Utica PEG-C User's Manual
Contents
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3. 5 SVD IVYNLVN SONILVY 15 2003 PAGE 26 3741801
4. FIGURE 14 15 GENERAL INSTRUCTIONS Before seasonal start up it is advisable to have a competent service agency check the boiler for soot and scale in the flues clean the burners and check the gas input rate to maintain high operating efficiency On steam boilers make certain the boiler is filled to the water line as indicated in figure 15 The gauge cocks should be normally open To remove dirt from the gauge glass the petcock may be opened to flush out the glass Aa a DISCHARGE WILL BE BOILING HOT WATER The radiator valves on a steam system must be either wide open or tightly shut Do not attempt to regulate room temperature by partially closing the radiator valve Air vents on steam radiators and the supply main release air from the system If radiators do not heat satisfactorily make sure the air vents are clean and operational The lever of the safety valve shown in figure 15 below on the boiler should be operated periodically to make sure that it is functioning properly Aa DISCHARGE WILL BE BOILING HOT WATER AND STEAM The safety valve should open before the steam pressure exceeds the 15 reading on the gauge figure 15 to right If this pressure is exceeded and the safety valve does not open it must be replaced If the safety valve leaks steam when the boiler is operating at normal pressures it should be immediately o
5. Page 26 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE lt 9 SERIES PEG C US CAST IRON GAS FIRED BOILERS INSTALLATION MANUAL AND OPERATING INSTRUCTIONS Published April 1997 C S A Certified Tested for 100 Ibs Printed in USA for Natural gas ASME Working Made in USA or Propane Pressure Safety Symbols The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels DANGER DANGER Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury WARNING WARNING Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury CAUTION CAUTION Indicates a potential hazardous situation which if not avoided MAY result in minor or moderate injury It may also be used to alert against unsafe practices READ ALL INSTRUCTIONS BEFORE INSTALLING WARNING 1 Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 DO NOT obstruct air openings to the boiler room 3 Modification substitution or elimination of factory equipped supplied or specified components may result in property damage personal injury or the loss of life ae the owner Installation and service of this boiler must be performed by a qualified installer 5 To the installer Leave all instructions w
6. FIGURE 15 PAGE 16 CLEAN THE BOILER FLUEWAYS 1 Remove the burners from the combustion chamber by raising the burners upward from the manifold orifices and pulling toward the front of the boiler To remove the burner with the pilot burner attached first disconnect the pilot line tubing and thermocouple or pilot generator leads at the main electric gas valve Do not remove the pilot line tubing at the pilot as the pilot burner orifice may drop out and become damaged or lost 2 Disconnect the vent pipe from the draft hood 3 Remove the draft hood The draft hood is attached to the flue collector at the top by sheet metal screw s 4 Remove the top jacket panel It is attached to the jacket by sheet metal screws 5 Remove the flue collector from the boiler casting by loosening the nuts on the J bolts at either side of the flue collector 6 Place a sheet of heavy paper or similar material over the bottom of the combustion chamber and brush down the flue passageways The soot and scale will collect on the paper and is easily removed with the paper 7 With the paper still in place in the combustion chamber clean the top of the boiler castings of the boiler putty or silicone used to seal between the castings and the flue collector Make certain chips are not lodged in the flueways When the cleaning process is completed restore the boiler components to their original position Use boiler putty or GE 15
7. 3 PEG187 4 PEG 225 5 PEG262 6 PEG300 7 3 100 2 13 02 E Right Hand Section 1 4 HW06901 NUT 5 16 18WISLOCK 4 Fully assembled heat exchangers 5 HW 011 10TIE ROD 1 4 10 25 PEG112 2 10022802 4 SECTION PEG112C 1 HW 011 02 TIE ROD 1 4X13 PEG150 10022803 5 SECTION PEG150C 1 HW 011 04 TIE ROD 1 4X17 PEG187 10022804 6 SECTION PEG187C 1 HW 011 05 TIE ROD 1 4X19 PEG225 10022805 7 SECTION PEG225C 1 HW 011 07 TIE ROD 1 4X23 PEG262 10022806 8 SECTION PEG262C 1 HW 011 08 TIE ROD 1 4X25 PEG300 10022807 9 SECTION PEG300C 1 6 PF 007 02 PIPE FIT PLG 2 1 7 251 1 2 00 J BOLT 1 4 20 3 5 16 2 8 43300976 NIPPLE 2 MACH PEG112C 4 PEG150 6 PEG187 8 PEG 225 10 262 12 14 9 HW 016 02 DRAIN LONG 1 10 1570001 VALVE POP SAFETY 3 4 1 11 1150001 COUPLING 3 4 1 12 PF 005 10 PIPE FIT NPL 3 4 X 6 1 FIGURE 23 PAGE 23 PEG C REPLACEMENT PARTS FRONT PANEL CONTROLS 14 13 13 FRONT PANEL SEE PAGE 22 9 5 6 ITEM PART ITEM PART NUMBER DESCRIPTION OTY NUMBER DESCRIPTION OTY 1 00400 GAUGEWTRLEVEL 1 9 753 1 3 00 90 SYPHON 1 2 PF 033 02 PIPE FIT NPL 1 2 4 1 10 PF 025 01 1 4 TEE 1 3 WCO1901 ELWCOPS 802U 24 1 11 PF 026 05 1 4 X 3 NIPPLE 1 WITH PROBE 12 GA 003 00 PRESSURE GAUGE 1 4 006 02 POPRIVITFLUE3 16 2 13 PF 027 01 1 4 ELBOW 90 1 5 32421901 SENSOR BRACKET 1 14 SS 001 01 PRESSURESWITCH 1 6 002101 C
