UTICA BOILERS DVB-50, DVB-150, DVB-100, DVB-200, DVB-125 Installation, Operation & Maintanance Manual

DVB SERIES

R

Gas Fired Boilers For Forced Hot Water

INSTALLATION, OPERATION &

MAINTANANCE MANUAL

An ISO 9001-2000 Certified Company

Utica BOiLERS

P.O. Box 4729
Utica, NY 13504-4729

MEMBER: The Hydronics Institute

P/N 37615501, Rev. B [02/09]

GaS FiRED BOiLERS FOR FORcED HOt WatER

H

KEEP tHiS MaNUaL NEaR BOiLER aND

REtaiN FOR FUtURE REFERENcE.

taBLE OF cONtENtS

Introduction ..........................................................................................................................................4

Boiler Ratings, Capacities & Dimensions ............................................................................................5

Ventilation & Combustion Air ...............................................................................................................7

Connecting Supply & Return Piping ..................................................................................................10

Applicable Federal Codes .................................................................................................................13

Vent System Modication ..................................................................................................................13

Connecting Gas Service ....................................................................................................................14

Electrical Wiring .................................................................................................................................15

Lighting Instructions...........................................................................................................................17

Sequence of Operations ....................................................................................................................18

General Instruction For Seasonal Startup & Maintenance ................................................................19

Replacement Parts ............................................................................................................................22

iMPORtaNt: Read the following instructions

cOMPLEtELY before installing!

SaFEtY SYMBOLS

The following dened symbols are used throughout this manual to notify the reader of potential hazards of varying

risk levels.

DANGER

!

indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.

CAUTION

!

Indicates a potentially hazardous situation which,

if not avoided, could result in minor or moderate

injury or property damage.

indicates a potentially hazardous situation which,
if not avoided, could result in death, serious
injury or substantial property damage.

indicates special instructions on installation,

operation or maintenance which are important

but not related to personal injury hazards.

WARNING

!

NOTICE

C.S.A. Certied for

Natural gas or Propane

Tested for 100 lbs.

ASME Working Pressure

2

iNtRODUctiON

WARNING

!

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

and liquids.

2. DO NOt obstruct air openings to the boiler

room.

3. Modication, substitution or elimination of factory
equipped, supplied or specied 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 Com-

monwealth of Massachusetts the installation
must be performed by a Licensed Plumber

or Licensed Gas Fitter.

5.

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

6.

When installed in 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.

7.

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.).

8.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS

ONLY. *The boiler must not be installed on carpeting.
Minimum clearances to combustible constructions are:

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

FRONT .....................................................6 IN.

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

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

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

WARNING

!

improper installation, adjustment, alteration,

service or maintenance can cause injury or

property damage.

The installation must conform to the requirements of

1.

the authority having jurisdiction or, in absence of such
requirements, to the latest revision of the National Fuel
Gas Code, ANSI Z223-1. (Available from the American
Gas Association, 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.

2.

Where required by the authority having jurisdiction, the

installation must conform to American Society of Me-

chanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME No.

CSD-1.

3.

This boiler is classied as a Category I and III and vent

installation shall be in accordance with the latest revision
of the National Fuel Gas Code, ANSI Z223.1 or applicable
provisions of the local building codes.

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

VENT PIPE ..............................................6 IN.

NOTES:

• Greater clearances for access should supersede re pro­tection clearances.

* For installation on combustible ooring Special Base MUST
BE USED. (See Replacement Parts Section)

4.

LOCATE BOILER on level, solid base as near the outside

wall as possible and centrally located with respect to the
heat distribution system as practicable.

3

BOiLER RatiNGS, caPacitiES & DiMENSiONS

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.

BOiLER DiMENSiONS

Model #

-50 ½" 11¼ 2⅛ 3 6⅜ 27 1¼" 1 83%

-100 ½" 15⅛ 4⅛ 3 6⅜ 27 1¼" 2 82%

-125 ½" 19 6 3 6⅜ 27 1¼" 3 82%

-150 ½" 19 6 4 6⅜ 27 1¼" 3 80%

-200 ½" 22⅞ 8 4 7 28 1¼" 4 80%

noTE: For altitudes above 2,000 ft. ratings should be reduced at the rate of 4% for each 1,000 ft. above sea level.

Natural

Gas inlet

a B c D E

DiMENSiONS FOR NatURaL GaS

Dimensions

4

Pump size

Supply

& Return

tappings

Number

of

Burners

aFUE

Ratings

BOiLER RatiNGS, caPacitiES & DiMENSiONS

a.G.a.

Model #

-50 50,000 42,000 37,000 1 2.4 83%

-100 100,000 82,000 71,000 2 4.0 82%

-125 125,000 103,000 90,000 3 5.6 82%

-150 150,000 122,000 106,000 3 5.6 80%

-200 199,999 160,000 139,000 4 7.2 80%

input

Btu/Hr.

Heating

capacity

Btu/Hr.

i=B=R

NetOutput

Btu/Hr

No.

of

Burners

Water

content

(Gals.)

aFUE

Ratings

sTanDaRD EQUiPMEnT: Boiler Jacket, Cast Iron Boiler Battery, Combination Aquastat Relay, Theraltimeter

Gauge, Circulator, Main Gas Burners, Electric Ignition System, A.S.M.E relief Valve, Drain Valve, Induced Draft
Fan, and Safety Pressure Switch

All boilers are design certied for installation on non-combustible oors. For installation on combustible oors, use

combustible oor kit.

