ECR International Utica Boilers UB95M-200 User manual

INSTALLATIONMANUAL
UB95M-200GAS-FIREDDIRECTVENT
MODULATINGHOTWATERBOILER
UTICA BOILERS
PO Box 4729
Utica, NY 13504-4729
www.uticaboilers.com
An ISO 9001-2000 Certified Company
P/N 240006103U, Rev. 1.1 [04/06]

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GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER
INSTALLATION MANUAL
P/N# 240006103U, Rev. 1.1 [04/06] • Printed in USA • Made In USA
TABLE OF CONTENTS
I Introduction.......................................... 3
II Safety Symbols.................................... 4
III Rules for Safe Installation and Operation 4
IV Boiler Ratings and Capacities............. 5
V Before Installing The Boiler.................. 6
VI Placing The Boiler................................ 9
VII Near Boiler Piping................................ 10
VIII Combustion Air and Vent Pipe............. 11
IX Gas Supply Piping............................... 13
X Electrical Wiring................................... 15
XI Controls and Accessories.................... 16
XII Maintenance and Cleaning.................. 18
XIII Boiler Wire Diagram............................ 21
XIV Piping and Wiring Appendix................. 22
Keep this manual near boiler
and retain for future reference.
I - INTRODUCTION
This appliance is a gas-fired direct vent modulat-
ing cast aluminum hot water boiler. A revolutionary
cast aluminum monoblock heat exchanger means
better heat transfer and thermal storage than simi-
larly sized cast iron boilers, which results in higher
efficiency. The heating system water absorbs large
amounts of heat from the cast aluminum heat ex-
changer, cooling the flue gases and causing con-
densation. Sealed combustion, premix gas burner,
and low flame temperature means drastically re-
duced CO and NOx emissions, which contribute to
a cleaner and healthier environment.
This appliance, unlike normal residential atmo-
spheric and induced draft units, takes its combus-
tion air directly from the outdoors (sealed combus-
tion) and does not compete with building occupants
for fresh air. Sealed combustion (also known as
“direct vent”) is the safest and best way to obtain
plenty of clean combustion air. The forced draft fan
draws in the outside combustion air to mix with gas,
which flows into the pre-mix burner and combusts.
The fan then forces the resulting flue gases from
the boiler unit and provides a positive removal of
the flue gases from the building through inexpen-
sive and readily available PVC and CPVC pipes.

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III. RULES FOR SAFE INSTALLATION AND OPERATION
WARNING
This appliance has been equipped for resi-
dential installations. If used for commercial
applications, any and all additional code re-
quirements must be adhered to for installa-
tion. This may require additional controls,
including but not limited to an external wa-
ter cut off, a manual reset high temperature
limit, and wiring and/or piping modifications.
The manufacturer is not responsible for any
field installation changes made to a boiler
installation which are not described or ac-
knowledged in this manual.
IMPORTANT: Failure to follow these instruc-
tions could cause a malfunction of the boiler
and result in death, serious bodily injury, and/or
property damage. For assistance or additional
information, consult a qualified installer, service
agency, or the gas supplier.
WARNING
This boiler contains ceramic fiber materials.
Use care when handling these materials per
the instructions specified under “Modulating
Burner” in Section XI of this manual.
1. Check all applicable state and local building
codes and utility company requirements before
installation. This installation must conform with
these requirements in their entirety. In the absence
of these codes, use NFPA installation codes and
good industry practice.
2. Before servicing the boiler, allow it to cool. Al-
ways shut off any electricity and gas supply con-
nected to the boiler prior to servicing.
3. Inspect gas line for leaks.
4. Be certain gas input rate is correct. Overfiring
may result in early failure of the boiler components.
This may cause dangerous operation. Underfiring
may result in too much air for the pre-mix burner
causing poor or loss of combustion.
5. Never vent the products of combustion from this
boiler to an enclosed space. Always vent to the out-
doors. Never vent to another room or to inside a
building.
6. Be sure there is adequate outdoor air supply to
boiler for complete combustion.
7. Follow a regular service and maintenance sched-
ule for efficient and safe operation.
8. Keep boiler area clean of debris and free of com-
bustible and flammable materials.
9. Proper through-the-wall or through-the-roof
combustion venting shall be in accordance with the
materials and methods described in this manual.
Installation must comply with local codes.
10. This boiler and related hot water heating sys-
tems are not do-it-yourself items. They must be in-
stalled and serviced by qualified professionals.Rat-
The following defined symbols are used throughout this manual to notify the reader of potential hazards
of varying risk levels.
II - SAFETY SYMBOLS AND WARNINGS
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
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CAUTION
Indicates a potentially 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!!

