Allied Engineering MG50, MG75, MG100, MG125, MG150 Installation Manual

INSTALLATION AND SERVICE MANUAL

MG & SG SERIES BOILERS

FOR MODELS MG-50 TO MG-150 AND SG-135 TO SG-270

SEE REAR COVER FOR INDEX

This manual must only be used by a qualified
heating installer, service technician or gas supplier.

See Section 3.10 for Installer’s Checklist

See Section 4.3 for Service Checklist

Manufactured by

Allied Engineering Company

Manufacturers of Gas and Electric Boilers, Stainless Steel Tanks, Heat Exchangers and Electric Boosters.

94 Riverside Drive, North Vancouver, B.C. V7H 2M6 • Telephone [phone] • FAX [phone]

PN2152451 Price $10

Division of E-Z-Rect Manufacturing Ltd.

Branches: Calgary • Edmonton • Toronto

A

A

MG SERIES BOILERS

DIMENSIONS AND SPECIFICATIONS

Standard Model Includes:

• Zone Control Board with Transformer

• Stainless Steel Burners

• Combination Gas Valve

• Dual Safety High-Limit Aquastat

• Temperature / Pressure Gauge

• A.S.M.E. Pressure Relief Valve

• Drain Valve

• Draft Hood

• Blocked Vent Safety Switch

• Flame Roll-out Safety Switch

• Automatic Vent Damper

“PS” Packaged Models Include
Standard Model Parts plus:

• Circulating Pump

• Custom Cast Iron Pump Adapter

• Expansion Tank

• Air Purger

• Combination Fill / Regulator Valve

• Automatic Air Vent

llow 18” (457 mm) minimum in front for servicing.

Minimum clearances to combustible material: Top 24” (610 mm), Sides 2” (51 mm), Rear 2” (51 mm), Flue 6" (153 mm)

PPROVED FOR COMBUSTIBLE FLOORS & CLOSET INSTALLATION.

The Super Hot product improvement program may result in changes to the design and / or specifications being made without notice.

MODEL

NUMBER

MG50 50 14.7 42.4 12.4 11.5 29.2 5.25 13.3 4.0 10.2 39.2 99.6 4.5 11.4 125 57

MG75 75 22.0 63.5 18.6 14.5 36.8 5.25 13.3 5.0 12.7 39.5 100.3 4.5 11.4 150 68

MG100 100 29.3 84.6 24.8 17.5 44.5 5.25 13.3 5.0 12.7 39.5 100.3 4.5 11.4 175 80

MG125 125 36.6 105.5 30.9 20.5 52.1 6.50 16.5 6.0 15.2 40.5 102.9 4.5 11.4 200 91

MG150 150 44.0 126.5 37.1 23.5 59.7 6.50 16.5 6.0 15.2 40.5 102.9 4.5 11.4 225 102

* For altitudes above 2,000 feet, refer to Section 3.6 to determine the appropriate Input derate or contact the factory.
** Output based on boilers equipped with electronic ignition.

INPUT* OUTPUT** DIM A DIM B DIM C DIM D DIM E

MBH kW MBH kW in cm in cm in cm in cm in cm lb kg

SHIPPING
WEIGHT

Options:

• Natural Gas add suffix "N" - Propane models add suffix “P”

• Electronic Ignition add suffix “E” - Hot Surface Ignition add suffix “HS”

• Add 35 pounds weight (16 kg) for packaged boilers - add suffix “PS”

2

A

A

SG SERIES BOILERS

DIMENSIONS AND SPECIFICATIONS

Standard Model Includes:

• Zone Control Board with Transformer

• Stainless Steel Burners

• Combination Gas Valve

• Dual Safety High-Limit Aquastat

• Temperature / Pressure Gauge

• A.S.M.E. Pressure Relief Valve

• Drain Valve

• Draft Hood

• Blocked Vent Safety Switch

• Flame Roll-out Safety Switch

• Automatic Vent Damper

“PS” Packaged Models Include
Standard Model Parts plus:

• Circulating Pump

• Custom Cast Iron Pump Adapter

• Expansion Tank

• Air Purger

• Combination Fill / Regulator Valve

• Automatic Air Vent

llow 24” (609 mm) minimum in front for servicing.

