UTICA BOILERS DV Guide

USER'S
INFORMATION
MANUAL
P/N 37615901, Rev. B [3/2011]
SERIES DV
GAS FIRED HOT WATER HEATING BOILER
WARNING: If the information in this manual is not
followed exactly, a re or explosion may result causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other ammable
vapors and liquids in the vicinity of this or any
other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.•
Do not touch any electrical switch; do not use•
any phone in your building.
Immediately call your gas supplier from a •
neighbor's phone. Follow the gas supplier's
instructions.
If you cannot reach your gas supplier, call the •
re department.
Installation and service must be performed by a
qualied installer, service agency or the gas
supplier.
Do not use this boiler if any part has been under water. Immediately call a qualied service technician to
inspect the boiler and to replace any part of the control system and any gas control which has been under
water.
Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to
the pump. Instead, shut off the gas supply at a location external to the appliance.
Utica Boilers
2210 Dwyer Avenue, Utica NY 13504-4729
Phone: [phone] • Fax: [phone]
e-mail: [e-mail]
web site: www.ecrinternational.com

2
USERS INFORMATION MANUAL
INSTRUCTIONS FOR OPERATION AND MAINTENANCE
OF GAS FIRED HOT WATER HEATING BOILER
RETAIN FOR FUTURE REFERENCE
SAFETY SYMBOLS & WARNINGS
Following dened symbols are used throughout this manual
to notify reader of potential hazards of varying risk levels.
DANGER
!
DANGER
Indicates a hazardous situation which, if
not avoided, WILL result in death or serious
injury.
NOTICE
Indicates information which should be
followed to ensure proper installation and
operation.
!
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or serious
injury.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, may result in minor or moderate
injury.
Utica Boilers recommends all boiler maintenance be
performed by a trained heating technician.
Before any procedures are attempted on this appliance,
it is necessary to determine if ignition system is electric
or standing pilot system. If you are uncertain, contact
manufacturer before proceeding.

3
LIGHTING INSTRUCTIONS
!
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 the system, and also make certain the
system is vented of air. Refer to following
appropriate lighting instruction.
LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM
!
WARNING
If you do not follow these instructions exactly,
a re or explosion may result causing property
damage, personal injury or loss of life.
This appliance is equipped with an ignition device A. which automatically lights the pilot. Do not try to
light the appliance by hand.
Before operating, smell all around the appliance area B. for gas. Be sure to smell next to the oor because
some gas is heavier than air and will settle on the
oor. Read "What To Do If You Smell Gas" on front
page of this manual.
Use only your hand to push in or turn the gas control C. knob. Never use tools. If the knob will not push in
or turn by hand, don’t try to repair it, call a qualied
service technician. Force or attempted repair may
result in a re or explosion.
Do not use this appliance if any part has been under D. water. Immediately call a qualied service technician
to inspect the appliance and to replace any part of
the control system and any gas control which has
been under water. E.
F.
Operating Instructions For Intermittent Pilot
System
STOP! 1. Read the safety information above.
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 pilot by
hand.
Remove jacket front panel. 5.
Turn gas control knob clockwise 6. to “OFF.” See
Figure 1.
Wait (5) minutes to clear out any gas. If you then smell 7.
gas, STOP! Follow “What To Do If You Smell Gas” on
front cover of this manual. If you don’t smell gas, go on
to the next step.
Turn gas control knob counterclockwise
8. to “ON.”
Replace jacket front panel. 9.
Turn on all electric power to the appliance. 10.
Set thermostat to desired setting. 11.
If the appliance will not operate, follow the instructions 12.
“To Turn Off Gas To Appliance” on page 4 and call a
qualied service technician or your gas supplier.
Figure 1 - Intermittent Pilot

4
LIGHTING INSTRUCTIONS
To Turn Off Gas To Appliance
Set the 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.
Replace jacket panel. 4.
GENERAL INSTRUCTIONS
Before seasonal start-up, have qualied service agency
check boiler for soot and scale in the ues, clean burners
and check gas input rate to maintain high operating
efciency.
!
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.
Verify proper operation after service.
Service agency or owner should make certain system is
lled with water to minimum pressure and open air vents,
if used, to expel any air that may have accumulated in the
system. Check the entire piping system and, if any leaks
appear, have them repaired.
Figure 2 - Circulator
Many circulators like the one pictured in Figure 2 (above)
require periodic servicing. Motor usually has openings at
each end to lubricate bearings.
Put about one half teaspoon of SAE 20 or 30 non-detergent
motor oil in each opening twice a year.
!
CAUTION
Do Not Over Oil!!
Many circulators have oil opening for shaft bearing. This
should be oiled at same time for quiet operation. Follow
manufacturer's instructions for oiling shaft bearing.
Venting system should be inspected at start of each heating
season. Check vent pipe from boiler to chimney for signs of
deterioration by rust or sagging joints. Repair if necessary.
Remove vent pipe at base of chimney or ue and using a
mirror, check vent for obstruction and make certain vent is
in good working order.
Figure 3 - Boiler Flue Gas Passageways
BURNERS
ORIFICES GAS VALVE
HOLD DOWN
BOLT
FLUE
COLLECTOR
VENTER
ASSEMBLY
A1795