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IV - BOILER RATINGS AND CAPACITIES
ings above are for sea level applications. The boiler
automatically derates input at a rate of 2% for every
1000 feet above an elevation of 2000 feet (see Table
2). The boiler will also derate relative to the calorific
value of the gas being used. Use the formula speci-
fied in “Measure The Natural Gas Input Rate” in Sec-
tion VII of the Control Manual and Operating Instruc-
tions (P/N# 240006104) to determine the proper rate
due to derated gas. No alterations to the boiler are
required for altitudes above sea level.
These low pressure gas-fired hot water boilers are
design certified by CSA International, for use with
natural and propane gases. The boilers are con-
structed and hydrostatically tested for a maximum
working pressure of 50 PSIG (pounds per square
inch gauge) in accordance with ASME (American
Society of Mechanical Engineers) Boiler and Pres-
sure Vessel Code Section IV Standards for heating
boilers.
The Boilers are certified in accordance with ANSI
(American National Standards Institute) Z21.13
standards as gas-fired, direct vent, condensing,
hot water boilers.
TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES
Boiler Input Rate
(MBH)(1)
Heating Capacity
(MBH)(1)(2)
Net I=B=R Rating
(MBH)(1)
AFUE(2) Flue Diameter Shipping
Wt.
High Fire 200 190 165 95% 2” CPVC & 3” PVC 284 lbs.
Low Fire 80 76 66
(1) 1 MBH = 1,000 Btuh (British Thermal Units Per Hour)
(2) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
TABLE 2: 95M-200 HIGH ALTITUDE DERATE CHART
Boiler Input
Rate (MBH)
Altitude (In Feet)
3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
High Fire 196 192 188 184 181 177 174 170
Low Fire 78.4 76.8 75.3 73.8 72.3 70.9 69.5 68.1
The Heating Capacity indicates the amount of heat
available after subtracting the losses up the stack.
Most of this heat is available to heat water. A small
portion is heat loss from the jacket and surfaces of
the boiler, and it is assumed that this heat stays in
the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied
to heat the radiation or terminal units (i.e., finned
tube baseboard, cast iron radiators, radiant floor,
etc.) The difference between the Heating Capacity
and the Net I=B=R Rating, called the piping and
pickup allowance, establishes a reserve for heating
the volume of water in the system and offsetting
heat losses from the piping. The Net I=B=R Rat-
ings shown are based on a piping and pickup factor
of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net I=B=R
Rating of the boiler selected should be greater than
or equal to the calculated peak heating load (heat
loss) for the building or area(s) served by the boiler
and associated hot water heating systems. The
manufacturer should be consulted before selecting
a boiler for installations having unusual piping and
pickup requirements.
V - BEFORE INSTALLING THE BOILER
Review the following before installing the boiler.
CODES
This boiler product is a gas-fired, direct vent, con-
densing boiler and must be installed in accordance
with all applicable federal, state and local building
codes including, but not limited to the following:
United States - Installation shall conform with
National Fuel Gas Code (NFPA-54/ANSI Z223.1-
latest edition)
Canada - Installation shall be in accordance with
CSA-B149.1 and .2 installation codes.
Where required by the authority having jurisdiction,
the installation must conform to the ASME Safety
Code for Controls and Safety Devices for Automati-
cally Fired Boilers, No.CSD-1.
The installation must conform to the requirements
of the authority having jurisdiction or, in the ab-
sence of such requirements, to the National Fuel
Gas Code, ANSI Z223.1 - latest revision.

