Utica Boilers JE Operation and Installation Manual
Contents
1. 1 Top Front Panel 400 30909 ea T Top Front 800 tosoos20 1 Boilers having total inputs of 400 MBH as complying with ANSI Z21 13 Models 300 and 400 the standard combustion side controls meet CSD 1 and no changes to the standard component carton are required Description MATERIAL LISTS Figure la CSD 1 500 Gas Train Table 3 CSD 1 Electronic Ignition Base Material List 1 90 Street Elbow Back 14693040 2 Manual Shutoff Valve 14657001 3 Y x 2 Nipple Black 14607201 Tee Black 14693076 5 Y x Bushing 106000 Ya x 2 Nipple Black 131001 vA Ys Street Elbow Black 14657007 Ya Manual Shutoff Valve 1465700 Ya x 2 2 Nipple Black 14607000 10 1 Gas Pres Regulator 6 w c 1465700 43357103 14657019 14657008 114000 N A 11 Ya Magnetic Valve w Connector Assembly 12 NPT x Tube M Connector 13 Bushing Control STP W Alarm A Control Mounting Panel CSD 1 24 GA Galv 109006833 Control CSD Lockout Daughter Board 1140008 1 Control Mounting Panel 109006832 18 Screws 8 x Self Tap 201000001 14 15 16 7 Figure 1b CSD 1 500 Gas Train Table 3 Continued fim Demen Compression Fitting e NPT x Tube 14657025 1465702 1460780 1465701 1465700 14657012 14662315 ES Brass Coupling Male x 16 24 Ye x 2 2 Nipple Black 90 Elbow 500 Only Ma2. e Tappings E amp F LWCO auto and manual and pump control Installer supply and size the steam top and water bottom equalizing pipe lengths so the horizontal cast line on the control body is 28 above floor Secondary control is 24 above the floor See Figure 2 Table 5b CSD 1 Steam Trim Carton Material List For Boiler Feed Pump Return Part No 41257104 tem Description PartNo am Pressure Switch Control Manual Reset 14662311 LWCO and Pump Control primary 14626306 90 Brass Syphon Brass Nipple Y x 372 IG Brass Tee Y x Ve x A Brass Coupling 72 SEQUENCE OF OPERATION C S FROM CONTROL BOX GAS VALVE TO IGNITION CONTROL PILOT 1145 2 LOCKOUT CONTROL Call For Heat Control recognizes call for heat when power is applied to 24V terminal on control module Since control receives signal from the thermostat when call for heat is terminated heating cycle immediately terminates and all control outputs will shut off Ignition Trial Period Control energizes pilot gas valve and spark outputs for ignition trial time of 12 seconds If flame is sensed during 12 seconds of ignition trial spark output is de energized main gas valve is energized and control enters steady heat mode If flame is not established within ignition trial period control de energizes the spark and gas valve and operates as described below in Ignition Failure Re try S
3. 3 sa a Boilers having total inputs of 400 MBH or less as complying with ANSI Z21 13 Models 300 and 400 the standard combustion side controls meet CSD 1 and no changes to the standard component carton are required b There are additional parts on base assemblies for boilers having total inputs from 500 to 1 500 MBH Models 500 to 1500 to meet CSD 1 See Table 2 CSD 1 Component Carton Material List for details c For steam boilers there is an additional CSD 1 steam trim carton for gravity or condensate pump return Part 41257103 or an additional CSD 1 steam trim carton for boiler feed pump return Part 41257104 See appropriate CSD 1 Steam Trim Carton Material List Tables 5a and 5b for details Table 2 CSD 1 Component Carton Material List gere remm re 300 CSD 1 400 CSD 1 500 CSD 1 300 BaseAssembiyosp ss e 1 TT 400 Base Assembly sD 1 550001671 ea L 1 T 500 Base Assembly csD 1 1 300 Intermediate Jacket Garton ea L 400 Intermediate Jacket Garton ssoooseza ea SOT 7506 Intermediate Jacket Carton 550001675 1 F300DratHood f esma ea 4cbrftHod es 500 Draft oc ars TL Control Panel Assemby 55000101 ea Control Panel Assembly CSD 1 3001400 550001589 Control Panel Assembly CSD 1500 ea j SSCS r Front Paner3oo
