UTICA BOILERS PEG-C User manual

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
PEG-C
GAS FIRED BOILERS
FOR STEAM HEATING
Utica Boilers  P.O. Box 4729  Utica, NY 13504

TABLE OF CONTENTS
Safety Sy bols & Warnings ................................................................................. Page 1
Installation Procedure ........................................................................................... Page 2
Ventilation and Co bustion Air ...................................................................... Pages 3-4
Connecting Supply and Return Piping ............................................................... Page 5-6
Vent Installation .................................................................................................... Page 7
Vent Syste Modification ..................................................................................... Page 8
Vent Da per Installation and Instructions ........................................................... Page 9
Connecting Gas Service ..................................................................................... Page 10
Electrical Wiring .................................................................................................. Page 10
Ther ostat Installation ....................................................................................... Page 11
Lighting Instructions ................................................................................... Pages 11-13
Nor al Sequence of Operation .......................................................................... Page 14
Connecting Supply And Return Piping Water-Chilled Mediu ........................... Page 15
General Instructions .................................................................................... Pages 16-20
Replace ent Parts Lists ............................................................................. Pages 20-25
Ratings, Data and Di ensions .......................................................................... Page 26
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SERIES PEG-C
CAST IRON
GAS FIRED BOILERS
INSTALLATION MANUAL AND
OPERATING INSTRUCTIONS
Published April 1997
Printed in USA
Made in USA
C.S.A. Certified
for Natural gas
or Propane
Tested for 100 lbs.
ASME Working
Pressure

PAGE 1
IMPORTANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.
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. To the owner: Installation and service of this boiler ust be perfor ed by a qualified
installer.
5. To the installer: Leave all instructions with the boiler for future reference.
6. 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.
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.
WARNING: ALL INSTALLATIONS OF BOILERS AND VENTING
SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN
ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS 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.
Safety Symbols
The following defined sy bols are used throughout this anual to notify the
reader of potential hazards of varying risk levels.

INSTALLATION PROCEDURE
WARNING: I proper installation, adjust ent, alteration, service or
aintenance can cause injury or property da age.
1. The installation ust confor to the require ents of the authority having jurisdiction
or, in absence of such require ents, to the latest revision of the National Fuel Gas Code,
ANSI Z223.1. (Available fro the A erican Gas Association, Pleasant Valley Road,
Cleveland, Ohio 44134.) Reference should also be ade to local gas utility regulations and
other codes in effect in the area that 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 is classified as a Category 1 appliance and the vent installation shall be
in accordance with Part 7 & 11 of the latest revision of the National Fuel Gas Code noted
above or applicable provisions of the local building codes. See Vent Installation on page 7.
4. This boiler eets safe lighting and other preference criteria with the gas anifold and
control asse bly provided on the boiler per the latest revision of ANSI Z21.13b.
5. This 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 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 installing 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 NONCOMBUSTIBLE FLOORS ONLY. *The boiler ust
not be installed on carpeting. Mini u clearances to co bustible construction are:
TOP.................................................................... 24 IN.
FRONT .......................................................... ALCOVE
FLUE COLLECTOR ............................................. 6 IN.
REAR ................................................................... 8 IN.
SIDES .................................................................. 6 IN.
NOTE: GREATER CLEARANCES FOR ACCESS SHOULD SUPERSEDE FIRE
PROTECTION CLEARANCE.
PAGE 2

PAGE 3
FIGURE 1
ENTILATION & COMBUSTION AIR
WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT BE
OBSTRUCTED. BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE
COMBUSTION AIR CAN BE MAINTAINED
* Unconfined 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).
** Confined 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).
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.

FIGURE 4
PAGE 4
FIGURE 3FIGURE 2
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
above.
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. See figure 3 above.
3. If horizontal ducts are used, each opening and duct shall have a ini u free
area 1 square inch per 2,000 BTU per hour of total input rating of all appliances in the enclosed
space. See figure 4 at right.
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

