mg series boilers installation and service manual
Contents
1. 63 5 PS Packaged Models Include 156 2 Standard Model Parts plus 39 8 cm oll 24 8 cm e Circulating Pump E i Custom Cast Iron Pump Adapter 6 e Expansion Tank 15 2 4 3 5 Air Purger Combination Fill Regulator Valve I 610cem Automatic Air Vent Allow 18 457 mm minimum in front for servicing Minimum clearances to combustible material Top 24 610 mm Sides 2 51 mm Rear 2 51 mm Flue 6 153 mm APPROVED FOR COMBUSTIBLE FLOORS amp CLOSET INSTALLATION The Super Hot product improvement program may result in changes to the design and or specifications being made without notice MODEL INPUT OUTPUT DIMA DIMB DIM DIM D DIME MBH kW MBH kW in cm in cm in cm in cm in cm Ib kg MG50 50 147 424 124 11 5 292 525 133 40 102 392 99 6 4 5 11 4 125 57 MG75 75 220 635 186 14 5 368 525 13 3 5 0 127 39 5 100 3 4 5 11 4 150 68 MG100 100 29 3 846 248 17 5 44 5 525 13 3 5 0 127 39 5 100 3 4 5 11 4 175 80 MG125 125 36 6 105 5 30 9 20 5 52 1 6 50 165 6 0 152 40 5 102 9 4 5 11 4 200 91 MG150 150 44 0 126 5 37 1 23 5 59 7 6 50 165 6 0 152 40 5 102 9 4 5 11 4 225 102 For altitudes above 2 000 feet refer to Section 3 6 to determine the appropriate Input de rate or contact the fac2. 3 About Our Manuals 22 2 4 1 Lighting Iristr ctions ii dete 4 13 Safety Instr clloris 5 cer uo E ete a Eee 4 1 2 Lighting Instructions for Intermittent Electronic with Combination Gas Valve 5 1 3 To Turn off Gas to the Boiler or Emergency 5 1 4 Controller Programming and Service Codes 6 VA EM DE TCU 6 1 4 2 Installer pee e Ee eror e ea 7 1 4 3 Operating ChecKOUL ret Y dee et aeuo eR rele 8 TAA RIT 8 1 4 5 Operating State Codes and 8 2 Installation Instr ctioris os uua n Era RE ERR RE 11 24 IER 11 2 2 Installation Codes and Requirements 11 ESUNMBWcnm M 11 2 4 12 25 Air Supply for Combustion and Ventilation eene 12 2 6 Corrosive 2 reete tna ute eed gana nO REIN 12 22 E 13 28 Automatic V
3. emere erre nnn nennen 22 4 2 Cleaning Procedures E 22 4 3 EU 23 44 Caution Water 24 4 5 Refractory Handling ERREEN 24 5 Replacement Parts X 25 6 Wiring DIAgratmJs 27 7 Troubleshooting Guide 1 ce creen erc ree teer rere 29 8 NOTES e EEE 31 9 ipee E 32
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5. INSTALLATION AND SERVICE MANUAL MG SERIES BOILERS FOR MODELS MG 50 E TO MG 150 E SEE REAR COVER FOR INDEX C WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or loss of life Please carefully read this manual For assistance or additional information consult a qualified installer service agency or the gas supplier 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 Telephone 604 929 1214 www alliedboilers com Branches Calgary Edmonton Toronto Denver PN1362736 DIMENSIONS AND SPECIFICATIONS Standard Model Includes AST NE 25 6 Electronic Ignition AUTOMATIC e Zone Control Board with Transformer VENT DAMPER i E e Stainless Steel Burners e Combination Gas Valve ur DRAFT HOOD z High Limit Sensor e Temperature Pressure Gauge i sr A S M E Pressure Relief Valve i ES cm Drain Valve xf Draft Hood E cm q Blocked Vent Safety Switch OPTIONAL OUTLET 2 NPT MALE D e Flame Roll out Safety Switch CIRCULATING CE INLET 2 NPT MALE Automatic Vent Damper CAST 25 ADAPTER
6. WARNING The following instructions are intended as a guide for qualified persons Before lighting the boiler the pre startup instructions of Section 3 1 MUST be performed If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 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 This boiler does not have a continuous pilot flame It is equipped with an ignition device which a utomatically lights the pilot Do not try to light the pilot by hand In the event of failure of any component either the system will not operate or it will go into safety lockout 1 Make sure the Gas Valve and all electrical power to the boiler are OFF 2 Setroom thermostat to the lowest setting 3 Connect a manometer at pressure tapping on downstream section of gas valve 4 Wait five minutes to clear out any gas If you smell gas STOP Follow the safety instructio ns provided in Section 1 1 under WHAT TO DO IF YOU SMELL GAS Remember that propane does not vent upward naturally 5 Program the controller following Section 1 4 and test as follows Set thermostat above room temperature to call for heat and turn power on for the boiler b Watch for spark at pilot burner All models w
7. Hot MG series boilers are designed for use in closed loop systems and are not intended for open systems as in heating pool water or systems where water is constantly replenished Operating the boiler an open system will result in premature failure of the heat exchanger Super Hot boilers may be used to heat water in open systems indirectly by installing a heat exchanger such as the Super Hot C Coil to separate open and closed systems Heating systems with low temperature return water may cause flue gas moisture to condense on the boiler heat transfer surfaces causing corrosion and restricting flue gas flow Also low temperature return water may overcool the flue gases resulting in reduced vent suction These are natural phenomena and are independent of the boiler design a guide to avoiding such corrosion and draft problems it is imperative that the return water be not less than 135 F 57 C MG SERIES BOILERS MUST ALWAYS BE USED WITH FORCED SYSTEM CIRCULATION 15 MG Series Boilers Installation and Service Manual 213 PRESSURE RELIEF VALVE A pressure relief valve is supplied as standard equipment The pressure relief valve is 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 should be installed on the boiler outlet with its spindle vertical The connection between the boiler and
8. on boiler rating plate 29 Bypass or mixing valve has been used to prevent return water less than 242 135 F All applicable venting codes have been met Air openings sized to provide 0 adequate supply air for combustion flue gas dilution and ventilation and will 2 2 2 5 2 6 2 7 not be blocked off L Check for spillage at draft hood and other areas susceptible to spillage 3 7 Operate the boiler for 15 minutes then clock and calculate Btu h input rate The input rate must not exceed that specified on the boiler rating plate 3 6 Clocked BTU H Input Rate Perform check of temperature controls aquastat optional aquastat when 34 38 used and thermostat L Test any other controls as specified by the manufacturer Visually inspect main burners and pilot to ensure proper flame operating 33 characteristics and ignition extinction is ok Allow the boiler to cycle a few times to ensure functions are operating correctly Close main shut off valve and check that burners and pilot flame extinguish Clearly identify emergency shut off devices and make the user or owner aware of their location and method of operation Fill in the contact information on the cover of the User s Information Manual and leave both manuals in the envelope adjacent to the boiler NOTE INSTALLER S RESPONSIBILITY Before leaving installations installers shall ensure that an appliance accessory component or equipment install