Minimum clearances to combustible material: Top 24” (610 mm), Sides 2" (51 mm), Rear 2" (51 mm), Flue 6" (153 mm)

PPROVED FOR COMBUSTIBLE FLOORS & CLOSET INSTALLATION.

The Super Hot product improvement program may result in changes to the design and / or specifications being made without notice.

MODEL

NUMBER

SG135 135 39.6 112 32.8 14.7 37.3 9.5 24.1 6.0 15.2 45.3 115 4.5 13.9 0.50” 191 87

SG180 180 52.8 150 44.0 17.7 45.0 9.5 24.1 6.0 15.2 45.3 115 4.5 13.9 0.50” 222 101

SG225 225 65.9 188 55.1 20.7 52.6 9.5 24.1 7.0 17.8 46.5 118 6.5 16.5 0.75” 253 115

SG270 270 79.1 225 65.9 23.7 60.2 9.5 24.1 8.0 20.3 47.6 121 7.5 19.0 0.75” 284 129

* For altitudes above 2,000 feet, refer to Section 3.6 to determine the appropriate Input derate or contact the factory.
** Output based on boilers equipped with electronic ignition.

INPUT* OUTPUT** DIM A DIM B DIM C DIM D DIM E

MBH kW MBH kW in cm in cm in cm in cm in cm NPT lb kg

GAS

CONN. F

SHIPPING
WEIGHT

Options:

• Natural Gas add suffix "N" - Propane models add suffix “P”

• Electronic Ignition add suffix “E” - Hot Surface Ignition add suffix “HS”

• High/Low fire add suffix “M” - Consult Factory for Availability

• Add 45 pounds weight (20 kg) for packaged boilers - add suffix “PS”

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MG & SG Series Boilers – Installation and Service Manual

ABOUT OUR MANUALS

Your Super Hot boiler has been provided with two manuals:

• User's Information Manual - This manual is intended for the owner or user of the boiler and provides
information on routine operation and maintenance, and emergency shutdown.

• Installation and Service Manual - This manual must only be used by a qualified heating installer,
service technician or gas supplier. Installation or service by anyone unqualified to do so may

result in severe personal injury, death or substantial property damage.

Both manuals should be kept in the envelope provided and affixed adjacent to the boiler so that they are
readily available for future reference.

Lighting Instructions Section 1

1.1 SAFETY INSTRUCTIONS

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.

A. BEFORE LIGHTING smell all around the

boiler area for gas. Be sure to smell next to
the floor because some gas is heavier than
air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas
supplier's instructions.

• If you cannot reach your gas supplier,

call the fire department.

B. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will
not push in or turn by hand, don't try to repair
it, call a qualified service technician. Force or
attempted repair may result in a fire or
explosion.

C. Do not use this boiler if any part has been

under water. Immediately call a qualified
service technician to inspect the appliance
and to replace any part of the control system
and any gas control which has been under
water.

1.2 LIGHTING INSTRUCTIONS

Determine the ignition system that applies from the list below and go to the applicable lighting instruction
section.

• Standing pilot with combination gas valve (Section 1.3)

• Intermittent electronic & hot surface ignition with combination gas valve (Section 1.4)

If you are unsure which type of gas valve or ignition system your boiler is equipped with, check the
lighting instructions sticker on the boiler or contact the factory.

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MG & SG Series Boilers – Installation and Service Manual

1.3 LIGHTING INSTRUCTIONS FOR STANDING PILOT WITH COMBINATION

GAS VALVE.

1 This boiler has a pilot which must be lighted

by hand. When lighting the pilot, follow these
instructions exactly. Ensure gas supply to
boiler is turned on.

2 STOP! Read the safety instructions in

Section 1.1.

3 Set the room thermostat to lowest setting.
4 Turn off all electrical power to the boiler.
5 Remove control access panel if necessary.
6 Push in gas control knob slightly and turn

clockwise

NOTE: Knob cannot be turned from "PILOT"

to "OFF" unless knob is pushed in slightly.
Do not force.

7. Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor.
If you smell gas, STOP! Follow "A" in the
safety instructions in Section 1.1. If you don't
smell gas, go to step 8.

 to "OFF".

8. Find pilot burner - follow
aluminum tube from gas valve.
The pilot is on the far left side
of the burner tray.

9. Depress gas control knob and
turn counterclockwise

"PILOT".

