Utica Boilers JE Operation and Installation Manual

JE Series

Cast Iron Commercial

Natural Gas Steam Boiler

INSTALL ATION, OPER ATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N# 240010349, Rev. B [02/2014]

CAST IRON HOT WATER OR STEAM BOILER

Contents

Ratings And Capacities .................................................................................................... 3

Shipment Check List ....................................................................................................... 4

Accessory Carton Check List............................................................................................. 5

Safety Information ......................................................................................................... 6

Before Installing ............................................................................................................. 7

Ventilation And Combustion Air........................................................................................8

Vent Installation ........................................................................................................... 10

Boiler Dimensions ......................................................................................................... 13

Installation – Assembly ................................................................................................. 14

Tappings ..................................................................................................................... 24

Boiler Piping ............................................................................................................... 25

Connecting Gas Service ................................................................................................. 28

Electrical Wiring ........................................................................................................... 29

Wiring Diagrams ........................................................................................................... 30

Operation And Service ................................................................................................... 31

Checking And Adjusting ................................................................................................. 33

Cleaning And Maintenance ............................................................................................. 34

Pilot System Troubleshooting Table ................................................................................. 35

SAFETY SYMBOLS

!

DANGER

Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury.

!

WARNING

Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.

!

CAUTION

Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.

Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.

KEEP THIS MANUAL NEAR BOILER.

RETAIN FOR FUTURE REFERENCE.

WARNING

!

NOTICE

Indicates information which should be followed to
ensure proper installation and operation.

2

RATINGS AND CAPACITIES

Ratings and Capacities - Chart 1

Input/Size

(Mbh)

300

400

500

600

700

800

900

1000

1100

1200

1300

Output (1)

Gross

Output

Mbh

233

310

388

465

543

620

698

775

853

930

1008

Net AHRI

Ratings (2)

Steam

(Sq

Ft)

729

971

1213

1454

1696

1938

2183

2421

2667

2908

3150

Steam

Mbh

175

233

291

349

407

465

524

581

640

698

756

Flue Outlet No. &

8” 10” 12” I.D. x Ht.

Size

1

1

1

2

1 1

2

1 1

2

1

2

3

1

2

Chimney

Size (6)

8”x20’

10”x20’

12”x20’

12”x20’

12”x20’

14”x20’

14”x20’

14”x20’

16”x20’

16”x20’

16”x20’

Flue

Collector

Size to

Chimney

8

10

12

12

12

14

14

14

16

16

16

Horse-

power

Gross

Output

(4)

6.96

9.25

11.58

13.88

16.21

18.51

20.84

23.13

25.46

27.76

30.09

Therm.

Eff.

77.0

77.0

77.0

1400

1500

1085

1163

3392

3633

814

872

1

2

3

18”x20’

18”x20

18

18

32.39

34.72

1) Ratings are at sea level to 2,000 feet. For altitudes above 2,000 feet, reduce all ratings 4% for each 1,000 feet above
sea level

2) Net steam ratings based on an allowance of 1.333 (300-1500). Contact Technical Support before selecting boiler for
installations having unusual piping and pick-up factors, such as intermittent system operations, extensive piping systems, etc.

3) Ratings in square feet are computed at 240 Btuh/square foot for steam boilers.

4) Ratings based on 33,500 Btuh per horsepower.

5) Pressure drop based on given ow from single outlet and returning to single inlet at the opposite end of the boiler.

6) Chimney sizes shown are one option based on a typical venting system as shown in Figure 6, and sized according to the National
Fuel Gas Code, assuming Type B double wall vent and vent connectors, Other venting system designs are acceptable as shown on
Flue Connection And Venting section of this manual. For further chimney design and sizing information, consult the National
Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision, or ASHRAE HVAC Systems and Equipment Handbook, Chimney, Gas Vent, and
Fireplace Systems, or the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances. NFPA 211. Follow standard
engineering practice.

3

END

BASE

*****

END

****

JACKET

**

PANEL

CARTON

PANEL

CARTON

***

TRIM

STEAM

CARTON

LESS LOW

1

ITEM #

550002860

1

ITEM #

550002871

1

CARTON

ACCESSORY

WATER

CUTOFF

1

1

1

1

1

1

41200066

SHIPMENT CHECK LIST

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

41200067

41200068

1

1

1

1

1

1

41200069

1

1

1

1

1

1

**

TRIM

STEAM

CARTON

500

400

*COMPONENT CART.

300

MODEL

KIT #

550002863

KIT #

550002862

KIT #

550002861

RIGHT

41154050

INNER

SECTIONS

41154052

-

-

1

1

2

(SA-1)

41200061

-

1

-

1

-

-

1

1

3

4

(SA-2)

41200062

-

-

-

1

2

1

1

1

5

6

-

2

-

1

7

(SA-3)

41200063

1

1

-

1

8

(SA-4)

41200064

-

2

1

1

10

-

3

-

1

11

2

-

1

1

12

2

1

-

1

13

3

-

-

1

14

2

-

-

1

9

For further component information see Parts, Kits and Optional Accessories Manual provide

with your boiler see pages listed.

* SEE PAGE 8 - COMPONENT CARTON PARTS LIST

** SEE PAGE 7 - STEAM CARTON PARTS LIST

*** SEE PAGE 3 - ACCESSORY CARTON PARTS LIST

**** SEE PAGE 8 - JACKET END PANEL CARTON PARTS LIST

***** SEE PAGE 4 - BASE PANEL CARTON PARTS LIST

LEFT

41154051

Model

1

300

1

400

1

500

1

600

1

700

1

800

1

900

1

1000

1

1100

1

1200

1

1300

1

1400

1

1500

4

ACCESSORY CARTON CHECK LIST

ACCESSORY CARTON

BOILER MODEL NUMBERS AND QUANTITIES

PARTS

DESCRIPTION PART NO.

COMPLETE ACCY CRTN #

4” Push Nipples 43300977 6 8 10 12 14 16 18 20 22 24 26 28 30

5/8” - 11NC x 7
Stud

5/8” - 11NC Hex
Nut

5/8” Flat Washer 14695306 12 16 20 24 28 32 36 40 44

Non-Asbestos
Furnace Cement

- Pint

FB-1 Fitting Bag 41200051 1 1 1 - - - - - - - - - -

FB-2 Fitting Bag 41200052 - - - 1 1 1 1 1 - - - - -

FB-3 Fitting Bag 41200053 - - - - - - - - 1 1 1 1 1

3/4” Drain Valve 14622001 1 1 1 1 1 1 1 1 1 1 1 1 1

Nipple Paste ­4oz.

14695304 6 8 10 12 14 16 18 20 22 24 26 28 30

1330005 12 16 20 24 28 32 36 40 44 48 52 56 60

1440001 2 2 2 2 2 2 2 2 2 2 2 2 2

14691302 1 1 1 1 1 1 1 1 1 1 1 1 1

300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500

48 52 56 60

1” Sq. Head Plugs 1395004 4 4 4 4 4 4 4 4 4 4 4 4 4

Junction Box
Assembly 1-3
Base

Hercules Grrip 1/4
Pint

550002870 1 1 1 1 1 1 1 1 1 1 1 1 1

14691302 1 1 1 1 1 1 1 2 2 2 2 2 2

5

SAFETY INFORMATION

Safety Information

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

When Your Boiler Arrives

When boiler arrives be sure to save and refer to
instructions.