4. REFER TO THE MANUFACTURES INSTRUCTIONS HONEYWELL VR8304M GAS VALVE ROBERTSHAW 7000 DERHC GAS VALVE WIRING SCHEMATIC LEGEND GND LOW WATER CUT OFF HIGH VOLT POWER SUPPLY FS FIELD SUPPLIED PRESSURE SWITCH MV MAIN VAL VE PV PILOT VALVE PSS PILOT SAFETY SWITCH EWF ELECTRIC WATER OPTIONAL 3 FEEDER FIELD INSTALLED P P PLUG PIN C S CAP SOCKET HIGH VOLT FIELD INSTALLED LOW VOLT FIELD INSTALLED 4 24 Vac N O CONTROL ELECTRONIC a Narr CIRCUIT V GND PRI EE RT sec Je C CDS 1 CONTROL MANUAL RESET OPTIONAL IGNITION MODULE TO ADDITIONAL TO ADDITIONAL BASES BASES LOW VOLTAGE WIRING 12 ELECTRICAL WIRE DIAGRAMS CSD 1 STEAM BOILERS WITH BOILER FEED PUMP RETURN COMMERCIAL BOILER CSD 1 CONTROLS 1 BASE STEAM FEED PUMP NEC CLASS II LOW VULT CIRCUIT PS HIGH VOLT POWER SUPPLY PER NEC AND ITEMS SUPPLIED LOCAL CODES BY INSTALLER PS MANUAL RESET OVERCURRENT SERVICE DISCONNECT PROTECTION RECOMMENDED ELECTRONIC LWCO 24 V MANUAL RESET DRY CONTACT FOR FEED PUMP ll FIELD SUPPLIED LWCO PUMP CONTROL 150 S NOTE FOR ADDITIONAL WIRING INFORMATION ON FIELD INSTALLED COMPONENTS REFER TO THE MANUFACTURES INSTRUCTIONS TO ADDITIONAL BOILER BASECS HONEYWELL VR8304M GAS VALVE ROBERTSHAW 7000 DERHC GAS VALVE WIRING SCHEMATIC GND LEGEND HIGH VOL
5. DED ELECTRONIC LWCO 24 V MANUAL RESET 3 24 V COPTIONAL gt eo STEAM APPLICATIONS TO ADDITIONAL BOILER BASECS NOTE FOR ADDITIONAL WIRING INFORMATION ON FIELD INSTALLED COMPONENTS REFER TO THE MANUFACTURES INSTRUCTIONS HONEYWELL VR8304M GAS VALVE ROBERTSHAW 7000 DERHC GAS VALVE LEGEND LOW WATER CUT OFF FS FIELD SUPPLIED PS PRESSURE SWITCH MV MAIN VALVE PV PILOT VALVE PSS PILOT SAFETY SWITCH WIRING SCHEMATIC HIGH VOLT POWER SUPPLY e 1 0 ELECTRIC WATER FEEDER P P PLUG PIN C S CAP SOCKET HIGH VOLT FIELD INSTALLED LOW VOLT FIELD INSTALLED 24 Voc CONTROL ELECTRONIC NEC CLASS II LOW LWCO 24 Vv MANUAL RESET VOLT CIRCUIT GND IGNITION MODULE D ADDITIONAL TO ADDITIONAL BASES BASES LOW VOLTAGE WIRING 11 ELECTRICAL WIRE DIAGRAMS CSD 1 STEAM BOILERS WITH CONDENSATE PUMP GRAVITY RETURN COMMERCIAL BOILER CSD 1 CONTROL 2 3 BASE STEAM GRAVITY COND HIGH VOLT POWER SUPPLY PER NEC AND ITEMS SUPPLIED LOCAL CODES BV INSTALLER J BOX DVERCURRENT SERVICE DISCONNECT PROTECTION RECOMMENDED Q PS ELECTRONIC LwcO 24 V MANUAL RESET PS MANUAL RESET oo EWF 24 V OPTIONAL STEAM APPLICATIONS TO ADDITIONAL BOILER BASECS NOTE FOR ADDITIONAL WIRING INFORMATION ON FIELD INSTALLED COMPONENTS
6. ONTROL C S CAP SOCKET HIGH VOLT FIELD INSTALLED LOW VOLT FIELD INSTALLED PS LWCO MANUAL PUMP RESET 24 Voc N O CUNTRUL ELECTRDNIC NEC CLASS II LDW LWCO 24 v5 MANUAL RESET VOLT CIRCUIT CDS 1 CONTROL MANUAL RESET IGNITION OPTIONAL MODULE TO ADDITIONAL TO ADDITIONAL BASES BASES LOW VOLTAGE WIRING 14 NOTES 15
7. ONTROL WIRING PILOT SAFETY SHUTOFF VALVE HONEYWELL V8046C WHITE BLACK BLACK BLACK MAIN GAS VALVE HONEYWELL VR8304M H En WHITE PV SITE MV PV PV PV C ALARM ALARM YELLOW S 1003 612A ALARM CONTACTS GND BOILER m R T z 24 VAC AC SPARK STAT u GREEN _ te COM E 1145 2 BOARD fal d TRABE SPARK CABLE TO PILOT TRANSFORMER CO O 24V OUTPUT L2 LI ELECTRICAL WIRE DIAGRAMS GAS VALVE CONTROL WIRING The suggested schematic wiring diagrams are included Please use the appropriate one for the installation CSD 1 ROBERT SHAW 7000 DE RHC GAS VALVE CONTROL WIRING MAIN GAS VALVE PILOT SAFETY ROBERT SHAW 7000 DE RHC SHUTOFF VALVE CONTROL 1003 612A ALARM CONTACTS UT 1145 2 CABLE TO PILOT TO CONTROL BOX TO PILOT GROUND 10 ELECTRICAL WIRE DIAGRAMS CSD 1 STEAM BOILERS WITH CONDENSATE PUMP GRAVITY RETURN COMMERCIAL BOILER CSD 1 CONTROL 1 BASE STEAM GRAVITY COND NEC CLASS r LOW VOLT 7 O CIRCUIT PS HIGH VOLT POWER SUPPLY PER NEC AND ITEMS SUPPLIED LOCAL CODES BV INSTALLER PS MANUAL RESET OVERCURRENT SERVICE DISCONNECT PROTECTION RECOMMEN