This boiler is a Category III Designed Certied appliance which requires a special horizontal through the wall venting

system. Only HEAT-FAB SAF-T-VENT™, FLEX-L STAR-34™, ProTech™ FasNSeal, and Z-FLEX Z-VENT™ vent
material products shall be used.

Should a chimney installation be required, see venting addendum.

See venting addendum for maximum vent lengths and proper congurations.

MEA number for the boilers is 415-90-E.

Electric service to be 120 Volts, 15 Amps, 60 Hz.

**For equivalent square feet of radiation, divide I=B=R output by 150.

5

VENtiLatiON & cOMBUStiON aiR

WaRNiNG

! !

aiR OPENiNGS tO cOMBUStiON aREa MUSt NOt BE OBStRUctED.
BY FOLLOWiNG tHE iNStRUctiONS BELOW, aDEQUatE
cOMBUStiON aiR caN BE MaiNtaiNED.

cOMBUStiON aiR REQUiREMENtS

(Minimum square inch openings)

*UNcONFiNED aREa **cONFiNED aREa

INSIDE

OUTSIDE

MODEL #

-50 10 100 13 25

-100 20 100 25 50

-125 25 125 32 63

-150 30 150 38 75

-200 40 200 50 100

COMBUSTION AIR
1 SQ. IN/5000 BTU/
HR (SEE Figure #2)

COMBUSTION AIR

1 SQ. IN. /1000

BTU/HR

(SEE Figure #1)

* Unconned 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).

** Conned 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).

Ventilation of the boiler room must be adequate to

1.

provide sufcient air to properly support combustion

per the latest revision of the National Fuel Gas Code,
ANSI Z223.1.

2.

When a boiler is located in an unconned space in a

building or conventional construction frame, masonry
or metal building, inltration normally is adequate to
provide air for combustion and ventilation. However, if
the equipment is located in a building of tight construction

(See the National Fuel Gas Code, ANSI Z223.1 latest

OUTSIDE COMBUSTION AIR

VERTICAL

DUCTS 1 SQ. IN.

/4000 BTU/HR

(SEE Figures #2

& 3)

revision), the boiler area should be considered as a con-

ned space. In this case air for combustion and ventilation

shall be provided according to paragraph #5. If there is

any doubt, install air supply provisions in accordance with

the latest revision of the National Fuel Gas Code.

When a boiler is installed in an unconned space, in a

3.

building of unusually tight construction, air for combus-

tion 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 pro-

vided. 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

HORIZONTAL

DUCTS 1 SQ. IN.

/2000 BTU/HR

(SEE Figure #4)

6

VENtiLatiON & cOMBUStiON aiR

VENT PIPE

BASEBOARD

VENTS

BOILER

12"

12"

OUTLET
AIR

VENTILATION LOUVERS

(EACH END OF ATTIC)

INLET

AIR

VENTILATION

LOUVRES FOR

UNHEATED

CRAWL SPACE

BOILER

OUTLET
AIR

VENTILATION LOUVERS
(EACH END OF ATTIC)

-- SLAB --

INLET AIR DUCT

12"

buildings, the conned 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 sufcient volume so that the
combined volume of all spaces meets the criteria for an

unconned space. See

Figure #1.

Figure #1

Figure #2

When the boiler is installed in a conned space and all air

5.

is provided from the outdoors the conned 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 mini-

mum dimension of rectangular air ducts shall be not less

than 3 x 3 inches or 9 square inches.

When installing two openings, one must commence A.

within 12 inches from the top and the other within 12

inches from the bottom of the enclosure. The open-

ings shall communicate directly, or by ducts, with the

outdoors or spaces (crawl or attic) that freely commu-

nicate with the outdoors. One of the following methods

must be used to provide adequate air for ventilation

and combustion.

When communicating with the outdoors by means of II.

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

gure #3

.

Figure #3

(DUCT ENDS 1 FT.

ABOVE THE FLOOR)

When directly communicating with the outdoors, each I.

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

.

7

BOILER

-- SLAB --

INLET AIR DUCT

12"

INLET AIR DUCT

12"

VENtiLatiON & cOMBUStiON aiR

If horizontal ducts are used, each opening and duct III.

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

gure #4

.

Figure #4

In calculating free area using louvers, grilles or screens

6.

for the above, consideration shall be given to their block-

ing 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 specied. 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 xed in the open position or interlocked with the
boiler so they are opened automatically during the boiler

operation.

One permanent opening, commencing within 12 inches B.

of the top of the enclosure, 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 verti-

cal 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 connec-

tors in the conned space.

8

cONNEctiNG SUPPLY & REtURN PiPiNG

CIRCULATOR

VALVE

EXPANSION

TANK

VALVE

RETURN

SUPPLY

12"

MAX.

CIRCULATOR

FLOW

VALVE

SYSTEM

TEMPERATURE

GAUGE

"B"

"A"

SYSTEM

PRIMARY

6"

FEED

WATER

ZONE

CIR.

VALVE

FLOW
VALVE

EXPANSION

TANK

VALVE

SYSTEM
TEMPERATURE
GAUGE

RETURN

SUPPLY

"A"

"B"

6"

FEED

WATER

6"

EXPANSION

TANK

TEMPERATURE

SYSTEM

GAUGE

SUPPLY

RETURN

4 WAY MIXING

VALVE

ZONE

CIR.