WARNING

!

Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.

WARNING

!

Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors

and liquids.
DO NOT obstruct air openings to the boiler room.

Modication, substitution or elimination of factory
equipped, supplied or specied components may

result in personal injury or loss of life.
TO THE OWNER - Installation and service of this

boiler must be performed by a qualied installer.

TO THE INSTALLER - Leave all instructions with
boiler for future reference.

When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.

1.

Never test for leaks with an open ame. Use soap suds

to check all connections. This will avoid any possibility

of re or explosion.

2.

Boiler is congured for operation with natural gas.
Over-ring will result in premature failure of boiler

sections and cause dangerous operation. Verify there is
adequate gas supply piping.

3.

Never vent this boiler into enclosed space. Always
connect boiler to chimney and vent to outside. Never
vent to another room or inside abuilding.

4.

Verify there is adequate air supply for complete
combustion.

5.

Follow regular service and maintenance schedule for

efcient and safe operation.

Inspect each item received for visible damage. If any
parts are damaged, report this to freight company
immediately and request them to call and make
inspection before you make any installation. Have
inspector prepare a signed report. Send copy of
report to manufacturer.

We must have the signed inspection report of the
freight company to prove their liability.

Read these instructions carefully before beginning
the installation to be sure all packages have been
received. It is recommended that you follow the
step-by-step instructions for best assembly results.
Before discarding any packing material carefully
examine for loose parts. Also store all parts received
where they will not be lost or damaged.

Codes Governing Installation

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/NFPA54.

Where required by the authority having jurisdiction, the
installation must conform to the standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1. Additional controls and safety
devices are required for CSD-1.

Installation

Boiler is designed to provide wide heating capacity range
with multiple burner modules, each equipped with its own
set of controls. For purposes of orientation, gas manifold
location is considered the front. Instructions are written
for assembly of boiler starting with left side and working to
right side.

!

WARNING

Fire hazard. Do not install boiler on non-combustible

ooring such as carpeting or wood ooring. Failure

to follow these instructions could result in death or
serious injury.

6.

DO NOT install boiler on non-combustible ooring such
as carpeting or wood ooring.

6

BEFORE INSTALLING

Boiler Location

Locate boiler on level, non-combustible foundation as near

to chimney or ue as possible. Allow 24 inches at front and

sides of boiler for servicing and cleaning. When installed in
utility room, the door should be wide enough to allow the
largest boiler parts to enter, or permit replacement of any
other appliance in the same room.
Installing contractor must provide ventilated
foundation for boiler when installing:

• Over a room

• Over electrical wiring or cables of any kind

• If concrete oor is not cured or water is
channeled under concrete oor

Minimum Vent Pipe Clearance

If the vent pipe must go through a crawl space, double
wall vent pipe should be used. Where vent passes through
a combustible wall or partition, use a ventilated metal
thimble. The thimble should be 4 inches larger in diameter
than vent pipe. If boiler is installed with single wall
galvanized type vent pipe, it must have 6 inches clearance
between its surface and any combustible material. If

UL listed type B (insulated) vent pipe is used, clearance

between it and combustible material to be as listed by pipe
manufacturer.

Fire hazard. Do not install boiler on combustible

ooring such as carpeting or wood ooring. Failure

to follow these instructions could result in death or

Combustion Air

Provide combustion and ventilation air in accordance
with the section “Air for Combustion and Ventilation”, of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or
applicable provisions of the local building codes.

Chimney And Vent Pipe Connection

This is a very important part of the heating system. It must
be clean, the right size, properly constructed and in Good
Condition. No boiler can function properly with a bad

chimney. See Pages 8-12 for specic venting instructions.

Flue pipe should be same size as draft hood outlet from
boiler to ue collector. See Chart 1 for Typical Chimney Size.
Maintain a minimum upward slope of 1/4 inch per linear foot
from boiler to the chimney. Fasten joints together with sheet
metal screws to prevent sagging.

serious injury.

!

WARNING

CHART 2

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY,

MINIMUM CLEARANCES TO

COMBUSTIBLE CONSTRUCTION

Inputs of

400 MBH or

less

Top 52” 52”

Front 18” 18”

Flue Collector 6 “ 6”

Rear 18” 24”

Sides 18” 24”

Steam/Water

Piping

Greater clearances (24”) for access should supersede

re protection clearances.

1” 1”

Inputs over

400 MBH

7

VENTILATION AND COMBUSTION AIR

WARNING

!

Asphyxiation hazard. Ensure enough air is available
for proper combustion, avoiding hazard due to lack
of oxygen.

!

WARNING

Air openings to combustion area shall not be
obstructed. Follow Chart 3 to insure adequate
combustion air is maintained.

COMBUSTION AIR REQUIREMENTS –

(MINIMUM SQUARE INCHES OPENING)

*UNCONFINED AREA **CONFINED AREA

MODEL

NUMBER

300 1 75 300 75 150

400 1 100 400 100 200

500 1 125 500 125 250

600 2 150 600 150 300

700 2 175 700 175 350

800 2 200 800 200 400

900 2 225 900 225 450

1000 2 250 1000 250 500

1100 3 275 1100 275 550

1200 3 300 1200 300 600

1300 3 325 1300 325 650

1400 3 350 1400 350 700

1500 3 375 1500 375 750

* 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).

BOILER

MODULES

OUTSIDE

COMBUSTION

AIR 1 SQ. IN

/4000 Btu/hr

(SEE FIG. 2)

INSIDE

COMBUSTION

AIR 1 SQ. IN.

/1000 Btu/hr

(SEE FIG. 1)

Chart #3

OUTSIDE COMBUSTION AIR

HORZ.

VERT. DUCTS

1 SQ. IN.

/4000 Btu/hr

DUCTS

1 SQ. IN.

/2000 Btu/

hr

8

VENTILATION AND COMBUSTION AIR

Figure 1 Figure 2

Combustion

Air

Openings

Vent-Piping

Combustion Air supplied from

inside the building

Combustion Air

Openings with

Motorized Dampers

Vent-Piping

Combustion Air supplied from

outside the building

Important Vent-Piping Note: Sloped vent pipe at
least 1/4” for every 1’ to the vent terminal.

1.

Provide combustion and ventilation air in accordance
with the section “Air for Combustion and Ventilation”,
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
or applicable provisions of the local building codes.

2.

Boiler is located in unconned space in building or

conventional construction frame, masonry or metal

building, inltration normally is adequate to provide air

for combustion and ventilation. However, if equipment
is located in building of tight construction (See National
Fuel Gas Code, ANSI Z223.1), boiler area should be

considered as conned space. If there is any doubt,

install air supply provisions in accordance with latest
revision of National Fuel Gas Code.