8. Repeat the process if necessary Water may be checked to make sure it is free from oil by drawing off a sample at the skimming tee If the sample is reasonably free from oil it will not froth when boiled on stove This test does not indicate the amount of sediment which may lay in the bottom of the boiler It is therefore necessary that the boiler be further cleaned by blowing down BLOWING DOWN BOILER Before blowing down the boiler fill itto the water line Light burners and allow five pounds of steam pressure to build up Run a temporary connection from one of the drain valves to a nearby sewer Connect to a drain valve on the opposite end of the boiler from feed water inlet if possible Shut off the gas burners open drain valve and blow down the entire contents of boiler Allow boiler to thoroughly cool and slowly refill to water line Repeat step 2 as many times as required until blow off water is clear Owner should blow down boiler at least once each month of the heating season A tT eH WATER WILL BE BOILING HOT USING CLEANING COMPOUND If an exceptional amount of dirt or sludge seems to be present in the boiler a boiler cleaning compound made by a reputable manufacturer may be used according to the instructions of the manufacturer of the compound When any type of cleaning compound is used care must be taken to thoroughly flush all traces of the compound out of the boiler Following blow down allow the boiler to cool Add
9. 808 silicone to seal around the flue collector and castings Make certain the burner ends are inserted in the slots at the back of the combustion chamber and well down in position over the burner orifices Follow the lighting instructions on the boiler to put the burners back in operation CHECK SAFETY CONTROL CIRCUIT after burner adjustments are made for satisfactory operation 07 10k g Label wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after service 1 Pilot with main burner operating turn the pilot gas adjusting screw clockwise until pilot gas is turned off See figures 11 and 12 on pages 12 amp 13 Within 90 seconds the main gas control should close shutting off the gas to the main burner After check pilot operation Relight following lighting instructions on pages 10 12 2 Pressure control on steam boilers remove cover and note pressure setting With the boiler operating decrease the setting When setting is lower than boiler pressure the control will open closing the automatic main gas valve After checking pressure control reset control to original setting 3 Mechanical Low water cut off Operation may checked by opening the blow off valve located in the lower portion of the body This will drain water quickly from the cut off body and break circuit to automatic main gas valve Owner should blow off this contr
10. and its gas connection must be leak tested before placing the boiler in operation To check for leaks in gas piping use a Soap and water solution or other approved method DO NOT USE AN OPEN FLAME INSTALL MANUAL VALVE WITHIN 5 ft gt ABOVE R 3 The boiler and its individual shutoff WHERE REQUIRED BY LOCAL CODES valve must be disconnected from the gas g supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psi 3 5 kPa The boiler must be isolated from the gas supply piping system 3 lt 8 MINUMUM by closing its individual manual shutoff valve has during any pressure testing of the gas supply T 1 GAS CON Ol INLET piping system at test pressures equal to or less than 1 2 psig 3 5 kPa FIGURE 10 ELECTRICAL WIRING SEE ADDENDUM A FOR WIRING DIAGRAMS AND COMPONENT CODING Electrical wiring must conform with the latest revision of the National Electrical Code ANSI NFPA No 70 and or local authority having jurisdiction 1 The boiler when installed MUST BE electrically grounded in accordance with these requirements 2 Install a fused disconnect switch b
11. be assumed that wood louvers will have 20 25 free area and metal louvers and grilles will have 60 75 free area Louvers and grilles should be fixed in the open position or interlocked with the boiler so they are opened automatically during the boiler operation CONNECTING SUPPLY AND RETURN PIPING 1 Suggested piping for steam heating system can be seen in figure 5 below Actual piping may vary based on system design and local conditions 2 Suggested piping fora modular steam boiler using pumped returns may be seen in figures 6a and 6b on page 6 Actual piping may vary based on system design and local conditions 3 Refer to pages 17 amp 18 for procedures on cleaning and skimming off impurities 4 Near Boiler Piping is crucial for proper performance of a replacement steam boiler and should always be considered as part of the boiler installation Always be sure to include cleanout and skimming tees in the near boiler piping These Tees are necessary for proper cleaning and servicing of the boiler 5 For further piping information refer to the I B R installation piping guide SUGGESTED PIPING FOR A SINGLE STEAM BOILER HEATING SYSTEM Recommended Sizing PEG 112 150 2 PEG 187 225 2 57 PEG 262 300 SUPPLY N PIPE 15 LARGER INCREASE SIZE TO EQUAL RETURN PIPE SIZE 24 lt CLOSE NIPPLE WATER a SKIMMING TEE FROM BOTTOM OF