WATER

FEED

iMPORtaNt: circulators in the following
illustrations are mounted on the system supply
side, but mounting on the system return side is

also acceptable practice.

Connect supply and return piping as suggested in

1. gure
#5

, when the boiler is used in connection with refriger-

ated systems.

The chilled medium MUST BE PIPED IN PARALLEL A.

with the boiler.

Use appropriate valves to prevent the chilled medium B.

from entering the heating boiler.

During heating cycle open valves A and B, close I.

valves C and D.
During cooling cycle, open valves C and D, close II.

valves A and B.

C. Maintain a minimum clearance of one inch to hot C.
water pipes.

2.

When the boiler is connected to heating coils located in

air handling units where they may be exposed to refrig-

erated air circulation, the boiler piping system MUST
BE supplied with ow control valves or other automatic
means to prevent gravity circulation of the boiler water
during the cooling cycle.

Figure #5

Figure #6

BYPass PiPinG

3.

Hot water boilers installed above radiation level must be

provided with a low water cut-off device.

4.

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

circulation.

5.

Hot water boilers and system must be lled 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 t the system or
the condition of the installation. This method of piping,

however, is not typically required for baseboard heat-

ing systems. Typical installations where bypass piping is

used are as follows:

This method is used to protect boilers from conden-A.

sation forming due to low temperature return water.
Generally noticed in large converted gravity systems or

other large water volume systems. See

This method is used to protect systems using radiant B.

gure #6

.

panels and the material they are encased in from high
temperature supply water from the boiler. And protect

the boiler from condensate. See

gure #7

and

#8

.

Figure #7

MiXinG ValVE PiPinG

9

cONNEctiNG SUPPLY & REtURN PiPiNG

CIRCULATOR

VALVE

EXPANSION

TANK

VALVE

RETURN

SUPPLY

12"

MAX.

CIRCULATOR

FLOW

VALVE

SYSTEM

TEMPERATURE

GAUGE

"B"

"A"

SYSTEM

PRIMARY

6"

FEED

WATER

Figure #8

PRiMaRY sEConDaRY PiPinG wiTh BYPass

This method is used to protect boilers from condensate C.

forming as well as protecting the heating system from
high water temperatures, see

NOtE #1: When using bypass piping, adjust

gure #8

.

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.

Installation using circulators is shown in

7. gure #9

8. gure #10

Installation using zone valves is shown in

9.

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

.

.

10

cONNEctiNG SUPPLY & REtURN PiPiNG

TANK

SYSTEM

CIRCULATOR

CIRCULATOR

REDUCED PRESSURE
BACKFLOW PREVENTER

FLOW CONTROL

OR CHECK VALVE

OUTLET

HOT WATER

TRAP

THERMAL

WIRING FOR

THERMOSTAT/

PUMP CONTROL

INLET

COLD WATER

RELIEF VALVE

DRAIN COCK

6"

6"

WATER

FEED

PRESSURE
REDUCING

VALVE

GATE

VALVE

CIRCULATOR

DRAIN COCK

RELIEF VALVE

HOT WATER

OUTLET

THERMAL

TRAP

PUMP CONTROL

WIRING FOR

THERMOSTAT/

SYSTEM RETURN

PIPING

INLET

COLD WATER

VALVE

TANK ZONE

6"

6"

PRESSURE
REDUCING

VALVE

BACKFLOW PREVENTER

REDUCED PRESSURE

GATE VALVE

Figure #9

Figure #10

aLL iNStaLLatiONS OF BOiLERS aND VENtiNG SHOULD BE DONE ONLY BY a QUaLiFiED EXPERt aND
iN accORDaNcE WitH tHE aPPROPRiatE iNStaLLatiON 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.

WARNING

!

11

aPPLicaBLE FEDERaL cODES

NFPA 54/ANSI Z223.1, National Fuel Gas Code and NFPA/

ANSI 211, Chimneys, Fireplaces, Vents and Solid Fuel Burning
Appliances. These codes contain information on special gas
vents for Category II, III and IV appliances, vent sizing, location,
air space clearances to combustibles and safe installation
practices. The gas vent installer should be familiar with these

Federal Codes as well as Local Codes and Regulations.

GENERaL iNFORMatiON GaS VENtS aND

aPPLiaNcES:

By Federal Codes, gas appliances are categorized by the

pressure and temperature of the ue gas vented from the
appliance. Category I and II appliances are natural draft (draft
hood) vented, with high ue gas temperatures (Category I), and
low ue gas temperatures (Category II). Category III and IV
appliances are fan forced vents with high temperature (Category
III) and low temperature (Category IV) ue gasses. Appliance
efciency is directly related to ue gas temperature. Higher
efciency appliances remove more heat from the gas, so they

VENt SYStEM MODiFicatiON

will have lower temperature ue products. When ue gas
temperatures are lowered, corrosive condensates may form
in the gas vent or in the appliance. Condensates may form
in Category II, III, IV appliance vents, so special, corrosive
resistant venting systems are required for higher efciency

appliances.

WARNING

!

Vents for category i appliances may not be suitable
for use with category ii, iii, or iV appliances because
condensate may corrode the vent.

WARNING

!

