UTICA BOILERS MAGB Technical Document

Utica Boilers  P.O. Box 4729  Utica, NY 13504
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
MAGB
MODULAR GAS FIRED BOILERS
FOR FORCED HOT WATER

PAGE 1
TABLE OF CONTENTS
Safety Sy bols & Warnings .................................................................................. Page 2
Engineering and Di ensional Data ................................................................. Pages 3-4
Typical Lay-Out for Gas Fired Syste s ............................................................... Page 5
Supply and Return Piping ................................................................................... Pages 6
Installation Procedure ......................................................................................... Pages 7
Ventilation and Co bustion Air ..................................................................... Pages 8-10
Vent Installation.................................................................................................. Page 10
Vent Da per Installation and Instructions.......................................................... Page 11
Vent Syste Modification ................................................................................... Page 12
Connecting Boilers with Refrigeration Syste s ................................................ Pages 13
Connecting Gas Service .................................................................................... Page 14
Electrical Wiring.................................................................................................. Page 15
Ther ostat Installation ........................................................................................ Page 15
Lighting Instructions .................................................................................... Pages 15018
Nor al Sequence of Operation ........................................................................... Page 18
General Instructions .................................................................................... Pages 19-21
Checking Gas Input Rate to Boiler ..................................................................... Page 21
Controls ............................................................................................................... Page 22
Wiring Diagra ................................................................................................. Pages 23
Replace ent Parts List and General Asse bly .......................................... Pages 24-30
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SERIES MAGB
CAST IRON
GAS FIRED BOILERS
INSTALLATION MANUAL AND OPERATION INSTRUCTIONS
Published February 1995
Printed in USA
Made In USA

PAGE 2
IMPORTANT!
1. READ ALL INSTRUCTIONS BEFORE INSTALLING.
2. To the owner: Installation and service of this boiler ust be perfor ed by a qualified
installer.
3. To the installer: Leave all instructions with the boiler for future reference.
WARNING!
1. Keep boiler area clear and free fro co bustible aterials, gasoline and other
fla able vapors and liquids.
2. DO NOT obstruct air openings to the boiler roo .
3. Modification, substitution or eli ination of factory equipped, supplied or specified
co ponents ay result in property da age, personal injury or the loss of life.
4. When this product is installed in the Co onwealth of Massachusetts the installation
ust be perfor ed by a Licensed Plu ber or Licensed Gas Fitter.
Safety Symbols
DANGER
DANGER - Indicates an i inently hazardous situation which, if not avoided, WILL
result in death or serious injury.
WARNING
WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury
CAUTION
CAUTION - Indicates a potential hazardous situation which, if not avoided, MAY result
in inor or oderate injury. It ay also be used to alert against unsafe practices.
The following defined sy bols are used throughout this anual to notify the
reader of potential hazards of varying risk levels.

PAGE 3
SERIES MAGB GAS FIRED BOILERS
ENGINEERING DIMENSIONAL DATA
MODEL NUMBER SHIPPING WATER ABC
NUMBER OF WEIGHT CONTENT INCHES INCHES INCHES
MAGB MODULES (LBS.) (GALLONS)
500 2 945 17.6 62.250" 26.625" 13.313"
600 2 1065 20.8 70.000" 30.500" 15.250"
750 3 1400 26.4 97.875" 26.625" 13.313"
900 3 1600 31.2 109.500" 30.500" 15.250"
1000 4 1890 35.2 133.500" 26.625" 13.313"
1200 4 2135 41.6 149.000" 30.500" 15.250"
1500 5 2665 52.0 188.000" 30.500" 15.250"
1800 6 3200 62.4 228.000" 30.500" 15.250"
2100 7 3730 72.8 267.500" 30.500" 15.250"
2400 8 4265 83.2 307.000" 30.500" 15.250"

