Utica Boilers MGB Series II/MGC Series Operation and Installation Manual
Contents
1. ZONE 4 __ O o ZONE 3 a USE FULL PORT ZONE Ok VALVE o ZONE 2 __ GH O O CIRCULATOR ax O ll O ZONE 1 PRIORITY ZONE WATER INLET DHW Mm CIRCULATOR HN KX BOILER EXPANSION 6 TANK J ah Figure 9 Multi Zone System With Zone Valves And DHW With Zone Valve ZONE 4 O P O p ZONE 3 OX O p ZONE 2 CH amp DHW OX O _ SYSTEM CIRCULATOR WATER INLET C1 0 0 K pad USE FULL PORT ZONE BOILER EXPANSION VALVE FOR OPTIMUM TANK TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR QO _ Q Jl 5 VENT INSTALLATION 3 Boiler series is classified as a Category I Vent installation shall be in accordance with Venting of Boiler and venting installations shall be performed Equipment of the National Fuel Gas Code ANSI by a qualified expert and in accordance with the Z223 1 NFPA 54 or applicable provisions of the local appropriate manual Installing or venting boiler building codes or other gas appliance with improper methods or 4 Inspect chimney Verify chimney is constructed materials may result in serious injury or death due according to NFPA 211 Vent or vent connector shall to fire or to asphyxiation from poisonous gases such be Type B or metal pipe having resistance to heat and as carbon monoxide with is odorless and invisible corrosion not less than that of galvanized sheet steel or aluminum not less than 0 016 inch thick No 28 Ga 5 Connec2. 4 Thermostat should be installed on inside wall about four feet above floor 5 NEVER install thermostat on outside wall 6 Do not install thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures televisions fireplace or chimney 7 Check thermostat operation by raising and lowering thermostat setting as required to start and stop burners 8 Instructions for final adjustment of thermostat are packaged with thermostat adjusting heating anticipator calibration etc 15 10 WIRING DIAGRAM Figure 13 Integrated High Limit Electronic Ignition Control 240008781 Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life SPARK FLAME IGNITER SENSE Q GAS JOG ressesie e e QO OH LIMIT SWITCH 7 a 0 Q OU a E G m 0 8 S M gm m A008800 E i a o O ae D He kais o io SE 0 Ao me ad 000 HEE era JO A omega oa f E H j Ee H f E A OPTIONAL DEPENDING ON CONFIGURATION Inducer is not an option 16 10 WIRING DIAGRAM Figure 14 Integrated High Limit Electronic Ignition Control 240008781 CH PUMP DAMPER BLUE 5 Z GAS VALVE O RED g f amp FLUE SENSOR D ROLLOUT SENSOR Ioe CHT T TEMP SENSOR 115V 24V SOVA PILOT FLAME SENSE 17 10 WIRING DIAGRAM Figure 15 Integrated High Limit Ele
3. UTICA MGB SERIES II BOILERS CAST IRON GAS FIRED BOILERS Models FOR FORCED HOT WATER MGB 75J MGB 100J INSTALLATION OPERATION MGB 125J amp MAINTENANCE MANUAL MGB 150J MGB 170J MGB 200J ots 67 f ERTIES ie oe For Natural Gas Tested For 100 psi ASME Working Pressure Manufactured by ECR International Inc Gi e C r 2201 Dwyer Avenue Utica NY 13501 Ww web site www ecrinternational com An 150 9001 2008 Certified Company P N 240009005 Rev H 10 2014 DIMENSIONS Figure 1 Dimensions A 114 Supply 3y L 52 wu Ww gt D ri ml Mae urg Gas A B D 50 75 x Propane gas inlet all units 1 2 C is minimum height for low water cutoff installation 27 TABLE OF CONTENTS 1 Ratings amp Data Natural Gas amp Propane Gas 4 2 Installation Procedure ss sasae anaa aana naa 5 3 Ventilation amp Combustion Air sssss sae aeeaene 6 4 Connecting Supply and Return Piping 7 5 Vent TNS LANGUION sasasi aaa kaa KANE aa EA A AA a a 12 6 Vent System Modification ssssssssrersrrsrsrrerss 12 7 Vent Damper Installation amp Instructions 13 6 C nn cting Gas SCC Gace chic ote demas aa aga aaa 14 9 Electrical SECON asasaji scene ag a aaa a kaanan agi 15 10 WIfihg Diagraifi 2csscocssectetseccegsceesssecetsceene nia 16 11 Lighting Instructions ss sasare aaa
4. Use IS 808 GE Boiler flue gas passageways may be inspected by a light silicone available from distributor to seal around flue and mirror Remove burner door Figure 17 Place trouble collector and boiler castings lamp in flue collector through draft relief opening With mirror positioned above burners flue gas passageways can be checked for soot or scale 20 13 GENERAL INSTRUCTIONS Figure 18 Gas Burner Flame LIGHT BLUE OUTER MANTEL INNER BLUE MANTEL BURNERS lt N N D S EN p LK GAS VALVE ORIFICES Figure 20 Gas Burner Pilot PROPER FLAME ADJUSTMENT 3 8 TO 1 2 INCH 9 5 TO 12 7 MILLIMETRE INSULATED ELECTRODE 2al e Make visual inspection of main burner and pilot flames at start of heating season and again in mid season Main burner flame should have well defined inner blue mantel with lighter blue outer mantel Check burner throats and burner orifices for lint or dust obstruction Figures 18 and 19 Pilot flame should envelop 38 to 12 inch of tip of ignition sensing electrode See Figure 20 To adjust pilot flame remove pilot adjustment cover screw and turn inner adjustment screw counterclockwise to increase or clockwise to decrease pilot flame Be sure to replace cover screw after adjustment to prevent possible gas leakage See Figure 16 Page 19 Check burners and pilot for signs of corrosion rust or scale buildup Area around boiler must be kept c