Vents for category iii appliances may not be suitable

for use with Category I appliances because ue gas

temperatures may be too high.

When an existing boiler is removed from a common venting
system, the common venting system is likely to be too large
for the proper venting of the appliances remained connected
to it. If this situation occurs, the following test procedure must

be followed:

4.

5.

REMOVaL OF BOiLER FROM VENtiNG SYStEM

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.

6.

7.

Seal an unused opening in the common venting system.

1.

Visually inspect the venting system for proper size and

2.

horizontal pitch and determine there is no blockage or re-

striction, leakage, corrosion and other deciencies which

could cause an unsafe condition.

3.

Insofar as is practical, close all building doors and win­dows and all doors between the space in which the

appliances remaining connected to the common venting
system are located and other spaces of the building. Turn
on clothes dryers and any other appliance not connected
to the common venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts, so they
operate at maximum speed. Do not operate a summer
exhaust fan. Close replace dampers.

Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance
will operate continuously.

Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the ame of a
match or candle, or smoke from a cigarette, cigar or pipe.

After it has been determined that each appliance remain-

ing connected to a common venting system properly

vents when tested as outlined above, return doors, win-

dows, exhaust fans, replace dampers and any other gas

burning appliances to their previous condition of use.

Any improper operation of the common venting system
should be corrected so the installation conforms with

the latest revision of the National Fuel Gas Code, ANSI

Z223.1. When resizing any portion of the common venting
system, the common venting system should be resized to

approach the minimum size as determined using the ap-

propriate tables in the latest revision of the National Fuel
Gas Code, ANSI Z223.1.

12

cONNEctiNG GaS SERVicE

Connect gas service from meter to control assembly in

1.

accordance with ANSI Z223.1 and local codes or utility.
A ground joint union should be installed for easy removal
of gas control for servicing. A drip leg or trap must be
installed at the bottom of a vertical section of piping at the
inlet to the boiler. A pipe compound resistant to the action
of liquied petroleum gases must be used on all threaded
pipe connections. Check with the local utility for location

of manual shutoff valve if required. See

2.

The gas line should be of adequate size to prevent undue
pressure drop and never smaller than the pipe size of the
main gas control valve. See chart below.

Maximum Capacity of Pipe in Cubic Feet of

Gas Per Hour

(Gas pressure = 0.5 psig or less,

pre sure drop = .5 in.w/c)

Nomi-

nal Iron

Pipe

Size

10' 20' 30' 40' 60' 80' 100'
½" 175 120 97 82 66 57 50
¾" 360 250 200 170 138 118 103

1" 680 465 375 320 260 220 195

1¼" 1400 950 770 660 530 460 400

For additional information refer to the National Fuel
Gas Code Handbook, Latest Revision.

DO NOt USE aN OPEN FLaME.

Length of Pipe (Feet)

WARNING

!

gure #11

.

Figure #11

PRESSURE

MIN. SUPPLY 5" w.c. 11" w.c.

MAX. SUPPLY 14" w.c. 14" w.c.

MANIFOLD 3.5" w.c. 10.5" w.c.

NATURAL PROPANE

GAS

To check for leaks in gas piping, use a soap and water

3.

solution or other approved method.

4.

Disconnect the boiler from the gas supply piping system

during any pressure testing of the gas piping. After recon-

necting, leak test the gas connection and boiler piping
before placing the boiler back into operation.

13

ELEctRicaL WiRiNG

Electrical wiring must conform with the latest revision of the

National Electrical Code, ANSI / NFPA No. 70 and/or local

authority having jurisdiction.

When an external electrical source is utilized, the boiler,

1.

when installed, MUST BE electrically grounded in accor-

dance with these requirements.

2.

Install a fused disconnect switch between boiler and me­ter at a convenient location.

cOMPONENt aND WiRE cODiNG KEYS

The keys that follow pertain to the

tROL aND iNtERMittENt iGNitiON WiRiNG

diagrams.

COMPONENT KEy CODING

Thermostat (millivolt) TH-1
Thermostat (24 Volt) TH-2
Thermostat (Line Voltage) TH-3
Transformer (120V/24V 40VA) TR-1
Transformer (120V/24V 50VA) TR-2

24 Volt Gas Valve LGV
24 Volt Gas Valve LGV-1
Pressure Switch PS
Manual Reset Pressure Sw. MR-PS

Control Terminal

Relay Coil 1K
Relay Contacts 1K1
Relay Contacts 1K2
Limit Switch LS

Manual Switch MS
Circulator CIR

Energy Cut-Off ECO
Pilot Safety Coil PSC

Wire Connection

HOt WatER cON-

* NOT ALL COMPONENTS LISTED ARE USED IN ALL CON-

TROL SYSTEMS.

Hot water control and intermittent ignition wiring for boilers
with fail safe relay. See gure #12.

NOTES:
* Switches are shown in position during the heating

cycle.

* If any of the original wiring supplied with the boiler
is replaced it must be replaced with like wire size and
type of insulation or equivalent.

WIRING CODE KEy

LINE VOLTAGE BY FACTORY

LOW VOLTAGE BY FACTORY

LINE VOLTAGE BY INSTALLER

LOW VOLTAGE BY INSTALLER

Low Water Cut Off LWCO
Electric Water Feeder EWF
Power Generator PG
Roll-Out Switch RSW

14

PILOT

PILOT

ELEctRicaL WiRiNG

Figure #12

hoT waTER ConTRol anD inTERMiTTEnT iGniTion wiRinG

15

ELEctRicaL WiRiNG

tHERMOStat iNStaLLatiON

Thermostat should be installed on an inside wall about

1.

four feet above the oor.