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Installers - Follow local regulations with respect
to installation of Carbon Monoxide Detectors.
Follow maintenance recommendations in this
manual.
BOILER SIZING
Check to be sure you have selected the
boiler with the proper capacity before con-
tinuing the installation. The I=B=R Rating of
the boiler selected should be greater than
or equal to the calculated peak heating load
(heat loss) for the building or area(s) served
by the boiler and associated hot water heat-
ing systems. See “Table 1: Sea Level Rat-
ings - Natural and Propane Gases” in Sec-
tion IV of this manual.
Heat loss calculations should be based on
approved industry methods.
CONSIDERATIONS FOR BOILER LOCATION
Before selecting a location for the boiler, the follow-
ing should be considered. Each boiler considered
for installation must be:
Supplied with the correct type of gas (natural
gas or propane).
Connected to a suitable combustion air in-
take piping system to supply the correct
amounts of fresh (outdoor) air for combustion
(15’ minimum length/60’ maximum length).
Connected to a suitable venting system to
remove the hazardous products of gas com-
bustion (15’ minimum length/60’ maximum
length).
Connected to a suitable hot water heating
system.
Supplied with a suitable electrical supply for
all boiler motors and controls.
Connected to a properly located thermostat or
operating control (not included with boiler).
Placed on level surface (must NOT be in-
stalled on carpeting).
Condensate drain line must be pitched down
to floor drain or external condensate pump
with reservoir at ¼” per foot (wood frame or
blocks may be used to raise boiler).
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LOCATING THE BOILER
1. Select a location which is level, central to the pip-
ing systems served and as close to the vent and air
intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e.
larger clearances) than required fire protection
clearances, must be used for the boiler installation.
Accessibility clearances may be achieved with the
use of removable walls or partitions.
3. The boiler is approved for installation in closets
and on combustible floors. This boiler shall NOT be
installed on carpeting.
4. The clearances shown in Table 3 below indicate
required clearances per CSA listing.
A minimum 1” clearance must be maintained be-
tween combustible construction and each of the
right, top and back surfaces of the boiler. Allow at
least 24” at the front and left side and 8”at the top
for servicing. No combustible clearances are re-
quired to venting or combustion air intake piping.
5. Equipment shall be installed in a location which fa-
cilitates the operation of venting and combustion air
intake piping systems as described in this manual.
6. Advise owner of boiler to keep venting and com-
bustion air intake passages free of obstructions.
Both the venting and combustion air intake piping
systems connected to the outdoors must permit
flow through the piping systems without restrictions
for the boiler to operate.
7. The boiler shall be installed such that the auto-
matic gas ignition system components are protect-
ed from water (dripping, spraying, rain, etc.) during
TABLE 3: BOILER CLEARANCES*
Dimension Combustible
Construction
Accessibility/
Cleaning Service
Top 1” 8” 8”
Left Side 1” 24” 24”
Right Side 1” - -
Base 1” - -
Front 0 24” 24”
Back 6” - -
Intake/Vent Piping 0 - -
Near Boiler Hot
Water Piping 1” - -
* All distances measured from the cabinet of the boiler.

