UTICA BOILERS PEG112C User manual

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
PEG-C
GAS FIRED BOILERS
FOR STEAM HEATING
Utica Boilers  P.O. Box 4729  Utica, NY 13504
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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
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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.
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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
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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.
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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
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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.
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PAGE 6
FIGURE 6b
SUGGESTED PIPING FOR A MODULAR STEAM BOILERS
PUMPED RETURNS
GRAVITY RETURNS
FIGURE 6a
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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
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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
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