Utica Boilers JE Operation and Installation Manual
Contents
1. C S BLU TO ADDITIONAL BOILER 5 lt 52 HONEYWELL ROBERTSHAW EWF 24 V COPTIONAL gt VR8300M 7000 DERHC GAS VALVE GAS VALVE WIRING WIRING WIRING SCHEMATIC GND LEGEND HIGH VOLT POWER SUPPLY LWCO LOW WATER CUT FS FIELD SUPPLIED HL HIGH LIMIT MV MAIN VALVE PV PILOT VALVE PSS PILOT SAFETY SHUTOFF WTS WATER TEMPERATURE SENSOR EWF ELECTRIC WATER FEEDER P P PLUG PIN C S CAP SOCKET HIGH VOLT FIELD INSTALLED LOW VOLT FIELD INSTALLED PS HL MANUAL RESET OPTIONAL VOLT CIRCUIT GND IGNITER SENSOR IGNITION MODULE TO ADDITIONAL TO ADDITIONAL BASES BASES LOW VOLTAGE WIRING 30 OPERATION AND SERVICE Control Functions And Operation Control module performs following basic functions 1 Opens and closes first pilot operator of gas valve 2 Provides spark for igniting pilot burner 3 Senses pilot burner flame 4 Shuts off spark after pilot flame is lit 5 Opens and closes second main operator Functions occur in two stages trial for pilot ignition and main burner operation as described below Trial For Pilot Ignition 1 On every call for heat system start control performs internal safe start check If flame simulating condition is present system will not start 2 During normal start c2. 5 15 5 p sop 951 20 5 YUM 914 99 9 101 0051 00 ON JO ZHZ 5 55 abney Ul SJUNOW 0402 2 0051 005 3215 431108 EFA DR Egi dWNd 0334 Y31109 21415414 440103 ALVSNAGNOD 445 440109 TANNOQW 445 NOILVNIGWOO YaLVM MOT TOULNOO dWNd 113 430444 TANNOQOW 31 445 4dOLND 4 444 113 440109 531035 9 ol Ninaa OL 5 5 apis ajzisoddo A ddns JUNOW FLON NMOHS SNOILOANNOD 11V JYV SONIddVL YATION 5 54145 5431108 WVALS Figure 33 Boiler Tappings 25 BOILER PIPING Figure 34 STEAM BOILER PIPING STEAM SUPPLY STEAM CROSS LOW WATER CUT OFF EQUALIZER 20 MIN SKIM TEE Optional Location for Make up Water Connections FLUSH PLUGS WET RETURN Install Safety Valve As Close To Boiler As Possible STEAM BOILER PIPING See Figure 34 Do not install shut off or steam valve between Full size steam header is recommended by safety valve and boiler manufacture on all steam systems as shown above Risers should be full 4 and at least 20 in height Use skimmer tee as shown
3. 54 latest revision ASHRAE HVAC Systems and Equipment Handbook Chimney Gas Vent and Fireplace Systems or the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances NFPA 211 Follow standard engineering practice SHIPMENT CHECK LIST 3579 LST SLYVd NOLYVD TANVd 4544 4944 JJS 1611 SLYVd NOLYVD TANWd 1 7 8 4944 JJS xxx 1611 61 4 AYOSSADOV 3944 JJS xxx LST SLYVd WYLS 4944 346 xx 1611 61 4 NOLYVD 8 9 335 5 295 INO 59110559252 pue 31 5 DOS 104 900071 6 900021 8900021 WS 19000 50004 990002 2 055322 1431 5 1945 T4ANVd 1 ACCESSORY CARTON CHECK LIST ACCESSORY CARTON BOILER MODEL NUMBERS AND QUANTITIES PARTS PART COMPLETE Ea 4 Push Nipples Push 4 Push Nipples 43300977 ger feet e elelee atete eteta ied 5 8 Flat Washer Flat Washer 14695306 Non Asbestos Furnace Cement 1440001 1 FB 1 Fitting Bag Bag 41200051 Fi
4. Steam Piping Size Area of Main Steam Cross Header Pipe should be equal Header _ Riser Equalizer to larger than total area of Steam Supply Mains 300 to 900 leading from Header and should never be smaller than 1000 to 1200 Supply tappings on Boiler Return Header should be 1300 to 1500 piped to both ends of Boiler Area of Return Header should be equal to total area of Return Mains or larger Pipe steam cross headers with swing joints or equipped with slip joint connector to prevent expansion and contraction of steam header from damaging boiler Each installation has preferred piping arrangement according to system requirements Installer s heating engineer or using standard engineering practice choice of arrangements and sizes of headers should be decided 26 BOILER PIPING Figure 35 High Steam Quality Drop Header Piping Arrangement gt gt dn J2W NUALAY LIM 164 834 SAHONI 0 9 NOISNAWIG SWALSAS 344 OML waste S3HONT 82 Ya NOISNAWIC 53155 3414 wos WY Ss ANJA 94 19574 JON 92514 27 CONNECTING GAS SERVICE WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance Do not touch any electrical switch do not use any phone in your
5. NOTICE Figure 14 Start jacket assembly at left side 1 Attach lower jacket end panel left to two Z bars on base end closures through two slotted holes on bottom of jacket end panel Use 2 10 gt screws See Figure 14 2 Attach middle jacket end panel left to lower jacket Figure 15 end panel with middle laying over lower Line up holes Use 5 10 75 screws See Figure 15 3 Attach upper jacket end panel left to middle jacket end panel with upper behind middle Line up holes Use 6 10 x screws Ensure bare metal plate is inserted between casting ridge and draft hood This holds panel in place See Figure 16 Figure 16 17 INSTALLATION ASSEMBLY 4 Position top front intermediate panel so back edge of top Figure 17 hangs on adjustable clips on front of draft hood s Left edge hangs on bracket on left upper jacket end Adjustable Clips panel B Right edge with integral bracket hangs on tie rod s See Figure 17 Bracket 5 Attach top front intermediate panel to lower base Figure 18 brackets through four slotted holes in panel Use 4 10 x 72 screws See Figure 18 6 On multiple base boilers each additional top front intermediate panel attaches in same way working your way from left to right Figure 18 18 INSTALLATION ASSEMBLY 19 Manufacture recommends assembling jacket panels after piping is com
6. CHART 2 FOR INSTALLATION ON NON COMBUSTIBLE COMBUSTIBLE CONSTRUCTION 400 Flue Collector Steam Water 1 Piping FLOORS ONLY MINIMUM CLEARANCES TO Inputs of s _ __5 Greater clearances 24 for access should supersede fire protection clearances VENTILATION AND COMBUSTION AIR Asphyxiation hazard Ensure enough air is available Air openings to combustion area shall not be for proper combustion avoiding hazard due to lack obstructed Follow Chart 3 to insure adequate of oxygen combustion air is maintained COMBUSTION AIR REQUIREMENTS Chart 3 MINIMUM SQUARE INCHES OPENING UNCONFINED AREA CONFINED AREA OUTSIDE COMBUSTION AIR HORZ VERT DUCTS DUCTS 1 SQ 1 SQ 4000 Btu hr 2000 Btu OUTSIDE INSIDE BOILER COMBUSTION COMBUSTION NUMBER MODULES AIR 1 SQ AIR 1 SQ IN 4000 Btu hr 1000 Btu hr SEE FIG 2 SEE FIG 1 1000 Unconfined area A space whose volume 15 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 length Confined area A space whose volume is 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 VENTILATION AND COMBUSTION AIR Figure 1 Combustion Air Openings Combustion Air supplied from o inside the building Important Vent Piping Note