PAGE 4
MODEL AGA AGA NET I=B=R FLUE COMMON CHIMNEY
NUMBER INPUT OUTPUT WATER RATINGS OUTLET VENT DIAMETER
MAGB BTU/HR. BTU/HR. BTU/HR. SQ. FT. DIA.&NO. DIA. & HEIGHT
** 8" 9"
500 500,000 *410,000 356,500 2,377 2 10" 12" X 15'
600 600,000 480,000 423,000 2,817 2 12" 14" X 15'
750 750,000 *615,000 533,000 3,553 3 12" 14" X 20'
900 900,000 720,000 634,000 4,226 3 14" 16" X 20'
1000 1,000,000 *820,000 713,000 4,753 4 14" 16" X 20'
1200 1,200,000 960,000 845,000 5,635 4 16" 18" X 20'
1500 1,500,000 1,200,000 1,057,000 7,043 5 16" 20" X 20'
1800 1,800,000 1,440,000 1,268,000 8,452 6 18" 20" X 30'
2100 2,100,000 1,680,000 1,479,000 9,861 7 20" 22" X 30'
2400 2,400,000 1,920,000 1,690,000 11,289 8 22" 24" X 30'
* DOE HEATING CAPACITY
**For elevations above 2000 feet ratings should be reduced at a rate of 4% for each
1000 feet above sea level.
**For equivalent square feet of radiation, divide I=B=R output by 150.
SERIES MAGB GAS FIRED BOILERS
ENGINEERING DIMENSIONAL DATA

PAGE 5
TYPICAL LAY-OUTS FOR
GAS FIRED SYSTEMS

PAGE 6
SUPPLY AND RETURN PIPING

INSTALLATION PROCEDURE
WARNING: I proper installation, adjust ent, alteration, service or ainte-
nance can cause injury or property da age.
1. The installation ust confor to the require ents of the authority having jurisdiction
or, in the absence of such require ents, to the latest revision of the National Fuel Gas Code,
ANSI Z223. (Available fro the A erican Gas Association, 8501 E. Pleasant Valley Road,
Cleveland, Ohio 44134). Reference should also be ade to local gas utility regulations and
other codes in effect in the area in which the installation is to be ade.
2. Where required by the authority having jurisdiction, the installation ust confor to
A erican Society of Mechanical Engineers Safety Code for Controls and Safety Devices
For Auto atically Fired Boilers, No.CSD-1.
3. This boiler series is classified as a Category 1 and the vent installation shall be in
accordance with Part 7 of the National Fuel Gas Code noted above or applicable provisions
of the local building codes.
4. This boiler has et safe lighting and other perfor ance criteria with the gas anifold
and control asse bly on the boiler per the latest revision of ANSI Z21.13.
5. The boiler shall be installed such that the gas ignition syste co ponents are
protected fro water (dripping, spraying, rain, etc.) during appliance operation and service,
(circulator replace ent, condensate trap, control replace ent, etc.).
6. LOCATE BOILER on level, solid base as near the chi ney as possible and centrally
located with respect to the heat distribution syste as practical.
7. Allow 24 inches at the front and right side for servicing and cleaning.
8. When installed in a utility roo , the door should be wide enough to allow the largest
boiler part to enter, or to per it replace ent of another appliance such as a water heater.
9. FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY *. The boiler ust
not be installed on carpeting. Mini u clearances to co bustible construction are:
TOP ................................. 18 IN.
FRONT ............................ ALCOVE
FLUE CONNECTOR ....... 6 IN.
REAR .............................. 4 IN.
CONTROL SIDE ............. 9 IN.
OTHER SIDE .................. 3 IN.
NOTE: Greater clearances for access should supersede fire protection clearances.
* For installation on co bustible flooring special base part no. 325-2-8.00 ust be used.
10. The MEA nu ber for this boiler series is 19-79 Vol. II.
PAGE 7

PAGE 8
ENTILATION AND COMBUSTION AIR
WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT
BE OBSTRUCTED. BY FOLLOWING THE CHART BELOW, ADEQUATE
COMBUSTION AIR CAN BE MAINTAINED.
FIGURE 1 FIGURE 2
COMBUSTION AIR REQUIREMENTS
(MINIMUM SQUARE INCHES OPENING)
*UNCONFINED AREA **CONFINED AREA
OUTSIDE INSIDE OUTSIDE COMBUSTION AIR
MODEL NUMBER COMBUSTION COMBUSTION VERT. DUCTS HORZ. DUCTS
NUMBER OF AIR 1 SQ. IN AIR 1 SQ. IN. 1 SQ. IN. 1 SQ. IN.
MAGB MODULES /4000 BTU/HR /1000 BTU/HR /4000 BTU/HR /2000 BTU/HR
(SEE FIG. 2) (SEE FIG. 1)
500 2 125 500 125 250
600 2 150 600 150 300
750 3 188 750 188 375
900 3 225 900 225 450
1000 4 250 1000 250 500
1200 4 300 1200 300 600
1500 5 375 1500 375 750
1800 6 450 1800 450 900
2100 7 525 2100 525 1050
2400 8 600 2400 600 1200
* Unconfine area: A space whose volu e is not less than 50 cubic feet per
1000 BTU per hour of all appliances installed in that space (cubic feet of space = height
x width x length).
** Confine area: A space whose volu e is less than 50 cubic feet per 1000
BTU per hour of all appliances installed in that space (cubic feet of space = height x
width x length).