10. Push in control knob all the way and hold in.
Immediately light the pilot with a match.
Continue to hold the control knob in for about
(1) minute after the pilot is lit. Release knob
and it will pop back up. Pilot should remain lit.
If it goes out, repeat steps 6 through 10.

• If the knob does not pop up when

released, stop and immediately call your
service technician or gas supplier.

• If the pilot will not stay lit after several

tries, turn the gas knob clockwise
"OFF" and call your service technician or
gas supplier.

11. Turn gas control knob counterclockwise
"ON".

12. Replace control access panel if necessary.

13. Turn on all electrical power to the boiler.

14. Set room thermostat to desired setting.

To turn off gas to boiler or emergency shut-off

Follow Section 1.5.

 to

PILOT
BURNER

THERMO­COUPLE

 to

 to

1.4 LIGHTING INSTRUCTIONS FOR INTERMITTENT ELECTRONIC &
HOT SURFACE IGNITION WITH COMBINATION GAS VALVE.

1. This boiler is equipped with an ignition device
which automatically lights the pilot. Do not
to light the pilot by hand. Ensure gas supply
to the boiler is turned on.

2. STOP! Read the safety instructions in
Section 1.1.

3. Set the room thermostat to lowest setting.

4. Turn off all electrical power to the appliance.

5. Remove control access panel if necessary.

6. Push in gas control knob slightly and turn
clockwise

NOTE: On some gas valves the knob cannot

 to "OFF".

try

be turned to "OFF" or “ON” position unless
knob is pushed in slightly. Do not force.

7. Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor. If
you smell gas, STOP! Follow "A" in the safety
instructions in Section 1.1. If you don't smell
gas, go to the next step.

8. Turn gas control knob counterclockwise

 to "ON".

9. Replace control access panel if necessary.

10. Turn on all electrical power to the Boiler.

11. Set room thermostat to desired setting.

12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Boiler" in
Section 1.5 and call your service technician or
gas supplier.

To turn off gas to boiler or emergency shut-off

Follow Section 1.5.

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MG & SG Series Boilers – Installation and Service Manual

1.5 TO TURN OFF GAS TO THE BOILER OR EMERGENCY SHUT-OFF.

WARNING

Should boiler overheat, or the gas supply fail to shut off, do not turn off or disconnect the
electrical supply to the circulating pump. Instead, shut off the gas supply at a location external
to the boiler.

1. Set the thermostat to the lowest setting.

2. Turn all electrical power to the boiler off.

3. Remove control access panel on the boiler if necessary.

4. Push in gas control knob slightly and turn clockwise

5. Replace control access panel if necessary.

 to "OFF". Do not force it.

Installation Instructions Section 2

2.1 RECEIVING

INSPECT SHIPMENT FOR POSSIBLE DAMAGE. All goods are carefully manufactured, inspected,

checked and packed by experienced workers. The manufacturer's responsibility ceases upon delivery of
goods to the carrier in good condition. Any claims for damage, shortage in shipment or non-delivery must
be filed immediately against the carrier by the consignee.

Use care when receiving and unpacking the boiler. Dropping the boiler may cause damage and prevent
safe and proper operation.

2.2 INSTALLATION CODES AND REQUIREMENTS

All applicable national, provincial/state, and local codes, laws, regulations, and ordinances must be
followed. They expand on and take precedence over any recommendations in this booklet. Authorities
having jurisdiction shall be consulted before installations are made.

In Canada, the installation must conform to the requirements of the authority having jurisdiction or, in the
absence of such requirements, to the CAN/CSA B149 Installation Codes (current edition). All electrical
wiring must be in accordance with the Canadian Electrical Code, CSA C22.1 Part 1 (current edition) and
applicable local codes.

In the United States of America, the 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
(current edition). All electrical wiring must be in accordance with the National Electrical Code, ANSI/NFPA
70 (current edition) and applicable local codes.

Where required by the authority having jurisdiction, follow the Standard for Controls and Safety Devices
for Automatically Fired Boilers, ANSI/ASME CSD-1 (current edition).

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MG & SG Series Boilers – Installation and Service Manual

2.3 LOCATION

MG and SG boilers are intended for indoor installation only. Observe the following minimum clearances
from the boiler to combustible materials:

Minimum Clearances to Combustible Materials

Model

MG

SG

• Minimum clearance from the boiler front to combustible materials for SG and MG is 6 in (153 mm);
however, a front clearance of 18" (457 mm) for MG boilers and 24” (609 mm) for SG boilers is
recommended for servicing.

