Super Hot MG SERIES Installation And Service Manual

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Service manual (33 pages)

Installation and service manual (33 pages)

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Page 1 INSTALLATION AND SERVICE MANUAL MG SERIES BOILERS FOR MODELS MG-50-E TO MG-150-E SEE REAR COVER FOR INDEX Improper installation, adjustment, alteration, service or maintenance can cause property WARNING damage, injury, or loss of life Please carefully read this manual. For assistance or additional information, consult a qualified installer, service agency or the gas supplier.
Page 2: Dimensions And Specifications
For altitudes above 2,000 feet, refer to Section 3.6 to determine the appropriate Input de-rate or contact the factory. ** Based on piping and pickup allowance of 1.15 The Super Hot product improvement program may result in changes to the design and / or specifications being made without notice.
Page 3 MG Series Boilers – Installation and Service Manual Boiler Water Flow Data NOTE: The boiler should be properly sized for its heating application and maintain an adequate water flow rate during operation. Significantly oversizing the boiler or decreasing boiler water flow rate will cause excessive stage cycling and may result in premature failure of components.
Page 4: About Our Manuals
MG Series Boilers – Installation and Service Manual ABOUT OUR MANUALS Your Super Hot boiler has been provided with two manuals:  User's Information Manual - This manual is intended for the owner or user of the boiler and provides information on routine operation and maintenance, and emergency shutdown.
Page 5 MG Series Boilers – Installation and Service Manual LIGHTING INSTRUCTIONS FOR INTERMITTENT ELECTRONIC WITH COMBINATION GAS VALVE 1. This boiler is equipped with an ignition device NOTE: On some gas valves the knob cannot be turned to "OFF" or “ON” position unless knob which automatically lights the pilot.
Page 6: Run Mode
MG Series Boilers – Installation and Service Manual CONTROLLER PROGRAMMING AND SERVICE CODES 2012 NRCan and DOE Compliance and Operation Operation of this control may delay the burner operation while the residual heat is circulated out of the boiler. The integrated boiler control module provides ignition sequence, flame monitoring and safety shutoff for intermittent pilot spark ignition.
Page 7: Installer Mode
MG Series Boilers – Installation and Service Manual 1.4.2 INSTALLER MODE To enter the adjustment mode: 1. Press with Up ▲, Down ▼, and “I” keys (see Figure 1) simultaneously for three seconds. 2. Press and release the “I” key until the parameter (listed in the Table 2) requiring adjustment is displayed.
Page 8 MG Series Boilers – Installation and Service Manual 1.4.3 OPERATING CHECKOUT After adjusting parameters, put the boiler into operation and observe operation through at least one complete cycle to make sure that the controller operates properly. See controller troubleshooting section to assist in determining boiler operation.
Page 9 MG Series Boilers – Installation and Service Manual Table 3 - State Codes Display Code State Specific Description Operation Sequence Idle/Standby The boiler is in standby - no call for heat. ↔ Run circulator Heat request present but boiler water temperature sufficiently high to run circulator pump only (no ignition sequence).
Page 10 MG Series Boilers – Installation and Service Manual  If the controller is displaying “ ” followed by a number, use the error code definitions in the Table 4 to determine the problem and possible causes. Table 4 - Error Codes...
Page 11: Installation Codes And Requirements
 Boiler must be installed on a stable and level foundation.  MG Series boilers can be installed on a combustible floor but must not be installed directly on carpeting.  A hot water boiler installed above radiation level or as required by Authority Having Jurisdiction must be provided with a low water cutoff device at the time of boiler installation.
Page 12: Gas Service Piping
MG Series Boilers – Installation and Service Manual GAS SERVICE PIPING The boiler and its gas connection must be leak tested before placing the boiler in operation. The gas controls furnished are suitable for a maximum operating gas pressure of 1/2 psi (14 inches water column).
Page 13 MG Series Boilers – Installation and Service Manual VENTING The responsibility of providing a suitable vent of adequate draft capacity and in good usable condition is that of the gas fitter/installer. Interference with the air supply for the boiler shall be prohibited.
Page 14: Automatic Vent Damper
MG Series Boilers – Installation and Service Manual d) Place in operation the boiler being inspected. Follow the lighting instructions. Adjust the thermostat so the boiler will operate continuously. e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
Page 15: Corrosion Prevention (Internal)
Do not draw water from the heating system for cleaning, flushing, etc. Super Hot MG series boilers are designed for use in closed loop systems and are not intended for open systems, as in heating pool water or systems where water is constantly replenished. Operating the boiler in an open system will result in premature failure of the heat exchanger.
Page 16: Pressure Relief Valve
As a guide to avoiding such corrosion and draft problems, it is imperative that the return water be not less than 135°F (57°C). MG SERIES BOILERS MUST ALWAYS BE USED WITH FORCED SYSTEM CIRCULATION. 2.13 PRESSURE RELIEF VALVE A pressure relief valve is supplied as standard equipment.
Page 17: Pre-Start-Up
MG Series Boilers – Installation and Service Manual Startup Instructions Section 3 PRE-STARTUP a. Fill entire heating system with water and vent or purge air from system. Add water as needed to reach boiler operating pressure. Water should be of suitable quality. Do not use water with high hardness.
Page 18: Check Burner System
MG Series Boilers – Installation and Service Manual CHECK BURNER SYSTEM To maintain safe and efficient operation, examine the burner system regularly through the inspection hole near the pilot tube. Check condition of burner system Check ignition and extinction It is possible for parts of the burners system to...
Page 19: For Canada
MG Series Boilers – Installation and Service Manual CHECK INPUT & ORIFICES For safety, the input shown on rating plate must not be exceeded. Check with the table below that the orifice size and input rate shown on your boiler rating plate match your application, i.e. boiler model, fuel type, and altitude.
Page 20: Check For Gas Leaks
MG Series Boilers – Installation and Service Manual Small adjustments to the input rate can be made by varying the manifold pressure. Normally it should be adjusted no more than 0.2 inch w.c. for natural gas or 0.5 inch w.c. for propane from the manifold pressure specified on the rating plate.
Page 21: Installer's Checklist
MG Series Boilers – Installation and Service Manual 3.10 INSTALLER'S CHECKLIST Reference Section The information printed on the boiler rating plate matches the application (i.e.  altitude and fuel type).  All applicable electrical codes have been met. 2.2, 2.14 ...
Page 22: Service & Maintenance Instructions
MG Series Boilers – Installation and Service Manual Service & Maintenance Instructions Section 4 SERVICE & MAINTENANCE INSTRUCTIONS WARNING Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. WARNING If any part of this boiler has been under water, inspect the boiler and replace any part of the control system and any gas control which has been under water.
Page 23: Service Checklist
MG Series Boilers – Installation and Service Manual SERVICE CHECKLIST Reference Section Do not store anything against the boiler or allow dirt or debris to accumulate in the  area immediately surrounding the boiler. The flow of supply and exhaust air must not be obstructed.
Page 24: Refractory Handling Procedure
MG Series Boilers – Installation and Service Manual CAUTION: WATER REPLENISHMENT Avoid unnecessary replenishment of system water. It can allow oxygen to enter the system and cause serious corrosion problems. As well, an excessive amount of minerals may be deposited in the heat exchanger.
Page 25: Replacement Parts
MG Series Boilers – Installation and Service Manual Replacement Parts Section 5 NOTE: To supply the correct part it is important that you state the boiler model number, serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with Return Goods Authorization Form (R.G.A.), completely filled in with the boiler serial number, model...
Page 26 MG Series Boilers – Installation and Service Manual...
Page 27 MG Series Boilers – Installation and Service Manual Wiring Diagrams Section 6 Simplified Wiring Instructions IMPORTANT  Disconnect power source to boiler before wiring zone control board.  All wiring must comply with applicable codes, ordinances and regulations.  The non-replaceable fuse on the board will be blown if 240 Vac is connected to the board or if the 24 Vac system is even momentarily shorted out.
Page 28 MG Series Boilers – Installation and Service Manual...
Page 29: Troubleshooting Guide
MG Series Boilers – Installation and Service Manual Troubleshooting Guide Section 7 Problem Possible Cause Solution   Boiler will not fire. No power. Check power switches and wiring.   No gas supply to boiler. Check gas source and pressure.
Page 30 MG Series Boilers – Installation and Service Manual Problem Possible Cause Solution   High voltage wiring is loose, broken or Pilot flame will not light on No spark. grounded. Repair wiring. electronic ignition.   Ignition electrodes are damaged.
Page 31 MG Series Boilers – Installation and Service Manual NOTES Section 8...
Page 32 MG Series Boilers – Installation and Service Manual NDEX Section 9 Section Page Dimensions and Specifications – MG Series Boilers ..................2 Boiler Water Flow Data ..........................3 About Our Manuals ............................4 Lighting Instructions ......................... 4 Safety Instructions ..........................4 Lighting Instructions for Intermittent Electronic with Combination Gas Valve ........

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