9. or corrosion Check for dislodged venting or possible leaks in venting ducts Remove the draft hood from the boiler and inspect the flueways for the presence of soot or rust scale Inspect the draft hood and smoke pipe connecting the draft hood to the flue for rust or corrosion before replacing the draft hood The presence of soot rust scale or corrosion indicates misadjustment 4 2 Inspect and if necessary clean the pilot burner and main burner Check burners to see that they are not cracked or dislodged 3 3 4 2 Visually check the pilot and main burner flames A yellow flame caused by improper adjustment is always accompanied by formation of soot which if allowed to continue will partially restrict free passage of products of combustion to the flue 3 3 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 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 3 9 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 for weeping at pressure relief valve outlet during normal operation 2 13 Listen for unusual audible sounds in the boiler Any audible sounds in the boiler system may be indications of sca
10. the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 current edition and and or the Canadian Electrical Code CSA C22 1 Part 1 current edition Field wiring shall conform to Section 2 2 and to the temperature limitations of T 63 F 35 C rise or better Make connections as shown in the wiring diagrams provided For details of electrical wiring for different pilots and controls refer to wiring diagrams included in this manual 16 MG Series Boilers Installation and Service Manual Startup Instructions Section 3 3 1 5 D o 02095 boiler operating pressure Water should be of suitable quality Do not use water with high hardness Check for and repair any leaks in water piping Check burners to see that they are not dislodged Check for proper installation of pressure relief valve draft hood and venting Check that the electrical wiring matches the wiring diagram in this manual or on the boiler and retest any leaks found Operate circulating pump and vent all radiation units and high points in system piping 3 2 STARTUP Fill entire heating system with water and vent or purge air from system Add water as needed to reach Check if the flame roll out safety switch and blocked vent safety switch are properly located and wired Use a soap solution to check for leaks in gas piping from meter to boiler pilot and manifold Repair
11. 2 NEUTRAL Strip wire ends to a maximum of 3 16 before inserting into terminal block Tighten terminal screw clamps Connect ground wire to ground screw G on the boiler control panel B Zones Remove zone one plug in terminal block Connect 24 Vac thermostat leads to terminals TH1 and TH2 on plug in terminal block Connect normally closed zone valve 24 Vac motor leads to terminals ZV1 and 242 Connect zone valve end switch leads to terminals ES1 and ES2 Strip wire ends to a maximum of 3 16 before inserting into terminal block Tighten terminal screw clamps Re insert plug in terminal block into mating connector on Zone Control Board Repeat for zones 2 3 and 4 as required C Optional Second Pump A second pump 120 Vac 1 6 HP maximum may be connected to terminals P2 HOT and P2C NEUTRAL D Jumpers Jumpers J1 and J2 are factory set for a multi zone installation E For Single zone Applications Install jumper J2 and connect 24 Vac thermostat leads to terminals TH1 and TH2 on Zone 1 plug in terminal block 27 MG Series Boilers Installation and Service Manual 39und TVIWH3H L NOLLINSI HadlAvO LN3A 892 YSTIONLNOO VI9 6S TIS3MA3NOH 9NISIM 9 3809143 ANSS3O3N AT8W3SSV 1014 JOVIdIY J318v3ovid3s 1314 LON 53 AYI 10144 d3sn 38 ISAW IN3IVAInO3 SLI MO 3MIM 2 601 38 15 431108 GaNddAS SV 3 T
12. 35 000 Btu h x 0 96 129 600 Btu h FOR UNITED STATES Natural Gas Propane 0 to 2 000 feet Over 2 000 feet 0 to 2 000 feet Over 2 000 feet 51 orifice Input must be reduced Input must be reduced MG Standard input 4 foreach 1000 feet 860 arife 4 for each 1000 feet p above sea level standard input above sea level Reference National Fuel Gas Code ANSI Z223 1 8 1 2 High Altitude Example of High Altitude De rate Boiler MG 100 Altitude 5 000 feet Standard Input 0 to 2 000 ft 100 000 Btu h from page 2 Reduction for 5 000 ft 4 x 5 20 Input at 5 000 ft De rate Standard Input by 20 100 000 Btu h x 1 0 20 100 000 Btu h x 0 80 80 000 Btu h 19 MG Series Boilers Installation and Service Manual Small adjustments to the input rate can be made by varying the manifold pressure Normally it should be adjusted no more than 0 2 inch w c for natural gas or 0 5 inch w c for propane from the manifold pressure specified on the rating plate WARNING Exceeding the allowable input rate can produce dangerous concentrations of carbon monoxide and cause the boiler to overheat resulting in severe personal injury death or substantial property damage Carbon monoxide is a lethal colorless and odorless gas Input Rate Test Consult gas company to determine the heating value of the gas supplied in Btu per cubic feet Operate boiler for 15 minutes starting with al
13. ATIVWHON 3HL NI 53 3NOZ ANWA SV9 SilVALOV HOLIMS QN3 MN3dAVO IN3A OIIVWOLOV M3dWVO IN3A OIVWOlnv 5 VL9 6S TI3MA3NOH 7719665 TI3MA3NOH GYVOd NO AVI3H HONOYHL S dWnd WALSAS S3lVALLOV HOLIMS CNA JAYA 3NOZ JAWA 3NOZ S3lVAUOV IVISOWN3HL 3NOZ NOLLVYAdO 9NILV3H 731312395 3SIMM3HIO 5531 0 90A SI ONIMIM INVHOVIO OILVIN3HOS SALON 28 MG Series Boilers Installation and Service Manual Troubleshooting Guide Section 7 Problem Boiler will not fire Boiler goes on and off at frequent intervals Boiler fires continuously Rumbling and moaning sound in boiler Gas odor Flame roll out on ignition or during operation Possible Cause No power Solution Check power switches and wiring No gas supply to boiler Check gas source and pressure Gas supply pipes are not purged of air Purge gas line No heat demand Check if thermostat setting is above room temperature and aquastat setting is above boiler water temperature Flame roll out or blocked vent safety switch is not reset Push reset and diagnose cause Flow switch or low water cut off Check pump capacity amp flow direction Check for correct water levels and air locks Gas valve failure closed position Check gas valve and replace if necessary Thermocouple failure Check thermocouple and replace if
14. Code ANSI Z223 1 or Section 7 Venting Systems and Air Supply for Appliances of the B149 Installation Codes or applicable provisions of the local building codes The venting shall be supported as required by applicable code s Horizontal runs shall slope upward not less than 4 inch per foot 21 mm m from the boiler to the vent terminal This unit must be installed with the factory supplied draft hood in place The draft hood is a safety device designed to control chimney drafts that might affect combustion or blow out the pilot The draft hood supplied with the boiler must not be altered The minimum skirt height as indicated on the draft hood must be maintained Vent connectors serving the boiler must not be connected into any portion of mechanical draft systems operating under positive pressure Vent Terminal Information The minimum distance from the termination of a vent terminal to adjacent public walkways adjacent buildings operable windows and building openings shall be not less than those values specified in the National Fuel Gas Code ANSI Z223 1 and or CAN CGA Installation Codes For proper operation the vent terminal must be kept free of snow and other debris at all times To prevent discoloration and degradation of building materials by flue gases and flue gas condensation ensure that the vent terminal is installed clear of nearby obstacles In all cases installation shall be in accordance with code Ma
