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Operation Manual - Whaley Food Service
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2. USER S INFORMATION MANUAL GAS BOILERS FOR MODELS MG 50 TO MG 150 MS 75 TO MS 150 SG 135 TO SG 495 AAE 480 TO AAE 3000 WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance 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 a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier The installer identified below has ensured that the boiler installed by them complies with the necessary code requirements and is in safe working order DATE OF INSTALLATION INSTALLED BY COMPANY ADDRESS PHONE Manufactured by Allied Engineering Company Division of E Z Rect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Heat Exchangers and Electric Boosters 94 Riverside Drive North Vancouver B C V7H 2M6 e Telephone 604 929 1214 e FAX 604 929 5184 Branches Calgarv e Edmonton e Toronto PN2152451 PRICE 6 MG SG amp AAE Series Boilers User
3. OUTER am SEDIMENT TRAP CASING i oo0 NOT SUPPLIED MG U 033 04 FIGURE 2 TYPICAL GAS TRAIN ASSEMBLY AND CONTROL COMPONENT LAYOUT FOR RESIDENTIAL INSTALLATIONS 10 MG SG amp AAE Series Boilers User s Information Manual ed 21 TYPICAL COMMERCIAL BOILER COMPONENT LOCATIONS ITEM DESCRIPTION ITEM DESCRIPTION 1 MAIN ON OFF SWITCH PANEL 11 90 ELBOW 11 12_ MANUAL SHUT OFF VALVE FIRING VALVE HIGH GAS PRESSURE SWITCH WHEN USED OPERATING HIGH LIMIT AQUASTAT MAIN GAS VALVE TEMPERATURE PRESSURE GAUGE REDUNDANT GAS VALVE SAFETY HIGH LIMIT AQUASTAT P2S PILOT SHUT OFF VALVE PILOTSTAT OR PILOT SOLENOID VALVE MANUAL MAIN SHUT OFF VALVE AB COCK PILOT REGULATOR LOW GAS PRESSURE SWITCH WHEN USED P2R PILOT SHUT OFF VALVE FOR MULTIPLE PILOTS ONLY MANIFOLD ASSEMBLY 1 4 TEE amp PLUG PILOT BURNER UNIT t ITEM 13 IS REQUIRED ON BOILERS WITH AN INPUT OVER 2500 M B H ITEM 13 amp 18 ARE REQUIRED ON U S BOILERS CSD 1 WITH AN INPUT OVER 2500 M B H THERMOCOUPLE STANDING PILOT ONLY PILOT GAS SEDIMENT TRAP NOT SUPPLIED OUTER CASING BASE ASSEMBLY NOTES 1 SOME MODELS MAY BE SUPPLIED WITH A COMBINATION GAS VALVE 2 SOME MODELS MAY BE SUPPLIED WITH A DUAL OPERATING SAFETY HIGH LIMIT AQUASTAT 3 ITEMS SHOWN MAY NOT BE PRESENT ON ALL MODELS AAE U 021 05 FIGURE 2 TYPICAL GAS TRAIN ASSEMBLY AND CONTROL COMPONENT LAYOUT FOR COMMERCIAL INSTALLATIONS 11 MG SG
4. amp AAE Series Boilers User s Information Manual 22 INDEX Section Page 1 About Our Manuall co 514 st geaptettesctiae Sie etd eect a eal a ee ths 2 2 Safety InstrUCtEMS x xi idea se A eee the el ee ae A etek li 2 3 Lighting INStructIONS sis ia a eA e de eee ee ete vd eed a ie ed vata 2 4 Lighting Instructions for Standing Pilot with Combination Gas Valve sm me enmennnnzzennnenzzennnzzznzzi 3 5 Lighting Instructions for Intermittent Electronic amp Hot Surface Ignition with Combination Gas Valve 3 6 Lighting Instructions for Standing Pilot with Non Combination Gas Valve sse sssseennnzzennenzzzennenzznnnta 4 7 Lighting Instructions for Intermittent Electronic with Combination Gas Valve nn 5 8 To Turn off Gas to the Boiler or Emergency Shut Off nn nn 5 9 l Area around Boilers iii i g a a ei A adie eet 6 10 Check for Gas Leaks ice jA cats at eae a At in 6 11 Corrosive Atmospheres sse ii ini Ia ni la bintdeeanilapab alate aae 6 12 Air Supply for Combustion and Ventilation ss nanna ann nanna nanna nn nt 7 13 Gheck for Draft Hood Spillage is ii a a ta a A aladheletannaieees 7 TAL BUMETSVSTONA sta f f a a a a a a a l yeas 7 15 Boller Wate ii is f iaa Ai in as ad a de 8 16 Pressure Relef Valve ies ati tis iet ea a aka coca dee ka ch sano ich SA tua as bla La Gap reat fe 8 17 Blocked Vent and Flame Roll Out Safety Switches ss nn 8 18 Inspection amp Maintenance Schedule
5. for weeping at pressure relief valve outlet during normal operation 16 Listen for unusual audible sounds in the boiler 15 Read temperature and pressure gauge Check with qualified installer or service o agency to determine acceptable temperature and pressure range for your heating system Combustible materials gasoline and other flammable vapors and liquids should not 9 be stored in the area of the boiler If any problems are identified during your inspection contact a qualified service agency for corrective measures Once every year at the beginning of the heating season Have a qualified service technician remove the draft hood from the boiler and inspect the flueways for the presence of soot or rust scale The draft hood and smoke pipe connecting the draft hood to the flue must be inspected for rust or corrosion before replacing the draft hood The presence of soot rust scale or corrosion indicates misadjustment o Have a qualified service technician inspect the pilot burner and main burner The qualified service technician should follow the Maintenace Checklist and other applicable safety information found in the Installation and Service Manual MG SG amp AAE Series Boilers User s Information Manual 20 TYPICAL RESIDENTIAL BOILER COMPONENT LOCATIONS 6 FLAME ROLL OUT SAFETY SWITCH 8 AUTOMATIC VENT DAMPER _ _ 9 ZONECONTROLBOARD OUTLET THERMOCOUPLE 70 LEAD WIRE PILOT GAS
