Page 2 - Installation and Service Manual Upsilon-Series
Installation and Service Manual Upsilon-Series 2 Version: from sv 4.1 05-2013
Page 3 - Content
Installation and Service Manual Upsilon-Series 3 Content 1 Introduction ............................................................................................................................................. 4 2 Regulations .........................................................................
Page 4 - Introduction; present the customer with the user’s manual.; and exhaust classification.
Installation and Service Manual Upsilon-Series 4 1 Introduction These instructions describe the functioning, installation, use and primary maintenance of A.O.Smith central heating boilers for the United Kingdom and Ireland. Where necessary the different regulations for each country are separately de...
Page 5 - G C
Installation and Service Manual Upsilon-Series 5 description components figure 1.a 1 heat exchanger 1 (All UB-types) 2 heat exchanger 2 (UB 110 and UB 140) 3 ignition unit 4 fan unit 5 damper 6 gas valve 7 automatic air vent 8 main switch 230V 9 boiler contol unit 10 control unit MMI 11 connection t...
Page 7 - Regulations; have been given supervision or instructions.
Installation and Service Manual Upsilon-Series 7 2 Regulations The following regulations apply to the installation of A.O.Smith central heating boilers: Legislation and Regulations. Gas Safety (Installation and Use) Regulations. All gas appliances must by law, be installed by a competent person, eg....
Page 8 - result of insufficient care taken during transport.
Installation and Service Manual Upsilon-Series 8 Take note of the following when maintenance or adjustments are needed: - The boiler must be able to function during these activities; for this reason, the boiler’s supply voltage, gas pressure and water pressure must be maintained. Ensure that there i...
Page 9 - Scope of delivery
Installation and Service Manual Upsilon-Series 9 3 Scope of delivery The boiler will be delivered ready for use. The delivery package includes the following: • Boiler and housing: • Boiler pump(s); • Cascade control system; • Automatic air vent(s); • Siphon; • Lid ø100 air supply (with screw); • PG ...
Page 10 - Description
Installation and Service Manual Upsilon-Series 10 4 Description The Upsilon is a condensing and modulating CH-boiler. The boiler has one or two stainless steel heat exchangers with smooth pipes. A high- tec principle with durable materials suitable for room sealed open flue or over pressure cascade ...
Page 11 - Installation and mounting; The Upsilon cascade can be mounted in 3 ways:; and servicing and installing the flue system (refer to chapter 7).
Installation and Service Manual Upsilon-Series 11 5 Installation and mounting Install the boiler in a well-ventilated boiler room in accordance to the actual regulations. The installation location of the CH-boiler(s) has to be, and remain, frost-free. It is NOT necessary to have a purpose provided a...
Page 12 - C. Hang the boilers on the suspension brackets.; Lifting and carrying precautions:; - Do not lift and twist at the same time.
Installation and Service Manual Upsilon-Series 12 5.1 Wall-mounted in line A . Position the pipe work header against the wall. When using several pipe work headers: couple the pipe work headers and supplied gaskets, M12 (DN65) or M16 (DN100) bolts, spring washers and nuts. Align the pipe work header...
Page 13 - Attention: Use the correct holes in the column!
Installation and Service Manual Upsilon-Series 13 5.2 Free-standing in line A . Position the pipe work header in the required location. When using several pipe work headers: couple the pipe work headers using the supplied gaskets, M12 (DN65) or M16 (DN100) bolts, spring washers and nuts. Align the p...
Page 15 - Connecting the boiler; boiler flow and return.
Installation and Service Manual Upsilon-Series 15 5.4 Connecting the boiler A. Remove the remaining packaging part from the bottom of the boiler. Note: this packaging part is provided with boiler parts which are needed for mounting the boiler. B. Cap the connections that are not used on the pipe wor...
Page 16 - Hydraulic and gas pipe line system; Install the CH-system in accordance with present legislation.; Low velocity header; There are 3 low velocity headers available:; Set of bends; side of the low velocity header and to connect the gas line.
Installation and Service Manual Upsilon-Series 16 6 Hydraulic and gas pipe line system 6.1 Heating system Install the CH-system in accordance with present legislation. The pipe work headers are available in 2 dimensions, i.e. DN65 and DN100 and are connected to one another by the flange couplings an...
Page 17 - Expansion vessel
Installation and Service Manual Upsilon-Series 17 Required components that are not supplied by A.O.Smith: - The installation pump; - The condensate discharge system. - The installation water filter; - Air and dirt separator - Gas filter; - Hot water supply - Regulation valve; 6.2 Expansion vessel Th...
Page 18 - Water type definition:
Installation and Service Manual Upsilon-Series 18 - On installation and during additions or changes at a later stage, A.O.Smith recom- mends to keep a record of the type of water used, its quality at the time, and if ap- plicable, which additives and quantities were added. Parameter Value Water type...