CONNECTING SUPPLY AND RETURN PIPING
1. Suggested piping for stea heating syste can be seen in figure 5 below. Actual
piping ay vary based on syste design and local conditions.
2. Suggested piping for a odular stea boiler using pu ped returns ay be seen in
figures 6a and 6b on page 6. Actual piping ay vary based on syste design and local
conditions.
3. Refer to pages 17 & 18 for procedures on cleaning and ski ing off i purities.
4. "Near Boiler Piping" is crucial for proper perfor ance of a replace ent stea boiler
and should always be considered as part of the boiler installation. Always be sure to include
cleanout and ski ing tees in the near boiler piping. These "Tees" are necessary for proper
cleaning and servicing of the boiler.
5. For further piping infor ation refer to the I=B=R installation piping guide.
PAGE 5
FIGURE 5
SUGGESTED PIPING FOR A SINGLE STEAM
BOILER HEATING SYSTEM
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 6
FIGURE 6b
SUGGESTED PIPING FOR A MODULAR STEAM BOILERS
PUMPED RETURNS
GRAVITY RETURNS
FIGURE 6a

ENT INSTALLATION
WARNING: This boiler shall not be connected to any portion of a echanical
draft syste operating under positive pressure.
1. The vent pipe ust slope upward fro the boiler not less than 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 elbows. No portion of the vent pipe should have dips or sags.
3. This boiler series is classified as a Category 1 appliance and the vent installation shall
be in accordance with Part 7 & 11 of the latest revision of the National Fuel Gas Code or
applicable provisions of the local building codes.
4. Inspect chi ney to ake certain it is constructed according to National Board of Fire
Underwriters.
5. Attach draft hood to flue collector at rear of boiler, (See figure 7, below), with sheet
etal screw(s) through hole(s) provided. 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).
6. Connect flue pipe sa e as draft hood to chi ney. Bolt or screw joints together to avoid
sag. 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
ANSI Z223.1. Protect co bustible ceiling and walls near flue pipe 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 areas of each additional
flue.
PAGE 7
WARNING: ALL
INSTALLATIONS OF BOILERS
AND VENTING SHOULD BE
DONE ONLY BY A QUALIFIED
EXPERT AND IN ACCORDANCE
WITH THE APPROPRIATE UTICA
BOILERS 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. FIGURE 7

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:
At the ti e of re oval of 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 any unused openings 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 in the building. Turn on clothes dryers and any appliance not
connected to the co on venting syste . Turn on any exhaust fans, such as range hoods
and bathroo exhausts, so they will operate at axi u speed. Do not operate a su er
exhaust fan. Close fireplace da per.
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 the co on
venting syste properly vents when tested as outlined above, return doors, windows,
exhaust fans, fireplace da pers and any other gas burning appliance to their previous
conditions 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 Gas Fuel Code, ANSI Z223.1.
PAGE 8

PAGE 9
ENT DAMPER INSTALLATION
AND INSTRUCTIONS
INSTALLATION
NOTE: REFER TO FIGURE 8 BELOW FOR STEPS 1-7
1. Place Vent Da per on or as close to vent outlet of boiler as possible.
2. Re ove Locknut fro connector at the free end of the Da per wire harness.
3. Feed Da per connector and Da per wire harness through bracket hole on Da per Motor
fra e.
4. Replace and tighten locknut onto Da per wire harness connector.
5. Plug Da per connector into socket on Da per Motor fra e.
INSTRUCTIONS
1. Ensure that only the boiler is serviced by the Vent Da per. See figure 9 above.
2. Clearance of not less than 6 inches between Vent Da per and co bustible
construction ust be aintained. Additional clearance should be allowed for service
of the Vent Da per.
3. Vent Da per ust be in 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 ostats heat anticipator ust be adjusted to atch the total current draw of
all controls associated with the boiler during a heating cycle.
6. The Vent Da per wire harness ay be re oved and installed in flexible etal conduit
if local codes or jurisdiction requires. If this is necessary, the flexible etal conduit
ust be ounted to a J-box and all appropriate connections ust be ade to this J-
box.
FIGURE 8 FIGURE 9

PAGE 10
CONNECTING GAS SER ICE
Connect gas service eter to control asse bly in accordance with the latest revision of
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 or trap ust be installed at the botto of a vertical
section of piping at the inlet to the gas valve. 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 10 below.
1. 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.
2. The boiler and its gas connection ust be leak tested before placing the boiler in
operation. To check for leaks in gas piping, use a soap and water solution or other approved
ethod.
WARNING: DO NOT USE
AN OPEN FLAME.
3. The boiler and its individual shutoff
valve ust be disconnected fro the gas
supply piping syste during any pressure
testing of that syste at test pressures in
excess of 1/2 psi (3.5 kPa). The boiler ust
be isolated fro the gas supply piping syste
by closing its individual anual shutoff valve
during any pressure testing of the gas supply
piping syste at test pressures equal to or
less than 1/2 psig (3.5 kPa).
ELECTRICAL WIRING
SEE ADDENDUM "A" FOR WIRING DIAGRAMS AND COMPONENT CODING
Electrical wiring ust confor with the latest revision of the National Electrical Code, ANSI/
NFPA No. 70 and/or local authority having jurisdiction.
WARNING: 1. 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.
FIGURE 10

LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM.
FOR YOUR SAFETY READ BEFORE OPERATING.
A. This appliance is equipped with an ignition syste which auto atically lights the pilot.
Do not try to light the pilot 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 switch.
* Do not use any phone in your building.
* I ediately call your gas supplier fro a neighbor's phone.
* Follow your gas supplier's instructions.
* If you cannot reach your gas supplier, call the fire depart ent.
PAGE 11
THERMOSTAT INSTALLATION
1. Ther ostat should be installed on an inside wall at least two feet fro an uninsulated
or outside wall, approxi ately 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 fixtures
E. Television
F. Fireplace or chi neys
4. Check ther ostat operation by raising and lowering ther ostat 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.).
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.
Be ore any procedures are attempted on this appliance, it is necessary to
determine i the ignition system is intermittent or continuous pilot system. I you are
uncertain, contact the manu acturer be ore proceeding.
CAUTION: Be ore operating, make certain steam boiler is ull o water
to water line and system is vented o air. See the operating lighting instructions.

C. Use only your hand to push in or turn 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 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 anual.
2. Set 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. See figure 11, below.
5. Re ove access panel (if present)
6. Push in gas control knob slightly and
turn clockwise to "OFF."
7. Wait five (5) inutes to clear out any
gas. If you then s ell gas, STOP, Follow B
in the safety infor ation What To Do IF You
S ell Gas. If you dont s ell gas, go 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 and call a qualified service
technician or your gas supplier.
LIGHTING PROCEDURE FOR BOILER WITH
CONTINUOUS PILOT.
FOR YOUR SAFETY READ BEFORE LIGHTING
A. Read warning at the beginning of this instruction.
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. Follow B in the
lighting instructions for safety infor ation for what to do if you s ell gas on page 10.
D. Use only your hand to push in or turn the gas control knob or reset button. Never use
tools. If the knob or reset button will not push in or the knob will not turn by hand, dont try
to repair it. Call a qualified service technician. Force or atte pted repair ay result in fire
or explosion. See figure 12, on page 13.
PAGE 12
INTERMITTENT PILOT GAS VALVE
FIGURE 11

PAGE 13
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 SYSTEM
1. Stop! Read the safety infor ation at
the beginning of this anual.
2. Set ther ostat to lowest setting.
3. Turn off all electric power to the
appliance.
4. Re ove anifold cover and burner
door, (figures 13 & 15 on pages 14 & 16).
5. Turn gas control knob clockwise to off (See Note #1).
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 s ell gas, sto ! Follow safety infor ation
What to do if you s ell gas, located on page 10 of this anual. 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 ounted on the base or on one of the burner tubes.
8. Turn gas control knob counterclockwise 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. Continue to hold the gas control knob or reset button
for about one (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 10.
* If knob or button does not pop up when released, stop and i ediately call your
service technician or gas supplier.
* If the pilot will not stay lit after several tries, turn the gas control knob clockwise
to off (see note #1 above) and call a service technician or gas supplier.
10. Replace burner door and anifold cover, (figures 13 & 15 on pages 14 & 16).
11. Turn gas control knob counterclockwise to "on".
TO TURN OFF GAS TO APPLIANCE
1. Set the ther ostat to the lowest setting.
2. Turn off all electric power to the appliance if service is to be perfor ed.
3. Re ove access panel (if present)
4. Turn gas control knob clockwise to off. (See note #1) in the lighting
instructions. Do not force.
CONTINUOUS PILOT GAS VALVE
FIGURE 12