12. in a building of unusually tight construction airfor combustion and ventilation must be obtained from outdoors or from spaces freely communicating with the tenet outdoors A permanent opening or openings having a total free area of not less than 1 square inch per 5 000 BTU per hour of total input rating of all appliances shall be provided Ducts may be used to convey makeup air VENT PIPE from the outdoors and shall have the same cross sectional area ofthe openingstowhich they are connected os om 4 When air for combustion and ventilation is from inside buildings the confined space shall be provided with two permanent openings one starting 12 inches from the top FIGURE 1 and one 12 inches from the bottom of the enclosed space Each opening shall have a minimum free area of 1 square inch per one thousand 1000 BTU per hour of the total input rating of all appliances in the enclosed space but must not be less than one hundred 100 square inches These openings must freely communicate directly with other spaces of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space PAGE 3 5 When the boiler is installed in a confined space and air is provided from the outdoors the confined space shall be provided with one or two permanent openings according to metho
13. the gas input as described above Primary air adjustment is not necessary therefore air shutters are not furnished as standard equipment Air shutters can be furnished on request when required by local codes or conditions A visual check of the main burners and pilot flames should be made at the start of the heating season and again at mid season The main burner flame should have a well defined inner blue mantel with a lighter blue outer mantel If the flame does not appear this way check the burner throats and burner orifices for lint or dust obstruction See figure 17 above The pilot flame should envelop 3 8 to 1 2 inch of the tip of the pilot sensor See figure 18 on page 20 To adjust the pilot flame remove the pilot adjustment screw and turn the inner adjustment screw clockwise to decrease or counterclockwise t increase pilot flame See figures 11 and 12 on pages 12 amp 13 Be sure to replace cover screw after adjustment to prevent possible gas leakage The burners and pilot should be checked for signs of corrosion rust or scale build up The area around the boiler should be kept clear and free of combustible materials gasoline and other flammable vapors and liquids PAGE 19 The free flow of combustion and ventilation air to the boiler and boiler room should not be restricted or blocked It is suggested that a qualified service agency be employed to make an annual inspection of the boiler and heat
14. 2504 BASE WITH INSUL PEG225C PEG112 amp 150 24V 5612505 BASE WITH INSUL PEG262C VG01102 GAS VALVE VR8204 3010 5612506 BASE WITH INSUL PEG300C PEG112 amp 150 SPARK 6 3342701 BURNER ASSY W PILOT 1 VG01103 GAS VALVE VR8304H4206 BRACKET amp SHUTTER PEG187 300 SPARK 7 3342601 BURNER ASSY W SHUTTER VG01201 VR8300H4006 262 PEG112C 5 PEG150 7 PEG187 9 PEG187 300 24V 3 352 1 1 03 GAS ORIFICE 47 NATURAL 352 1 1 04 GAS ORIFICE 56 LP PEG112C 6 PEG150 8 PEG187 10 PEG 225 12 PEG262 14 PEG300 16 225 11 PEG262 13 15 8 32411302 BRN ACCESS DOOR 112 1 32411303 BRN ACCESS DOOR PEG150C 32411304 BRN ACCESS DOOR PEG187C 32411305 BRN ACCESS DOOR PEG225C 4 32425301 BASE PLATE PEG112C 32411306 BRN ACCESS DOOR PEG262C 32425302 BASE PLATE PEG150C 32411307 BRN ACCESS DOOR PEG300C 32425303 BASE PLATE PEG187C 9 HW 005 01 SCREW 1 4 20X1 2 SELF TAP FIGURE 21 PAGE 21 32425303 BASE PLATE PEG187C 5 5 gt 5 SN 2 ITEM PART ITEM PART NUMBER DESCRIPTION OTY NUMBER DESCRIPTION OTY 1 31423001 SIDE PANEL LEFT ALL 1 6 344 2 1 02 DRAFT HOOD PEG112C 1 2 31422802 FRONT PANEL PEG112C 1 344 2 1 03 150 31422803 FRONT PANEL PEG150C 344 2 1 04 DRAFT HOOD PEG187C 31422804 FRONT PANEL PEG187C 344 2 1 05 DRAF
15. 5 12 NOILVTIVLSNI GAS FIRED BOILERS FOR STEAM HEATING Utica Boilers P O Box 4729 Utica NY 13504 TABLE CONTENTS Safety Symbols Warnings Page 1 Installation 2 Ventilation and Combustion Air Pages 3 4 Connecting Supply and Return Piping Page 5 6 Vent InstallatioN a E aa ea Page 7 Vent System Modification Page 8 Vent Damper Installation and Instructions Page 9 Connecting Gas Service a Page 10 2 A ene eel veer ke ther Page 10 Thermostat Installation 11 Pages 11 13 Normal Sequence of Operation Page 14 Connecting Supply And Return Piping Water Chilled Medium Page 15 General INSIMUCHONS Oe lars ee Ol srt Pages 16 20 Replacement Parts Lists Pages 20 25 Ratings Data and DIMENSIONS
