ECR International UTICA BOILERS MGC 3 Series Instruction manual
MGC
SERIES 3
GAS-FIRED
HOT WATER BOILERS
With Hydrolevel Control
INSTALLATION, OPERATION & MAINTENANCE MANUALManufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 325 5479
www.ecrinternational.com
PN 240013087 REV. D [12/01/2022]
C.S.A. Certied
For Natural Gas Or Propane
Tested For 50 psi.
ASME
Working Pressure
Models
MGC-8D
MGC-8DP
MGC-9D
MGC-9DP
2
Fully Assembled Boiler Vent Damper Pump (Optional) *Drain Valve
*ASME Safety Relief
Valve *Tridicator *Fuse Link w/
Instruction Tag *Nipple 3/4”x6-1/2 “
Includes Essential
Documents and Warranty
11x17 Wire Diagrams
Document Package *Circulator Harness
Check our website frequently for updates: www.ecrinternational.com
Information and specications outlined in this manual in eect at the
time of printing of this manual. ECR International reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
* Items found in parts box included with your boiler.
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
For Parts lists see manual 240013154 included with your boiler literature package.
ITEMS INCLUDED WITH YOUR BOILER
PN 240013087 Rev. D [12/01/2022]
3
1 - Dimensions................................................................................ 4
2 - Safety Symbols And Warnings ...................................................... 5
3 - Locating The Boiler ..................................................................... 7
4 - Connecting Supply And Return Piping.............................................9
5 - Ventilation & Combustion Air .......................................................14
6 - Chimney And Vent Pipe Connection...............................................15
7 - Vent Damper Operation ..............................................................17
8 - Gas Supply Piping ......................................................................18
9 - Electrical Wiring.........................................................................19
10 - Wiring Diagram........................................................................20
11 - General Instructions .................................................................21
12 - Lighting Instructions.................................................................22
13 - Operating Your Boiler................................................................23
14 - Service Hints ...........................................................................26
15 - Maintaining Your Boiler .............................................................27
16 - Boiler Ratings And Capacities.....................................................28
Appendix A - Control Function ..........................................................29
Appendix B - Vent Damper Installation...............................................32
TABLE OF CONTENTS
PN 240013087 Rev. D [12/01/2022]
4
1 - DIMENSIONS
Figure 1 - Dimensions
Figure 1 - Dimensions
*
1 1/4” RETURN
PN 240013087 Rev. D [12/01/2022]
Table 1 - Dimensions
BOILER
MODEL
NUMBER
DIMENSIONS (INCH.)
BOILER
WATER
VOLUME
GALLONS
FLUE
DIAMETER
“A”
WIDTH
MGC-8 7 27½10.10
MGC-9 7 30¾ 11.60
Add 5½” to height for vent Damper.
5
2 - SAFETY SYMBOLS AND WARNINGS
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
!
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury.
!
This is the safety alert symbol. Symbol alerts
you to potential personal injury hazards. Obey all
safety messages following this symbol to avoid
possible injury or death.
Become familiar with symbols identifying potential hazards.
2.1. Safety Information
WARNING
Do not tamper with or use this boiler for any
purpose other than its intended use. Failure to follow
these instructions could result in death or serious
injury. Use only manufacturer recommended parts
and accessories.
!
CAUTION
Laceration, burn hazard. Metal edges and parts
may have sharp edges and/or may be hot. Use
appropriate personal protection equipment to
include safety glasses and gloves when installing
or servicing this boiler. Failure to follow these
instructions could result in minor or moderate injury.
!!
NOTICE
Used to address practices not related to personal
injury.
WARNING
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.
!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald and
cause permanent injury.
persons are more likely to be permanently injured by
hot water. Never leave them unattended in bathtub or
shower. Never allow small children to use a hot water
tap or draw their own bath.
description, or if state laws or local codes require
certain water temperatures at hot water taps, you
must take special precautions:
• Use lowest possible temperature setting.
• Install some type of tempering device, such as
an automatic mixing valve, at hot water tap or
water heater. Automatic mixing valve must be
selected and installed according to manufacturer's
recommendations and instructions.
• Water passing out of drain valves may be
extremely hot. To avoid injury:
• Make sure all connections are tight.
•
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note: Warning for Infants, Children, and Elderly:
Great care must be taken when exposing the
aforementioned groups to warm or hot water as they
can be badly burned in exposure times less than half
of the time for an adult.
PN 240013087 Rev. D [12/01/2022]
6
WARNING
Keep boiler area clear and free from combustible
liquids.