Page 19 - any residual pollution.
Installation and Service Manual Upsilon-Series 19 6.4 Gas line Mount the gas line in accordance with present legislation. If required, mark the gas line in accordance with present legislation. United Kingdom: The gas supply must comply to the current Gas Safety, Installation & Use Regulations. I...
Page 20 - Condensate drain; Routing of the pipework,
Installation and Service Manual Upsilon-Series 20 6.5 Condensate drain All A.O.Smith wall hung gas fired condensing boilers contain a syphonic condensate trap to collect and release condensate. The amount of condensate formed is determind by the type of boilers and the water temperature produced by ...
Page 21 - Final discharge options.
Installation and Service Manual Upsilon-Series 21 Final discharge options. The condensate pipe can only terminate into any one of the five areas as shown in the diagrams on this page. Draining of the condensation water to the external rain guttering is not permitted in view of the danger of freezing...
Page 22 - Flue gas system; The flue gas exhaust system and air supply system consists of:; - Boiler Class indicated on the boiler’s type plate (Flue category); - The supplier’s installation instructions
Installation and Service Manual Upsilon-Series 22 7 Flue gas system The flue gas exhaust system and air supply system consists of: - Flue gas pipe; - Air supply pipe; - Roof or wall terminal. The flue gas exhaust system and air supply system must comply with: United Kingdom: The flue gas outlet and ...
Page 23 - Parallel boiler connection; The air supply (3) of the concentric part is closed by a lid ø150mm.; Concentric boiler connection; The air supply opening has a diameter of ø150mm.
Installation and Service Manual Upsilon-Series 23 7.1 Parallel boiler connection The boiler comes as standard with a parallel connection for the flue gas outlet and air supply system. The air supply opening (1) has a diameter of ø100mm. The air supply channel can be connected to it, or, if it involv...
Page 24 - of the boiler will be IPX0D instead of IPX4D.; Individual flue gas outlet; has to be prevented at all times.
Installation and Service Manual Upsilon-Series 24 7.3 Connecting the flue gas outlet-/air supply system Upsilon-boilers can be used both in an “open” and in “closed" system. Open: The required combustion air is taken from the immediate environment (boi- ler room). For this purpose, please comply...
Page 25 - the inlet pipe may be required.; be 1m below the bottom of the window opening.; towards the outside to prevent rainwater from coming in.
Installation and Service Manual Upsilon-Series 25 Possible warranty claims will not be honoured if incorrect changes result in non compliance with the installation manual or local rules and regulations. The flue gas system should be built up using only A.O.Smith program products. Combinations with o...
Page 26 - Cutting the concentric pipe goes as follows:
Installation and Service Manual Upsilon-Series 26 The appliance produces a white wisp of condensation (pluming). This wisp of condensation is harmless, but can be unattractive, particularly in the case of outlets in outside walls. At this time there are 2 different ways of connecting the flue gas/ai...
Page 27 - Collective flue gas outlet
Installation and Service Manual Upsilon-Series 27 7.5 Collective flue gas outlet Opting for a collective flue gas outlet is determined by: - The position of the boilers with regard to their outlet area - Sufficient space above the boilers - Large number of boilers You may opt for: - Collective flue ...
Page 28 - Collective flue gas outlet under-pressure; Diameter and venting lengths of the flue gas outlet/air supply:
Installation and Service Manual Upsilon-Series 28 7.5.1 Collective flue gas outlet under-pressure Diameter and venting lengths of the flue gas outlet/air supply: - Open system, with under-pressure (calculated with thermal draft) under atmospheric circumstances. Table 7.5.1.a Diameter and venting len...
Page 29 - Collective flue gas outlet over-pressure
Installation and Service Manual Upsilon-Series 29 7.5.2 Collective flue gas outlet over-pressure An installation with a collective flue gas outlet over-pressure in combination with individually controlled boilers (e.g. 0-10 V control), where no bus cable 0310289 is connected, is NOT allowed. Diamete...
Page 30 - Condensate vent collective flue gas outlet system; and may be made of PVC.
Installation and Service Manual Upsilon-Series 30 7.6 Condensate vent collective flue gas outlet system Flue gases condensate inside the outlet system. Anticipate approx. 1 litre of con- densate per m3 of natural gas spent on heating. The resulting condensate has to be drained. Therefore, collective...
Page 31 - Electrical connections
Installation and Service Manual Upsilon-Series 31 8 Electrical connections The appliance complies with the CE Machinery Directive 89/392/EEC. The EC Low Voltage Directive 72/23/EEC and the EC EMC Directive 89/336/EEC. - A 230V -50Hz mains electrical supply is required fused externally at 6,3A. - A d...
Page 33 - External controls; - T10 must be connected; are necessary. See chapter 9.4 to adjust the flow temperature.