15. FT SIDE REFRACTORY HOLDER 6 FLUE COLLECTOR NOZZLE d LEFT SIDE REFRACTORY 8 BAFFLE 9 FLUE COLLECTOR 10 DOOR 11 CONTROL PANEL 12 INSPECTION DOOR 13 ROLL OUT SHIELD 14 FRONT REFRACTORY HOLDER 15 FRONT REFRACTORY 16 FRONT SEAL 17 MG MODEL HEAT EXCHANGER ASSEMBLY 18 REAR SEAL MG MODELS ONLY 19 REAR REFRACTORY 20 REAR REFRACTORY HOLDER 21 REAR PANEL 22 MANIFOLD 23 BURNER 24 FRONT BURNER SUPPORT 25 BURNER TRAY 26 REAR BURNER SUPPORT 27 BOILER BASE 28 RIGHT SIDE REFRACTORY 29 BOILER LEG 30 RIGHT SIDE REFRACTORY HOLDER 31 RADIATION SHIELD 32 RIGHT SIDE PANEL 33 PILOT BURNER ASSEMBLY NOT SHOWN 34 FIBERGLASS INSULATION C W FOIL NOT SHOWN 35 FIBREFRAX BLANKET INSULATION NOT SHOWN FIGURE 5 GENERAL ASSEMBLY PARTS LIST 26 MG Series Boilers Installation and Service Manual Wiring Diagrams Section 6 Simplified Wiring Instructions IMPORTANT e Disconnect power source to boiler before wiring zone control board e All wiring must comply with applicable codes ordinances and regulations The non replaceable fuse on the board will be blown if 240 Vac is connected to the board or if the 24 Vac system is even momentarily shorted out A Line Voltage Connections Connect 120 Vac 60 Hz single phase power to terminals L1 HOT and L
16. WNIDINO 3HL 50 4172 SIN3W3MInO3N 3000 WOOT MO IVIONIAOMd IWNOLVN M3HlO ANY 1 17222 52 7272 VQvNvO 4 SIN3NA3uInO3H 3002 W901 MO ALVIS 33H10 ONY OZ VddN ISNV vsh 0 NI Q3TIVISNI 38 15 1 S31ON ONIOIANAS 30 QNv ONITIVISNI 380438 N3MOd 193NNOOSIQ HIV3Q AYAPNI 383 A3S 350 2 NVO QHVZVH 1 91119313 HOUMS ONJ 5 Alidvs HOLMS 1 5 0392018 110 7104 MNOL4O IMOSN3S 00 021 3 95 91870 1108 NO TANVd 10 1 02 GANINDAY SV AlddNS 20 02 HLIM 531435 NI 3MIM OL SNOLLONYLSNI S YSYNLOVANNYW 340 112 YALWM MOTIO4 QN3931 ONIMIM 55 12 01315 SSVIO O3N ONIMIM 11314 SSVIO O3N ONIMIM AMOIOV3 SSVIO O3N ONIMIM 012 3 MEDI vae LL 1L1L LL il8vo 5 9 10114 IN3LLIAM3INI 19665 ANVONOO3S C 9 L msoma INOZ 9 e AVISOMIHL 2 INOZ 9
17. 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 and tighten cap FIGURE 3 PILOT FLAME combustion to the flue Under typically Check for lifting ADJUSTMENT operating conditions the flame should have a distinct bright blue inner cone and a blue orange Flames should not lift excessively from the burner ports The flames may lift slightly during ignition or when the burners are cold outer cone If any of the above problems are observed or the burner system does not operate properly immediately take corrective measures 3 4 AQUASTAT ADJUSTMENT An optional aquastat may be installed to control the main burner firing by sensing outlet water temperature The optional aquastat should be set a minimum of 20 F 10 C above the setting of the high limit of the integrated boiler controller 3 5 GAS MANIFOLD PRESSURE The designated manifold pressures are as shown in the table below A 1 8 NPT tapping is provided on the manifold or gas valve for connecting a manometer to check this pressure Both natural gas and propane models are furnished with gas valves which have a built in gas pressure regulator If necessary adjust to the proper value by
18. d as recommended in Section 2 5 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 e bleaches and chlorinated cleaning products paints and sprays e water softeners calcium or sodium chloride e leaking refrigeration equipment e 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 corrosion 12 MG Series Boilers Installation and Service Manual 27 VENTING The responsibility of providing a suitable vent of adequate draft capacity and in good usable condition is that of the gas fitter installer Interference with the air supply for the boiler shall be prohibited Vent installation and type of gas vent or vent connector MUST follow all applicable national provincial state and local codes laws regulations and ordinances as described in Section 2 2 For boilers for connection to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas
19. d should be resistant to the action of liquefied petroleum gases Check for gas leaks in piping before placing the boiler in operation by using a soap and water solution DO NOT USE AN OPEN FLAME INSTALLER MUST IDENTIFY EMERGENCY SHUT OFF DEVICES All piping and fittings must be installed as per codes in Section 2 2 2 5 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 other air supply and venting considerations must conform to Section 2 2 The boiler room must never be under a negative pressure Always provide air openings sized 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 The venting terminations must always be kept clear of obstructions i e snow ice Louvers and grilles used in the air supply and ventilation system should be kept clear of any dust dirt or debris which will block proper air flow 2 6 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 supplie
20. ed by them comply with the Code requirements and the person initially activating the appliance shall ensure that the appliance is in safe working order CSA B149 1 00 Natural Gas and Propane Installation Code 21 MG Series Boilers Installation and Service Manual Service amp Maintenance Instructions Section 4 41 SERVICE amp MAINTENANCE INSTRUCTIONS WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation WARNING If any part of this boiler has been under water inspect the boiler and replace any part of the control system and any gas control which has been under water 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 In addition the owner or user will have the boiler inspected by qualified service technician or gas supplier s service person at least once every year at the beginning of the heating season for continued safe operation Note that some operating conditions may require more frequent inspections The qualified service technician or gas supplier s service person should follow the Service Checklist The Service Checklist must only be used by a qualified service technician or gas suppliers service person Verify pro
21. ed with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Ensure gas supply NOTE On some gas valves the knob cannot be turned to OFF or position unless knob is pushed in slightly Do not force to the boiler is turned on 7 Wait five 5 minutes to clear out gas 2 STOP Read the safety instructions in Then smell for gas including near the floor If Section 1 1 you smell gas STOP Follow A in the safety 3 Setthe room thermostat to lowest setting instructions in Section 1 1 If you don t smell 4 Turn off all electrical power to the appliance gas go to the next step 5 Remove control access panel if necessary 8 Turn gas control knob counterclockwise 6 Push in gas control knob slightly and turn 9 to ON clockwise to OFF 9 Replace control access panel if necessary 10 Turn on all electrical power to the Boiler 11 Set room thermostat to desired setting su S CONTROL 12 If the appliance will not operate follow the instructions To Turn Off Gas To Boiler in Section 1 5 and call your service technician or gas supplier ceps To turn off gas to boiler or emergency shut off Follow Section 1 3 1 3 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 l
