Utica Boilers PEG E Series Operation and Installation Manual

PEG-E

GAS-FIRED

Models

PEG075EID

PEG112EID
PEG150EID
PEG187EID
PEG225EID
PEG262EID
PEG299EID

STEAM BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

MODEL

PEGEID

Electronic

Intermittent

Ignition

An ISO 9001-2008 Certied Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N# 240009937, Rev. B [05/2014]

DIMENSIONS

Figure 1 - Dimensions

16⅝"

12⅜"

2" NPT

25"

13½"

2" NPT

½"
NPT
Plug

5½"

Floor

A

Safety
Relief
Valve

B

29"

Depth C

2" NPT

2" NPT

Models 075 112 150 187 225 262 299

Width (A)

Height (B)

Depth (C)

Gas

Connection Size (G)

Flue Diameter

Table 1 - Physical Data

10 7/8" 14 1/8" 17 3/8" 20 5/8" 23 7/8" 27 1/8" 30 3/8"

35 7/8"

28 3/8" 28 3/8" 29 3/8" 30 3/8" 30 3/8" 30 3/8" 30 3/8"

½ NPT ½ NPT ½ NPT ¾ NPT ¾ NPT ¾ NPT ¾ NPT

5" 5" 6" 7" 7" 7" 7"

2

BOILER RATINGS AND CAPACITIES

Table 2 Ratings and Capacities

Natural Gas & Propane (LP)

Boiler Model

Number

Input

MBH (1)

Heating
Capacity
MBH (1)

Net AHRI Rating (2)

Steam,

MBH

Steam,

Sq. Ft.

AFUE, %

No. of

Sections

Vent Pipe

Size

PEG075EID 75 62 47 195 82.2 3 5"

PEG112EID 112 93 70 292 82.4 4 5"

PEG150EID 150 125 94 391 82.6 5 6"

PEG187EID 187 156 117 488 82.8 6 7"

PEG225EID 225 188 141 587 83.0 7 7"

PEG262EID 262 219 164 685 83.2 8 7"

PEG299EID 299 250 188 782 83.4 9 7"

Heating Capacity and AFUE are based on DOE (Department of Energy) test procedures.

1.

Input rating for sea level to 2,000 ft. above sea level. Altitudes over 2000 ft. above
sea level, reduce input rate 4% for every 1000 ft.

2. Net AHRI steam ratings shown are based on a piping and pickup allowance of 1.333.
Consult manufacturer before selecting a boiler for installations having unusual piping
and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.

3

TABLE OF CONTENTS

Important Safety Information ....................... 5

Locating the Boiler ...................................... 6

Hydronic Piping .......................................... 8

Fresh Air for Combustion ............................12

Chimney and Vent Pipe Connection ..............13

Vent Damper Operation ..............................15

Gas Supply Piping ......................................16

Electrical Wiring ........................................17

Operating Instructions ................................18

Operating Your Boiler .................................19

Checking and Adjusting ..............................20

Start-up Cleaning ......................................22

General Maintenance .................................23

Troubleshooting .........................................24

Wire Diagrams ..........................................25

Optional Hydronic Piping .............................28

Introduction

Boiler is designed for use in closed heating systems where
all steam is returned as condensate and make-up water is
minimal. Boiler is not designed for or intended for use in
open systems using 100% make-up water.

Prior to Installation

• Verify correct boiler for type of gas being used
natural or propane. See Rating Plate.

• Verify boiler size and dimensions. See Figure 1 and
Table 1, page 2.

• Verify ratings and capacity data for natural gas. See
Table 2.

Installation Requirements

• Supply boiler with correct gas (natural or propane),
fresh air for combustion, and suitable electrical supply.

• Connect boiler to adequate venting and piping
systems.

• Provide boiler with properly located and adjusted
thermostat.

Installation of boiler in building under construction, use
precaution to insure clean combustion air supply during
construction process. Airborne particulate from construction
materials can clog burner ports and cause incomplete
combustion and sooting.

Complete all steps for safe and proper heating system
operation.

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

GAS FIRED STEAM BOILERS

Check our website frequently for updates: www.ecrinternational.com

Information and specications outlined in this manual in effect at the

time of printing of this manual. ECR International reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

4

IMPORTANT SAFETY INFORMATION

General

Boiler and venting installation shall be completed by
qualied agency.

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.

Become familiar with symbols identifying potential
hazards.

This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.

!

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.

Installation shall conform to requirements of
authority having jurisdiction or in absence of such

requirements to the National Fuel Gas Code,

ANSI Z223.1/NFPA 54.

Where required by authority having jurisdiction,
installation shall conform to Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1. Controls can be added to make
this boiler CSD-1 compliant. Check with your local

codes for requirements.

Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is
not limited to installation by licensed plumber or gas

tter.

WARNING

!

Installing or venting a boiler or any other gas
appliance with improper methods or materials could
result in death or serious injury due to re or to
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible.

!

CAUTION

Indicates a hazardous situation which, if not avoided,
may result in minor or moderate injury.

NOTICE

Used to address practices not related to personal
injury.

WARNING

!

Fire, explosion, asphyxiation hazard. Keep boiler
area clear and free from combustible materials,
gasoline and other ammable vapors and liquids.