DO NOT obstruct air openings to the boiler room.
result in personal injury or loss of life.
Installation and service of this boiler shall be performed
When this product is installed in the Commonwealth
of Massachusetts the installation shall be performed
by a Licensed Plumber or Licensed Gas Fitter.
!
WARNING
Combustion chamber insulation in this product
can be converted to cristobalite in very high
temperature applications. The International Agency
for Research on Cancer (IARC) has concluded,
Crystalline silica inhaled in the form of quartz
or cristobalite from occupational sources is
carcinogenic to humans (Group1). Avoid breathing
dust and contact with skin and eyes. Use NIOSH
respirator is based on the OSHA requirements
for cristobalite at the time this document was
written. Other types of respirators may be
needed depending on the job site conditions.
Current NIOSH recommendations can be found
on the NIOSH website https://www.cdc.gov/
niosh/topics/silica/. NIOSH approved respirators,
manufacturers, and phone numbers are also listed
clothing, gloves, and eye protection. Apply enough
water to the combustion chamber lining to prevent
dust. Wash potentially contaminated clothes
separately from other clothing. Rinse clothes
washer thoroughly.
NIOSH stated First Aid. Eye: Irrigate immediately.
Breathing: Fresh air.
WARNING
Fire, Explosion, Asphyxiation, Electrical shock
hazard! Flooding will result in damages such as
electrical problems, corrosion, inoperative parts,
mold and other unforeseen issues which can
occur over time. Any equipment determined by
excess of water or other liquid, shall be replaced.
Failure to follow these directions will result in a
Hazardous Situation.
!
!
2 - SAFETY SYMBOLS AND WARNINGS
To Installer leave all instructions with boiler for future
reference.
WARNING
This prod
uct contains Fibrous glass. Fibrous
possible human carcinogen. When disturbed as a
airborne and, if inhaled, may be hazardous to
your health. It can harm the eyes, skin, and the
been listed by the State of California as a possible
cause of cancer through inhalation. Adhere
to the following precautions and procedures.
Avoid breathing dust and contact with skin and
N95). Other types of respirators may be needed
depending on the job site conditions. Current NIOSH
recommendations can be found on the NIOSH
website https://www.cdc.gov/niosh/. Approved
respirators, manufacturers, and phone numbers
are also listed on this website. Wear appropriate
personal protective clothing to prevent skin contact,
as well as gloves and eye protection. Wash skin
daily at end of each work shift, and prior to eating,
drinking, smoking, etc. Workers whose clothing
may have been contaminated should change into
uncontaminated clothing before leaving the work
premises. Wash potentially contaminated clothes
separately from other clothing. Rinse clothes washer
thoroughly. Follow all Local, State and Federal
guidelines for disposal.
NIOSH stated First Aid. Eye: Irrigate immediately.
Breathing: Fresh air.
!
PN 240013087 Rev. D [12/01/2022]
7
3 -LOCATING THE BOILER
Table 2 -
MINIMUM CLEARANCE DIMENSIONS
Inches (mm)
Top 6”
(152mm)
Rear 6”
(152mm)
Control Side 7” (178mm)
Opposite Side 6” (152mm)
Front 18” (457mm)
Flue/Vent Connector 6” (152mm)
Near Boiler Piping 2” (51mm)
NOTE: Greater clearances for access should supersede fire
protection clearances.
front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.
1.
Installation shall 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/NFPA 54, and/or
Natural Gas and Propane Installation Code, CAN/
CSA B149.1.
2.
Where required by the authority having
jurisdiction, the installation shall conform to the
Standard for Controls and Safety Devices for
Automatically red Boilers, ANSI/ASME CSD-1.
3.
The Installer shall verify that at least one carbon
monoxide alarm has been installed within a
residential living space or home following the
alarm manufactuer’s instructions and applicable
local codes before putting the appliance into
operation.
4.
installation shall be in accordance with "Venting of
Equipment”, of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or "Venting Systems and Air Supply
for Appliances," of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
5.
Boiler has met safe lighting and other performance
criteria with the gas manifold and control assembly on
the boiler per the latest revision of ANSI Z21.13/CGA
4.9.
6.
Install boiler such that gas ignition system components
are protected from water (dripping, spraying, rain,
etc.) during appliance operation and service, (circulator
replacement, condensate trap, control replacement,
etc.).
7.
Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
8.
Allow 24 inches (610mm) at front and right side for
servicing and cleaning.
9.
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)
6"
BOILER
18"
6"
Front
7"
Control
Side
10.
FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
(Combustible Floor Addendum) included in literature
envelope provided with boiler and outlined in National
Fuel Gas Code, ANSI Z223.1/NFPA 54. Do Not Install
Boiler on carpeting.
3.1 Installation Requirements
CAUTION
Boiler weight exceeds 200 pounds (90.7 kg). Do not
lift boiler without assistance.
!
WARNING
Fire hazard. Do not install boiler on combustible
instructions could result in death or serious injury.
!
PN 240013087 Rev. D [12/01/2022]
8
3.3 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent the potential of freezing.
• Drainage of water (or water/ antifreeze solution) during
boiler service or from safety relief valve discharge.
• Access to system water piping, gas supply, and
electrical service.
•
capable of supporting the weight of the boiler, water,
and equipment.
•
wet.
3 - LOCATING THE BOILER
Items to Avoid Products Which May Contain These
Items Areas Where These Items May Be
Found
Chlorine, Fluorine, and Compounds
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Swimming pool or spa chemicals
De-icing salts or chemicals
Carbon Tetrachloride
Swimming pools and pool storage areas
Airborne Particulates
Drywall dust
Road or gravel dust
Dryer lint
Cat litter
Acids, Solvents, etc.
Paint, Varnish, Turpentine, etc.
Cleaning Solvents
Hydrochloric acid/muriatic acid
Cements, adhesives and glues
Photo processing plants
Garages with workshops
establishments
Laundry Chemicals
Laundry detergents, bleaches, fabric
softeners, etc.
Antistatic fabric softeners (dryer sheets)
Dry cleaning/laundry areas and
establishments
Other
Permanent wave solutions
Refrigerants (Freon, etc) (only where
the refrigerant may be leaking from the
appliance)
Beauty shops
Refrigeration repair shops
Notes:
passages possibly resulting in unsafe operation. In this case, unit servicing shall include
the room be generously ventilated (well in excess of combustible air requirements), and
homeowner seal laundry supply containers, and minimize room vapors.
. Piping allowing fresh air in should also be considered. See Section 5-1.
Table 3-1: CONTAMINANTS
• Horizontal run to chimney shall be as short as possible.
• System piping exposed to freezing conditions: Use
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
PN 240013087 Rev. D [12/01/2022]
9
4 - CONNECTING SUPPLY AND RETURN PIPING
RELIEF VALVE
DISCHARGE
LINE
Check local
codes for
maximum
distance
from oor
or allowable
safe point of
discharge.
Figure 2 - Safety Relief Valve
1.
Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements. Install safety relief valve using pipe
2.
Install safety relief valve with spindle in vertical
position.
3.
relief valve.
4.
Install discharge piping from safety relief valve. See
Figure 2.
• Use ¾” or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
• Terminate freely to atmosphere where discharge is
clearly visible and no risk of freezing.
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
WARNING
Burn and scald hazard. Safety relief valve shall be
installed with spindle in upright position only,
following ASME BPV code. Failure to follow these
instructions could result in death or serious injury.
!
PN 240013087 Rev. D [12/01/2022]
10
4.3 Flush and Rinse System
Flush the entire system and rinse thoroughly to ensure no
sludge will be introduced into the heating body of the boiler.
NOTICE
If damage due to frozen pipes is a possibility, install
appropriate safeguards and alarms on the heating
system to prevent property damage due to frozen
and burst pipes should the boiler heating system
become inoperative due to a power outage, safety
lockout or component failure.
4.4 Water Treatment
Manufacturer recommends a water analysis be done on
based on the analysis results. For extremely hard water or
pH below 7.0 consult your local water treatment company.
Manufacturer recommends a water analysis be done on
based on the analysis results.
For extremely hard water or pH below 7.0 consult your
local water treatment company.
• If CH water is very hard or full of impurities, it must be
or malfunction could be caused. Recommended water
quality is
:
o Hardness Less than 150 mg/L
o Acidity level 7-8 pH
o Sediments Particle size less than 50 micron
• If the water quality is outside these ranges, consult a local
water treatment specialist for recommendations.
• If the water is treated, do not use petroleum based
products or products containing mineral oil or hydrocarbons
in order to avoid likely damage to parts made from rubber
compounds (o-rings).
4 - CONNECTING SUPPLY AND RETURN PIPING
WARNING
• Poison hazard. Ethylene glycol is toxic. Do not
use ethylene glycol.
• Never use automotive or standard glycol
antifreeze, even ethylene glycol made for hydronic
systems.
