ECR UTICA HEATING UH15B Series Instruction manual

P/N 1305026UH, Rev. F [08/2011]
UTICA HEATING
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
UH15B SERIES
Cast Iron Gas Fired Boilers
For Forced Hot Water
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
MODEL NUMBERS:
UH15B045, UH15B070, UH15B096,
UH15B120, UH15B145, UH15B175,
UH15B195, UH15B245, UH15B295

2
TABLE OF CONTENTS
KEEP MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SAFETY SYMBOLS & WARNINGS
The following defined symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
Ratings & Data - Natural Gas & Propane Gas ...3
Installation Procedure.........................................4
Ventilation & Combustion Air..............................5
Connecting Supply & Return Piping...................6
Vent Installation................................................11
Vent System Modification.................................11
Vent Damper Installation & Instructions............12
Connecting Gas Service...................................13
Electrical Section..............................................13
Wiring Diagram.................................................14
Lighting Instructions..........................................18
Normal Sequence of Operation........................20
General Instructions .........................................20
Checking Gas Input Rate To Boiler ..................22
Replacement Parts...........................................23
Conversion Kits ................................................29
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death, serious injury.
!
WARNING
Indicates a hazardous situation which, if not
avoided, may result in death, serious injury.
!
WARNING
All installations of boilers and venting should
be done only by a qualified expert and in
accordance with the appropriate manual.
Installing or venting a boiler or any other
gas appliance with improper methods or
materials may result in serious injury or
death due to fire or to asphyxiation from
poisonous gases such as carbon monoxide
which is odorless and invisible.
!
WARNING
Keep boiler area clear and free from
combustible materials, gasoline and other
flammable vapors and liquids.
Do not obstruct air openings to the boiler
room.
Modification, substitution or elimination
of factory equipped, supplied or specified
components may result in, personal injury or
loss of life.
To the owner - installation and service of
this boiler must be performed by a qualified
installer.
To the installer - leave all instructions with the
boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts installation
must be performed by a licensed plumber or
licensed gas fitter.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, may result in injury.
Tested For 100 psi
ASME
Working Pressure
H
C.S.A. Certified
For Natural Gas Or Propane
NOTICE
Indicates information which should be followed to
ensure proper installation and operation.
IMPORTANT: Read the following instructions COMPLETELY before
installing!!
INSTALLATIONMANUALANDOPERATINGINSTRUCTIONS