Modication, substitution or elimination of factory
equipped, supplied or specied components could
result in death or serious injury.

5

LOCATING THE BOILER

Locating the Boiler

1.

Select level location as centralized with piping system,
and as near chimney as possible.

2.

Place crated boiler at selected location. Remove all
crate material. Please recycle responsibly.

!

WARNING

Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.

3.

Do not install boiler on carpeting. For installation

on non-combustible oors only. For installation on
combustible ooring, special base must be used. (See
Replacement Parts Manual.)

4.

Use metal shims under boiler base legs for nal leveling
if needed.

5.

Install boiler in location that permits satisfactory
combustion of gas, proper venting, and maintenance
of ambient temperature at safe limits under normal
conditions of use. Boiler location should not interfere
with proper circulation of air. Introduce outside air
if normal inltration does not provide necessary
air.“Fresh Air for Combustion” on page 12.

6.

Notify owner to keep air passages free of obstruction.
Ventilating and combustion air must enter boiler room
without restrictions.

Table 3 -

Minimum Clearance Dimensions

Top 6"

Rear 6"

Control Side 7"

Opposite Side 6"

Front Alcove

Flue/Vent
Connector

Near Boiler Piping 1/2"

6"

Figure 2 - Minimum Clearances To Combustible
Construction

View from top

of boiler

7”

(178mm)

Figure 3 - Draft Hood Installation

6” (152mm)

Rear

Boiler

Control Side

Front

ALCOVE

6”

(152mm)

Opposite Side

Screw

7.

Install boiler so automatic gas ignition system
components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service.

Draft Hood Installation

!

WARNING

Asphyxiation, carbon monoxide hazard. Failure to
follow these instructions could result in improper
combustion and possible leakage of combustion
products into the living space.

Follow directions given in Figure 3. Attach draft diverter,
and blocked vent switch. Mount vent damper. See
"Connecting Vent Damper and Vent Connector" page 13.
See Wiring Diagrams pages 26 and 27.

Top and side panels not shown for clarity.

1.

Slide draft hood over ue collector.

2.

Through holes in jacket top, secure with 1 or 2 screws,
based on boiler size.

6

Draft Hood

LOCATING THE BOILER

!

DANGER

Burn, scald hazard. Pressuretrol must be installed
by a qualied service agency in accordance with
manufacturer’s instructions, all applicable codes and
requirements of authority having jurisdiction. Failure to
follow the information in these instructions exactly will
result in death or serious injury. Qualied service agency
is responsible for proper installation.

Pressuretrol Assembly

Installation Instructions: See Figure 4.

1.

Attach pressuretrol assembly (A) to site glass
assembly, using proper pipe sealant.

2.

Remove pressuretrol cover.

3.

Route wire harness through black plastic bushing (B).

4.

Attach two wires. Wires are not polarity sensitive, can
place on either terminal.

5.

Replace pressuretrol cover.

Figure 4 - Pressuretrol Assemly

A

B

7

HYDRONIC 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 safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum
distance from oor or allowable safe point of discharge.

• Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.

• Have no intervening shutoff valve between safety 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 valve and discharge line.

• Install safety valve with spindle in vertical position.

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

• Support safety valve discharge piping.

• Be short and straight as possible.

• Terminate with plain end, not threaded.

• 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 5 - Safety Valve

Safety Valve

Discharge
Piping

Check local codes

for maximum
distance from
oor or other

allowable safe

point of discharge

6" Above Floor

8

HYDRONIC PIPING

Consider near boiler piping as part of the boiler for proper
water level control and to produce dry steam.

Correct near boiler piping is crucial to proper operation of
boiler and heating system.

Follow these recommendations carefully.

1.

Place boiler in selected location as near chimney as
possible.

2.

Install safety valve. Figure 5 and Warning on Page 8.

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

• Install elbows close to safety valve outlet and

downstream of union (if used).

3.

Boiler is equipped with two 2" supply connections and
two 2" return connections, one each on both left and
right sides of boiler. Plug unused connections with
furnished 2" plug and 2 x ¾ " bushing for drain valve.

4.

When using both supply tappings to pipe system as
shown in Figure 6b , Page 10.

• Fit headers with header offsets, swing joints, or equip
with expansion joints, so thermal expansion and
contraction of header does not damage boiler. Do not
weld headers.

5.

Recommended near boiler piping for gravity return
systems is shown in Figure 8 page 11. For gravity return
systems, bottom of lowest steam carrying pipe, dry
return or end of steam main, must be at least 28” above
normal water level line on left side of boiler.

6.

Equip all boilers in gravity return systems with Hartford
Loop as shown in Figure 6a and 6b page 10.

7.

Piping vertical risers from boiler to header, risers must
be minimum of 24" high above water line.

8.

Steam riser(s) and header shall be 2" pipe.

9.

Equalizer line shall be minimum 1-1/2" pipe size.

10.

Near boiler piping shall include 2" tee with female
adapter and cap located on supply line as shown for
skimming (i.e. surface blow-down).

11.

For pumped return systems, follow condensate pump
or boiler feed pump manufacturer’s instructions for
proper installation and hookup. See Table 4 and Figure
7 page 11.

12.

