Utica Boilers MGB, II-MGC Installation Manual

MGB SERIES II

CAST IRON GAS FIRED BOILERS

Models

MGB-75J
MGB-100J
MGB-125J
MGB-150J
MGB-170J

MGB-200J

FOR FORCED HOT WATER

INSTALLATION, OPER ATION

& MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

An ISO 9001-2008 Certified Company

C.S.A. Certied

For Natural Gas Or Propane

Tested For 100 psi.

ASME

Working Pressure

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240009005, Rev. H [10/2014]

Figure 1 - Dimensions

DIMENSIONS

"D"

"A"

"B"

1¼" Supply

3½"

4¼"

4¼"

14"

27"

5½"

3"

1¼" Return

"C"*

2½"

4½"

Table 1 - Dimensions

Boiler No.

50 ½" 11⅛" 4" 30¾" 36¼" 1¼"

75 ½" 15 5" 30¾" 37¾" 1¼"

100 ½" 15 6" 30¾" 37¼" 1¼"

125 ½" 18⅞" 6" 30¾" 37¼" 1¼"

150 ½" 18⅞" 7" 30¾" 37¾" 1¼"

170 ½" 22¾" 7" 30¾" 38¾" 1¼"

200 ½" 22¾" 8" 30¾" 38¾" 1¼"

* Propane gas inlet, all units, 1/2"
** C is minimum height for low water cutoff installation

Natural

Inlet*

Gas

A B C** D

Dimensions

Pump size Supply &

Return Tappings

2

TABLE OF CONTENTS

1 - Ratings & Data - Natural Gas & Propane Gas ......4

2 - Installation Procedure .....................................5

3 - Ventilation & Combustion Air ............................6

4 - Connecting Supply and Return Piping ................7

5 - Vent Installation ........................................... 12

6 - Vent System Modication ............................... 12

7 - Vent Damper Installation & Instructions ........... 13

8 - Connecting Gas Service ................................. 14

9 - Electrical Section .......................................... 15

10 - Wiring Diagram ......................................... 16

11 - Lighting Instructions ................................... 19

12 - Normal Sequence of Operation ..................... 20

13 - General Instructions .................................... 20

14 - Checking Gas Input Rate To Boiler ................. 22

Appendix A - Control Module ............................... 23

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.

3

1 - RATINGS & DATA - NATURAL GAS & PROPANE GAS

Table 2 - Ratings and Capacities

Boiler

No.
50J

75J
100J
125J
150J
170J
200J

(1)

Input

Mbh

50

75
100
125
150
170
200

(1)

Heating

Capacity Mbh

52
63

83
104
124
139
165

(2)

Net AHRI

Rating Water

Mbh

36
55
72

90
108
121
143

AFUE

83.5

83.1

83.0

82.0

83.0

82.0

82.0

No.

of

Burners

1
2
2
3
3
4
4

(3)

Recommended

Air Cushion

Tank

15
15
30
30
30
30
30

Water

Content

(Gals.)

2.4

4.0

4.0

5.6

5.6

7.2

7.2

EXPLANATORY NOTES

-- All boilers are design certied for installation on noncombustible oor.

-- For installation on combustible oors use combustible oor kit.

-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be
reduced to 10 feet. Refer to the latest revision of NFGC part 11.

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

-- The MEA number for the this boiler is 19-79-E.

(1) Input rating for sea level to 2,000 ft. (610m) above sea level.

United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1000 ft (304m) above sea

level.

(2) Net AHRI Water Ratings 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.

For forced hot water systems where boiler and all piping within area to be heated, boiler may be selected on basis of
its heating capacity.

(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and

radiation.

STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Intermittent Electric Ignition Pilot
System, Vent Damper Relay, Theraltimeter Gauge, Circulator With Return Piping To Boiler, Main Gas Burners, Gas Control
(Includes Automatic Gas Valve, Gas Pressure Regulator, Intermittent Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter),
A.S.M.E. Relief Valve, Drain Valve, Spill Switch, Rollout Switch, Combination Gas Control, Automatic Vent Damper. Not Shown
Are: Wiring Harness, Thermocouple, Non-linting Safety Pilot.

4

2 - INSTALLATION PROCEDURE

!

WARNING

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

1.

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.

2.

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.

3.

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.

4.

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

4.9.

5.

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.).

6.

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

7.

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

8.

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.

9.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS
ONLY - For installation on combustible ooring special
base must be used. (See Repair Parts, Optional Kits
Manual). Do not install boiler on carpeting. Minimum
clearances to combustible construction are:

TOP ....................................18 IN. (457mm)

FRONT .........................................ALCOVE *

FLUE CONNECTOR ................. 6 IN. (152mm)

REAR ................................... 4 IN. (102mm)

CONTROL SIDE ..................... 9 IN. (229mm)

OTHER SIDE ........................... 3 IN. (76mm)

HOT WATER PIPING ................ Per Local Code

NOTE: Greater clearances for access should supersede fire

protection clearances.
* 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 Clearances to Combustible

Construction (as seen from above)

4"

3"

BOILER

Front

9"

18"

5

3 - 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 jurisdictions.

