UTICA BOILERS MGC-8D User manual

P/N 240011125, Rev. C [07/22/2015]
MGC
GAS-FIRED
HOT WATER BOILERS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
Models
MGC-8D
MGC-8DP
MGC-9D
MGC-9DP
C.S.A. Certied for
Natural gas or
Propane
Tested for 50 psi.
ASME Working
Pressure

2
P/N 240011125, Rev. C [07/22/2015]
1 - DIMENSIONS
Table 1 - Dimensions
BOILER
MODEL
NUMBER
DIMENSIONS (INCH.)
FLUE
DIAMETER
“A”
WIDTH
MGC-8 7 27½
MGC-9 7 30¾
Add 5½” to height for vent Damper.
Figure 1 - Dimensions
* Minimum acceptable height for Low Water Cutoff probe.
*

3
P/N 240011125, Rev. C [07/22/2015]
2 - BOILER RATINGS AND CAPACITIES
Table 2 - Ratings and Capacities
BOILER
MODEL
NUMBER (1)
† NATURAL GAS † PROPANE GAS AFUE
Input (3)
Mbh
(1)
Heating
Capacity
(3) Mbh
(2)
NET AHRI
RATING
Water,
(3) Mbh
INPUT (3)
MBH
HEATING
CAPACITY (3)
MBH
NET AHRI
RATING
INTERMITTENT
IGNITION WITH
VENT DAMPER
MGC-8 262.5 220 191 245 206 179 83.9
MGC-9 299 251 218 280 235 204 83.7
† Input rating for sea level to 2,000 ft. (610m) above sea level. Over 2000 ft (610m) above sea level.
Reduce input rate 4% for every 1000 ft (304m) above sea level.
+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.
(1) Add model number sufce ‘P’ for Propane.
(2) Net AHRI Water rating shown based on piping and 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.
(3) MBH = 1,000 Btuh = British Thermal Unit Per Hour
Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or terminal units. Net
AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on AHRI Standard as published by
The Hydronics Institute.
- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of
the building.
- Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.
BOILERS FOR USE AT HIGH ALTITUDE
Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level.
For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner orice size.
For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above
sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54 or manufacturer for correct orice sizing information.

4
3 - TABLE OF CONTENTS
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
WARNING
Keep boiler area clear and free from combustible
materials, gasoline and other ammable vapors
and liquids.
DO NOT obstruct air openings to the boiler room.
Modication, substitution or elimination of factory
equipped, supplied or specied components may
result in personal injury or loss of life.
TO THE OWNER - Installation and service of this
boiler must be performed by a qualied installer.
TO THE INSTALLER - Leave all instructions with
boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.
!
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.
!
SAFETY SYMBOLS & WARNINGS
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
NOTICE
Used to address practices not related to personal
injury.
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
!
1 - Dimensions................................................... 2
2 - Ratings And Capacities ................................... 3
3 - Table of Contents........................................... 4
4 - Installation Procedure .................................... 5
5 - Ventilation & Combustion Air ........................... 6
6 - Connecting Supply And Return Piping ............... 7
7 - Chimney And Vent Pipe Connection .................11
8 - Vent Damper Operation .................................14
9 - Gas Supply Piping.........................................15
10 - Electrical Wiring..........................................15
11 - Wiring Diagrams.........................................16
12 - General Instructions....................................19
13 - Lighting Instructions ...................................20
14 - Operating Your Boiler ..................................21
15 - Maintaining Your Boiler ................................23
16 - Service Hints..............................................24
17 - Equipment And Optional Accessories ............25
Appendix A - Control Module ...............................27
P/N 240011125, Rev. C [07/22/2015]

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4 - INSTALLATION PROCEDURE
Table 3 - 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 1/2” (13mm)
WARNING
Improper installation, adjustment, alteration,
service or maintenance could result in death or
serious injury.
!
WARNING
Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
1. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
ooring special base must be used. (See Replacement
Parts Section.) Boiler shall not be installed on
carpeting.
NOTE: Greater clearances for access should supersede fire
protection clearances.
* Denition of Alcove is three sided space with no wall in
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 must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
2. Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically red Boilers,
ANSI/ASME CSD-1.
3. Boiler series is classied as a Category I. Vent
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.
4. 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.
5. 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.).
6. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
7. Allow 24 inches (610mm ) at front and right side for
servicing and cleaning.
8. 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
P/N 240011125, Rev. C [07/22/2015]

