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.

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

Chimney

Size (6)

8”x20’

10”x20’

12”x20’

14”x20’

16”x20’

Flue

Collector

Size to

Chimney

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

1400

1500

1085

1163

3392

3633

814

872

18”x20’

18”x20

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.

END

BASE

*****

END

****

JACKET

PANEL

CARTON

PANEL

CARTON

***

TRIM

STEAM

CARTON

LESS LOW

ITEM #

550002860

ITEM #

550002871

CARTON

ACCESSORY

WATER

CUTOFF

41200066

SHIPMENT CHECK LIST

41200067

41200068

41200069

TRIM

STEAM

CARTON

500

400

*COMPONENT CART.

300

MODEL

KIT #

550002863

KIT #

550002862

KIT #

550002861

RIGHT

41154050

INNER

SECTIONS

41154052

(SA-1)

41200061

(SA-2)

41200062

(SA-3)

41200063

(SA-4)

41200064

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

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

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

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

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.

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

to check all connections. This will avoid any possibility

of re or explosion.

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.

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

Verify there is adequate air supply for complete combustion.

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.

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

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

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/

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.

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.

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.

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.

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.

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.

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

Figures 1 & 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.

Consult dimensional drawing for number and size of

ue pipes required for each size boiler.

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

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.

Insulate ue pipe where it passes near combustible

material.

Rigidly support pipe with hangers and straps.

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

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

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.

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