6. the need for service Check flame color An extremely yellow flame as seen on a burning candle or match is an indication of incomplete combustion and is usually accompanied by the formation of soot and carbon monoxide carbon monoxide is a lethal colorless and odorless gas If soot is allowed to accumulate it will partially restrict free passage of products of combustion to the flue Under typically operating conditions the flame should have a distinct bright blue inner cone and a blue orange outer cone If any of the above problems are observed or the burner system does not operate properly immediately contact a qualified service agency for adjustment or corrective measures MG SG amp AAE Series Boilers User s Information Manual 15 BOILER WATER Avoid unnecessary replenishment of system water It can allow oxygen to enter the system and cause serious corrosion problems As well minerals dissolved in the water supply will precipitate when heated minerals preferentially deposit in the heat exchanger Do not draw water from the heating system for cleaning flushing etc Any audible sounds in the boiler system may be indications of scaling or lack of sufficient water flow and the system should be checked without delay Scaling is due to improper maintenance It is not the fault of the boiler Scale damage is not covered by warranty In cold weather conditions take precautionary measures to ensure the system will main
7. ON GAS VALVE This boiler has a pilot which must be lighted by hand When lighting the pilot follow these instructions exactly Ensure gas supply to boiler is turned on STOP Read the safety instructions in Section 2 Set the room thermostat to lowest setting Turn off all electrical power to the boiler Remove control access panel if necessary Push in gas control knob slightly and turn GAS CONTROL KNOB SHOWN IN ON POSITION clockwise to OFF NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed in slightly Do not force Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow A in the safety instructions above If you don t smell gas go to step 8 8 Find pilot burner follow aluminum tube from gas valve The pilot is on the far left side of the burner tray 9 Depress gas control knob and turn counterclockwise to PILOT 10 Push in control knob all the wav and hold in Immediatelv light the pilot with a match Continue to hold the control knob in for about 1 minute after the pilot is lit Release knob and it will pop back up Pilot should remain lit If it goes out repeat steps 6 through 10 e lf the knob does not pop up when released stop and immediatelv call vour service technician or gas supplier e If the pilot will not stay lit after several tries turn the gas knob clockwis
8. building under water Immediately call a qualified e Immediately call your gas supplier from a service technician to inspect the appliance neighbor s phone Follow the gas and to replace any part of the control system supplier s instructions and any gas control which has been under e If you cannot reach your gas supplier waier call the fire department 3 LIGHTING INSTRUCTIONS Your boiler is equipped with one of four optional ignition systems Determine the ignition system that applies from the list below and go to the applicable lighting instruction section e Standing pilot with combination gas valve Section 4 e Intermittent electronic amp hot surface ignition with combination gas valve Section 5 e Standing pilot with non combination gas valve Section 6 e Intermittent electronic ignition with non combination gas valve Section 7 Note A combination gas valve combines the operating and safety shut off into one valve body and is typical in residential installations A non combination gas valve system utilizes separate valve bodies for operating and safety shut off and is typical in commercial installations If you are unsure which type of gas valve or ignition system your boiler is equipped with check the lighting instructions sticker on the boiler or contact the factory MG SG amp AAE Series Boilers User s Information Manual 4 N Oo oO N 2 OY CO LIGHTING INSTRUCTIONS FOR STANDING PILOT WITH COMBINATI