5. 4 Bypass Piping With Mixing Valve FROM SYSTEM TO SYSTEM lt WATER INLET EXPANSION TANK ALTERNATE CIRCULATOR LOCATION BOILER PRESSURE BALL VALVE AIR SEPARATOR D eens REDUCER VALVE O SHUT OFF K 3 WAY MIXING H a AANE TIN CHECK VALVE te HOSE BIB Figure 5 Bypass Piping Fixed Low Temp Only With Zone Valve E FROM SYSTEM __ _ _ TO SYSTEM a SYSTEM CIRCULATOR EXPANSION ALTERNATE TANK BOILER CIRCULATOR LOCATION 4 PRESSURE BALL VALVE AIR SEPARATOR D EA REDUCER VALVE O SHUT OFF Sx ZONE VALVE Be waive PQ CHECK VALVE 8 Installation using circulators and zone valves are shown in Figures 6 through 9 For further piping information refer to AHRI Installation and Piping Guide Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions 9 Install discharge piping from safety relief valve See Warning Page 7 4 CONNECTING SUPPLY AND RETURN PIPING Figure 6 Single Zone System With DHW CH CIRCULATOR WATER INLET EXPANSION po TANK DHW V CIRCULATOR BOILER PRIORITY ZONE ag Figure 7 Multi Zone System With Circulators And DHW ZONE 4 WATER INLET DHW CIRCULATOR m Q DH kK EXPANSION TANK BOILER 10 4 CONNECTING SUPPLY AND RETURN PIPING Figure 8 Multi Zone System With Zone Valves And DHW With Circulator
6. minimum volume not available o Standard Method Cannot be used if known air infiltration rate is less than 0 40 air changes per hour See Table 3 for space with boiler only Use equation for multiple appliances Volume 50 ft x Total Input Mbh o Known Air Infiltration Rate See Table 3 for space with boiler only Use equation for multiple appliances Do not use an air infiltration rate ACH greater than 0 60 Volume 21 ft ACH x Total Input Mbh o Refer to National Fuel Gas Code for opening requirements between connection indoor spaces e All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors o Two Permanent Opening Method Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure Direct communication with outdoors or communicating through vertical ducts Provide minimum free area of 1 in per 4 Mbh of total input rating of all appliances in enclosure Communicating through horizontal ducts Provide minimum free area of 1 in per 2 Mbh of total input rating of all appliances in enclosure o One Permanent Opening Method Provide opening commencing within 12 inches of top of enclosure Provide minimum clearance of 1 inch on sides and back and 6 inches on front of boiler does not supersede clearance to combustible materials Refer to National Fuel Gas Code for additional requirements for louvers grilles s
7. must be D These methods are used 10 DEDI EL 2 E T radiant panels and material they are encased in PING ION Maker Curso WE l l from high temperature supply water from boiler 4 Boiler connected to heating system utilizing multiple and protect boiler from condensation zoned circulators each circulator must be supplied with flow control valve to prevent gravity circulation 5 Hot water boilers and system must be filled with water and maintained to minimum pressure of 12 psi 6 For Low Water Cutoff see Figure 1 for minimum height NOTE 2 Bypass loop must be same size piping Use Kit 240010831 Follow instruction enclosed with as supply and return piping the kit Other LWCO s for their manufacture specific instructions 1 Boiler used in connection with refrigeration system install so chilled medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler See Figure 2 2 Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 3 Hot water boilers installed above radiation level or NOTE 1 When using bypass piping adjust valves Vi amp V2 until desired system temperature is obtained See Figure 5 page 9 4 CONNECTING SUPPLY AND RETURN PIPING Figure
8. 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 Figure 16 Intermittent Pilot GAS INLET INLET PRESSURE TAP PRESSURE REGULATOR ADIUSTMENT BENEATH COVER SCREW GAS CONTROL KNOB PILOT FLOW ADJ SCREW BENEATH COVER SCREW OUTLET PRESSURE TAP GAS OUTLET Turn gas control knob clockwise to OFF Wait 5 minutes to clear out any gas If you then smell gas STOP Follow What To Do If You Smell Gas in the Safety information to the left If you don t smell gas go on to the next step 7 Turn gas control knob counterclockwise to ON 8 Turn on all electric power to the appliance 9 Set thermostat to desired setting 10 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call qualified service technician or your gas supplier TO TURN OFF GAS TO THE APPLIANCE 1 Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Push in gas control knob slightly and turn clockwise to OFF DO NOT FORCE Call qualified service technician 12 NORMAL SEQUENCE OF OPERATION Thermostat actuates on call for heat Figure 17 Blocked Vent Safety Switch Roll out completing circuit to control Completed Safety Switch circuit to control will first activate circulator and damper which w
9. to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements Figure 2 Safety Relief Valve RELIEF VALVE OL DISCHARGE gt LINE Check local codes for maximum distance from floor or allowable safe point of discharge ba BOILER 4 CONNECTING SUPPLY AND RETURN PIPING Circulators in following illustrations are mounted on system supply side mounting on system return side is also acceptable practice Figure 3 Circulators Mounted on Supply System Boiler Used In Configuration with Chiller System See Special Conditions Page 9 AIR 5 SEPARATOR GATE 4 VALVE TO HEATING pn A A AND COOLING V 2 Iba ELEMENT CIRCULATOR o i A BACKFLOW NA FEED PROTECTION EXPANSION WATER DEVICE TANK PRESSURE REDUCING lt lt VALVE CHECK VALVE RETURN PIPING a AND COOLING aia ELEMENT PURGE VALVE 7 Bypass piping is optional which gives ability to adjust supply boiler water temperature to fit system or condition of installation This method of piping however is not typically required for baseboard heating systems Typical installations where bypass piping is used are as follows A This method is used to protect boilers from condensation forming due to low temperature return water Generally noticed in large converted gravity systems or other large water volume systems Figures 4 and 5 as required by authority having jurisdiction
