ECR International MGB-50J Gebrauchsanweisung

P/N 240011584, Rev. A [07/30/2016]

An ISO 9001-2008 Certified Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

MGB

CAST IRON GAS FIRED BOILERS

FOR FORCED HOT WATER

with Honeywell Control

INSTALL ATION, OPER ATION

& MAINTENANCE MANUAL

Models

MGB-50J

MGB-75J

MGB-100J

MGB-125J

MGB-150J

MGB-170J

MGB-200J

Tested For 100 psi.

ASME

Working Pressure

C.S.A. Certied

For Natural Gas

Or Propane

Table 1 - Dimensions

Boiler No. Natural Gas

Inlet*

Dimensions Pump size Supply &

Return Tappings

ABCD** EF

50 ½" 11⅛" 5½"4" 30¾" 36¼" 5¾" 1¼"

75 ½" 15" 7½"5" 30¾" 37¾" 5¾" 1¼"

100 ½" 15" 7½"6" 30¾" 37¼" 6" 1¼"

125 ½" 18⅞" 9½"6" 30¾" 37¼" 6" 1¼"

150 ½" 18⅞" 9½"7" 30¾" 37¾" 6¾" 1¼"

170 ½" 22¾"11½"7" 30¾" 38¾" 6¾" 1¼"

200 ½" 22¾"11½"8" 30¾" 38¾" 7¾" 1¼"

* Propane gas inlet, all units, 1/2"

** D is minimum height for low water cutoff installation

DIMENSIONS

P/N 240011584 Rev. A [07/30/2016]

Figure 1 - Dimensions

"E"

4½"

1¼" Return

"B"

"F"

14"

4¼"

1¼" Supply

2½"

"A"

"D"**

3½"

27"

5½"

"C"

Safety Symbols & Warnings

The following dened symbols are used throughout this

manual to notify the reader of potential hazards of varying

risk levels.

SAFETY SYMBOLS AND WARNINGS

NOTICE

Used to address practices not related to personal

injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

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

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.

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

Safety Symbols and Warnings ............................3

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

Installation Procedure .......................................5

Ventilation & Combustion Air.............................. 6

Connecting Supply and Return Piping ..................7

Connecting Supply and Return Piping ..................8

Vent Installation ............................................. 12

Vent System Modication................................. 12

Vent Damper Installation & Instructions............. 13

Connecting Gas Service................................... 14

Electrical Section ............................................ 15

Wiring Diagram ............................................. 16

Lighting Instructions ....................................... 18

Normal Sequence of Operation ......................... 19

General Instructions ....................................... 19

Checking Gas Input Rate To Boiler .................... 21

Appendix A - Control Module................. ........... 22

Appendix B-1 - Vent Damper Harness ............... 30

Appendix B-2 - Vent Damper Troubleshooting..... 31

CAUTION

Laceration, burn hazard. Metal edges and parts

may have sharp edges and/or hot. Use appropriate

personal protection equipment to include safety

glasses and gloves when installing or servicing this

boiler. Failure to follow these instructions could result

in minor or moderate injury.

P/N 240011584 Rev. A [07/30/2016]

Table 2 - Ratings and Capacities

Boiler

No.

(1)

Input

Mbh

(1)

Heating

Capacity Mbh

(2)

Net AHRI

Rating Water

Mbh

AFUE No.

Burners

(3)

Recommended

Air Cushion

Tank

Water

Content

(Gals.)

(1)

High

Altitude Input

Mbh

50J 50 42 37 83.5 115 2.4 45

75J 75 63 55 83.1 215 4.0 67.5

100J 100 83 72 83.0 230 4.0 90

125J 125 104 90 82.0 330 5.6 112.5

150J 150 124 108 83.0 330 5.6 135

170J 170 139 121 82.0 430 7.2 153

200J 200 165 143 82.0 430 7.2 180

RATINGS & DATA - NATURAL GAS & PROPANE GAS

P/N 240011584 Rev. A [07/30/2016]

EXPLANATORY NOTES

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

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

-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be

reduced to 10 feet. Refer to the latest revision of NFGC part 11.

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

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

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

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

level.

Canada, 2000 ft (610m) to 4500 (1350m) above sea level reduce input per table. Over 4500 ft (1350m) above sea

level. Contact Provincial authority having jurisdiction.

(2) Net AHRI Water Ratings shown based on piping and pickup allowance of 1.15. Consult manufacturer before selecting

boiler for installations having unusual piping and pickup requirements, such as intermittent system operation,

extensive piping systems, etc.

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

its heating capacity.

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

radiation.

STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Intermittent Electric Ignition Pilot

System, Vent Damper Relay, Theraltimeter Gauge, Circulator With Return Piping To Boiler, Main Gas Burners, Gas Control

(Includes Automatic Gas Valve, Gas Pressure Regulator, Intermittent Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter),

A.S.M.E. Relief Valve, Drain Valve, Spill Switch, Rollout Switch, Combination Gas Control, Automatic Vent Damper. Not Shown

Are: Wiring Harness, Thermocouple, Non-linting Safety Pilot.

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.

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.

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.

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.

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.).

Locate boiler on level, solid base as near chimney as

possible and centrally located with respect to heat

distribution system as practical.

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

servicing and cleaning.

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.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS

ONLY - For installation on combustible ooring special

base must be used. (See Repair Parts, Optional Kits

Manual). Do not install boiler on carpeting. Minimum

clearances to combustible construction are:

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

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

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

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

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

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

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

NOTE: Greater clearances for access should supersede fire

protection clearances.

* Denition of Alcove is three sided space with no wall in

front of boiler. ANSI standard for alcove is 18 inches from

front of appliance to leading edge of side walls as shown

below.

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

BOILER

18"

Front

Minimum Clearances to Combustible Construction

(as seen from above)

P/N 240011584 Rev. A [07/30/2016]

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.

xEngineered Installations. Must be approved by

authority having jurisdictions.

xMechanical 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.

xAll Indoor Air. Calculate minimum volume for all

appliances in space. Use a different method if

minimum volume not available.

оStandard Method. Cannot be used if known air

inltration rate is less than 0.40 air changes per

hour. See Table 3 for space with boiler only. Use

equation for multiple appliances.

Volume ≥ 50 ft3x Total Input [Mbh]

оKnown Air Inltration Rate. See Table 3 for

space with boiler only. Use equation for multiple

appliances. Do not use an air inltration rate

(ACH) greater than 0.60.

Volume ≥ 21 ft3/ACH x Total Input [Mbh]

оRefer to National Fuel Gas Code for opening

requirements between connection indoor spaces.

xAll Outdoor Air. Provide permanent opening(s)

communicating directly or by ducts with outdoors.

оTwo Permanent Opening Method. Provide opening

commencing within 12 inches of top and second

opening commencing within 12 inches of bottom

enclosure.

Direct communication with outdoors or

communicating through vertical ducts. Provide

minimum free area of 1 in2per 4 Mbh of total

input rating of all appliances in enclosure.

Communicating through horizontal ducts.

Provide minimum free area of 1 in2per 2

Mbh of total input rating of all appliances in

enclosure.

оOne Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.

Provide minimum clearance of 1 inch on sides

and back and 6 inches on front of boiler (does not

supersede clearance to combustible materials).

xRefer to National Fuel Gas Code for additional

requirements for louvers, grilles, screens and air

ducts.

xCombination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for application information.

National Gas and Propane Installation Code Requires

providing air supply in accordance with:

xSection 8.2 and 8.3 when combination of appliances

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

kW).