3.

Boiler is installed in unconned space, in building of

tight construction, air for combustion and ventilation
must be obtained from outdoors or from spaces freely
communicating with outdoors. Permanent opening
or openings having 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 outdoors and shall have
same cross-sectional area of openings to which they
are connected.

4.

When air for combustion and ventilation is from inside

buildings, conned space shall be provided with two

permanent openings, one starting 12 inches from top
and one 12 inches from bottom of enclosed space. Each
opening shall have minimum free area of 1 square inch
per one thousand (1000) Btu per hour of total input
rating of all appliances in enclosed space, but must
not be less than one hundred (100) square inches.
Openings must freely communicate directly with other

spaces of sufcient volume so combined volume of all
spaces meets criteria for unconned space. Figure 1.

5.

When boiler is installed in conned space and all
air is provided from outdoors conned space shall

be provided with one or two permanent openings
according to methods A or B (see page 10). When
ducts are used, they shall be of same cross sectional
area as free area of area of openings to which they
connect. Minimum dimension of rectangular air ducts
shall be not less than 3 x 3 inches or 9 square inches.

9

VENTILATION AND COMBUSTION AIR

A. When installing two openings, one must commence

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

1) When directly communicating with outdoors,
each opening shall have minimum free area of
1 square inch per 4,000 Btu per hour of total
input rating of all equipment in enclosure. Refer
to Figure 2 on previous page.

2) When communicating with outdoors by
means of vertical ducts, each opening shall
have minimum free area 1 square inch per
4,000 Btu per hour of total input rating of all
appliances in the enclosed space.

3) If horizontal ducts are used, each opening
and duct shall have minimum free area 1
square inch per 2,000 Btu per hour of total
input rating of all appliances in the enclosed
space.

6. In calculating free area using louvers, grilles or

B. One permanent opening, commencing within 12

inches of top of enclosure, shall be permitted where
equipment has clearances of at least 1 inch from
sides, 1 inch from back, and 6 inches from front
of boiler. Opening shall directly communicate with
outdoors or shall communicate through vertical
or horizontal duct to outdoors or spaces (crawl
or attic) that freely communicate with outdoors.
Openings must have minimum free area of 1
square inch per 3000 Btu per hour of total input
rating of all equipment located in enclosure. Free
area must be no less than sum of areas of all vent

connectors in conned space.

screens for above, consideration shall be given
to their blocking effect. Screens used shall not be
smaller than 1/4 inch mesh. If free area through
design of louver or grill is known, it should be used
in calculating size opening required to provide free

area specied. If design and free area is not known,

it may be assumed that wood louvers will have 20­25% free area and metal louvers and grilles will
have 60-75% free area. Louvers and grilles should

be xed in open position or interlocked with boiler

so they are opened automatically during boiler
operation.

VENT INSTALLATION

WARNING

!

Vent connectors serving appliances vented by
natural draft shall not be connected into any
portion of mechanical draft systems operating
under positive pressure.

1.

The vent pipe must slope upward from the boiler
not less than 1/4” for every 1’ to the vent terminal.

Figures 1 & 2.

2.

Horizontal portions of the venting system shall be
supported rigidly every 5 feet and at the elbows. No
portion of the vent pipe should have dips or sags.

Flue Connection And Venting

Vent installations shall be in accordance with “Venting of
Equipment”, of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54, or applicable provisions of the local building
codes.

1.

Consult dimensional drawing for number and size of

ue pipes required for each size boiler.

2.

Maintain minimum upward slope of 1/4 inch per linear
foot from the boiler to chimney.

3.

Run ue pipe directly as possible. Keep turns to a
minimum. Insert ue pipe into, but not beyond, inside

wall of chimney. Do not connect into a chimney serving

an open replace.

4.

Insulate ue pipe where it passes near combustible

material.

5.

Rigidly support pipe with hangers and straps.

6.

Extend chimneys at least 2 feet above any object
within radius of 15 feet, including roof.

7.

Install hood on all ue pipes which extend through roof.

In most locations, venting of boiler relies on natural
draft. In as much as energy available from natural
draft is quite low, serious thought should be given to
vent system design, i.e., adequate size, use of gradual
transitions, tees, elbows, etc., close proximity of boiler
and chimney. On all boilers, vertical risers must be at
least as large as vent openings on draft-hood.

manufacturer makes no specic recommendations

regarding application of draft inducers that may be
used with this boiler. If draft inducer is used, it is up to
installing contractor and draft inducer manufacturer to
determine proper application.

Boiler

10

VENT INSTALLATION

Flue Connection And Venting - Continued

Simple vent system consists of 6-foot minimum vertical

Figure 3

rise immediately off draft-hood, as shown in Figure 3.

Terminate this vertical ue above building roof with suitable

rain cap at least 2 feet above surrounding obstructions,
i.e., parapets, adjacent buildings, penthouses, etc. This
type of vent system applies to single draft-hood boilers
ONLY, and has limited practical use, because it is restricted
to single-story boiler rooms and because of problems

encountered in roof ashing.

Vertical venting system shown in Figure 3 cannot be used
on multiple-base boilers because of physical interference of
multiple rain caps.

IMPORTANT: Extend chimneys at least 2 feet above any

For multiple-base boilers, pant leg venting system shown in

object within radius of 15 feet, including roof.

Figure 4 can be applied, if desired.

Vent system shown in Figure 5 is commonly used. With

Figure 5

vent diameters sized to match ue outlets, minimum

vertical rise of 4 feet above draft-hood must be maintained
for proper operation. Refer to Chart 1 for typical chimney
sizes. Requirements for this type of system are: an
adequately sized chimney, adequate combustion air, and
outlet end of horizontal run must be no more than 6 feet
from chimney with no more than one 90° elbow in this run
as shown.

For installations where required minimum 4-foot vertical
rise cannot be maintained, diameter of horizontal run must
be increased one inch for each foot of riser reduction. This
procedure will reduce resistance of system, and if chimney
is adequate boiler will vent properly.

IMPORTANT: Extend chimneys at least 2 feet above any

object within radius of 15 feet, including roof.

Figure 4

IMPORTANT: Extend chimneys at least 2 feet above any

object within radius of 15 feet, including roof.

11

VENT INSTALLATION

Figure 6

Bafe Size (Inches)

Riser 8 10 12

A 6 8 10

IMPORTANT: Extend chimneys at least 2 feet above any

object within radius of 15 feet, including roof.

Shown is suggested size of xed
bafe for different size risers.

Flue Connection And Venting - Continued
In certain cases where these short rises of less than 4

feet have been used, spillage of combustion products has
occurred at the draft-hoods farthest from the chimney.
Assuming the chimney is adequately sized, one acceptable
method to correct this spillage problem is to permanently

bafe the riser(s) closest to the chimney to reduce the

excess of room air entering those draft-hoods. DO NOT

BAFFLE ENOUGH TO CAUSE SPILLAGE. The use of xed
bafes in the short risers above the boiler draft-hood are

acceptable as spelled out in American National Standard
NFPA 54/ANSI Z223.1 National Fuel Gas Code, latest
revision.

Fabricate these xed bafes, using 20-gauge steel. See
Figure #6. Permanently attach the bafe to the inside of

the riser(s). Trial and error will dictate the degree to which
each should be positioned to avoid draft-hood spillage
at the far end of the boiler. Be careful to avoid bending

the xed bafe so it will obstruct the ue gas ow in the

horizontal collector.

Removing Existing Boiler From Common Venting
System

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

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

1.

Seal any unused openings in the common venting
system.

2.

Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or

restriction, 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 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 replace dampers.

4.

Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.

5.

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.

6.

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, replace dampers and any other gas-burning

appliance to their previous conditions of use.

7.

Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
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
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.

12

BOILER DIMENSIONS

Front View

Supply

1

2

3

AA

A

Top View

D E

C

Return

Supply Supply

Left Side View

Supply

Water Line

38”

29½”

Floor Line

F

Flue Outlets

Return

ALL SUPPLY AND RETURN

CONNECTIONS ARE 4 INCH

Chart 4

Boiler

Model

No.

300
400

500

600
700
800
900

1000

1100
1200
1300
1400
1500

Water

Content in

Gallons

20
25
30

35
40
45
50
55

60
65
70
75
80

Shipping

Weight

Lbs.

922

1133

1344

1555
1766
1977
2188
2399

2610
2821
3032
3243
3454

A Jacket

Width
L to R

20 3/4

25

29 1/4

33 1/2
37 3/4

42

46 1/2

50

54 3/4

59
63 1/4
67 1/2
71 3/4

* Note - See page 14 Base Assembly

AA

Base &

Battery

Length

16 3/4

21

25 1/4

29 1/2
34 3/4

38
42 1/4
46 1/2

50 3/4

55
59 1/4
63 1/2
67 3/4

C D E F

10 3/8
12 1/2
14 5/8

10 3/8
10 3/8
12 1/2
12 1/2
14 5/8

10 3/8
12 1/2
10 3/8
12 1/2
14 5/8

–
–
–

12 3/4
14 7/8

17
19 1/8
21 1/4

14 7/8

17

17
19 1/8
21 1/4

–
–
–

–
–
–
–
–

17

17
21 1/4
21 1/4
21 1/4

10 3/8
12 1/2
14 5/8

10 3/8
12 1/2
12 1/2
14 5/8
14 5/8

12 1/2
12 1/2
14 5/8
14 5/8
14 5/8

*Boiler Modules

*1 *2 *3

300
400
500

300
300
400
400
500

300
400
300
400
500

x
x
x

300
400
400
500
500

400
400
500
500
500

400
400
500
500
500

x
x
x

x
x
x
x
x

13

INSTALLATION – ASSEMBLY

Base Assembly

300, 400 and 500 boilers are the basic models.

• 300 model has (6) burners

• 400 model has (8) burners

• 500 model has (10) burners

Combinations of basic models are used to assemble 600
through 1500 models.

Refer to Chart 3 for proper order of assembly. When two or
more bases are used to assemble boiler, verify tops of bases
are even.

1.

Fasten bases together with 5/16 cap bolts and nuts.

2.

Insert two bolts in front posts and two in rear posts as
shown in Figure 7A .

3.

After bases are fastened, install base end panels.
Install end panels before assembling sections. See

Figure 7B.

NOTICE

Figure 7A

Figure #7A

Figure 7B

Bolts with nuts in
the front and rear
posts

Verify bases are level after assembly.

Section Assembly

1.

Start sections from left or right end of base.

2.

Place end section on base with center-line of section
directly over joint of base end closure.

3.

With boilers having two or more bases, as you progress
be sure parting line (center-line of section) of intermediate

sections fall on junction of two bases. See Figure 8.

Figure 8

Alignment
of section
along side

Note: First

Section Alignment

is critical. Use side

of base to align

rst section. Do

not allow side to

overhang base.

14

INSTALLATION – ASSEMBLY

1.

When starting section assembly, clean nipples and
nipple ports.

2.

Coat nipples and nipple ports with Hercules Grrip or
other good sealant. See Figure 9.

3.

Place nipples in ports. Take care to seat them
squarely to prevent cocking. Figure 10.

4.

When pulling sections together with tie rods, insert
tie rods in holes nearest to nipple ports. Move tie rods
to proper location, if necessary, only after sections are
fully pulled together. See insert Figure 11.

Figure 9

Figure 10

5.

Oil or lubricate threads, insert rods in lugs with
washers under nuts and tighten uniformly and
evenly so that sections are pulled parallel as they go
together. When all sections are pulled up, locate tie rods
in alternating pairs of upper and lower holes between
adjacent sections. See Figure 11.

6.

Be sure both ends of completed section assembly are
resting evenly on both ends of base.

7.

Apply furnace cement at joints of sections front, top
and back. Apply furnace cement where sections join
the base. See Figure 12.

8.

Place necessary plugs and control wells in correct
locations. See Figure 31 page 24.

A. Plug all other tappings, leaving air vent in top of

one of end sections, and connect water.

B. Fill boiler with water until it runs out air vent. See

Figure 31 port D page 24.

C. Hydrostatically test boiler in accordance with

applicable codes.
D. Check for leaks before continuing with assembly.
E. Drain and remove unnecessary plugs.

Figure 11

Figure 12

Apply non-asbestos furnace cement to joints on all sides of boiler.

15

INSTALLATION – ASSEMBLY

Attaching Draft Hoods

1.

Attach draft hoods to boiler sections after applying
boiler Hercules Grrip to top of boiler sections where
hoods and sections meet.

2.

Use J-bolts to attach front of draft hoods to slots in
section anges. See Figure 13.

Figure 13

Draft Hood

Draft hood notched
to t over sections

J-bolt & nut
attach to front
of hood

Draft hood
clean-out
covers

16

INSTALLATION – ASSEMBLY

Installing Boiler Jacket Panels

NOTICE

Start jacket assembly at left side.

1.

Attach lower jacket end panel (left) to two Z-bars on
base end closures through two slotted holes on bottom

of jacket end panel. Use (2) #10 x ½” screws. See

Figure 14.

2.

Attach middle jacket end panel (left) to lower jacket
end panel with middle laying over lower. Line up holes.

Use (5) #10 x ½” screws. See Figure 15.

Figure 14

Figure 15

3.

Attach upper jacket end panel (left) to middle jacket
end panel with upper behind middle. Line up holes.

Use (6) #10 x ½” screws. Ensure bare metal plate is

inserted between casting ridge and draft hood. This
holds panel in place. See Figure 16.

Figure 16

17

INSTALLATION – ASSEMBLY

4.

Position top/front intermediate panel so back edge of top
hangs on adjustable clips on front of draft hood(s);

A. Left edge hangs on bracket on left upper jacket end

panel,

B. Right edge with integral bracket hangs on tie

rod(s).