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operation and service (circulator replacement, con-
trol replacement, etc.).
8. The boiler must be located where ambient room
temperatures (minimum possible temperatures
where boiler is installed assuming boiler is not in
operation and therefore contributes no heat to the
space) are always at or above 32°F to prevent
freezing of liquid condensate.
COMBUSTION AIR AND
VENT PIPE REQUIREMENTS
8" MINIMUM
VERTICAL SEPARATION
BETWEEN COMBUSTION
AIR INTAKE AND VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
3'' MAXIMUM
SEPARATION
15'' MAXIMUM
COMBUSTION
AIR
12''
MIMIMUM
Figure 1 - Roof Vent/Intake Terminations
Figure 2 - Sidewall Vent/Intake Terminations
OVERHANG
12" MINIMUM
90°
VENT
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
3"
MAXIMUM
SEPARATION
18"
MAXIMUM
15"
MAXIMUM
LESS THAN 12" CLEARANCE
12"
MINIMUM
12"
MINIMUM
12" OR MORE CLEARANCE
90°
BRACKET
VENT
18"
MAXIMUM
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
12" MINIMUM
OVERHANG
3"
MAXIMUM
SEPARATION
12"
MINIMUM
12"
MINIMUM
This boiler requires a dedicated direct vent system.
In a direct vent system, all air for combustion is
taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere.
Combustion air and vent pipe connections must
terminate together in the same atmospheric pres-
sure zone, either through the roof or sidewall (roof
termination preferred). See Figures 1 and 2 for re-
quired clearances.
If the concentric vent termination is being used, re-
fer to Figure 3 for proper setup.
CAUTION
Keep boiler area clean of debris and free of
flammable and combustible materials, va-
pors, and liquids.
WARNING
Failure to follow these warnings could result
in fire, property damage, personal injury, or
death.
When vent pipe is exposed to tempera-
tures below freezing, such as when it pass-
es through an unheated space or when a
chimney is used as a chaseway, vent pipe
must be insulated with ½”Armaflex or
equivalent. In extremely cold climate ar-
eas, use ¾”Armaflex or equivalent.
Combustion air must be clean outdoor
air. Combustion air must not be taken
from inside the structure because that air
is frequently contaminated by halogens,
which include fluorides, chlorides, phos-
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ROOF
OVERHANG
12" MINIMUM
VENT MAINTAIN 12" IN. CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL OR GRADE
COMBUSTION AIR
1" MAXIMUM
12" MINIMUM
Figure 3 - Concentric Vent Terminations
(Continued on next page)

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Figure 4 - Concentric Vent w/Dimensions
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WARNING
(Continued from previous page)
phates, bromides and iodides. These ele-
ments are found in aerosols, detergents,
bleaches, cleaning solvents, salts, air
fresheners, paints, adhesives, and other
household products.
Locate combustion air inlet as far away as
possible from swimming pool and swim-
ming pool pump house. All combustion
air and vent pipes must be airtight and
watertight. Combustion air and vent pip-
ing must also terminate exactly as shown
in Figures 1 and 2. If a concentric vent
termination is being used, refer to Fig-
ures 3 through 5 for proper setup.
Vent connections serving appliances
vented by natural draft shall not be con-
nected into any portion of mechanical
draft systems operating under positive
pressure.
Solvent cements are combustible. Keep
away from heat, sparks, or open flame.
Use only in well ventilated areas. Avoid
breathing in vapor or allowing contact
with skin or eyes.
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Figure 5 - Concentric Vent Roof Installation
CONDENSATE DRAIN REQUIREMENTS
At the rear of the unit a ½” PVC pipe nipple with
NPT threads is provided for the attachment of the
condensate drain line. Attach the ½” PVC tee in
the parts bag to act as a vent as shown. Attach ½”
PVC from this point to either a drain or an exter-
nal condensate pump (not furnished). If the drain
level is above the condensate trap, a condensate
pump must be used. The condensate pump must
be designed for a flue gas condensate application.
The condensate drain line must be pitched down to
the floor at a minimum of ¼” per foot and must be
routed within the conditioned space to avoid freez-
ing of condensate and blockage of the drain line. If
the unit will be started immediately upon comple-
tion of installation, prime trap by filling with water
until water is seen at the vent.
NOTES:
Condensate trap is integral to the boiler.
Wood frame or blocks may be used to raise the boiler to
maintain drain pitch or to be above external condensate
pump reservoir.
There is a 115 volt AC receptacle provided on the con-
trol panel to provide power for an external condensate
pump (if needed).
1.
2.
3.