PAGE 9
ENTILATION & COMBUSTION CONTINUED
1. Ventilation of the boiler roo ust be adequate to provide sufficient air to properly
support co bustion per the latest revision of the National Fuel Gas Code, ANSI Z223.1
section 5.3.
2. When a boiler is located in an unconfined space in a building or conventional construction
fra e, asonry or etal building, infiltration nor ally is adequate to provide air for
co bustion and ventilation. However, if the equip ent is located in a building of unusually tight
construction (See the national Fuel Gas Code, Ansi Z223.1 section 1.7), the boiler area
should be considered as a confined space. In this case air for co bustion and ventilation shall
be provided according to part 5 on page 4. If there is any doubt, install air supply provisions
in accordance with the latest revision of the National Fuel Gas Code.
3. When a boiler is installed in an unconfined space, in a building of unusually tight
construction, air for co bustion and ventilation ust be obtained fro outdoors or fro
spaces freely co unicating with the outdoors. A per anent opening or openings having a
total free area of not less than 1 square inch per 5,000 BTU per hour of total input rating of
all appliances shall be provided. Ducts ay be used to convey akeup air fro the outdoors
and shall have the sa e cross-sectional area of the openings to which they are connected.
4. When air for co bustion and ventilation is fro inside buildings, the confined space shall
be provided with two per anent openings, one starting 12 inches fro the top and one 12
inches fro the botto of the enclosed space. Each opening shall have a ini u free area
of 1 square inch per one thousand (1000) BTU per hour of the total input rating of all appliances
in the enclosed space, but ust not be less than one hundred (100) square inches. These
openings ust freely co unicate directly with other spaces of sufficient volu e so that the
co bined volu e of all spaces eets the criteria for an unconfined space. See figure 1 on
page 8.
5. When the boiler is installed in a confined space and all air is provided fro the outdoors
the confined space shall be provided with one or two per anent openings according to
ethods A or B. When ducts are used, they shall be of the sa e cross sectional area as the
free area of the area of the openings to which they connect. The ini u di ension of
rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches.
A. When installing two openings, one ust co ence within 12 inches fro the top and
the other within 12 inches fro the botto of the enclosure. The openings shall co unicate
directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely co unicate with
the outdoors. One of the following ethods ust be used to provide adequate air for
ventilation and co bustion.
1. When directly co unicating with the outdoors, each opening shall have a
ini u free area of 1 square inch per 4,000 BTU per hour of total input rating of all
equip ent in the enclosure. See figure 2 on page 8.
2. When co unicating with the outdoors by eans of vertical ducts, each
opening shall have a ini u free area 1 square inch per 4,000 BTU per hour of total input
rating of all appliances in the enclosed space.
3. If horizontal ducts are used, each opening and duct shall have a ini u free

