ECR International GreenMountain GMGS075E Gebrauchsanweisung

P/N# 240009192, Rev. D [9/2013]

GMGS

Cast Iron

Steam

Gas Fired

Boilers

INSTALL ATION, OPER ATION & MAINTENANCE MANUAL

Models

GMGS075E GMGS225E

GMGS112E GMGS262E

GMGS150E GMGS299E

GMGS187E

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

DIMENSIONS

Figure 1 - Dimensions

BOILER MODEL

NUMBER (1)

Dimensions (Inches)

Intermittent

Ignition w/Vent

Damper

Flue Diameter "A" Width

GMGS075E 5 11¼

GMGS112E 6 14½

GMGS150E 6 17¾

GMGS187E 7 21

GMGS225E 7 24¼

GMGS262E 7 27½

GMGS299E 7 30¾

Add 5½" to height for Vent Damper

(1) Add model number sufx 'P' for Propane Gas.

Table 1 - Ratings and Capacities

BOILER MODEL

NUMBER

No. of

Sec.

†Natural Gas

Intermittent

Ignition w/Vent

Damper

Fuel Type Input

*MBTUH

Heating

Capacity

*MBTUH

AFUE(%) Net AHRI

Rating *Mbh

Net AHRI

Rating Sq. Ft.

Radiation

(1) GMGS075E 3Natural Gas 75 62 82.7 47 196

(1) GMGS112E 4Natural Gas 112 91 82.0 68 283

(1) GMGS150E 5Natural Gas 150 122 82.0 92 383

(1) GMGS187E 6Natural Gas 187 153 82.0 115 479

(1) GMGS225E 7Natural Gas 225 183 82.0 137 571

(1) GMGS262E 8Natural Gas 262 214 82.0 161 671

(1) GMGS299E 9Natural Gas 299 245 82.0 184 767

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

† For altitudes above 2,000 ft. reduce input rate 4% for each 1,000 ft. above sea level.

Heating Capacity is based on DOE (Department of Energy) test procedure.

(1) Add model number sufx 'P' for Propane Gas.

Net AHRI steam Ratings shown are based on a piping and pickup allowance of 1.333.

Base selection of boiler size on "Net AHRI Rating" being equal to or greater than installed radiation in square feet.

Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements,such as

intermittent system operation, exhaust piping systems, etc.

RATINGS AND CAPACITY

Dimensions ................................................ 2

Ratings and Capacity .................................. 3

Safety Symbols .......................................... 5

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

System Piping ............................................ 7

Installation - System Piping ........................10

Fresh Air for Combustion ............................11

Chimney and Vent Pipe Connection ..............12

Vent Damper Operation ..............................14

Gas Supply Piping ......................................15

Electrical Wiring ........................................16

Operating Instructions ................................17

Operating Your Boiler .................................18

Checking and Adjusting ..............................19

Start-up Cleaning ......................................21

General Maintenance .................................22

Service Hints ............................................23

Wiring Diagrams ........................................24

Wiring diagrams ........................................25

Controls and Accessories ............................26

Repair Parts ..............................................27

TABLE OF CONTENTS

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

GAS FIRED STEAM BOILERS

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

time of printing of this manual. Manufacturer reserves the right to

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

notice and without incurring any obligation, whatsoever.

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 page 2.

• Verify ratings and capacity data for natural gas. See

Table 1 page 3.

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.

SAFETY SYMBOLS

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.

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.

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.

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.

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.

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.

LOCATING THE BOILER

Locating the Boiler

Select level location as centralized with piping system,

and as near chimney as possible.

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.

Do not install boiler on carpeting. For installation

on non-combustible oors only. For installation on

combustible ooring, special base must be used. See

Repair Parts page 27.

Use metal shims under boiler base legs for nal leveling

if needed.

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 11.

Notify owner to keep air passages free of obstruction.

Ventilating and combustion air must enter boiler room

without restrictions.

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 8. Attach draft diverter,

and blocked vent switch. Mount vent damper. See

"Connecting Vent Damper and Vent Connector" page 12.

See Wiring Diagrams page 25.

Table 2 -

Minimum Clearance Dimensions

Top 6"

Rear 6"

Control Side 7"

Opposite Side 6"

Front Alcove

Flue/Vent

Connector

SYSTEM 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.

Check local codes

for maximum

distance from

oor or other

allowable safe

point of discharge

Safety Valve

Discharge

Piping

6" Above Floor

Figure 3 - Safety Valve

SYSTEM 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.

Place boiler in selected location as near chimney as

possible.

Install safety valve. Figure 3 and Warning on Page 7.

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

• Install elbows close to safety valve outlet and

downstream of union (if used).

Boiler is equipped with two 2½" supply connections

and two 2½" return connections, one each on both left

and right sides of boiler. Plug unused connections with

furnished 2½" plug (furnished).

When using both supply tappings to pipe system as

shown in Figure 5, 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.

• 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.

System takeoffs from the header must never be

bullheaded. If the steam main goes in two directions,

there must be two takeoffs from the header, one for each

main.

All boilers in gravity return systems must be equipped

with a Hartford Loop as shown in Figure 5.

When piping the vertical risers from the boiler to the

header, the bottom of the header must be a minimum

of 24 inches above the water level line on the right side

of the boiler.

Steam riser(s) and header shall be 2½” pipe size.

Equalizer line shall be minimum 1½” pipe size.

10.

The near boiler piping shall include a 2½” tee with a

plug located on the supply line as shown for skimming

(i.e. surface blowdown).

11.

The near boiler piping shall include a 1-1/2 ball valve

in the return piping as shown for bottom blowdown and

draining.

12.

For gravity return systems, the bottom of the lowest

steam carrying pipe, be it a dry return, or the end of the

steam main, must be at least 28” above the normal water

level line on the right side of the boiler. This is known as

“Dimension A.”

13.

For pumped return systems, follow the condensate

pump or boiler feed pump manufacturer’s instructions

for proper installation and hookup.

14.

In connecting the cold water supply to the water inlet

valve, make sure that a clean water supply is available.

When the water supply is from a well or pump, a sand

strainer should be installed at the pump.

For Use With Cooling Units

Install boiler, when used in connection with refrigeration

system, so chilled medium is piped in parallel with boiler

with appropriate valves to prevent chilled medium from

entering the boiler. See Figure 6.

Figure 4 - Recommended Near Boiler Piping Using One Supply Tapping

SYSTEM PIPING

INSTALLATION - SYSTEM PIPING

Figure 6 - Chilled Water Piping

VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING

VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING

Figure 5 - Recommended Near Boiler Piping Using Two Supply Tappings

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