3
Model No. Input Mbh (1)
Heating
Capacity
Mbh (1)
Net I=B=R
Rating Water
Mbh (1) **
AFUE Elect.
Ign. AFUE Stdg. Pilot No. Of Burners Recommended Air Cushion Tank (3)
Water
Content
(Gals.)
15B045 45 37 32 82.0% 80.0% 1 15 2.4
15B070 70 57 50 82.0% 80.0% 2 15 4.0
15B096 96 79 69 82.0% 80.0% 2 30 4.0
15B120 120 98 85 82.0% 80.0% 3 30 5.6
15B145 145 119 103 82.0% 80.0% 3 30 5.6
15B175 175 141 123 80.5% 80.0% 4 30 7.2
15B195 195 157 137 80.5% 80.0% 4 30 7.2
15B245 245 197 171 80.5% 80.0% 5 30 8.8
15B295 295 237 206 80.5% 80.0% 6 60 10.4
EXPLANATORY NOTES
--All boilers are design certified for installation on noncombustible floor.
--For installation on combustible floors use combustible floor kit.
--Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be reduced to 10 feet. Refer to the latest revision of
NFGC.
--Electric service to be 120 Volts, 15 Amps, 60 Hz.
--The MEA number for the this boiler is 39-86-E Vol VIII.
(1) For elevations above 2000 feet, ratings should be reduced at a rate of 4% for each 1000 feet above sea level.
(2) Base on 170° temperature in radiators.
(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and radiation.
--Net I=B=R Water Ratings based on piping an pickup allowance of 1.15. Consult manufacturer before selecting boiler for installations having unusual piping
and pickup requirements, such as intermittent system operation, extensive piping systems, etc..
STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Vent Damper Relay, Temperature - Pressure Gauge, Circulator With Return
Piping To Boiler, Main Gas Burners, Combination 24 Volt Gas Control (Includes Automatic Gas Valve, Gas Pressure Regulator, Automatic Pilot, Safety Shutoff,
Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief Valve, Drain Valve, Spill Switch, Rollout Switch, Automatic Vent Damper. Not Shown Are: Wiring Harness,
Thermocouple, Non-linting Safety Pilot.
OPTIONAL EQUIPMENT: Intermittent Electric Ignition Pilot System.
RATINGS&DATA-NATURALGAS&PROPANEGAS
Model No. Natural Gas
Inlet* Dimensions (Inches) Pump Size Supply & Return Tappings
ABCDEF
15B045 ½" 11¼ 5⅝427⅛20
7
16
4
15
16
1¼"
15B070 ½" 15⅛7528⅛20
15
16
4
15
16
1¼"
15B096 ½" 15⅛7528⅛20
15
16
4
15
16
1¼"
15B120 ½" 19 9½ 6 29⅛21
7
16
5
7
16
1¼"
15B145 ½" 19 9½ 6 29⅛21
7
16
5
7
16
1¼"
15B175 ½" 22⅞11
3
16
730⅛21
15
16
5
15
16
1¼"
15B195 ½" 22⅞11
3
16
730⅛21
15
16
5
15
16
1¼"
15B245 ¾” 26¾ 13
6
16
831⅛22
7
16
6
15
16
1¼"
15B295 ¾” 30⅝15
5
16
932⅛22
15
16
8
15
16
1¼"
* Propane Gas Inlet (All Units) 1/2”

4
Installation must conform to requirements of 1.
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
Where required by the authority having jurisdiction, 2.
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
Boiler series is classified as Category I. Vent installation 3.
shall be in accordance with “Venting of Equipment,” of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or
applicable provisions of the local building codes.
Boiler has met safe lighting and other performance 4.
criteria with the gas manifold and control assembly on
the boiler per ANSI Z21.13/CGA 4.9.
Boiler shall be installed such that the gas ignition 5.
system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation and service, (circulator replacement,
condensate trap, control replacement, etc.).
Locate boiler on level, solid base as near the chimney 6.
as possible and centrally located with respect to heat
distribution system as practical.
Allow 24 inches at front and right side for servicing and 7.
cleaning.
When installed in utility room, door should be wide 8.
enough to allow largest boiler part to enter, or to
permit replacement of another appliance such as a
water heater.
FOR INSTALLATION ON NON-COMBUSTIBLE
9.
FLOORS ONLY - For installation on combustible
flooring special base must be used. (See Replacement
Parts Section.) Boiler can not be installed on
carpeting.
Minimum clearances to combustible construction are:
10.
TOP .................................................. 18 in.
FRONT .........................................ALCOVE *
FLUE CONNECTOR ............. ...................6 in.
REAR .................................................. 8 in.
CONTROL SIDE ................ ..................9 in.
OTHER SIDE .......................3 in. HOT WATER
PIPES .............................................. 1/2 in.
NOTE: Greater clearances for access should supersede
fire protection clearances.
* The definition of an Alcove is a three sided space with no
wall in front of the boiler. The ANSI standard for an alcove
is 18 inches from the front of an appliance to the leading
edge of the side walls as shown below.
Minimum Clearances To Combustible
Construction (As Seen From Above)
3"
8"
BOILER
18"
9"
!
WARNING
Improper installation, adjustment, alteration,
service or maintenance can cause injury.
INSTALLATIONPROCEDURE

