Utica Boilers Ssc Operation And Installation Manual
2015-05-18
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Stainless Steel Condensing Boiler Connection Instructions To Additional Heating Devices Kit #55002875 Kit installation shall be completed by qualified agency. ! WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this instruction and understand all requirements, including requirements of authority having jurisdiction, before beginning installation. Installation not complete until appliance operation is verified per Installation, Operation & Maintenance Manual provided with boiler. Boiler installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: • United States • National Fuel Gas Code, ANSI Z223.1/NFPA 54. • National Electrical Code, NFPA 70. • Canada • Natural Gas and Propane Installation Code, CAN/CSA B149.1. • Canadian Electrical Code, Part I, Safety Standard for Electrical Installations, CSA C22.1 TABLE 1 - Parts Supplied With Kit Description Part Qty AR822 Control Z140C 2 System Sensor 240008465 1 System Sensor Well 240008466 1 Well Clip 240008467 1 Kit Instructions 240010355 1 P/N 240010355 Rev. A [01/2014] TABLE OF CONTENTS Process Flow...................................................................................................................3 Background....................................................................................................................4 Application Concept.........................................................................................................4 Heating Priority Establishment...........................................................................................4 Water Flow Arrangement..................................................................................................4 Water Temperature Control...............................................................................................4 SECTION A - Stainless Condensing Boiler Operating with HIGH Temperature Heating Device.......5 A1. Pipe the system.....................................................................................................5 A2. Connect Electrical Wires..........................................................................................5 A3. Connect CH Call For Heat Wire................................................................................. 5 A4. Connect DHW Call For Heat wire, if applicable............................................................ 5 A5. Setting the Additional Heating Device........................................................................ 5 A6. Set The Stainless Condensing Boiler CH .................................................................... 6 A7. Set The Stainless Condensing Boiler DHW Setting....................................................... 6 A8. Create CH Call For Heat And Verify System Works As Intended..................................... 6 A9. Create DHW Call For Heat, If Applicable, And Verify System Works As Intended.............. 6 Figure A1 - Piping for Stainless Condensing Boiler and High Temperature Additional Heating Device..........7 Figure A2 - Piping for Stainless Condensing Boiler and Open System, High Temperature Additional Heating Device (Cannot be pressurized)...........................................................................................8 Figure A3- Call for Heat wiring Connection for Stainless Condensing Boiler Operating with High Temperature Additional Heating Device.................................................................................................................................9 Figure A4 - Call for CH wiring Connection for High Temperature Additional Heating Device...................... 10 Figure A5 - Argus Control S-4 Switch..................................................................................................11 SECTION B - Stainless Condensing Boiler Operating with LOW Temperature Heating Device 12 B1. Pipe The System.................................................................................................. 12 B2. Connect Electrical Wires........................................................................................ 12 B3. Connect Ch Call For Heat Wire................................................................................ 12 B4. Connect DHW Call For Heat wire, if applicable.......................................................... 