22. elow the water temperature and the burner should shut off Set the aquastat higher than the water temperature and the main burner should ignite Return the aquastat to its original setpoint and make sure boiler cycles normally Repeat this type of check on the optional aquastat when used thermostat and other system controls to ensure all are working satisfactorily If any of the safety or controls do not function necessary corrections should be made immediately 3 9 CHECK FOR GAS LEAKS To identify gas leaks smell for gas around boiler area and gas piping connections See Section 1 1 To check a specific area for leakage 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 Gas leaks must be repaired immediately 20 MG Series Boilers Installation and Service Manual 3 10 INSTALLER S CHECKLIST Reference Section a The information printed on the boiler rating plate matches the application i e 35 altitude and fuel type L All applicable electrical codes have been met 2 2 2 14 L Gas piping has been purged and checked for leaks with a soap solution 2 2 2 4 2 9 System is filled with water and all air has been purged Only oxygen barrier 2 11 2 12 tubing has been used manometer has been used to check the manifold pressure and gas supply 32 35 pressure against requirements printed
23. ent 14 2 9 Blocked Vent and Flame Roll out Safety 14 2 10 Boller Pipitig aree atre pao pret KE RR ax da 15 2 11 Corrosion Prevention Internal retten bea 15 2 12 System Operating Requirements 15 2 13 Pressure Relief Valve ssssssssssssssesessseseseeeee enne nennen nmerne insi enhn tenens nes n ennt te rers 16 214 Electrical WING inerte raten te ir n et ea 16 3 Startup 17 OM MEL JC c 17 SAMEDI 17 3 9 CHECK Burner SyStelm uc io ecce hcec aee ER depu 18 34 eee eec t er ede Maa idea yu dv yw d pre 18 3 5 Gas Manifold PressUre etc peterent eee 18 3 6 Check Input amp OrlflCGs ett trt a eene ud e ERE A COLLE YR RR 19 3 4 Check for Draft Hood Spillage orte tetra cet nea v ee puedo a 20 3 9 Check of Controls 20 3 9 Check for Gas Leaks 20 3 10 Installers CHECKISE 21 4 Service amp Maintenance Instructions 22 41 Service amp Maintenance
24. f the boiler by either the Blocked Vent or the Flame Roll out safety switch is an indication that carbon monoxide may be improperly venting into the premises and the boiler must be serviced by a qualified person who is capable of determining the cause of the shut down and can take corrective action Carbon monoxide is a lethal colorless and odorless gas FIGURE 2 MOUNTING LOCATION OF BLOCKED VENT SAFETY SWITCH AND WIRE ROUTING WIRES TO WIRING AUTOMATIC HARNESS VENT DAMPER BLOCKED BLOCKED Sinn CLIP VENT SCREWS VENT SAFETY SAFETY DRAFT SWITCH DRAFT SWITCH DRAFT HOOD HOOD WIRED TO WIRED TO BOILER BOILER HM CONTROLS Ea CONTROLS WIRING HARNESS 2 L Fs ALTERNATE 1 ALTERNATE 2 ALTERNATE 3 14 MG Series Boilers Installation and Service Manual 210 BOILER PIPING SYSTEM The boiler piping system of a hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle The boiler when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chi
25. flash a three digit number i e 220 followed by F or C This indicates that the boiler water temperature of 220 F is set Other operating parameters display the settings in a similar fashion Table 1 Run Mode Parameters Text Description Display STA Status see status numbers BT Boiler temperature ht SP Operating setpoint oP HL High limit setpoint L HDF Differential set point Hd F FLA Flame current FLA RUN Run time hours rin CYC Boiler cycles L4E ERR Error see error numbers Err MG Series Boilers Installation and Service Manual 1 4 2 INSTALLER MODE To enter the adjustment mode 1 Press with Up A Down and I keys see Figure 1 simultaneously for three seconds 2 Press and release the I key until the parameter listed in the Table 2 requiring adjustment is displayed Press with Up A or Down V key until the parameter has reached the desired value 4 After 60 seconds without any key inputs the control will automatically return to the RUN Mode Table 2 Installer Mode Options 3 Digit 7 Segment Display 1 Screen 2 Screen setting value 3 Screen Default Range Description HL high limit 180 F 130 to 220 F Adjust high limit setting VOLETE 3 Adjust high limit HdF high limit differential For C 15 F 10 to 30 F differential Ur pump o
26. hich it was supplied e Connect the wiring harness from the boiler to the automatic vent damper as indicated on the supplied wiring drawings The automatic vent damper position indicator should be clearly visible after installation Aminimum clearance of not less than 6 inches 153 mm must be maintained between the automatic vent damper device and combustible construction Provision must be made for service access to the automatic vent damper The automatic vent damper must be in the open position when the boiler s main burner is operating e For orientation other than vertical refer to automatic vent damper installation instructions 2 9 BLOCKED VENT AND FLAME ROLL OUT SAFETY SWITCHES All boilers with an input of 300 000 Btu h and under are equipped with blocked vent and flame roll out safety switches The blocked vent safety switch is installed in the clip provided on the draft hood Figure 2 Alternate 1 or is mounted with screws Figure 2 Alternate 2 The blocked vent safety switch is pre wired at the factory either directly to the boiler controls Figure 2 Alternate 1 amp 2 or through a wiring harness for a boiler with an automatic vent damper Figure 2 Alternate 3 If the vent becomes blocked a boiler shut down will occur Ensure that the vent is free of obstructions The flame roll out safety switch will cause a boiler shutdown if the heat exchanger becomes blocked with soot or corrosion WARNING Shut down o
27. ill automatically lockout if no pilot flame detected within 15 seconds Automatic retry will occur in 5 minutes 6 Turn Gas Valve to ON Pilot burner should ignite followed by main burners Check main and pi burners and adjust pilot if necessary as described in Section 3 3 7 Assure that all other gas appliances are turned off including their pilot flames 8 Check manifold pressure reading on the manometer and make necessary adjustments Che that burner input matches rating plate input 9 Return thermostat and controls to normal operation settings 17 is lot MG Series Boilers Installation and Service Manual 3 5 CHECK 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 Check ignition and extinction It is possible for parts of the burners system to Ignition should flow quickly and smoothly across become plugged cracked eroded and or all the burners Popping noises or explosions dislodged resulting in unsafe operation from the burners during ignition extinction or Pilot Flame normal burner operation indicates the need for service Remove cap screw cover on gas valve then adjust gas flow to the point where the sensor rod is completely enveloped by the flame Figure 3 but not necessarily glowing red Replace Check flame color An extremely yellow flame as seen on a burning
