Utica Boilers MGB Series II/MGC Series Operation and Installation Manual
Contents
1. Check for good metal to metal contact between pilot burner bracket and the main burner 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 e Verify ignition cable provides good electrical continuity STEP 2 moisture resistant thermoplastic insulated wire with 105 C 2219F minimum rating Check ceramic flame rod insulator for cracks or evidence 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 STEP 3 Check spark ignition circuit 30 APPENDIX A CONTROL MODULE Disconnect ignition cable at SPARK terminal on mod ule Electrical shock hazard Ignition circuit generates over 10 000 volts Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury Energize module and listen for audible sparking noise When operating normally there should be buzzing noise turns on and off twice per second for duration of 1 7 seconds depending on model STEP 4 Verify pilot and main burner lightoff e Initiate call for heat Turn thermostat above room temperature Ignition sequence may be delayed by thermal purge until boiler water temperatur2. 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 IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT You may avoid inconvenience and service calls by checking these points before you call for service Possible Cause What to do Thermostat is not set correctly Reset thermostat above room temperature Burner is not operating properly Check flame If it is yellow burner is not getting enough air No electric power to boiler Controls out of adjustment Radiators not heating Circulating pump not running Poor electrical contact Rollout switch blown Spill switch blown Vent damper not operating Possible Cause Gas input amount is incorrect Possible Cause Dirt on seat Water logged expansion tank Or if flame is blue and noisy and seems to lift off burner burner is getting too much air Contact your service technician Check over current protection Verify electric power supply circuit is Reset according to instructions Open radiator vents to expel air Check flow control valve if used It may be in closed position Check over current protection Check relay operation Check all control terminals and wire joints Have your service agent check heat exchanged for blockage Replace rollout switch with exact replacement Have your service agent check venting system and chimn
3. 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 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 4 INSTALLATION PROCEDURE Improper installation adjustment alteration Fire hazard Do not install boiler on service or maintenance could result in death or serious injury combustible flooring or carpeting Failure to follow these instructions could result in death or serious injury 1 Install
4. 17 EQUIPMENT AND OPTIONAL ACCESSORIES ROLLOUT SWITCH BLOCKED VENT SAFETY SWITCH FLAME ROLLOUT SAFETY SHUTOFF BLOCKED VENT SAFETY SHUTOFF Rollout switch is temperature sensitive fuse link Blocked vent safety switch is manual reset disc device Located on boiler base just outside fire box thermostat with fixed setpoint 340 F 171 C and In event of heat exchanger flueway blockage causing normally closed contacts It is located at relief opening flame to roll out of fire box fuse does not change in of integral draft diverter In event of chimney or venting appearance when blown system blockage causing products of combustion to spill If rollout switch blows it must be replaced with out of relief opening spill switch disc heats up and spill exact replacement Check heat exchanger flueways switch contacts open shutting down flow of gas to main for blockage when restoring system to operating burners by removing power to gas valve condition DO NOT operate system without rollout In event spill switch contacts open reset button on switch back of switch will pop up Blocked vent safety switch must be reset manually after switch has cooled off by pushing reset button down Check venting system and chimney for blockage when restoring system to operating condition DO NOT operate boiler without Blocked vent safety switch 26 APPENDIX A CONTROL MODULE A 1 Installation Environment Considerations If you do not follow these instru
5. boiler top 2 Pipe to tank continuously rises up to tank so air can bubble up to it DIAPHRAGM TYPE EXPANSION TANK Diaphragm type expansion tank takes place of conventional expansion tank Carefully read instructions packed with your tank assembly Tank comes with 10 12 pounds per square inch air charge This is the same as pressure produced in sys tem by automatic fill valve When system is first filled tank will contain little or no water As water is heated its pressure increases It expands into tank compressing air in tank Compressed air cushion permits water in system to expand as temperature changes Diaphragm type tank can be mounted on air purger fitting or at any convenient place in supply or return line AIR ELIMINATING FITTING AIR PURGER Air purger is used to remove excess air from system It is installed in supply line It will eliminate air from water before it reaches radiators and bleed off this air MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM TYPE EXPANSION TANK Before system is filled with water there is air in pipes and radiation units Some of it will be trapped as system is filled It is possible to eliminate most of this air through air vent on radiation units Main air vent will speed and simplify this Install on highest point in supply main when all radiation is below top of boiler AUTOMATIC FILL VALVE For a safe efficient operation hot water system must be completely filled with wa
6. 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 sent OR Flame signal present when not expected Appropriate alarm is sent Pilot valve diagnostics Pilot valve circuitry diagnostics during pre purge Self check performed at start up again at beginning of heat cycle and 17 Current leakage detection during Wait for Recovery State Self check performed at start up again at beginning of heat cycle and Wait Torte poen during Wait for Recovery State Control has signaled damper pressure switch 18 Wei far dampar do dpen to close and is waiting for completion P p 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 19 Wait for damper to close Checked at beginning of heat cycle before opening damper If damper does not open in 60 seconds control goes to State 21 20 Wait for damper to open Damper has not opened end swich not closed at beginning of heat Failed close cycle Alarm message is sent control is NOT in lockout 21 Wait for damper to clo