Installation and Service Manual Upsilon-Series 33 figure 8.f 4. Bus communication: 4-pole connector Position Connection Application PG Bus communication cable IP67 The 0310289 bus communication cable mutually connects the cascaded boilers by 4-pole connectors on the side of the connection terminals ...
Page 34 - load control
Installation and Service Manual Upsilon-Series 34 3. 0-10 Volt-control At a heat demand of the 0-10 Volt controller a signal is sent out and varies from 0-10 Volt. This signal is translated by the Upsilon boiler to a set value (desired flow water temperature or load) which is send via the data bus t...
Page 37 - Boiler control; Display
Installation and Service Manual Upsilon-Series 37 9 Boiler control The boiler has a control unit. This control takes care of most of the manual settings but also provides numerous settings to adjust the control exactly to the installation and user requirements. Display The LCD screen is backlit. The...
Page 38 - Operational status; Standby; OK
Installation and Service Manual Upsilon-Series 38 9.1 Operational status - Standby Standby. Boiler is ready for operation. - Vent.Phase Ventilation stage - Ignition phase Ignition stage - Burner lit CH Burner active for heating - Burner lit DHW Burner active for hot water - CH T > Tset Burner off...
Page 40 - The standard read-out offers 3 information screens.; Cascade param. is shown; Switching on the Heating, DHW and Pump program
Installation and Service Manual Upsilon-Series 40 The standard read-out offers 3 information screens. Switching to different screen scan be found using the + or - button 1. "Good"- read-out Good with actual day and time (see above) 2. Operational status Refer to chapter 9.1 for explanation o...
Page 41 - Setting the maximum flow water temperature with On/Off-control; Press the right arrow button until CH temp:
Installation and Service Manual Upsilon-Series 41 9.4 Setting the maximum flow water temperature with On/Off-control P101 = 0 Setting the maximum flow water temperature with connected outdoor sensor T4 (starting with illuminated display): 1. Press the right arrow button: The display shows: Basic Set...
Page 42 - Filling the heating system; hose from the water tap is then connected to it.; for quality requirements of the filling water.; Venting program; the – button 1x: Vent Prog is now displayed]; FILL
Installation and Service Manual Upsilon-Series 42 VentProg. OK - + OK - + 9.5 Filling the heating system When all boilers have been electrically commissioned as described above, then the heating system can be filled. Each boiler is fitted with a filling and drain valve. The filling hose from the wat...
Page 43 - Basic settings; the blue illumination will switch off after 2 min.
Installation and Service Manual Upsilon-Series 43 10 Basic settings Menu structure There are 2 setting levels 1. Basic level (manager/user) Blue screen 2. Setting level (Installer): Green screen With the illumination switched off, first press on one of the buttons to switch the illumination on and t...
Page 44 - Menu structure at Setting level; sec. The screen colour will change from blue to green.
Installation and Service Manual Upsilon-Series 44 Menu structure at Setting level With the illumination switched off, first press on one of the buttons to switch the illumination on and then continue with the setting. Having pressed the last button, the green illumination will switch off after 2 min...
Page 45 - Parameters
Installation and Service Manual Upsilon-Series 45 11 Parameters For operation and menu overview, refer to chapter Boiler control and Basic settings. Basic settings Basic settings PARA factory setting Description Range CH prog off CH-program on/off DHW prog off DHW-program on/off Pump prg off Pump pr...
Page 49 - Activate factory settings; Activating the factory settings from user level only:; Put out of operation
Installation and Service Manual Upsilon-Series 49 11.1 Activate factory settings Do the following to reactivate factory settings (any changed settings will be lost): Activating the factory settings from user level only: From the standard blue screen display: 1. Select using the right arrow button: B...
Page 50 - Inspection and maintenance; Maintenance intervals; whatever comes first.; secured against opening.; Checks prior to commissioning; one have to check and adjust the zero-pressure control and O; leakages by use of leakage detection spray.
Installation and Service Manual Upsilon-Series 50 13 Inspection and maintenance Boiler maintenance is only to be carried out by qualified staff with calibrated equipment. When replacing spare parts only original A.O.Smith Service parts are to be used. Please contact A.O. Smith. 13.1 Maintenance inte...
Page 51 - Emission check; Measuring is only allowed using the top test nipple (refer to arrow).
Installation and Service Manual Upsilon-Series 51 13.2.1 Emission check In order to be able to check on the boiler’s emission during its years of operation, it is recommended to measure the maximum air displacement of the boiler on commissioning. This value may be different for each boiler type. Thi...
Page 52 - Check O
Installation and Service Manual Upsilon-Series 52 13.2.2 Check O 2 The O 2 percentage is set by the factory. It has to be checked during inspection, maintenance and faults. It can be checked as follows: - Ensure that the boiler is at maximum load and can dump the heat generated; - Press down the arr...