28. intain a minimum clearance of 4 feet 1 22 m horizontally and in no case above or below unless a 4 foot 1 22 m clearance is maintained from electric meters gas meters regulators and relief equipment Removal of an Existing Boiler When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 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 d Place in operation the boiler being inspected F
29. ion All electrical wiring must be in accordance with the Canadian Electrical Code CSA C22 1 Part 1 current edition and applicable local codes In the United States of America the 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 Z223 1 current edition All electrical wiring must be in accordance with the National Electrical Code ANSI NFPA 70 current edition and applicable local codes Where required by the authority having jurisdiction follow the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 current edition 2 3 LOCATION MG boilers are intended for indoor installation only Observe the following minimum clearances from the boiler to combustible materials Minimum Clearances to Combustible Materials Sides Rear Top Front service Model in mm in mm in mm in mm MG 2 51 2 51 24 610 18 457 e Minimum clearance from the boiler front to combustible materials is 6 in 153 mm however a front clearance of 18 457 mm is recommended for servicing e Maintain a clearance of 6 152 mm from draft hood and the flue pipe in any direction e Allow ample space for boiler inlet and outlet connections and gas connection e Boiler must be installed on a stable and level foundation MG Series boilers can be installed on a combustible fl
30. l parts at room temperature and check input by clocking gas meter with all other gas appliances turned off including their pilot flames Use the following formula 3600 x High Heating Value of Gas in Btu Cu ft x Volume of Gas in Cu ft Clocked Time in Seconds INPUT Btu h To ensure accuracy for rating clock enough cubic feet of gas so that there is at least one revolution of the test dial and the clocked time is at least 60 seconds 3 7 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 vent 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 While performing this test make sure all exhaust fans air movers and gas appliances are operating and doors and windows are closed If the combustion products are escaping from the relief opening of the draft hood IMMEDIATELY shutdown the boiler and make proper adjustments or repairs 3 8 CHECK OF CONTROLS After the unit has been operated for awhile lower the aquastat setting b
31. ld 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 4 5 REFRACTORY HANDLING PROCEDURE WARNING The mineral block and fiberglass wool used in this product are RCFs Refractory Ceramic Fibers RCFs pose a possible cancer hazard by inhalation and can cause respiratory skin and eye irritation After mineral block has been fired it will produce increased levels of nuisance dust and poses increased carcinogenic risk Follow the precautionary measures below before attempting service or access PRECAUTIONARY MEASURES e Avoid breathing fibers and contact with skin and eyes e Use a National Institute for Occupational Safety and Health NIOSH approved dust mist respirator e Wear long sleeved loose fitting clothing gloves and eye protection Wash work clothes separately from other clothing Rinse washer thoroughly Operations such sawing blowing tearout and spraying may generate airborne fiber concentration requiring additional protection Use a vacuum with a HEPA filter for clean up Dispose of all RCF scrap and dust in a closed airtight plastic bag FIRST AID MEASURES Eye contact Flush eyes with water to remove dust for at least 15 minutes If irritation persists seek immediate medical attention e Skin contact Wash affected area gently with soap and warm water after handling e Difficulty brea
32. ling 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 2 12 Check the temperature and pressure gauge and expansion tank pressure is within an acceptable range for the heating system Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Combustible materials gasoline and other flammable vapors and liquids should not be stored in the area of the boiler Check should be made on ignition system operation controls and safety shut off valves for gas tightness 2 9 If applicable inspect low water cutoff for proper operation Check for proper operation of the blocked vent and flame roll out safety switches Ooo oOo The emergency shut off devices are identified and the owner is aware of their location and method of operation 23 MG Series Boilers Installation and Service Manual 44 CAUTION WATER REPLENISHMENT Avoid unnecessary replenishment of system water It can allow oxygen to enter the system and cause serious corrosion problems As well an excessive amount of minerals may be deposited 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 shou
33. lled medium from entering the boiler 2 11 CORROSION PREVENTION INTERNAL The use of oxygen barrier tubing is recommended to protect the system and its components e g pump from corrosion Should your system include non oxygen barrier tubing please contact the factory or a heating professional for recommendations If freeze protection is required use an inhibited propylene glycol solution which is specifically designed for hydronic heating systems and always maintained at a neutral pH e g Fernox Alphi 11 or equivalent Follow the supplier s instructions for proper use and maintenance Do not use automotive antifreeze Some types of chemical additives can cause problems such as accelerated corrosion and result in premature failure of the boiler heat exchanger and or system components especially when not properly used or maintained Corrosion is a preventable condition and is not covered by the product warranty 212 SYSTEM OPERATING REQUIREMENTS WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 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 Super