See

Figure 17.

Figure 17

Adjustable Clips

Bracket

Installed

Front Jacket Panel

Front Jacket

Panel

Right Edge

Integral
Bracket

5.

Attach top/front intermediate panel to lower base

brackets through four slotted holes in panel. Use (4)

#10 x ½” screws. See Figure 18.

6.

On multiple base boilers, each additional top/front
intermediate panel attaches in same way (working your
way from left to right). Figure 18.

Figure 18

18

INSTALLATION – ASSEMBLY

NOTICE

Manufacture recommends assembling jacket panels
after piping is completed. Skip step 7 proceed to
step 8.

7.

Attach upper jacket end panel (right) so left edge
hangs on bracket on top/front intermediate panel.
Insert bare metal plate in same manner as left panel.
See Figure 19.

A. Attach side panel to base bracket through to slotted

holes. See Figure 20

Figure 19

Figure 20

Figure 21

B. For added support attach side panel to draft hood.

A

B

19

INSTALLATION – ASSEMBLY

See Figure 21.

If boiler piping is preassembled jacket can be assembled as
follows. See Figures 22A and 22B.

8.

Attach middle jacket end panel (right) to upper jacket
end panel with middle laying over upper. Line up holes.

Use (6) #10 x ½” screws. See Figure 22A.

9.

Attach lower jacket end panel (right) to middle jacket

end panel with lower behind middle. Line up holes. Use

(5) #10 x ½” screws.

10.

Attach lower jacket end panel to two Z-bars on base
end closures through two slotted holes on bottom

of jacket end panel. Use (2) #10 x ½” screws. See

Figure 22B.

Figure 22A

Figure 22B

11.

Position top of rear jacket panel(s) to draft hood bafe
ange. Secure with (2) #10 x ½” screws. Secure bottom

of rear jacket panel(s) to bracket(s) on boiler base using
(2) #10 x ½” screws. See Figure 23.

Figure 23

20

INSTALLATION – ASSEMBLY

12.

Attach burner door knobs with #8-32 x ¼” screws and
#8-32 hex nuts.

13.

Slide bottom of lower access door(s) in slots on top of
manifold brackets. See Figure 24.

14.

Position control access jacket panel(s) so tabs slide into
slots on top/front intermediate jacket panel(s).

15.

Attach control access jacket panel to front jacket. Use

(2) #10 x ½” screws. See Figure 25.

16.

Each boiler base includes:

• Factory installed lighting Instruction Labels.

• Factory installed Data plate indicating required gas
type, ring rate, and gas pressure for that base.

These plates are located on Jacket Top/Front Panels.

• Field installed rating plate showing total Input and
Output Ratings. Rating plate is shipped in AC Carton
and is to be mounted on side Jacket End Panel by
installing contractor.

Figure 24

Figure 25

17.

Attach any Local Code Label, not provided by
manufacturer, to boiler.

Figure 26

NOTE: Attachment of control access jacket panel can
wait until controls have been mounted to front jacket
panel.

21

INSTALLATION – ASSEMBLY

Control Mounting And Installation

Electrical controls, J-box, etc. can be mounted on either left
or right jacket end panel.

Boiler safeties (LWCO, etc.) and respective piping must be
mounted on opposite end of boiler electrical controls.

1.

Attach J-box assembly to jacket end panel. Align with

holes in end panel. Use (4) #10 x ½” screws. See

Figure 27.

2.

Attach control panel to front jacket panel align with

predrilled holes. Use (4) #10 x ½” screws. Secure

harness to control panel with zip-ties. Attach wire clips
to side and front panels (3). Route wires through clips.
See Figure 28A.

Figure 28A

Figure 27

CLIPCLIP

3.

Orient harness of control panel assembly so correct
(female) plug is toward J-box and will connect to J-box
harness. See Figure 28A.

4.

Connect plugs on harnesses. See Figure 28B.

Figure 28B

CLIP

22

INSTALLATION – ASSEMBLY

5.

Connect plugs on harnesses. See Figure 29.

6.

On multiple base boilers, mount remaining control
panels to intermediate jacket panels following steps 4
& 5.

7.

On each base, connect gas valve harness. Refer to
Wiring Diagram page 30.

Figure 29

8.

Connect pilot spark wire after control panel installation.
See Figure 30.

Figure 30

23

TAPPINGS

Figure 31 shows end section and provided tappings.
Tappings are same in both right and left end sections.

OPENING SIZE STEAM

A 4” Supply and Return

B ½”

C ¾” Drain, Left End

C ¾” Drain, Right End

D ½” Plugged

E 1” Accessories

*F 1” Safety Valve

G ¾”

*If using opening F for other than Safety Valve
or Safety Relief Valve, or Safety/Relief valve
is larger than 1”, Install Safety/Relief Valve in
Header Piping as near boiler as possible.

BOILER TRIM

Following controls are supplied as standard
equipment. Details of their function and operation
will be found in section on Checking and Adjustments
page 33.

Primary LWCO and Gauge
Glass Set

Plugged or Electronic (Probe
Type) LWCO

Figure 31

D

A

Figure 32

F

B

G

B

A

C

E

STEAM TRIM

1.

Low Water Cut-Off (mounted externally) with blow-off
valve

2.

High Pressure Limit Control

3.

Pressure Gauge

4.

Water Gauge Glass Set

5.

Siphon Loop

6.

Safety Valve 15 psi. See page 27 for installation location.

STEAM TRIM ASSEMBLY

Field assemble Steam Trim, Low Water Cut-Off, High
Pressure Limit Control, Pressure Gauge, Water Gauge
Glass Set and Siphon Loop, as shown in Figure 32.
See Figure 31 and Chart above for location of
controls.

NOTICE

Do not place any shutoff between pressure relief
valve and boiler, or on discharge pipes between
such safety valves and atmosphere. Installation of
pressure relief valve shall conform to requirements
of ANSI/ASME Boiler and Pressure Vessel Code,
Section IV.

WATER LEVEL
29” TO FLOOR

Field Assembled

24

TO RETURN

CITY WATER SUPPLY

CITY WATER SUPPLY

WATER

LINE

A

TO RETURN

WATER

LINE

A

1.1/2

67 SERIES

CUTOFF

WATER

LINE

NO. 150

OR

NO. 93

Figure 33 - Boiler Tappings

BOILER PIPING

STEAM BOILERS - SERIES S

NOTE: Mount electrical supply on opposite side.

AND ELECTRIC BOILER FEED PUMP

CUTOFF USED WITH CONDENSATE RECEIVER

McDONNELL PUMP CONTROL AND LOW-WATER

CUTOFF

SEPARATE McDONNEL FEEDER AND

SEPARATE McDONNEL LOW-WATER

No. 247 mechanical feeder or No.

101-24V electric feeder with transformer

- for use on closed heating systems only.

BOILER SIZE USE

300 THRU 1500

NOTE: For multiple installation with condensate tank and single boiler feed

pump, use No. 93 on each boiler to operate motorized valve in each boiler

feed line.