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in which the appliances remaining connected
to the common venting system are located and
other spaces of the building. Turn on clothes
dryer and any appliance not connected to the
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom ex-
haust, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close
fire dampers.
4. Place in operation the appliance being inspect-
ed. Follow the lighting instructions. Adjust ther-
mostat so appliances will operate continuously.
5. Test for spillage at the draft hood relief open-
ing after 5 minutes of main burner operation. Use
the flame of a match or candle, or the smoke
from a cigarette, cigar or pipe.
6. After it has been determined that each ap-
pliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans and any other gas-burning appliance to
their previous condition of use.
7. Any improper operation of the common vent-
ing system should be corrected so the instal-
lation conforms with the National Fuel Code,
NFPA-54/ANSI -Z223.1-latest revision, or sec-
tion 5 of CSA-B149 for Canadian standards.
When resizing any portion of the common vent-
ing system, the common venting system should
be resized to approach the minimum size as de-
termined using the appropriate tables in part 11
in the National Fuel Gas Code, NFPA-54/ANSI-
Z223.1-latest revision, or section 5 of CSA-B149
for Canadian standards.
VI - PLACING THE BOILER
WARNING
The boiler must be located on a surface that
can support the weight of the installed boiler.
The boiler should be placed to provide the most
direct connections to the combustion air, vent and
system piping as possible.
Place crated boiler as close to selected location
as possible and uncrate boiler. The uncrated boiler
may be moved into position with an appliance dol-
ly or 2-wheel hand truck. The dolly or hand truck
should be inserted under the right hand side of the
boiler. It is possible to slide the boiler for a short
distance on a smooth floor or surface.
NOTE: Refer to “Locating The Boiler” in Section V of this
manual for required clearances for servicing and mainte-
nance.
FOUNDATION REQUIREMENTS
Boiler must be placed on level surface. Boiler is
NOT to be installed on carpeting.
NOTES:
If boiler is not level condensate drain lines will not func-
tion properly. Adjustable feet are located on the boiler to
make up for minor surface irregularities or tilt.
Wood frame or blocks may be used to raise boiler to
maintain drain pitch or to be above external condensate
pump reservoir.
REMOVAL OF EXISTING BOILER
FROM COMMON VENT SYSTEM
When an existing boiler is removed from a com-
mon 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 appliances remaining
connected to the common venting system are not
in operation.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restrictions, leakage, corrosion
and other deficiencies which could cause an un-
safe condition.
3. When it is practical, close all building doors
and windows and all doors between the space
1.
2.

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VII - NEAR BOILER PIPING
CAUTION
Copper supply and return piping must NOT be
installed directly into aluminum boiler section
castings due to galvanic corrosion between
dissimilar metals. Iron or steel bushings or
pipe nipples should be used between copper
system piping and boiler to make final con-
nection to boiler. Also, the use of dielectric
unions is acceptable. The packaged boiler is
furnished with iron piping where necessary
for the supply and return connections.
When the installation of the boiler is for a new
heating system, first install all of the radiation units
(panels, radiators, baseboard, or tubing) and the
supply and return mains. After all heating system
piping and components have been installed, make
final connection of the system piping to the boiler.
A hot water boiler installed above radiation level
must be equipped with a low water cut off device.
A periodic inspection is necessary, as is flushing
of float type devices, per low water cut off manu-
facturers specific instructions. This boiler is factory
equipped with a manual reset probe-type low water
cut off.
EXPANSION TANK AND MAKE-UP WATER
CAUTION
Non-potable water only piped directly to
boiler.
Determine required system fill pressure, system
design temperature, and system water content.
Boiler contains 2.6 gallons (US). Size expansion
tank accordingly. Consult expansion tank manufac-
turer for proper sizing information. Connect prop-
erly sized expansion tank (not furnished) as shown
in Figure 6 for diaphragm type expansion tank. For
diaphragm type expansion tanks, adjust the tank
air pressure to match the system fill pressure. In-
stall air vent (furnished) as shown for diaphragm
type expansion tank system only. Install make-up
water connections as shown and per local codes.
If a pressure reducing valve is used, adjust to
match the system fill pressure. In connecting the
cold make-up water supply to the boiler, make sure
that clean water supply is available. When the wa-
ter supply is from a well or pump, a sand strainer
should be installed at the pump.
PRESSURE RELIEF VALVE /
TEMPERATURE PRESSURE GAUGE
The boiler is furnished with a relief valve in the
boiler parts bag. Provide ¾” piping from the sup-
plied relief valve to a local floor drain, but leave
an air gap between piping and drain. No shutoff of
any description shall be placed between safety re-
lief valve and the boiler, or on the discharge pipes
IMPORTANT: For piping examples using the Gas-Fired Direct Vent Modulating Hot Water Boiler,
see the Piping Appendix in Section XIV of this manual.
Figure 6 - Diaphragm Type
Expansion Tank Piping
Figure 7 - Relief Valve Discharge Piping