9. corrosion MG SG amp AAE Series Boilers User s Information Manual 12 AIR SUPPLY FOR COMBUSTION AND VENTILATION A sufficient air supply MUST be provided to this boiler Air openings to the boiler room provide the air for combustion flue gas dilution and ventilation and are always required regardless whether the air is taken from inside or outside The air opening size and location as well as exhaust venting considerations must conform to the applicable codes If any alteration of the air supply and venting system is required contact a qualified service agency The boiler room must never be under a negative pressure Air openings should be sized by your installer not only to the dimensions required for the total input of all fuel fired appliances in the boiler space but also to handle the air movement rate of any exhaust fans or air movers using air from the building or space Make sure the venting terminations are always kept clear of obstructions i e snow ice etc Louvers and grilles used in your air supply and ventilation system should be checked regularly and cleaned of any dust dirt or debris which will block proper air flow 13 CHECK FOR DRAFT HOOD SPILLAGE WARNING Continuous spillage at the draft hood relief opening may result in severe personal injury death or substantial property damage After the main burners have operated for 5 minutes check to see that combustion products are going up the chimney or gas ve
10. ding near the floor If you smell gas STOP Follow A in the safety instructions in Section 2 If you don t smell gas go to the next step Find pilot burner follow metal tube from pilot gas control The pilot burner s is between the two main burners behind the pilot burner inspection door Turn on the pilot manual gas shut off valve s and hold the button down on the 1 safety pilotstat while lighting 1 pilot burner with a match Continue to hold the button down for about one minute after the pilot is lit Release the button which will pop back up Pilot should remain lit If the button does not pop back up when released stop turn the pilot manual gas shut off valve s off and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn the pilot manual gas shut off valve s off and call your service technician or gas supplier 7 If applicable repeat step 5 for EACH succeeding safety pilotstat until all pilots are lit 8 Turn main manual gas shut off valve s to ON 9 Turn on all electrical power to the boiler 10 Set thermostat to desired setting to put system back in service Relight Operation Five minutes complete shut off period is required before attempting to relight the boiler To relight the boiler follow the Start System procedure above To turn off gas to boiler or emergency shut off Follow Section 8 MG SG amp AAE Series B
11. e to OFF and call your service technician or gas supplier 11 Turn gas control knob counterclockwise U to ON 12 Replace control access panel if necessary 13 Turn on all electrical power to the boiler 14 Set room thermostat to desired setting To turn off gas to boiler or emergency shut off Follow Section 8 PILOT THERMO BURNER COUPLE LIGHTING INSTRUCTIONS FOR INTERMITTENT ELECTRONIC amp HOT SURFACE IGNITION WITH COMBINATION GAS VALVE This boiler is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Ensure gas supply to the boiler is turned on STOP Read the safety instructions in Section 2 Set the room thermostat to lowest setting Turn off all electrical power to the appliance Remove control access panel if necessary Push in gas control knob slightly and turn clockwise O to OFF GAS CONTROL KNOB SHOWN IN ON POSITION NOTE On some gas valves the knob cannot be turned to OFF or ON position unless knob is pushed in slightly Do not force 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow A in the safety instructions in Section 2 If you don t smell gas go to the next step 8 Turn gas control knob counterclockwise O to ON 9 Replace control access panel if necessary 10 Turn on all electrical power to the Boiler 11 Set
