UTICA BOILERS PEG-C Bedienungsanleitung

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

PEG-C

GAS FIRED BOILERS

FOR STEAM HEATING

Utica Boilers  P.O. Box 4729  Utica, NY 13504

TABLE OF CONTENTS

Safety Sy bols & Warnings ................................................................................. Page 1

Installation Procedure ........................................................................................... Page 2

Ventilation and Co bustion Air ...................................................................... Pages 3-4

Connecting Supply and Return Piping ............................................................... Page 5-6

Vent Installation .................................................................................................... Page 7

Vent Syste Modification ..................................................................................... Page 8

Vent Da per Installation and Instructions ........................................................... Page 9

Connecting Gas Service ..................................................................................... Page 10

Electrical Wiring .................................................................................................. Page 10

Ther ostat Installation ....................................................................................... Page 11

Lighting Instructions ................................................................................... Pages 11-13

Nor al Sequence of Operation .......................................................................... Page 14

Connecting Supply And Return Piping Water-Chilled Mediu ........................... Page 15

General Instructions .................................................................................... Pages 16-20

Replace ent Parts Lists ............................................................................. Pages 20-25

Ratings, Data and Di ensions .......................................................................... Page 26

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

SERIES PEG-C

CAST IRON

GAS FIRED BOILERS

INSTALLATION MANUAL AND

OPERATING INSTRUCTIONS

Published April 1997

Printed in USA

Made in USA

C.S.A. Certified

for Natural gas

or Propane

Tested for 100 lbs.

ASME Working

Pressure

PAGE 1

IMPORTANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.

WARNING:

1. Keep boiler area clear and free fro co bustible aterials, gasoline and other

fla able vapors and liquids.

2. DO NOT obstruct air openings to the boiler roo .

3. Modification, substitution or eli ination of factory equipped, supplied or specified

co ponents ay result in property da age, personal injury or the loss of life.

4. To the owner: Installation and service of this boiler ust be perfor ed by a qualified

installer.

5. To the installer: Leave all instructions with the boiler for future reference.

6. When this product is installed in the Co onwealth of Massachusetts the installation

ust be perfor ed by a Licensed Plu ber or Licensed Gas Fitter.

DANGER

DANGER - Indicates an i inently hazardous situation which, if not avoided, WILL

result in death or serious injury.

WARNING

WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD

result in death or serious injury

CAUTION

CAUTION - Indicates a potential hazardous situation which, if not avoided, MAY result

in inor or oderate injury. It ay also be used to alert against unsafe practices.

WARNING: ALL INSTALLATIONS OF BOILERS AND VENTING

SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN

ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL.

INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE

WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS

INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM

POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS

ODORLESS AND INVISIBLE.

Safety Symbols

The following defined sy bols are used throughout this anual to notify the

reader of potential hazards of varying risk levels.

INSTALLATION PROCEDURE

WARNING: I proper installation, adjust ent, alteration, service or

aintenance can cause injury or property da age.

1. The installation ust confor to the require ents of the authority having jurisdiction

or, in absence of such require ents, to the latest revision of the National Fuel Gas Code,

ANSI Z223.1. (Available fro the A erican Gas Association, Pleasant Valley Road,

Cleveland, Ohio 44134.) Reference should also be ade to local gas utility regulations and

other codes in effect in the area that the installation is to be ade.

2. Where required by the authority having jurisdiction, the installation ust confor to

A erican Society of Mechanical Engineers Safety Code for Controls and Safety Devices

For Auto atically Fired Boilers, No.CSD-1.

3. This boiler is classified as a Category 1 appliance and the vent installation shall be

in accordance with Part 7 & 11 of the latest revision of the National Fuel Gas Code noted

above or applicable provisions of the local building codes. See Vent Installation on page 7.

4. This boiler eets safe lighting and other preference criteria with the gas anifold and

control asse bly provided on the boiler per the latest revision of ANSI Z21.13b.

5. This boiler shall be installed such that the gas ignition syste co ponents are

protected fro water (dripping, spraying, rain, etc.) during appliance operation and service,

(circulator replace ent, condensate trap, control replace ent, etc.).

6. LOCATE BOILER on level, solid base as near chi ney as possible and centrally

located with respect to the heat distribution syste as practical.

7. ALLOW 24 inches at the front and right side for servicing and cleaning.

8. When installing in a utility roo , the door should be wide enough to allow the largest

boiler part to enter, or to per it replace ent of another appliance such as a water heater.

9. FOR INSTALLATION ON NONCOMBUSTIBLE FLOORS ONLY. *The boiler ust

not be installed on carpeting. Mini u clearances to co bustible construction are:

TOP.................................................................... 24 IN.

FRONT .......................................................... ALCOVE

FLUE COLLECTOR ............................................. 6 IN.

REAR ................................................................... 8 IN.

SIDES .................................................................. 6 IN.

NOTE: GREATER CLEARANCES FOR ACCESS SHOULD SUPERSEDE FIRE

PROTECTION CLEARANCE.