5
Table 1 - Minimum Room Volume, Indoor Air Only*
Input Mbh Standard
Method Known Air Infiltration Rate Method (Air Changes Per Hour)
0.1 0.2 0.3 0.4 0.5 0.6
45 2250 9450 4725 3150 2363 1890 1575
70 3500 14700 7350 4900 3675 2940 2450
96 4800 20160 10080 6720 5040 4032 3360
120 6000 25200 12600 8400 6300 5040 4200
145 7250 30450 15225 10150 7613 6090 5075
175 8750 36750 18375 12250 9188 7350 6125
195 9750 40950 20475 13650 10238 8190 6825
245 12250 51450 25725 17150 12863 10290 8575
295 14750 61950 30975 20650 15488 12390 10325
* Table values based on boiler only. Add volume for any additional appliances.
VENTILATION&COMBUSTIONAIR
!
WARNING
Air openings to combustion area must not
be obstructed. Following instructions below,
adequate combustion air can be maintained.
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
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 volume for
all appliances in space. Use a different method if
minimum volume not available.
Standard Method.A. Cannot be used if known air
infiltration rate is less than 0.40 air changes per
hour. See Table 1 for space with boiler only. Use
equation for multiple appliances.
Volume ≥50 ft3x Total Input [Mbh]
Known Air Infiltration Rate.B. See Table 1 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate
(ACH) greater than 0.60.
Volume ≥21 ft3⁄ACH x Total Input [Mbh]
Refer to National Fuel Gas CodeC. for opening
requirements between connected indoor spaces.
All Outdoor Air.• Provide permanent opening(s)
communicating directly or by ducts with outdoors.
Two Permanent Opening MethodA. . 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.
One Permanent Opening MethodB. . 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 CodeC. for additional
requirements for louvers, grilles, screens and air
ducts.
Combination Indoor and Outdoor Air.• Refer to
National Fuel Gas Code for application information.

6
Hydronic Piping - General
Install piping in accordance with authority having juris-•
diction.
Support system piping and safety relief valve discharge•
piping.
Special Conditions
System piping exposed to freezing conditions: Use•
inhibited proplyene glycol solutions certified by fluid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
Boiler installed above radiation level (or as required by•
authority having jurisdiction). Install low water cutoff.
Boiler used in connection with refrigeration system.•
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
See Figure 2.
System piping connected to heating coils located in air•
handling unit exposed to refrigerated air circulation.
Install flow control valves or other automatic means to
prevent gravity circulation of boiler water during cooling
cycle.
Safety Relief Valve
NOTICE
Boiler rated at 100 psig maximum allowable
working pressure. Boiler provided with 30
psig safety relief valve. Field source safety
relief valve for system pressures greater
than 30 psig. Temperature-Pressure Gauge
provided with boiler is satisfactory for 30-50
psig operation. Replace Temperature-Pressure
Gauge for system pressure over 50 psig. Scale
on dial must be graduated to not less than
1½ nor more than 3½ time safety relief valve
pressure settings.
Install safety relief valve and air vent using pipe fittings•
provided with boiler. See figure on page 3.
Install safety relief valve with spindle in vertical position.•
Do not install shutoff valve between boiler and safety•
relief valve.
Systems with automatic fill valves require back flow•
prevention device.
Install discharge piping from safety relief valve. See• Figure 1.
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).•
When boiler is connected to heating system utilizing•
multiple zoned circulators, each circulator must be
supplied with flow control valve to prevent gravity
circulation.
Hot water boilers and system must be filled with water•
and maintained to minimum pressure of 12 p psig.
Bypass piping is an option which gives ability to adjust•
the supply boiler water temperature to fit the system or
condition of installation. This method of piping, however,
is not typically required for baseboard heating systems.
Typical installations where bypass piping is used are as
follows:
This method is used to protect boilers fromA.
condensation forming due to low temperature
return water. Generally noticed in large converted
gravity systems or other large water volume
systems. Figure 3.
These methods are used to protect systems usingB.
radiant panels and the material they are encased
in from high temperature supply water from the
boiler and protect boiler from condensation.
NOTE#1: When using bypass piping, adjust valves V1 & V2
until desired system temperature is obtained.
NOTE#2: Bypass loop must be same size piping as the
supply and return piping.
Installation using circulators and zone valves are shown•
in Figures 3-8. For further piping information refer to
I=B=R Installation and Piping Guide.
CONNECTINGSUPPLY&RETURNPIPING
!
WARNING
Burn and scald hazard. Safety relief valve
could discharge steam or hot water during
operation. Install discharge piping per these
instructions.