• Maintain a clearance of 6" (152 mm) from draft hood and the flue pipe in any direction.

• Allow ample space for boiler inlet and outlet connections, and gas connection.

• Boiler must be installed on a stable and level foundation.

• MG & SG Series boilers can be installed on a combustible floor but must not be installed directly on

carpeting.

• A hot water boiler installed above radiation level must be provided with a low water cutoff
device at the time of boiler installation.

• This boiler must be installed such that gas ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation and service.

Sides Rear Top Front (service)

in. mm in. mm in. mm in. mm

2 51 2 51 24 610 18 457

2 51 2 51 24 610 24 610

2.4 GAS SERVICE PIPING

The boiler and its gas connection must be leak tested before placing the boiler in operation. The gas
controls furnished are suitable for a maximum operating gas pressure of 1/2 psi (14 inches water
column).

The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in excess

The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff
valve during any pressure testing at test pressures equal to or less than
column).

A manual main shut-off valve should be installed in the gas line outside the boiler jacket and as required
in Section 2.2. The valve should be readily accessible for turning on and off.

A drip pocket or sediment trap should be installed in the gas supply line upstream of the gas controls and
as close to the boiler as possible (example shown in Figure 3 in Section 6).

The pipe compound used should be resistant to the action of liquefied petroleum gases. Check for gas
leaks in piping before placing the boiler in operation by using a soap and water solution. DO NOT USE

AN OPEN FLAME.

INSTALLER MUST IDENTIFY EMERGENCY SHUT-OFF DEVICES.

All piping and fittings must be installed as per codes in Section 2.2.

of 1/2 psig (14 inches water column).

1/2 psig (14 inches water

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MG & SG Series Boilers – Installation and Service Manual

2.5 AIR SUPPLY FOR COMBUSTION AND VENTILATION

A sufficient air supply MUST be provided to this boiler. Air openings to the boiler room provide the air for
combustion, flue gas dilution and ventilation and are always required, regardless whether the air is taken
from inside or outside. The air opening size and location (as well as other air supply and venting
considerations) must conform to Section 2.2.

The boiler room must never be under a negative pressure. Always provide air openings sized not only to
the dimensions required for the total input of all fuel-fired appliances in the boiler space, but also to
handle the air movement rate of any exhaust fans or air movers using air from the building or space.

The venting terminations must always be kept clear of obstructions (i.e. snow, ice, etc.). Louvers and
grilles used in the air supply and ventilation system should be kept clear of any dust, dirt, or debris which
will block proper air flow.

2.6 CORROSIVE ATMOSPHERES

If a gas boiler is to be installed near a corrosive or potentially corrosive air supply, the boiler should be
isolated from it and outside air should be supplied as recommended in Section 2.5.

Chemical vapors from products containing chlorine or fluorine must be avoided. Even though these
chemicals may be safe to breathe, corrosive substances can become liberated when passed through a
gas flame. Even at low concentrations, these chemicals can significantly contaminate the air supply and
shorten the life of any gas burning appliance. The following is a list of some of the products which should
be avoided:

• bleaches and chlorinated cleaning products

• paints and sprays

• water softeners (calcium or sodium chloride)

• leaking refrigeration equipment

• freon from common aerosol dispensers

These chemicals are especially commons near swimming pools, beauty shops, dry cleaning
establishments, laundry areas, workshops, and garages. The warranty is void when failure is due to

corrosion.

2.7 VENTING

The responsibility of providing a suitable vent of adequate draft capacity and in good usable condition is
that of the gas fitter/installer. Interference with the air supply for the boiler shall be prohibited.

Vent installation and type of gas vent or vent connector MUST follow all applicable national,
provincial/state, and local codes, laws, regulations, and ordinances as described in Section 2.2.

For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with Part 7,
Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1 or Section 7, Venting Systems and
Air Supply for Appliances, of the CAN/CGA B149, Installation Codes, or applicable provisions of the local
building codes.

The venting shall be supported as required by applicable code(s). Horizontal runs shall slope upward not
less than ¼ inch per foot (21 mm/m) from the boiler to the vent terminal.