PAGE 2

PAGE 3

FIGURE 1

ENTILATION & COMBUSTION AIR

WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT BE

OBSTRUCTED. BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE

COMBUSTION AIR CAN BE MAINTAINED

* Unconfined area: A space whose volu e is not less than 50 cubic feet per 1000

BTU per hour of all appliances installed in that space (cubic feet of space = height x

width x length).

** Confined area: A space whose volu e is less than 50 cubic feet per 1000 BTU per

hour of all appliances installed in that space (cubic feet of space = height x width x

length).

1. Ventilation of the boiler roo ust be adequate to provide sufficient air to properly

support co bustion per the latest revision of the National Fuel Gas Code, ANSI Z223.1

section 5.3.

2. When a boiler is located in an unconfined space in a building or conventional construction

fra e, asonry or etal building, infiltration nor ally is adequate to provide air for

co bustion and ventilation. However, if the equip ent is located in a building of unusually tight

construction (See the national Fuel Gas Code, Ansi Z223.1 section 1.7), the boiler area

should be considered as a confined space. In this case air for co bustion and ventilation shall

be provided according to part 5 on page 4. If there is any doubt, install air supply provisions

in accordance with the latest revision of the National Fuel Gas Code.

3. When a boiler is installed in an unconfined

space, in a building of unusually tight

construction, air for co bustion and ventilation

ust be obtained fro outdoors or fro

spaces freely co unicating with the

outdoors. A per anent opening or openings

having a total free area of not less than 1

square inch per 5,000 BTU per hour of total

input rating of all appliances shall be provided.

Ducts ay be used to convey akeup air

fro the outdoors and shall have the sa e

cross-sectional area of the openings to which

they are connected.

4. When air for co bustion and ventilation

is fro inside buildings, the confined space

shall be provided with two per anent

openings, one starting 12 inches fro the top

and one 12 inches fro the botto of the

enclosed space. Each opening shall have a

ini u free area of 1 square inch per one thousand (1000) BTU per hour of the total input

rating of all appliances in the enclosed space, but ust not be less than one hundred (100)

square inches. These openings ust freely co unicate directly with other spaces of

sufficient volu e so that the co bined volu e of all spaces eets the criteria for an

unconfined space.

FIGURE 4

PAGE 4

FIGURE 3FIGURE 2

5. When the boiler is installed in a confined space and all air is provided fro the outdoors

the confined space shall be provided with one or two per anent openings according to

ethods A or B. When ducts are used, they shall be of the sa e cross sectional area as the

free area of the area of the openings to which they connect. The ini u di ension of

rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches.

A. When installing two openings, one ust co ence within 12 inches fro the top and

the other within 12 inches fro the botto of

the enclosure. The openings shall

co unicate directly, or by ducts, with the

outdoors or spaces (crawl or attic) that freely

co unicate with the outdoors. One of the

following ethods ust be used to provide

adequate air for ventilation and co bustion.

1. When directly co unicating

with the outdoors, each opening shall have a

ini u free area of 1 square inch per 4,000

BTU per hour of total input rating of all

equip ent in the enclosure. See figure 2

above.

2. When co unicating with the

outdoors by eans of vertical ducts, each

opening shall have a ini u free area 1

square inch per 4,000 BTU per hour of total input rating of all appliances in the enclosed

space. See figure 3 above.

3. If horizontal ducts are used, each opening and duct shall have a ini u free

area 1 square inch per 2,000 BTU per hour of total input rating of all appliances in the enclosed

space. See figure 4 at right.

B. One per anent opening, co encing within 12 inches of the top of the enclosure,

shall be per itted where the equip ent has clearances of at least 1 inch fro the sides, 1

inch fro the back, and 6 inches fro the front of the boiler. The opening shall directly

co unicate with the outdoors or shall co unicate through a vertical or horizontal duct to

the outdoors or spaces (crawl or attic) that freely co unicate with the outdoors. The

openings ust have a ini u free area of 1 square inch per 3000 Btu per hour of the total

CONNECTING SUPPLY AND RETURN PIPING

1. Suggested piping for stea heating syste can be seen in figure 5 below. Actual

piping ay vary based on syste design and local conditions.

2. Suggested piping for a odular stea boiler using pu ped returns ay be seen in

figures 6a and 6b on page 6. Actual piping ay vary based on syste design and local

conditions.

3. Refer to pages 17 & 18 for procedures on cleaning and ski ing off i purities.

4. "Near Boiler Piping" is crucial for proper perfor ance of a replace ent stea boiler

and should always be considered as part of the boiler installation. Always be sure to include

cleanout and ski ing tees in the near boiler piping. These "Tees" are necessary for proper

cleaning and servicing of the boiler.

5. For further piping infor ation refer to the I=B=R installation piping guide.

PAGE 5

FIGURE 5

SUGGESTED PIPING FOR A SINGLE STEAM

BOILER HEATING SYSTEM

input rating of all equip ent located in the enclosure. The free area ust be no less than the

su of the areas of all vent connectors in the confined space.