10. GGED PILOT FILTER LOW GAS SUPPLY PRESSURE PILOT ADJUSTMENT AT MINIMUM thermal purge until boiler water temperature is below 140 F 60 C e Watch pilot burner during ignition sequence Verify ignition spark continues after pilot is lit Verify pilot lights and spark stops verify main LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM burner does not light DIRTY ORIFICE e If so ensure adequate flame current as follows DIRTY LINT SCREEN IF USED i DIRTY PRIMARY AIR OPENING Turn off boiler at circuit breaker or fuse box IF THERE IS ONE Clean flame rod with emery cloth JM oa PILOT ADJUSTMENT AT MINIMUM Verify electrical connections are clean and tight Replace damaged wire WAVING BOUE FLAME CHECK FOR PD EXCESSIVE DRAFT AT PILOT Check for cracked ceramic insulator which can 1 LOCATION cause short to ground and replace igniter sensor if wig RECIRCULATING PRODUCTS OF COMBUSTION necessary At gas valve disconnect main valve wire from MV a terminal Turn on power and set thermostat to call for heat Pilot NOISY LIFTING CHECK FOR should light main burner will remain off because main BLOWING FLAME e HIGH GAS PRESSURE valve actuator is disconnected Check pilot flame Verify it is blue steady and envelops 3 8 to 1 2 in 10 to 13 mm of flame rod See Figure 24 for possible flame problems and causes E If necessary adjust pilot flame
11. ak Check Gas Piping Pressure test boiler and gas connection before placing Sediment Trap boiler in operation TO GAS CONTROL INLET MAXIMUM CAPACITY OF PIPE IN CUBIC FEET OF GAS HOUR Gas Pressure 0 5 psig or less Pressure Drop 5 in W C Table 4 Length of Nominal Iron Pipe Size Pipe Feet 577 For additional information refer to the National Fuel Gas Code Handbook 14 e Pressure test over 1 2 psig 3 5 kPa Disconnect boiler and its individual gas shutoff valve from gas Supply system e Pressure test at 1 2 psig 3 5 kPa or less Isolate boiler from gas supply system by closing manual gas shutoff valve e Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition source e Correct leaks immediately and retest 9 ELECTRICAL SECTION Electrical shock hazard Turn OFF electrical power Supply at service panel before making electrical connections Failure to do so could result in death or serious injury ELECTRICAL WIRING 1 See wiring diagrams on the following two pages for details 2 Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to National Electrical Code ANSI NFPA 70 3 LWCO kit 550002998 includes wiring instructions and wiring diagrams THERMOSTAT INSTALLATION
12. anana 19 12 Normal Sequence of Operation 41544 20 13 General InstructionS s ssssssssssrsrrsrsresrsresnns 20 14 Checking Gas Input Rate To Boiler 22 Appendix A Control Module ccccseessnenreeseeens 23 Safety Symbols amp Warnings The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels A DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Used to address practices not related to personal injury KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE IMPORTANT Read the following instructions COMPLETELY before installing 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 Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids DO NOT obstruct air openings to the boiler room Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life TO THE OWNER Installation
13. and service of this boiler must be performed by a qualified installer TO THE INSTALLER Leave all instructions with boiler for future reference When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter 1 RATINGS amp DATA NATURAL GAS amp PROPANE GAS A LIDI o maf CERTIFIED Table 2 Ratings and Capacities www ahridirectory org 2 3 1 1 Net AHRI Recommended Water Boiler Input Heating Rating Water Air Cushion Content Capacity Mbh Mbh EXPLANATORY NOTES All boilers are design certified for installation on noncombustible floor For installation on combustible floors use combustible floor kit Recommended chimney height 20 feet In special cases where conditions permit chimney height may be reduced to 10 feet Refer to the latest revision of NFGC part 11 Electric service to be 120 Volts 15 Amps 60 Hz The MEA number for the this boiler is 19 79 E 1 Input rating for sea level to 2 000 ft 610m above sea level United States over 2000 ft 610m above sea level Reduce input rate 4 for every 1000 ft 304m above sea level 2 Net AHRI Water Ratings shown based on piping and pickup allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc For forced hot wat
14. by turning pilot HARD SHARP FLAME THIS FLAME IS CHARACTERISTIC adjustment screw on gas control clockwise to decrease OF MANUFACTURED GAS or counterclockwise to increase pilot flame Following CHECK FOR adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Figure 16 page 19 Set temperature below room set point to end call for heat HIGH GAS PRESSURE ORIFICE TOO SMALL Correct Pilot Flame 3 8 to 1 2 inch in flame See Figure 20 Page 21 27 IMPORTANT In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the Same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil UTICA BOILERS UTICA 2201 Dwyer Avenue BOILERS TT Utica NY 13501 web site www ecrinternational com