PAGE 14
NORMAL SEQUENCE OF OPERATION
On a call for heat:
1.) The ther ostat will actuate co pleting the circuit between T and T.
2.) The da per will then open thus closing the end switch co pleting the circuit, and
ignition will begin.
3.) In the event that the boiler stea pressure exceeds the pressure control setting,
the pressure control will interrupt the circuit to the boiler ignition syste . The power will
re ain off until the stea pressure drops below the pressure control setting.
4.) In the event a low water condition occurs, an auto atic low water cut-off device
will interrupt the circuit to the ignition syste until the low water condition is satisfied,
(i.e., anually restore the water or utilize an electric water feeding device which will
auto atically restore boiler water to its nor al operating level).
5.) In the event the flow of co bustion products through the boiler venting syste
beco es blocked, a blocked vent safety switch will shut the ain burner gas off (See figure
13 below).
6.) In the event the flow of co bustion products through the flueways beco es blocked
a fla e rollout switch will shut the ain burner gas off (See figure 13 below).
FIGURE 13

PAGE 15
CONNECTING SUPPLY AND
RETURN PIPING, WATER CHILLED MEDIUM
1. When the boiler is used in connection with refrigerated syste , connect supply and
return piping as suggested in figure 14 below.
A. The chilled ediu MUST BE IN PARALLEL with the boiler.
B. 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 between co bustible aterials and
hot water pipes.
* Reduced pressure backflow preventer ust be present under provisions required by
the Environ ental Protection Agency, (EPA).
2. 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.
3. A hot water boiler installed above radiation level ust be provided with a low water
cutoff device either as a part of the boiler or at the ti e of boiler installation.
4. Suggested piping for stea heating syste can be seen in figure 5 on page 5. Actual
piping ay vary based on syste design and local conditions.
FIGURE 14

PAGE 16
GENERAL INSTRUCTIONS
Before seasonal start up it is 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.
On stea boilers ake certain the boiler is filled to the water line as indicated in figure
15. The gauge cocks should be nor ally open. To re ove dirt fro the gauge glass the
petcock ay be opened to flush out the glass.
WARNING: DISCHARGE WILL BE BOILING HOT WATER.
The radiator valves on a one-pipe stea syste ust be either wide open or tightly shut.
Do not atte pt to regulate roo te perature by partially closing the radiator valve.
Air vents on stea radiators and the supply ain release air fro the syste . If radiators
do not heat satisfactorily, ake sure the air vents are clean and operational.
The lever of the safety valve, shown in figure 15 below, on the boiler should be operated
periodically to ake sure that it is functioning properly.
WARNING: DISCHARGE WILL BE BOILING HOT WATER AND STEAM.
The safety valve should open before the stea pressure exceeds the 15 lb. reading on the
gauge, (figure 15 to right). If this pressure is
exceeded and the safety valve does not
open, it ust be replaced. If the safety valve
leaks stea when the boiler is operating at
nor al pressures, it should be i ediately
replaced. Corrosion can build up rapidly at
the valve seat and prevent its functioning as
a safety device.
During the heating season the drain cock,
on the botto rear of the boiler, should be
opened once a onth to flush out the boiler
so the device will be free to function properly.
Use a pail to catch the discharge.
WARNING: DISCHARGE
WILL BE BOILING HOT WATER.
If the water in a stea boiler appears to be dirty or oily, or the water level in the gauge
glass fluctuates considerably, the boiler should be cleaned and ski ed (See page 18 for
instructions). A co petent service person will use approved cleaning co pounds and
properly clean and flush out the boiler. He/she should also clean or replace air vents and traps,
clean flue passages and check for proper operation of all controls and safety devices.
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 access door, (figure 15 above). Place a trouble la p in the flue collector through the
draft-hood relief opening. With the irror positioned above the burners, the flue gas
passageways can be checked for soot or scale.
FIGURE 15