Connecting cold water supply to water inlet valve,
verify clean water supply is available. When water
supply is from well or pump, install sand strainer at
pump.

• Place system takeoffs from header between equalizer
and riser to header nearest equalizer. System takeoffs
must never be between two risers. If steam main goes
in two directions, place two takeoffs from header, one
for each main.

Table 4 - Steam Flow Rates (Gross)

Sections Flow Rates LBS/HR

3

4 94.7 LBS/HR

5 126.8 LBS/HR

6 158.1 LBS/HR

7 190.2 LBS/HR

8 221.5 LBS/HR

9 252.8 LBS/HR

63.4 LBS/HR

9

HYDRONIC PIPING

Figure 6a - Recommended Near Boiler Piping Using One Supply Tapping

Main Vent

28"

24"

Hartford Loop

Close Nipple

Equalizer 1½"

For Alternate Piping Congurations

See Page 28 and 29

2"

Sections Risers Headers Equalizers

3 2" 2" 1½

4 2" 2" 1½

Header

Cap To

Skimmer Tee

Water Line

24"

Floor

Figure 6b - Recommended Near Boiler Piping Using Two Supply Tappings

Sections Risers Headers Equalizers

5 (2) 2" 2" 1½

Main Vent

Header

6 (2) 2" 2" 1½

7 (2) 2" 2½" 1½

8 (2) 2" 3 1½

9 (2) 2" 3 1½

28"

24"

Hartford Loop

Close Nipple

2"

Equalizer 1½"

24"

Cap To

Skimmer Tee

Water Line

For Alternate Piping Congurations

See Pages 28 and 29

Floor

10

HYDRONIC PIPING

Figure 7 - Recommended Near Boiler Piping For Pumped Return Systems

Figure 8 - Recommended Near Boiler Piping For Gravity Return Systems

11

FRESH AIR FOR COMBUSTION

!

WARNING

Air openings to combustion area must not be
obstructed. Follow instructions below, to maintain
adequate 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 volume for all
appliances in space. Use a different method if minimum
volume not available.

C. Refer to National Fuel Gas Code for opening

requirements between connected indoor spaces.

• 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).

C. 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.

A. Standard Method. See Table 5 for space with natural

gas boiler only. Use equation for multiple appliances
and/or propane.

Room Volume is greater than 50 cubic feet multiplied
by Total Input [Mbh]

B. Known Air Inltration Rate. See Table 5 for

space with boiler only. Use equation for multiple
appliances. Do not use an air inltration rate air
changes per hour (ACH) greater than 0.60.

Room volume is greater than 21 cubic feet divided by
ACH (air changes per hour) x Total Input [Mbh]

Table 5 - Minimum Room Volume, Indoor Air Only*

Input Mbh

75 3750 15750 7875 5250 3938 3150 2625

112.5 5625 23625 11813 7875 5906 4725 3938

150 7500 31500 15750 10500 7875 6300 5250

187 9350 39270 19635 13090 9818 7854 6545

225 11250 47250 23625 15750 11813 9450 7875

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.

Standard

Method

0.1 0.2 0.3 0.4 0.5 0.6

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

12

CHIMNEY AND VENT PIPE CONNECTION

WARNING

!

4.

Installing or venting a boiler or any other gas
appliance with improper methods or materials could
result in death or serious injury due to re or to

5.

6.

asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible.

Boiler and venting installations shall be performed

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.

7.

8.

9.

10.

Chimney Inspection

Chimney must be clean, right size, properly constructed
and in good condition.

Installation must conform to requirements of the authority
having jurisdiction or, in absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1/NFPA 54. See
Figure 9, page 14.

Connecting Vent Damper and Vent Connector

Vent or vent connector shall be Type B or metal pipe
having resistance to heat and corrosion not less than that
of galvanized sheet steel not less than No. 26 gauge. See
Table 1 for size of vent (ue opening).

1.

Position furnished vent damper on top of ue outlet
collar. Fasten damper securely to ue outlet collar with
sheet metal screws.

• Verify 1/2 square inch (approximately 3/4" diameter)
hole in damper blade is plugged using plug supplied
with vent damper.

• Verify damper blade has clearance to operate inside
of diverter.

• Do not modify draft diverter or vent damper.

Vent Pipe

• Fasten sections of vent pipe with 3 sheet metal screws

• Support horizontal portions of vent system to prevent

• Use stovepipe wires or metal strapping every 5’ to

• Vent pipe through crawl space, use double wall vent

• Vent pipe passing through combustible wall or partition,

Minimum Vent Pipe Clearance - Wood and other
combustible materials must not be closer than 6”
from any surface of single wall metal vent pipe.
Listed Type B vent pipe or other listed venting
systems shall be installed in accordance with their
listing.

Boiler is equipped with factory wired harness that plugs
into vent damper. Connect thermostat to orange and
white wires marked 24 volt thermostat on boiler.

Vent pipe must be same size as ue outlet collar.
Slope pipe up from boiler to chimney not less than 1/4”

per foot.
Run pipe as directly as possible with as few elbows as

possible.
Do not connect to replace ue.
End of vent pipe must be ush with inside face of

chimney ue.
Horizontal run should not be longer than 3/4 the

chimney height (HT). See Figure 9 page 14.

at each joint to make piping rigid.

sagging.

support pipe from above.

pipe.

use ventilated metal thimble. Thimble should be 4"
larger in diameter than vent pipe.