15. creens and air ducts Combination Indoor and Outdoor Air Refer to National Fuel Gas Code for application information Table 3 Space With Boiler Only Standard Method Room Cubic Feet Volume Known Air Infiltration Rate Method ACH Air Changes Per Hour 2500 10500 5250 3500 2625 2100 1750 2625 3500 4375 4 CONNECTING SUPPLY AND RETURN PIPING Burn or Scald Hazard Discharge line shall be installed to relief valve outlet connection to avoid burns scalding or water damage due to discharge of steam and or hot water during operation Discharge line shall e connect to relief valve outlet and piped down to safe point of disposal Check local codes for maximum distance from floor or allowable safe point of discharge e be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line e have no intervening shutoff valve between safety relief valve and discharge to atmosphere do not plug or place any obstruction in discharge line e terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing e allow complete drainage of the valve and the discharge line e be independently supported and securely anchored to avoid applied stress on the relief valve e be as short and straight as possible e terminate with plain end not threaded e be constructed of material suitable for exposure to temperatures of 375 F 191 C or greater Refer
16. ctronic Ignition Control 240008781 gt ka O a O UU U O O 5 D A O O 5 J T ka T O O D O Yd TIVLSNI SHL Ad JDVIIOAMO1 TL 4YATIVLSNI JHL AZJOVHIOAINN FP AYOLDV4 JHL Ad JDVLIOA MOT AYOLDW4 JHL wo u Ag IDYVITOA IN 1 nn NGO LHM Z DNIYIM a gt WY J C D c O lal O O D D E O D Q Un E O 2 a Q 3 Un oO D Q 2 o D D os O 0 V 2 i O gt gt h Cc O WY ra sD Q Un e9 C YOLWINDUID Mma did IHM ml DOG O Q OOG DOO C BEH VL9OE6S VY O m OL U ZH09 AOC XO8 NOLLINNL KINO SYOLONGNOD YaddOd ISN Lg a Pee 7 3009 W301 ANY 939 DIN HLIM JINYGYOIJIY NI SNOILOJNNOO MJI V AOZT HOLMS TIIS O gt 7 COO L YOSNAS yadwva Hums JS awal INJA INOTIOY ISTI 1011d YIWYOJSNYUL gt lt 18 11 LIGHTING INSTRUCTIONS If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life e This appliance is equipped with an ignition device which automatically lights burner Do NOT try to light this burner by hand e Before operating smell all around appliance area for gas Be sure to smell next to floor because some gas is heavier than air and will settle to the floor Use only your hand to turn th
17. d module and gas control e Do not use corrosive chemicals around or on module or gas control e Controls can be damaged by excessively high temperatures Verify adequate air circulation around control is maintained when installing boiler A 2 Electrical Connections Connect Module Connectors Figure 13 Page 16 e Connect L1 amp L2 leads inside J box using wire nuts Secure J box cover e Connect Circulator harness to circulator Harness comes plugged into module with Molex plug e Connect thermostat connection to yellow wires marked TT using wire nuts e Ensure remaining Molex plug connectors have not worked loose during transit e Check sensing bulb is fully inserted in well and is not loose A 3 Adjusting Settings To discourage unauthorized changing of settings procedure to enter adjustment mode is required To enter adjustment mode press UP DOWN and I buttons simultaneously for three seconds Press and release I button until parameter requiring adjustment is displayed See Figure 12 page 16 o SP_ Setpoint 180 F default setting adjustable between 130 and 220 F Note on some models this is HL High Limit o Df Setpoint Differential 15 F default setting adjustable between 10 and 30 F 0 NO F Press UP or DOWN button until parameter has reached desired value After 60 seconds without any button inputs control automatically returns to READ mode Degrees Fahrenheit A 4 Disp
18. e gas shutoff valve Never use tools If valve will not turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in fire or explosion e Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water ok whe Before lighting any type of pilot burner standing or intermittent verify the hot water boiler and system are full of water to minimum pressure of 12 psi in the system also verify system is vented of air Set operating control of thermostat to below normal setting Refer to following appropriate lighting instruction LIGHTING PROCEDURE FOR BOILER WITH INTERMITTENT PILOT SYSTEM A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the appliance by hand WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switches do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department 19 OPERATING INSTRUCTIONS FOR INTERMITTENT PILOT SYSTEM 1 STOPI Read the safety information to the left 2 Setthe thermostat to lowest setting 3 Turn off all electric
19. er systems where boiler and all piping within area to be heated boiler may be selected on basis of its heating capacity 3 Tank sized for non ferrous baseboard or radiant panel systems Increase size for cast iron baseboard and radiation STANDARD EQUIPMENT Boiler Jacket Cast Iron Boiler Battery High Limit Control Intermittent Electric Ignition Pilot System Vent Damper Relay Theraltimeter Gauge Circulator With Return Piping To Boiler Main Gas Burners Gas Control Includes Automatic Gas Valve Gas Pressure Regulator Intermittent Pilot Safety Shutoff Pilot Flow Adjustment Pilot Filter A S M E Relief Valve Drain Valve Spill Switch Rollout Switch Combination Gas Control Automatic Vent Damper Not Shown Are Wiring Harness Thermocouple Non linting Safety Pilot 2 INSTALLATION PROCEDURE Improper installation adjustment alteration service Fire hazard Do not install boiler on combustible Or maintenance could result in death or serious flooring or carpeting Failure to follow these injury instructions could result in death or serious injury 9 FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY For installation on combustible flooring special base must be used See Repair Parts Optional Kits Manual Do not install boiler on carpeting Minimum clearances to combustible construction are 1 Installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to t