7
WARNING
To avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation, a
discharge line shall be installed to relief valve outlet connection.
Discharge line shall:
connect to relief valve outlet and piped down to safe point of disposal. Check local codes for•
maximum distance from floor or allowable safe point of discharge.
be of pipe size equal to or greater than that of the relief valve outlet over the entire length of•
discharge line;
have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not•
plug or place any obstruction in discharge line.
terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;•
allow complete drainage of the valve and the discharge line;•
be independently supported and securely anchored to avoid applied stress on the relief valve;•
be as short and straight as possible;•
terminate with plain end (not threaded);•
be constructed of material suitable for exposure to temperatures of 375° F; or greater.•
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.
Figure 1
Check local codes
for maximum
distance from floor
or allowable safe
point of discharge.
Discharge Line
Safety Relief Valve
CONNECTINGSUPPLY&RETURNPIPING

8
IMPORTANT: Circulators in following illustrations are mounted on system supply side, but mounting on system return
side is also acceptable practice.
Figure 2
CONNECTINGSUPPLYANDRETURNPIPING
EXPANSION
TANK
CHECK
VALVE
B
D
FEED
WATER
C
RETURN PIPING
FROM HEATING
AND COOLING
ELEMENT
WATER
CHILLER
SUPPLY PIPING
TO HEATING
AND COOLING
ELEMENT
CIRCULATOR
A
PRESSURE
REDUCING
VALVE
PROPER
BACKFLOW
PROTECTION
DEVICE
GATE
VALVE
PURGE
VALVE

9
BOILER ALTERNATE
CIRCULATOR
LOCATION
TO SYSTEM FROM SYSTEM
V2V1
CIRCULATOR
SHUT-OFF
VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
BALL VALVE AIR SEPARATOR
ZONE VALVE
EXPANSION
TANK
WATER INLET
SYSTEM
CIRCULATOR
Figure 4 - BYPASS PIPING - FIXED LOW TEMP ONLY
CONNECTINGSUPPLYANDRETURNPIPING
Figure 3 - BYPASS PIPING -AUTOMATIC MIXING VALVE
BOILER
WATER INLET
ALTERNATE
CIRCULATOR
LOCATION
TO SYSTEM FROM SYSTEM
CIRCULATOR PRESSURE
REDUCER VALVE BALL VALVE AIR SEPARATOR
EXPANSION
TANK

10
ZONE 3
ZONE 2
ZONE 1 (PRIORITY ZONE)
BOILER
ZONE 4
DHW CIRCULATOR
WATER INLET
CIRC 2
CIRC 3
CIRC 4
CIRCULATOR
SHUT-OFF
VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
BALL VALVE AIR SEPARATOR
ZONE VALVE HOSE BIB FLOW CONTROL
VALVE
EXPANSION
TANK
BOILER
DHW
CIRCULATOR
CH CIRCULATOR
PRIORITY ZONE
CIRCULATOR
EXPANSION
TANK
WATER INLET
FLOW CONTROL
VAVLE SHUT-OFF
VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
BALL VALVE
AIR SEPARATOR
ZONE VALVE
HOSE BIB
CONNECTINGSUPPLYANDRETURNPIPING
Figure 5 - Single Zone System With DHW Priority
Figure 6 - Multi-zone System with Circulators and DHW Priority

11
ZONE 3
ZONE 2
ZONE 1 (PRIORITY ZONE)
BOILER
WATER INLET
ZONE 4
*USE FULL PORT ZONE
VALVE.
DHW
CIRCULATOR
CH
CIRCULATOR
CIRCULATOR
FLOW CONTROL
VALVE SHUT-OFF VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
BALL VALVE AIR SEPARATOR
ZONE VALVE HOSE BIB
EXPANSION
TANK
ZONE 3
ZONE 2
ZONE 1 (PRIORITY ZONE)
BOILER
WATER INLET
CH & DHW
SYSTEM
CIRCULATOR
*USE FULL PORT ZONE
VALVE. FOR OPTIMUM TANK
PERFORMANCE, CONSIDER
USING ZONE CIRCULATOR
(SEE FIGURE 5)
ZONE 4
CIRCULATOR
SHUT-OFF
VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
EXPANSION
TANK
AIR SEPARATOR
ZONE VALVE HOSE BIB
FLOW CONTROL
VALVE
CONNECTINGSUPPLYANDRETURNPIPING
Figure 7 - Multi-zone System With Zone Valves And DHW Priority (With Circulator)
Figure 8 - Multi-zone System With Zone Valves And DHW Priority (With Zone Valve)