12. lve The pressure relief valve is a code requirement If discharge occurs during normal operation call a qualified service agency immediately Discharge indicates an unsafe pressure condition or a malfunctioning pressure relief valve Avoid contact with the hot water discharged to prevent personal injury 17 BLOCKED VENT AND FLAME ROLL OUT SAFETY SWITCHES Applicable to all boilers with an input rating less than 300 000 BTU HR e This boiler is equipped with a Blocked Vent shut off system The safety switch will shut down the boiler should the vent or flue become partially or completely blocked Should this occur do not attempt to re light the burner Contact a qualified service technician to ensure it is safe to re light the boiler e This boiler is equipped with a Flame Roll out shut off system The safety switch will shut down the boiler should flames roll out of the combustion chamber Should this occur do not attempt to re light the burner Contact a qualified service technician to ensure it is safe to re light the boiler 18 INSPECTION amp MAINTENANCE SCHEDULE This boiler has been designed to provide years of trouble free performance in normal installations The owner or user should conduct a general external examination covering all items on the User Checklist at the beginning of each heating season and in mid heating season to assure continued good performance In addition have the boiler inspected by qualified service technicia
13. n of gas flow 5 Replace control access panel if necessary If the boiler does not operate properly immediately contact a qualified service agency for adjustment or corrective measures MG SG amp AAE Series Boilers User s Information Manual 9 AREA AROUND BOILER Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surrounding the boiler It is unsafe for the flow of supply and exhaust air to be obstructed in any way Should your boiler be subjected to fire flood or some other unusual condition turn off all gas and electrical supply If you are unable to turn off the gas call your gas company or gas supplier at once Do not put the boiler in operation again until it has been ascertained by a qualified agency that the controls are functioning correctly The installer should always clearly identify the emergency shut off devices and make the owner aware of their location and method of operation WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under waiter 10 CHECK FOR GAS LEAKS To identify gas leaks smell for gas around boiler area and gas piping connections To check a specific area for leakage
14. n or gas suppliers service person annually at the beginning of the heating season for continued safe operation Note that some operating conditions may require more frequent inspections MG SG amp AAE Series Boilers User s Information Manual 19 USER CHECKLIST Reference Section Check air openings are not restricted and will not be blocked off Adequate supply 12 O airis necessary for combustion flue gas dilution and ventilation When the boiler has operated for several minutes check for spillage at draft hood 13 venting ducts and other areas susceptible to spillage Check externallv the draft hood and vent svstem for soot rust scale or corrosion O Checkfor dislodged venting or possible leaks in venting ducts Visually inspect main burners and pilot to ensure proper flame operating o nae eter Pt TAL ok 14 characteristics and ignition extinction is ok o Visually check burners to see that they are not cracked or dislodged 14 Check that gas piping is secured Smell for gas leaks around boiler and gas piping connections Gas leaks can also be checked for using a soap solution do not use 10 an open flame to check for leaks Note Propane is heavier than air and pools in a low area in the event of a leak o Visually inspect for leaks in the water piping and at water piping connections Circulating pumps used with hot water heating systems should be inspected for water leaks Check
15. nt properly by passing a lighted match or smoke from a cigar cigarette or pipe around the edge of the relief opening of the draft hood If the chimney or gas vent is drawing properly the match flame or smoke will be drawn into the draft hood If not the combustion products will tend to extinguish this flame If the combustion products are escaping from the relief opening of the draft hood IMMEDIATELY shutdown the boiler and contact a qualified service agency to make proper adjustments or repairs 14 BURNER SYSTEM To maintain safe and efficient operation examine the burner system regularly through the inspection hole near the pilot tube Check condition of burner system Over time it is possible for parts of the burners system to become plugged cracked eroded and or dislodged resulting in unsafe operation Pilot Flame The pilot flame should be adjusted to the point where the thermocouple tip or sensor rod is completely enveloped by the flame Figure 1 but not necessarily glowing red Check for lifting Flames should not lift excessively from the burner ports The flames may lift slightly during ignition or when the burners are cold FIGURE 1 PILOT FLAME ADJUSTMENT Check ignition and extinction Ignition should flow quickly and smoothly across all the burners Popping noises or explosions from the burners during ignition extinction or normal burner operation indicate
16. oilers User s Information Manual 7 LIGHTING INSTRUCTIONS FOR INTERMITTENT ELECTRONIC IGNITION WITH NON COMBINATION GAS VALVE This boiler is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Before turning on the electrical power switch be sure all gas supply lines are purged of air and power supply to control is the correct voltage If the pilot or main burners are not lit or the control system is locked out due to flame failure close the main and pilot gas shut off valves and call your service technician or gas supplier If you smell gas STOP Follow A in the safety instructions in Section 2 Check Control Operation 1 STOP Read Section 2 the safety instructions in Start System 1 Turn on the main and pilot manual gas shut off valves 2 For 100 shut off check close main and pilot 2 Set thermostat above room temperature and manual gas shut off valves turn off all turn on all electrical power to the boiler electric power to the boiler and wait for five 3 Once the pilot flame is proven the controller minutes to clear out any gas opens the main burner gas valves The pilot 3 Then smell for gas including near the floor flame will ignite the gas as it exits the main If you smell gas STOP Follow safety burner ports instructions in Section 2 If you don t smell 4 Set thermostat to the desired setting to put gas go to the next step s
17. room thermostat to desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Boiler in Section 8 and call your service technician or gas supplier To turn off gas to boiler or emergency shut off Follow Section 8 MG SG amp AAE Series Boilers User s Information Manual 6 LIGHTING INSTRUCTIONS FOR STANDING PILOT WITH NON COMBINATION GAS VALVE The pilot s in the boiler can be lit by hand or spark by an electric controller Before turning on the electrical power switch be sure all gas supply lines are purged of air and power supply to control is the correct voltage If the pilot burner s are not lit or a flame safeguard controller is provided and locked out due to flame failure close the main and pilot manual gas shut off valves and call your service technician or gas supplier If you smell gas STOP Follow A in the safety instructions in Section 2 To take the control system out of lockout if provided either press the reset button or interrupt power to the boiler depending on the boiler controller provided Some controllers will retry ignition automatically after 5 minutes lockout Start System 1 2 STOP Read the safety instructions in Section 2 Set the thermostat to the lowest setting close the main and pilot manual gas shut off valves turn off all electric power to the boiler and wait for five minutes to clear out any gas Then smell for gas inclu
18. s Information Manual 1 ABOUT OUR MANUALS Your Super Hot boiler has been provided with two manuals e User s Information Manual This manual is intended for the owner or user of the boiler and provides information on routine operation and maintenance and emergency shutdown e Installation and Service Manual This manual must only be used by a qualified heating installer service technician or gas supplier Installation or service by anyone unqualified to do so may result in severe personal injury death or substantial property damage Both manuals should be kept in the envelope provided and affixed adjacent to the boiler so that they are readily available for future reference 2 SAFETY INSTRUCTIONS WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A BEFORE LIGHTING smell all around the B Use only your hand to push in or turn the gas boiler area for gas Be sure to smell next to control knob Never use tools If the knob will the floor because some gas is heavier than not push in or turn by hand don t try to repair air and will settle on the floor it call a qualified service technician Force or attempted repair may result in a fire or WHAT TO DO IF YOU SMELL GAS explosion e Do not try to light any appliance l BO e Do not touch any electrical switch do not C Do not use this boiler if any part has been use any phone in your