This unit must be installed with the factory supplied draft hood in place. The draft hood is a safety device
designed to control chimney drafts that might affect combustion or blow out the pilot. The draft hood
supplied with the boiler must not be altered. The minimum skirt height as indicated on the draft hood
must be maintained.

Vent connectors serving the boiler must not be connected into any portion of mechanical draft systems
operating under positive pressure.

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MG & SG Series Boilers – Installation and Service Manual

Vent Terminal Information

The minimum distance from the termination of a vent terminal to adjacent public walkways, adjacent
buildings, openable windows and building openings shall be not less than those values specified in the
National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA Installation Codes.

For proper operation, the vent terminal must be kept free of snow and other debris at all times.

To prevent discoloration and degradation of building materials by flue gases and flue gas condensation,
ensure that the vent terminal is installed clear of nearby obstacles. In all cases, installation shall be in
accordance with code.

Maintain a minimum clearance of 4 feet (1.22 m) horizontally, and in no case above or below, unless a 4
foot (1.22 m) clearance is maintained from electric meters, gas meters, regulators and relief equipment.

Removal of an Existing Boiler

When an existing boiler is removed from a common venting system, the common venting system is likely
to be too large for proper venting of the appliances connected to it.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance
remaining connected to the common venting system placed in operation, while the other appliances
remaining connected to the common venting system are not in operation.

a) Seal any unused openings in the common venting system.

b) Visually inspect the venting system for proper size and horizontal pitch and determine 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 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 fireplace dampers.

d) Place in operation the boiler being inspected. Follow the lighting instructions. Adjust the thermostat

so the boiler will operate continuously.

e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the

flame of a match or candle, or smoke from a cigarette, cigar or pipe.

f) 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, fireplace
dampers and any other gas burning appliance to their previous conditions of use.

g) Any improper operation of the common venting system should be corrected so the installation

conforms with the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA Installation Codes. When
re-sizing any portion of the common venting system, the common venting system should be resized
to approach the minimum size as determined using the appropriate tables in Part 11 of the National
Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA Installation Codes.

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MG & SG Series Boilers – Installation and Service Manual

2.8 AUTOMATIC VENT DAMPER

This boiler is supplied with an automatic vent damper. The following instructions must be observed:

• The automatic vent damper should be installed at the top of the factory supplied draft hood (Figure 1 ­Alternate 3). No modifications to the automatic vent damper are permitted.

• The venting system must be arranged so that only the boiler is served by the automatic vent damper
with which it was supplied.

• Connect the wiring harness from the boiler to the automatic vent damper as indicated on the supplied
wiring drawings.

• The automatic vent damper position indicator should be clearly visible after installation.

• A minimum clearance of not less than 6 inches (153 mm) must be maintained between the automatic

vent damper device and combustible construction. Provision must be made for service access to the
automatic vent damper.

• The automatic vent damper must be in the open position when the boiler's main burner is operating.

• For orientation other than vertical, refer to automatic vent damper installation instructions

2.9 BLOCKED VENT AND FLAME ROLL-OUT SAFETY SWITCHES

All boilers with an input of 300,000 Btu/h and under are equipped with blocked vent and flame roll out
safety switches. The blocked vent safety switch is installed in the clip provided on the draft hood (Figure
1 - Alternate 1) or is mounted with screws (Figure 1 - Alternate 2). The blocked vent safety switch is pre­wired at the factory either directly to the boiler controls (Figure 1 - Alternate 1 & 2), or through a wiring
harness for a boiler with an automatic vent damper (Figure 1- Alternate 3). If the vent becomes blocked a
boiler shut down will occur. Ensure that the vent is free of obstructions.

The flame roll out safety switch will cause a boiler shutdown if the heat exchanger becomes blocked with
soot or corrosion.

WARNING

Shut down of the boiler by either the “Blocked Vent” or the “Flame Roll-out” safety switch is an
indication that carbon monoxide may be improperly venting into the premises and the boiler
must be serviced by a qualified person who is capable of determining the cause of the shut
down and can take corrective action. Carbon monoxide is a lethal, colorless and odorless gas.

ALTERNATE 1 ALTERNATE 2

ALTE RNAT E 3

FIGURE 1 - MOUNTING LOCATION OF BLOCKED VENT SAFETY SWITCH AND WIRE ROUTING

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