8. SUPPLEMENTAL INSTALLATION AND OPERATING INSTRUCTIONS CSD 1 COMMERCIAL BOILER CONTROLS P N 240010413 Rev A 12 2013 CSD 1 COMMERCIAL BOILER CONTROLS 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 Your commercial boiler is furnished with combustion side water or steam controls to meet our interpretation of the American Society of Mechanical Engineers ASME Safety Code for Controls and Safety Devices for Automatically Fired Boilers No CSD 1 Installation shall conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision Where required by the authority having jurisdiction the installation shall conform to the American Society of Mechanical Engineers ASME Safety Code for Controls and Safety Devices for Automatically Fire Boilers No CSD 1 CSD 1 controls and this installation may be subject to approval by local inspectors Additional parts or equipment may be required Consult local authorities having jurisdiction before the installation of the boiler CSD 1 controls furnished with commercial boilers are applicable to boilers with inputs above 400 000 Btu hr Models 500 1500 Additional parts required by CSD 1 standards may be necessary to make
9. T POWER SUPPLY pu EL CUT OFF MV MAIN VALVE PV PILOT VALVE PSS PILOT SAFETY SWITCH FP FEED PUMP P P PLUG PIN O wens C S CAP SOCKET FIELD INSTALLED PUMP CONTROL HIGH VOLT FIELD INSTALLED LOW VOLT FIELD INSTALLED 84 Voc CONTROL ELECTRONIC NEC CLASS II LOW Lwco 24 V gt MANUAL RESET VOLT CIRCUIT GND IGNITER SENSOR CDS 1 CONTROL MANUAL RESET OPTIONAL IGNITION MODULE TO ADDITIONAL TO ADDITIONAL BASES BASES LOW VOLTAGE WIRING 13 ELECTRICAL WIRE DIAGRAMS CSD 1 STEAM BOILERS WITH BOILER FEED PUMP RETURN COMMERCIAL BOILER CSD 1 CONTROL 2 3 BASE STEAM FEED PUMP eee CIRCUIT HIGH VOLT POWER SUPPLY PER NEC AND ITEMS SUPPLIED J BUX LOCAL CODES BY INSTALLER DVERCURRENT SERVICE DISCONNECT PROTECTION RECOMMENDED 21 PIP2A 0000 ELECTRONIC LWCD 24 v MANUAL RESET DRY CONTACT FOR FEED PUMP lt FIELD SUPPLIED gt LWCO PUMP CONTROL 150 S NOTE TO ADDITIONAL FOR ADDITIONAL WIRING BOILER BASE S INFORMATION ON FIELD INSTALLED COMPONENTS REFER TO THE MANUFACTURES INSTRUCTIONS HONEYWELL VR8304M GAS VALVE ROBERTSHAW 7000 DERHC GAS VALVE WIRING SCHEMATIC GND LEGEND HIGH VOLT POWER SUPPLY LWCO LOW WATER CUT OFF PS PRESSURE SWITCH MV MAIN VALVE PV PILOT VALVE PSS PILOT SAFETY SWITCH FP FEED PUMP LWCO P P PLUG PIN FIELD INSTALLED PUMP C
10. ded on control will shut off all outputs and enter either soft or hard lockout state Main valve is interlocked with the pilot valve and voltage can only be detected on main valve when pilot valve is energized Control locks out the first time as soft lockout then retries after 5 minutes and enters hard lockout state Lockout should be manually reset as described in Lockout Flame Present With Gas Off If flame is sensed for longer than 2 seconds during a period when gas valve should be closed control will enter lockout Power Interruptions Power interruptions less than 0 15 seconds will not cause control to interrupt heat sequence while power interruptions over 0 25 seconds will cause the control to reset lockout and ignition trial counters Power interruptions of any duration will not cause a lockout or any other operation requiring manual intervention Lockout Controller automatically resets from first lockout in 5 minutes If second lockout occurs before call for heat is satisfied it will require manually resetting by depressing red button on CSD 1 daughter board This can be reached with a pencil through the vent holes A red LED will also indicate lockout and can be seen through the vent holes ELECTRICAL WIRE DIAGRAMS GAS VALVE CONTROL WIRING The suggested schematic wiring diagrams are included Please use the appropriate one for the installation CSD 1 HONEYWELL VR8304M H MAIN GAS VALVE C