• 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 volume for all
appliances in space. Use a different method if
minimum volume not available.

о Standard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per
hour. See Table 3 for space with boiler only. Use
equation for multiple appliances.

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

о Two Permanent Opening Method. Provide opening

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

о One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides
and 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]

о Known Air Inltration Rate. See Table 3 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]

о Refer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

Table 3 - Space With Boiler Only

Room Cubic Feet Volume

Input Mbh

50 2500 10500 5250 3500 2625 2100 1750

75 3750 15750 7875 5250 3938 3150 2625

100 5000 21000 10500 7000 5250 4200 3500

125 6250 26250 13125 8750 6563 5250 4375

150 7500 31500 15750 10500 7875 6300 5250

170 8500 35700 17850 11900 8925 7140 5950

200 10000 42000 21000 14000 10500 8400 7000

Standard

Method

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

0.1 0.2 0.3 0.4 0.5 0.6

6

4 - CONNECTING SUPPLY AND RETURN PIPING

!

WARNING

Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from oor or allowable safe point of discharge.

• be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge
line;

• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or

place any obstruction in discharge line.

• terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;

• allow complete drainage of the valve and the discharge line;

• be independently supported and securely anchored to avoid applied stress on the relief valve;

• be as short and straight as possible;

• terminate with plain end (not threaded);

• be constructed of material suitable for exposure to temperatures of 375° F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.

Figure 2 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable
safe point of

discharge.

7

AIR

SEPARATOR

4 - CONNECTING SUPPLY AND RETURN PIPING

Circulators in following illustrations are mounted on system supply side, mounting on system return side is also
acceptable practice.

Figure 3 ­See Special Conditions, Page 9

Circulators Mounted on Supply System, Boiler Used In Conguration with Chiller System.

1.

Boiler used in connection with refrigeration system,
install so chilled medium is piped in parallel with boiler
with appropriate valves to prevent chilled medium from
entering boiler. See Figure 2.

2.

Boiler piping system of hot water boiler connected to
heating coils located in air handling units where they
may be exposed to refrigerated air circulation must be
equipped with ow control valves or other automatic
means to prevent gravity circulation of boiler water
during cooling cycle.

3.

Hot water boilers installed above radiation level or
as required by authority having jurisdiction must be
provided with low water cut-off device.

4.

Boiler connected to heating system utilizing multiple
zoned circulators, each circulator must be supplied with
ow control valve to prevent gravity circulation.

5.

Hot water boilers and system must be lled with water
and maintained to minimum pressure of 12 psi.

6.

For Low Water Cutoff, see Figure 1 for minimum height.
Use Kit #240010831. Follow instruction enclosed with
the kit. Other LWCO's for their manufacture specic
instructions.

7.

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

A. This method is used to protect boilers from

condensation forming due to low temperature
return water. Generally noticed in large converted
gravity systems or other large water volume
systems. Figures 4 and 5.

B. These methods are used to protect systems using

radiant panels and material they are encased in
from high temperature supply water from boiler
and protect boiler from condensation.

NOTE#1: When using bypass piping, adjust
valves V1 & V2 until desired system temperature
is obtained. See Figure 5, page 9.

NOTE#2: Bypass loop must be same size piping
as supply and return piping.

8

4 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Bypass Piping With Mixing Valve

TO SYSTEM

WATER INLET

EXPANSION

TANK

FROM SYSTEM

CIRCULATOR

SHUT-OFF
VALV E

PRESSURE
REDUCER VALVE

CHECK VALVE

BOILER

BALL VALVE

3 WAY MIXING
VALV E

ALTERNATE

CIRCULATOR

LOCATION

Figure 5 - Bypass Piping - Fixed Low Temp Only With Zone Valve

TO SYSTEM

BOILER

V2V1

ALTERNATE

CIRCULATOR

LOCATION

SYSTEM

CIRCULATOR

WATER INLET

EXPANSION

TANK

AIR SEPARATOR

HOSE BIB

FROM SYSTEM

CIRCULATOR

SHUT-OFF
VALV E

8. Installation using circulators and zone valves are

shown in Figures 6 through 9. For further piping
information refer to AHRI Installation and Piping
Guide.

PRESSURE
REDUCER VALVE

CHECK VALVE

BALL VALVE

ZONE VALVE

AIR SEPARATOR

!

WARNING

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

9. Install discharge piping from safety relief valve. See

Warning, Page 7.

9