2.

Never install a thermostat on an outside wall.

Check thermostat operation by raising and lowering ther-

3.

mostat setting as required to start and stop the burners.

4.

Instructions for the nal adjustment of the thermostat are

packaged with the thermostat (adjusting heating anticipa-

tor, calibration, etc.)

LiGHtiNG 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.

THINGS TO AVOID WHEN LOCATING THERMO-

STATS

DEaD SPOtS:

Corn e r s and alcoves Behind doors

cOLD SPOtS: HOt SPOtS:

Concealed pipes or

ducts

Stairwells - drafts

Unheated rooms on

other side of wall

Outside walls

CAUTION

!

Before operating, make certain the boiler and
system are full of water to minimum pressure
(this is usually 12 lbs. per square inch on most
systems) and system is vented of air. See the
operating and lighting instructions.

Concealed pipes

Fireplace

Direct sunlight

or chimney

TV sets

Radios

Lamps

Kitchens

FOR YOUR SaFEtY REaD BEFORE OPERatiNG

WARNING

!

If these instructions are not followed exactly, a
re or explosion may result causing property

damage, personal injury or loss of life.

This appliance is equipped with an ignition device A.

which automatically lights the pilot. Do not try to light
the pilot by hand.

BEFORE OPERATING smell all around the appli-B.

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

WHat tO DO iF YOU SMELL GaS

Do not try to light any appliance.•

Do not touch any electrical switch•

D• o not use any phone or mobile electronics in your
building.

Immediately call your gas supplier from a neighbor’s •

phone.

Follow the gas supplier’s instructions. •

If you cannot reach your gas supplier, call the re de-•

partment.

Use only your hand to move the system control C.

switch. Never use tools. If the switch will not move
by hand, don’t try to repair it, call a qualied service
technician. Force or attempted repair may result in a
re or explosion.

WARNING

!

Force or attempted repair may result in a

re or explosion.

Do not use this appliance if any part has been under D.

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

under water.

16

LiGHtiNG iNStRUctiONS

INLET OUTLET

LiGHtiNG PROcEDURE FOR BOiLER WitH

iNtERMittENt PiLOt SYStEM

StOP!

1.

tion manual.

2.

Set thermostat to lowest setting.

Turn off all electric power to the appliance.

3.

This appliance is equipped with an ignition device which

4.

automatically lights the burner. DO NOT try to light the
burner by hand.

5.

Turn the gas control knob clockwise

Figure #13

6.

Wait ve (5) minutes to clear out any gas. Then smell for
gas, including near the oor. If you smell gas,

Follow “What To Do If You Smell Gas” in the safety infor-

mation section. If you don’t smell gas, go on to the next

step.

7.

Turn the gas control knob counterclockwise

8.

Turn on all electrical power to the appliance.

Set the thermostat to desired setting.

9.

Read the safety information in the user’s informa-

to “OFF”. (See

)

StOP!

to “ON”.

cian or gas supplier.

tO tURN OFF GaS tO aPPLiaNcE

Set the thermostat to lowest setting.

1.

Turn off all electric power to the appliance if service is to

2.

be preformed.

3.

Turn gas control knob clockwise
Force.

to “OFF” Do Not

Figure #13

If the appliance will not operate, follow the instructions “To

10.

Turn Off Gas To Appliance” and call your service techni-

SEQUENcE OF OPERatiONS

ON a caLL FOR HEat:

The thermostat will actuate, completing the circuit be-

1.

tween terminals T and T.

2.

The R8222C relay coil will energize thus pulling in the
relay contacts.

3.

The circulator starts and power is switched to the limit.

If limit circuit is closed the venter motor and TF-2 trans-

former are energized.

4.

The venter motor starts and develops static pressure.

When the static pressure is reached the pressure switch

5.

pulls in completing the circuit between TF-2 and the inter-

mittent ignition control.

6.

The intermittent ignition control opens the pilot valve
and ignites pilot. After pilot is proven the main burner will

ignite.

7.

In the event the boiler water temperature exceeds the

high limit setting the power will be interrupted to the ven-

ter motor, and TF-2 thus interrupting power to the ignition
system. Power will remain off until the water temperature

drops below the high limit setting. The circulator will con-

tinue to operate under this condition until the thermostat is
satised.

8.

Should the air ow (static pressure) be interrupted (ex-

ample blocked ue, etc.), the pressure switch will sense a

drop in pressure, opening the circuit between the igni-

tion system and TF-2. The venter motor will continue to
operate until static pressure is reached or thermostat is
satised.

9.

In the event the ow of combustion products through
any part of the boiler ueway becomes blocked, a ame
safety roll-out switch will shut off the main burners. If this
condition occurs, do not attempt to place the boiler back

operation.

17

10.

When the thermostat is satised power is interrupted to
the relay coil and the relay drops out cutting power to the
circulator, venter motor, and TF-2.

GENERaL iNStRUctiON FOR SEaSONaL StaRtUP & MaiNtENaNcE

VENT PIPE

ELBOW

VENT SYSTEM FOR
LENGTHS 15' AND UNDER

VENT SYSTEM FOR
LENGTHS OVER 15'

CONDENSATE TRAP

ASSY. NOTE, NOT REQUIRED ON

MODELS DV125 THRU 200.