NOTICE

2.

Install vent damper to service only single boiler for
which it is intended.

• Damper position indicator shall be in visible location
following installation.

• Locate damper so it is accessible for servicing.

Optional - damper may be installed in horizontal or
vertical position as close to ue outlet as possible.

• Horizontal installations. See Figure 10, page 15.

• Alternate installations see steps below. See Figure 11

page 15.

A. Do not install vent damper on vent pipe curve.
B. Do not run wires near high temperature surfaces.

Use stand-off brackets if necessary.

3.

Damper must be in open position when appliance main
burners are operating.

Removing Existing Boiler from Common Venting
System

When an existing boiler is removed from a common
venting system, the common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it.

At the time of removal of an existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while the other appliances remaining connected
to the common venting system are not in operation.

1.

Seal any unused openings in the common venting
system.

2.

Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deciencies
which could cause an unsafe condition.

13

CHIMNEY AND VENT PIPE CONNECTION

3 FT (914mm)

MIN.

2 FT (610mm)

MIN.

3.

Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close replace dampers.

4.

Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.

5.

Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the ame of
a match or candle, or smoke from a cigarette, cigar or
pipe.

6.

After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas-burning appliance to their previous
conditions of use.

7.

Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
When resizing any portion of the common venting
system, the common venting system should be resized
to approach the minimum size as determined using the
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.

Figure 9 - Typical Masonry Chimney Requirements

Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.

14

VENT DAMPER OPERATION

Check vent damper and all ue product carrying
areas of boiler annually for deterioration from
corrosion or other sources. If you see corrosion or
other deterioration, contact your service agent for
repairs.
Check vent damper operation as follows:

1.

When boiler is off, check vent damper positions
indicator points to closed position. See Figure 12.

2.

Turn thermostat or controller up to call for heat and
check vent damper indicator points to open position
See Figure 12.

3.

Turn thermostat or controller down again and check
damper position indicator returns to closed position.

4.

Return thermostat to desired position.

Inspect vent damper at least once a year by
trained service technician.

!

WARNING

Asphyxiation or burn hazard. Improper operation of
vent damper may result in serious injury or death
due to re or to asphyxiation from poisonous gases
such as carbon monoxide which is odorless and
invisible.

Manual Operation of Vent Damper

• Place vent damper in open position to permit burner
operation by using “HOLD DAMPER OPEN” switch,
located on damper controller.

• Thermostat controls burner ring as before, while
damper remains open.

Figure 10 - Horizontal Installation

Horizontal Installation

NO

YES YES

NO

Install vent damper

with actuator to sides

of vent only. Do not

vent.

Actuator may
be installer in

any position.

To Boiler

Chimney

To Boiler

Flow

Vent Damper

To

Flow

To

Chimney

mount above or below

Vent Damper

Figure 11 - Alternate Vent Damper Installation

Caution: Do not

install Vent Damper

within 6" (152mm)

of combustible

material

Install Damper Here

Do Not
Install

Here

• DO NOT turn damper open manually, motor damage

will result.

• Set switch to “AUTOMATIC OPERATION” to close vent
damper during burner off cycle.

• For further information, and for vent damper
troubleshooting guide, refer to manual packaged with
vent damper.

Chimney

Boiler

Water Heater

Figure 12 - Vent Damper Position Indicator

Flue Gas

Flow

Damper Closed

CLOSED

OPEN

ROTATION

Flue Gas Flow

Damper Open

CLOSED

OPEN

ROTATION

Showing Open and Closed Positions

15

GAS SUPPLY PIPING

3” Minimum

Sediment

Trap

Manifold

Floor Line

Automatic

Gas Valve

Ground

Joint

Union

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the re
department.

General

• Use piping materials and joining methods acceptable

to authority having jurisdiction. In absence of such
requirements National Fuel gas Code, ANSI Z223.1/
NFPA 54.

• Size and install gas piping system to provide sufcient

gas supply to meet maximum input at not less than
minimum supply pressure.

Table 6 Natural Gas Propane

Min. Supply Pressure 5" w/c 11" w/c

Max. Supply Pressure 13.5" w/c 13.5" w/c

Manifold Pressure 3.5" w/c 10.5" w/c

• Support piping with hooks straps, bands, brackets,

hangers, or building structure components to prevent or
dampen excessive vibrations and prevent strain on gas
connection. Gas valve will not support piping weight.

• Use thread (joint) compound (pipe dope) suitable for

natural and liqueed petroleum gas.

• Install eld sourced manual main shutoff valve, ground

joint union, and sediment trap upstream of gas valve.
See Figure 13.

See Table 6.

!

DANGER

Fire Hazard. Do not use matches, candles, open
ames, or other methods providing ignition source.
Failure to comply will result in death or serious
injury.

Leak Check Gas Piping

Pressure test boiler and gas connection before placing
boiler in operation. Avoid excessive pressure that could
damage pressure regulators, valves, or meters.

•

Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve.

•

Locate leakage using gas detector, noncorrosive
detection uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open ames, or other methods
providing ignition source.

•

Correct leaks immediately and retest.