• Ethylene glycol can attack gaskets and seals used
in hydronic systems.
• Do not use petroleum based cleaning or sealing
compounds boiler system.
•
water.
• Use only inhibited propylene glycol solutions
use with closed water heating system.
•
glycol before installing new Boiler.
• Provide user with Material Safety Data Sheet
!
PN 240013087 Rev. D [12/01/2022]
11
4 - CONNECTING SUPPLY AND RETURN PIPING
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 radiation level or as required
by Authority having jurisdiction.
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 12.
B. Boiler connected to heating coils located in air handling
units where they may be exposed to refrigerated air
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 13.)
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
temperatures below 140°F are desired (e.g. radiant
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 13.
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.
1.
Boiler is shipped assembled. Install discharge piping
from safety relief valve. See Warning, Page 9.
2.
Install temperature pressure gauge.
• Apply pipe sealant to threads on shaft of gauge.
• 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
diagrams.
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions. Failure
to follow these instructions could result in death or
serious injury.
!
PN 240013087 Rev. D [12/01/2022]
12
Figure 5 - Chilled Water Piping
Figure 4 - Typical Hot Water Piping
4 - CONNECTING SUPPLY AND RETURN PIPING
CIRCULATOR
PUMP
PN 240013087 Rev. D [12/01/2022]
13
Figure 6 - Bypass Piping - Circulator On Supply
Figure 7 - Bypass Piping - Circulator On Return
Bypass Piping Required For High Mass (Large Water Content) Systems
4 - CONNECTING SUPPLY AND RETURN PIPING
PN 240013087 Rev. D [12/01/2022]
14
5 - VENTILATION & COMBUSTION AIR
Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Natural
Gas and Propane Installation Code, CAN/CSA B149.1, or
applicable provisions of local building codes.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
• Engineered Installations. Must be approved by
authority having jurisdiction.
• Mechanical Air Supply. Provide minimum of 0.35
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.
• All Indoor Air. Calculate minimum allowable room
method if minimum volume not available.
A. Standard Method. Cannot be used if known air
hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.
3x Total Input [Mbh]
B.
space with boiler only. Use equation for multiple
(ACH) greater than 0.60.
21 ft3
C. Refer to National Fuel Gas Code for opening
requirements between connected indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
A. Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in² per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in² per 2
Mbh of total input rating of all appliances in
enclosure.
B. One Permanent Opening Method. Provide 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 combustible materials).
• Refer to National Fuel Gas Code for additional
requirements for louvers, grilles, screens and air
ducts.
• Combination Indoor and Outdoor Air. Refer to National
Fuel Gas Code for application information.
PN 240013087 Rev. D [12/01/2022]
Table 4 - Minimum Room Volume, Indoor Air Only*
Room Cubic Feet Volume
Input Mbh Standard
Method
0.1 0.2 0.3 0.4 0.5 0.6
262.5 13125 55125 27563 18375 13781 11025 9188
299 14950 62790 31395 20930 15698 12558 10465
* Table values based on boiler only. Add volume for any additional appliances.
15
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 “Venting Systems and Air Supply for
Appliances,” of the Natural Gas and Propane Installation
Code, CAN/CSA B149.1, 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
CAN/CSA B149.1, or applicable provisions of local building
codes.
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 they are:
a) enclosed in a chase, or
b)
3. Where possible it is recommended to common vent
boiler and water heater.
4. For multiple boiler installations, consult boiler
manufacturer for venting recommendations.
6 - CHIMNEY AND VENT PIPE CONNECTION
WARNING
Boiler and venting installations shall be performed
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
such as carbon monoxide with is odorless and
invisible.
!
1.
Vent pipe must slope upward from the boiler not less
than ¼ inch for every 1 foot (21 mm/m) to verticle
vent terminal.
2.
Horizontal portions of venting system shall be
supported rigidly every 5 feet and at the elbows. No
portion of vent pipe should have any dips or sags.
Requirements
3.
installation shall be in accordance with “Venting of
Equipment,” of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or “Venting Systems and Air Supply
for Appliances,” of the Natural Fuel Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
4.
Inspect chimney. Chimney shall be constructed and
lined according to NFPA 211 and NFPA 54/ANSI Z223.1.
Vent connector shall be Type B, or metal pipe having
resistance to heat and corrosion not less than that of
galvanized sheet steel or aluminum not less than 26
gauge thick, 24 gauge for 6 and 7 inch.