7. of heating season visually check pilot end main burner flames See Figure 16 SAFETY RELIEF VALVE Refer to page 7 for important information To test safety relief valve refer to valve manufacturer s in structions packaged with relief valve Call Technical Support if manufacturer s instruction are not located EXPANSION TANK Tank may become waterlogged or may receive excess of air Frequent automatic opening of safety relief valve indicates water logging High boiler temperature accompanied by unusually low radiation unit temperature and knocking indicates excess air in tank To correct 1 Close valve between boiler and tank Drain tank until empty 2 Check all tank plugs and fittings Tighten as necessary 3 Open valve between boiler and tank Water will rise to normal height in tank if you have automatic fill valve otherwise manually refill system BOILER FLUE PASSAGES Recommend following checked annually by qualified service agent e flue passages e burner adjustment e operation of controls Before start of each season or whenever system has been shut down for some time recheck whole system for leaks and recheck boiler and vent pipe for leaks Replace or patch any boiler seals that are faulty VENT PIPE Venting and piping should be checked at least once a season If vent piping shows any sign of leaking replace immediately WATER SYSTEM If system is to remain out of service during freezin
8. radiation level or as required by Authority having jurisdiction Install low water cutoff device at time of installation See Figure 1 for minimum probe height Use kit 550002998 Follow instruction enclosed with kit With other LWCO s use their manufacturer specific instructions Periodic inspection is necessary as is flushing of float type devices per manufacturers specific instruction FOR USE WITH COOLING UNITS A Boiler used in connection with refrigeration system must be installed so that chilled medium is piped in parallel with heating boiler Appropriate valves must be used to prevent chilled medium from entering heating boiler See Figure 5 page 9 B Boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle LOW WATER TEMPERATURE AND LARGE WATER CONTENT SYSTEM See Figures 6 and 7 Page 10 Significant condensation may form in boiler and or venting system if boiler is operated for long period of time with return temperatures of less than 120 F Condensate is corrosive and can cause severe damage to boiler and venting system Minimum design return water temperature to prevent condensation in boiler and venting is 120 F Minimum high limit setting is 140 F 1 Boiler used in heating system where design water
9. temperatures below 140 F are desired e g radiant floor heating 4 way mixing valve or suitable alternative is required to prevent low temperature return water from entering boiler Follow mixing valve manufacturer s instructions 2 Boiler connected to system having large water content such as former gravity system install system bypass See Figures 6 and 7 page 10 3 If boiler water reset control is used to operate boiler minimum reset supply water temperature setpoint must be at least 140 F unless mixing valve is used as in 1 above 6 CONNECTING SUPPLY AND RETURN PIPING Figure 4 Typical Hot Water Piping RETURN LINE Figure 5 Chilled Water Piping VALVES A amp B OPEN FOR HEATING CLOSE FOR COOLING VALVES C amp D CLOSE FOR HEATING OPEN FOR COOLING CHILLER 6 CONNECTING SUPPLY AND RETURN PIPING Bypass Piping Required For High Mass Large Water Content Systems Figure 6 BYPASS PIPING CIRCULATOR ON SUPPLY RETURN FROM SYSTEM THROTTLING VALVE THROTTLING VALVE ka Y SUPPLY TO SYSTEN FILLTROL WITH AIR PURGER ADJUST THE TwO THROTTLING VALVES TO MAINTAIN AT LEAST 120 F IN THE BOILER RETURN Figure 7 BYPASS PIPING CIRCULATOR ON RETURN RETURN FROM SYSTEM THROTTLING VALVE THROTTLING VALVE SUPPLY TO SYSTEM FILLTROL WITH AIR PURGER ADJUST THE TwO THROTTLING VALVES TO NAINTAIN AT LEAST 120 F THE BOILER RETURN 10 7 CHIMN
10. they are a enclosed in a chase or b lined with type B vent pipe or listed flexible vent liner or other certified chimney lining system 3 Where possible it is recommended to common vent boiler and water heater 4 For multiple boiler installations consult boiler manufacturer for venting recommendations Connecting The Vent Damper And Vent Connector Refer to Figure 1 page 2 for size and location of vent flue opening NOTICE Damper blade on furnished vent damper has 1 2 square inch hole approximately 3 4 diameter Boilers equipped with intermittent ignition hole should be plugged by using plug supplied with vent damper 1 Position furnished vent damper on top of flue outlet collar Fasten damper securely to flue outlet collar with sheet metal screws Verify damper blade has clearance to operate inside of diverter Do not modify either draft diverter or vent damper during installation As An Option Damper may be installed in horizontal or vertical position closer to flue outlet collar preferred See Figures 8 9 and 10 and enclosed vent damper instructions 2 Install vent damper to service only single boiler for which it is intended Damper position indicator shall be in visible location following installation Locate damper so it is accessible for servicing 3 Damper must be in the open position when appliance main burners are operating 4 Boiler is equipped with factory wired harness th