5
GENERAL INSTRUCTIONS
Before seasonal start up it is advisable to have qualied
service agency check boiler for soot and scale in the ues,
clean burners and check gas input rate to maintain high
operating efciency. Service agency should make certain
system is lled with water to minimum pressure and
open air vents - if used - to expel any air that may have
accumulated in system. Entire piping system should also be
checked and if any leaks appear, they should be repaired
immediately.
Venting system should also be inspected at start of each
heating season. Vent pipe from boiler should be checked for
signs of deterioration or sagging joints. Repair if necessary.
Following procedure should be followed to clean and check
ue gas passageways:
Remove burners from combustion chamber by raising 1.
burners up from manifold orices and pulling toward
front of boiler, (See Figure 4)
Disconnect vent pipe from vent adapter. 2.
Remove jacket front panel. (See Figure 5) 3.
Check venter assembly suction pressure. 4.
Connect slope manometer between venter and •
pressure switch with tee and additional tubing and
connectors.
Turn boiler on and read suction pressure on •
manometer. Reading should be negative (-) .55
± .05 inches of water column or higher for DV50
thru 150 and negative (-) .65 ± .05 inches of water
column or higher for DV200. If this reading is not
attainable, contact qualied service agency.
Remove ue collector and venter assembly from boiler 5.
castings by loosening hold-down bolts located on each
side of ue collector. (See Figure 3)
Visually inspect venter assembly for any unusual wear 6.
or dirt build up.
If venter has oil cups lubricate venter motor once a 7.
month during heating season with few drops of non-
detergent motor oil (SAE 20 or 30). Do not over oil.
Place sheet of heavy paper or similar material in 8.
bottom of combustion chamber and brush down ue
passageways. Soot and scale will collect on paper and
is easily removed with paper.
Visual check of main burner and pilot ames should be
made at start of heating season and again in mid-season.
Main burner ame should have well dened inner blue
mantel with lighter blue outer mantel. (See Figure 6) If
ame does not appear this way, check burner throats and
burner orices for lint or dust obstructions.
Pilot ame should envelop 3/8 to 1/2 inch of tip of ignition
electrode (See Figure 7). To adjust pilot ame, remove pilot
adjustment cover screw on gas valve and turn inner screw
clockwise to decrease or counterclockwise to
increase pilot ame. See Figure 1. Be sure to replace cover
screw after adjustment to prevent possible gas leakage.
Burners and pilot should be checked for signs of corrosion,
rust or scale build-up, and cleaned with nylon bristle brush.
Area around boiler must be kept clear and free of
combustible materials, gasoline and other ammable
vapors and liquids.
Free ow of combustion and ventilating air to boiler and
boiler room must not be restricted or blocked.
In event ow of combustion products through ueways
or boiler venting system becomes blocked, ame roll-out
safety switch will shut off main burner gas. See Figure 5.
If this condition occurs, do not attempt to place boiler in
operation. Contact qualied service agency.
It is suggested that qualied service agency be employed
to make annual inspection of boiler and heating system.
They are experienced in making inspection outlined above
and in event repairs or corrections are necessary, they can
make proper changes for safe operation of boiler.

6
GENERAL INSTRUCTIONS
Figure 6 - Burner Flame
Figure 4 - Burners, Burner Orices
GAS VALVE
ORIFICES
BURNERS
Figure 5 - Boiler Front with Safety Switch
COMBUSTION
BURNER
(REMOVED)
BURNERS GAS
VENT PIPE
CHAMBER
DOOR
VALVE
ADAPTER
ROLL-OUT SAFETY
BURNER
SWITCH
JACKET
FRONT
PANEL
Figure 7 - Burners Pilot Flame
IGNITION ELECTRODE
3/8” TO 1/2”
IN FLAME

7
NOTES

8
NOTES
Date of Installation:
Boiler Model #:
Installed By:
Utica Boilers
2210 Dwyer Avenue, Utica NY 13504-4729
Phone: [phone] • Fax: [phone]
e-mail: [e-mail]
web site: www.ecrinternational.com