11. equence Ignition Failure Re Try Sequence After an unsuccessful ignition trial control checks to see if maximum number of ignition trials 2 trials has been completed If maximum number of ignition trials has been completed control will lockout See Lockout next page for details If maximum number of ignition trials has not been completed control delays for 5 minute inter purge period After the inter purge control attempts another ignition trial Refer back to Ignition Trial Period for details Steady State Heating Control keeps pilot gas valve and main gas valve energized while continuously monitoring call for heat and flame status Control will remain in this steady state heating mode until power is removed by a thermostat satisfied b pressure switch opening or c flame being lost If call for heat is satisfied power is removed from control de energizing pilot gas valve and main gas valve If flame is lost control will shut off main gas valve within one second leave pilot gas on and immediately start ignition trial Control checks to see if maximum number of flame losses 2 per call for heat has been reached If maximum number of flame losses has been reached control locks out See Lockout section for details SEQUENCE OF OPERATION Gas Valve Sensing If either or both the pilot and main gas valves are sensed to be on when commanded to be off or if no voltage appears at gas valve output which was comman
12. nction with primary LWCO equipped on boiler When using two LWCOs place manual reset lower than automatic LWCO Water must be visible in gauge glass when manual reset trips e Figure 3 shows how to raise automatic Series 67 LWCO 1 inch e Remove 1 from long side of 1 4 diameter 90 brass siphon tube e Remove nipple in series 67 and replace with 1 Y long nipple and street elbow e Water level control device located on condensate receiver tank and controls condensate return pump is not supplied Figure 2 Steam Boiler Feed Pump Return D McDonnell Series LWCO 93 or 150 M Reset LWCO Figure 3 Steam Gravity and Condensate Pump Return T ii PRESSURE LIMIT STEAM PRESSURE SN SIPHON LOOP WATER LEVEL 29 TO FLOOR Table 5a CSD 1 Steam Trim Carton Material List for Gravity Return or Condensate Pump Return Part No 41257103 LWCO w Manual Reset secondary 240007388 Bushing Steel or Cast 1 x 1 14657016 Pressure Switch Control Manual Reset 14662311 90 Brass Syphon Y 14643004 ELB ST 1 2 45 DEG BRASS 240007541 6 NIPPLE 1 2 X 1 2 LG_ BRASS 240007542 BOILER FEED PUMP RETURN Boiler feed pump return additional parts See Table 5b See Figure 2 for installed locations of additional parts e Tappings B amp B Water gauge glass set and pressuretrol requires fittings 4 7 in Table 5b e Tapping D Steam gauge and pressuretrol requires fitting 8 in Table 5b