11. E FLUE SENSOR 115V 24V 50VA ROLLOUT SENSOR PILOT FLAME SENSOR 11 WIRING DIAGRAMS Figure 14 Integrated High Limit Electronic Ignition Control 240008781 YATIVLSNI AHL Ad MOI YATIVISNI JHL A835vrioAaN emm AYOLIVA JHL A8 JDVLIOA MOT AYOLDV4 JHL eme ONIYIM ZHO9 AOCL X08 NOLLONN SYOLONGNOD 3394405 ASN S4009 1v201 ANY 232 DSN 3ONVQUO22V NI SNOILOANNOD DV AOZT L gt Lr c Uu La a 5 Uu gt E Uu 4 a D c D a Uu Q a a wn 5 o D I o cus uc Ono o Uu E B 4 E L o c i gt 4 Uu j Uu c 5 gt gt 30111945 MN3A8OJSNVHL ANd Q 15 LO NES _ I TM e OAA H VLOS6S j ma O HOLIMS O 17 N asas Houms INJA 270 05 9 21015 4 1 1019 12 GENERAL INSTRUCTIONS FILLING SYSTEM WITH WATER Close air vents on all radiation units Open valves NOTICE to these units Never run water in a hot empty boiler e Verify boiler and expansion tank drain valves are closed Air bleed screw on tank drain fitting should
12. EY AND VENT PIPE CONNECTION Boiler and venting installations shall be performed by a qualified expert and in accordance with the appropriate manual Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide with is odorless and invisible Boilers connecting to gas vents or chimneys vent installations shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable provisions of the local building codes Check Your Chimney It must be clean right size properly constructed and in good condition Chimney Sizing Chimney sizing and vent installation must be in accordance with The National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable provisions of local building codes This is a high efficiency boiler with low stack temperature Following recommendations are in addition to requirements of the National Fuel Gas Code 1 Type B double wall vent pipe is recommended for vent connector Single wall vent connectors should not be used unless following conditions are true a Except for basement boiler is not installed in unheated space b Total horizontal portion of vent connector not including elbows is less than 5 feet in length 2 Outside chimneys i e chimneys exposed to outdoors below roof line should not be used unless
13. LE OF CONTENTS 1 DIMENSIONS ci ens 2 2 Ratings And 3 3 Table of Contents o ee end 4 4 Installation Procedure 5 5 Ventilation amp Combustion Air 6 6 Connecting Supply And Return Piping 7 7 Chimney And Vent Pipe Connection 11 8 Vent Damper Operation 14 9 Gas Supply 9 15 10 Electrical 15 11 Wiring Diagratris divas tene 16 12 General 19 13 Lighting Instructions 20 14 Operating Your Boiler 21 15 Maintaining Your 23 16 Service Inte coire o e 24 17 Equipment And Optional Accessories Appendix A Control Module 27 SAFETY SYMBOLS amp WARNINGS The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels 4 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
14. SS 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 A Utica NY 13501 web site www ecrinternational com
15. UTICA Models MGC 8D MGC 8DP MGC 9D MGC 9DP MGC SERIES GAS FIRED HOT WATER BOILERS INSTALLATION OPERATION amp MAINTENANCE MANUAL C S A Certified for Natural gas or Propane eecr An 150 9001 2008 Certified Company Tested for 50 psi ASME Working Pressure Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com P N 240009268 Rev D 10 2014 1 DIMENSIONS Figure 1 Dimensions ASME VENT DAMPER TEMP J PRESS GAUGE CONTROL 1 1 4 DRAIN VALVE ROLLOUT GAS SWITCH VALVE FRONT LEET SIE RIGHT SIDE Minimum acceptable height for Low Water Cutoff probe Table 1 Dimensions DIMENSIONS INCH BOILER MODEL FLUE NUMBER DIAMETER WIDTH MGC 8 7 271 MGC 9 7 30 Add 515 to height for vent Damper 2 BOILER RATINGS AND CAPACITIES LIDI oe Tabie 2 Ratings and Capacities www ahridirectory org NATURAL GAS PROPANE GAS AFUE 2 e NET AHRI HEATING T Input 2 Heating INPUT 9 INTERMITTENT NUMBER Mbh Capacity RATING MBH CAPACITY RATING IGNITION WITH 3 Mbh Water MBH VENT DAMPER 3 Mbh MGC 8 262 5 220 191 245 206 179 83 9 MGC 9 299 251 218 280 235 204 83 7 t Input rating for sea level to 2 000 ft 610m above sea level Over 2000 ft 610m above sea level Reduce input rate 4 for ever
16. ait for recovery 58 Igniter flame rod shorted to burner ground Repair or replace igniter Wait for recovery 59 Line Voltage error voltage out of specification high or low 15 37V 44 Wait for recovery 66Hz Applies only to thermostats having on board transformer 60 Polarity is wrong in this case Wait for recovery Thermostat input higher than threshold 61 Line voltage unstable possibly too may heavy loads switching on and off Wait for recovery causing erratic supply voltage Soft lockout maximum number of retries exceeded 62 Soft lockout Soft lockout is reset after one hour if alarm reason disappears 63 Soft lockout maximum number of recycles exceeded Soft lockout 64 Soft Lockout electronics failure On board self diagnostics detected error Soft lockout 65 Over temperature error Sensor measured temperature in excess of SOR lockout 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 touch 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 Verify ignition system grounding Nuisance shutdowns are often caused poor or erratic grounding Common ground is required for module and pilot burner igniter sensor
17. at plugs into vent damper 5 Slope pipe up from boiler to chimney not less than 1 4 per foot 6 Run pipe as directly as possible with as few elbows as possible 7 Do not connect to fireplace flue End of vent pipe must be flush with inside face of chimney flue Use a sealed in thimble for chimney connection Fasten sections of vent pipe with sheet metal screws to make piping rigid Support horizontal potions of vent system to prevent sagging Use stovepipe wires every 5 to support pipe from above Use double wall vent pipe if vent pipe must go through crawl space Where vent pipe passes through combustible wall or partition use ventilated metal thimble Thimble should be 4 inches larger in diameter than vent p 11 7 CHIMNEY AND VENT PIPE CONNECTION Boiler and venting installations shall be performed by a qualified expert and in 5 accordance with the appropriate manual Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due to 6 fire or to asphyxiation from poisonous gases such as carbon monoxide with is odorless and invisible Do not connect boiler to any portion of 7 mechanical draft system operating under positive pressure Minimum Vent Pipe Clearance Wood and other combustible materials must not be closer than 6 from any surface of single wall metal vent pipe Listed Type B vent pipe or other listed venting syste
