Utica Gas-fired Boiler User Manual

MGBMGB

MGB

MGBMGB

GAS FIRED BOILERS

FOR FORCED HOT WATER

UCTIONSUCTIONS

UCTIONS

TING INSTRTING INSTR

TING INSTR

Utica Boilers, • P.O. Box 4729 • Utica, NY 13504

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ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

ABLE OF CONTENTSABLE OF CONTENTS

Safety Symbols & Warnings ........................................................................ Page 2

Installation Procedure .................................................................................. Page 3

Ventilation and Combustion Air .................................................................... Pages 4-6

Connecting Supply and Return Piping .......................................................... Pages 6-9

Vent Installation ........................................................................................... Page 9

Vent System modification ............................................................................ Page 10

Vent Damper Installation and Instructions .................................................... Page 11

Connecting Gas Service ............................................................................. Page 12

Electrical Wiring ........................................................................................... Page 13

Thermostat Installation ................................................................................. Page 13

Lighting Instructions ..................................................................................... Pages 13-16

Normal Sequence of Operation .................................................................... Page 16

General Instructions ..................................................................................... Pages 17-19

Checking Gas Input Rate to Boiler ............................................................... Pages 19-20

Replacement Parts Lists .............................................................................. Pages 20-25

Ratings and Data ......................................................................................... Page 26

Dimensions .................................................................................................. Page 27

KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE

SERIES MGB CAST IRON GAS FIRED BOILERS

INSTALLATION MANUAL AND

OPERATION INSTRUCTIONS

C.S.A. Certified for Natural gas

or Propane

Published February 1989 Revised June 1998 Printed in USA Made In USA

PAGE 1

Tested for 100 lbs.

ASME Working

Pressure

Safety SymbolsSafety Symbols

Safety Symbols

Safety SymbolsSafety Symbols

The following defined symbols are used throughout this manual to notify the

reader of potential hazards of varying risk levels.

ANGERANGER

ANGER

ANGERANGER

DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL

result in death or serious injury.

WARNINGWARNING

WARNING

WARNINGWARNING

WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD

result in death or serious injury

CACA

UTIONUTION

UTION

CACA

UTIONUTION

CAUTION - Indicates a potential hazardous situation which, if not avoided, MAY result

in minor or moderate injury. It may also be used to alert against unsafe practices.

IMPORIMPOR

IMPOR

IMPORIMPOR

1. Keep boiler area clear and free from combustible materials, gasoline and other

flammable vapors and liquids.

2. DO NOT obstruct air openings to the boiler room.

3. Modification, substitution or elimination of factory equipped, supplied or specified

components may result in property damage, personal injury or the loss of life.

4. To the owner: Installation and service of this boiler must be performed 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 Commonwealth of Massachusetts the installation

must be performed by a Licensed Plumber or Licensed Gas Fitter.

VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT ANDVENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND

VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND

VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT ANDVENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERSIN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS

IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS

IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERSIN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHERMANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER

MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER

MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHERMANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAYGAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY

GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY

GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAYGAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TORESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO

RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO

RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TORESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBONASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON

ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON

ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBONASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE.MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

MONOXIDE WHICH IS ODORLESS AND INVISIBLE.MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

ANT!ANT!

ANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.

ANT!ANT!

WARNING:WARNING:

WARNING:

WARNING:WARNING:

WARNING:

WARNING:WARNING:

ALL INSTALLATIONS OF BOILERS ANDALL INSTALLATIONS OF BOILERS AND

ALL INSTALLATIONS OF BOILERS AND

ALL INSTALLATIONS OF BOILERS ANDALL INSTALLATIONS OF BOILERS AND

PAGE 2

INSTINST

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OCEDUREOCEDURE

OCEDURE

OCEDUREOCEDURE

WARNING: Improper installation, adjustment, alteration, service or maintenance

can cause injury or property damage.