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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 Sections
8.2, 8.3 or 8.4 of 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
volume for all appliances in space. Use a different
method if minimum volume not available.
A. Standard Method. Cannot be used if known air
inltration rate is less than 0.40 air changes per
hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.
Volume ≥ 50 ft3x Total Input [Mbh]
B. Known Air Inltration Rate. See Table 4 for
space with boiler only. Use equation for multiple
appliances. Do not use an air inltration rate
(ACH) greater than 0.60.
Volume ≥ 21 ft3⁄ACH x Total Input [Mbh]
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.
Canada
National Gas and Propane Installation Code Requires
providing air supply in accordance with:
• Section 8.2 and 8.3 when combination of appliances
has a total input of up to and including 400 Mbh (120
kW).
• Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW).
• Refer to Natural Gas and Propane Installation Code
for specic air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.
Table 4 - Minimum Room Volume, Indoor Air Only*
Room Cubic Feet Volume
Input Mbh Standard
Method
Known Air Inltration Rate Method (Air Changes Per Hour)
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.
P/N 240011125, Rev. C [07/22/2015]

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6 - 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
ttings provided with boiler. See Figure 2
2. Install safety relief valve with spindle in vertical
position.
3. Do not install shutoff valve between boiler and safety
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).
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
P/N 240011125, Rev. C [07/22/2015]

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6 - CONNECTING SUPPLY AND RETURN PIPING
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
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 install low
water cutoff device at time of installation. See Figure 1
for minimum probe height. Use kit #550002998. follow
instruction enclosed with kit. With other LWCO’s use their
manufacturer specic instructions.
Periodic inspection is necessary, as is ushing of oat type
devices, per manufacturers specic instruction.
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 9.
B. Boiler connected to heating coils located in air handling
units where they may be exposed to refrigerated air
circulation, piping system shall be equipped with ow
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 10.)
Signicant condensation may form in boiler and/or venting
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
oor heating), 4-way mixing valve or suitable
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 10.
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 7.
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
may require additional ttings and parts, as shown on
diagrams.
P/N 240011125, Rev. C [07/22/2015]

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Figure 5 - Chilled Water Piping
Figure 4 - Typical Hot Water Piping
6 - CONNECTING SUPPLY AND RETURN PIPING
P/N 240011125, Rev. C [07/22/2015]

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Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY
Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN
Bypass Piping Required For High Mass (Large Water Content) Systems
6 - CONNECTING SUPPLY AND RETURN PIPING
P/N 240011125, Rev. C [07/22/2015]

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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.
This is a high efciency boiler with low stack temperature.
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) lined with type B vent pipe, or listed exible vent
liner, or other certied chimney lining system.
3. Where possible it is recommended to common vent
boiler and water heater.
4. For multiple boiler installations, consult boiler
manufacturer for venting recommendations.
Connecting The Vent Damper And Vent Connector
Refer to Figure 1, page 2 for size and location of vent (ue
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. Position furnished vent damper on top of ue outlet
collar. Fasten damper securely to ue outlet collar with
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
position, closer to ue outlet collar preferred. See
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. Do not connect to replace ue.
8. End of vent pipe must be ush with inside face of
chimney ue. Use a sealed-in thimble for chimney
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.
7 - CHIMNEY AND VENT PIPE CONNECTION
WARNING
Boiler and venting installations shall be performed
by a qualied expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to re or to asphyxiation from poisonous gases
such as carbon monoxide with is odorless and
invisible.
!
P/N 240011125, Rev. C [07/22/2015]