12 B5. Setting the Additional Heating Device...................................................................... 12 B6. Set the Stainless Condensing Boiler........................................................................ 13 B7. Create CH Call For Heat And Verify The System Works As Intended............................. 13 B8. Create DHW Call For Heat And Verify The System Works As Intended.......................... 13 Figure B1 - Stainless Condensing Boiler with Low Temperature, Closed System Additional Heating Device.....13 Figure B2 - Stainless Condensing Boiler with Low temperature, Open System Additional Heating Device ........14 Figure B3 - Wiring Call for Heat Stainless Condensing Boiler with Low Temperature Additional Heating Device...15 Figure B4 -Wiring DHW Stainless Condensing Boiler with Low Temperature Additional Heating Device...16 2 PROCESS FLOW START Read through the BACKGROUND section and understand the design concept HIGH Temperature Device Additional heating device is Low temperature device? LOW Temperature Device or High temperature device? Install the system following procedure in Section A Install the system following procedure in Section B Test the system and confirm it works properly for both CH and DHW 3 BACKGROUND BACKGROUND Water Temperature Control Application Concept VIII. The system is configured so the Stainless Condensing boiler control system will modulate its firing rate to sustain Supply Water Temperature at the setting point in all conditions. I. Kit is for applications that employ ECR Stainless Condensing boiler to work with an additional heating device. • When Additional Heating Device is supplying heat at its full capacity. II. If the additional heating device can constantly supply hot water at 165°F or HIGHER, it is considered a HIGH Temperature Heating Device. Follow installation procedure in SECTION A. Following are common High Temperature Heating Devices • When Additional Heating Device is supplying heat at reduced capacity. • When Additional Heating Device is not supplying heat. • Indoor wood water boiler • Outdoor wood water boiler • Electric boiler Heating Priority Establishment IX. The two heating units are configured to supply heat in the following manner. III. If Additional Heating Device only constantly supplies hot water at LESS THAN 165°F, it is considered a LOW Temperature Heating Device. Follow installation procedure in SECTION B. Following are common Low Temperature Heating Devices. • When the Additional Heating Device alone CANNOT maintain supply water temperature at or higher than the temperature set point of the Stainless Condensing boiler, the Stainless Condensing boiler will fire. • Geothermal hot water heating device • Solar water heating device • Electric hot water heat pump • When the Additional Heating Device alone CAN maintain a supply water temperature higher than the temperature set point of the Stainless Condensing boiler, the Stainless Condensing boiler will NOT fire. IV. Heating capacity of the additional heating device will be fully utilized when available. V. Stainless Condensing boiler will fire only when the additional heating device cannot satisfy heat demand. Water Flow Arrangement VI. The piping connection establishes flow where water flows through the two heating devices (Stainless Condensing boiler and Additional Heating Device) in a sequential manner. The goal is to make the two heating units work together at the maximum possible system heating efficiency. If the additional heating device is a HIGH temperature device, return water goes into the Stainless Condensing boiler first. The purpose is to have the stainless condensing boiler work in the condensing regime as much as possible. SECTION A. If the additional heating device is a LOW temperature heating device, return water flows into additional heating device first to fully utilize the capacity of the additional heating device. SECTION B. VII. The water flow arrangement takes advantage of the Stainless Steel Condensing boiler's built in primary loop and internal water pump. 4 SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE SECTION A 2-5. Remove or deactivate Low Limit control on Additional Heating Device, if available. Stainless Condensing boiler working with HIGH Temperature Heating Device A3. Connect CH Call For Heat Wires 3-1. Install one of the supplied call for heat controls, AR822, onto wall. 3-2. Remove jumper in AR822 between Terminal-L1 and Terminal-3. 3-3. Connect Additional Heating Device and Stainless Condensing boiler. See Figure A3. • Connect two wires, from room thermostat or from zone control board, to input T-Terminals (Terminal-R and Terminal-W) in AR822. A1. Pipe the system 1-1. Pipe the heating system and install all required components following installation instructions of Additional Heating Device, i.e. a wood boiler. 1-2. Connect the Additional Heating Device and Stainless Condensing boiler together as shown in Figure A1. If the Additional Heating Device can be pressurized. 1-3. Install Stainless Condensing boiler System Sensor on the supply side of the piping (supply side of Additional Heating Device) as shown in Figure A1. If the Additional Heating Device CAN NOT be pressurized (i.e. and open system) connect the Stainless Condensing Boiler and Additional Heating Device as shown in Figure A2. 1-4. All near boiler piping requirements of the Additional Heating Device have to be satisfied. Refer to installation and operation manuals of the Additional Heating Device. 1-5. Manufacture recommends Additional Heating Device bypass valve. Close the bypass valve when Additional Heating Device is used. When Additional Heating Device will not supply heat for extended period of time, open the bypass valve. This is important when Additional Heating Device is an outdoor wood boiler. Water from the system will not be cooled from circulating through the unused system. 1-6. Install expansion tank, air vent, and filling pipe at upstream (inlet) side of system pump. • Connect Terminal-5 and Terminal-6 in AR822 to Stainless Condensing boiler CH T-T terminals. • Connect Terminal-3 and Terminal-4 in AR822 to CH T-T input of Additional Heating Device. • Connect line voltage wires to Terminal-L2 and Terminal-L1 in AR822. A4. Connect DHW Call For Heat wires, if applicable 4-1. Install supplied call for heat control, AR822, onto wall. 4-2. Remove jumper in AR822 between Terminal-L1 and Terminal-3. 4-3. Connect Additional Heating Device and Stainless Condensing boiler following Figure A4. • Connect two wires, from hot water tank thermostat or from zone control board, to input T-Terminals (Terminal-R and Terminal-W) in AR822. • Connect Terminal-5 and Terminal-6 in AR822 to Stainless Condensing boiler CH T-T terminals. A2. Connect Electrical Wires 2-1. Follow instructions in Additional Heating Device manuals when wiring (1) all high voltage wires and (2) Low voltage wires other than Call For Heat wire. 2-2. Follow instructions in Stainless Condensing boiler Installation, Operation and Maintenance Manual when connecting (1) all high voltage wires and (2) Low voltage wires other than Call For Heat wire. 2-3. Connect system pump to Additional Heating Device, if applicable. 2-4. All zone pumps and zone valves, if controlled by heating device, should be connected to and controlled by the Additional Heating Device, if applicable. • Connect Terminal-3 and Terminal-4 in AR822 to CH T-T input of Primary Heating Device. • Connect line voltage wires to Terminal-L2 and Terminal-L1 in AR822. A5. Setting the Additional Heating Device 5-1. Set CH supply temperature setting of Additional Heating Device according to heating system requirement, i.e. 170°F. 5-2. Set DHW supply temperature setting of Additional Heating Device according to hot water tank requirement, i.e. 180°F. 5 SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE A7. Set The Stainless Condensing Boiler DHW Setting 7-1 Set DHW supply temperature setting of stainless condensing boiler to temperature about 10°F lower than corresponding DHW setting point on Additional Heating Device, i.e. 170°F. A6. Set The Stainless Condensing Boiler CH 6-1. Set stainless Condensing boiler to be Master boiler in Cascade mode. Change S4-switch to ON position, (away from S4 mark on control board). See Figure A5. 6-2. Change boiler address to Cascade 1 following procedure below. • Press down and hold “Enter” button and immediately press down and hold “Menu” button for 5 seconds to enter into Installer Menu. A8. Create CH call for heat and verify system works as intended. • Use arrow keys to go to “Boiler Config” A9. Create DHW call for heat, if applicable, and verify system works as intended. • Press “Enter” key • Press “Enter” key again. The number after “Boiler Address:” will be flashing. • Use arrow keys to change this number to 1. • Press “Enter” key, number will stop flashing. • Press “Menu” key twice to exit Installer Menu. • CASCADE 1 should appear on user interface. 6-3a Set System Temperature Setting for Stainless Condensing boiler. If outdoor reset is activated (CH Mode 1 or CH Mode 2) and if heating system requires a reset curve different from the default curve. • Change Outdoor Reset curve. Detailed instructions can be found in boiler Installation, Operation and Maintenance Manual (IOM). • Set “Boiler Max” parameter to about 20°F lower than setting point of Additional Heating Device, i.e. 150°F. 6-3b If outdoor reset function is deactivated (CH mode 0), follow procedure below to set System Temperature Setting point. • Press “Menu” button. • Scroll down to “Setting” using arrow keys. • Press “Enter” key. • Press “Enter” key again. The number after “Cascade CH Setting” will be flashing. • Use arrow keys to change this number to about 20°F lower than setting point of Additional Heating Device, i.e. 150°F. • Press “Enter” key. Number will stop flashing. • Press “Menu” key twice to exit setting mode. 6 SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE Figure A1 - Piping for Stainless Condensing Boiler and High Temperature Additional Heating Device ADDITIONAL HEATING DEVICE (Closed System) ADDITIONAL ADDITIONAL HEATING HEATING DEVICE DEVICE BY BYPASS VALVE PASS VALVE SYSTEM SENSOR 7 SYSTEM PUMP SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE Figure A2 - Piping for Stainless Condensing Boiler and Open System, High Temperature Additional Heating Device (Cannot be pressurized) ADDITIONAL HEATING DEVICE (OPEN SYSTEM NON-PRESSURIZED) ISOLATION FLATE PLATE HEAT EXCHANGER ADDITIONAL HEATING DEVICE PUMP SYSTEM SENSOR 8 SYSTEM PUMP SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE Figure A3 - Call for Heat wiring Connection for Stainless Condensing Boiler working with High Temperature Additional Heating Device ROOM THERMOSTAT AR822-II T T 5 6 L2 L1 3 NOTE: REMOVE FACTORY INSTALLED JUMPER BETWEEN L1 & 3 4 CH T T 120V CH T T ADDITIONAL HEATING DEVICE 9 SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE Figure A4 - Call for HDW wiring Connection for High Temperature Additional Heating Device HOT WATER TANK THERMOSTAT AR822-II T T 5 6 L2 L1 3 NOTE: REMOVE FACTORY INSTALLED JUMPER BETWEEN L1 & 3 4 DHW T T 120V DHW T T ADDITIONAL HEATING DEVICE 10 SECTION A - STAINLESS CONDENSING BOILER OPERATING WITH HIGH TEMPERATURE HEATING DEVICE Figure A5 - Argus Control S-4 Switch S4 Switch ON OFF 11 SECTION B - STAINLESS CONDENSING BOILER OPERATING WITH LOW TEMPERATURE HEATING DEVICE SECTION B Stainless Condensing boiler working with LOW Temperature Heating Device 2-5. If there is a Low Limit control on the Additional Heating Device, such low limit control has to be removed or deactivated. B1. Pipe The System 1-1. Pipe the heating system and install all required components following requirements of the Additional Heating Device. 1-2. Connect Additional Heating Device and Stainless Condensing boiler together as shown in Figure B1, if the Additional Heating Device is a closed system (can be pressurized). If the Additional Heating Device is an open system (CANNOT be pressurized), pipe the Stainless Condensing Boiler and Additional Heating Device as shown in Figure B2. 1-3. All piping requirements of Additional Heating Device shall be satisfied. Refer to installation and operation manuals of the Additional Heating Device. 1-4. Manufacture recommends use of The Additional Heating Device bypass valve. The bypass valve should be closed when Additional Heating Device is used. When Additional Heating device does not supply heat for extended period of time, open this bypass valve. This is important when Additional Heating Device is an outdoor device. Water from the system will not be cooled from circulating through the unused system. 1-5. Install the expansion tank at the upstream (inlet) side of the system pump. B3. Connect CH Call For Heat Wire 3-1. Install supplied call for heat control, AR822, onto wall. 3-2. Remove jumper in AR822 between Terminal-L1 and Terminal-3. 3-3. Connect Additional Heating Device and Stainless Condensing boiler. Refer to Figure B3. • Connect two wires, from room thermostat or from zone control board, to input T-Terminals (Terminal-R and Terminal-W) in AR822. • Connect Terminal-5 and Terminal-6 in AR822 to Stainless Condensing boiler CH T-T terminals. • Connect Terminal-3 and Terminal-4 in AR822 to CH T-T input of Additional Heating Device. 3-4. Connect line voltage wires to Terminal-L2 and Terminal-L1 in AR822. B4. Connect DHW Call For Heat wire, if applicable 4-1. Install one of the supplied call for heat controls, AR822, onto wall. 4-2. Remove jumper in AR822 between Terminal-L1 and Terminal-3. 4-3. Connect Additional Heating Device and Stainless Condensing boiler. Refer to Figure B4. • Connect two wires, from hot water tank thermostat or from zone control board, to input T-Terminals (Terminal-R and Terminal-W) in AR822. • Connect Terminal-5 and Terminal-6 in AR822 to Stainless Condensing boiler DHW T-T terminals. • Connect Terminal-3 and Terminal-4 in AR822 to DHW T-T input of Additional Heating Device. • Connect line voltage wires to Terminal-L2 and Terminal-L1 in AR822. B2. Connect Electrical Wires 2-1. Follow the instructions in Additional Heating Device manuals when wiring (1) all high voltage wires and (2) low voltage wires other than Call For Heat wire. 2-2. Follow instructions in Installation, Operation and Maintenance Manual of the Stainless Condensing boiler when connecting (1) all high voltage wires and (2) Low voltage wires other than the Call For Heat wire. 2-3. Power the system pump by heating zone control board if applicable. If there is no heating zone control board in the heating system, power the system pump with the Stainless Condensing boiler. Use relays to prevent current over draw. 2-4. All zone pumps and zone valves should be controlled by either the heating zone control board or the Stainless Condensing boiler. B5. Setting the Additional Heating Device 5-1 Set CH Supply Temperature Setting of Additional Heating Device to value close to maximum possible setting, i.e. 160°F. 5-2 Set DHW Supply Temperature Setting of Additional Heating Device to value close to maximum possible setting, i.e. 160°F. 12 SECTION B - STAINLESS CONDENSING BOILER OPERATING WITH LOW TEMPERATURE HEATING DEVICE B6. Set the Stainless Condensing Boiler 6-1 Set CH Supply Temperature Setting point for Stainless Condensing boiler according to heating system requirement, i.e.175°F. Detailed instructions are available in the IOM of Stainless Condensing boiler. 6-2 Set DHW supply temperature setting of Stainless Condensing boiler to temperature required for hot water tank, i.e. 180°F. B7. Create CH call for heat and verify the system works as intended. B8. Create DHW call for heat and verify the system works as intended. Figure B1 - Stainless Condensing Boiler with Low Temperature, Closed System Additional Heating Device (Can be pressurized) SOLAR PANEL LOW TEMPERATURE ADDITIONAL HEATING DEVICE ADDITIONAL ADDITIONAL HEATINGDEVICE DEVICE HEATING BY PASS VALVE BYPASS VALVE 13 SECTION B - STAINLESS CONDENSING BOILER OPERATING WITH LOW TEMPERATURE HEATING DEVICE Figure B2 - Stainless Condensing Boiler with Low temperature, Open System Additional Heating Device (CANNOT be pressurized) LOW TEMPERATURE ADDITIONAL HEATING DEVICE (OPEN SYSTEM NON-PRESSURIZED) ADDITIONAL HEATING DEVICE PUMP ISOLATION FLATE PLATE HEAT EXCHANGER SYSTEM PUMP 14 SECTION B - STAINLESS CONDENSING BOILER OPERATING WITH LOW TEMPERATURE HEATING DEVICE Figure B3 - Wiring Call for Heat Stainless Condensing Boiler with Low Temperature Additional Heating Device ROOM THERMOSTAT AR822-II T T 5 6 L2 L1 3 NOTE: REMOVE FACTORY INSTALLED JUMPER BETWEEN L1 & 3 4 CH T T 120V CH T T ADDITIONAL HEATING DEVICE 15 SECTION B - STAINLESS CONDENSING BOILER OPERATING WITH LOW TEMPERATURE HEATING DEVICE Figure B4 - Wiring DHW Stainless Condensing Boiler with Low Temperature Additional Heating Device ROOM THERMOSTAT AR822-II T T 5 6 L2 L1 3 4 NOTE: REMOVE FACTORY INSTALLED JUMPER BETWEEN L1 & 3 DHW T T 120V DHW T T ADDITIONAL HEATING DEVICE 16
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