34. llowed to fire To that end on a call for heat the burner remains off while the circulator runs until the boiler temperature drops to the thermal purge temperature limit or the time delay is exceeded Both of these parameters are adjustable When the boiler temperature falls below the thermal purge temperature limit or the time delay expires the burner is allowed to fire In addition to the thermal purge temperature and thermal purge time delay parameters two other conditions release the integrated boiler controller from thermal purge and allow the burner to run in order to maintain comfort in the space The boiler temperature has dropped 10 F from the boiler water temperature measured at the beginning of the call for heat Boiler temperature is cooling at a rate greater than 5 F minute while the circulator is running 1 4 5 OPERATING STATE CODES AND TROUBLESHOOTING When there is a problem during a call for heat or boiler operation the controller provides specific information to help resolve the issue quickly If the controller is displaying 5ER by a number use the state code definitions in Table 3 to determine the problem and possible causes MG Series Boilers Installation and Service Manual Table 3 State Code Definitions Display Code State Specific Description Operation Sequence Idle Standby The boiler is in standby no call for heat Run circulator Heat request present b
35. mum number of retries exceeded Err e B3 Soft lockout Maximum number of recycles exceeded Internal failure Electronics failure Caused by general Err e Soft lockout electronics failure such as relay open or shorted contacts flame sensing circuit error or A to D error Err B5 Over temperature error Sensor measured temperature in excess of ECO limit 10 MG Series Boilers Installation and Service Manual Installation Instructions Section 2 2 1 RECEIVING INSPECT SHIPMENT FOR POSSIBLE DAMAGE All goods are carefully manufactured inspected checked and packed by experienced workers The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage shortage in shipment or non delivery must be filed immediately against the carrier by the consignee Use care when receiving and unpacking the boiler Dropping the boiler may cause damage and prevent safe and proper operation 2 2 INSTALLATION CODES AND REQUIREMENTS All applicable national provincial state and local codes laws regulations and ordinances must be followed They expand on and take precedence over any recommendations in this booklet Authorities having jurisdiction shall be consulted before installations are made Canada the installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the CAN CSA B149 Installation Codes current edit
36. n Set pilot pressure to correct pressure Poor connections in wiring to flame sensor Repair wiring Electrodes are damaged Replace electrodes Ignition electrodes improperly adjusted Ignition electrodes are wet dirty or improperly adjusted for electronic ignition only Correct adjustment of electrodes Check clean change and or adjust the electrodes Poor connections in wiring to flame sensor Incorrect orifice sizing Repair wiring Check orifice and replace if necessary Inadequate combustion and ventilation air Check and adjust Dusty environment Clean Low return water temperature Adjust system Manifold pressure too high Insufficient circulation Adjust manifold pressure Check pump clean and replace if necessary Air trapped in piping Purge system Improper system wiring Faulty thermostat or controller Test and correct Check adjust and replace if necessary Faulty controller or aquastat Check adjust and replace if necessary Faulty wiring 30 Check wiring for short circuits and repair MG Series Boilers Installation and Service Manual NOTES Section 8 31 MG Series Boilers Installation and Service Manual INDEX Section 9 Section Page Dimensions and Specifications MG Series 2 Boller Water Flow Data
37. necessary Faulty wiring Check wiring of aquastats zone valves and thermostats for loose or broken wires and repair Faulty controller aquastat thermostat or zone valve Check and replace if necessary Pilot not lit Poor flow in boiler or circulator failure See Pilot flame will not light on electronic ignition Check pump for proper capacity amp flow direction Replace if necessary Thermostat heat anticipator or aquastat set too low Check and adjust Boiler oversized or insufficient radiation Check and adjust if necessary Wrong type of thermostat or controller Gas valve failure open position Check and replace if necessary Check gas valve replace if necessary Faulty wiring Check wiring of aquastats zone valves and thermostats for short circuits or incorrect wiring Faulty controller aquastat thermostat or zone valve Boiler is overheated and safety high limit aquastat fails to cut out Check and replace if necessary Check aquastats and adjust or replace if necessary Improper wiring Check and correct Foreign matter in heat exchanger Flush heat exchanger if necessary Poor circulation Check pump for correct flow Air trapped in heating system Negative draft Purge air Incorrect vent size or blocked vent Insufficient combustion air to boiler Check combustion and ventilation air opening in boiler
38. ocation external to the boiler Set the thermostat to the lowest setting Turn all electrical power to the boiler off Remove control access panel on the boiler if necessary Push in gas control knob slightly and turn clockwise O to OFF Do not force it a Replace control access panel if necessary MG Series Boilers Installation and Service Manual 1 4 CONTROLLER PROGRAMMING AND SERVICE CODES 2012 NRCan and DOE Compliance and Operation Operation of this control may delay the burner operation while the residual heat is circulated out of the boiler The integrated boiler contro module provides ignition sequence flame monitoring safety shutoff for intermittent pilot spark ignition It also provides limit rated water temperature control for with two separate sensors in one casing 3 wire The control is located on the front panel inside the boiler The control display along with Up A Down and I keys may be used to view boiler operating status and program parameters Figure 1 1 4 1 RUN MODE In the RUN mode status items and parameters are viewable Figure 1 Control Display To read settings press and release the T key to find the parameter of interest Each setting will alternately flash between the relevant display code listed in the Table 1 and its corresponding value For example press and release I key until HL _ setpoint is displayed it will then
39. ollow the lighting instructions Adjust the thermostat so the boiler will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 13 MG Series Boilers Installation and Service Manual f 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 g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 and or CAN CGA Installation Codes When re sizing 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 Part 11 of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA Installation Codes 2 8 AUTOMATIC VENT DAMPER This boiler is supplied with an automatic vent damper The following instructions must be observed The automatic vent damper should be installed at the top of the factory supplied draft hood Figure 1 Alternate 3 No modifications to the automatic vent damper are permitted e The venting system must be arranged so that only the boiler is served by the automatic vent damper with w