13. nual Shutoff Valve Ye Pipe Cap 30 Wire Harness Base to Base 240006732 1 4 x 1 Nipple Black 300 400 Only 14657009 Ground Wire Spark White 371 1 21 01 Not Shown 0 1 2 3 4 5 6 7a 7b 8 9 30 32 3 STEAM SIDE CONTROLS Steam Side Control Two low water cutoff devices and two pressuretrols one with auto reset and the second with manual reset are required In order to make the two low water cutoff devices work in the appropriate sequence manufacture recommends locating both devices at same end of boiler There are three different control systems for three different types of condensate returns Identify the three different types of condensate returns e Gravity return condensate is returned by gravity e Condensate pump return condensate is returned by pump s controlled by the water level in the condensate receiver tank e Boiler Feed Pump Return condensate is returned by pump s controlled by the water level in the boiler Gravity Return And Condensate Pump Return With gravity and condensate pump return additional control components are the same See Table 5a and Figure 2 for tappings e Tappings B amp B location shown in Figure 2 Installation shown in Figure 3 Primary LWCO and Pressuretrol with gauge glass set e Tappings D or F Figure 2 Manual reset pressuretrol and 14 90 brass syphon e Tappings E amp F Secondary LWCO w manual reset Use in conju
14. quence is as follows 1 Turn on power Set thermostat to call for heat 2 Ignition starts to spark and lights pilot flame 3 Ignition continues sparking about 12 seconds after pilot lights 4 Main burners ignite NOTICE A longer pilot flame recognition time is a design feature of this module and is correct Gas Pressure Requirements e Maximum allowable inlet gas pressure natural gas only to controls in CSD 1 gas train is 14 w c Va psig Verify inlet gas pressure is at least 5 w c but no greater than 14 w c If gas pressure entering the building is greater than 14 w C installing contractor must provide overpressure protection on downstream piping to prevent buildup of downstream pressures in excess of 14 w c in event the fuel system pressure regulator fails Alternatively gas pressure entering the building may be reduced with additional_gas pressure regulator outdoors If inlet gas pressure to this additional regulator is less than 14 w c then overpressure protection may not be required Consult local authority s having jurisdiction before installing gas supply piping to the boiler MATERIAL LISTS Table 1 CSD 1 Complete Boiler Material List CSD 1 Component Carton b Inner R 300 CSD 1 400 CSD 1 500 CSD 1 P pao 1 2 sas moo 7 ECO AA EE A E CO eee AAA A 2 jJ AA G 100 1 18 jif nrrr s mo ia Jr 3
15. this boiler compliant This supplemental instruction manual should be used in conjunction with the Installation Operation and Maintenance manual for your specific boiler CSD 1 Component Installation Based on parts listed in Installation Operation and Maintenance manual for your particular boiler the following changes should be made Complete Boiler Material List See Table 1 CSD 1 Complete Boiler Material List Combustion Side Control e Models 300 and 400 no changes are required to existing gas trains e Models 500 through 1500 requirements include A Intermittent pilot control module is required to have maximum 15 second pilot flame establishing period and ability to perform safety shutdown and lockout in event of loss of flame signal at pilot B The intermittent pilot module and manual reset switch are used to replace the existing pilot module C Also an independent pilot gas line which includes manual shutoff valve pressure regulator and safety shutoff valve two leak test valves on main gas valve and manual shutoff valve located downstream of the main gas valve are added See See Table 2 CSD 1 Component Carton Material List for component carton material list which replaces the corresponding list in the installation manuals e See Table 3 CSD 1 Electronic Ignition Base Material List e Installed locations of additional components see Figures la and 1b For CSD 1 combustion side control light off se
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