18. ation must conform to the requirements of the authority having jurisdiction or in the 1 FOR INSTALLATION ON NON COMBUSTIBLE absence of such requirements to the National FLOORS ONLY For installation on combustible Fuel Gas Code ANSI Z223 1 NFPA 54 flooring special base must be used See Replacement Parts Section Boiler can not be 2 Where required by the authority havin 4 installed on carpeting jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically fired Boilers ANSI ASME CSD 1 3 Boiler series is classified as a Category I Vent installation shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI Table 3 MINIMUM CLEARANCE DIMENSIONS Z223 1 NFPA 54 or applicable provisions of the mm local building codes 4 Boiler has met safe lighting and other 152mm performance criteria with the gas manifold and Rear 152mm control assembly on the boiler per the latest Control Side 178mm revision ANSI a i Opposite Side 152mm 5 Install boiler such that gas ignition system 457mm components are protected from water dripping spraying rain etc during appliance operation Flue Vent Connector 152mm and service circulator replacement condensate Near Boiler Piping 51mm trap control replacement etc 6 Locate boiler on level solid base as near chimney as possible and centrally located with respec
19. ause of problem See Table 7 page 30 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 6 page 28 shows codes that could arise on inte grated display during fault Suggestions are provided in Table 6 for servicing these potential errors 29 APPENDIX A CONTROL MODULE Table 7 Troubleshooting Error Codes Error Code Definition Consequence Number 4 Flame current too low Check for flame Non critical alarm 6 Flame sensed out of normal sequence before opening or after closing gas Sait lockout valve 18 Gas valve relays welded Five consecutive soft lockouts Hard lockout 23 Flame sensed during prepurge before gas valve signaled opened Soft lockout Sensor 1 error Temperature sensor in well is not reading correctly Verify it is connected to board Replace if necessary 55 Atmospheric damper end switch failed to close end switch contacts stuck Wait for recovery open 56 Atmospheric damper end switch failed to open end switch contacts stuck Wait for recovery close 57 Igniter flame rod shorted to burner ground W
20. be closed Open valve in line from boiler to expansion tank Open water inlet to your boiler and leave it open Start with lowest radiation unit Open air vent on this unit When all air has escaped and water starts to flow from vent close it Go to next radiation unit and repeat this process Repeat until you have covered every radiation units in the system ending up at highest unit in system If your units have automatic vents manual venting is unnecessary but it will speed up the proper filling of your system If your system is closed expansion tank system you may leave it open to refill system automatically as needed Check temperature pressure gauge Not position of hand indicating pressure This should be between 10 and 15 psi Any lowering of this movable hand below 10 psi Will indicate loss of water due to leakage Automatic fill valve should compensate for this Instructions are packaged with the valve 19 13 LIGHTING INSTRUCTIONS 5 Remove lower front panel 6 Rotate the gas control knob clockwise w to If you do not follow these OFF instructions exactly a fire or explosion may result causing property damage personal injury or loss of life Figure 15 Automatic Gas Valve PRESSURE REGULATOR ADJUSTMENT WIRING e This appliance is equipped with an ignition UNDER CAP SCREW TERMINALS 2 device which automatically lights burner Do NOT try to light this burner by hand e Before operating
21. ctions exactly a fire or explosion may result causing property damage personal injury or loss of life eDo 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 around 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 14 Page 18 e L1 amp L2 leads inside J box using wire nuts Secure J box cover e Circulator harness to circulator Harness comes plugged into module with Molex plug e 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 e Refer to enclosed addendum for wiring instructions when using indirect hot water heater A 3 Adjusting Settings To discourage unauthorized changing of settings pro cedure 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 para
22. d fires or shuts off burner based on this tem perature data 1 When Call for Heat occurs control enables circulator and monitors boiler water temperature to determine whether thermostat can be satisfied without firing burners 2 Control determines burner operation is required module proceeds to start burner see state codes list and heats water in boiler until setpoint tem perature is achieved or thermostat is satisfied 3 Burner is de activated ignition module completes heating cycle returns to idle and waits for tem perature 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 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 7 Flame stabilization Flame signal is being established Variation in signal is allowed during this state 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
23. e 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 burner does not light e If so ensure adequate flame current as follows Turn off boiler at circuit breaker or fuse box Clean flame rod with emery cloth Verify electrical connections are clean and tight Replace damaged wire Check for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary At gas valve disconnect main valve wire from MV terminal Turn on power and set thermostat to call for heat Pilot should light main burner will remain off because main 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 19 for possible flame problems and causes If necessary adjust pilot flame by turning pilot adjustment screw on gas control clockwise to decrease or counterclockwise to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly to assure proper gas control operation Figure 16 page 20 Set temperature below room set point to end call for heat e Recheck ignition sequence as follows Reconnect main valve wire Adjust thermostat above room temperature Verify ignition sequence at burner If spark does not stop afte