12
When existing boiler is removed from a common venting
system, the system is likely to be too large for the proper
venting of the appliances still connected to it.
REMOVAL OF BOILER FROM VENTING SYSTEM
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.
Seal any unused opening in the common venting 1.
system.
Visually inspect the venting system for proper size and 2.
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 3.
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 other appliance not
connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they operate at maximum speed. Do
not operate a summer exhaust fan. Close fireplace
dampers.
Place in operation the appliance being inspected. Follow 4.
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
Test for spillage at the draft hood relief opening after 5.
5 minutes of main burner operation. Use the flame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
After it has been determined that each appliance 6.
remaining connected to a common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas burning appliances to their previous
condition of use.
Any improper operation of the common venting system 7.
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
When re-sizing any portion of the common venting
system, the common venting system should be re-sized
to approach the minimum size as determined using the
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
Vent pipe must slope upward from boiler not less then 1.
¼ inch per 1 foot to the vent terminal.
Horizontal portions of venting system shall be 2.
supported rigidly every 5 feet and at elbows. No portion
of vent pipe should have any dips or sags.
This boiler series is classified as Category I. Vent 3.
installation shall be in accordance with “Venting of
Equipment,” of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of the local
building codes.
Vent connectors serving appliances vented by natural
4.
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.
Connect flue pipe from draft hood to chimney. Bolt or
5.
screw joints together to avoid sags. Flue pipe should
not extend beyond inside wall of chimney. Do not
install manual damper in flue pipe or reduce size of
flue outlet except as provided by the latest revision
of ANSI Z223.1. Protect combustible ceiling and walls
near flue pipe with fireproof insulation. Where two or
more appliances vent into a common flue, the area of
the common flue must be at least equal to the area
of the largest flue plus 50 percent of the area of each
additional flue.
!
WARNING
All installations of boilers and venting should
be done only by a qualified expert and in
accordance with the appropriate manual.
Installing or venting a boiler or any other gas
appliance with improper methods or materials
may result in serious injury or death due to
fire or to asphyxiation from poisonous gases
such as carbon monoxide with is odorless and
invisible.
VENTINSTALLATION
VENTSYSTEMMODIFICATION

13
LOCKNUT
HARNESS
CONN.
DAMPER
CONN.
DAMPER
MOTOR
INSTALLER
HOOK-UP
CLOSE-UP OF
INSTALLER
HOOK-UP
DAMPER WIRE
HARNESS
HI LIMIT
CONTROL
FACTORY WIRED
CONTROL
VENT DAMPER
VENT
OUTLET
VENT
DAMPER
NOTE: Refer to Figure 9 for steps 1-6.
Place Vent Damper on or as close to vent outlet of 1.
boiler as possible. Figure 9. Do not modify draft hood
or vent damper during installation.
Remove Vent Damper Motor cover. 2.
Feed damper wire harness connector through bracket 3.
hole on Damper Motor frame.
Tighten locknut onto Damper wire harness connector. 4.
Plug Damper connector into socket on Damper Motor 5.
frame.
Replace Damper Motor cover and wire Damper in 6.
accordance with Figure 9.
REFER TO DAMPER MANUFACTURER'S
INSTALLATION INSTRUCTIONS FOR
POSITION OF DAMPER
CONTROL BOX
ACCEPTABLE VENT
DAMPER LOCATIONS
BOILER HOT WATER HEATER
CHIMNEY
UN-ACCEPTABLE
DAMPER LOCATIONS
Ensure only boiler is serviced by Vent Damper. 1. Figure
10.
Clearance of not less than 6 inches between Vent 2.
Damper and combustible material must be maintained.
Additional clearance should be allowed for service of
Vent Damper.
Vent Damper must be in open position when appliance 3.
main burners are operating.
Vent Damper position indicator must be in visible 4.
location following installation.
Thermostat's heat anticipator must be adjusted to 5.
match total current draw of all controls associated with
boiler during heating cycle.
VENTDAMPERINSTALLATION&INSTRUCTIONS
Figure 9 - DAMPER INSTALLATION Figure 10 - DAMPER LOCATION