7. 25 Connecting Gas 5 2 _ _ 28 Electrical Wiring _______ _____ ___________ 29 Wiring ______ 30 Operation And 21 Checking 33 E E 34 Pilot System Tr ubleshooting Table acess 25 SAFETY SYMBOLS KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE DANGER Indicates a hazardous situation which if not Fire explosion asphyxiation and electrical shock avoided WILL result in death or serious injury hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation 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 Indicates information which should be followed to ensure proper installation and operation RATINGS AND CAPACITIES Art CERTIFIED Ratings and Capacities Chart 1 www ahridirectory org Net AHRI Flue Outlet No amp Chimney Collector Gross Steam Si
8. AND SERVICE WHAT TO 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 neighbor s phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fire department Ignition Cable Verification 1 Cable must not run in continuous contact with a metal surface or spark voltage will be greatly reduced Connections to stud terminal on control and on igniter sensor must be clean and tight Loose connections may not conduct flame current even though ignition spark is satisfactory Check the cable electrical continuity 2 3 4 Grounding Verification Ground is required for pilot burner igniter sensor mounting bracket and control GND terminal If ground is poor or erratic safety shutdown may occur even though operation is normal at checkout If nuisance shutdowns occur check grounding Startup And Checkout If any failure of system component system will not operate If system does not perform as outlined in Start System below refer to Pilot System Troubleshooting Table Start System 1 Turn power to control s on Turn off gas supply 2 Check control s operation as follows A Set Thermostat or controller above room temperature to call for heat B Watch for spark at pilot burner s Turn gas supply D Appliance is equipped with automatic ignition devi
9. Sloped vent pipe at least 1 4 for every 1 to the vent terminal 1 Provide combustion and ventilation air in accordance with the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 1 54 or applicable provisions of the local building codes Boiler is located in unconfined space in building or conventional construction frame masonry or metal building infiltration normally is adequate to provide air for combustion and ventilation However if equipment is located in building of tight construction See National Fuel Gas Code ANSI Z223 1 boiler area should be considered as confined space If there is any doubt install air supply provisions in accordance with latest revision of National Fuel Gas Code Boiler is installed in unconfined space in building of tight construction air for combustion and ventilation must be obtained from outdoors or from spaces freely communicating with outdoors Permanent opening or openings having 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 from outdoors and shall have same cross sectional area of openings to which they are connected Figure 2 4 5 Combustion Air Openings with Motorized Dampers Combustion Air supplied from non outside the building When air for combustion and ventilation is fr
10. JE Series Cast Iron Commercial N m Boil BOILERS atural Gas Stea oiler INSTALLATION OPERATION amp MAINTENANCE MANUAL Am CERTIFI ctory org MAY a Manufactured by r ECR International Inc 1117 we An 150 9001 2008 Certified Company 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com P N 240010349 Rev B 02 2014 CAST IRON WATER OR STEAM BOILER Contents R tings Capacities 3 Shipment Check LSE aie 4 Accessory Ubuaaelucaoaeusaenundaes 5 Safety 6 _____ ________ _ _______ Ventilation Combustion 8 Vent Installaatio 10 Boiler DIMENSIONS 13 Installation ASSemDIy 14 24 Boiler PIDIN
11. alve 15 psi See page 27 for installation location gt STEAM TRIM ASSEMBLY Field assemble Steam Trim Low Water Cut Off High Pressure Limit Control Pressure Gauge Water Gauge TN Glass Set and Siphon Loop as shown in Figure 32 260 See Figure 31 and Chart above for location of controls CUT OFF z WATER LEVEL 29 TO FLOOR NOTICE Do not place any shutoff between pressure relief valve and boiler or on discharge pipes between Field Assembled such safety valves and atmosphere Installation of pressure relief valve shall conform to requirements of ANSI ASME Boiler and Pressure Vessel Code Section IV 24 BOILER PIPING 7 4 T NOISNAWIG 15 5 55390 IWILYWd YO SSADOUd 403 7 4 Z NOISNAWIG SWALSAS 435010 403 19209 95991 AT eT 9 445015 403 49 10q UO 26 5 duind 5 pue yue 5 404 310 UO 10 H0N9 YPM 104 310
12. building 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 A 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 Gas Supply Connection Natural Gas Only 1 Use piping materials and joining methods acceptable to authority having jurisdiction In absence of such requirements USA National Fuel Gas Code ANSI Z223 1 NFPA 54 On multiple base boilers connect gas service with branch lines from common main Install ground joint union in each branch line for easy servicing of gas controls Provide sediment trap up stream of gas valve Figure 36 Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure See Chart 6 for pipe sizes for gas mains Pressure test boiler and gas connection before placing boiler in operation 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 op
