UTICA BOILERS MGC-8D Installation, Operation & Maintenance Manual

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Installation, operation and maintenance manual (32 pages)

Installation, operation & maintenance manual (36 pages)

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Models

MGC-8D

MGC-8DP

MGC-9D

MGC-9DP

An ISO 9001-2008 Certified Company

MGC SERIES

GAS-FIRED

HOT WATER BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

C.S.A. Certiﬁ ed for

Natural gas or

Propane

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Tested for 50 psi.

ASME Working

Pressure

240009268

P/N

, Rev. A [03/2012]

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Summary of Contents for UTICA BOILERS MGC-8D

Page 1 MGC SERIES GAS-FIRED HOT WATER BOILERS Models MGC-8D INSTALLATION, OPERATION & MGC-8DP MAINTENANCE MANUAL MGC-9D MGC-9DP C.S.A. Certiﬁ ed for Tested for 50 psi. Natural gas or ASME Working Propane Pressure Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501...
Page 2: Dimensions
1 - DIMENSIONS Figure 1 - Dimensions Table 1 - Dimensions DIMENSIONS (INCH.) BOILER MODEL FLUE “A” NUMBER DIAMETER WIDTH MGC-8 27½ MGC-9 30¾ Add 5½” to height for vent Damper.
Page 3: Ratings And Capacities
2 - BOILER RATINGS AND CAPACITIES Table 2 - Ratings and Capacities † NATURAL GAS † PROPANE GAS AFUE BOILER NET AHRI HEATING MODEL NET AHRI Heating Input INPUT INTERMITTENT RATING NUMBER CAPACITY Capacity RATING IGNITION WITH Water, VENT DAMPER MGC-8 262.5 83.9...
Page 4: Table Of Contents
3 - TABLE OF CONTENTS 1 - Dimensions ............ 2 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE 2 - Ratings And Capacities ........3 3 - Table of Contents ..........4 4 - Installation Procedure ........5 IMPORTANT: Read the following instructions COMPLETELY before installing!! 5 - Ventilation &...
Page 5: Installation Procedure
4 - INSTALLATION PROCEDURE WARNING WARNING Improper installation, adjustment, alteration, Fire hazard. Do not install boiler on service or maintenance could result in death or combustible ﬂ ooring or carpeting. Failure to serious injury follow these instructions could result in death or serious injury.
Page 6: Ventilation & Combustion Air
5 - VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance • All Outdoor Air. Provide permanent opening(s) with the section “Air for Combustion and Ventilation,” communicating directly or by ducts with outdoors. of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or Two Permanent Opening Method.
Page 7: Connecting Supply And Return Piping
6 - CONNECTING SUPPLY AND RETURN 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: •...
Page 8 6 - CONNECTING SUPPLY AND RETURN PIPING Verify clean water supply is available to water inlet WARNING valve. Install sand strainer when water supply is from Burn and scald hazard. Safety relief valve a well or pump. could discharge steam or hot water during Install hot water boiler above radiation level or as operation.
Page 9 6 - CONNECTING SUPPLY AND RETURN PIPING Figure 4 - Typical Hot Water Piping Figure 5 - Chilled Water Piping...
Page 10 6 - CONNECTING SUPPLY AND RETURN PIPING Bypass Piping Required For High Mass (Large Water Content) Systems Figure 6 - BYPASS PIPING - CIRCULATOR ON SUPPLY Figure 7 - BYPASS PIPING - CIRCULATOR ON RETURN...
Page 11: Chimney And Vent Pipe Connection
7 - CHIMNEY AND VENT PIPE CONNECTION Connecting The Vent Damper And Vent WARNING Connector Boiler and venting installations shall be Refer to Figure 1, page 2 for size and location of vent (ﬂ ue opening). performed by a qualiﬁ ed expert and in accordance with the appropriate manual.
Page 12 7 - CHIMNEY AND VENT PIPE CONNECTION Place in operation the appliance being inspected. WARNING Follow the lighting instructions. Adjust thermostat Boiler and venting installations shall be so appliance will operate continuously. performed by a qualiﬁ ed expert and in Test for spillage at the draft hood relief opening accordance with the appropriate manual.
Page 13: Vent Damper Operation
8 - VENT DAMPER OPERATION Figure 8 - Vent Damper Installation Figure 9 - Vent Damper Placement Annually check vent damper and all ﬂ ue product For further information, and vent damper carrying areas of appliance, with particular attention troubleshooting guide, refer to manual packaged with given to deterioration from corrosion or other vent damper.
Page 14: Gas Supply Piping
9 - GAS SUPPLY PIPING • Pressure test over 1/2 psig (3.5 kPa). Disconnect CAUTION boiler and its individual gas shutoff valve from gas WHAT TO DO IF YOU SMELL GAS supply system. • Do not try to light any appliance. •...
Page 15: Electrical Wiring
10 - ELECTRICAL WIRING VENT DAMPER WIRING WARNING Boiler is equipped with factory wired harness with 4 Electrical shock hazard. Turn OFF electrical pin molex plug, that plugs into 4 pin molex receptacle power supply at service panel before making inside vent damper operator.