оDoes not have draft control device.

xSection 8.4 when combination of appliances has total

input exceeding 400 Mbh (120 kW).

xRefer 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 3 - Space With Boiler Only

Room Cubic Feet Volume

Input Mbh Standard

Method

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

0.1 0.2 0.3 0.4 0.5 0.6

50 2500 10500 5250 3500 2625 2100 1750

75 3750 15750 7875 5250 3938 3150 2625

100 5000 21000 10500 7000 5250 4200 3500

125 6250 26250 13125 8750 6563 5250 4375

150 7500 31500 15750 10500 7875 6300 5250

170 8500 35700 17850 11900 8925 7140 5950

200 10000 42000 21000 14000 10500 8400 7000

P/N 240011584 Rev. A [07/30/2016]

CONNECTING SUPPLY AND RETURN PIPING

Check local

codes for

maximum

distance

from oor

or allowable

safe point of

discharge.

RELIEF VALVE

DISCHARGE

LINE

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:

xconnect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum

distance from oor or allowable safe point of discharge.

xbe of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge

line;

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

place any obstruction in discharge line.

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

xallow complete drainage of the valve and the discharge line;

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

xbe as short and straight as possible;

xterminate with plain end (not threaded);

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

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

requirements.

Figure 2 - Safety Relief Valve

P/N 240011584 Rev. A [07/30/2016]

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

acceptable practice.

AIR

SEPARATOR

Boiler used in connection with refrigeration system,

install so chilled medium is piped in parallel with boiler

with appropriate valves to prevent chilled medium from

entering boiler. See Figure 3.

Boiler piping system of hot water boiler connected to

heating coils located in air handling units where they

may be exposed to refrigerated air circulation must be

equipped with ow control valves or other automatic

means to prevent gravity circulation of boiler water

during cooling cycle.

Hot water boilers installed above radiation level or

as required by authority having jurisdiction must be

provided with low water cut-off device.

Boiler connected to heating system utilizing multiple

zoned circulators, each circulator must be supplied with

ow control valve to prevent gravity circulation.

Hot water boilers and system must be lled with water

and maintained to minimum pressure of 12 psi.

For Low Water Cutoff, see Figure 1 for minimum height.

Use Kit #550002998 and follow instructions enclosed

with kit. For other LWCO's follow their manufacture

specic instructions.

Bypass piping is optional which gives ability to

adjust supply boiler water temperature to t system

or condition of installation. This method of piping,

however, is not typically required for baseboard heating

systems. Typical installations where bypass piping is

used are as follows:

A. This method is used to protect boilers from

condensation forming due to low temperature

return water. Generally noticed in large converted

gravity systems or other large water volume

systems. Figures 4 and 5.

B. These methods are used to protect systems using

radiant panels and material they are encased in

from high temperature supply water from boiler

and protect boiler from condensation.

NOTE#1: When using bypass piping, adjust

valves V1 & V2 until desired system temperature

is obtained. See Figure 5, page 9.

NOTE#2: Bypass loop must be same size piping

as supply and return piping.

CONNECTING SUPPLY AND RETURN PIPING

Figure 3 -

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

See Special Conditions, Page 9

P/N 240011584 Rev. A [07/30/2016]

BOILER

WATER INLET

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM FROM SYSTEM

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE

3 WAY MIXING

VALVE

AIR SEPARATOR

HOSE BIB

EXPANSION

TANK

8. Installation using circulators and zone valves are

shown in Figures 6 through 9. For further piping

information refer to AHRI Installation and Piping

Guide.

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per these instructions.

9. Install discharge piping from safety relief valve. See

Warning, Page 7 and Figure 2.

CONNECTING SUPPLY AND RETURN PIPING

BOILER ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM FROM SYSTEM

V2V1

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE AIR SEPARATOR

ZONE VALVE

EXPANSION

TANK

WATER INLET

SYSTEM

CIRCULATOR

Figure 4 - Bypass Piping With Mixing Valve

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

P/N 240011584 Rev. A [07/30/2016]

CONNECTING SUPPLY AND RETURN PIPING

Figure 6 - Single Zone System With DHW

Figure 7 - Multi Zone System With Circulators And DHW

P/N 240011584 Rev. A [07/30/2016]

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