Utica Boilers MGB, II-MGC Installation Manual

Models

MGC SERIES

GAS-FIRED

HOT WATER BOILERS

MGC-8D

MGC-8DP

MGC-9D

MGC-9DP

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

C.S.A. Certied for

Natural gas or

Propane

Tested for 50 psi.

ASME Working

Pressure

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240009268, Rev. D [10/2014]

Figure 1 - Dimensions

1 - DIMENSIONS

* Minimum acceptable height for Low Water Cutoff probe.

Table 1 - Dimensions

DIMENSIONS (INCH.)

BOILER MODEL NUMBER

MGC-8 7 27½

MGC-9 7 30¾

Add 5½” to height for vent Damper.

FLUE

DIAMETER

“A”

WIDTH

2 - BOILER RATINGS AND CAPACITIES

Table 2 - Ratings and Capacities

† NATURAL GAS † PROPANE GAS AFUE

(2)

BOILER

MODEL

NUMBER

(1)

Input

Mbh

(3)

(1)

Heating

Capacity

(3)

Mbh

MGC-8 262.5 220 191 245 206 179 83.9

MGC-9 299 251 218 280 235 204 83.7

†

Input rating for sea level to 2,000 ft. (610m) above sea level. Over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea level. + Heating Capacity based on D.O.E. (Department of Energy) test procedure.

(1)

Add model number sufce ‘P’ for Propane.

(2)

Net AHRI Water rating shown based on piping and pickup allowance of 1.15. Consult manufacturer before selecting

boiler for installations having unusual piping and pickup requirements, such as intermittent system operation,

extensive piping systems, etc.

(3)

MBH = 1,000 Btuh = British Thermal Unit Per Hour

NET AHRI

RATING

Water,

(3)

Mbh

INPUT

MBH

(3)

HEATING

CAPACITY

MBH

(3)

NET AHRI

RATING

INTERMITTENT

IGNITION WITH

VENT DAMPER

Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or terminal units. Net AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on AHRI Standard as published by The Hydronics Institute.

- Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of the building.

- Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.

BOILERS FOR USE AT HIGH ALTITUDE

Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level.

For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner orice size.

For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above

sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54 or manufacturer for correct orice sizing information.

3 - TABLE OF CONTENTS

1 - Dimensions .................................................... 2

2 - Ratings And Capacities ....................................3

3 - Table of Contents ............................................ 4

4 - Installation Procedure .....................................5

5 - Ventilation & Combustion Air ............................6

6 - Connecting Supply And Return Piping ................7

7 - Chimney And Vent Pipe Connection ................. 11

8 - Vent Damper Operation ................................. 14

9 - Gas Supply Piping ......................................... 15

10 - Electrical Wiring .......................................... 15

11 - Wiring Diagrams ......................................... 16

12 - General Instructions .................................... 19

13 - Lighting Instructions ................................... 20

14 - Operating Your Boiler .................................. 21

15 - Maintaining Your Boiler ................................ 23

16 - Service Hints .............................................. 24

17 - Equipment And Optional Accessories ............ 25

Appendix A - Control Module ............................... 27

SAFETY SYMBOLS & WARNINGS

The following dened symbols are used throughout

this manual to notify the reader of potential hazards of varying risk levels.

DANGER

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

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions COMPLETELY before installing!!

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.

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.

NOTICE

Used to address practices not related to personal injury.

4 - INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury.

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/NFPA 54.

Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for

Automatically red Boilers, ANSI/ASME CSD-1.

Boiler series is classied as a Category I. Vent

installation 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.

Boiler has met safe lighting and other performance criteria with the gas manifold and control assembly on the boiler per the latest revision of ANSI Z21.13/CGA 4.9.

Install boiler such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service, (circulator replacement, condensate trap, control replacement, etc.).

Locate boiler on level, solid base as near chimney as possible and centrally located with respect to heat distribution system as practical.

Allow 24 inches (610mm ) at front and right side for servicing and cleaning.

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

WARNING

Fire hazard. Do not install boiler on

combustible ooring or carpeting. Failure to

follow these instructions could result in death or serious injury.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY - For installation on combustible

ooring special base must be used. (See Replacement Parts Section.) Boiler can not be

installed on carpeting.

Table 3 -

Top 6” (152mm)

Rear 6” (152mm)

Control Side 7” (178mm)

Opposite Side 6” (152mm)

Front

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 2” (51mm)

NOTE: Greater clearances for access should supersede fire

* Denition of Alcove is three sided space with no

wall in front of boiler. ANSI standard for alcove is 18 inches from front of appliance to leading edge of side walls as shown below.

MINIMUM CLEARANCE DIMENSIONS

Inches (mm)

18” (457mm)

protection clearances.

Minimum Clearances to Combustible

Construction (as seen from above)

BOILER

Front

Control

Side

18"

5 - VENTILATION & COMBUSTION AIR

Provide combustion air 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 local building codes.

Provide make-up air where exhaust fans, clothes

dryers, and kitchen ventilation equipment interfere with proper operation.

National Fuel Gas Code recognizes several methods of obtaining adequate ventilation and combustion air. Requirements of the authority having jurisdiction may override these methods.

