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Models
MGB-50J
MGB-75J
MGB-100J
MGB-125J
MGB-150J
MGB-170J
MGB-200J
An ISO 9001-2008 Certified Company
CAST IRON GAS FIRED BOILERS
FOR FORCED HOT WATER
with Honeywell Control
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
C.S.A. Certified
For Natural Gas
Or Propane
MGB
Tested For 100 psi.
ASME
Working Pressure
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
240011584
P/N
, Rev. A [07/30/2016]
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Summary of Contents for ECR International MGB-50J
- Page 1 MGB-170J MGB-200J C.S.A. Certified For Natural Gas Tested For 100 psi. Or Propane ASME Working Pressure Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com 240011584 , Rev. A [07/30/2016] An ISO 9001-2008 Certified Company...
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Page 2: Dimensions
DIMENSIONS Figure 1 - Dimensions 27" "A" 1¼" Supply 5½" "B" "C" 3½" 3" "F" 1¼" Return "E" "D"** 4¼" 14" 2½" 4¼" 4½" P/N 240011584 Rev. A [07/30/2016]... -
Page 3: Table Of Contents
SAFETY SYMBOLS AND WARNINGS Dimensions ............2 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Safety Symbols and Warnings ......3 Ratings & Data - Natural Gas & Propane Gas ..4 Installation Procedure ........5 IMPORTANT: Read the following instructions COMPLETELY before installing!! Ventilation &... -
Page 4: Ratings & Data - Natural Gas & Propane Gas
RATINGS & DATA - NATURAL GAS & PROPANE GAS EXPLANATORY NOTES All boilers are design certified for installation on noncombustible floor. For installation on combustible floors use combustible floor kit. Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be reduced to 10 feet. -
Page 5: Installation Procedure
INSTALLATION PROCEDURE WARNING WARNING Improper installation, adjustment, alteration, service Fire hazard. Do not install boiler on combustible or maintenance could result in death or serious flooring or carpeting. Failure to follow these injury instructions could result in death or serious injury. FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS Installation must conform to the requirements of the ONLY - For installation on combustible flooring special... -
Page 6: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance x All Outdoor Air. Provide permanent opening(s) with the section “Air for Combustion and Ventilation,” of the communicating directly or by ducts with outdoors. National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections о... -
Page 7: Connecting Supply And Return Piping
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: x connect to relief valve outlet and piped down to safe point of disposal. -
Page 8: Connecting Supply And Return Piping
CONNECTING SUPPLY AND RETURN PIPING Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice. Figure 3 - Circulators Mounted on Supply System, Boiler Used In Configuration with Chiller System. See Special Conditions, Page 9 SEPARATOR Boiler used in connection with refrigeration system, Bypass piping is optional which gives ability to... - Page 9 CONNECTING SUPPLY AND RETURN PIPING Figure 4 - Bypass Piping With Mixing Valve TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE SHUT-OFF 3 WAY MIXING CHECK VALVE HOSE BIB VALVE VALVE Figure 5 - Bypass Piping - Fixed Low Temp Only With Zone Valve...
- Page 10 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]...
- Page 11 CONNECTING SUPPLY AND RETURN PIPING Figure 8 - Multi Zone System With Zone Valves And DHW (With Circulator) Figure 9 - Multi Zone System With Zone Valves And DHW (With Zone Valve) P/N 240011584 Rev. A [07/30/2016]...
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Page 12: Vent Installation
VENT INSTALLATION Boiler series is classified as a Category I. Vent WARNING installation shall be in accordance with "Venting of Boiler and venting installations shall be performed Equipment," of the National Fuel Gas Code, ANSI by a qualified expert and in accordance with the Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances,"... -
Page 13: Vent Damper Installation & Instructions
VENT DAMPER INSTALLATION & INSTRUCTIONS DAMPER INSTRUCTIONS DAMPER INSTALLATION Follow Damper installation instructions provided with damper. See Figure 10. Figure 11 - Vent Damper Placement Figure 10 - Damper Motor Wiring Damper Motor UN-ACCEPTABLE DAMPER LOCATIONS CHIMNEY Damper Wire REFER TO DAMPER MANUFACTURER'S Haness INSTALLATION INSTRUCTIONS FOR POSITION OF DAMPER... -
Page 14: Connecting Gas Service
CONNECTING GAS SERVICE General CAUTION x Use piping materials and joining methods acceptable WHAT TO DO IF YOU SMELL GAS to authority having jurisdiction. In absence of such x Do not try to light any appliance. requirements: x USA - National Fuel gas Code, ANSI Z223.1/NFPA 54 x Do not touch any electrical switch;... -
Page 15: Electrical Section
ELECTRICAL SECTION WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. ELECTRICAL WIRING See wiring diagrams on the following two pages for details. -
Page 16: Wiring Diagram
WIRING DIAGRAM Figure 13 - Integrated High Limit Electronic Ignition Control WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. P/N 240011584 Rev. A [07/30/2016]... - Page 17 WIRING DIAGRAM Figure 14 - Integrated High Limit Electronic Ignition Control P/N 240011584 Rev. A [07/30/2016]...