13. ce which automatically lights the pilot Do not try to light appliance 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 on floor Read What To Do If You Smell Gas on front page of this manual above F Use only your hand to push in or turn gas control knob Never use tools If knob will not push in or turn by hand don t try to repair it call qualified service technician Force or attempted repair may result in a fire or explosion 32 G 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 control system and any gas control which has been under water 3 System start A Spark will turn on and pilot gas valve will open at once Pilot burner s should ignite after gas reaches pilot burner s B Spark ignition should cut off when pilot flame is established C Main gas valve should open and main burners should ignite after gas reaches burner ports Light off may not be satisfactory until gas input and combustion air have been adjusted 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 Pilot Flame Adjustment 1 Pilot flame should envelop 3 8 to 1 2 inch of tip of insulated rod on ign
14. d evenly so that sections are pulled parallel as they go together When all sections are pulled up locate tie rods in alternating pairs of upper and lower holes between adjacent sections See Figure 11 Be sure both ends of completed section assembly are resting evenly on both ends of base Apply furnace cement at joints of sections front top and back Apply furnace cement where sections join the base See Figure 12 Place necessary plugs and control wells in correct locations See Figure 31 page 24 A Plug all other tappings leaving air vent in top of one of end sections and connect water Fill boiler with water until it runs out air vent See Figure 31 port D page 24 C Hydrostatically test boiler in accordance with applicable codes D Check for leaks before continuing with assembly E Drain and remove unnecessary plugs 15 Figure 9 Apply non asbestos furnace cement to joints on all sides of boiler INSTALLATION ASSEMBLY Attaching Draft Hoods 1 Attach draft hoods to boiler sections after applying boiler Hercules Grrip to top of boiler sections where hoods and sections meet 2 Use J bolts to attach front of draft hoods to slots in section flanges See Figure 13 16 Figure 13 Draft Hood _ Draft hood notched to fit over sections J bolt amp nut attach to front of hood Q Draft hood clean ou covers INSTALLATION ASSEMBLY Installing Boiler Jacket Panels
15. ee R DIAMETER RISER PLAN VIEW ENLARGED Shown is suggested size of fixed baffle for different size risers IMPORTANT Extend chimneys at least 2 feet above any object within radius of 15 feet including roof Flue Connection And Venting Continued In certain cases where these short rises of less than 4 feet have been used spillage of combustion products has occurred at the draft hoods farthest from the chimney Assuming the chimney is adequately sized one acceptable method to correct this spillage problem is to permanently baffle the riser s closest to the chimney to reduce the excess of room air entering those draft hoods DO NOT BAFFLE ENOUGH TO CAUSE SPILLAGE The use of fixed baffles in the short risers above the boiler draft hood are acceptable as spelled out in American National Standard NFPA 54 ANSI Z223 1 National Fuel Gas Code latest revision Fabricate these fixed baffles using 20 gauge steel See Figure 6 Permanently attach the baffle to the inside of the riser s Trial and error will dictate the degree to which each should be positioned to avoid draft hood spillage at the far end of the boiler Be careful to avoid bending the fixed baffle so it will obstruct the flue gas flow in the horizontal collector 12 Removing Existing Boiler From Common Venting System When existing boiler is removed from common venting system common venting system is likely to be too large for proper venting of appl
16. eet above any object within radius of 15 feet including roof Install hood on all flue pipes which extend through roof In most locations venting of boiler relies on natural draft In as much as energy available from natural draft is quite low serious thought should be given to vent system design i e adequate size use of gradual transitions tees elbows etc close proximity of boiler and chimney On all boilers vertical risers must be at least as large as vent openings on draft hood Boiler manufacturer makes no specific recommendations regarding application of draft inducers that may be used with this boiler If draft inducer is used it is up to installing contractor and draft inducer manufacturer to determine proper application VENT INSTALLATION Flue Connection And Venting Continued Simple vent system consists of 6 foot minimum vertical rise immediately off draft hood as shown in Figure 3 Terminate this vertical flue above building roof with suitable rain cap at least 2 feet above surrounding obstructions i e parapets adjacent buildings penthouses etc This type of vent system applies to single draft hood boilers ONLY and has limited practical use because it is restricted to single story boiler rooms and because of problems encountered in roof flashing Vertical venting system shown in Figure 3 cannot be used on multiple base boilers because of physical interference of multiple rain caps For multiple base boi
17. en flames or other methods that can provide ignition source e Correct leaks immediately and retest 28 Minimum Operating Gas Supply Pressure 300 500 600 1000 1300 11500 5 _____ 400 700 900 1100 1200 1400 All eer err or eee All Manifold Pressure Models ss inches we Chart 6 TABLE OF PIPE SIZES IN INCHES FOR GAS MAINS NATURAL GAS Boiler No 2 2 fv 2 fe fa a fv ove ov 27 Figure 36 INSTALL MANUAL VALVE WITHIN 6 ft 183cm OF THE BOILER AND 5 ft 152cm ABOVE THE FLOOR WHERE REQUIRED BY LOCAL CODES 3 8 cm Minimum DRIP LEG TO GAS CONTROL INLET ELECTRICAL WIRING Adjust Thermostat Heat Anticipator 1 Set heat anticipator setting per thermostat Electrical shock hazard Turn OFF electrical power manufacture instructions supply at service panel before making any line 2 Follow thermostat manufacture instructions for final voltage connections Failure to do so could result adjustment in death or serious injury 3 When set above temperature indicated on thermometer boiler burners should ignite Verify thermostat s turns boiler off when room temperature Label all wires prior to disconnection when servicing reaches selected setting and starts boiler when room controls Wiring errors can cause improper and temperature falls few degrees dangerous operatio