20. he National Fuel Gas Code ANSI Z223 1 NFPA 54 2 Where required by the authority having jurisdiction the installation must conform to the Standard for Controls TOP ns aseueantueasetapeceadaceatawencts 18 IN 457mm and Safety Devices for Automatically fired Boilers CONLE ALCOVE ANSI ASME CSD 1 FLUE CONNECTOR nossos 6 IN 152mm 3 Boiler series is classified as a Category I Vent REAR Na AN EEA I NE 4 IN 102mm installation shall be in accordance with Venting of CONTROL SIDE ceeeeeeeeeee 9 IN 229mm Equipment of the National Fuel Gas Code ANSI OTHER SIDE sanisgewtenieuceeensrnaas 3 IN 76mm Z223 1 NFPA 54 or applicable provisions of the local HOT WATER PIPING Per Local Code building codes 4 Boiler has met safe lighting and other performance NOTE Greater clearances for access should supersede fire criteria with the gas manifold and control assembly on protection clearances the boiler per the latest revision of ANSI Z21 13 CGA Definition of Alcove is three sided space with no wall in 4 9 front of boiler ANSI standard for alcove is 18 inches from 5 Install boiler such that gas ignition system components front of appliance to leading edge of side walls as shown are protected from water dripping spraying rain below etc during appliance operation and service circulator replacement condensate trap control replacement etc 6 Locate boiler on level solid base as near chimney as pos
21. ided in Table 6 page 26 for servicing these potential errors Error Code Number 4 6 18 23 32 Js 56 57 58 59 60 61 62 63 64 65 APPENDIX A CONTROL MODULE Table 7 Troubleshooting Error Codes Definition Flame current too low Check for flame Flame sensed out of normal sequence before opening or after closing gas valve Gas valve relays welded Five consecutive soft lockouts Flame sensed during prepurge before gas valve signaled opened Sensor 1 error Temperature sensor in well is not reading correctly Verify it is connected to board Replace if necessary Atmospheric damper end switch failed to close end switch contacts stuck open Atmospheric damper end switch failed to open end switch contacts stuck close Igniter flame rod shorted to burner ground Igniter flame rod shorted to burner ground Repair or replace igniter Line Voltage error voltage out of specification high or low 15 37V 44 66Hz Applies only to thermostats having on board transformer Polarity is wrong in this case Thermostat input higher than threshold Line voltage unstable possibly too may heavy loads switching on and off causing erratic supply voltage Soft lockout maximum number of retries exceeded Soft lockout is reset after one hour if alarm reason disappears Soft lockout maximum number of recycles exceeded Soft Lockout electronics failure On board self diagnostics detected error Over tem
22. idence of exposure to extreme heat which can permit leakage to ground Replace pilot burner igniter sensor and provide shield if necessary If flame rod or bracket is bent out of position restore to correct position 26 APPENDIX A CONTROL MODULE STEP 3 Check spark ignition circuit e Recheck ignition sequence as follows Disconnect ignition cable at SPARK terminal on module Reconnect main valve wire Adjust thermostat above room temperature Electrical shock hazard Ignition circuit generates Verify ignition sequence at burner over 10 000 volts Turn OFF electrical power If spark does not stop after pilot lights replace supply at service panel before making electrical module connections Failure to do so could result in death If main burner does not light or if main burner lights or serious injury and system locks out check module ground wire and gas control as described in troubleshooting table See Table 6 Page 24 Energize module and listen for audible sparking noise When operating normally there should be a buzzing noise that turns on and off twice per second for duration of 1 7 seconds depending on model Figure 24 Troubleshooting Pilot Flame STEP 4 Verify pilot and main burner lightoff APPEARANCE CAUSE e Initiate call for heat Turn thermostat above room SMALL BLUE FLAME CHECK FOR LACK OF GAS FROM temperature Ignition sequence may be delayed by e CLOGGED ORIFICE FILTER CLO
23. ill close end switch inside damper Completes circuit to ignition system ignition takes place Intergral Draft Hood Y is Blocked Vent Safety Switch In event boiler water temperature exceeds high limit setting on boiler mounted high limit control power is interrupted between control system and ignition system Power remains off until boiler water temperature drops below high limit setting Circulator continues to operate under this condition until thermostat is Satisfied Burner Door lt l srati Sy V Burners In event flow of combustion products through boiler venting system becomes blocked blocked vent safety switch shuts main burner gas off Similarly if boiler flue way becomes blocked flame rollout safety switch shuts main burner gas off Figure 16 If either of these conditions occur DO NOT ATTEMPT TO PLACE BOILER BACK INTO OPERATION CONTACT CERTIFIED SERVICE AGENCY Rollout Switch 4 Section Boiler zaidi ar Base Rollout Switch 239 Jacket Base Section Boiler Panel Orifices VY 13 GENERAL INSTRUCTIONS Before seasonal start up have a certified service agency check boiler for soot and scale in flues clean burners and check gas input rate to maintain high operating efficiency This procedure should be followed to clean flue gas passageways Remove burners from combustion chamber by raising burners up from manifold orifices and pulling toward Label all wires prio