*These items available through your Distributor.

Gauge Glass Tappings

No. 47-2* Control Mounts in

DIMENSION A - 2 = 2 ½ inches

FOR CLOSED HEATING SYSTEMS

DIMENSION A - 1 = 1 ½ inches

FOR PROCESS OR PARTIAL PROCESS SYSTEMS

DIMENSION A = 2 • 2 ½

FOR CLOSED HEATING SYSTEMS

BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS SHOWN

COMBINATION

McDONNELL FEEDER CUTOFF

BOILER SIZE USE

300 THRU 1500

NOTE: For multiple boiler installation with gravity return, use feeder Cutoff

Combination or separate feeder and separate cutoff on each boiler.

25

Figure 34

SKIM TEE

BOILER PIPING

STEAM BOILER PIPING

Optional Location

for Make-up

Water

Connections

29½”

Install Safety Valve As Close To Boiler As Possible

STEAM BOILER PIPING See Figure 34

• Full size steam header is recommended by
manufacture on all steam systems as shown above.

• Risers should be full 4” and at least 20” in height. Use

skimmer tee as shown.

• Area of Main Steam Cross Header Pipe should be equal
to or larger than total area of Steam Supply Mains
leading from Header and should never be smaller than
Supply tappings on Boiler. Return Header should be
piped to both ends of Boiler. Area of Return Header
should be equal to total area of Return Mains or larger.

• Pipe steam cross headers with swing joints, or
equipped with slip joint connector, to prevent
expansion and contraction of steam header from
damaging boiler.

• Each installation has preferred piping arrangement
according to system requirements. Installer’s heating
engineer or using standard engineering practice choice
of arrangements and sizes of headers should be
decided.

WARNING

!

Do not install shut-off or steam valve between
safety valve and boiler.

Steam Piping Size

Model Header Riser Equalizer

300 to 900 4” 4” 2”

1000 to 1200 4” 4” 2 ½”

1300 to 1500 4” 4” 3”

26

BOILER PIPING

Figure 35 - High Steam Quality Drop Header Piping Arrangement

20” MIN

Note: Single

Main Riser May

Be Used.

27

Water

for Make-up

Connections

Optional Location

CONNECTING GAS SERVICE

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.

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

department.

!

DANGER

Fire Hazard. Do not use matches, candles, open

ames, or other methods providing ignition source.

Failure to comply will result in death or serious
injury.

Gas Supply Connection, Natural Gas Only

1.

Use piping materials and joining methods acceptable

to authority having jurisdiction. In absence of such

requirements USA - National Fuel Gas Code, ANSI

Z223.1/NFPA 54

2.

On multiple base boilers, connect gas service with
branch lines from common main.

3.

Install ground joint union in each branch line for easy
servicing of gas controls.

4.

Provide sediment trap up stream of gas valve. Figure 36.

5.

Size and install gas piping system to provide sufcient

gas supply to meet maximum input at not less than
minimum supply pressure. See Chart 6 for pipe sizes
for gas mains.

6. Pressure test boiler and gas connection before

placing boiler in operation.

•

Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from
gas supply system.

•

Pressure test at 1/2 psig (3.5 kPa) or less.
Isolate boiler from gas supply system by closing
manual gas shutoff valve.

•

Locate leakage using gas detector, noncorrosive

detection uid, or other leak detection method

acceptable to authority having jurisdiction. Do

not use matches, candles, open ames, or other

methods that can provide ignition source.

•

Correct leaks immediately and retest.

Chart 5

Minimum Operating Gas Supply Pressure

Models

300 500 600 1000 1300 1500

Models

400 700 800 900 1100 1200 1400

All

Models

All

Models

TABLE OF PIPE SIZES IN INCHES FOR GAS MAINS

Boiler

No

300 1¼ 1¼ 1¼ 1¼ 1¼ 1¼ 1½ 1½ 1½

400 1¼ 1¼ 1¼ 1¼ 1½ 1½ 1½ 1½ 2

500 1¼ 1¼ 1¼ 1½ 1½ 1½ 2 2 2

600 1¼ 1½ 1½ 1½ 2 2 2 2 2

700 1¼ 1½ 1½ 2 2 2 2 2 2½

800 1½ 1½ 2 2 2 2 2 2½ 2½

900 1½ 2 2 2 2 2 2½ 2½ 2½

1000 1½ 2 2 2 2 2½ 2½ 2½ 2½

1100 2 2 2 2 2 2½ 2½ 2½ 2½

1200 2 2 2 2 2½ 2½ 2½ 2½ 3

1300 2 2 2 2½ 2½ 2½ 2½ 3 3

1400 2 2 2 2½ 2½ 2½ 3 3 3

1500 2 2 2½ 2½ 2½ 2½ 3 3 3

Maximum Gas Supply Pressure

20’ 30’ 40’ 50’ 60’ 80’ 100’ 125’ 150’

5.0 inches w.c.

5.3 inches w.c.

13.5 inches w.c.

Manifold Pressure

3.5 inches w.c.

Chart 6

(NATURAL GAS)

Figure 36

28

ELECTRICAL WIRING

!

WARNING

Electrical shock hazard. Turn OFF electrical power
supply at service panel before making any line
voltage connections. Failure to do so could result
in death or serious injury.

!

CAUTION

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

Electrical Wiring

1.

Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to
National Electrical Code, ANSI/NFPA 70.

2.

Install fused disconnect switch between boiler and
electrical panel in convenient location.

3.

Secure wiring from high temperature limit control to boiler
jacket or gas piping to prevent accidental disconnect from
controls.

4.

Tape all wiring to gas valves securely to gas supply lines
or run in appropriate conduit.

Adjust Thermostat Heat Anticipator

1.

Set heat anticipator setting per thermostat
manufacture instructions.

2.

Follow thermostat manufacture instructions for nal

adjustment.

3.

When set above temperature indicated on
thermometer, boiler burners should ignite. Verify
thermostat(s) turns boiler off when room temperature
reaches selected setting and starts boiler when room
temperature falls few degrees.

4.

Set thermostat for desired temperature.

MULTIPLE

BASE BOILERS

5.

Thermostat Installation

1.

Follow instructions included with your thermostat.

2.

Locate thermostat about 5 feet above oor on inside wall.

3.

Keep thermostat(s) at desired room temperature.
If windows are opened or heat is not needed, set
thermostat(s) to lower setting.

PLACES TO AVOID LOCATING THERMOSTAT

Dead Spots

Hot Spots

Cold Spots

Behind Doors

Corners and Alcoves

Concealed Pipes

Fireplaces

TV Sets

Lamps

Direct Sunlight

Kitchens

Concealed Pipes or Ducts

Stairwells

Drafts

Unheated Rooms on other side of Wall

29

Commercial Boiler, 1, 2 & 3 Base

WIRING DIAGRAMS

LOW VOLTAGE WIRING

30

OPERATION AND SERVICE

Control Functions And Operation

Control module performs following basic functions:

1.

Opens and closes rst (pilot) operator of gas valve.