• Engineered Installations. Must be approved by authority having jurisdiction.

• Mechanical Air Supply. Provide minimum of

0.35 cfm per Mbh for all appliances located within space. Additional requirements where exhaust fans installed. Interlock each appliance to mechanical air supply system to prevent main burner operation when mechanical air supply system not operating.

• All Indoor Air. Calculate minimum allowable room volume for all appliances in space. Use a different method if minimum volume not available.

A. Standard Method. Cannot be used if known

air inltration rate is less than 0.40 air

changes per hour. See Table 4 for space with boiler only. Use equation for multiple appliances.

• All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors.

A. Two Permanent Opening Method. Provide

opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom of enclosure.

 Direct communication with outdoors or

communicating through vertical ducts.

Provide minimum free area of 1 in² per 4

Mbh of total input rating of all appliances in enclosure.

 Communicating through horizontal ducts.

Provide minimum free area of 1 in² per 2

Mbh of total input rating of all appliances in enclosure.

B. One Permanent Opening Method. Provide

opening commencing within 12 inches of top

of enclosure. Provide minimum clearance of

1 inch on sides/back and 6 inches on front of boiler (does not supersede clearance to combustible materials).

• Refer to National Fuel Gas Code for additional

requirements for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to National Fuel Gas Code for application information.

Volume ≥ 50 ft3 x Total Input [Mbh]

B. Known Air Inltration Rate. See Table 4

for space with boiler only. Use equation for multiple appliances. Do not use an air

inltration rate (ACH) greater than 0.60.

Volume ≥ 21 ft3⁄ACH x Total Input [Mbh]

C. Refer to National Fuel Gas Code for opening

requirements between connected indoor spaces.

Table 4 - Minimum Room Volume, Indoor Air Only*

Room Cubic Feet Volume

Input

Mbh

Standard

Method

Known Air Inltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

262.5 13125 55125 27563 18375 13781 11025 9188 299 14950 62790 31395 20930 15698 12558 10465

* Table values based on boiler only. Add volume for any additional appliances.

6 - CONNECTING SUPPLY AND RETURN PIPING

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements. Install safety relief valve using

pipe ttings provided with boiler. See Figure 2

Install safety relief valve with spindle in vertical position.

Do not install shutoff valve between boiler and safety relief valve.

Install discharge piping from safety relief valve. See Figure 2.

• Use ¾” or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

Figure 2 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

• Terminate pipe with plain end (not threaded).

6 - CONNECTING SUPPLY AND RETURN PIPING

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

Boiler is shipped assembled. Install discharge

piping from safety relief valve. See Warning, Page

Install temperature pressure gauge.

• Apply pipe sealant to threads on shaft of gauge.

• Thread gauge into supply water tee. See Figure

NOTICE

DO NOT TIGHTEN GAUGE BY HAND!! Gauge should be tightened using crescent wrench or 9/16” open end wrench. See Figure 3.

Connect supply and return lines to boiler.

Connections may require additional ttings and

parts, as shown on diagrams.

Verify clean water supply is available to water inlet valve. Install sand strainer when water supply is from a well or pump.

Install hot water boiler above radiation level or as required by Authority having jurisdiction. Install low water cutoff device at time of installation. See Figure 1 for minimum probe height. Use kit #550002998. Follow instruction enclosed with kit. With other

LWCO’s use their manufacturer specic instructions. Periodic inspection is necessary, as is ushing of oat type devices, per manufacturers specic instruction.

FOR USE WITH COOLING UNITS

A. Boiler used in connection with refrigeration

system, must be installed so that chilled medium is piped in parallel with heating boiler. Appropriate valves must be used to prevent chilled medium from entering heating boiler. See Figure 5 page 9.

B. Boiler connected to heating coils located in air

handling units where they may be exposed to refrigerated air circulation, piping system shall

be equipped with ow control valves or other

automatic means to prevent gravity circulation of boiler water during cooling cycle.

Figure 3 - Temperature Pressure Gauge

LOW WATER TEMPERATURE AND LARGE WATER CONTENT SYSTEM (See Figures 6 and 7, Page 10.)

Signicant condensation may form in boiler and/or

venting system if boiler is operated for long period of time with return temperatures of less than 120° F.

Condensate is corrosive and can cause severe damage to boiler and venting system. Minimum design return water temperature to prevent condensation in boiler and venting is 120°F. Minimum high limit setting is 140°F.

Boiler used in heating system where design water temperatures below 140°F are desired

(e.g. radiant oor heating), 4-way mixing valve

or suitable alternative is required to prevent low temperature return water from entering boiler.

Follow mixing valve manufacturer’s instructions.

Boiler connected to system having large water content (such as former gravity system), install system bypass. See Figures 6 and 7, page 10.

If boiler water reset control is used to operate boiler, minimum reset supply water temperature setpoint must be at least 140°F, unless mixing valve is used as in (1) above.

6 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Typical Hot Water Piping

Figure 5 - Chilled Water Piping

6 - CONNECTING SUPPLY AND RETURN PIPING

Bypass Piping Required For High Mass (Large Water Content) Systems

Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY

Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN

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