6. In calculating free area using louvers, grilles or screens for the above, consideration

shall be given to their blocking effect. Screens used shall not be s aller than 1/4 inch esh.

If the free area through a design of louver or grill is known, it should be used in calculating

the size opening required to provide the free area specified. If the design and free area is

not known, it ay be assu ed that wood louvers will have 20-25% free area and etal

louvers and grilles will have 60-75% free area. Louvers and grilles should be fixed in the open

position or interlocked with the boiler so they are opened auto atically during the boiler

operation.

PAGE 6

FIGURE 6b

SUGGESTED PIPING FOR A MODULAR STEAM BOILERS

PUMPED RETURNS

GRAVITY RETURNS

FIGURE 6a

ENT INSTALLATION

WARNING: This boiler shall not be connected to any portion of a echanical

draft syste operating under positive pressure.

1. The vent pipe ust slope upward fro the boiler not less than 1/4 inch for every 1 foot

to the vent ter inal.

2. Horizontal portions of the venting syste shall be supported rigidly every 5 feet and

at elbows. No portion of the vent pipe should have dips or sags.

3. This boiler series is classified as a Category 1 appliance and the vent installation shall

be in accordance with Part 7 & 11 of the latest revision of the National Fuel Gas Code or

applicable provisions of the local building codes.

4. Inspect chi ney to ake certain it is constructed according to National Board of Fire

Underwriters.

5. Attach draft hood to flue collector at rear of boiler, (See figure 7, below), with sheet

etal screw(s) through hole(s) provided. The vent or vent collector shall be Type B or etal

pipe having resistance to heat and corrosion not less than that of galvanized sheet steel or

alu inu not less than 0.016 inch thick (No. 28 GA).

6. Connect flue pipe sa e as draft hood to chi ney. Bolt or screw joints together to avoid

sag. Flue pipe should not extend beyond inside wall of chi ney. Do not install anual

da per in flue pipe or reduce size of flue outlet except as provided by the latest revision of

ANSI Z223.1. Protect co bustible ceiling and walls near flue pipe with fireproof insulation.

Where two or ore appliances vent into a co on flue, the area of the co on flue ust

be at least equal to the area of the largest flue plus 50 percent of the areas of each additional

flue.

PAGE 7

WARNING: ALL

INSTALLATIONS OF BOILERS

AND VENTING SHOULD BE

DONE ONLY BY A QUALIFIED

EXPERT AND IN ACCORDANCE

WITH THE APPROPRIATE UTICA

BOILERS MANUAL. INSTALLING

OR VENTING A BOILER OR ANY

OTHER GAS APPLIANCE WITH

IMPROPER METHODS OR

MATERIALS MAY RESULT IN

SERIOUS INJURY OR DEATH

DUE TO FIRE OR TO

ASPHYXIATION FROM

POISONOUS GASES SUCH AS

CARBON MONOXIDE WHICH IS

ODORLESS AND INVISIBLE. FIGURE 7

ENT SYSTEM MODIFICATION

When an existing boiler is re oved fro a co on venting syste , the co on venting

syste is likely to be too large for the proper venting of the appliances re ained connected

to it. If this situation occurs, the following test procedure ust be followed:

At the ti e of re oval of an existing boiler, the following steps shall be followed with

each appliance re aining connected to the co on venting syste placed in operation,

while the other appliances re aining connected to the co on venting syste are not in

operation.

A. Seal any unused openings in the co on venting syste .

B. Visually inspect the venting syste for proper size and horizontal pitch and deter ine

there is no blockage or restriction, leakage, corrosion and other deficiencies which could

cause an unsafe condition.

C. Insofar as is practical, close all building doors and windows and all doors between

the space in which the appliances re aining connected to the co on venting syste are

located and other spaces in the building. Turn on clothes dryers and any appliance not

connected to the co on venting syste . Turn on any exhaust fans, such as range hoods

and bathroo exhausts, so they will operate at axi u speed. Do not operate a su er

exhaust fan. Close fireplace da per.

D. Place in operation the appliance being inspected. Follow the lighting instructions.

Adjust ther ostat so appliance will operate continuously.

E. Test for spillage at the draft hood relief opening after 5 inutes of ain burner

operation. Use the fla e of a atch or candle, or s oke fro a cigarette, cigar or pipe.

F. After it has been deter ined that each appliance re aining connected to the co on

venting syste properly vents when tested as outlined above, return doors, windows,

exhaust fans, fireplace da pers and any other gas burning appliance to their previous

conditions of use.

G. Any i proper operation of the co on venting syste should be corrected so the

installation confor s with the latest revision of the National Fuel Gas Code, ANSI Z223.1.

When resizing any portion of the co on venting syste , the co on venting syste

should be resized to approach the ini u size as deter ined using the appropriate tables

in appendix G in the latest revision of the National Gas Fuel Code, ANSI Z223.1.

PAGE 8

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