24. lay In RUN mode status items and parameters are viewable Example to display setpoint control flashs sp setpoint followed by temperature i e 135 followed by F or C To read settings press and release I key to find parameter of interest Example press and release I until setpoint sp is displayed followed by three digit number i e 190 followed by F or C Press I button again will display S1T Sensor 1 Temperature followed by three digit number and corresponding degree designator See Display Readout Figure 22 Display Readout Display Shows SER 9 Ik 9P dF F hr Text Description sta Current State sit Sensor 1 Temperature sp Setpoint df Setpoint Differential hr Heat Request Status err Error Code Err fla Flame Current F L H F Degrees Fahrenheit OF 6 Degrees Celsius Of uh uA Micro Amps 23 A 5 Operation APPENDIX A CONTROL MODULE 2 Control determines burner operation is required Module continuously monitors boiler water temperature and module proceeds to start burner see state codes list fires or shuts off burner based on this temperature data and heats water in boiler until setpoint temperature is 4 R achieved or thermostat is satisfied 1 When Call for Heat occurs control enables circulator l TT and monitors boiler water temperature to determine Burner is de activated ignition module completes whether thermostat can be satisfied without firing heating c
25. lear and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler room must not be restricted or blocked Inspect field sourced low water cutoffs annually or as recommended by low water cutoff manufacturer Flush float type low water cutoffs per manufacturer s instructions Employ a qualified service agency to make annual inspection of boiler and heating system They are experienced in making the inspections outlined above and in event repairs or corrections are necessary trained technicians make the proper changes for safe operation of the boiler 14 CHECKING GAS INPUT RATE TO BOILER e Adjust gas input to boiler by removing protective cap on Figure 21 High Limit Control Location pressure regulator and turning screw clockwise N to increase input and counterclockwise yN to decrease i High Limit and input Operating Control e Manifold pressures are taken at outlet side of gas valve e To check for proper flow of natural gas to boiler divide input rate shown on rating plate by heating value of gas obtained from local gas company This determines number of cubic feet of gas required per hour e With all other gas appliances off determine flow of gas through meter for two minutes and multiply by 30 to get hourly rate Burner Access e Make minor adjustments to gas input as described Door above See Figure 16 page 18 e Cha
26. nge burner orifices if final manifold pressure varies more than plus or minus 0 3 inches water column from specified pressure listed on boiler rating plate e Primary air adjustment is not necessary therefore ia a air shutters are not furnished as standard as Valve equipment CHECK SAFETY CONTROL CIRCUIT Test ignition system safety shutoff device after placing boiler in operation Figure 15 page 19 1 Intermittent Pilot With main burner operating turn pilot gas adjusting screw clockwise f N enti pilot gas is turned off Within 90 seconds main gas control closes shutting off gas to main burner 2 High Limit Control Remove plastic cover and note temperature setting Refer to appendix A for adjustment procedure Decrease setting to minimum and operate boiler When boiler water temperature exceeds control temperature setting control will open circuit closing automatic main gas valve Figure 21 22 APPENDIX A CONTROL MODULE A 1 Installation Environment Considerations If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life e Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water e Do not allow water to drip on controls Prevent condensation by allowing air circulation aroun
27. not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions e If you cannot reach your gas supplier call the fire department Figure 12 Gas Piping INSTALL MANUAL VALVE WITHIN 6 ft 183cm OF General e Use piping materials and joining methods acceptable to authority having jurisdiction In absence of such requirements National Fuel gas Code ANSI Z223 1 NFPA 54 e Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure See Table 4 e Support piping with hooks straps bands brackets hangers or building structure components to prevent or dampen excessive vibrations and prevent strain on gas connection Boiler will not support piping weight e Use thread joint compound pipe dope suitable for liquefied petroleum gas e Install field sourced manual main shutoff valve ground joint union and sediment trap upstream of gas valve See Figure 12 Table 5 Natural Gas Min Supply Pressure THE BOILER AND saik LA 2En Max Supply Pressure Pee seni ey WHERE REQUIRED BY LOCAL CODES Ah DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury 3 8 cm Minimum Le
28. per to open Wait for damper to close Wait for damper to open Failed close Wait for damper to close Failed open sent OR Flame signal present when not expected Appropriate alarm is sent Pilot valve circuitry diagnostics during pre purge Self check performed at start up again at beginning of heat cycle and during Wait for Recovery State Self check performed at start up again at beginning of heat cycle and during Wait for Recovery State Control has signaled damper pressure switch to close and is waiting for completion If damper pressure switch does not close within 60 seconds control goes to State 20 Damper is closed and control waits for damper to open Checked at beginning of heat cycle before opening damper If damper does not open in 60 seconds control goes to State 21 Damper has not opened end swich not closed at beginning of heat cycle Alarm message is sent control is NOT in lockout Damper has not closed despite actuator de energized Alarm message is sent control is NOT in lockout 24 APPENDIX A CONTROL MODULE A 6 Boiler High Limit Temperature Controller e When water temperature reaches setpoint controller ends heating cycle e When water temperature drops below setpoint minus differential controller restarts heat cycle to re heat boiler water e If water temperature exceeds maximum allowed temperature 220 F or 104 C controller enters manual reset lockout sta