24. ey for blockage or down draft condition Reset spill switch Consult troubleshooting guide in Effikal manual packaged with vent damper IF BURNER IS NOISY What to do Contact your service agent RELIEF VALVE LEAKING What to do Open valve manually Allow water to run and clear valve seat Drain tank see instructions HAVE YOUR SERVICE AGENT CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT 24 17 EQUIPMENT AND OPTIONAL ACCESSORIES EXPANSION TANK Expanding water flows into expansion tank Tank should be correct size Tank is filled with air As water expands it compresses air in the tank to form air pressure cushion This spring like cushion serves to maintain correct operating water pressure regardless of water temperature This assures full measure of water even in highest radiation unit of system It also prevents blowing off of safety relief valve Air in tank in beginning with system filled with cold water is sufficient for proper operation Tank also serves as trap for excess air in system Air would cause gurgling in pipes and in efficient circulation in radiators if left in system It is possible for tank to become waterlogged filled with water It can also become overfilled with air This can happen after filling system with new water Fittings provided on tank and in line to tank are for bleeding off excess water or air When installing this tank it is important 1 Tank be higher than
25. fe point of pendent of other discharge piping discharge e Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate e Run pipe as short and straight as possible to location protecting user from scalding and prop erly drain piping e Install union if used close to safety relief valve outlet e Install elbow s if used close to safety relief valve outlet and downstream of union if used e Terminate pipe with plain end not threaded 6 CONNECTING SUPPLY AND RETURN PIPING Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these instructions 1 Boiler is shipped assembled Install discharge piping from safety relief valve See Warning Page 7 2 Install temperature pressure gauge e Apply pipe sealant to threads on shaft of gauge e Thread gauge into supply water tee See Figure 3 NOTICE DO NOT TIGHTEN GAUGE BY HAND Gauge should be tightened using crescent wrench or 9 16 open end wrench See Figure 3 3 Connect supply and return lines to boiler Connections may require additional fittings and parts as shown on diagrams Figure 3 Temperature Pressure Gauge Verify clean water supply is available to water inlet valve Install sand strainer when water supply is from a well or pump Install hot water boiler above
26. g weather always drain it completely water left in to freeze will crack pipes and or boiler CLEANING YOUR BOILER AND BURNERS Flue passages between sections should be examined yearly and cleaned if necessary To clean e Remove burners pilot and vent pipe Remove top and front jacket panels Remove two screws attaching intermediate front panel to left and right side jacket panels Remove draft diverter and intermediate front panel as a unit Carefully remove cerafelt gasket strips Clean passageways between sections with flexible handle wire brush Remove dirt from bottom of boiler and from between sections by vacuuming Verify all flame ports in burners are open and clear Shake out or blow out all loose dirt in burners Reseal seams between adjacent sections as necessary with 400 F RTV silicone sealant Reassemble all parts Verify tightness of pilot connections and condition of burner flames after reassembly See Figures 16 and 17 page 21 Verify vent pipe connections to chimney are secure and no obstructions are present HOUSEKEEPING e Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids e Keep boiler area clear of debris and other materials obstructing flow of combustion and ventilation air 23 16 SERVICE HINTS WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building
27. ing jurisdiction may Mbh of total input rating of all appliances override these methods in enclosure Engineered Installations Must be approved by Communicating through horizontal ducts authority having jurisdiction Provide minimum free area of 1 in per 2 e Mechanical Air Supply Provide minimum of Mbh of total input rating of all appliances 0 35 cfm per Mbh for all appliances located in enclosure within space Additional requirements where B One Permanent Opening Method Provide exhaust fans installed Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating opening commencing within 12 inches of top of enclosure Provide minimum clearance of 1 inch on sides back and 6 inches on front of boiler does not supersede clearance to All Indoor Air Calculate minimum allowable room combustible materials volume for all appliances in space Use a different e Refer to National Fuel Gas Code for additional method if minimum volume not available requirements for louvers grilles screens and air A Standard Method Cannot be used if known ducts air infiltration rate is less than 0 40 air e Combination Indoor and Outdoor Air Refer changes per hour See Table 4 for space to National Fuel Gas Code for application with boiler only Use equation for multiple information appliances Volume 50 ft x Total Input Mbh B Known Air Infiltration Rate See Tab
28. instructions To Turn Off Gas To Appliance and call your service technician or gas supplier e Do not try to light any appliance TO TURN OFF GAS TO APPLIANCE e Do not touch any electrical switches do not use any phone in your building 1 Setthe thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed 3 Push in gas control knob slightly and turn clockwise w to OFF Do not force 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 STOP Read the safety information above Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Q N 20 14 OPERATING YOUR BOILER AUTOMATIC GAS VALVE Automatic Gas Valve opens or closes according to heat requirements of thermostat and temperature limit control It closes if pilot goes out Each individual control must be operating correctly before any gas can pass to burners Any one control can hold gas supply from burner regardless of demand of any other control SAFETY PILOT Safety Pilot prevents flow of gas to burner if pilot goes out or will not ignite GAS VALVE SAFETY SHUTDOWN TEST Ignition system safety shutoff device must be te
29. le 4 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 C Refer to National Fuel Gas Code for opening requirements between connected indoor spaces Table 4 Minimum Room Volume Indoor Air Only Room Cubic Feet Volume Was Standard Known Air Infiltration Rate Method Air Changes Per Hour JM NCC UN CORN RR CR UR x Table values based on boiler only Add volume for any additional appliances 6 CONNECTING SUPPLY AND RETURN PIPING Figure 2 Safety Relief Valve Burn and scald hazard Safety relief valve could discharge steam or hot water during operation Install discharge piping per these RELIEF VALVE instructions DISCHARGE gt 1 Refer to local codes and appropriate ASME Boiler LINE p and Pressure Vessel Code for additional installa ab tion requirements Install safety relief valve using r1 pipe fittings provided with boiler See Figure 2 m 2 Install safety relief valve with spindle in vertical position 3 Do not install shutoff valve between boiler and safety relief valve Check local 4 Install discharge piping from safety relief valve codes for BOILER See Figure 2 maximum e Use 34 or larger pipe distance e Use pipe suitable for temperatures of 375 F from floor 1919C or greater or allowable e Individual boiler discharge piping shall be inde sa
30. meter requiring adjustment is displayed See Figure 12 page 16 o SP Setpoint 180 F default setting ad justable between 130 and 220 F Note on some models this is HL High Limit o Df Setpoint Differential 15 F default set ting adjustable between 10 and 30 F o F_ Degrees Fahrenheit Press UP or DOWN button until parameter has reached desired value After 60 seconds without any button inputs control automatically returns to READ mode A 4 Display 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 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 18 Display Readout Display Text Description Shows SER sta Current State 1 Sensor 1 Temperature 5 it sp Setpoint oP hr Err dff Setpoint Differential hr Heat Request Status err Error Code fla Flame Current F F Degrees Fahrenheit t uA C Degrees Celsius uA Micro Amps 27 APPENDIX A CONTROL MODULE A 5 Operation Module continuously monitors boiler water tempera ture an
31. ms shall be installed in accordance with their listing Removing Existing Boiler From Common Venting System When an existing boiler is removed from common venting system common venting system is likely to be too large for proper venting of appliances remaining connected to it At time of removal of existing boiler following steps shall be followed with each appliance remaining connected to the 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 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 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 22 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft ho
32. od 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 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 re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 8 VENT DAMPER OPERATION Figure 8 Vent Damper Installation HORIZONTAL INSTALLATION FLOW NO GED SS TO FURNACE VENT DAMPER TO CHIMNEY NO OR BOILER INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY DO NOT MOUNT ABOVE ORBELOW VENT VERTICAL INSTALLATION TO CHIMNEY VENT DAMPER FLOW ACTUATER MAY BE INSTALLED IN ANY POSITION TO FURNACE OR BOILER Annually check vent damper and all flue product carrying areas of appliance with particular attention given to deterioration from corrosion or other sources If you see corrosion or other deterioration contact your heating contractor for re
33. ostat operation by raising and lowering thermostat setting as required to start and stop the burners 5 Instructions for the final adjustment of the thermostat are packaged with the thermostat adjusting heating anticipator calibration etc Set heat anticipator at 2 amps 24 volt thermostat connects to aquastat terminals T and TV 15 VENT DAMPER WIRING Boiler is equipped with factory wired harness with 4 pin molex plug that plugs into 4 pin molex receptacle inside vent damper operator Vent damper must be connected for boiler to operate If any of the original wire as supplied with this appliance must be replaced It must be replaced with type 105 C thermoplastic wire or its equivalent 11 WIRING DIAGRAMS Figure 12 Integrated High Limit Electronic Ignition Control 240008781 Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or SPARK FLAME loss of life IGNITER SENSE 24 VAC TRANSFORMER GAS CONTROL amp Ww IL B 0 2 4 e e s 8 F E a B 8008800 B 000 TI a T nn 0 B 000 HE d E H d Es H d E A OPTIONAL DEPENDING ON CONFIGURATION Inducer is not an option 11 WIRING DIAGRAMS Figure 13 Integrated High Limit Electronic Ignition Control 240008781 CH PUMP GAS VALV
34. pairs Check vent damper operation as follows e When boiler is off check vent damper positions indicator points to closed position Figure 10 e Turn thermostat or controller up to call for heat and check vent damper indicator points to open position e Turn thermostat or controller down again and check damper position indicator returns to closed position Vent Damper Manual Operation Vent damper may be placed in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller Thermostat will control burner firing as before while damper will remain open DO NOT turn damper open manually or motor damage will result Set switch to AUTOMATIC OPERATION to close vent damper during burner off cycle Figure 9 Vent Damper Placement CAUTION DO NOT INSTALL THE VENT DAMPER NOT WITHIN 6 in 152 mm OF COMBUSTABLE MATERIAL INSTALL DAMPER CHIMNEY WATER HEATER BOILER For further information and vent damper troubleshooting guide refer to manual packaged with vent damper Inspect vent damper at least once a year by a qualified service technician Figure 10 Vent Damper Position Indicator o o V uU z Pe g P e a S 8 B 2 P 2 m o m o m 5 2 m 5 2 o o DAMPER CLOSED DAMPER OPEN SHOWING OPEN AND CLOSED POSITION 13 9 GAS SUPPLY PIPING WHAT TO DO IF YOU SMELL GAS e Do not try to light an
35. r pilot lights replace module If main burner does not light or if main burner lights and system locks out check module ground wire and gas control as described in troubleshooting table See Table 7 Page 30 Figure 19 Troubleshooting Pilot Flame CAUSE CHECK FOR LACK OF GAS FROM CLOGGED ORIFICE FILTER CLOGGED PILOT FILTER LOW GAS SUPPLY PRESSURE PILOT ADJUSTMENT AT MINIMUM APPEARANCE SMALL BLUE FLAME _ LAZY YELLOW FLAME CHECK FOR LACK OF AIR FROM DIRTY ORIFICE DIRTY LINT SCREEN IF USED DIRTY PRIMARY AIR OPENING IF THERE IS ONE PILOT ADJUSTMENT AT MINIMUM CHECK FOR EXCESSIVE DRAFT AT PILOT LOCATION RECIRCULATING PRODUCTS OF COMBUSTION WAVING BLUE FLAME l ZA f 1 CHECK FOR HIGH GAS PRESSURE NOISY LIFTING BLOWING FLAME DA _ HARD SHARP FLAME THIS FLAME IS CHARACTERISTIC OF MANUFACTURED GAS CHECK FOR HIGH GAS PRESSURE ORIFICE TOO SMALL Correct Pilot Flame 3 8 to 1 2 inch in flame See Figure 16 Page 21 Sil 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 UNLE
36. re to comply will result in death or serious injury 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 open flames or other methods providing ignition source e Correct leaks immediately and retest Table 5 Gas Pipe Sizes NATURAL GAS Pipe Capacity BTU Per Hour Input Includes Fittings iua Va i 1 20 92 000 190 000 350 000 625 000 40 63 000 130 000 245 000 445 000 60 50 000 105 000 195 000 365 000 PROPANE GAS Pipe Capacity BTU Per Hour Input Includes Fittings Length of Copper Tubing Iron Pipe Pipe FT 5s 3 4 Yo 3 4 20 131 000 216 000 189 000 393 000 40 90 000 145 000 129 000 267 000 60 72 000 121 000 103 000 217 000 Outside diameter Measure length of pipe or tubing from gas meter or propane second stage regulator Figure 11 Gas Piping Manual Main M 2 Shut Off Valve Automatic Gas Valve 3 Minimum Sediment Trap Floor Line 14 10 ELECTRICAL WIRING Elec
37. se Damper has not closed despite actuator de energized Failed open Alarm message is sent control is NOT in lockout 28 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 state e For models having reset capability press any onboard button or cycle power to reset Figure 20 Basic Control Algorithm Example 200 F 93 3 C SETPOINT GAS VALVE OFF 15 F 8 C DIFFERENTIAL GAS VALVE ON 70 F 21 C A 7 Troubleshooting Following service procedures are provided as general guide 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 c
38. smell all around appliance area for gas Be sure to smell next to floor OUTLET PRESSURE TAP GROUND TERMINALS 2 because some gas is heavier than air and ourera will settle to the floor SS e Use only your hand to turn the gas J PILOT shutoff valve Never use tools If valve erudi NS cca will not turn by hand do not try to repair GAS CONTROL KNOB UNDER CAP SCREW 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 7 Wait five 5 minutes to clear out any gas Then has been under water Immediately call smell for gas including near the floor If you smell a qualified service technician to inspect gas STOP Immediately call your gas supplier appliance and to replace any part of control from a neighbor s phone Follow the gas system and any gas control which has been supplier s instructions If you don t smell gas under water go to next step LIGHTING PROCEDURE FOR BOILER WITH 8 Rotate gas control knob counterclockwise Nto INTERMITTENT PILOT SYSTEM ON For Your Safety Read Before Operating 9 Replace lower front panel A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to 10 Turn on all electric power to the appliance light appliance by hand 11 Set thermostat to desired setting 12 If the appliance will not operate follow the WHAT TO DO IF YOU SMELL GAS
39. sted after placing boiler in operation RELIGHT Electric and gas shall be off for 5 minutes before relighting THERMOSTAT Keep it set at desired room temperature If windows are to be opened or heat is not needed move thermostat pointer to lower setting NOTICE In event of failure of any component system will not operate or will go into safety lockout System is completely self checking On every call for heat each component must be functioning properly to permit operation Safety lockout system has to be reset by turning thermostat to lowest setting for one minute then back to normal setting ADJUST PILOT BURNER Pilot flame should surround 3 8 to 1 2 of the pilot sensor See Figure 16 If flame needs adjusting do it as follows 1 Remove screw cover over pilot adjusting screw 2 Insert small screwdriver and adjust flame as needed Turn screw counterclockwise to increase flame clockwise to decrease 3 Replace screw cover over pilot adjusting screw Figure 16 Pilot Flame PROPER FLAME ADJUSTMENT 3 8 TO 1 2 INCH 9 5 TO 12 7 MILLIMETRE INSULATED ELECTRODE MAIN BURNER S e Main burners do not require primary air adjustment and are not equipped with primary air shutters Main burner flames form sharp blue inner cones in softer blue outer mantel with no yellow Puffs of air from blowing on flame or stamping on floor will cause flames to turn orange momentarily This is no
40. t to NOTE Greater clearances for access should supersede fire heat distribution system as practical protection clearances 7 Allow 24 inches 610mm at front and right side wall in front of boiler ANSI standard for alcove is 18 inches from front of appliance to leading edge of side walls as shown below 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 Minimum Clearances to Combustible Construction as seen from above BOILER Control Side 5 VENTILATION amp COMBUSTION AIR Provide combustion air and ventilation air in accordance e All Outdoor Air Provide permanent opening s with the section Air for Combustion and Ventilation communicating directly or by ducts with outdoors of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable provisions of local building codes A Two Permanent Opening Moro Provide opening commencing within 12 inches of top Provide make up air where exhaust fans clothes and second opening commencing within 12 dryers and kitchen ventilation equipment interfere inches of bottom of enclosure Wipo open O Direct communication with outdoors or National Fuel Gas Code recognizes several methods communicating through vertical ducts of obtaining adequate ventilation and combustion air Provide minimum free area of 1 2 per 4 Requirements of the authority hav
41. t unusual Remain still when observing main burner flames If flame appearance is not correct check main burner orifices burner throat and flame ports for dust and lint obstruction It may be necessary to remove rollout shield to observe main burner flames Replace rollout shield after observation Refer to Figure 17 Figure 17 Burner OUTER MANTEL NOAA 014141678170 174 67410141018 01 04141410 T Hug ow og io TD 17 SHARP INNER CONES ADJUST LIMIT CONTROLS Instructions for each control are included with controls Settings can be changed Refer to Appendix A page 27 for information 2 14 OPERATING YOUR BOILER CHECK THERMOSTAT OPERATION A When set above temperature indicated on thermostat boiler should ignite Verify thermostat turns boiler off when room temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees After setting limit control to limit setting check to see if it shuts off gas supply to burners Turn your thermostat up to call for heat and let boiler run until temperature of water reaches limit setting Gas valve should shut off and circulator running until thermostat is satisfied or water cools enough to restart burners through limit control Set thermostat for desired temperature Conditions in your home and location of thermostat will govern this setting 22 15 MAINTAINING YOUR BOILER BURNERS Beginning
42. ter Adding new water when needed can be done manually by use of hand valve in water supply line Requires regular atten tion to system s needs Automatic fill valve accom plishes this without attention Install in supply line on hot water boilers only Valve operates through water pressure differentials It does not require electrical connection DRAIN VALVE Manual valve provides means of draining all water from boiler and system It is often installed in 3 4 tapping at bottom of end boiler section Or it can be installed in tee where return line enters boiler WATER TEMPERATURE CONTROL Water temperature limit control in relay is adjustable and may be set as necessary It may be set as low as 104 F 40 C or as high as 220 F 104 C This depends on type and amount of radiation involved and weather conditions CIRCULATING PUMP Every forced hot water system requires circulating pump Separate pump or zone valve is required for each zone if you have a two or more zone system Pump must have capacity to provide circulation required by your system Pump is connected into main just ahead of boiler It is also wired to electrical system VENT DAMPER This product is automatic motorized stack damper developed to increase efficiency of heating system by reducing standby losses from heating apparatus and conditioned air space Damper closes chimney vent when burner is off and fully opens it when combustion is required 25
43. trical 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 NOTICE Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to National Electrical Code ANSI NFPA 70 ELECTRIC POWER SUPPLY Run separate 120 volt circuit from separate over current protective device in electrical service entrance panel This should be a 15 ampere circuit Locate shut off switch at boiler It must be turned off during any maintenance Connect 120 volt power supply to control leads L1 HOT and L2 LWCO kit 550002998 includes wiring instructions and diagrams If using another LWCO refer to specific manufacturer instructions supplied by appropriate manufacturer Run a 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod THERMOSTAT INSTALLATION 1 Thermostat should be installed on an inside wall about four feet above the floor NEVER install thermostat on outside wall Do not install a thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures televisions a fireplace or a chimney 4 Check therm
44. y 1000 ft 304m above sea level Heating Capacity based on D O E Department of Energy test procedure Add model number suffice P for Propane 2 Net AHRI Water rating 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 39 MBH 1 000 Btuh British Thermal Unit Per Hour Ratings marked Net AHRI Ratings indicate amount of remaining heat input used to heat radiation or terminal units Net AHRI Ratings shown are based on allowance of 1 15 in accordance with factors shown on AHRI Standard as published by The Hydronics Institute Selection of boiler size should be based upon Net AHRI Rating being equal to or greater than calculated heat loss of the building Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements BOILERS FOR USE AT HIGH ALTITUDE Boiler is factory equipped for use at altitudes of 0 2 000 feet above sea level For use at altitudes above 2 000 feet above sea level input ratings are reduced by change in main burner orifice size For altitudes above 2 000 feet above sea level input ratings should be reduced at rate of 4 for each 1 000 feet above sea level Consult National Fuel Gas Code ANSI Z223 1 NFPA 54 or manufacturer for correct orifice sizing information 3 TAB
45. y 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 CHECK GAS SUPPLY Gas pipe to your boiler must be correct size for length of run and for total BTU per hour input of all gas utilization equipment connected to it See Table 5 for proper size Be sure your gas line complies with local codes and gas company requirements CONNECTING THE GAS PIPING Gas line enters boiler from right side 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 Use pipe joint compound suitable for LP gas on male threads only e Use ground joint unions e Install sediment trap upstream of gas controls e Use two pipe wrenches when making connection to gas valve to keep it from turning e Install manual shut off valve in vertical pipe about 5 feet above floor e Tighten all joints securely e Propane gas connections should only be made by licensed propane installer e Two stage regulation should be used by propane installer e Propane gas piping should be checked out by propane installer CHECKING GAS PIPING A DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failu
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