18. ere they will not be lost or damaged Codes Governing Installation Installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI 7223 1 54 Where required by the authority having jurisdiction the installation must conform to the standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Additional controls and safety devices are required for CSD 1 Installation Boiler is designed to provide wide heating capacity range with multiple burner modules each equipped with its own set of controls For purposes of orientation gas manifold location is considered the front Instructions are written for assembly of boiler starting with left side and working to right side BEFORE INSTALLING Boiler Location Locate boiler on level non combustible foundation as near to chimney or flue as possible Allow 24 inches at front and sides of boiler for servicing and cleaning When installed in utility room the door should be wide enough to allow the largest boiler parts to enter or permit replacement of any other appliance in the same room Installing contractor must provide ventilated foundation for boiler when installing e Over a room e Over electrical wiring or cables of any kind e If concrete floor is not cured or water is channeled under concrete floor Combustion Air Provide combustion and vent
19. esult in premature failure of boiler sections and cause dangerous operation Verify there is adequate gas supply piping 3 Never vent this boiler into enclosed space Always connect boiler to chimney and vent to outside Never vent to another room or inside abuilding 4 Verify there is adequate air supply for complete combustion 5 Follow regular service and maintenance schedule for efficient and safe operation Fire hazard Do not install boiler on non combustible flooring such as carpeting or wood flooring Failure to follow these instructions could result in death or serious injury 6 DO NOT install boiler on non combustible flooring such as carpeting or wood flooring When Your Boiler Arrives When boiler arrives be sure to save and refer to instructions Inspect each item received for visible damage If any parts are damaged report this to freight company immediately and request them to call and make inspection before you make any installation Have inspector prepare a signed report Send copy of report to manufacturer We must have the signed inspection report of the freight company to prove their liability Read these instructions carefully before beginning the installation to be sure all packages have been received It is recommended that you follow the step by step instructions for best assembly results Before discarding any packing material carefully examine for loose parts Also store all parts received wh
20. han metal threads 5 Turn clockwise to increase input and counterclockwise to decrease input rate 6 Replace Regulator Cap High Limit Control While boiler is operating set high limit control below boiler water temperature and main burners should shut off Return control to normal setting Main burners should restart Burn and scald hazard Discharge of water vapor and steam may scald Failure to follow these instructions could result in death or serious injury Pressure Relief Valve 1 Pressure relief valve on boiler is required 2 Runa pipe from pressure relief valve outlet to appropriate open drain 3 Pipe must be of same size as outlet on valve and open end must not be threaded 4 Run drain in area not subject to freezing Failure to do so may cause water damage or injury should valve release 5 If valve discharge occurs valve fails to open as described above contact service technician to replace relief valve and inspect heating system to determine cause as this may indicate equipment malfunction 6 Follow valve manufacture instructions for testing and maintenance Burner And Pilot Flame 1 Manufacture recommends visual check of burners and pilot flame monthly during heating season by owner and once year by service technician See Figure 39 2 Look for deterioration from corrosion of burners pilot burners and boiler base frame 3 Clean boiler base interior and exterior Burner And Pilot Fla
21. hour of total input rating of all equipment in enclosure Refer to Figure 2 on previous page 2 When communicating with outdoors by means of vertical ducts each opening shall have minimum free area 1 square inch per 4 000 Btu per hour of total input rating of all appliances in the enclosed space 3 If horizontal ducts are used each opening and duct shall have minimum free area 1 square inch per 2 000 Btu per hour of total input rating of all appliances in the enclosed space B One permanent opening commencing within 12 inches of top of enclosure shall be permitted where equipment has clearances of at least 1 inch from sides 1 inch from back and 6 inches from front of boiler Opening shall directly communicate with outdoors or shall communicate through vertical or horizontal duct to outdoors or spaces crawl or attic that freely communicate with outdoors Openings must have minimum free area of 1 square inch per 3000 Btu per hour of total input rating of all equipment located in enclosure Free area must be no less than sum of areas of all vent connectors in confined space In calculating free area using louvers grilles or screens for above consideration shall be given to their blocking effect Screens used shall not be smaller than 1 4 inch mesh If free area through design of louver or grill is known it should be used in calculating size opening required to provide free area specified If design and free area is not kn
22. iances remaining connected to it At time of removal of existing boiler following steps shall be followed with each appliance remaining connected to common venting system placed in operation while other appliances remaining connected to common venting system are not in operation 1 Seal any unused openings in the common venting system 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 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 of 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 dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 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 it has been determined that each appliance remaining connected to the common venting system properly vents when tested as