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Page 18: Lighting Instructions
LIGHTING INSTRUCTIONS OPERATING INSTRUCTIONS FOR INTERMITTENT WARNING PILOT SYSTEM If you do not follow these instructions STOP! Read the safety information to the left. exactly, a fire or explosion may result Set the thermostat to lowest setting. causing property damage, personal injury Turn off all electric power to the appliance. -
Page 19: Normal Sequence Of Operation
NORMAL SEQUENCE OF OPERATION Thermostat actuates on call for heat, Figure 16 - Blocked Vent Safety Switch, Roll-out completing circuit to control. Completed Safety Switch circuit to control will first activate circulator Intergral Draft and damper which will close end switch inside Hood damper. - Page 20 GENERAL INSTRUCTIONS x Make visual inspection of main burner and pilot flames Figure 17 - Gas Burner Flame at start of heating season and again in mid-season. Main burner flame should have well defined inner blue mantel with lighter blue outer mantel. Check burner throats and burner orifices for lint or dust obstruction.
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Page 21: Checking Gas Input Rate To Boiler
CHECKING GAS INPUT RATE TO BOILER x Adjust gas input to boiler by removing protective cap on Figure 20 - High Limit Control Location pressure regulator and turning screw clockwise increase input and counterclockwise to decrease High Limit and input. Operating Control x Manifold pressures are taken at outlet side of gas valve. -
Page 22: Appendix A - Control Module
APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations A.3 Adjusting Settings To discourage unauthorized changing of settings, procedure WARNING to enter adjustment mode is required. If you do not follow these instructions To enter adjustment mode, press UP, DOWN, and I buttons exactly, a fire or explosion may result simultaneously for three seconds. - Page 23 APPENDIX A - CONTROL MODULE A.5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes list) Module continuously monitors boiler water temperature and and heats water in boiler until setpoint temperature is fires or shuts off burner based on this temperature data. achieved or thermostat is satisfied.
- Page 24 APPENDIX A - CONTROL MODULE Table 6 conti. - Vent Damper Models Operation State Codes State Code Definition Explanation Order Number 2. Other possible state codes System is purging before ignition trial; includes Pilot Valve circuit diagnostics. On vent Pre-purge damper models, this is so quick it will typically be over before the display can flash this code, and therefore will rarely be visible.
- Page 25 APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller A.7 Troubleshooting x When water temperature reaches setpoint, controller x Following service procedures are provided as general ends heating cycle. guide. x When water temperature drops below setpoint minus x On lockout and retry models, meter readings between differential, controller restarts heat cycle to re-heat gas control and ignition module must be taken within...
- Page 26 APPENDIX A - CONTROL MODULE Table 7 - Troubleshooting Error Codes Error Display clearing ( once error condition has disappeared) Error Clears itself Up/down Cycle Code Definition Push when root key when Power Explanation Things to look for Number problem is status is solved displayed...
- Page 27 APPENDIX A - CONTROL MODULE Table 7 - Troubleshooting Error Codes - conti. Error Display clearing ( once error condition has disappeared) Error Clears itself Up/down Cycle Code Definition Push when root key when Power Number Explanation Things to look for problem is status is solved...
- Page 28 APPENDIX A - CONTROL MODULE A.9 Intermittent Pilot STEP 2: Verify ignition system grounding. Nuisance shutdowns are Ignition System Checks often caused by poor or erratic grounding. Common ground is required for module and pilot burner/ STEP 1: Check ignition cable. igniter sensor.
- Page 29 APPENDIX A - CONTROL MODULE STEP 3: Check spark ignition circuit. x Recheck ignition sequence as follows. Disconnect ignition cable at SPARK terminal on module. — Reconnect main valve wire. WARNING — Adjust thermostat above room temperature. — Verify ignition sequence at burner. Electrical shock hazard.
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Page 30: Appendix B-1 - Vent Damper Harness
APPENDIX B - VENT DAMPER B.1 Vent Damper Harness - Molex Plugs xIf boiler ignites: Go to section B.2 "Vent Damper Troubleshooting Guide". WARNING NOTE: Prior to replacing the damper, be Do Not negate the action of any existing safety sure the problem is not with wire connections orperational controls. -
Page 31: Appendix B-2 - Vent Damper Troubleshooting
APPENDIX B - VENT DAMPER TROUBLESHOOTING B.2 Vent Damper Troubleshooting Guide WARNING Do Not negate the action of any existing safety orperational controls. Avoidance of these instructions could result in death or serious injury. When servicing controls, all wires must be Note labeled prior to disconnection. - Page 32 APPENDIX B - VENT DAMPER TROUBLESHOOTING For troubleshooting only. Verify damper is in Note open position. Use service switch to keep damper in open position. Place jumper between 2 & 3. If appliance fires, remove jumper and plug receptacle back into damper controller plug.
- Page 33 NOTES P/N 240011584 Rev. A [07/30/2016]...
- Page 34 NOTES P/N 240011584 Rev. A [07/30/2016]...
- Page 35 P/N 240011584 Rev. A [07/30/2016]...
- Page 36 IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
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