16. BOILER FIGURE 5 PAGE 5 SUGGESTED PIPING FOR MODULAR STEAM BOILERS PUMPED RETURNS FIGURE 6a GRAVITY RETURNS FIGURE 6b PAGE 6 VENT INSTALLATION This boiler shall not be connected to any portion mechanical draft system operating under positive pressure 1 The vent pipe must slope upward from the boiler not less than 1 4 inch for every 1 foot to the vent terminal 2 Horizontal portions of the venting system shall be supported rigidly every 5 feet and at elbows No portion of the vent pipe should have dips or sags 3 This boiler series is classified as a Category 1 appliance and the vent installation shall be in accordance with Part 7 amp 11 of the latest revision of the National Fuel Gas Code or applicable provisions of the local building codes 4 Inspect chimney to make certain it is constructed according to National Board of Fire Underwriters 5 Attach draft hood to flue collector at rear of boiler See figure 7 below with sheet metal screw s through hole s provided The vent or vent collector shall be Type B or metal pipe having resistance to heat and corrosion not less than that of galvanized sheet steel or aluminum not less than 0 016 inch thick No 28 GA 6 Connect flue pipe same as draft hood to chimney Bolt or screw joints together to avoid sag Flue pipe
17. EDE FIRE PROTECTION CLEARANCE PAGE 2 VENTILATION amp COMBUSTION AIR A AIR OPENINGS TO COMBUSTION AREA MUST OBSTRUCTED BY FOLLOWING THE INSTRUCTIONS BELOW ADEQUATE COMBUSTION AIR CAN BE MAINTAINED Unconfined area A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all appliances installed in that space cubic feet of space height x width x length Confined area A space whose volume is less than 50 cubic feet 1000 BTU per hour of all appliances installed in that space cubic feet of space height x width x length 1 Ventilation of the boiler room must be adequate to provide sufficient air to properly support combustion per the latest revision of the National Fuel Gas Code ANSI Z223 1 section 5 3 2 When a boiler is located in an unconfined space ina building or conventional construction frame masonry or metal building infiltration normally is adequate to provide air for combustion and ventilation However ifthe equipmentis located in a building of unusually tight construction See the national Fuel Gas Code Ansi 2223 1 section 1 7 the boiler area should be considered as a confined space In this case air for combustion and ventilation shall be provided according to part 5 on page 4 If there is any doubt install air supply provisions in accordance with the latest revision of the National Fuel Gas Code 3 When aboileris installed in an unconfined space
18. ONTROLFIXEDTEMP 2 15 PF 026 01 CLOSENIPPLE1 4 NPL 1 ONE ON DRAFT HOOD 16 PF05601 PIPEFITNPL1 2 X3 1 7 37513301 WIRE ROLL OUT 1 17 PF 034 01 1 2 BRASSCOUPLING 2 8 HW06501 SCR 6X1 4 SLOT 2 FIGURE 24 PAGE 24 REPLACEMENT PARTS ELECTRICAL RIGHT PANEL SEE PAGE TO DAMPER gt s TEGAS VALVE lt S S S TO DRAFT 2 S Y ITEM PART NUMBER NUMBER DESCRIPTION OTY 1 EF 013 01 ELEC 4 4 1 2 2 2 37414401 WIRE PRES SWITCH TO J BOX 34 1 3 37424501 HARNESS ELWCO TO J BOX 18 1 4 PB00702 IGN WIRE 30 CIDE MODELS ONLY 1 5 37413602 HARNESS IGN MOD GAS VALVE 12 1 6 PB00604 SPK CTL 58600 1013 1 7 37413201 WIRE SPILL SWITCH 47 1 8 37413801 WIRE TO CONTROLS 27 1 9 601 WIRE CLAMP 3600 WHITE 1 10 37413002 WIRE TRANSFORMER WHITE 15 1 11 37413001 WIRETRANSFORMER BROWN 15 1 12 3641601 TRANSFORMER ASSEMBLY 24V 1 13 37413101 DAMPER CABLE 53 1 14 3641501 ELEC 4 4 COVER TERM STRIP 1 FIGURE 25 25 ACIS LHS AIS 1331 ____________ y 5 1 ul dnyoid
19. T HOOD PEG225C 31422805 FRONT PANEL PEG225C 344 2 1 06 DRAFT HOOD PEG262C 31422806 FRONT PANEL PEG262C 344 2 1 07 31422807 FRONT PANEL PEG300C 31423302 REAR PANEL PEG112C 1 3 31421002 MANIFOLD COVER PEG112C 1 31423303 REAR PANEL PEG150C 31421003 MANIFOLD COVER PEG150C 31423304 REAR PANEL PEG187C 31421004 MANIFOLD COVER PEG187C 31423305 REAR PANEL PEG225C 31421005 MANIFOLD COVER PEG225C 31423306 REAR PANEL PEG262C 31421006 MANIFOLD COVER PEG262C 31423307 REAR PANEL PEG300C 31421007 MANIFOLD COVER PEG300C 8 1182005 DAMPER PEG112C 5 1 4 31423002 SIDE PANEL RIGHT ALL 1182006 DAMPER PEG150C 6 5 3442702 FLUE COLLECTOR PEG112C 1182007 DAMPER PEG187C 7 3442703 FLUE COLLECTOR PEG150C 1182008 DAMPERPEG225C amp 262C 8 3442704 FLUE COLLECTOR PEG187C 1182009 DAMPER PEG300C 9 3442705 FLUE COLLECTOR PEG225C 9 31423502 TOP PANEL PEG112C 1 3442706 FLUE COLLECTOR PEG262C 31423503 TOP PANEL PEG150C 3442707 FLUE COLLECTOR PEG300C 31423504 TOP PANEL PEG187C 31423505 TOP PANEL PEG225C 31423506 TOP PANEL PEG262C FIGURE 22 31423507 TOP PANEL PEG300C PAGE 22 5 ITEM PART ITEM PART NUMBER DESCRIPTION OTY NUMBER DESCRIPTION OTY 1 100 2 15 01 E Left Hand Section 1 13 HW 003 02 NUT 1 4 20 HEX SLT 4 2 100 2 14 01 E Center Section 14 HW 008 01 WASH 5 16 FLAT STLZP 2 PEG112C 2 PEG150
20. When the boiler is used in connection with refrigerated system connect supply and return piping as suggested in figure 14 below A The chilled medium MUST BE IN PARALLEL with the boiler B Use appropriate valves to prevent the chilled medium from entering the heating boiler a During heating cycle open valves A and B Close valves C and D b During cooling cycle open valves C and D Close valves A and B C Maintain a minimum clearance of one inch between combustible materials and hot water pipes Reduced pressure backflow preventer must be present under provisions required by the Environmental Protection Agency EPA 2 When the boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation the boiler piping system MUST be supplied with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 3 A hot water boiler installed above radiation level must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation 4 Suggested piping for steam heating system can be seen in figure 5 on page 5 Actual piping may vary based on system design and local conditions KREDUCED PRESSURE BACKFLOW PREVENTER SUPPLY PIPING TO HEATING AND COOLING ELEMENT 65511555 RETURN PIPING FROM HEATING AND COOLING ELEMENT