29. perature error Sensor measured temperature in excess of maximum allowable limit Note Soft lockout time is 1 hour or manual reset Hard lockout requires manual reset A 9 Intermittent Pilot Ignition System Checks STEP 1 Check ignition cable e Verify ignition cable does not make contact with metal Surfaces e Verify only factory supplied Ignition cable or approved replacement is used e Verify connections to ignition module and igniter or igniter sensor are clean and tight e Verify ignition cable provides good electrical continuity STEP 2 Consequence Non critical alarm Soft lockout Hard lockout Soft lockout Wait for recovery Wait for recovery Wait for recovery Wait for recovery Wait for recovery Wait for recovery Wait for recovery Wait for recovery Soft lockout Soft lockout Soft lockout Soft lockout Verify ignition system grounding Nuisance shutdowns are often caused by poor or erratic grounding igniter sensor Common ground is required for module and pilot burner Check for good metal to metal contact between pilot burner bracket and the main burner minimum rating Check ground lead from GND BURNER terminal on module to pilot burner Verify connections are clean and tight If wire is damaged or deteriorated replace with No 14 18 gauge moisture resistant thermoplastic insulated wire with 105 C 221 F Check ceramic flame rod insulator for cracks or ev
30. r to disconnection when servicing front of boiler Figure 19 controls Wiring errors could cause improper and 2 Disconnect vent pipe from draft hood dangerous operation 3 Remove top jacket panel Verify proper operation after servicing 4 Remove combination flue collector and draft hood from Service agency will verify system is filled with water to boiler castings by loosening nuts on hold down bolts minimum pressure and open air vents if used to expel any located on each side of collector Figure 17 air accumulated in the system Check entire piping system 5 Place sheet of heavy paper or similar material over and if any leaks appear have them repaired bottom of base and brush down flue passageways Soot Circulators need to be checked and maintained and scale will collect on paper and is easily removed Refer to circulator manufacturer s instructions with the paper Inspect venting system at the start of each heating 6 With paper still in place in base clean top of boiler season Check vent pipe from boiler to chimney for signs of castings of boiler putty or silicone used to seal between deterioration by rust or sagging joints Repair if necessary castings and flue collector Verify chips are not lodged Remove vent pipe at base of chimney or flue and using a in flue passageways mirror check vent for obstruction and verify vent isin good When cleaning process is complete restore boiler working order components to their original position
31. ration Use the flame of At the time of removal of an existing boiler the following a match or candle or smoke from a cigarette cigar or steps shall be followed with each appliance remaining ae connected to the common venting system placed in 6 After it has been determined that each appliance operation while the other appliances remaining connected remaining connected to a common venting system to the common venting system are not in operation properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel gas Code ANSI Z223 1 NFPA 54 When re sizing any portion of the common venting 1 Seal an unused opening in the common venting system 2 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 3 Insofar as is practical close all building doors and system the common venting system should be re sized windows and all doors between the space in which the to approach the minimum size determined using the appliances remaining connected to the common venting appropriate tables in Chapter 13 of the National Fuel system are located and other spaces of the b
32. sible and centrally located with respect to heat distribution system as practical 7 Allow 24 inches 610mm at front and right side for Minimum Clearances to Combustible servicing and cleaning Construction as seen from above 8 When installed in utility room door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater BOILER Front 3 VENTILATION amp COMBUSTION AIR Provide combustion air and ventilation air in accordance with the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable provisions of local building codes Provide make up air where exhaust fans clothes dryers and kitchen ventilation equipment interfere with proper operation National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air Requirements of the authority having jurisdiction may override these methods e Engineered Installations Must be approved by authority having jurisdictions Mechanical Air Supply Provide minimum of 0 35 cfm per Mbh for all appliances located within space Additional requirements where exhaust fans installed Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating All Indoor Air Calculate minimum volume for all appliances in space Use a different method if