CONDENSATE DRAIN

It is suggested that a qualied service agency be employed to

make an annual inspection of the boiler and the heating sys-

tHE PROcEDURE FOR cLEaNiNG tHiS SYStEM

tem. They are experienced in making the inspection outlined

below.

In the event repairs or corrections are necessary they can
make the proper changes for safe operation of the boiler.

CAUTION

!

Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation.

FOLLOWS:

Remove tubing from condensate tee.A.
Empty all liquid from tubing.B.

Rinse tubing inside & out in a sink with water.C.
If tubing cannot be cleaned inside, the tubing should be D.

replaced with the same type and size of tubing.

Replace tubing as described inE.

with water.)

gure #14

. (Fill trap

Verify proper operation after service.

If the venter has oil cups, lubricate venter motor once a month

during the heating season with a few drops of non-detergent

motor oil (SAE 20 or 30). Replace the rubber plugs when
nished.

CAUTION

!

DO NOt OVER OiL.

BEGiNNiNG OF EacH HEatiNG SEaSON

Before seasonal start-up, it is highly advisable to have a

1.

certied service agency inspect the system:

Check the boiler for soot and scale build up in the ues. A.

Clean the burners.B.

Check the gas input rate to maintain high operating ef-C.

ciency.

2.

The service agency should make certain the system is
lled with water to minimum pressure (approximately 12
pounds per square inch) and open air vents (if used) to
expel any air that may have accumulated in the system.

7.

Visually inspect entire piping system and if any leaks F.

appear, have them repaired as soon as possible. DO
NOT use petroleum based stop leak compounds.

check venter assembly static pressure as fol-6.
lows:

With the boiler off, disconnect the white compression A.

tting on the pressure switch.

Connect a slope manometer to the compression tting B.

with additional tubing.
Turn the boiler on and read suction pressure on the C.

manometer. Reading should be negative (-) .55 ± .05
inches of water column or higher for the 50B thru 150B
and negative (-) .65 ± .05 inches of water column or

higher for the 200B.

If static pressures are not at the minimum allowable level
(listed above), check vent pipe for obstructions.

Figure #14

3.

Check automatic air vents for leakage.

Inspect venting system at the start of each heating sea-

4.

son. Check the pipe from the boiler for signs of deteriora-

tion and sagging joints. Repair if necessary. Remove the
vent pipe from the boiler and check for obstructions.

5.

Clean condensate tee & trap. Periodic cleaning of the

condensate collection system is required. When a con-

densate collection system is installed in a venting system,
it is recommended that the cleaning become a part of the

annual servicing.

18

GAS VALVE

ORIFICES

BURNERS

COMBUSTION

BURNER
(REMOVED)

BURNERS

GAS

VENT PIPE

CHAMBER

DOOR

VALVE

ADAPTER

ROLL-OUT SAFETY

BURNER

SWITCH

JACKET

FRONT
PANEL

BURNERS

ORIFICES

GAS VALVE

HOLD DOWN

BOLT

FLUE
COLLECTOR

VENTER
ASSEMBLY

A1795

GENERaL iNStRUctiON FOR SEaSONaL StaRt UP aND MaiNtENaNcE

The following procedure should be followed to clean and

8.

check the boiler ue passageways:

Remove the burners from the combustion chamber by A.

raising the burners up from the manifold orices and

pulling toward the front of the boiler. See

gure #15

Figure #15

Disconnect the white compression tting from the pres-D.
sure switch.

Disconnect venter wires from relay.E.

.

Remove the ue collector and venter from the boiler F.

castings by loosening the hold-down bolts located on

each side of the collector. See

gure #17

.

Figure #17

Disconnect the vent pipe from the vent adapter.B.
Remove the top jacket panel. See C.

Figure #16

Figure #16

.

Visually inspect the venter assembly for any unusual G.

wear or dirt build up. Clean with vacuum if necessary.

Place a sheet of heavy paper or similar material over H.

the bottom of the combustion chamber and brush down
the ue passageways. The soot and scale will collect
on the paper and is easily removed with the paper.

Vacuum out base and ueways and reassemble the I.

boiler in reverse order.

Seal ue collector and vent adapter with high tempera-J.

ture silicone. (+400°)

Start boiler to ensure proper operating condition.K.

9.

Keep the area around the boiler clean and free of com-

bustible materials such as gasoline, paints, paint thinner
and other such ammable vapors and liquids.

10.

The free ow of combustion and ventilating air to the
boiler and boiler room must not be restricted or blocked.

11.

Some circulators require periodic servicing. These circula-

tors usually have oil cups or openings at each end of
the motor and one for the shaft bearing. Put about one
teaspoon of SAE 20 or 30 non-detergent motor oil in each

19

IGNITION ELECTRODE

3/8” TO 1/2”

IN FLAME

GENERaL iNStRUctiON FOR SEaSONaL StaRt UP aND MaiNtENaNcE

INLET OUTLET

opening twice per year. DO NOT OVER OIL. Follow the
manufacturers instructions attached to the circulator.

When oil cups or holes are not provided, bearings are

either permanently lubricated or water lubricated.

12.

Visually check the main burners and pilot ame at the
start of each heating season and again midway through

the season.