19. spray a mixture of soap and water onto the suspected area active bubbling indicates a gas leak DO NOT TEST FOR LEAKS WITH AN OPEN FLAME Propane or liquefied petroleum LP is heavier than air may collect or pool in a low area in the event of a leak from defective equipment This gas may then ignite resulting in a fire or explosion Smell near to the ground and low points when checking for propane gas leaks If you smell gas STOP Follow A in the safety instructions in Section 2 11 CORROSIVE ATMOSPHERES If a gas boiler is to be installed near a corrosive or potentially corrosive air supply the boiler should be isolated from it and outside air should be supplied Chemical vapors from products containing chlorine or fluorine must be avoided Even though these chemicals may be safe to breathe corrosive substances can become liberated when passed through a gas flame Even at low concentrations these chemicals can significantly contaminate the air supply and shorten the life of any gas burning appliance The following is a list of some of the products which should be avoided bleaches and chlorinated cleaning products paints and sprays water softeners calcium or sodium chloride leaking refrigeration equipment freon from common aerosol dispensers These chemicals are especially commons near swimming pools beauty shops dry cleaning establishments laundry areas workshops and garages The warranty is void when failure is due to
20. tain a minimum return temperature of 138 F Lower return temperatures will cause condensation on the heat exchanger or in the venting system and reduce draft suction In addition low temperatures in the system may result in extensive damage due to freezing if the system should shutdown possibly due to a safety switch shutdown for any length of time Chemical inhibitors are not recommended as their improper use or maintenance can cause accelerated corrosion resulting in premature failure of the boiler heat exchanger and or system 16 PRESSURE RELIEF VALVE A pressure relief valve is supplied as standard equipment The pressure relief valve provides extra protection against damage that could be caused by malfunctioning controls or excessive water pressure If a pressure relief valve is not used the warranty is void The pressure relief valve must be installed by a qualified installer in accordance with local codes and should not be tampered with in any way The outlet of the pressure relief valve should be positioned over a Suitable drain The drain pipe must pitch down from the pressure relief valve and should be no smaller than the outlet of the pressure relief valve The end of the drain line should not be concealed or threaded and should be protected from freezing No valve of any type should be installed between the pressure relief valve and unit or in the drain line Extensive runs traps or bends reduce the capacity of the pressure relief va
21. ystem back in service 4 Set the thermostat above room temperature and turn on all electric power to the boiler to energize the electronic ignition and pilot Relight Operation Five minutes complete shut off period is required valve After a few seconds the control before attempting to relight the boiler To relight system should lockout and all functions are the boiler follow the Start System procedure off above 5 To take the control system out of lockout either press the reset button or interrupt To turn off gas to boiler or emergency shut power to the boiler depending on the boiler off controller Some controllers will retry ignition Follow Section 8 automatically after 5 minutes lockout 8 TO TURN OFF GAS TO THE BOILER OR EMERGENCY SHUT OFF WARNING Should boiler overheat or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the circulating pump Instead shut off the gas supply at a location external to the boiler Set the thermostat to the lowest setting Turn all electrical power to the boiler off unless boiler is overheating see WARNING above Remove control access panel on the boiler if necessary BONS For combination valve Push in gas control knob slightly and turn clockwise to OFF Do not force it For non combination valve Close the main and pilot manual gas shut off valves The valve is OFF when handle is perpendicular to the directio
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