1. The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest revision of the National Fuel Gas Code, ANSI Z223. (Available from the American Gas Association, 8501 E. Pleasant Valley Road, Cleveland, Ohio 44134). Reference should also be made to local gas utility regulations and other codes in effect in the area in which the installation is to be made. When installed in Canada: The latest revision of the CAN1-B149.1 and/or B149.2 Installation Codes for GasBurning Equipment and/or local codes.

2. Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices For Automatically Fired Boilers, ANSI/ASME No.CSD-1.

3. This boiler series is classified as a Category 1 and the vent installation shall be in accordance with Part 7 of the National Fuel Gas Code noted above when installed in the United States. In Canada refer to the CAN1-B149.1 and or B149.2 Installation Codes for Gas-Burning Equipment. Also refer to applicable provisions of the local building codes.

4. This 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. The boiler shall be installed such that the 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 the chimney as possible and centrally located with respect to the heat distribution system as practical.

7. Allow 24 inches at the front and right side for servicing and cleaning.

8. When installed in a utility room, the door should be wide enough to allow the largest boiler part to enter, or to permit replacement of another appliance such as a water heater.

9. FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY . For installation on combustible flooring special base part no. 325-2-8.00 must be used. The boiler can not be installed on carpeting. Minimum clearances to combustible construction are:

TOP ........................................ 18 IN.

FRONT ................................... ALCOVE

FLUE CONNECTOR ...............6 IN.

REAR ...................................... 4 IN.

CONTROL SIDE .....................9 IN.

OTHER SIDE ..........................3 IN.

NOTE: Greater clearances for access should supersede fire protection clearances.

PAGE 3

VENTILAVENTILA

VENTILA

VENTILAVENTILA

WARNING:WARNING:

WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT BE

WARNING:WARNING:

OBSTRUCTED. BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE COMBUSTION AIR CAN BE MAINTAINED

TION & COMBTION & COMB

TION & COMB

TION & COMBTION & COMB

USTION USTION

USTION

USTION USTION

AIRAIR

AIR

AIRAIR

COMBCOMB

COMB

COMBCOMB

OUTSIDE INSIDE OUTSIDE COMBUSTION AIR

MODEL COMBUSTION COMBUSTION VERTICAL HORIZONTAL

NUMBER AIR 1 SQ. IN AIR 1 SQ. IN. DUCTS DUCTS

MGB /5000 BTU/HR /1000 BTU/HR 1 SQ. IN. 1 SQ. IN.

(SEE FIG. 4) (SEE FIG. 3) /4000 BTU/HR /2000 BTU/HR MGB 38 8 100 10 19 MGB 50 10 100 13 25 MGB 75 15 100 19 38

MGB 100 20 100 25 50 MGB 125 25 125 32 63 MGB 150 30 150 38 75 MGB 175 35 175 44 88 MGB 200 40 200 50 100 MGB 225 45 225 57 113 MGB 275 55 275 69 138 MGB 300 60 300 75 150

USTION USTION

USTION

USTION USTION

(MINIMUM SQUARE INCHES OPENING)

*UNCONFINED AREA

AIR REQAIR REQ

AIR REQ

AIR REQAIR REQ

UIREMENTSUIREMENTS

UIREMENTS

UIREMENTSUIREMENTS

****

**CONFINED AREA

****

* Unconfined area: A space whose volume 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 volume 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 room must be adequate to provide sufficient air to properly support combustion 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 frame, masonry or metal building, infiltration normally is adequate to provide air for combustion and ventilation. However, if the equipment 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 combustion and ventilation shall be provided according to part 5 on page 5. 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

PAGE 4

construction, air for combustion and ventilation must be obtained from outdoors or from spaces freely communicating with the outdoors. A permanent 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 may be used to convey makeup air from the outdoors and shall have the same cross-sectional area of the openings to which they are connected.

4. When air for combustion and ventilation is from inside buildings, the confined space shall be provided with two permanent openings, one starting 12 inches from the top and one 12 inches from the bottom of the enclosed space. Each opening shall have a minimum 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 must not be less than one hundred (100) square inches. These openings must freely communicate directly with other spaces of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.