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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.
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
restriction, leakage, corrosion and other deciencies
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
summer exhaust fan. Close replace dampers.
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
5 minutes of main burner operation. Use the ame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
7 - CHIMNEY AND VENT PIPE CONNECTION
6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
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
Boiler and venting installations shall be performed
by a qualied expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to re or to asphyxiation from poisonous gases
such as carbon monoxide with is odorless and
invisible.
!
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
!
P/N 240011125, Rev. C [07/22/2015]

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8 - VENT DAMPER OPERATION
Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement
Annually check vent damper and all ue product carrying
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:
• When boiler is off, check vent damper positions
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
burner ring as before, while damper will remain open. DO
NOT turn damper open manually or motor damage will
result. Set switch to “AUTOMATIC OPERATION” to close
vent damper during burner off cycle.
For further information, and vent damper troubleshooting
guide, refer to manual packaged with vent damper.
Inspect vent damper at least once a year by a
qualied service technician.
Figure 10 - Vent Damper Position Indicator
P/N 240011125, Rev. C [07/22/2015]

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9 - 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.
• If you cannot reach your gas supplier, call the re
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.
• Install manual shut-off valve in vertical pipe about 5
feet above oor.
• 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
ames, or other methods providing ignition source.
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
boiler and its individual gas shutoff valve from gas
supply system.
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve.
• Locate leakage using gas detector, noncorrosive
detection uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open ames, or other methods
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
⅝” 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
3” Minimum
Sediment
Trap
Manifold
Floor Line
Automatic
Gas Valve
Ground
Joint
Union
Figure 11 - Gas Piping
P/N 240011125, Rev. C [07/22/2015]

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10 - ELECTRICAL WIRING
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:
• USA- National Electrical Code, ANSI/NFPA 70.
• Canada - Canadian Electrical Code, Part I, CSA C22.1:
Safety Standard for Electrical Installations.
ELECTRIC POWER SUPPLY
Run separate 120 volt circuit from separate over current
protective device in electrical service entrance panel. This
should be a 15 ampere circuit. Locate shut-off switch at
boiler. It must be turned off during any maintenance.
Connect 120 volt power supply to control leads L1 (HOT)
and L2.
LWCO kit 550002998 includes wiring instructions and
diagrams. If using another LWCO, refer to specic
manufacturer instructions supplied by appropriate
manufacturer.
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
four feet above the oor.
2. NEVER install thermostat on outside wall.
3. Do not install a thermostat where it will be affected
by drafts, hot or cold pipes, sunlight, lighting xtures,
televisions, a replace, or a chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop the
burners.
5. Instructions for the nal adjustment of the thermostat
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.
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.
!
NOTICE
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
VENT DAMPER WIRING
Boiler is equipped with factory wired harness with 4 pin
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.
P/N 240011125, Rev. C [07/22/2015]

16
11 - WIRING DIAGRAMS
Figure 12 - Integrated High Limit Electronic Ignition Control
I
WARNING
Modication, substitution or elimination of factory
equipped, supplied or specied components may
result in personal injury or loss of life.
!
P/N 240011125, Rev. C [07/22/2015]

17
11 - WIRING DIAGRAMS
Figure 13 - Integrated High Limit Electronic Ignition Control
P/N 240011125, Rev. C [07/22/2015]

18
12 -GENERAL INSTRUCTIONS
FILLING SYSTEM WITH WATER
• Close air vents on all radiation units. Open valves to
these units.
• Verify boiler and expansion tank drain valves are closed.
• Air bleed screw on tank drain tting should be closed.
• Open valve in line from boiler to expansion tank. Open
water inlet to your boiler and leave it open. Start with
lowest radiation unit. Open air vent on this unit. When
all air has escaped and water starts to ow from vent,
close it.
• Go to next radiation unit, and repeat this process.
Repeat until you have covered every radiation units in
the system (ending up at highest unit in system).
• If your units have automatic vents, manual venting is
unnecessary but it will speed up the proper lling of
your system.
• If your system is closed expansion tank system, you
may leave it open to rell system automatically as
needed.
• Check temperature pressure gauge. Not position of hand
indicating pressure. This should be between 10 and 15
psi. Any lowering of this movable hand below 10 psi.
Will indicate loss of water due to leakage. Automatic
ll valve should compensate for this. Instructions are
packaged with the valve.
NOTICE
Never run water in a hot empty boiler.
P/N 240011125, Rev. C [07/22/2015]