Figure 13 - Gas Piping At Boiler

Propane Installation

!

WARNING

Fire, explosion, asphyxiation hazard. Verify boiler
is equipped with propane gas orices and gas valve
is congured for propane. Failure to follow these
instructions may result in serious injury or death.

•

Connections by licensed propane dealer only.

•

Use two stage regulator provided by propane
supplier.

•

Have propane supplier check piping.

16

ELECTRICAL WIRING

!

WARNING

Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.

NOTICE

Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.

Electric Power Supply

Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to
National Electrical Code, ANSI/NFPA 70.

Line Voltage Connections

A. Provide individual 120V, 15 amp circuit

(recommended) with fused disconnect or service

switch as required by authority having jurisdiction.
B. Locate a shut-off switch at the boiler.
C. Connect 120V electrical supply to primary leads on

24 volt transformer. Securely fasten with wire nuts.

Thermostat Installation

1.

Install thermostat on inside wall per manufacturer's
instructions.

2.

NEVER install thermostat on outside wall.

3.

Do not install thermostat where it will be affected by
drafts, hot or cold pipes, sunlight, lighting xtures,
televisions, replace, or chimney.

4.

Check thermostat operation by raising and lowering
thermostat setting as required to start and stop
burners.

5.

Instructions for nal adjustment of thermostat see
manufacturer's instructions.

Electronic Thermostats

A. Some electronic thermostats may lose their

memory or shut down. With probe type low water
cutoff, this may occur each time low water cutoff
detects low water condition. If this is the case, an
isolation relay is required for thermostat circuit.
See Figure 17 page 25.

B. Some electronic thermostats are not acceptable

for use with steam systems, check manufacturer
suggested use.

17

OPERATING INSTRUCTIONS

For Your Safety Read Before Operating

!

WARNING

If you do not follow these instructions
exactly, a re or explosion may result

causing property damage, personal injury
or loss of life.

• This appliance is equipped with an ignition device
which automatically lights burner. Do NOT try to

light this burner by hand.

• Before operating smell all around appliance area
for gas. Be sure to smell next to oor because
some gas is heavier than air and will settle to the
oor.

• Use only your hand to turn the gas shutoff
valve. Never use tools. If valve will not turn

by hand, do not try to repair it, call a qualied
service technician. Force or attempted repair may
result in re or explosion.

• Do not use this appliance if any part has

been under water. Immediately call a qualied
service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.

1.

STOP! Read the safety information on this page.

2.

Set the thermostat to lowest setting.

3.

Turn off all electric power to the appliance.

4.

This appliance is equipped with an ignition device which
automatically lights the pilot. Do not try to light the
pilot by hand.

Figure 14 - Gas Valve

GAS CONTROL KNOB SHOWN
IN "ON" POSITION

5.

Remove front panel.

6.

Rotate the gas control knob clockwise to“OFF”.

7.

Wait ve (5) minutes to clear out any gas. Then smell
for gas, including near the oor. If you smell gas,
STOP! Follow “B” in the safety information on this page
If you don’t smell gas, go to next step.

8.

Rotate the gas control knob counterclockwise
to “ON.”

9.

Replace front panel.

10.

Turn on all electric power to the appliance.

11.

Set thermostat to desired setting.

12.

If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.

• If you cannot reach your gas supplier, call the re
department.

To Turn Off Gas To Appliance

1.

Set the thermostat to lowest setting.

2.

Turn off all electric power to the appliance if service is
to be performed.

3.

Push in gas control knob slightly and turn clockwise to

“OFF” Do not force.

18

OPERATING YOUR BOILER

!

WARNING

Burn Hazard. Never run water into a hot empty
boiler. Failure to follow these instructions could
result in death or serious injury.

Filling System With Water

Steam heating systems boiler is partially lled with water.
Fill boiler to correct level for proper system operation.

Correct water level is about halfway up glass water level
gauge as marked on boiler jacket.

1.

Close boiler drain valve.

2.

Open valves at top and bottom of glass water level
gauge.

3.

Open ll valve. Allow water to run into boiler.

4.

Continue to ll boiler until water reaches indicated
water line about halfway up glass gauge.

Water Level

• Normal water level is 24" above the oor as shown on
left side of boiler.

Thermostat

A. Set thermostat to desired room temperature.
B. Set thermostat to lower setting if heat is not

required

C. System is self-checking. If failure of any component

system will not operate or will go into safety
lockout.

D. On call for heat, each component must function

properly to permit operation.

E. Turn thermostat to lowest setting for one minute

and back to normal setting to reset on safety
lockout.

• Determine water level when boiler is off and cold, when
all water in the system is inside the boiler and return
piping below water line, and everything above water
line is air, no steam.

• When boiler is making steam, water level drops two to
three inches below normal water line.

19

CHECKING AND ADJUSTING

Adjust Pilot Burner

Pilot ame should surround 3/8” to 1/2” of pilot sensor. See
Figure 15.

To adjust Flame.

1.

Remove screw cover over pilot adjusting screw. See
Figure 14.

2.

Insert small screwdriver and adjust ame as needed.
Turn screw counterclockwise to increase ame, clock­wise to decrease.

3.

Replace screw cover over pilot adjusting screw.

Figure 15 - Pilot Burner

Main Burners

• Main burners do not require primary air adjustment and
are not equipped with primary air shutters.

• Main burner ames form sharp blue inner cones in
softer blue outer mantel, with no yellow. Remain still
when observing main burner ames.

• Check main burner orices, burner throat and ame
ports for dust and lint obstruction if ame appearance
is not correct.

• Remove rollout shield if necessary to observe main
burner ames. See Figure 16.

• Replace rollout shield after observation.

Figure 16 - Main Burner

Gas Valve Safety Shutdown Test

1.

Test ignition system safety shutoff device after placing
boiler in operation.

2.

Boilers equipped with intermittent ignition, with
main burners ring, disconnect ignition cable from
intermittent pilot control box. Gas valve will shut off
main burners.

3.

TURN OFF ELECTRIC POWER to boiler before
reconnecting ignition cable, to prevent electric shock.

20

CHECKING AND ADJUSTING

Adjust Steam Pressure Control

• Steam pressure limit control (pressuretrol) shuts
off gas to main burners when steam pressure in
boiler reaches cut-off setpoint (i.e. sum of cut-in and
differential setpoints).

• Burners rere when steam pressure drops to cut-in
setpoint.

• System pressure requirements are based on size and
condition of pipes, and load.

• Cut-in setting of pressuretrol should never be less than
twice system pressure drop for good system operation.

A. In typical single family residence with clean one-

pipe heating system and cast iron radiation, cut-in
is usually set at minimum setting, i.e. 1/2 psi.

• Steam radiation is sized based on square feet of
equivalent direct radiation (EDR). This is based on
steam pressure in the radiator of just less than 2 psi.

• Set differential adjustment at 1 psi, i.e. steam pressure
required in radiators. Results in cut-off setpoint of 1½
psi.

• Larger systems or other types of systems such as two
pipe systems, or systems with convectors or fan coil
units, pressuretrol settings need to be determined on
system-by-system basis.

• Cut-in setpoint is determined by system pressure drop
to furthest radiator or terminal unit. Double system
pressure drop as safety factor, resulting in the rule
cut-in setting should never be less than twice system
pressure drop.

• Differential setpoint is steam pressure required at
terminal heating units.

Boiler will now operate in correct pressure range. It
maintains enough steam pressure to send steam out to
furthest radiator, and not go over optimum steam pressure
required at the radiators.

Checking Controls

Low Water Cut-Off

A. Turn off power to boiler or turn thermostat down to

lowest setting.

B. Drain water to below visible bottom of water gauge

glass. Turn power on and turn thermostat to call for
heat.

C. Gas valve opens for approximately 15 seconds

(time delay on probe type LWCO), gas valve will
close and red indicator illuminates on LWCO.

D. When water is restored, it waits 30 seconds before

reactivating burner circuit.

Boiler Equipped With Optional VXT-24 Water Feeder

E. Continue thermostat call for heat after low water

cut off recognizes low water condition.

F. One minute time delay, water feeder starts feeding

water to boiler.

G. Feeder feeds for one minute, and then goes into

another one minute waiting period.

H. Cycle of alternately waiting and feeding will repeat

until the water level in boiler rises and makes
contact with probe, satisfying water feeder and
igniting burners.

• In either case, one and two inches of water should
be visible in glass gauge when both water feeder is
satised, and burners are allowed to ignite.

• Time delays in feed cycles are designed to prevent
boiler from ooding due to slow return lines.

• To check pressure limit, run boiler until pressure
reaches system demand. Turn pressure screw and drop
pressure setting until boiler shuts down. This shows the
pressure limit is operating properly.

• Refer to control manufacturer’s instructions for more
information.

Check Thermostat Operation

Thermostat set above temperature indicated on
thermometer, boiler should ignite.

Verify thermostat turns boiler off when room temperature
reaches selected setting and starts boiler operating when
room temperature falls few degrees.

Set thermostat for desired temperature. Conditions in your
home and location of thermostat will govern this setting.

21

START-UP CLEANING

!

WARNING

7.

Following service procedures must be performed
by qualied service agent. Boiler owner shall not
attempt these steps. Failure to do so could result in
death or serious injury.

It is very important to clean a new steam boiler after it has
been installed and put into continuous operation.

This must be done to remove any accumulation of oil,
grease, sludge, etc., that may have be present in system.
These substances may cause boiler water to foam and
surge, producing an unsteady water line, throwing
water into steam header, and possibly preventing steam
generation.

Follow skimming and blow-down steps in order to remove
contaminants.

8.

Following nal blow-down, allow boiler to cool.

• Add fresh water slowly up to normal water line.

• Start burners.

• Maintain at least 180°F for 15 minutes to remove

dissolved gasses from fresh water.

• Shut off burners.

Allow system to operate for one week to give majority
of system dirt a chance to work its way back to boiler.

• Check water in gauge glass. Gauge glass should be

dry above water line.

• Water line should not bounce more than one inch

when boiler is steaming.

• If you see water droplets carrying over from top of

gauge glass, or excessive bouncing of water line,
boiler needs further cleaning.

Skimming and Blow-down

!

WARNING

Burn Scald Hazard. Water temperatures in excess
of 125°F. Failure to follow these instructions could
result in death or serious injury.

New boilers must be skimmed at time of installation to
remove threading oil and other impurities that oat on
surface of water.

1.

Remove cap from skimmer female adapter tee and pipe
to oor drain or bucket. See Figures 6a and 6b page

10. Raise water level to skimmer tapping.

2.

Fire burners to maintain water temperature of 180­200°F.

3.

Feed water to boiler to maintain water level. Adjust
water feed rate to maintain continuous ow of 1 gallon
per minute. Do not allow boiler to steam.

4.

Continue skimming until water runs clear. This may
take several hours.

5.

Drain boiler completely to remove any foreign material.

6.

Fill boiler to water line.

• Fire burners, allow normal steam pressure to build
up.

• Take water sample and boil it on stove to see if it
foams. If it does, this indicates boiler needs to be
cleaned.

NOTICE

Clean water with no additives is essential to proper
operation of your boiler and heating system. Boiler
cleaners and chemical cleaning, if used and not
rinsed properly, may be harmful to the system.

If cleaning is necessary, repeat skimming and blow-down
procedure above. A long skim will be all you need to clean
the boiler.

In more troublesome cases it may be desirable to ush the
system while, in very extreme cases, it may be necessary
to chemically clean and ush heating system.

Consult boiler manufacturer before introducing any
chemicals into boiler.

Check water level frequently. Be sure top and bottom
valves on gauge are always open so actual water level is
shown at all times.

• Run connection from boiler drain valve to safe
discharge point outside.

• Shut off gas burners, open drain valve, allow all of
water in boiler to drain out.

• Close drain valve.

• Allow boiler to cool, slowly rell boiler to water line.

• Repeat this step as many times as necessary until

blow-down water is clear.

22

GENERAL MAINTENANCE

Low Water Cut-Off

Low Water Cut-Off interrupts electrical current to burner
when water line in boiler drops to low level.

Check Low Water Cut-Off monthly to verify it is providing
proper protection. See “Checking and Adjusting” on page

21.

Remove Low Water Cut-Off probes beginning of each
heating season for inspection and cleaning. More cleaning
may be required on boilers requiring frequent additions of
make up water.

Boiler Flue Passages and Burners

Beginning of heating season visually check pilot and main
burner ames. See page 20.

Recommend you have ue passages, burner adjustment,
and operation of controls checked once each year by
trained Service Technician.

Before start of each season or whenever system has been
shut down for some time, check system, boiler and vent
pipe for leaks.

Boiler Water Treatment Other Than Cleaners

In steam systems where system is tight, free from leaks,
and all steam is returned to boiler as condensate, amount
of make up water is small. Water treatment is generally not
required.

In steam systems with less than 90% of steam being
returned as condensate, or with very hard or corrosive
make up water, treatment may be desirable. Follow
recommendations of your local boiler water treatment
specialist.

Foaming, Priming, or Surging

These terms are used to describe uctuating water line ­when water leaves boiler with steam. It is caused by any
combination of following:

1. Threading oil and organic matter in boiler water. Follow

2.

3.

Vent Pipe

Check vent piping at lease once a season. Verify vent pipe
connections to chimney are secure and no obstructions
are present. If vent piping shows sign of leaking, replace it
immediately.

4.

Safety Valve

See Manufacturer's Instructions.

instructions under “Start-up Cleaning.”
Faulty quick vents that do not release air until sizeable

pressure is built up - if old style, replace - if dirty, clean
until you can easily blow through valve.

Adjustment of steam limit control to wide differential
increases difculty if quick vents are old style, slow­releasing type or dirty. Always set steam limit control
differential as low as possible.

Soap and chemicals in boiler water cause extreme
surging. Boiler cleaners and chemical cleaning additives
are not recommended. If used and not rinsed properly,
may be harmful to the system.

Cleaning Boiler Flue Passages and Burners

1. Remove burners, pilot, vent pipe, top and front jacket
panels. Remove hold-down nuts and bolts from ue
collector.

2. Use putty knife to cut through silicone. Lift ue collector
off boiler sections. Remove old silicone material.

3. Clean passageways between sections with ue brush.
Remove dirt from bottom of boiler and from between
sections by vacuuming.

4. Verify all ame ports in burners are open and clear.
Shake or blow out loose dirt in burners.

5. Apply generous bead of 400°F RTV silicone to four
mounting surface anges of ue collector. Mount ue
collector on heat exchanger. Tighten nuts and bolts.

6. Seal front edge and four corners of ue collector to
heat exchanger with silicone sealant.

7. Use ashlight to verify there are no gaps in silicone
seal.

8. Install draft diverter, vent damper, vent pipe, and
jacket top and front cover.

9. Reassemble all parts.

10. Check tightness of pilot connections and condition of

burner ames after reassembly. See Figures 15 and 16.

23

TROUBLESHOOTING

You may avoid inconvenience and service calls by checking these points before you call for service.

!

CAUTION

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.

• If you cannot reach your gas supplier, call the re
department.

Symptom Possible Cause What To Do

System Not
Heating or Not
Giving Enough
Heat

Burner is Noisy

Walls or Windows
Sweating

Safety valve
Leaking

Thermostat is not set correctly Reset thermostat above room temperature.