21. appliance and the vent installation shall be in accordance with Part 7 amp 11 of the latest revision of the National Fuel Gas Code noted above or applicable provisions of the local building codes See Vent Installation on page 7 4 This boiler meets safe lighting and other preference criteria with the gas manifold and control assembly provided on the boiler per the latest revision of ANSI 221 136 5 This boiler shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement condensate trap control replacement etc 6 LOCATE BOILER on level solid base as near chimney as possible and centrally located with respect to the heat distribution system as practical 7 ALLOW 24 inches at the front and right side for servicing and cleaning 8 When installing in a utility room the door should be wide enough to allow the largest boiler part to enter or to permit replacement of another appliance such as a water heater 9 FOR INSTALLATION ON NONCOMBUSTIBLE FLOORS ONLY The boiler must not be installed on carpeting Minimum clearances to combustible construction are ak eet 24 IN teas telat ALCOVE FLUE COLLECTOR 6 IN REAR asset Soa 8 IN SIDES 6 IN NOTE GREATER CLEARANCES FOR ACCESS SHOULD SUPERS
22. call for heat 1 The thermostat will actuate completing the circuit between T and T 2 The damper will then open thus closing the end switch completing the circuit and ignition will begin 3 In the event that the boiler steam pressure exceeds the pressure control setting the pressure control will interrupt the circuit to the boiler ignition system The power will remain off until the steam pressure drops below the pressure control setting 4 In the event a low water condition occurs an automatic low water cut off device will interrupt the circuit to the ignition system until the low water condition is satisfied i e manually restore the water or utilize an electric water feeding device which will automatically restore boiler water to its normal operating level 5 In the event the flow of combustion products through the boiler venting system becomes blocked a blocked vent safety switch will shut the main burner gas off See figure 13 below 6 In the event the flow of combustion products through the flueways becomes blocked a flame rollout switch will shut the main burner gas off See figure 13 below SAFETY RELIEF VALVE DRAFT HOOD BLOCKED VENT SAFETY SWITCH LOW WATER CUT OFF PIPE TO WITHIN OF FLOOR MANIFOLD COVER BURNERS ROLL OUT SAFETY SWITCH GAS VALVE FIGURE 13 PAGE 14 CONNECTING SUPPLY AND RETURN PIPING WATER CHILLED MEDIUM 1
23. ds A or B When ducts are used they shall be of the same cross sectional area as the free area of the area of the openings to which they connect The minimum dimension of rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches A When installing two openings one must commence within 12 inches from the top and CHIMNEY VENTILATION LOUVERS ae VENTILATION LOUVERS EACH END OF ATTIC GAS VENT EACH END OF ATTIC VENT J fe VENT PIPE FLOOR VENTILATION LOUVERS FOR UNHEATED CRAWL SPACE FIGURE 2 FIGURE 3 the other within 12 inches from the bottom of Sy the enclosure The openings shall GAS VENT communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors One of the following methods must be used to provide adequate air for ventilation and combustion PEPEN 1 When directly communicating with the outdoors each opening shall minimum free area of 1 square inch per 4 000 1 BTU per hour of total input of a equipment enclosure See figure 2 zo above 2 When communicating with the outdoors by means of vertical ducts each opening shall have a minimu
24. etween Vent Damper and combustible construction must be maintained Additional clearance should be allowed for service of the Vent Damper 3 Vent Damper must be in open position when appliance main burners are operating 4 The Vent Damper position indicator must be in a visible location following installation 5 The thermostats heat anticipator must be adjusted to match the total current draw of all controls associated with the boiler during a heating cycle 6 The Vent Damper wire harness may be removed and installed in flexible metal conduit if local codes or jurisdiction requires If this is necessary the flexible metal conduit must be mounted to a J box and all appropriate connections must be made to this J box PAGE 9 CONNECTING GAS SERVICE Connect gas service meter to control assembly in accordance with the latest revision of ANSI 2223 1 and local codes or utility A ground joint union should be installed for easy removal of gas control for servicing A drip or trap must be installed at the bottom of a vertical section of piping at the inlet to the gas valve A pipe compound resistant to the action of liquefied petroleum gases must be used on all threaded pipe connections Check with the local utility for location of manual shutoff valve if required See figure 10 below 1 The gas line should be of adequate size to prevent undue pressure drop and never smaller than the pipe size of the main gas control valve 2 The boiler