23. ilation 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 the local building codes Chimney And Vent Pipe Connection This is a very important part of the heating system It must be clean the right size properly constructed and in Good Condition No boiler can function properly with a bad chimney See Pages 8 12 for specific venting instructions Flue pipe should be same size as draft hood outlet from boiler to flue collector See Chart 1 for Typical Chimney Size Maintain a minimum upward slope of 1 4 inch per linear foot from boiler to the chimney Fasten joints together with sheet metal screws to prevent sagging Minimum Vent Pipe Clearance If the vent pipe must go through a crawl space double wall vent pipe should be used Where vent passes through a combustible wall or partition use a ventilated metal thimble The thimble should be 4 inches larger in diameter than vent pipe If boiler is installed with single wall galvanized type vent pipe it must have 6 inches clearance between its surface and any combustible material If UL listed type B insulated vent pipe is used clearance between it and combustible material to be as listed by pipe manufacturer Fire hazard Do not install boiler on combustible flooring such as carpeting or wood flooring Failure to follow these instructions could result in death or serious injury
24. ing 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 Utica NY 13501 web site www ecrinternational com
25. iter sensor See Figure 38 If adjustment is required remove pilot adjustment cover screw and turn inner adjustment screw clockwise to decrease or counterclockwise to increase pilot flame Replace cover screw after adjustment to prevent possible gas leakage Test Ignition system safety shutoff device after placing boiler in operation Disconnect sensor wire from ignition module Burner operation should stop Figure 38 Proper Flame Adjustment PROPER FLAME ADJUSTMENT 3 8 TO 1 2 INCH 9 5 TO 12 7 MILLIMETRES INSULATED ELECTRODE CHECKING AND ADJUSTING Verify Burner Input Check boiler for proper Btu input rate Do not exceed Input rate stamped on nameplate of boiler located on end jacket panel Verify primary air supply to main burners is properly adjusted for complete combustion If boiler is shut down for service gas and electric must be off for 5 minutes before relighting Verify boiler for proper Btu Input proceed as follows 1 With main burners operating measure gas Input to boiler by reading the gas meter 2 Verify all other appliances connected to same meter are shut off 3 Rate of gas flow cu ft per hour multiplied by Btu value of gas should match Btu input shown on boiler nameplate 4 If it is not within 2 adjust Pressure Regulator to obtain desired flow Adjustment stem can be found cap regulator top Adjustment screw is plastic and may require slightly greater turning force t
26. lers pant leg venting system shown in Figure 4 can be applied if desired Vent system shown in Figure 5 is commonly used With vent diameters sized to match flue outlets minimum vertical rise of 4 feet above draft hood must be maintained for proper operation Refer to Chart 1 for typical chimney sizes Requirements for this type of system are an adequately sized chimney adequate combustion air and outlet end of horizontal run must be no more than 6 feet from chimney with no more than one 90 elbow in this run as shown For installations where required minimum 4 foot vertical rise cannot be maintained diameter of horizontal run must be increased one inch for each foot of riser reduction This procedure will reduce resistance of system and if chimney is adequate boiler will vent properly Figure 4 ROOF EL ELL TYM 3dISLNO Figure 3 ROOF LINE TYM 0151 0 IMPORTANT Extend chimneys at least 2 feet above any object within radius of 15 feet including roof Figure 5 DIAMETER OF FLUE SHOWN IN DIMENSIONAL DATA CHART 1 IMPORTANT Extend chimneys at least 2 feet above any object within radius of 15 feet including roof 5 4 IMPORTANT Extend chimneys at least 2 feet above object within radius of 15 feet including roof 11 VENT INSTALLATION Figure 6 S
27. me Manufacture recommends flue passages burner adjustments and operation of boiler controls be checked once a year by a Service technician To clean flue passages A Remove burners and pilot s from boiler B Remove clean cut cover panel on draft hood to expose flue passages See Figure 13 page 16 C Clean flue passageways between sections with flexible handle wire brush Remove all dirt from bottom of boiler and reassemble all parts D Verify pilot connection s adjustment of pilot s and burner flames after reassembly Figure 39 Pilot and Flame Outer Mantle Outer Cone Burner Asphyxiation hazard Improper installation could result in death or serious injury Failure to follow these instructions could result in death or serious injury Venting System 1 Check chimney for correct size proper construction clean and in good condition to ensure proper combustion 2 You must provide enough fresh air for combustion 3 If your building is of tight construction it may be necessary to add fresh air duct to provide oxygen See Chart 3 page 8 4 Monthly during heating season check that sections of vent pipe are secure at all joints and fittings There should be at least two 2 sheet metal screws per joint 5 Check that vent pipe slopes at least 1 4 per foot up from boiler to chimney 6 Vent pipe should be securely fastened to prevent sagging 7 Check vent Pipe for any deterioration from corrosion o
28. n 4 Set thermostat for desired temperature Electrical Wiring 1 Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to National Electrical Code ANSI NFPA 70 2 Install fused disconnect switch between boiler and electrical panel in convenient location 3 Secure wiring from high temperature limit control to boiler jacket or gas piping to prevent accidental disconnect from controls 4 Tape all wiring to gas valves securely to gas supply lines or run in appropriate conduit Thermostat Installation 1 Follow instructions included with your thermostat 2 Locate thermostat about 5 feet above floor on inside wall 3 Keep thermostat s at desired room temperature If windows are opened or heat is not needed set thermostat s to lower setting PLACES TO AVOID LOCATING THERMOSTAT Behind Doors Dead Spots Corners and Alcoves Concealed Pipes Fireplaces TV Sets Lamps Direct Sunlight Kitchens Concealed Pipes or Ducts Stairwells Drafts Unheated Rooms on other side of Wall Cold Spots 29 WIRING DIAGRAMS Commercial Boiler 1 2 amp 3 Base COMMERCIAL BOILER 1 2 amp 3 BASE HIGH VOLT POWER SUPPLY PER AND ITEMS SUPPLIED J BDOX NEC CLASS II LOW VOLT CIRCUIT 5 LOCAL CODES BY INSTALLER OVERCURRENT SERVICE DISCONNECT PROTECTION RECOMMENDED J