ENT INSTALLATION
WARNING:This boiler is to be vented by natural draft and shall not be
connected to the echanical draft syste operating under positive pressure.
1. The vent pipe ust slope upward fro the boiler not less then 1/4 inch for every 1 foot
to the vent ter inal.
2. Horizontal portions of the venting syste shall be supported rigidly every 5 feet and at
the elbows. No portion of the vent pipe should have any dips or sags.
3. This boiler series is classified as a Category 1 and the vent installation shall be in
accordance with Part 7 of the National Fuel Gas Code noted above or applicable provisions
of the local building codes.
4. Inspect chi ney to ake certain it is constructed according to NFPA 211. The vent or
vent collector shall be Type B or etal pipe having resistance to heat and corrosion not less
than that of galvanized sheet steel or alu inu not less than 0.016 inch thick (No. 28 Ga).
5. Connect flue pipe fro draft hood to chi ney. Bolt or screw joints together to avoid
sags. Flue pipe should not extend beyond inside wall of chi ney. Do not install anual da per
in flue pipe or reduce size of flue outlet except as provided by the latest revision of
ANSIZ223.1. Protect co bustible ceiling and walls near flue pip with fireproof insulation.
Where two or ore appliances vent into a co on flue, the area of the co on flue ust
be at least equal to the area of the largest flue plus 50 percent of the area of each additional
flue.
PAGE 10
area 1 square inch per 2,000 BTU per hour of total input rating of all appliances in the enclosed
space.
B. One per anent opening, co encing within 12 inches of the top of the enclosure,
shall be per itted where the equip ent has clearances of at least 1 inch fro the sides, 1
inch fro the back, and 6 inches fro the front of the boiler. The opening shall directly
co unicate with the outdoors or shall co unicate through a vertical or horizontal duct to
the outdoors or spaces (crawl or attic) that freely co unicate with the outdoors. The
openings ust have a ini u free area of 1 square inch per 3000 Btu per hour of the total
input rating of all equip ent located in the enclosure. The free area ust be no less than the
su of the areas of all vent connectors in the confined space.
6. In calculating free area using louvers, grilles or screens for the above, consideration
shall be given to their blocking effect. Screens used shall not be s aller than 1/4 inch esh.
If the free area through a design of louver or grill is known, it should be used in calculating
the size opening required to provide the free area specified. If the design and free area is
not known, it ay be assu ed that wood louvers will have 20-25% free area and etal
louvers and grilles will have 60-75% free area. Louvers and grilles should be fixed in the open
position or interlocked with the boiler so they are opened auto atically during the boiler
operation.

PAGE 11
FIGURE 3 FIGURE 4
ENT DAMPER INSTALLATION AND INSTRUCTIONS
INSTALLATION FOR OPTIONAL VENT DAMPER
NOTE: Refer to Figure 3 below for steps 1 - 7.
1. Place Vent Da per on or as close to vent outlet of boiler as possible.
2. Re ove Vent Da per Motor cover.
3. Re ove locknut fro connector at the free end of the Da per wire harness.
4. Feed Da per and Da per wire harness connectors through bracket hole on Da per
Motor fra e.
5. Replace and tighten locknut onto Da per wire harness connector.
6. Plug Da per connector into socket on Da per Motor fra e.
7. Replace Da per Motor cover.
8. Wire Da per in accordance with figure 3 below.
INSTRUCTIONS
1. Ensure that only the boiler is serviced by the Vent Da per. See Figure 4, above.
2. Clearance of not less than 6 inches between Vent Da per and co bustible aterial
ust be aintained. Additional clearance should be allowed for service of Vent Da per.
3. Vent Da per ust be in the open position when appliance ain burners are
operating.
4. The Vent Da per position indicator ust be in a visible location following installation.
5. The ther ostat's heat anticipator ust be adjusted to atch the total current draw of
all controls associated with the boiler during a heating cycle.

PAGE 12
ENT SYSTEM MODIFICATION
When an existing boiler is re oved fro a co on venting syste , the co on venting
syste is likely to be too large for the proper venting of the appliances re ained connected
to it. If this situation occurs, the following test procedure ust be followed:
REMOVAL OF BOILER FROM VENTING SYSTEM
When re oving an existing boiler, the following steps shall be followed with each
appliance re aining connected to the co on venting syste placed in operation, while
the other appliances re aining connected to the co on venting syste are not in
operation.
A. Seal an unused opening in the co on venting syste .
B. Visually inspect the venting syste for proper size and horizontal pitch and deter ine
there is no blockage or restriction, leakage, corrosion and other deficiencies which could
cause an unsafe condition.
C. Insofar as is practical, close all building doors and windows and all doors between the
space in which the appliances re aining connected to the co on venting syste are
located and other spaces of the building. Turn on clothes dryers and any other appliance
not connected to the co on venting syste . Turn on any exhaust fans, such as range
hoods and bathroo exhausts, so they operate at axi u speed. Do not operate a
su er exhaust fan. Close fireplace da pers.
D. Place in operation the appliance being inspected. Follow the lighting instructions.
Adjust ther ostat so appliance will operate continuously.
E. Test for spillage at the draft hood relief opening after 5 inutes of ain burner
operation. Use the fla e of a atch or candle, or s oke fro a cigarette, cigar or pipe.
F. After it has been deter ined that each appliance re aining connected to a co on
venting syste properly vents when tested as outlined above, return doors, windows,
exhaust fans, fireplace da pers and any other gas burning appliances to their previous
condition of use.
G. Any i proper operation of the co on venting syste should be corrected so the
installation confor s with the latest revision of the National Fuel Gas Code, ANSI Z223.1.
When resizing any portion of the co on venting syste , the co on venting syste
should be resized to approach the ini u size as deter ined using the appropriate tables
in appendix G in the latest revision of the National Fuel Gas Code, ANSI Z223.