2.

Provides spark for igniting pilot burner.

3.

Senses pilot burner ame.

4.

Shuts off spark after pilot ame is lit.

5.

Opens and closes second (main) operator.

Functions occur in two stages - trial for pilot ignition and
main burner operation as described below.

Trial For Pilot Ignition

1.

On every call for heat (system start), control performs

internal safe-start check. If ame simulating condition is

present, system will not start.

2.

During normal start, control opens rst (pilot) valve
operator of gas control, which allows gas to ow to

pilot burner. At same time, electronic spark generator
in control produces 15,000 Volt spark pulse output
(open circuit). Voltage produces spark at igniter sensor
rod which ignites pilot burner.

3.

If pilot ame does not light or presence of pilot ame
is not detected back through ame-rod, control will not

open second (Main) valve operator of gas control.

4.

Control will continue to try to ignite pilot burner until

either ame is detected or thermostat (controller) is set

below call for heat.

Main Burner Operation

1.

When pilot ame is established, ame rectication

circuit is completed to burner ground.

2.

Control ame sensing circuit detects ame current,

shuts off spark generator and opens second (Main)

valve operator to allow gas to ow to main burners.

3.

Pilot ame ignites main burner conventionally.

Electronic control module cannot be repaired. If
troubleshooting procedure indicates malfunction in control,
control must be replaced. Intermittent Pilot systems must be
serviced by trained service technicians.

Preliminary Check

Make following visual checks before troubleshooting and
after maintenance.

1.

Check power switch.

2.

Open manual shutoff valves in gas line to boiler.

3.

Verify all wiring connections are clean and tight.

4.

Review control’s normal sequence of operation.

System Troubleshooting

1.

Set thermostat or controller above room temperature and
observe system response.

2.

Establish of system malfunction or deviation from
normal operation by using Pilot System Troubleshooting
Table, in following section.

3.

After any maintenance or repair, troubleshooting
sequence should be repeated until procedure ends with
normal system operation.

Component Verication

Verify Spark Ignition Circuit

Control electronic module and step-up transformer provides
spark ignition at 15,000 V (open circuit). Check circuit at
control module as follows:

1.

Turn off manual gas valve to prevent ow of gas.

!

WARNING

Electrical shock hazard. Do not touch either end
of jumper or stud terminal, high voltage circuit.
Failure to follow these instructions could result in
death or serious injury.

2.

Disconnect ignition cable at control stud terminal to
isolate circuit from pilot burner/igniter-sensor.

3.

Prepare short jumper lead using heavily insulated wire,
such as ignition wire.

4.

Energize control.

5.

Touch one end of jumper rmly to control ground

terminal (GND).

6.

Do not disconnect existing ground lead.

7.

Move free end slowly toward stud terminal to establish
spark.

8.

Pull lead wire slowly away from stud. Note length of
gap at which arcing discontinues.

9.

Arc length of 1/8 inch (3.2 mm) or more indicates
satisfactory voltage output.

10.

If no arc can be established or maximum gap is less
than 1/8 inch (3.2 mm), replace control.

31

OPERATION AND SERVICE

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.
Do not touch any electrical switch; do not use any

phone in your building.
Immediately call your gas supplier from

a neighbor’s phone. Follow gas supplier’s
instructions.

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

department.

Ignition Cable Verication

1.

Cable must not run in continuous contact with a metal
surface or spark voltage will be greatly reduced.

2.

Connections to stud terminal on control and on
igniter-sensor must be clean and tight.

3.

Loose connections may not conduct ame current even

though ignition spark is satisfactory.

4.

Check the cable electrical continuity.

Grounding Verication

Ground is required for pilot burner/igniter-sensor mounting
bracket, and control GND terminal. If ground is poor or
erratic, safety shutdown may occur even though operation
is normal at checkout. If nuisance shutdowns occur, check
grounding.

Startup And Checkout

If any failure of system component system will not operate.
If system does not perform as outlined in Start System,
below, refer to Pilot System Troubleshooting Table.

Start System

1.

Turn power to control(s) on. Turn off gas supply.

2.

Check control(s) operation as follows:
A. Set Thermostat or controller above room

temperature to call for heat.
B. Watch for spark at pilot burner(s).
C. Turn on gas supply.
D. Appliance is equipped with automatic ignition

device which automatically lights the pilot. Do not

try to light appliance by hand.
E. Before operating, smell all around appliance area

for gas. Be sure to smell next to oor because

some gas is heavier than air and will settle on

oor. Read “What To Do If You Smell Gas” on front

page of this manual.above.
F. Use only your hand to push in or turn gas control

knob. Never use tools. If knob will not push in or

turn by hand, don’t try to repair it, call qualied

service technician. Force or attempted repair may

result in a re or explosion.

32

G. Do not use this appliance if any part has been

under water. Immediately call a qualied service

technician to inspect the appliance and to replace
any part of control system and any gas control
which has been under water.

3.

System start:
A. Spark will turn on and pilot gas valve will open at

once. Pilot burner(s) should ignite after gas reaches
pilot burner(s).

B. Spark ignition should cut off when pilot ame is

established.

C. Main gas valve should open and main burners should

ignite after gas reaches burner ports.

Light-off may not be satisfactory until gas input and
combustion air have been adjusted.

DANGER

Fire Hazard. Do not use matches, candles, open

ames, or other methods providing ignition source.

Failure to comply will result in death or serious
injury.

Pilot Flame Adjustment

1.

Pilot ame should envelop 3/8 to 1/2 inch of tip of

insulated rod on igniter-sensor. See Figure 38.

2.

If adjustment is required, remove pilot adjustment
cover screw and turn inner adjustment screw clockwise

to decrease or counterclockwise to increase pilot ame.

3.

Replace cover screw after adjustment to prevent
possible gas leakage.

Test Ignition system safety shutoff device after placing
boiler in operation. Disconnect sensor wire from ignition
module. Burner operation should stop.

Figure 38 - Proper Flame Adjustment

CHECKING AND ADJUSTING

Verify Burner Input

Check boiler for proper Btu input rate. Do not exceed Input rate
stamped on nameplate of boiler located on end jacket panel.
Verify primary air supply to main burners is properly

adjusted for complete combustion.
If boiler is shut down for service, gas and electric must be
off for 5 minutes before relighting.

Verify boiler for proper Btu Input proceed as follows:

1.

With main burners operating, measure gas Input to
boiler by reading the gas meter.

2.

Verify all other appliances connected to same meter are
shut off.

3.

Rate of gas ow (cu. ft. per hour) multiplied by Btu

value of gas should match Btu input shown on boiler
nameplate.

4.

If it is not within +/- 2%, adjust Pressure Regulator

to obtain desired ow. Adjustment stem can be found

cap regulator top. Adjustment screw is plastic and
may require slightly greater turning force than metal
threads.

5.

Turn clockwise to increase input and counterclockwise
to decrease input rate.

6.

Replace Regulator Cap.

