UTICA BOILERS MGC-8D Gebrauchsanweisung

P/N 240009268, Rev. A [03/2012]

MGCSERIES

GAS-FIRED

HOT WATER BOILERS

INSTALLATION,OPERATION&

MAINTENANCEMANUAL

An ISO 9001-2008 Certified Company

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Models

MGC-8D

MGC-8DP

MGC-9D

MGC-9DP

C.S.A. Certiﬁed for

Natural gas or

Propane Tested for 50 psi.

ASME Working

Pressure

1 - DIMENSIONS

Table 1 - Dimensions

BOILER

MODEL

NUMBER

DIMENSIONS (INCH.)

FLUE

DIAMETER “A”

WIDTH

MGC-8 7 27½

MGC-9 7 30¾

Add 5½” to height for vent Damper.

Figure 1 - Dimensions

2 - BOILER RATINGS AND CAPACITIES

Table 2 - Ratings and Capacities

BOILER

MODEL

NUMBER (1)

† NATURAL GAS † PROPANE GAS AFUE

Input (3)

Mbh

(1)

Heating

Capacity

(3) Mbh

(2)

NET AHRI

RATING

Water,

(3) Mbh

INPUT (3)

MBH

HEATING

CAPACITY (3)

MBH

NET AHRI

RATING INTERMITTENT

IGNITION WITH

VENT DAMPER

MGC-8 262.5 220 191 245 206 179 83.9

MGC-9 299 251 218 280 235 204 83.7

†

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

Over 2000 ft (610m) above sea level.

Reduce input rate 4% for every 1000 ft (304m) above sea level.

+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.

(1) Add model number sufﬁce ‘P’ for Propane.

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

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

extensive piping systems, etc.

(3) MBH = 1,000 Btuh = British Thermal Unit Per Hour

Ratings marked “Net AHRI Ratings” indicate amount of remaining heat input used to heat radiation or terminal units. Net

AHRI Ratings shown are based on allowance of 1.15 in accordance with factors shown on AHRI Standard as published by

The Hydronics Institute.

Selection of boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated heat loss of the-

building.

Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.-

BOILERS FOR USE AT HIGH ALTITUDE

Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level.

For use at altitudes above 2,000 feet above sea level, input ratings are reduced by change in main burner oriﬁce size.

For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above

sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54 or manufacturer for correct oriﬁce sizing information.

3 - TABLE OF CONTENTS

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

ﬂammable vapors and liquids.

DO NOT obstruct air openings to the boiler

room.

Modiﬁcation, substitution or elimination

of factory equipped, supplied or speciﬁed

components may result in personal injury or

loss of life.

TO THE OWNER - Installation and service of

this boiler must be performed by a qualiﬁed

installer.

TO THE INSTALLER - Leave all instructions

with boiler for future reference.

When this product is installed in the

Commonwealth of Massachusetts the

installation must be performed by a Licensed

Plumber or Licensed Gas Fitter.

WARNING

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.

SAFETY SYMBOLS & WARNINGS

The following deﬁned symbols are used throughout

this manual to notify the reader of potential hazards

of varying risk levels.

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

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

4 - INSTALLATION PROCEDURE

Table 3 -

MINIMUM CLEARANCE DIMENSIONS

Inches (mm)

Top 6” (152mm)

Rear 6” (152mm)

Control Side 7” (178mm)

Opposite Side 6” (152mm)

Front 18” (457mm)

Flue/Vent Connector 6” (152mm)

Near Boiler Piping 2” (51mm)

WARNING

Improper installation, adjustment, alteration,

service or maintenance could result in death or

serious injury.

WARNING

Fire hazard. Do not install boiler on

combustible ﬂooring 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

ﬂooring special base must be used. (See

Replacement Parts Section.) Boiler can not be

installed on carpeting.

NOTE: Greater clearances for access should supersede fire

protection clearances.

* Deﬁnition of Alcove is three sided space with no

wall in front of boiler. ANSI standard for alcove is 18

inches from front of appliance to leading edge of side

walls as shown below.

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.

Where required by the authority having

jurisdiction, the installation must conform to the

Standard for Controls and Safety Devices for

Automatically ﬁred Boilers, ANSI/ASME CSD-1.

Boiler series is classiﬁed as a Category I. Vent

installation shall be in accordance with "Venting of

Equipment ," of the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 or applicable provisions of the

local building codes.

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.

5 - VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance

with the section “Air for Combustion and Ventilation,”

of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or

applicable provisions of local building codes.

Provide make-up air where exhaust fans, clothes

dryers, and kitchen ventilation equipment interfere

with proper operation.