14
Use piping materials and joining methods acceptable 1.
to authority having jurisdiction. In absence of such
requirements:
National Fuel Gas Code, ANSI Z223.1/NFPA 54•
Ground joint union should be installed for easy removal of
gas control for servicing. Drip leg or trap must be installed
at bottom of vertical section of piping at inlet to boiler. Pipe
compound resistant to action of liquefied petroleum gases
must be used on all threaded pipe connections. Check with
local utility for location of manual shutoff valve if required.
Figure 11.
Gas line should be of adequate size to prevent undue 2.
pressure drop and never smaller than pipe size of main
gas control valve. See Chart below.
Boiler and its gas connection must be leak tested
3.
before placing boiler in operation.
Boiler and its individual shutoff valve must be 4.
disconnected from gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psi (3.5 kPa).
Boiler must be isolated from gas supply piping system
by closing its individual manual shutoff valve during
any pressure testing of gas supply piping system at
test pressures equal to or less than 1/2 psi (3.5 kPa).
Natural Gas Propane
Min. Supply Pressure 5.0" w.c. 11.0" w.c.
Max. Supply Pressure 13.5" w.c. 13.5" w.c.
Manifold Pressure 3.5" w.c. 10.5" w.c.
ELECTRICAL WIRING
See wiring diagrams on the following four pages for
details.
Boiler must be electrically bonded to ground in accordance
with the requirements of the authority having jurisdiction
or, in the absence of such requirements, with the National
Electrical Code, ANSI/NFPA 70.
IMPORTANT: Install fused disconnect switch between boiler
and electrical panel at convenient location.
THERMOSTAT INSTALLATION
Thermostat should be installed on inside wall about 1.
four feet above floor.
NEVER install thermostat on outside wall. 2.
Do not install thermostat where it will be affected by 3.
drafts, hot or cold pipes, sunlight, lighting fixtures,
televisions, a fireplace, or chimney.
Check thermostat operation by raising and lowering 4.
thermostat setting as required to start and stop
burners.
Instructions for final adjustment of thermostat 5.
are packaged with thermostat (adjusting heating
anticipator, calibration, etc.)
!
WARNING
Do not use an open flame.
CONNECTINGGASSERVICE
ELECTRICALSECTION
Figure 11
Maximum Capacity Of Pipe In Cubic Feet Of Gas/Hour
(Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in.
w/c)
Length of
Pipe (Feet) Nominal Iron Pipe Size
½” ¾” 1” 1¼”
10 175 360 680 1400
20 120 250 465 950
30 97 200 375 770
40 82 170 320 660
60 66 138 260 530
80 57 118 220 460
100 50 103 195 400
For additional information refer to the National Fuel Gas
Code Handbook.

