lighting and Operating Instructions:

1. Set the thermostat to its lowest setting.

2. Turn off all electrical power to the appliance.

3. Do NOT try to light the burner by hand.

4. Remove the front jacket panel.

5. Turn off the gas ball valve (handle should be perpendicular to the gas pipe).

6. Wait 5 minutes for any gas to clear. Then smell for gas, including near the floor. If you smell gas, STOP! Follow the “What To Do If You Smell Gas” instructions. If you do not smell gas, proceed to the next step.

7. Turn the gas ball valve to the “on” position (handle should be parallel to the gas pipe).

8. Replace the front jacket panel.

9. Turn on all electrical power to the appliance.

10. Set the thermostat to the desired setting.

11. If the boiler will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

To Turn Off Gas To Appliance:

1. Set the thermostat to its lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove the front jacket panel.

4. Turn the gas ball valve off (handle should be perpendicular to the gas pipe).

5. Replace the front jacket panel.

Regular service and maintenance by a qualified service agency must be performed at least once every 12 months. The following checks should be performed at the specified intervals:

Beginning of Each Heating Season (Annual Service):

• Examine and clean (if necessary) the flue passages in the heat exchanger, burner, and condensate lines.

• Inspect the venting and air intake system for proper operation, deterioration, or leakage.

• Check for and remove any obstruction to the flow of combustion air or venting of flue gases.

• Inspect the condensate drain line for proper operation and check for deterioration or plugging.

• Check all gasketed joints for leakage.

• Check for piping leaks around the safety relief valve and other fittings.

• Verify the boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids.

Daily During Heating Season:

• Check for and remove any obstruction to the flow of combustion air or venting of flue gases.

• Check that the boiler area is free from combustible materials, gasoline, and other flammable vapors and liquids.

Monthly During Heating Season:

• Check for piping leaks around the safety relief valve and other fittings. If found, contact a qualified service agency.

• Test the safety relief valve according to the valve manufacturer’s instructions.

• Visually inspect the venting and air intake system for proper operation, deterioration, or leakage.

• Visually inspect the condensate drain pipe for blockage, leakage, or deterioration.

• Check air vent(s) for leakage.

• Perform a periodic inspection of the low water cut off as per the manufacturer’s instructions.

The following service procedures must be performed by a qualified service agent. The boiler owner shall not attempt these steps.

1. Prepare for Service:

• Before servicing, turn off electrical power to the boiler at the service switch. Close the manual gas valve to turn off the gas supply.

2. Examine and Clean Flue Passages:

• Examine flue passages by removing the blower/burner assembly from the casting.

• Clean any buildup of sediment or aluminum oxide (white powdery substance) as follows:

A. Remove the jacket front and top panels.

B. Confirm the manual gas valve is closed and disconnect the gas line at the union. Disconnect pressure switch hoses.

C. Disconnect wires to the gas valve and igniter.

D. Loosen but do not remove the five nuts attaching the blower adapter assembly to the boiler.

E. Remove the two igniter screws and carefully remove the igniter.

F. Remove the five nuts and remove the blower adapter assembly, burner, and gaskets.

G. Aluminum oxide deposits are water-soluble and can be rinsed away by inserting a hose into the burner opening and slowly running water through the flue side of the boiler and out the condensate drain.

H. Use a flexible handle nylon brush to loosen sediment on all accessible heating surfaces. Be careful not to get the brush stuck.

I. After brushing and rinsing, remove any remaining sediment with a shop vacuum.

J. Inspect the burner for any foreign matter. If it cannot be cleaned, it must be replaced.

K. Reinstall the burner and gaskets, and position the blower adapter assembly over the studs. Install the five nuts but do not tighten. Reinstall the igniter and gasket. Tighten the five nuts holding the blower adapter assembly.

L. Reconnect the gas line, pressure switch hoses, igniter wires, and gas valve wires.

3. Inspect Condensate Trap:

• Clean out any visible foreign material. Inspect for sediment or blockage and flush with water or vacuum. Follow instructions for “Filling Condensate Trap With Water.”

4. Inspect Flue Connector:

• Loosen the clamp on the vent tee, inspect the interior, and clean any sediment buildup. Reconnect the coupling.

To ensure the longevity and proper function of your UTICA BOILERS UB95M-200, adhere to the following water quality and treatment guidelines. These apply to ALL aluminum high-efficiency gas-fired water boilers.

Clean System First:

• BEFORE connecting the boiler, thoroughly clean and flush the heating system to remove sediment, flux, and residual additives.

Fill Water and Chemistry:

• System fluid pH must be maintained between 7.0 and 8.0.

• Maintain water hardness below 7 grains.

• Filling with chlorinated potable water is acceptable, but DO NOT fill the boiler with water containing chlorine in excess of 100 ppm.

Eliminate System Leaks:

• The continuous addition of make-up water adds oxygen, which can cause corrosion. Eliminate all system leaks immediately.

• Ensure the expansion tank is operational and properly sized to prevent relief valve weeping.

• This boiler is designed for closed-loop hydronic heating systems ONLY.

Antifreeze Guidelines:

• Use only antifreeze products recommended for use with aluminum boilers, as listed in the manual.

• Do not use antifreeze unless required.

• Always clean the system prior to using antifreeze.

• Follow the antifreeze manufacturer’s instructions for use, pH adjustment, and safety.

• Check antifreeze chemistry annually as it can break down over time.

• The use of antifreeze will reduce heating capacity by as much as 10-20%.

• Never exceed 50% antifreeze by volume.

The following is a list of compatible aluminum antifreeze and inhibitor suppliers for the UTICA BOILERS UB95M-200:

* These products may be used to adjust the pH level of the hydronic system, but on occasion may not resolve the pH issue. In these cases, it is recommended to flush the system and refill with untreated water and a new boiler manufacturer-approved antifreeze suitable for aluminum heat exchangers.

In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, the UTICA BOILERS UB95M-200 is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.