5. When the boiler is installed in a confined space and all air is provided from the outdoors the confined space shall be provided with one or two permanent openings according to methods A or B. When ducts are used, they shall be of the same cross sectional area as the free area of the area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches.

A. When installing two openings, one must commence within 12 inches from the top and the other within 12 inches from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. One of the following methods must be used to provide adequate air for ventilation and combustion.

1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure. See figure 2 below.

FIGURE 1

FIGURE 2

2. When communicating with the outdoors by means of vertical ducts, each opening shall have a minimum 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 on page 6.

3. If horizontal ducts are used, each opening and duct shall have a minimum 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 on page 6.

B. One permanent opening, commencing within 12 inches of the top of the enclosure,

PAGE 5

FIGURE 3 FIGURE 4

shall be permitted where the equipment has clearances of at least 1 inch from the sides, 1 inch from the back, and 6 inches from the front of the boiler. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. The openings must have a minimum free area of 1 square inch per 3000 Btu per hour of the total input rating of all equipment located in the enclosure. The free area must be no less than the sum 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 smaller than 1/4 inch mesh. 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 may be assumed that wood louvers will have 20-25% free area and metal 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 automatically during the boiler operation.

CONNECTING SUPPLCONNECTING SUPPL

CONNECTING SUPPL

CONNECTING SUPPLCONNECTING SUPPL

IMPORTANT: Circulators in the following illustrations are mounted on the system supply

side, but mounting on the system return side is also acceptable practice.

1. Connect supply and return piping as suggested in figure 5 on page 7, when the boiler is used in connection with refrigerated systems.

A. The chilled medium B. Use appropriate valves to prevent the chilled medium from 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 minimum clearance of one inch to hot water pipes.

2. When the boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, the boiler piping system MUST BE supplied with flow control valves or other automatic means to prevent gravity circulation of the boiler water

during the cooling cycle.

MUST BE PIPED IN PARALLELMUST BE PIPED IN PARALLEL

MUST BE PIPED IN PARALLEL with the boiler.

MUST BE PIPED IN PARALLELMUST BE PIPED IN PARALLEL

Y Y

AND RETURN PIPINGAND RETURN PIPING

AND RETURN PIPING

Y Y

AND RETURN PIPINGAND RETURN PIPING

PAGE 6

BYPASS PIPING

FIGURE 5

FIGURE 6

3. Hot water boilers installed above radiation level must be provided with a low water cutoff device.

4. When a boiler is connected to a heating system that utilizes multiple zoned circulators, each circulator must be supplied with a flow control valve to prevent gravity circulation.

5. Hot water boilers and system must be filled with water and maintained to a minimum pressure of 12 pounds per square inch.

6. Bypass piping is an option which gives the ability to adjust the supply boiler water temperature to fit the system or the condition of the installation. This method of piping, however, is not typically required for baseboard heating systems. Typical installations where bypass piping is used are as follows:

A. This method is used to protect

boilers from condensation forming due to low

MIXING VALVE PIPING

temperature return water. Generally noticed in large converted gravity systems or other large water volume systems. See figure 6 above.

B. These methods are used to protect systems using radiant panels and the material they are encased in from high temperature supply water from the boiler and protect the boiler from condensation. See figure 7 at right and 8 on page 8.

NOTE 1: When using bypass piping, adjust valves A and B until desired system temperature is obtained. NOTE 2: Bypass loop must be same size piping as the supply and return piping.

PAGE 7

FIGURE 7

PRIMARY SECONDARY PIPING WITH BY PASS

FIGURE 8

7. Installation using circulators is shown in figure 9 below.

FIGURE 9

8. Installation using zone valves is shown in figure 10 on page 9.

9. For further piping information refer to the I=B=R Installation and Piping Guide.

PAGE 8

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Utica Gas-fired Boiler User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual