Utica Boilers MGB Series II/MGC Series Operation and Installation Manual

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Models

MGC-8D MGC-8DP MGC-9D MGC-9DP

MGC SERIES

GAS-FIRED

HOT WATER BOILERS

INSTALLATION, OPERATION & MAINTENANCE MANUAL

C.S.A. Certified for

Tested for 50 psi.

Natural gas or

ASME Working

Propane

Pressure

 

An ISO 9001-2008 Certified Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com

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

1 - DIMENSIONS

Figure 1 - Dimensions

*

* Minimum acceptable height for Low Water Cutoff probe.

Table 1 - Dimensions

 

DIMENSIONS (INCH.)

BOILER

 

 

MODEL

FLUE

“A”

NUMBER

DIAMETER

WIDTH

 

 

 

MGC-8

7

27½

MGC-9

7

30¾

Add 5½” to height for vent Damper.

2

2 - BOILER RATINGS AND CAPACITIES

Table 2 - Ratings and Capacities

 

 

 

† NATURAL GAS

 

 

† PROPANE GAS

 

AFUE

 

 

 

 

 

 

 

 

 

 

BOILER

 

 

(2)

 

 

 

 

 

 

(1)

NET AHRI

 

 

HEATING

 

 

MODEL

 

Input (3)

Heating

INPUT

(3)

NET AHRI

INTERMITTENT

 

RATING

CAPACITY (3)

NUMBER

(1)

Mbh

Capacity

MBH

 

RATING

IGNITION WITH

 

 

Water,

 

MBH

 

 

 

(3) Mbh

 

 

 

VENT DAMPER

 

 

 

(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 suffice ‘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

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 orifice 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 orifice sizing information.

3

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 defined 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 flammable vapors and liquids.

DO NOT obstruct air openings to the boiler room.

Modification, substitution or elimination of factory equipped, supplied or specified

components may result in personal injury or loss of life.

TO THE OWNER - Installation and service of this boiler must be performed by a qualified 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

4 - 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 fired Boilers, ANSI/ASME CSD-1.

3.Boiler series is classified 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 flooring or carpeting. Failure to follow these instructions could result in death or serious injury.

1.FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY - For installation on combustible flooring special base must be used. (See Replacement Parts Section.) Boiler can not be installed on carpeting.

Table 3 - MINIMUM CLEARANCE DIMENSIONS

 

Inches

(mm)

 

 

 

Top

6”

(152mm)

Rear

6”

(152mm)

Control Side

7”

(178mm)

Opposite Side

6”

(152mm)

Front

18”

(457mm)

Flue/Vent Connector

6”

(152mm)

Near Boiler Piping

2”

(51mm)

NOTE: Greater clearances for access should supersede fire protection clearances.

* Definition 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)

6"

6" BOILER 7"

Control

Side

Front

18"

5

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 infiltration rate is less than 0.40 air changes per hour. See Table 4 for space with boiler only. Use equation for multiple appliances.

Volume ≥ 50 ft3 x Total Input [Mbh]

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.

B.Known Air Infiltration Rate. See Table 4 for space with boiler only. Use equation for multiple appliances. Do not use an air infiltration 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

Standard

Known Air Infiltration Rate Method (Air Changes Per Hour)

Mbh

Method

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

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.

1.Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements. Install safety relief valve using pipe fittings provided with boiler. See Figure 2

2.Install safety relief valve with spindle in vertical position.

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

4.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).

Terminate pipe with plain end (not threaded).

Figure 2 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local codes for maximum distance from floor or allowable safe point of discharge.

7

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.

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.Boiler is shipped assembled. Install discharge piping from safety relief valve. See Warning, Page

7.

2.Install temperature pressure gauge.

Apply pipe sealant to threads on shaft of gauge.

Thread gauge into supply water tee. See Figure 3.

NOTICE

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

3.Connect supply and return lines to boiler.

Connections may require additional fittings and parts, as shown on diagrams.

1 for minimum probe height. Use kit #550002998. Follow instruction enclosed with kit. With other

LWCO’s use their manufacturer specific instructions. Periodic inspection is necessary, as is flushing of float type devices, per manufacturers specific 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 flow 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.)

 

 

 

Significant 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.

 

 

 

1. Boiler used in heating system where design

 

 

 

water temperatures below 140°F are desired

 

 

 

(e.g. radiant floor 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.

 

 

 

2. Boiler connected to system having large water

 

 

 

content (such as former gravity system), install

 

 

 

system bypass. See Figures 6 and 7, page 10.

 

 

 

3. 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.

8

6 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Typical Hot Water Piping

Figure 5 - Chilled Water Piping

9

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

10

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