29. o bolts in front posts and two in rear posts as shown in Figure 7A Bolts with nuts in the front and rear posts 3 After bases are fastened install base end panels Install end panels before assembling sections See Figure 7B NOTICE Verify bases are level after assembly Section Assembly 1 Start sections from left or right end of base 2 Place end section on base with center line of section directly over joint of base end closure Figure 8 i Note First 3 With boilers having two or more bases as you progress Section Alignment be sure parting line center line of section of intermediate side sections fall on junction of two bases See Figure 8 of base to align Alignment first section Do of section not allow side to along side overhang base L 14 INSTALLATION ASSEMBLY When starting section assembly clean nipples and nipple ports Coat nipples and nipple ports with Hercules Grrip or other good sealant See Figure 9 Place nipples in ports Take care to seat them squarely to prevent cocking Figure 10 When pulling sections together with tie rods insert tie rods in holes nearest to nipple ports Move tie rods to proper location if necessary only after sections are fully pulled together See insert Figure 11 Oil or lubricate threads insert rods in lugs with washers under nuts and tighten uniformly an
30. o side and front panels 3 Route wires through clips See Figure 28A 3 Orient harness of control panel assembly so correct female plug is toward J box and will connect to J box harness See Figure 28A 4 Connect plugs on harnesses See Figure 28B Figure 28B 22 INSTALLATION ASSEMBLY Connect plugs on harnesses See Figure 29 Figure 29 On multiple base boilers mount remaining control panels to intermediate jacket panels following steps 4 amp 5 On each base connect gas valve harness Refer to Wiring Diagram page 30 Connect pilot spark wire after control panel installation Figure 30 See Figure 30 23 TAPPINGS Figure 31 shows end section and provided tappings Tappings are same in both right and left end sections Figure al OPENING SIZE STEAM ya Primary LWCO and Gauge A Glass Set o G y Plugged or Electronic Probe Type LWCO If using opening F for other than Safety Valve or Safety Relief Valve or Safety Relief valve is larger than 1 Install Safety Relief Valve in Header Piping as near boiler as possible BOILER TRIM Following controls are supplied as standard equipment Details of their function and operation will be found in section on Checking and Adjustments page 33 STEAM TRIM 1 Low Water Cut Off mounted externally with blow off valve High Pressure Limit Control Pressure Gauge Water Gauge Glass Set Siphon Loop Safety V
31. of manifold brackets See Figure 24 Position control access jacket panel s so tabs slide into slots on top front intermediate jacket panel s Attach control access jacket panel to front jacket Use 2 10 x 1 screws See Figure 25 Each boiler base includes e Factory installed lighting Instruction Labels e Factory installed Data plate indicating required gas type firing rate and gas pressure for that base These plates are located on Jacket Top Front Panels e Field installed rating plate showing total Input and Output Ratings Rating plate is shipped in AC Carton and is to be mounted on side Jacket End Panel by installing contractor Attach any Local Code Label not provided by manufacturer to boiler Figure 24 Figure 26 NOTE Attachment of control access jacket panel can wait until controls have been mounted to front jacket panel 21 INSTALLATION ASSEMBLY Control Mounting And Installation Electrical controls J box etc can be mounted on either left or right jacket end panel Boiler safeties LWCO etc and respective piping must be mounted on opposite end of boiler electrical controls 1 Attach J box assembly to jacket end panel Align with holes in end panel Use 4 10 x screws See Figure 27 Figure 27 2 Attach control panel to front jacket panel align with predrilled holes Use 4 10 x screws Secure harness to control panel with zip ties Attach wire clips t
32. om inside buildings confined space shall be provided with two permanent openings one starting 12 inches from top and one 12 inches from bottom of enclosed space Each opening shall have minimum free area of 1 square inch per one thousand 1000 Btu per hour of total input rating of all appliances in enclosed space but must not be less than one hundred 100 square inches Openings must freely communicate directly with other spaces of sufficient volume so combined volume of all spaces meets criteria for unconfined space Figure 1 When boiler is installed in confined space and all air is provided from outdoors confined space shall be provided with one or two permanent openings according to methods A or B see page 10 When ducts are used they shall be of same cross sectional area as free area of area of openings to which they connect Minimum dimension of rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches VENTILATION AND COMBUSTION AIR A When installing two openings one must commence within 12 inches from top and other within 12 inches from bottom of enclosure Openings shall communicate directly or by ducts with outdoors or spaces crawl or attic that freely communicate with outdoors One of following methods must be used to provide adequate air for ventilation and combustion 1 When directly communicating with outdoors each opening shall have minimum free area of 1 square inch per 4 000 Btu per
33. ontrol opens first pilot valve operator of gas control which allows gas to flow to pilot burner At same time electronic spark generator in control produces 15 000 Volt spark pulse output open circuit Voltage produces spark at igniter sensor rod which ignites pilot burner 3 If pilot flame does not light or presence of pilot flame is not detected back through flame rod control will not open second Main valve operator of gas control 4 Control will continue to try to ignite pilot burner until either flame is detected or thermostat controller is set below call for heat Main Burner Operation 1 When pilot flame is established flame rectification circuit is completed to burner ground 2 Control flame sensing circuit detects flame current shuts off spark generator and opens second Main valve operator to allow gas to flow to main burners 3 Pilot flame ignites main burner conventionally Electronic control module cannot be repaired If troubleshooting procedure indicates malfunction in control control must be replaced Intermittent Pilot systems must be serviced by trained service technicians Preliminary Check Make following visual checks before troubleshooting and after maintenance 1 Check power switch 2 Open manual shutoff valves in gas line to boiler 3 Verify all wiring connections are clean and tight 4 Review control s normal sequence of operation 31 System Troubleshooting 1 Set thermo
34. or acid for cleaning heating boilers it is difficult to completely remove them Injury may occur after cleaning process if these agents are used 34 Boiler Water Treatment In steam systems where system is tight free from leaks and all steam is returned to boiler as condensate amount of make up water is small Water treatment is not required On steam systems with less than 90 of steam being returned as condensate or with very hard or corrosive make up water treatment may be desirable Follow recommendations of ASME American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section VI latest version Between Heating Seasons Boilers should not be drained between heating seasons Steam boilers should be entirely filled with water during the summer months to exclude air Low Water Cutoff s Inspect low water cutoff s annually or as recommended by low water cutoff manufacture Flush float types per manufacturer s instructions General Housekeeping e Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids e Keep boiler area clear of obstructions to flow of combustion and ventilation air PILOT SYSTEM TROUBLESHOOTING TABLE Turn gas supply OFF Turn thermostat controller to call for heat Power to module 24V module NOTE Before troubleshooting familiarize yourself with startup and check procedure Check line voltage power low
35. outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use 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 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 Chapter 13 of the National Fuel Gas Code ANSI 2223 1 54 BOILER DIMENSIONS Front View Floor Line Top View Flue Outlets lt Return Supply AA Base amp Battery Length A Jacket Width LtoR Boiler Water Model Content in No Gallons Shipping Weight Lbs 300 922 25 1133 20 3 4 Note See page 14 Base Assembly 13 Left Side View ALL SUPPLY AND RETURN CONNECTIONS ARE 4 INCH Boiler Modules 19 1 8 21 1 4 21 1 4 21 1 4 INSTALLATION ASSEMBLY Base Assembly 300 400 and 500 boilers are the basic models 300 model has 6 burners 400 model has 8 burners e 500 model has 10 burners Combinations of basic models are used to assemble 600 through 1500 models Refer to Chart 3 for proper order of assembly When two or more bases are used to assemble boiler verify tops of bases are even Figure 7A me 1 Fasten bases together with 5 16 cap bolts and nuts 2 Insert tw
36. own it may 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 open position or interlocked with boiler so they are opened automatically during boiler operation VENT INSTALLATION Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure The vent pipe must slope upward from the boiler not less than 1 4 for every 1 to the vent terminal Figures 1 amp 2 Horizontal portions of the venting system shall be supported rigidly every 5 feet and at the elbows No portion of the vent pipe should have dips or sags Flue Connection And Venting Vent installations shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI 2223 1 NFPA 54 or applicable provisions of the local building codes 1 Consult dimensional drawing for number and size of flue pipes required for each size boiler Maintain minimum upward slope of 1 4 inch per linear foot from the boiler to chimney Run flue pipe directly as possible Keep turns to a minimum Insert flue pipe into but not beyond inside wall of chimney Do not connect into a chimney serving an open fireplace 10 Insulate flue pipe where it passes near combustible material Rigidly support pipe with hangers and straps Extend chimneys at least 2 f
37. pleted Skip step 7 proceed to step 8 7 Attach upper jacket end panel right so left edge hangs on bracket on top front intermediate panel Insert bare metal plate in same manner as left panel See Figure 19 Figure 20 A Attach side panel to base bracket through to slotted holes See Figure 20 Figure 21 B For added support attach side panel to draft hood 19 INSTALLATION ASSEMBLY See Figure 21 Figure 22A If boiler piping is preassembled jacket can be assembled as follows See Figures 22A and 22B 8 Attach middle jacket end panel right to upper jacket end panel with middle laying over upper Line up holes Use 6 10 x gt screws See Figure 22A 9 Attach lower jacket end panel right to middle jacket end panel with lower behind middle Line up holes Use 5 10 x screws Figure 22B 10 Attach lower jacket end panel to two Z bars on base end closures through two slotted holes on bottom of jacket end panel Use 2 10 x gt screws See Figure 22B 11 Position top of rear jacket panel s to draft hood baffle Figure 23 flange Secure with 2 10 x 12 screws Secure bottom of rear jacket panel s to bracket s on boiler base using 2 10 5 screws See Figure 23 20 12 13 14 15 16 17 INSTALLATION ASSEMBLY Attach burner door knobs with 8 32 x 1 4 screws 8 32 hex nuts Slide bottom of lower access door s in slots on top
38. r any other sources 8 Refer to Venting and Combustion Air instructions in this manual 33 CLEANING AND MAINTENANCE Cleaning The Steam Boiler Steam boilers must be cleaned prior to use in order to ensure efficient operation Grease oil sand and dirt cause scum to form on the surface of water in new boilers Heavier particles carried in grease may settle to bottom of boiler and form sludge If permitted to remain in boiler it will prevent generation of steam produces foaming and causes an unsteady water line Remove accumulation of oil and grease by blowing off boiler as follows 1 Install surface skim connection of at least 1 nominal pipe size in boiler using skim tee See Figure 35 page 27 Skim line should extend to within 18 of floor or appropriate drain A Insert valve in line close to boiler 2 Bring water line to center of outlet A Raise temperature to just below steaming B While burners are on open the valve in skim line and slowly feed clean water into boiler adjusting inlet water so boiler water remains hot C Continue skimming until water is clean 3 Close valves in boiler feed line and skim line 4 Bring boiler pressure to about 10 Ibs A Turn burners off B Open bottom drain valve permitting all water to drain from boiler 5 After boiler has cooled fill and flush out several times 6 Fill to proper water level and ready for normal service Do not use soda or any alkali vinegar
39. replace module Main B Lights Check for 24 Vac across MV MV PV terminals If no voltage replace module aln 0088 Check electrical connections between module and gas control If okay replace gas control or gas control operator System Runs Until Call For Heat Ends Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue If checks okay replace module Call For Heat Ends Check for proper thermostat controller operation System Shuts OFF Remove MV lead at module if valve closes recheck temperature controller and wiring if not replace gas control L 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 heat
40. stat or controller above room temperature and observe system response 2 Establish of system malfunction or deviation from normal operation by using Pilot System Troubleshooting Table in following section 3 After any maintenance or repair troubleshooting sequence should be repeated until procedure ends with normal system operation Component Verification Verify Spark Ignition Circuit Control electronic module and step up transformer provides spark ignition at 15 000 V open circuit Check circuit at control module as follows 1 Turn off manual gas valve to prevent flow of gas Electrical shock hazard Do not touch either end of jumper or stud terminal high voltage circuit Failure to follow these instructions could result in death or serious injury 2 Disconnect ignition cable at control stud terminal to isolate circuit from pilot burner igniter sensor 3 Prepare short jumper lead using heavily insulated wire such as ignition wire 4 Energize control 5 Touch one end of jumper firmly to control ground terminal GND 6 Do not disconnect existing ground lead 7 Move free end slowly toward stud terminal to establish spark 8 Pull lead wire slowly away from stud Note length of gap at which arcing discontinues 9 Arc length of 1 8 inch 3 2 mm or more indicates satisfactory voltage output 10 If no arc can be established or maximum gap is less than 1 8 inch 3 2 mm replace control OPERATION
41. tting Bag 41200052 Fiting Bag 4120005 3 4 Drain Valve 14622001 pee pep Peper 407 1 Sq Head Plugs Sq Head 1 Sq Head Plugs 1395004 1395004 Junction Box Assembly 1 3 550002870 Base in SAFETY INFORMATION Safety Information 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 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 Never test for leaks with an open flame Use soap suds to check all connections This will avoid any possibility of fire or explosion 2 Boiler is configured for operation with natural gas Over firing will r
42. voltage transformer limit controller thermostat controller and wiring Also check air proving switch on combustion air blowe system if used and that vent damper if used is open and end switch is made Pull ignition lead and check spark at module Spark okay models with vent damper plug make sure vent damper has not been installed then removed Replace vent damper if necessary Spark Across Igniter Sensor Gap other models replace module Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or bucking Take protective action to shield cable and boot from excessive temperatures Turn gas supply ON Pilot Burner Lights Check that all manual gas valves are open supply tubing and pressures good and pilot burner orifice is not blocked Check electrical connection between module and pilot operator on gas control Check for 24 Vac across PV MV PV terminals on module If voltage is okay replace gas control if not replace module Check continuity of ignition cable and ground wire Spark Stops When Pilot Lit Clean flame 1 9 9 YES Check electrical connections between flame rod and module e Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If problem persists
43. ze to Output 10 12 Chimney Mbh Input Size Mbh 8 20 300 233 400 310 10 x20 388 12 20 12 20 12 20 14 20 14 20 14 20 1100 853 2667 640 i 2 16 20 16 1200 930 2908 698 3 16 20 16 27 76 1300 1008 3150 756 1 2 16 20 16 30 09 770 1400 1085 3392 814 1 2 18 20 18 32 39 1500 1163 3633 872 3 18 20 18 34 72 1 Ratings are at sea level to 2 000 feet For altitudes above 2 000 feet reduce all ratings 4 for each 1 000 feet above sea level 2 Net steam ratings based on an allowance of 1 333 300 1500 Contact Technical Support before selecting boiler for installations having unusual piping and pick up factors such as intermittent system operations extensive piping systems etc 3 Ratings in square feet are computed at 240 Btuh square foot for steam boilers 4 Ratings based on 33 500 Btuh per horsepower 5 Pressure drop based on given flow from single outlet and returning to single inlet at the opposite end of the boiler 6 Chimney sizes shown are one option based on a typical venting system as shown in Figure 6 and sized according to the National Fuel Gas Code assuming Type B double wall vent and vent connectors Other venting system designs are acceptable as shown on Flue Connection And Venting section of this manual For further chimney design and sizing information consult the National Fuel Gas Code ANSI 2223 1
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