Page 53 - Maintenance activities; - Switch the device off using the mains switch,
Installation and Service Manual Upsilon-Series 53 13.3 Maintenance activities The following actions have to be taken in order to be able to carry out maintenance: - Switch the device off using the mains switch, - close the gas tap; Refer to figure 13.3.a: - Unscrew the 4 screws of quick-locks A, B, ...
Page 54 - Checking the non return valve in the upper casing, venturi and fan
Installation and Service Manual Upsilon-Series 54 - Remove the burner cassette (18) from the ventilator unit; - Check the burner cassette for wear and tear, pollution and any breakages. Clean the burner cassette with a soft brush and vacuum cleaner. In the case of breakages, always replace the compl...
Page 55 - Ignition electrode; A and B can be shown (heat exchanger symbol turns from A to B).; parts during dismantling to avoid damage of these parts.
Installation and Service Manual Upsilon-Series 55 Ignition electrode Replace the ignition electrode when necessary, but certainly every 4 years. This can be checked by reading out the ionisation current. The minimum ionisation cur- rent has be greater than 2,0 µA at full capacity. To read out the io...
Page 56 - Counter running hours; The screen turns green
Installation and Service Manual Upsilon-Series 56 Syphon (refer to fig. 13.3.f) Place a collector (i.e. a bucket) under the syphon to collect the dirty and aggressive condensate water. Wear protective clothing like latex gloves and safety glasses. - Dismantle the syphon by unscrewing the syphon cup ...
Page 57 - Error report; Error implies a blocking of the boiler and can only be solved by a
Installation and Service Manual Upsilon-Series 57 Block.B000sc00 ErrorE000sc00 MessageM000sc00 14 Error report On the display, errors found are shown in the form of a message or blocking on a blue screen or an error on a red screen. - Blocking This is a temporary error that will sort itself out, or ...
Page 58 - Warranty conditions; General warranty
Installation and Service Manual Upsilon-Series 58 15 Warranty conditions To register your warranty, visit the website www.aosmithinternational.com/content/ product-registration and fill in the Product Registration Form. Registering the boiler gives the owner of the boiler supplied by A.O. Smith Wate...
Page 59 - Scope of the warranty; that it has supplied.
Installation and Service Manual Upsilon-Series 59 15.4 Exclusions The warranty set out in articles 1 and 2 will not apply in the event of: a. damage to the central heating boiler caused by an external factor; b. misuse, neglect (including frost damage), modification, incorrect and/or unauthorized us...
Page 60 - Annex A; conditions on the heat exchangers are not valid.
Installation and Service Manual Upsilon-Series 60 Annex A Technical specifications Technical specifications Natural gas G20 Boiler type UB 70 UB 110 UB 140 Type heat exchanger HEX4 HEX4 HEX4 HEX2 HEX4 Input Hs CH kW 68,5 107,9 136,4 Qn Input Hi CH kW 61,8 97,3 123 Efficiency class according BED ...
Page 61 - Annex B System water additives; Additive type
Installation and Service Manual Upsilon-Series 61 Annex B System water additives When the filling water requirements as referred to in chapter Water Quality have been met, certain additives are allo- wed for the below mentioned applications and related dosage. Warranty on A.O.Smith delivered install...
Page 62 - Annex C Dimensions
Installation and Service Manual Upsilon-Series 62 Annex C Dimensions dimensions (in mm) Figure C.a Boiler type UB 70 UB 110 UB 140 Concentric flue system mm 100 / 150 100 / 150 100 / 150 Parallel flue system mm 2x 100 2x 100 2x 100 Gas pipe - g 1 1/4" 1 1/4" 1 1/4" Flow pipe CH - a 1 1/2...
Page 66 - wall hung
Installation and Service Manual Upsilon-Series 66 Upsilon 1 boiler, wall hung Upsilon 2 boilers, wall hung, max.200kW Upsilon 1 boiler, free-standing Upsilon 2 boilers, free-standing, max. 200kW Number of Upsilon ‐ boilers (UB 70, UB 110, UB 140) 1 2 1 2 Necessary articles: 0310265...
Page 67 - Annex D Declaration of conformity; CE DECLARATION OF CONFORMITY; the condensing boiler types: Upsilon UB 70
Installation and Service Manual Upsilon-Series 67 Annex D Declaration of conformity CE DECLARATION OF CONFORMITY Hereby declares A.O. Smith Water Products Company B.V. that, the condensing boiler types: Upsilon UB 70 UB 110 UB 140 are in conformity with the provisions of the following EC Directives,...
Page 68 - your installer
A.O. Smith UK, Unit B8 Amstrong Mall,Southwood Business Park, Farnborough, Hampshire GU14 0NRwww.aosmith.co.uk “A.O. Smith Water Heaters” is a trading name of Advance Services (Sales) Ltd. Reg. your installer