25. etween boiler and meter at a convenient location PAGE 10 THERMOSTAT INSTALLATION 1 Thermostat should be installed on an inside wall at least two feet from an uninsulated or outside wall approximately four feet above the floor 2 NEVER install a thermostat on an outside wall 3 Do not install a thermostat where it will be affected by A Drafts B Hot or cold pipes C Sun light D Lighting fixtures E Television F Fireplace or chimneys 4 Check thermostat operation by raising and lowering thermostat as required to start and stop the burners 5 Instructions for the final adjustment of the thermostat are packaged with the thermostat adjusting heating anticipator calibration etc LIGHTING INSTRUCTIONS A YOU DO NOT FOLLOW THESE INSTRUCTIONS EX ACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE Before any procedures are attempted on this appliance it is necessary to determine if the ignition system is intermittent or continuous pilot system If you are uncertain contact the manufacturer before proceeding A HE Before operating make certain steam boiler is full of water to water line and system is vented of air See the operating lighting instructions LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM FOR YOUR SAFETY READ BEFORE OPERATING A This appliance is equipped with an ignition system which automatically li
26. fresh water slowly Be certain to blow enough times as required to remove compounds from system PAGE 18 CHECKING AND ADJUSTING THE GAS IGNITION COMPONENTS The gas input to the boiler can be adjusted by removing the protective cap on the pressure regulator see figure 16 on page 19 and turning screw clockwise Nto increase input and counterclockwise to decrease input Natural gas manifold pressure should be set at approximately 3 5 inches water column Propane gas manifold pressure should be set at approximately 10 inches water column Manifold pressure is taken at the pressure tap on the outlet side of the gas valve see figures 11 and 12 on pages 12 and 13 Burner orifices should be changed if the final manifold pressure varies more than plus or minus 0 3 inch water column from the specified pressure To check for proper flow of natural gas to boiler divide the input rate on the rating plate by heating value of the gas as obtained from the local gas company This will determine the number of cubic feet of gas required per hour With all other gas appliances off determine LIGHT BLUE OUTER MANTEL INNER BLUE MANTEL PILOT ADJUSTMENT SCREW MAIN GAS H VALVE PILOT TUBE METAL TUBE L PRESSURE REGULATOR CAP FIGURE 16 FIGURE 17 the flow of gas through the meter for two minutes and multiply by 30 to get the hourly rate Make minor adjustments to
27. ghts the pilot Do not try to light the pilot by hand B Before operating smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow your gas supplier s instructions If you cannot reach your gas supplier call the fire department PAGE 11 Use only your hand to push in or turn gas control knob NEVER USE TOOLS If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and gas control which has been under water OPERATING INSTRUCTIONS FOR INTERMITTENT PILOT SYSTEMS 1 STOP Read the safety information in the user s information manual 2 Set thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand See figure 11 below 5 Remove access panel if present 6 Pus
28. h in gas control knob slightly INTERMITTENT PILOT GAS VALVE turn clockwise 1 7 Wait five 5 minutes to clear out any GAS gas Ifyouthensmell gas STOP Follow 7 in the safety information What To Do IF You LA Smell Gas If you don t smell gas go to the 4 next step PRE 8 Turn gas control knob counterclockwise N to ON 9 Replace control access panel IF PRESENT 10 Turn on all electric power to the appliance 11 thermostat to desired setting 12 If the appliance will not operate FIGURE 11 follow the instructions To Turn Off Gas To Appliance and call a qualified service technician or your gas supplier LIGHTING PROCEDURE FOR BOILER WITH CONTINUOUS PILOT FOR YOUR SAFETY READ BEFORE LIGHTING A Read warning at the beginning of this instruction GAS CONTROW KNOB B This appliance has a pilot which must be lighted by hand When lighting the pilot follow these instructions exactly C Before lighting smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor Follow in the lighting instructions for safety information for what to do if you smell gas on page 10 D Use only your hand to push i
29. ing system They are experienced in making the inspections outlined above and in the event repairs or corrections are necessary can make the proper changes for safe operation of the boiler Optional parts WC 001 00 67 U LWCO WC 004 01 101 Water Feeder WC 005 00 47 2 LWCO amp Feeder PILOT BRACKET IGNITION ELECTRODE PILOT FLAME MAIN BURNER PILOT BURNER FIGURE 18 PEG C REPLACEMENT PARTS PILOT 24VOLT ITEM PART DESCRIPTION OTY 1 01301 PILOT Q350A 24 VOLT 1 2 HW 024 01 SCREW 10 32X3 16 2 3 5 003 05 PILOT TUBE 1 4 24 1 4 1 4 1520001 THERMOCOUPLE Q309A FIGURE 19 1 2 3 4 ITEM PART PB 001 02 HW 024 01 5 003 05 00702 SPARK DESCRIPTION OTY PILOT Q345A SPARK 1 SCREW 10 32X3 16 2 PILOT TUBE 1 4 24 1 4 1 PILOTIGNITION CABLE 1 FIGURE 20 PAGE 20 REPLACEMENT PARTS ITEM PART ITEM PART DESCRIPTION OTY DESCRIPTION OTY 1 3542202 MANIFOLD PEG112C 1 32425304 BASE PLATE PEG225C 3542203 MANIFOLD PEG150C 32425305 BASE PLATE PEG262C 3542204 MANIFOLD PEG187C 32425306 BASE PLATE PEG300C 3542205 MANIFOLD PEG225C 5 5612501 BASEWITHINSULPEG112C 1 3542206 MANIFOLD PEG262C 5612502 BASE WITH INSULPEG150C 3542207 MANIFOLD PEG300C 5612503 BASE WITH INSUL PEG187C 2 VG 008 07 GAS VALVE VR8200H 3000 1 561