5.
screw joints together to avoid sags. Flue pipe should
not extend beyond inside wall of chimney more than
the latest revision of National Fuel Gas Code, ANSI
ANSI Z223.1/NFPA 54 or CAN/CSA B149.1. Protect
required by National Fuel Gas Code. Where two or
Chimney Inspection
Chimney must be clean, right size, properly constructed
and in good condition.
Installation must conform to requirements of the authority
having jurisdiction or, in absence of such requirements, to
The National Fuel Gas Code, ANSI Z223.1/NFPA 54.
Vent Pipe
• Fasten sections of vent pipe with 3 sheet metal screws
at each joint to make piping rigid.
• Support horizontal portions of vent system to prevent
sagging.
• Use stove pipe wires or metal strapping every 5’ to
support pipe from above.
• Vent pipe through crawl space, use double wall vent
pipe.
• Vent pipe passing through combustible wall or partition,
use ventilated metal thimble. Thimble should be 4"
larger in diameter than vent pipe.
NOTICE
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
systems shall be installed in accordance with their
listing.
PN 240013087 Rev. D [12/01/2022]
16
6 - CHIMNEY AND VENT PIPE CONNECTION
Connecting The Vent Damper And Vent Connector
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.
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
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. See Figure 9.
3.
Damper must be in the open position when appliance
main burners are operating.
4.
Boiler is equipped with factory wired harness that 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.
8.
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 pipe.
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
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
4.
Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5.
Test for spillage at the draft hood relief opening after
a match or candle, or smoke from a cigarette, cigar or
pipe.
6.
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
any other gas-burning appliance to their previous
conditions of use.
7.
Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1. 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,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
!
PN 240013087 Rev. D [12/01/2022]
17
7 - VENT DAMPER OPERATION
Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement
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 repairs. Check vent damper operation as
follows:
•
indicator points to closed position, Figure 10.
• Turn thermostat or controller up to call for heat and
check vent damper indicator points to open position.
• 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
DO
NOT turn damper open manually or motor damage will
result. Set switch to “AUTOMATIC OPERATION” to close
For further information, and vent damper troubleshooting
guide, refer to manual packaged with vent damper and
Appendix B of this manual.
Inspect vent damper at least once a year by a
qualied service technician.
Figure 10 - Vent Damper Position Indicator
PN 240013087 Rev. D [12/01/2022]
18
8 - GAS SUPPLY PIPING
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.
•
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 See Figure 11.
Gas line enters boiler from right side.
• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:
• USA - National Fuel gas Code, ANSI Z223.1/NFPA 54
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
• Use pipe joint compound suitable for LP gas on male
threads only.
• Use ground joint unions.
• Install sediment trap upstream of gas controls.
• Use two pipe wrenches when making connection to gas
valve to keep it from turning.
•
• Tighten all joints securely.
• Propane gas connections should only be made by
licensed propane installer.
• Two-stage regulation should be used by propane
installer.
• Propane gas piping should be checked out by propane
installer.
CHECKING GAS PIPING
DANGER
Fire Hazard. Do not use matches, candles, open
Failure to comply will result in death or serious
injury.
!
Pressure test boiler and gas connection before placing
boiler in operation
.
• Pressure test over 1/2 psig (3.5 kPa). Disconnect
supply system.
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
• Locate leakage using gas detector, noncorrosive
acceptable to authority having jurisdiction. Do not
providing ignition source.
• Correct leaks immediately and retest.
NATURAL GAS
Pipe Capacity - BTU Per Hour Input
Includes Fittings
Length of
Pipe - FT ½” ¾” 1” 1¼”
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
Pipe - FT
Copper Tubing * Iron Pipe
¾” ½” ¾”
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.
Table 5 - Gas Pipe Sizes
Figure 11 - Gas Piping
PN 240013087 Rev. D [12/01/2022]
19
9 - ELECTRICAL WIRING
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:
• USA- 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
Connect 120 volt power supply to control leads L1 (HOT)
and L2.
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
2.
NEVER install thermostat on outside wall.
3.
4.
Check thermostat operation by raising and lowering
thermostat setting as required to start and stop the
burners.
5.
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.
VENT DAMPER WIRING
Boiler is equipped with factory wired harness with 4 pin
NOTICE
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
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.
WARNING
Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.
!
PN 240013087 Rev. D [12/01/2022]
20
10 - WIRING DIAGRAM
Figure 12 - Integrated High Limit Electronic Ignition Control
WARNING
result in personal injury or loss of life.
!
PN 240013087 Rev. D [12/01/2022]
This manual suits for next models
4
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