Check the burner throats and burner orices for lint and A.
dust obstructions. See

gure #17

.

The main burner ame should have a well dened in-B.

ner blue mantel with a lighter blue outer mantel. See

gure #18

.

Figure #18

Turn inner screw (adjustment screw) clockwiseB. to
decrease and counterclockwise to increase the

pilot ame, see gure #20.

After adjustment, be sure to replace cover screw to C.

prevent possible gas leakage.
The main burners and the pilot burner should be D.

checked for signs of corrosion or scale build up.
Clean main burners and pilot burner with a steel bristle E.

brush.

cHEcK GaS iNPUt RatE tO BOiLER

Maximum permissible gas supply pressure must not be

1.

higher and minimum supply pressure must not be lower
than what is specied on the rating plate.

2.

To check for proper ow of natural gas to boiler using the
gas meter, proceed as follows:

Turn off the gas supply to all other appliances, except A.

the boiler.

With the boiler operating, determine the ow of gas B.

through the meter for two minutes and multiply by 30 to
get the hourly rate (in cubic feet).

The main burner ame should form a

sharp blue inner mantel with no yellow.

The pilot ame should envelop ⅜ to ½ inch of the tip of C.
the pilot sensing device. See

gure #19

Figure #19

Divide the input rate shown on the rating plate by the C.

heating value of the gas as obtained from the local gas
company. This will determine the number of cubic feet

of gas required per hour.

If minor adjustment is necessary, adjust the pressure D.

regulator on the combination gas control. Increase or

.

decrease manifold pressure to obtain gas input required

as described on the rating plate. To increase, turn the
regulator adjusting screw clockwise
clockwise

to decrease pressure, see Figure #20.

or counter-

The manifold pressures are taken at the outlet side of

the gas valve.
Relight all the other appliances turned off in step "a." E.

above. Be sure all pilot burners are operating.

Figure #20

Adjusting the pilot ame:

13.

Remove the pilot adjustment cover screw.A.

20

1

2

3

REPLacEMENt PaRtS

PiLOt

2

3

1

4

SPaRK PiLOt

item Part No. Description Qty.

5

1 109007296 PILOT BRACKET ASSEMBLY 1
2 HW-005.01 BRACKET SCREW 2
3 240007093 SPARK CABLE 1

4 14615005

PB-001.02 Natural Gas Q345A PILOT

5

240007096 LP Q345A Pilot

* Included with #3 - Pilot Tube Assembly Kit (above)

PILOT TUBING, 1/8" x 24"

1

1

ROLLOUt & SPiLL SWitcH

item # Description Part # Qty.

TEMP. SENSOR BRACKET 3262001

1

CONTROL-FIXED TEMPERATURE

2

THERMO (ROLLOUT SWITCH)

3

SCREW - #6 X ¼ HEX HD HW06501

The rollout switch is located on the base.
NOTE: The quantities above are for each switch.

AQ02101

1
1
2

21

1

2

3

4

5

6

7

BaSE

REPLacEMENt PaRtS

Item

#

BURNER TUBE 1 1/2"
BURNER TUBE 1 1/2"

1

BURNER TUBE 1 1/2"
BURNER TUBE 1 1/2"
BASE W/INSUL
BASE W/INSUL

2

BASE W/INSUL
BASE W/INSUL
BURNER DOOR ­BURNER DOOR -

3

BURNER DOOR ­BURNER DOOR ­MANIFOLD - -50 356-2-1.01
MANIFOLD - -100 356-2-1.02

4

MANIFOLD - -125 &150 356-2-1.03
MANIFOLD - -200 356-2-1.04

Description Part # Qty.

- -50

- -100 2

- -125 & 150 3

- -200 4

- -50

- -100

- -125 & 150

- -200

-50

-100

-125 & 150

-200

240005543

5611607
5611608
5611609

5611604
32512501
32523001
32523101
32523102

Item

#

1

1

1

1

5

SCREW 3/8" HEX HW005.01
GAS VALVE VR8204H-1006 - 50 - 150 SPARK

NAT

6

GAS VALVE VR8304H-4206 - - 200 SPARK NAT
GAS VALVE VR83043216 - -50 - 200 LP

ORIFICE 3.2mm - 50, 100, 150, 200 240007406
ORIFICE 2.9mm - 125 240007404

7

ORIFICE #47 LP - 50, 100, 150, 200 240007403
ORIFICE #49 LP - 125 240007402
Combustible Base Flooring - 50
Combustible Base Flooring - 100

NOT

Combustible Base Flooring - 125, 150 325-2-8.03

SHOWN

Combustible Base Flooring - 200 325-2-8.04

*

Orice Qty's per model: Model 50- qty 1. Model 100- qty 2. Model 125 & 150- qty

Description Part # Qty.

4

VG01101

VG01103
VG01104

1

*

325-2-8.01
325-2-8.02

3. Model 200- qty 4.

1

22

1

3

2

4

6

7

5

JacKEt

REPLacEMENt PaRtS

ITEM DESCRIPTION

1 PANEL - LEFT 50-200 3162702 1

PANEL - FRONT -50 315-2-19.01

2

3

4 PANEL - RIGHT -50-200 3162701 1

5

PANEL - FRONT -100 315-2-19.02
PANEL - FRONT -125 & 150 315-2-19.03
PANEL - FRONT -200 315-2-19.04
PANEL - BASE -50 315-2-12.01
PANEL - BASE -100 315-2-12.02
PANEL - BASE -125 & 150 315-2-12.03
PANEL - BASE -200 315-2-12.04

PANEL - SEPARATOR -50 31522401
PANEL - SEPARATOR -100 31522402
PANEL - SEPARATOR -125 & 150 31522403
PANEL - SEPARATOR -200 31522404

PART NUM-

BER

OTY.

