UTICA BOILERS MGC-8D, MGC-9D, MGC-9DP, MGC-8DP Installation, Operation And Maintenance Manual

Models

MGC-8D

MGC-8DP

MGC-9D

MGC

GAS-FIRED

HOT WATER BOILERS

INSTALLATION, OPERATION &

MGC-9DP

MAINTENANCE MANUAL

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 240011125, Rev. C [07/22/2015]

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

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P/N 240011125, Rev. C [07/22/2015]

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.

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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

P/N 240011125, Rev. C [07/22/2015]

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, and/or Natural Gas and Propane

Installation Code, CAN/CSA B149.1.

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 "Venting Systems and Air Supply
for Appliances," of the Natural Gas and Propane

Installation Code, CAN/CSA B149.1, 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.

1.

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

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

carpeting.

Table 3 -

Top 6”

Rear 6”

Control Side 7” (178mm)

Opposite Side 6” (152mm)

Front

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 1/2” (13mm)

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)

(152mm)

(152mm)

18” (457mm)

protection clearances.

Minimum Clearances to Combustible

Construction (as seen from above)

6"

6"

BOILER

7"

Control

Side

Front

18"

5

P/N 240011125, Rev. C [07/22/2015]

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 Sections

8.2, 8.3 or 8.4 of Natural Gas and Propane Installation

Code, CAN/CSA B149.1, 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.

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.

Canada

National Gas and Propane Installation Code Requires

providing air supply in accordance with:

• 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.

• Section 8.2 and 8.3 when combination of appliances

has a total input of up to and including 400 Mbh (120
kW).

• Section 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code

for specic air supply requirements for enclosure

or structure where boiler is installed, including air
supply openings and ducts.

Table 4 - Minimum Room Volume, Indoor Air Only*

Input Mbh

Standard

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.

Room Cubic Feet Volume

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

6

P/N 240011125, Rev. C [07/22/2015]

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.

Figure 2 - Safety Relief Valve

RELIEF VALVE

1.

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

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.

DISCHARGE

LINE

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

• 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).

7

P/N 240011125, Rev. C [07/22/2015]

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.

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 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.

1.

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.

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

P/N 240011125, Rev. C [07/22/2015]

6 - CONNECTING SUPPLY AND RETURN PIPING

Figure 4 - Typical Hot Water Piping

Figure 5 - Chilled Water Piping

9

P/N 240011125, Rev. C [07/22/2015]

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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