PAGE 13
CONNECTING BOILERS WITH
REFRIGERATION SYSTEMS
Refer to data on page
1. Connect supply and return piping as suggested in figure 5 below, when the boiler is
used in connection with refrigerated syste s.
2. The chilled ediu MUST BE PIPED IN PARALLEL with the boiler.
3. Use appropriate valves to prevent the chilled ediu fro entering the heating boiler.
A. During heating cycle open valves A and B, close valves C and D.
B. During cooling cycle, open valves C and D, close valves A and B.
C. Maintain a ini u clearance of one inch to hot water pipes.
D. When the boiler is connected to heating coils located in air handling units where
they ay be exposed to refrigerated air circulation, the boiler piping syste MUST BE
supplied with flow control valves or other auto atic eans to prevent gravity circulation of
the boiler water during the cooling cycle.
4. For further infor ation refer to the I=B=R Installation and Piping Guide.
FIGURE 5

PAGE 14
CONNECTING GAS SER ICE
1. Connect gas service fro eter to control asse bly in accordance with ANSI Z223.1
and local codes or utility. A ground joint union should be installed for easy re oval of gas
control for servicing. A drip leg or trap ust be installed at the botto of a vertical section
of piping at the inlet to the boiler. A pipe co pound resistant to the action of liquefied
petroleu gases ust be used on all threaded pipe connections. Check with the local utility
for location of anual shutoff valve if required. See figure 7 below.
2. The gas line should be of adequate size to prevent undue pressure drop and never
s aller than the pipe size of the ain gas control valve. See chart below.
3. To check for leaks in gas piping, use a soap and water solution or other approved
ethod. WARNING: DO NOT USE AN OPEN FLAME.
4. Disconnect the boiler fro the gas supply piping syste during any pressure testing
of the gas piping. After reconnecting, leak test the gas connection and boiler piping before
placing the boiler back into operation.
5. See figure 7 below for a typical gas line installation, and the table below for pipe sizes.
FIGURE 6 FIGURE 7
TABLE OF PIPE SIZES IN INCHES FOR NATURAL GAS MAIN
MODEL
NUMBER 20' 30' 40' 50' 60' 80' 100' 125'
500 1.25" 1.25" 1.50 1.50" 2.00" 2.00" 2.00" 2.00"
600 1.25" 1.25" 1.50" 1.50" 2.00" 2.00" 2.00" 2.00"
750 1.25" 1.50" 1.50" 2.00" 2.00" 2.00" 2.00" 2.00"
900 1.50" 2.00" 2.00" 2.00" 2.00" 2.00" 2.50" 2.50"
1000 1.50" 2.00" 2.00" 2.00" 2.00" 2.50" 2.50" 2.50"
1200 2.00" 2.00" 2.00" 2.00" 2.50" 2.50" 2.50" 2.50"
1500 2.00" 2.00" 2.50" 2.50" 2.50" 2.50" 3.00" 3.00"
1800 2.00" 2.00" 2.50" 2.50" 2.50" 3.00" 3.00" 3.00"
2100 2.50" 2.50" 2.50" 3.00" 3.00" 3.00" 3.00" 4.00"
2400 2.50" 2.50" 3.00" 3.00" 3.00" 3.00" 3.00" 4.00"