19
13 - LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the pilot
by hand.
OFF
ON
INLET
GAS CONTROL KNOB PILOT ADJUSTMENT
(UNDER CAP SCREW)
PILOT
OUTLET
OUTLET
WIRING
TERMINALS (2)
INLET
PRESSURE
TAP TERMINALS
(2)
GROUND
PRESSURE
TAP
PRESSURE REGULATOR ADJUSTMENT
(UNDER CAP SCREW)
OUTLET
5. Remove lower front panel.
6. Rotate the gas control knob clockwise to “OFF”.
7. Wait ve (5) minutes to clear out any gas. Then
smell for gas, including near the oor. If you smell
gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions.
If you don’t smell gas, go to next step.
8. Rotate gas control knob counterclockwise to
“ON”.
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is
to be performed.
3. Push in gas control knob slightly and turn clockwise
to “OFF” Do not force.
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
which automatically lights burner. Do NOT try to
light this burner by hand.
• Before operating smell all around appliance area
for gas. Be sure to smell next to oor because
some gas is heavier than air and will settle to the
oor.
• Use only your hand to turn the gas shutoff
valve. Never use tools. If valve will not turn
by hand, do not try to repair it, call a qualied
service technician. Force or attempted repair may
result in re or explosion.
• Do not use this appliance if any part has
been under water. Immediately call a qualied
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
!
LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM
For Your Safety, Read Before Operating!!
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
appliance by hand.
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 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.
!
Figure 14 - Automatic Gas Valve
P/N 240011125, Rev. C [07/22/2015]

20
14 - OPERATING YOUR BOILER
AUTOMATIC GAS VALVE
Automatic Gas Valve opens or closes according to heat
requirements of thermostat and temperature limit control.
It closes if pilot goes out. Each individual control must be
operating correctly before any gas can pass to burners. Any
one control can hold gas supply from burner regardless of
demand of any other control.
SAFETY PILOT
Safety Pilot prevents ow of gas to burner if pilot goes out,
or will not ignite.
GAS VALVE SAFETY SHUTDOWN TEST
Ignition system safety shutoff device must be tested after
placing boiler in operation.
RELIGHT
Electric and gas shall be off for 5 minutes before relighting.
THERMOSTAT
Keep it set at desired room temperature. If windows are to
be opened or heat is not needed, move thermostat pointer
to lower setting.
NOTICE
In event of failure of any component, system will
not operate or will go into safety lockout. System
is completely self-checking. On every call for heat,
each component must be functioning properly to
permit operation. Safety lockout system has to be
reset by turning thermostat to lowest setting for
one minute, then back to normal setting.
ADJUST PILOT BURNER
Pilot ame should surround 3/8” to 1/2” of the pilot sensor.
See Figure 15. If ame needs adjusting, do it as follows:
1. Remove screw cover over pilot adjusting screw.
2. Insert small screwdriver and adjust ame as needed.
Turn screw counterclockwise to increase ame, clockwise
to decrease.
3. Replace screw cover over pilot adjusting screw.
MAIN BURNER(S)
• Main burners do not require primary air adjustment and
are not equipped with primary air shutters.
• Main burner ames form sharp blue inner cones in softer
blue outer mantel, with no yellow.
• Puffs of air from blowing on ame or stamping on oor
will cause ames to turn orange momentarily. This is
not unusual. Remain still when observing main burner
ames.
• If ame appearance is not correct, check main burner
orices, burner throat and ame ports for dust and
lint obstruction. It may be necessary to remove rollout
shield to observe main burner ames. Replace rollout
shield after observation. Refer to Figure 16.
Figure 16 - Burner
ADJUST LIMIT CONTROLS
Instructions for each control are included with controls.
Settings can be changed. Refer to Appendix A page 26
for information.
Figure 15 - Pilot Flame
P/N 240011125, Rev. C [07/22/2015]