Page 16: Wiring Diagrams
11 - WIRING DIAGRAMS Figure 12 - Integrated High Limit Electronic Ignition Control (240008781) WARNING Modiﬁ cation, substitution or elimination of factory equipped, supplied or speciﬁ ed components may result in personal injury or loss of life. Inducer is not an option.
Page 17 11 - WIRING DIAGRAMS Figure 13 - Integrated High Limit Electronic Ignition Control (240008781)
Page 18 11 - WIRING DIAGRAMS Figure 14 - Integrated High Limit Electronic Ignition Control (240008781)
Page 19: General Instructions
12 -GENERAL INSTRUCTIONS FILLING SYSTEM WITH WATER NOTICE • Close air vents on all radiation units. Open valves Never run water in a hot empty boiler. to these units. • Verify boiler and expansion tank drain valves are closed. • Air bleed screw on tank drain ﬁ...
Page 20: Lighting Instructions
13 - LIGHTING INSTRUCTIONS 5. Remove lower front panel. WARNING 6. Rotate the gas control knob clockwise If you do not follow these “OFF”. instructions exactly, a ﬁ re or Figure 15 - Automatic Gas Valve explosion may result causing property damage, personal injury or loss of life.
Page 21: Operating Your Boiler
14 - OPERATING YOUR BOILER AUTOMATIC GAS VALVE Figure 16 - Pilot Flame Automatic Gas Valve opens or closes according to heat requirements of thermostat and temperature limit control. It closes if pilot goes out. Each individual control must be operating correctly before any gas can pass to burners.
Page 22 14 - OPERATING YOUR BOILER CHECK THERMOSTAT OPERATION When set above temperature indicated on thermostat, boiler should ignite. Verify thermostat turns boiler off when room temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees. After setting limit control to limit setting, check to see if it shuts off gas supply to burners.
Page 23: Maintaining Your Boiler
15 - MAINTAINING YOUR BOILER BURNERS CLEANING YOUR BOILER AND BURNERS Beginning of heating season visually check pilot end Flue passages between sections should be examined main burner ﬂ ames. See page 21. yearly and cleaned if necessary. To clean: SAFETY RELIEF VALVE •...
Page 24: Service Hints
16 - SERVICE HINTS EQUIPMENT AND OPTIONAL ACCESSORIES - WHAT THEY DO 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. •...
Page 25: Equipment And Optional Accessories
17 - EQUIPMENT AND OPTIONAL ACCESSORIES EXPANSION TANK AUTOMATIC FILL VALVE Expanding water ﬂ ows into expansion tank. Tank For a safe, efﬁ cient operation, hot water system must should be correct size. Tank is ﬁ lled with air. As water be completely ﬁ...
Page 26 17 - EQUIPMENT AND OPTIONAL ACCESSORIES ROLLOUT SWITCH SPILL SWITCH (FLAME ROLLOUT SAFETY SHUTOFF) (BLOCKED VENT SAFETY SHUTOFF) Rollout switch is temperature-sensitive fuse link Spill switch is manual reset disc thermostat with ﬁ xed device. Located on boiler base just outside ﬁ re box. setpoint (340°F (171°C)), and normally closed contacts.
Page 27: Appendix A - Control Module
APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations A.3 Adjusting Settings To discourage unauthorized changing of settings, pro- WARNING cedure to enter adjustment mode is required. If you do not follow these To enter adjustment mode, press UP, DOWN, and I instructions exactly, a ﬁ...
Page 28 APPENDIX A - CONTROL MODULE A.5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes Module continuously monitors boiler water tempera- list) and heats water in boiler until setpoint tem- ture and ﬁ res or shuts off burner based on this tem- perature is achieved or thermostat is satisﬁ...
Page 29 APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller A.7 Troubleshooting • Following service procedures are provided as • When water temperature reaches setpoint, general guide. controller ends heating cycle. • On lockout and retry models, meter readings •...
Page 30 APPENDIX A - CONTROL MODULE Table 7 - Troubleshooting Error Codes Error Code Deﬁ nition Consequence Number Flame current too low. Check for ﬂ ame. Non critical alarm Flame sensed out of normal sequence (before opening or after closing gas Soft lockout valve).
Page 31 APPENDIX A - CONTROL MODULE STEP 3: Check spark ignition circuit. — If spark does not stop after pilot lights, replace Disconnect ignition cable at SPARK terminal on mod- module. ule. — If main burner does not light or if main burner lights and system locks out, check module, WARNING ground wire and gas control as described in...
Page 32 UTICA BOILERS 2201 Dwyer Avenue Utica NY 13501 web site: www.ecrinternational.com...

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Mgc-8dp Mgc-9d Mgc-9dp Mgc series

UTICA BOILERS MGC-8D Installation, Operation & Maintenance Manual

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