ELECTRICAL WIRING
See Addendum "A" for individual wiring diagrams and componant coding.
See figures 16-18, on pages 23-2 , for multiple boiler wiring diagrams.
Electrical wiring ust confor with the latest revision of the National Electrical Code, ANSI/
NFPA No. 70 and/or the local authority having jurisdiction.
WARNING:1. When an external electrical source is utilized, the boiler, when
installed MUST BE electrically grounded in accordance with these require ents.
2. Install a fused disconnect switch between boiler and eter at a convenient location.
3. The MAGB series requires 120 Volts to operate.
THERMOSTAT INSTALLATION
1. The ther ostat should be installed on an inside wall about four feet above the
floor.
2. NEVER install a ther ostat on an outside wall.
3. Do not install a ther ostat where it will be affected by:
A. Drafts
B. Hot or Cold Pipes
C. Sun Light
D. Lighting Fixture
E. Television
F. A Fireplace or Chi ney
4. Check ther ostat operation by raising and lowering ther ostat setting as required to
start and stop the burners.
5. Instructions for the final adjust ent of the ther ostat are packaged with the
ther ostat (adjusting heating anticipator, calibration, etc.)
PAGE 15
LIGHTING INSTRUCTIONS
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EX-
ACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
Before any procedures are attempted on this appliance, it is necessary to
determine if the ignition system is electric or standing pilot. If you are uncertain,
contact the manufacturer before proceeding.
CAUTION: Before lighting any type of pilot burner (standing or
intermittent), make certain the 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
that the system is vented of air. Set the operating control of thermostat to a below
normal setting. Refer to the following appropriate lighting instruction.

LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEMS.
FOR YOUR SAFETY READ BEFORE OPERATING.
A. This appliance is equipped with an ignition device which auto atically lights the pilot.
Do not try to light the appliance by hand.
B. Before operating, s ell all around the appliance area for gas. Be sure to s ell next
to the floor because so e 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.
* I ediately call your gas supplier fro a neighbors phone. Follow the gas supplier's
instructions.
* If you cannot reach your gas supplier, call the fire depart ent.
C. 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 atte pted repair ay result in a fire or explosion.
D. Do not use this appliance if any part has been under water. I ediately call a
qualified service technician to inspect the appliance and to replace any part of the control
syste and any gas control which has been under water.
OPERATING INSTRUCTIONS FOR
INTERMITTENT PILOT SYSTEMS
1. STOP! Read the safety infor ation in the Users Infor ation Manual.
2. Set the ther ostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which auto atically lights the pilot.
Do not try to light the pilot by hand.
5. Re ove control access panel, if present.
6. Turn gas control knob clockwise to OFF. See figure 8.
7. Wait (5) inutes to clear out any gas. If you then s ell gas, STOP! Follow For Your
Safety What To Do If You S ell Gas in the
safety infor ation. If you dont s ell gas, go
on to the next step.
8. Turn gas control knob counterclockwise
to ON.
9. Replace control access panel (if
present).
10. Turn on all electric power to the
appliance.
11. Set ther ostat to desired setting.
12. If the appliance will not operate, follow
the instructions To turn off gas to appliance,
on page 18, and call a qualified service
technician or your gas supplier.
PAGE 16
FIGURE 8
INTERMITTENT PILOT GAS VALVE

LIGHTING PROCEDURE FOR BOILER WITH
CONTINUOUS PILOT
FOR YOUR SAFETY READ BEFORE LIGHTING
A. Read the warning at the beginning of the LIGHTING INSTRUCTIONS
B. This appliance has a pilot which ust be lighted by hand. When lighting the pilot,
follow these instructions exactly.
C. Before lighting, s ell all around the appliance area for gas. Be sure to s ell next to
the floor because so e gas is heavier than air and will settle on the floor. See the beginning
of these instructions for WHAT TO DO IF YOU SMELL GAS.
D. Use only your hand to push in or turn gas control knob or reset button. Never use tools.
If the 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 atte pted repair ay result in a fire or explosion.
E. Do not use this appliance if any part has been under water. I ediately call a qualified
service technician to inspect the appliance and to replace any part of the control syste
and any gas control which has been under water.
LIGHTING INSTRUCTIONS FOR CONTINUOUS PILOT
1. STOP! Read the safety infor ation at the beginning of these instructions.
2. Set the ther ostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. Re ove access panel (if present) and burner door.
5. Turn gas control knob clockwise to "OFF". See figure 9 below.
NOTE #1: So e gas control knobs cannot be turned fro "PILOT" to "OFF" unless
knob is pushed in slightly. DO NOT FORCE.
6. Wait (5) inutes to clear out any gas. If you then s ell gas, STOP! Follow for your
safety what to do if you s ell gas, at the beginning of these instructions. If you don't s ell
gas, go to the next step.
7. Find pilot. Follow etal tube fro gas
control. Depending on the odel of the boiler,
pilot is either ounted on the base or on one
of the burner tubes.
8. Turn gas control knob counterclock-
wise to "PILOT".
9. Push in gas control knob or reset
button if so equipped, all the way in and hold.
I ediately light the pilot with a atch.
PAGE 17
FIGURE 9
CONTINUOUS PILOT GAS VALVE