TO CLEAN THE BOILER FLUEWAYS:
1. Re ove the burners fro the co bustion cha ber by raising the burners upward
fro the anifold orifices and pulling toward the front of the boiler. To re ove the burner
with the pilot burner attached, first disconnect the pilot line tubing and ther ocouple or pilot
generator leads at the ain electric gas valve. Do not re ove the pilot line tubing at the pilot
as the pilot burner orifice ay drop out and beco e da aged or lost.
2. Disconnect the vent pipe fro the draft hood.
3. Re ove the draft hood. The draft hood is attached to the flue collector at the top by
sheet etal screw(s).
4. Re ove the top jacket panel. It is attached to the jacket by sheet etal screws.
5. Re ove the flue collector fro the boiler casting by loosening the nuts on the J bolts
at either side of the flue collector.
6. Place a sheet of heavy paper or si ilar aterial over the botto of the co bustion
cha ber and brush down the flue passageways. The soot and scale will collect on the paper
and is easily re oved with the paper.
7. With the paper still in place in the co bustion cha ber, clean the top of the boiler
castings of the boiler putty or silicone used to seal between the castings and the flue
collector. Make certain chips are not lodged in the flueways.
When the cleaning process is co pleted, restore the boiler co ponents to their original
position. Use boiler putty or GE IS-808 silicone to seal around the flue collector and castings.
Make certain the burner ends are inserted in the slots at the back of the co bustion cha ber
and well down in position over the burner orifices. Follow the lighting instructions on the
boiler to put the burners back in operation.
CHECK SAFETY CONTROL CIRCUIT, after burner adjust ents are ade, for
satisfactory operation.
CAUTION: Label all wires prior to disconnection when servicing
controls. Wiring errors can cause i proper and dangerous operation.
Verify proper operation after service.
1. Pilot: with ain burner operating turn the pilot gas adjusting screw clockwise
until pilot gas is turned off. See figures 11 and 12 on pages 12 & 13. Within 90 seconds the
ain gas control should close, shutting off the gas to the ain burner. After, check pilot
operation. Relight following lighting instructions on pages 10-12.
2. Pressure control - on stea boilers - re ove cover and note pressure setting. With
the boiler operating, decrease the setting. When setting is lower than boiler pressure, the
control will open, closing the auto atic ain gas valve. After checking pressure control,
reset control to original setting.
3. Mechanical Low water cut-off: Operation ay checked by opening the blow-off valve
located in the lower portion of the body. This will drain water quickly fro the cut-off body
and break circuit to auto atic ain gas valve. Owner should blow off this control at least
once each onth of the heating season.
WARNING: WATER WILL BE BOILING HOT.
PAGE 17

4. Electronic Low Water Cut-off: Operation ay be checked by opening the drain valve
in the back side of the boiler. This will drain the water fro the boiler and break the electronic
circuit to the auto atic gas valve.
IMPURITIES IN BOILER WATER of a stea boiler ay cause foa ing and an unsteady
water line, or prevent stea generation. They ay result in objectionable odors escaping
fro the vents on water boilers. This condition is caused by oil, grease, and sedi ent fro
pipe fittings collecting within the boiler and can be re edied only by giving the boiler a
thorough cleaning.
BOILERS CAN BE CLEANED by ski ing or blowing down.
CAUTION: The boiler should not be left unattended during the cleaning
process.
SKIMMING OFF IMPURITIES
So e of the i purities in the boiler water will float on the water and ust be ski ed off.
With the boiler e pty and cool, slowly begin to add water. After water has entered boiler
- never before - turn on ain gas burners and adjust fla e at ain anual shut-off valve
so that the water being added is kept just below boiling point. Avoid boiling and turbulence.
Gradually raise hot water level to ski ing tee, see figure 5 on page 5, installed at the
supply outlet piping of the boiler being careful not to raise it above the opening of the tee.
Ski until there are no i purities. Repeat the process if necessary.
Water ay be checked to ake sure it is free fro oil by drawing off a sa ple at the
ski ing tee. If the sa ple is reasonably free fro oil, it will not froth when boiled on stove.
This test does not indicate the a ount of sedi ent which ay lay in the botto of the boiler.
It is therefore necessary that the boiler be further cleaned by blowing down.
BLOWING DOWN BOILER
Before blowing down the boiler, fill it to the water line. Light burners and allow five pounds
of stea pressure to build up. Run a te porary connection fro one of the drain valves to
a nearby sewer. Connect to a drain valve on the opposite end of the boiler fro feed water
inlet, if possible. Shut off the gas burners, open drain valve and blow down the entire
contents of boiler.
Allow boiler to thoroughly cool and slowly refill to water line. Repeat step 2 as any ti es
as required until blow off water is clear. Owner should blow down boiler at least once each
onth of the heating season.
WARNING: WATER WILL BE BOILING HOT.
USING CLEANING COMPOUND
If an exceptional a ount of dirt or sludge see s to be present in the boiler, a boiler
cleaning co pound ade by a reputable anufacturer ay be used according to the
instructions of the anufacturer of the co pound. When any type of cleaning co pound
is used, care ust be taken to thoroughly flush all traces of the co pound out of the boiler.
Following blow down allow the boiler to cool. Add fresh water slowly. Be certain to blow
enough ti es as required to re ove co pounds fro syste .
PAGE 18