High Limit Control

While boiler is operating, set high limit control below boiler
water temperature and main burners should shut off. Return
control to normal setting. Main burners should restart.

Burner And Pilot Flame

Manufacture recommends ue passages, burner

adjustments and operation of boiler controls be checked
once a year by a service technician.

To clean ue passages:

BOILER FLUE PASSAGE

A. Remove burners and pilot(s) from boiler.
B. Remove clean-cut cover panel on draft hood to

expose ue passages. See Figure 13 page 16.

C. Clean ue passageways between sections with

exible handle wire brush. Remove all dirt from

bottom of boiler and reassemble all parts.

D. Verify pilot connection(s), adjustment of pilot(s)

and burner ames after reassembly.

Figure 39 - Pilot and Flame

Outer Mantle

Outer Cone

Burner

Manifold

WARNING

!

Burn and scald hazard. Discharge of water, vapor
and steam may scald. Failure to follow these
instructions could result in death or serious injury.

Pressure Relief Valve

1.

Pressure relief valve on boiler is required.

2.

Run a pipe from pressure relief valve outlet to
appropriate open drain.

3.

Pipe must be of same size as outlet on valve and open
end must not be threaded.

4.

Run drain in area not subject to freezing. Failure to
do so may cause water damage or injury should valve
release.

5.

If valve discharge occurs, or valve fails to open as
described above, contact service technician to replace
relief valve and inspect heating system to determine
cause, as this may indicate equipment malfunction.

6.

Follow valve manufacture instructions for testing and
maintenance.

Burner And Pilot Flame

1.

Manufacture recommends visual check of burners and

pilot ame monthly during heating season by owner

and once year by service technician. See Figure 39.

2.

Look for deterioration from corrosion of burners, pilot
burners and boiler base frame.

3.

Clean boiler base interior and exterior.

WARNING

!

Asphyxiation hazard. Improper installation could
result in death or serious injury. Failure to follow
these instructions could result in death or serious
injury.

Venting System

1.

Check chimney for correct size, proper construction,
clean and in good condition to ensure proper
combustion.

2.

You must provide enough fresh air for combustion.

3.

If your building is of tight construction, it may be necessary to
add fresh air duct to provide oxygen. See Chart 3, page 8.

4.

Monthly during heating season check that sections of

vent pipe are secure at all joints and ttings. There

should be at least two (2) sheet metal screws per joint.

5.

Check that vent pipe slopes at least 1/4” per foot up
from boiler to chimney.

6.

Vent pipe should be securely fastened to prevent
sagging.

7.

Check vent Pipe for any deterioration from corrosion or
any other sources.

8.

Refer to Venting and Combustion Air instructions in this
manual.

33

CLEANING AND MAINTENANCE

Cleaning The Steam Boiler

Steam boilers must be cleaned prior to use in order to

ensure efcient operation.

Grease, oil, sand and dirt cause scum to form on the
surface of water in new boilers. Heavier particles carried in
grease may settle to bottom of boiler and form sludge. If
permitted to remain in boiler it will prevent generation of
steam, produces foaming and causes an unsteady water
line. Remove accumulation of oil and grease by blowing off
boiler as follows:

1.

Install surface skim connection of at least 1¼” nominal
pipe size in boiler using skim tee. See Figure 35 page

27. Skim line should extend to within 18” of oor or

appropriate drain.
A. Insert valve in line close to boiler.

2.

Bring water line to center of outlet.
A. Raise temperature to just below steaming.

B. While burners are on, open the valve in skim line

and slowly feed clean water into boiler adjusting

inlet water so boiler water remains hot.

C. Continue skimming until water is clean.

3.

Close valves in boiler feed line and skim line.

4.

Bring boiler pressure to about 10 lbs.
A. Turn burners off.

B. Open bottom drain valve permitting all water to

drain from boiler.

5.

After boiler has cooled, ll and ush out several times.

6.

Fill to proper water level and ready for normal service.

Do not use soda or any alkali, vinegar or acid for cleaning

heating boilers, it is difcult to completely remove them.

Injury may occur after cleaning process if these agents are
used.

Boiler Water Treatment

In steam systems where system is tight, free from leaks,
and all steam is returned to boiler as condensate, amount
of make up water is small. Water treatment is not required.

On steam systems with less than 90% of steam being
returned as condensate, or with very hard or corrosive
make up water, treatment may be desirable. Follow
recommendations of ASME (American Society of Mechanical
Engineers) Boiler and Pressure Vessel Code, Section VI,
latest version.

Between Heating Seasons

Boilers should not be drained between heating seasons.

Steam boilers should be entirely lled with water during the

summer months to exclude air.

Low Water Cutoff(s)

Inspect low water cutoff(s) annually or as recommended

by low water cutoff manufacture. Flush oat types per

manufacturer’s instructions.

General Housekeeping

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

liquids.

• Keep boiler area clear of obstructions to ow of

combustion and ventilation air.

34

PILOT SYSTEM TROUBLESHOOTING TABLE

Turn gas supply OFF. Turn thermostat

(controller) to call for heat.

Power to module (24V module)

YES

Spark Across Igniter/Sensor Gap.

YES

Turn gas supply ON.

Pilot Burner Lights?

YES

NO

NO

NO

NOTE: Before troubleshooting, familiarize yourself with startup and check
procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring. Also, check air proving switch on combustion air blower
system (if used) and that vent damper (if used) is open and end switch is made.

Pull ignition lead and
check spark at module.

Spark okay?

NO

YES

• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or bucking. Take protective

action to shield cable and boot from excessive temperatures.

• Check that all manual gas valves are open, supply tubing and pressures are

good, and pilot burner orice is not blocked.

• Check electrical connection between module and pilot operator on gas control.

• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,

replace gas control: if not, replace module.

NOTE: If the control, goes into lockout, reset system.

• On models with vent damper plug,
make sure vent damper has not been
installed, then removed. Replace vent
damper if necessary.

• On other models, replace module.

Spark Stops When Pilot Lit?

YES

Main Burner Lights?

YES

System Runs Until Call For

Heat Ends.

YES

Call For Heat Ends

System Shuts OFF?

NO

NO

NO

NO

• Check continuity of ignition cable and ground wire.

• Clean ame rod.

• Check electrical connections between ame rod and module.

• Check for cracked ceramic ame rod insulator.

• Check that pilot ame covers ame rod and is steady and blue.

• Adjust pilot ame.

• If problem persists, replace module.

• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.

• Check electrical connections between module and gas control. If okay, replace

gas control or gas control operator.

NOTE: If the control, goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.

• Check that pilot ame covers ame rod and is steady and blue.

• If checks okay, replace module.

• Check for proper thermostat (controller) operation.

• Remove MV lead at module: if valve closes, recheck temperature controller and

wiring: if not, replace gas control.

YES

Troubleshooting Ends.

NO

Repeat procedure until trouble free operation is obtained.

35

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy

by reducing the boiler water temperature as the heating load decreases.

This feature is equipped with an override which is provided primarily to

permit the use of an external energy management system that serves the

same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of

300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com