PAGE 18
Continue to hold the gas control knob or reset button in for about 1 inute after the pilot is
lit. Release knob or button, and it will pop back up. Pilot should re ain lit. If it goes out, repeat
steps 5 through 9.
* If knob or button does not pop up when released, stop and i ediately 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". (See note #1), and call a qualified service technician or your gas supplier.
10. Replace burner door.
11. Turn gas control knob counterclockwise to "ON".
12. Replace access panel (if present).
13. Turn on all electric power to the appliance.
14. Set ther ostat to desired setting.
TO TURN OFF GAS TO APPLIANCE
1. Set the ther ostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be perfor ed.
3. Re ove control access panel (if present).
4. Push in gas control knob slightly and turn clockwise to "OFF", DO NOT
FORCE.
5. Replace control access panel (if present).
6. Call a qualified service technician.
NORMAL SEQUENCE OF OPERATION
For a single odule the ther ostat will actuate, co pleting the circuit to the aquastat.
The co pleted circuit to the aquastat will first activate the circulator and da per. When the
da per is fully open it will co plete the circuit to the ignition syste and ignition will take
place.
In the event the boiler water te perature exceeds the high li it setting on the boiler
ounted aquastat, power will be interrupted between the aquastat and the ignition syste .
The power will re ain off until the boiler water te perature drops below the high li it
setting. The circulator will continue to operate under this condition until the ther ostat is
satisfied.
In the event the flow of co bustion products through the boiler venting syste beco es
blocked, the blocked vent safety switch will shut the ain burner gas off. See figure 11, page
19. Si ilarly, if the boiler flueway beco es blocked, a fla e rollout safety switch will shut
the ain burner gas off. See figure 11, page 19. If either of these conditions occur, do not
attempt to place the boiler back into operation. Contact a qualified service agency.

PAGE 19
GENERAL INSTRUCTIONS
Before seasonal start-up, it as advisable to have a co petent service agency check the
boiler for soot and scale in the flues, clean the burners and check the gas input rate to
aintain high operating efficiency.
The service agency or owner should ake certain the syste is filled with water to
ini u pressure and open air vents, if used, to expel any air that ay have accu ulated
in the syste . Check the entire piping syste and if any leaks appear, have the repaired.
Many circulators like the one pictured in figure 10 below, require periodic servicing. The
otor usually has openings at each end to lubricate the bearings. Put about one half
teaspoon of SAE 20 or 30 non-detergent otor oil in each opening twice a year.
CAUTION: DO NOT OVER OIL.
Many circulators have an oil opening for the shaft bearing. This should be oiled at the
sa e ti e for quiet operation. Follow the anufacturer's instructions for oiling the shaft
bearing.
The venting syste should be inspected at the start of each heating season. Check the
vent pipe fro the boiler to the chi ney for signs of deterioration by rust or sagging joints.
Repair if necessary. Re ove the vent pipe at the base of the chi ney or flue and using a
irror, check for obstruction.
The boiler flue gas passageways ay be inspected by a light and irror. Re ove the
burner door, figure 11 below. Place a trouble la p in the flue collector through the draft relief
opening. With the irror positioned above the burners, the flue gas passageways can be
checked for soot or scale.
The following procedure should be followed to clean the flue gas passageways:
1. Re ove the burners fro the co bustion cha ber by raising the burners up fro
the anifold orifices and pulling toward the front of the boiler. See figure 11, below.
2. Disconnect the vent pipe fro the draft hood.
3. Re ove the top jacket panel.
FIGURE 10 FIGURE 11