1

1

1

23

HEat EXcHaNGER

1

2

3

5

4

7

8

6

9

REPLacEMENt PaRtS

Item

#

LEFT HAND SECTION 100-2-2.01 1

1

CENTER SECTION, -100
CENTER SECTION, -125 2

2

CENTER SECTION, -150 2
CENTER SECTION, -200 3

3

RIGHT SECTION 100-2-3.01 1
TIE ROD ¼ X 11½, -100 HW-011.01

4

TIE ROD 1/4X19.1/2 -200 HW-011.05

5

NUT 5/16-18 WISLOCK 6 1330001
PIPE FIT BUSH 3/4 X 1/4 NPT 1060002
PIPE-NPL 1.1/4X4.1/2 NPT 1310002 1
PUSH NIPPLE 2" MACH., -50
PUSH NIPPLE 2" MACH., -100 4

6

PUSH NIPPLE 2" MACH., -125 &150 6
PUSH NIPPLE 2" MACH., -200 8

BAFFLE -50 (2 per Flueway) 3461601 2
BAFFLE -100 (2 per Flueway)

9

BAFFLE -125 & 150 (2 per Flueway)
BAFFLE -200 (2 per Flueway)
WASH-5/16 FLAT STL ZP HW-008.01

7

NUT-1/4-20 HEX-STL ZP HW-003.02

8

DESCRIPTION Part Number Qty.

100-2-1.01

43300976

3472301

1

COMPLETE HEAT EXCHANGER ASSEMBLY

HEAT EXCHANGER 3 SECTION -100 100-2-7.01

2TIE ROD ¼ X 15½ -125 & 150 HW-011.03

6
1

2

4
6
8
4
2

HEAT EXCHANGER 4 SECTION -125 &150 100-2-7.02
HEAT EXCHANGER 5 SECTION -200 100-2-7.03
HEAT EXCHANGER 2 SECTION -50 100-2-7.06

24

PiPiNG & cONtROLS

3

4

5

7

8

9

10

11

12

6

2

1

REPLacEMENt PaRtS

ITEM DESCRIPTION P/N QTY.

1 HARNESS IGN/GV 36" 37413601 1
2 HARNESS - CIRCULATOR 72" 37519501 1
3 PIPE - NPL 1¼ X 4½ NPT 1 1310002 1
4 DRAIN - SHORT HW-016.03 1
5 PIPE - TEE 1¼ X ¾ X 1¼ 1510001 1
6 HARNESS- CONTROL/LIMIT 38" 37518901 1
7 GAUGE - THERALTIMETER 1260006 1
8 CONTROL L4080B AQ02201 1

9 WELL ¾" X 3" AQ-020.01 1
10 RELIEF VALVE 30# ¾" VR-001.01 1
11 PIPE - ELBOW ¾" 90° 1190001 1
12 PIPE - NPL ¾" X 4" 1310001 1

25

ELEctRicaL

4

5

1

6

8

9

7

2

3

REPLacEMENt PaRtS

ITEM DESCRIPTION P/N QTY.

1 CONTROL SUPPORT BRACKET 31522201 1
2 PLT SPARK CONTROL 14662070 1
3 WIRE ROLLOUT SWITCH 40" 37614501 1
4 TRANSFORMER - 40VA 550001339 2
5 CONTROL R8222C-1008 (RELAY) 1410001 1
6 9 TERM STRIP EF04001 1
7 SCREW 10-32X5/16 GREEN GROUND HW09001 1

PRESSURE SWITCH (FS6205A-2413) 50B - 150B SS00801 1

8

PRESSURE SWITCH (FS6273A-3065) 200B ONLY SS00802 1

9 HW TUBE SIL ORANGE 1/8ID HW09701 1

FULLY ASSEMBLED CONTROL BRACKET

CONTROL BRACKET SUB-ASSY 50B - 150B 31522901
CONTROL BRACKET SUB-ASSY 200B 31522902

(P/N 31522901 & 31522902 INCLUDE PART # 1-8 & ALL WIRING)

26

1

2

5

6

4

3

REPLacEMENt PaRtS

FLUE cOLLEctOR & VENtER cOMPONENtS

ITEM DESCRIPTION P/N QTY.

FLUE COLLECTOR -50 34524802

FLUE COLLECTOR -100 34524804

1

FLUE COLLECTOR -125 34524805

FLUE COLLECTOR -150 34524806

FLUE COLLECTOR -200 34524808

VENT ADAPTER -50, -100, & -125 345-2-7.01

2

VENT ADAPTER -150 & -200 345-2-7.02

3 VENTER MOUNTING PLATE -50 ONLY 34524902 1
4 HW SCR ¼ -20x ½ HW-005.01 5
5 VENTER -50–-200 DC00402 1
6 BOLT

5

⁄

"-18 x 1½ 14695039 2

16

1

1

27

P.O. Box 4729

Utica, NY 13504-4729