40. oor but must not be installed directly on carpeting hot water boiler installed above radiation level must be provided with a low water cutoff device at the time of boiler installation e This boiler must be installed such that gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service 11 MG Series Boilers Installation and Service Manual 24 GAS SERVICE PIPING The boiler and its gas connection must be leak tested before placing the boiler in operation The gas controls furnished are suitable for a maximum operating gas pressure of 1 2 psi 14 inches water column The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 14 inches water column The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing at test pressures equal to or less than 1 2 psig 14 inches water column A manual main shut off valve should be installed in the gas line outside the boiler jacket and as required in Section 2 2 The valve should be readily accessible for turning on and off A drip pocket or sediment trap should be installed in the gas supply line upstream of the gas controls and as close to the boiler as possible example shown in Figure 3 in Section 5 The pipe compound use
41. oubleshooting Diagnostics If the control loses flame signal during state code 7 or 8 or flame is e 10 Ier purge not detected during stat code 6 to 8 it will recycle through the 30 retry recycle delay seconds purge time and last 2 seconds part of pre purge time E E Wait for end switch to The end switch of venting damper has not opened at the beginning Lio open failed closed of the heat cycle The control is not in lockout E 29 Wait for end switch to Waiting time for pressure switch to close expired The control is not close failed open in lockout Err bg Softlockout System is shutdown and will re start following an enforced delay SEA lt gt 15 Wait for limit to close There may be a call for heat from the thermostat but the limit switch is open Flame out of sequence before Flame signal sensed before trial for ignition trial e Ib Flame out of sequence after trial Flame out of sequence during post purge Wait for flame loss Flame signal still present when not expected MG Series Boilers Installation and Service Manual If the controller is displaying Err followed by a number use the error code definitions in the Table 4 to determine the problem and possible causes Table 4 Error Codes Display State Solution End switch of ventin The end switch contacts stuck closed Check the
42. per operation after servicing 4 2 CLEANING PROCEDURE 1 Shutdown the boiler as described in the lighting instructions in Section 1 5 2 Inspect flue gas passages and burners for the presence of soot rust or scale 3 If necessary use a wire brush and vacuum to clean and remove any blockages Plugged burner ports must be cleared 4 Replace any parts which have severely corroded 5 Reassemble parts removed during cleaning as they were before ensuring air tightness of flue gas passages 6 Corrosion can be caused by low return water temperature or a contaminated air supply Sooting can be caused by improper burner adjustment Check and adjust as necessary T Return boiler to operation following lighting instructions in Section 1 5 22 MG Series Boilers Installation and Service Manual 4 3 SERVICE CHECKLIST Reference Section Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surrounding the boiler The flow of supply and exhaust air must not be obstructed 2 5 Check air openings are not restricted and complies with applicable code s Adequate supply air is necessary for combustion flue gas dilution and ventilation 2 2 2 5 2 6 2 7 When the boiler has operated for several minutes check for spillage at draft hood venting ducts and other areas susceptible to spillage 3 7 Check externally the draft hood and vent system for soot rust scale
43. removing cap and turning adjusting screw clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure Model Natural Gas Propane MG 3 5 W C 11 0 W C 18 MG Series Boilers Installation and Service Manual 3 6 CHECK INPUT amp ORIFICES For safety the input shown on rating plate must not be exceeded Check with the table below that the orifice size and input rate shown on your boiler rating plate match your application i e boiler model fuel type and altitude See MG Specifications to find a boiler model s input rate FOR CANADA Natural Gas Propane 0 to 2 000 feet 2 000 to 4 500 feet 0 to 2 000 feet 2 000 to 4 500 feet 51 orifice 51 orifice 60 orifice 61 orifice standard input standard input standard input 1096 de rate input NOTE For elevations above 4 500 feet reduce high altitude input 496 for each additional 1000 feet Reference Natural Gas and Propane Installation Code B149 1 3 22 High Altitude Installations MG Example of High Altitude De rate Boiler MG 150 Altitude 5 500 feet Standard Input 0 to 2 000 ft 150 000 Btu h from page 2 High Altitude Input 2 000 to 4 500 ft De rate Standard Input by 1096 see above table 150 000 Btu h x 1 0 10 150 000 Btu h x 0 90 135 000 Btu h Reduction for additional 1000 ft 4 1 4 Input at 5 500 ft De rate High Altitude Input by 4 135 000 Btu h x 1 0 04 1
44. room meets installation code requirements and combustion air flow openings in the boiler base and burner tray are not blocked Leak in gas system Carbon build up on the heat exchanger caused by improper venting ventilation air or low return water temperature See What to do if you smell gas on cover Have gas fitter test system and repair leaks Have a qualified service technician inspect and clean the heat exchanger and check and adjust the system Negative draft 29 Check venting MG Series Boilers Installation and Service Manual Problem Pilot flame will not light on electronic ignition Pilot lights but flame failure after trial for ignition Burner starts but flame will not stay established Boiler carbonizes forms Soot quickly Boiler overheats and System remains cold Boiler and heating system overheat Possible Cause No spark Solution High voltage wiring is loose broken or grounded Repair wiring Ignition electrodes are damaged Replace electrodes Ignition electrodes improperly adjusted Correct adjustment of electrode Faulty electronic ignition controller Replace controller No gas Confirm supply of gas to pilot and repair if necessary Gas supply pipes not purged of air Purge gas line Low pilot gas pressure Adjust pressure Dirt or foreign material in pilot Incorrect pilot flame pressure Clea
45. the envelope provided and affixed adjacent to the boiler so that they are readily available for future reference Lighting Instructions 1 1 SAFETY INSTRUCTIONS Section 1 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 boiler area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Donottry to light any appliance Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbors phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water MG Series Boilers Installation and Service Manual 1 2 LIGHTING INSTRUCTIONS FOR INTERMITTENT ELECTRONIC WITH COMBINATION GAS VALVE 1 This boiler is equipp