Thermostat not operating

Burner is not operating properly

No electric power to boiler

Controls out of adjustment Reset according to instructions.

Radiators not heating

Poor electrical contact

Chimney ue is blocked

Vent damper not operating

Gas input is incorrect Contact service technician.

Not enough ventilation Contact service technician.

Chimney ue is blocked

Dirt on seat Contact service technician.

Inspect and replace thermostat batteries, if necessary.
Contact service technician.

Inspect ame. If yellow, burner is not getting enough air. If
blue and noisy and seems to lift off burner, burner is getting
too much air. Contact service technician.

Verify electric power supply circuit is “ON”. Contact your
service technician to verify over current protection.

Inspect steam air vents for proper operation. Contact
service technician to inspect for faulty steam traps.

Contact your service technician to inspect all control
terminals and wire joints.

Spill switch contacts open, requiring manual reset of spill
switch. Contact service technician to inspect and correct
chimney problem.

Consult troubleshooting guide packaged with vent
damper.

Contact service technician to inspect and correct, if
necessary.

HAVE SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

24

WIRE DIAGRAMS

Figure 17 - Isolation Relay Wiring For Steam Boilers With Probe Type Low Water Cut Off And Using An

Electronic Thermostat - Optional

Figure 18 - Water Feeder Connection - Optional

Optional water feeder connection.

• Connect feeder N to terminal 2.

• Connect feeder H to terminal 1.

• Connect "FEED" or "W" to terminal A.

• For water feeders with 2 leads, connect feeder

common to terminal 2 and feeder hot to terminal A.

Note: Use of a solenoid valve or McDonnell & Miller

Model 101A water feeder may cause ooding and is not

recommended for use with this low water cut-off.

25

WIRE DIAGRAMS

G

LNG

120V AC FIELD

CONNECTIONS IN

ACCORDANCE WITH

NEC / CEC AND LOCAL

CODES. USE COPPER

CONDUCTORS ONLY

GAS VALVE

MV

MV/PV

PV

GRN

BLU

WHT

RED

INSIDE BOILER JACKET

OUTSIDE BOILER JACKET

ROLL

OUT

SWITCH

WHT

BLU

IGNITION MODULE

RED

WHT

BLU

PRESSURETROL

DIFF

KG/

2

CM

PSI

.6
.5

.3

.1

2

8

9

0.5

CUT IN

BLK

BLK

BLK

WHT

WHT

BLOCKED

VENT

SWITCH

WHT

BLK

120V / 24V, 50VA

TRANSFORMER

LWCO PROBE

BLK

BRN

YEL

ORG

NEC CLASS 2

LOW VOLTAGE

FIELD SUPPLIED

THERMOSTAT

T

(R)T(W)

LOW WATER

CUT OFF

PROBE

JP2

2

1 P1 P2

A

BURNER

JP1

FACTORY

INSTALLED

JUMPER

BLK

VENT DAMPER

P/N: 240009879
Revision: A

RED
WHT

PNK
BRN

WHT

WHT

WHT

YEL

ORG

WHT

BRN

BLK

BLK

BLK

C

R

C

R

IGNITOR

SPARK

SENSE

24V

PV

GND

(BURNER)

24V

(GND)

MV

MV/PV

(For full-sized Wire Diagrams, see Literature Envelope.)

Figure 19 - Wiring Diagram For Boilers With CG 400-2060 Probe Type Low Water Cut-Off

If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type
105°C Thermoplastic wire or its equivalent.

26

WIRE DIAGRAMS

120V / 24V, 50VA

TRANSFORMER

L N

LOW WATER

CUT OFF

JP2-1

JP2-2

JP2-3

NOTE:

CONNECTOR POSITION 3 IS

LABELED 1 ON LWCO CIRCUIT

BOARD JP2 MOLEX CONNECTOR

PRESSURETROL

BLOCKED VENT

SWITCH

THERMOSTAT

ROLL OUT

SWITCH

1

3

VENT DAMPER

IGNITION MODULE

24V

24V

(GND)

PV

GND

(BURNER)

MV SPARK

SENSE

MV/PV

PROBE

JP1-

BURNER

JP1-P1JP1-A

JP1-1

JP1-2

2

4

MV/PV

MV

GAS VALVE

GNDPV

JP1-P2

SPARK

IGNITOR

LOW WATER

CUT OFF PROBE

R C

HIGH VOLTAGE CONNECTIONS PER NEC AND LOCAL CODES

NEC CLASS 2

LOW VOLTAGE

(R) T (W) T

(For full-sized Wire Diagrams, see Literature Envelope.)

Figure 20 - Ladder Diagram For Boilers With CG 400-2060 Probe Type Low Water Cut-Off

27

OPTIONAL HYDRONIC PIPING

Figure 21 - Counter Flow Steam Systems

Hartford Loop

24"

2" Pipe

28"

Water Line

48"

Floor

24"

Floor

28

OPTIONAL HYDRONIC PIPING

Figure 22 - Drop Header for True Swing Joint

24"

28"

Water Line

Hartford Loop

24"

Floor

29

OPTIONAL PIPING HYDRONIC PIPING

30

SERVICE RECORD

Company Address & Phone #Company Name & Tech InitialsService PerformedDate

31

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com