30. ith the boiler for future reference 6 When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter Che ALL INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE PAGE 1 INSTALLATION PROCEDURE installation adjustment alteration service maintenance can cause injury or property damage 1 The installation must conform to the requirements of the authority having jurisdiction or in absence of such requirements to the latest revision of the National Fuel Gas Code ANSI 2223 1 Available from the American Gas Association Pleasant Valley Road Cleveland Ohio 44134 Reference should also be made to local gas utility regulations and other codes in effect in the area that the installation is to be made 2 Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices For Automatically Fired Boilers No CSD 1 3 This boiler is classified as a Category 1
31. m free area 1 square inch per 4 000 BTU per hour of total input rating of all appliances in the enclosed space See figure 3 above 3 If horizontal ducts are used each opening and duct shall have a minimum free area 1 square inch per 2 000 BTU per hour of total input rating of all appliances in the enclosed space See figure 4 at right FIGURE 4 One permanent opening commencing within 12 inches of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 inch from the sides 1 inch from the back and 6 inches from the front of the boiler The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl attic that freely communicate with the outdoors The openings must have a minimum free area of 1 square inch per 3000 Btu per hour of the total PAGE 4 input rating of all equipment located the enclosure The free area must no less than the sum of the areas of all vent connectors in the confined space 6 In calculating free area using louvers grilles or screens for the above consideration shall be given to their blocking effect Screens used shall not be smaller than 1 4 inch mesh If the free area through a design of louver or grill is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may
32. n or turn the gas control knob or reset button Never use tools If the knob or reset button will not push in or the knob will not turn by hand don t try to repair it Call a qualified service technician Force or attempted repair may result in fire or explosion See figure 12 on page 13 PAGE 12 Donotuse this appliance ifany parthas CONTINUOUS PILOT GAS VALVE been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system gas control which has been under water H LIGHTING INSTRUCTIONS FOR CONTINUOUS PILOT SYSTEM 1 Stop Read the safety information at the beginning of this manual 2 Set thermostat to lowest setting 3 Turn off all electric power to the appliance 4 Remove manifold cover and burner door figures 13 amp 15 on pages 14 amp 16 5 Turn gas control knob clockwise to off See Note 1 NOTE 1 Some gas control knobs cannot be turned from pilot to off unless knob is pushed in slightly Do not force 6 Wait 5 minutes to clear out any gas If you smell gas stop Followsafety information What to do if you smell gas located on page 10 of this manual If you don t smell gas go to the next step 7 Find pilot Follow me
33. ol at least once each month of the heating season A WARNING WATER WILL BE BOILING HOT PAGE 17 4 Electronic Low Water Cut off Operation be checked by opening the drain valve in the back side of the boiler This will drain the water from the boiler and break the electronic circuit to the automatic gas valve IMPURITIES IN BOILER WATER ofa steam boiler may cause foaming and an unsteady water line or prevent steam generation They may result in objectionable odors escaping from the vents on water boilers This condition is caused by oil grease and sediment from pipe fittings collecting within the boiler and can be remedied only by giving the boiler a thorough cleaning BOILERS CAN BE CLEANED by skimming or blowing down 7 The boiler should not be left unattended during the cleaning process SKIMMING OFF IMPURITIES Some of the impurities in the boiler water will float on the water and must be skimmed off With the boiler empty and cool slowly begin to add water After water has entered boiler never before turn on main gas burners and adjust flame at main manual shut off valve so that the water being added 15 kept just below boiling point Avoid boiling and turbulence Gradually raise hot water level to skimming tee see figure 5 page 5 installed at the supply outlet piping of the boiler being careful not to raise it above the opening of the tee Skim until there are no impurities