46. the relief valve must have at least the area of the valve inlet A discharge pipe should be used The discharge pipe outlet should be positioned over a suitable drain and so arranged that there will be no danger of being scalded The discharge pipe must pitch down from the valve and should be no smaller than the outlet of the valve The end of the discharge pipe should not be concealed or threaded and should be protected from freezing Extensive runs traps or bends could reduce the capacity of the pressure relief valve No valve of any type should be installed between the pressure relief valve and unit or in the discharge pipe The pressure relief valve is a code requirement Field installation of the relief valve must be consistent with the ANSI ASME Boiler and Pressure Vessel Code Section IV Avoid contact with the hot water discharged to prevent personal injury WARNING The pressure relief valve discharges pressurized hot water which can turn into steam Steam exiting the discharge outlet can explosively expand in any direction Always maintain a safe distance from the discharge pipe outlet in order to avoid potential contact with exiting hot water or steam 214 ELECTRICAL WIRING All electrical wiring must conform with the requirements in Section 2 2 Run a separate circuit from the electrical service panel through a fused disconnect switch to the boiler This boiler must be electrically bonded to ground in accordance with the requirements of
47. thing Move to an area of clean fresh air Seek immediate medical attention if difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 24 MG Series Boilers Installation and Service Manual Replacement Parts Section 5 NOTE To supply the correct part it is important that you state the boiler model number serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with Return Goods Authorization Form R G A completely filled in with the boiler serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued Refer to Figures 4 and 5 for replacement parts 8 FLAME ROLL OUT SAFETY SWITCH 9 BLOCKED VENT SAFETY SWITCH TEMPERATURE PRESSURE GAUGE MOUNTED ON MODELS MG 125 AND MG 150 ONLY SUPPLIED LOOSE ON ALL OTHER MODELS BOILER OUTLET IGNITER CABLE PILOT GAS SEDIMENT TRAP CASING pt NOT SUPPLIED FIGURE 4 TYPICAL GAS TRAIN ASSEMBLY AND CONTROL COMPONENT FOR RESIDENTIAL INSTALLATIONS 25 MG Series Boilers Installation and Service Manual NO DESCRIPTION 1 AUTOMATIC VENT DAMPER 2 DRAFT HOOD 3 TOP PANEL 4 LEFT SIDE PANEL 5 LE
48. tory Options e Natural Gas add suffix N Propane models add suffix P e Electric Ignition add suffix E Add 35 pounds weight 16 kg for packaged boilers add suffix PS MG Series Boilers Installation and Service Manual Boiler Water Flow Data NOTE The boiler should be properly sized for its heating application and maintain an adequate water flow rate during operation Significantly oversizing the boiler or decreasing boiler water flow rate will cause excessive stage cycling and may result in premature failure of components Typical Water Flow Versus Pressure Drop Across Boiler Model 20 F T D 30 F T D Number U S GPM P D FT U S GPM P D FT MG 50 4 0 14 3 0 1 0 MG 75 6 0 22 4 0 1 1 MG 100 8 0 3 5 6 0 2 2 MG 125 10 0 5 2 7 0 2 8 MG 150 12 0 8 0 8 0 3 5 MG Series Boilers Installation and Service Manual ABOUT OUR MANUALS Your Super Hot boiler has been provided with two manuals 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 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
49. ut boiler water temperature sufficiently high to run circulator pump only no ignition sequence Thermostat Calls For Heat e Self Test Hardware self check check of connected periphery it is performed at start up in the beginning of the heat cycle and in the Wait For recovery state Wait for recovery There is an external error and the control is waiting to recover no lockout Circulator output energizes Wait for end switch The control is waiting for the end switch of the vent damper to open SEA e g toopen at the beginning of a heat cycle If the end switch doesn t open in 60 seconds the control goes to error code Err e Wait for end switch The control is waiting for the end switch of venting damper to close at e 3 toclose the beginning of a cycle If the end switch doesn t close within 60 seconds the control goes to error code Err 29 o 4 Pump pre purge System is purging before ignition trial safety relay diagnostics thermal purge followed safety relay switch on during last 2 seconds this sate B Spark ignition System is sparking permanently 13 seconds whilst pilot gas valve activation relay is turned on e Prove flame System is proving flame signal typically 2 seconds SEA eH Running System is in running mode flame signal must be present Call For Heat Ends SEA OY Pump post purge System is purging at the end of a call for heat Tr
50. venting Err 9 e damper failed to open damper and replace it if necessary Err e Low flame current Check pilot assembly and replace it if necessary E E Flame sensed out of Flame sensed out of normal sequence before opening gas en normal sequence valve or after closing gas valve Gas valve relays Err e 18 welded 5 consecutive A manual reset is required soft lockouts Erg o 8J Flame sensed during during pre purge before gas valve signaled pre purge opened o Flame sensed during e sensed during post purge before gas valve signaled post purge closed 29 End switch of venting The end switch contacts stuck open Check the venting damper failed to close damper and replace it if necessary Temperature sensor or interface failure open or short E connection increased connection resistance dual sensor Sola Sensor error mismatch or failure of A D conversion invalid offset or gain too many failures during A D conversion Err e 81 Flame rod shorted to Check and adjust or replace if necessary burner ground Err e 5B AC line frequency error AC signal is too noisy or frequency is incorrect Err e 59 Line voltage error AC voltage out of specification high or low Err o Bl Thermostat input Check thermostat wiring and replace it if necessary higher than threshold E 5 Possibly too many heavy loads switching on and off cause rr 9 8 Line voltage unstable erratic supply voltage Err e Soft lockout Maxi
51. verrun time Sec 60 0 to 120 seconds Pump post purge time Maximal outdoor aEH ODR maximal temp For C 55 F 40 to 70 F temperature ni Minimal outdoor oEL lt ODR minimal temp gt For C 0 40 to 40 F temperature ini Minimal boiler htL minimal water temp For C 140 F 130 150 F temperature Thermal purging OFF minimal temperature EPL minimal boiler temp F or C 140 F parameter is available 120 to 160 F only if outdoor temperature is invalid Maximal thermal purge time parameter is maximal delay Min 2 1 to 10 minutes available only if outdoor temperature is invalid r t On or OFF N A N A Reset lockout Select degrees F or C F E For C F For C mods MG Series Boilers Installation and Service Manual 1 4 3 OPERATING CHECKOUT After adjusting parameters put the boiler into operation and observe operation through at least one complete cycle to make sure that the controller operates properly See controller troubleshooting section to assist in determining boiler operation The sensor should fit snugly and should touch the bottom of the well for best temperature response The sensor is held inside the well using the well clip 1 4 4 THERMAL PURGE The intent of thermal purge is to ensure usable residual heat in the boiler is circulated until it is sufficiently depleted from the system before the burner is a
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