National Fuel Gas Code recognizes several methods

of obtaining adequate ventilation and combustion air.

Requirements of the authority having jurisdiction may

override these methods.

Engineered Installations. Must be approved by•

authority having jurisdiction.

Mechanical Air Supply. Provide minimum of•

0.35 cfm per Mbh for all appliances located

within space. Additional requirements where

exhaust fans installed. Interlock each appliance

to mechanical air supply system to prevent main

burner operation when mechanical air supply

system not operating.

All Indoor Air. Calculate minimum volume for all•

appliances in space. Use a different method if

minimum volume not available.

Standard Method. Cannot be used if knownA.

air inﬁltration rate is less than 0.40 air

changes per hour. See Table 4 for space

with boiler only. Use equation for multiple

appliances.

Volume ≥50 ft3x Total Input [Mbh]

Known Air Inﬁltration Rate. See Table 4B.

for space with boiler only. Use equation

for multiple appliances. Do not use an air

inﬁltration rate (ACH) greater than 0.60.

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

Refer to National Fuel Gas Code for openingC.

requirements between connected indoor

spaces.

All Outdoor Air. Provide permanent opening(s)•

communicating directly or by ducts with outdoors.

Two Permanent Opening Method. ProvideA.

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.

One Permanent Opening Method. ProvideB.

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.

Table 4 - Minimum Room Volume, Indoor Air Only*

Room Cubic Feet Volume

Input

Mbh Standard

Method Known Air Inﬁltration Rate Method (Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

262.5 13125 55125 27563 18375 13781 11025 9188

299 14950 62790 31395 20930 15698 12558 10465

* Table values based on boiler only. Add volume for any additional appliances.

6 - CONNECTING SUPPLY AND RETURN PIPING

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from ﬂoor

or allowable

safe point of

discharge.

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

maximum distance from ﬂoor or allowable safe point of discharge;

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

discharge line;

have no intervening shutoff valve between safety relief 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 the valve and the discharge line;•

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

be as short and straight as possible;•

terminate with plain end (not threaded);•

be 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

6 - CONNECTING SUPPLY AND RETURN PIPING

Boiler is shipped assembled.

Install discharge

piping from safety relief valve. See Warning, Page

Install temperature pressure gauge.

Apply pipe sealant to threads on shaft of•

gauge.

Thread gauge into supply water tee. See Figure•

NOTICE

DO NOT TIGHTEN GAUGE BY HAND!! Gauge

should be tightened using crescent wrench or

9/16” open end wrench. See Figure 3.

Connect supply and return lines to boiler.

Connections may require additional ﬁttings and

parts, as shown on diagrams.

WARNING

Burn and scald hazard. Safety relief valve

could discharge steam or hot water during

operation. Install discharge piping per these

instructions.

Figure 3 - Temperature Pressure Gauge

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. Periodic

inspection is necessary, as is ﬂushing of ﬂoat type

devices, per manufacturers speciﬁc instruction.

FOR USE WITH COOLING UNITS

A. Boiler used in connection with refrigeration

system, must be installed so that chilled medium

is piped in parallel with heating boiler. Appropriate

valves must be used to prevent chilled medium

from entering heating boiler. See Figure 5 page 9.

B. Boiler connected to heating coils located in air

handling units where they may be exposed to

refrigerated air circulation, piping system shall

be equipped with ﬂow control valves or other

automatic means to prevent gravity circulation of

boiler water during cooling cycle.

LOW WATER TEMPERATURE AND LARGE WATER

CONTENT SYSTEM (See Figures 6 and 7, Page 10.)

Signiﬁcant condensation may form in boiler and/or

venting system if boiler is operated for long period of

time with return temperatures of less than 120° F.

Condensate is corrosive and can cause severe

damage to boiler and venting system. Minimum

design return water temperature to prevent

condensation in boiler and venting is 120°F.

Minimum high limit setting is 140°F.

Boiler used in heating system where design

water temperatures below 140°F are desired

(e.g. radiant ﬂoor heating), 4-way mixing valve

or suitable alternative is required to prevent

low temperature low return water from entering

boiler. Follow mixing valve manufacturer’s

instructions.

Boiler connected to system having large water

content (such as former gravity system), install

system bypass. See Figures 7 and 8, page 10.

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.

Figure 5 - Chilled Water Piping

Figure 4 - Typical Hot Water Piping

6 - CONNECTING SUPPLY AND RETURN PIPING

Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY

Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN

Bypass Piping Required For High Mass (Large Water Content) Systems

6 - CONNECTING SUPPLY AND RETURN PIPING

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