34. ppliances remaining connected to the common venting system are not in operation A Seal any unused openings in the common venting system B Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition C Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces in the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace damper D Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously E Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After ithas been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use G Any improper operation of the common venting system
35. should be corrected so the installation conforms with the latest revision of the National Fuel Gas Code ANSI 2223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in appendix in the latest revision of the National Gas Fuel Code ANSI 2223 1 PAGE 8 VENT DAMPER INSTALLATION AND INSTRUCTIONS INSTALLATION NOTE REFER TO FIGURE 8 BELOW FOR STEPS 1 7 1 Place Vent Damper on or as close to vent outlet of boiler as possible 2 Remove Locknut from connector at the free end of the Damper wire harness 3 Feed Damper connector and Damper wire harness through bracket hole on Damper Motor frame 4 Replace and tighten locknut onto Damper wire harness connector 5 Plug Damper connector into socket on Damper Motor frame INSTRUCTIONS LOCKNUT HARNESS INSTALLER CONN 7 HOOK UP CHIMNEY UN ACCEPTABLE VENT DAMPER LOCATION DAMPER REFER TO DAMPER MANUFACTURER S INSTALLATION INSTRUCTIONS FO DAMPER MOTOR INSTALLER HOOK UP ACCEPTABLE VENT DAMPER LOCATIONS PRESSURE SWITCH DAMPER_ WIRE 7 7 HARNESS T FACTORY WIRED HOT WATER HEATER RE 8 FIGURE 9 1 Ensure that only the boiler is serviced by the Vent Damper See figure 9 above 2 Clearance of not less than 6 inches b
36. should not extend beyond inside wall of chimney Do not install manual damper in flue pipe or reduce size of flue outlet except as provided by the latest revision of ANSI 2223 1 Protect combustible ceiling and walls near flue pipe with fireproof insulation Where two or more appliances vent into a common flue the area of the common flue must be at least equal to the area of the largest flue plus 50 percent of the areas of each additional flue INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA a BOILERS MANUAL INSTALLING OR VENTING A BOILER OR OTHER GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY RESULT SERIOUS INJURY OR DEATH OR RELIEF OPENING ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE FIGURE 7 PAGE 7 DRAFT HOOD VENT SYSTEM MODIFICATION When an existing boiler is removed from a common venting system the common venting system is likely to be too large for the proper venting of the appliances remained connected to it If this situation occurs the following test procedure must be followed 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 a
37. tal tube from gas control Depending on the model of the boiler pilot is mounted on the base or on one of the burner tubes 8 Turn gas control knob counterclockwise N to pilot 9 Push in gas control knob or reset button if so equipped all the way in and hold Immediately Light the pilot with a match Continue to hold the gas control knob or reset button for about one 1 minute after the pilot is lit Release knob or button and it will pop back up Pilot should remain lit If it goes out repeat steps 5 through 10 If knob or button does not pop up when released stop and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the gas control knob clockwise to off see note 1 above and call a service technician or gas supplier 10 Replace burner door and manifold cover figures 13 amp 15 on pages 14 amp 16 11 Turn gas control knob counterclockwise to FIGURE 12 TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the appliance if service is to be performed 3 Remove access panel if present 4 Turn gas control knob clockwise 7 to off See note 1 in the lighting instructions Do not force PAGE 13 NORMAL SEQUENCE OF OPERATION On a
38. w wares replaced Corrosion can build up rapidly at the valve seat and prevent its functioning as a safety device During the heating season the drain cock on the bottom rear of the boiler should be opened once a month to flush out the boiler so the device will be free to function properly Use a pail to catch the discharge DISCHARGE WILL BE BOILING HOT WATER If the water in a steam boiler appears to be dirty or oily or the water level in the gauge glass fluctuates considerably the boiler should be cleaned and skimmed See page 18 for instructions A competent service person will use approved cleaning compounds and properly clean and flush outthe boiler He she should also clean or replace air vents and traps clean flue passages and check for proper operation of all controls and safety devices The venting system should be inspected at the start of each heating season Check the vent pipe from the boiler to the chimney for signs of deterioration by rust or sagging joints Repair if necessary Remove the vent pipe at the base of the chimney or flue and using a mirror check for obstruction The boiler flue gas passageways may be inspected by a light and mirror Remove the burner access door figure 15 above Place a trouble lamp in the flue collector through the draft hood relief opening With the mirror positioned above the burners the flue gas passageways can be checked for soot or scale ESS
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