33. t flue pipe from draft hood to chimney Bolt or screw joints together to avoid sags Flue pipe should not extend beyond inside wall of chimney Do not Do not connect boiler to any portion of mechanical insta manual damper in flue pipe or reduce size of draft svstem operatina under positive pressure ue outlet except as provided by the latest revision o y P J E P ANSI 2223 13 Protect combustible ceiling and walls near flue pipe with fireproof insulation Where two or 1 Vent pipe must slope upward from the boiler not more appliances vent into a common flue the area of less then inch for every 1 foot 21mm m to vent the common flue must be at least equal to the area terminal of the largest flue plus 50 percent of the area of each 2 Horizontal portions of venting system shall be additional flue supported rigidly every 5 feet and at the elbows No portion of vent pipe should have any dips or sags 6 VENT SYSTEM MODIFICATION When an existing boiler is removed from a common venting system the system is likely to be too large for the 4 Place in operation the appliance being inspected Follow proper venting of the appliances sill connected to it If the lighting instructions Adjust thermostat so appliance this situation occurs the following test procedure must be WIL Operate on Unueusly followed 5 Test for spillage at the draft hood relief opening after REMOVAL OF BOILER FROM VENTING SYSTEM 5 minutes of main burner ope
34. te e For models having reset capability press any onboard button or cycle power to reset Figure 23 Basic Control Algorithm Example 200 F 93 3 C 15 F 8 C DIFFERENTIAL 70 F 21 C SETPOINT GAS VALVE OFF GAS VALVE ON 25 A 7 Troubleshooting e Following service procedures are provided as general guide e On lockout and retry models meter readings between gas control and ignition module must be taken within trial for ignition period Once ignition module shuts off lockout models must be reset through key buttons and display On retry models wait for retry or reset at thermostat Check for correct installation and wiring before replacing any component Control module cannot be repaired If it malfunctions it must be replaced Use only qualified service agent to service ignition systems 1 Perform checkout as first step in troubleshooting Check troubleshooting guide to pinpoint cause of problem See Table 6 page 26 2 If troubleshooting indicates ignition problem see Ignition System Checks to isolate and correct the problem 3 Perform checkout procedure following troubleshooting guide again to verify system is operating normally A 8 Troubleshooting Error Codes Integrated boiler control uses advanced diagnostic capability to assist in troubleshooting error conditions Table 5 shows codes that could arise on integrated display during fault Suggestions are prov
35. uilding Gas Code ANSI Z223 1 NFPA 54 Turn on clothes dryers and any other appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 12 7 VENT DAMPER INSTALLATION amp INSTRUCTIONS DAMPER INSTALLATION Follow Damper installation instructions provided with damper See Figure 10 Figure 10 Damper Motor Wiring Damper Motor Damper Wire Haness Vent Damper Vent Outlet Limit Control 13 DAMPER INSTRUCTIONS Figure 11 Vent Damper Placement UN ACCEPTABLE DAMPER LOCATIONS REFER TO DAMPER MANUFACTURER S INSTALLATION INSTRUCTIONS FOR POSITION OF DAMPER CONTROL BOX ACCEPTABLE VENT DAMPER LOCATIONS S N i Verify only boiler is serviced by Vent Damper Figure 11 Clearance of not less than 6 inches 152mm between Vent Damper and combustible material must be maintained Additional clearance should be allowed for service of Vent Damper Vent Damper must be in the open position when appliance main burners are operating Vent Damper position indicator must be in visible location following installation Thermostat s heat anticipator must be adjusted to match total current draw of all controls associated with boiler during heating cycle HOT WATER HEATER 8 CONNECTING GAS SERVICE WHAT TO DO IF YOU SMELL GAS e Do
36. ycle returns to idle and waits for temperature burners to drop again 4 Circulator is turned on throughout Call for Heat Table 6 Operation State Codes State Code Definition Explanation Number Idle Standby no call for heat 1 Circulator Heat request present Boiler temperature sufficiently high to run circulator pump only 4 Pre purge System is purging before ignition trial includes Pilot Valve circuit diagnostics 6 Spark System sparking Flame is not present up to 13 seconds eT Flame signal is being established Variation in signal is allowed during this state 7 Flame stabilization flame must be stable at end of period 8 Running System is running Flame signal must be present 9 Post Purge System is purging at end of call for heat Successful ignition was not detected and delay is called before retry 10 Retry Recycle Delay Flame signal was lost during state 7 or 8 and delay is called before retry 32 second delay 13 Soft lock out Soft lockout duration is one hour may override with manual reset 14 Hard lock out Manual reset is required for hard lockout 15 Wait for limit to close Possible thermostat call for heat limit switch is open Flame signal sensed before trial for ignition Appropriate alarm is sent OR 16 Flame out of sequence Flame signal sensed out of sequence during post purge Appropriate alarm is 17 18 19 20 21 Pilot valve diagnostics Current leakage detection Wait for recovery Wait for dam
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