15
WIRINGDIAGRAM
Figure 12 - 24V Standing Pilot

16
WIRINGDIAGRAM
Figure 13 - 24V Intermittent Ignition

17
WIRINGDIAGRAM
Figure 14 - 24V Standing Pilot with LWCO

18
WIRINGDIAGRAM
Figure 15 - 24V Interim Ignition With LWCO

19
Lighting Procedure For Boiler With Intermittent Pilot
System
For Your Safety, Read Before Operating!!
This appliance is equipped with an ignition deviceA.
which automatically lights the pilot. Do not try to
light the appliance by hand.
Before operating, smell all around the applianceB.
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
!
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switches; do not
use any phones in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
Use only your hand to push in or turn the gasC.
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 appliance if any part has beenD.
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.
Operating Instructions For Intermittent Pilot System
STOP! Read the safety information to the left on this 1.
page.
Set the thermostat to lowest setting. 2.
Turn off all electric power to the appliance. 3.
This appliance is equipped with an ignition device which 4.
automatically lights the pilot. Do not try to light the
pilot by hand. Figure 16.
Figure 16
Turn gas control knob clockwise 5. to “OFF.”
Wait (5) minutes to clear out any gas. If you then smell 6.
gas, STOP! Follow “What To Do If You Smell Gas” in the
safety information to left. If you don’t smell gas, go on
to the next step.
Turn gas control knob counterclockwise 7. to “ON.”
Turn on all electric power to the appliance. 8.
Set thermostat to desired setting. 9.
If the appliance will not operate, follow the instructions 10.
“ To Turn Off Gas To Appliance ” and call a qualified
service technician or your gas supplier.
!
WARNING
Before lighting any type of pilot burner
(standing or intermittent), make certain hot
water boiler and system are full of water to
minimum pressure of 12 lbs. Per square inch
in system, and also make certain system
is vented of air. Set operating control of
thermostat to “below” normal setting. Refer to
following appropriate lighting instruction.
!
WARNING
If you do not follow these instructions exactly,
a fire or explosion may result, causing
personal injury or loss of life.
Before any procedures are attempted on
this appliance, it is necessary to determine if
ignition system is electric or standing pilot.
If you are uncertain, contact manufacturer
before proceeding.
LIGHTINGINSTRUCTIONS

20
Lighting procedure for boiler with continuous pilot
For Your Safety, Read Before Lighting!
Read warning at beginning of " 1. Lighting
Instructions
" on previous page.
This appliance has a pilot which must be lighted by 2.
hand. When lighting the pilot, follow these instructions
exactly.
Before lighting, smell all around appliance area for 3.
gas. Be sure to smell next to floor because some gas
is heavier than air and will settle on floor. See section
" What To Do If You Smell Gas " on previous page.
Use only your hand to push in or turn gas control knob 4.
or reset button. Never use tools. If knob or reset button
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 appliance if any part has been under 5.
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.
Lighting Instructions For Continuous Pilot
STOP! 1. Read safety information above on this page.
Set thermostat to lowest setting. 2.
Turn off all electric power to appliance. 3.
Remove access panel and burner door. 4.
Turn gas control knob clockwise 5. to "OFF."
Figures 17 and 18.
NOTE: Some gas control knobs cannot be turned from
"PILOT" to "OFF" unless knob is pushed in slightly. DO
NOT FORCE.
Wait (5) minutes to clear out any gas. If you then smell 6.
gas, STOP! Follow " What To Do If You Smell Gas ."
If you don't smell gas, go to the next step.
Find pilot. Follow metal tube from gas control. 7.
Depending on model of boiler, pilot is either mounted
on base or on one of burner tubes.
Turn gas control knob counterclockwise 8. to
"PILOT."
Push in gas control knob or reset button if so equipped, 9.
all way in and hold. Immediately light pilot with match.
Continue to hold gas control knob or reset button in for
about 1 minute after pilot is lit. Release knob or button,
and it will pop up back up. Pilot should remain lit. If it
goes out, repeat steps 5 through 9.
If knob or button does not pop up when released,•
stop and immediately call a qualified service
technician or your gas supplier.
If the pilot will not stay lit after several tries, turn•
the gas control knob clockwise to "OFF." Call a
qualified service technician or your gas supplier.
Replace burner door. 10.
Turn gas control knob counterclockwise 11. to "ON."
Replace access panel. 12.
Turn on all electric power to the appliance. 13.
Set thermostat to desired setting. 14.
To Turn Off Gas To The Appliance
Set thermostat to lowest setting. 1.
Turn off all electric power to the appliance if service is 2.
to be performed.
Push in gas control knob slightly and turn clockwise 3.
to "OFF." DO NOT FORCE.
INLET
f
LIGHTINGINSTRUCTIONS
Figure 17
Figure 18