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HydroTherm MG Series Installation Manual And Replacement Parts List

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MG SERIES
INSTALLATION MANUAL
AND REPLACEMENT
PARTS LIST
Modular Power Gas Cast
Iron Water Heating Plants
770,000 to 2,310,000
Btuh Input
Applicable For Larger Heating
Plants Using Boiler Banks
Of 6-Modules Or Less
Heating Plant Design............................................
Code Compliance.................................................
Heating Plant Shipment........................................
Heating Plant Dimensions.....................................
Step 1: Planning Ahead.........................................
Step 2: Arranging Heating Plant............................
Step 3: Setting & Aligning Modules.......................
Step 1: Planning Ahead.........................................
Step 2: MC Heat Exchangers................................
Step 3: Supply & Return Headers.......................... 6
Step 4: Hydronic Components...............................
Step 5: Hydrotesting The System..........................
Step 1: Planning Ahead........................................ 11
& Slip Joints............................................. 12
Step 3: Breeching Runs.......................................
NOTE: If shop drawings have not been provided, refer to the Appendices at the rear of this manual for sizing
(breeching, chimney & gas piping) and control system data.
IN UNITED STATES: 260 NORTH ELM ST., WESTFIELD, MA 01085 • (413) 568-9571/FAX (413) 568-9613
IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONT L4W 1R3 • (905) 625-2991/FAX (905) 625-6610
2
Jacket Assembly................................................... 14
2
2
3
Burner Requirements........................................... 15
4
Step 1: Gas Main & Gas Headers........................ 15
5
Step 2: Test Gas Piping........................................ 16
5
Wiring Requirements............................................ 16
6
6
Step 1: Planning Ahead........................................ 17
7
Step 2: Start-Up & Adjustments............................ 17
8
APPENDICES
A: Breeching/Chimney Sizing............................... 18
B: Gas Pipe Sizing................................................ 20
C: Control Guidelines............................................ 22
13
MG2-605
42-9158
27

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  • Page 1: Table Of Contents

    MG2-605 42-9158 MG SERIES INSTALLATION MANUAL AND REPLACEMENT PARTS LIST Modular Power Gas Cast Iron Water Heating Plants 770,000 to 2,310,000 Btuh Input Applicable For Larger Heating Plants Using Boiler Banks Of 6-Modules Or Less SECTION 1: INTRODUCTION SECTION 5: INSTALLING JACKETS Heating Plant Design..........

  • Page 2: Section 1: Introduction

    Heating Modules: Each module is shipped unjacketed in crease in actual heating load. Hydrotherm has develop- its own carton and weighs 623 lbs. (maximum for MG- ed three basic methods (levels) of control which meet 385 module).

  • Page 3: Heating Plant Dimensions

    rect combination of “A” and “B” headers are furnished to manifold the complete heating plant. Control Equipment: When ordered, controls such as mo- torized valves, modulating aquastats, step controllers, Optional Heat Exchanger: When ordered, each heat thermostats, etc., are furnished in separate cartons. exchanger is shipped with the pipe and fittings required for installation.

  • Page 4: Section 2: Installing Modules

    SECTION 2: INSTALLING MODULES STEP 1: PLANNING AHEAD IMPORTANT TO NOTE NOTE: Modules employ atmospheric combustion. Combustion air must not be contaminated with halo- 1. Observe minimum clearances to combustibles. genated hydrocarbon vapors, cleaning fluid vapors, aerosol propellants, freon or other corrosive chemi- cals.

  • Page 5: Step 2: Arranging Heating Plant

    STEP 2: ARRANGING HEATING PLANT 1. Locate heating plant as close to the chimney as possi- 4. Make sure that any connecting breeching runs will not ble so breeching length to chimney is kept to a minimum. oppose or face each other, but rather, mix together in the Only 6"...

  • Page 6: Section 3: Installing Water Piping

    STEP 2: MC HEAT EXCHANGERS For installation of factory-supplied MC/MCI heat exchangers, refer to Hydrotherm MC & MCI Installation Guide (MC2) pack- aged with the heat exchanger. All external piping must be supported by hangers, not by the boilers or their accessories.

  • Page 7: Step 4: Hydronic Components

    STEP 3: SUPPLY & RETURN HEADERS (CONTINUED) EXAMPLES OF TYPICAL SUPPLY & RE- RETURN RETURN TURN WATER SUPPLY SUPPLY PIPING FOR HEADERS. BACK TO BACK NO MORE MORE THAN 6 MODULES IN-LINE - 6 MODULES OR LESS THAN SIX MODULES RETURN MAY BE DIRECTLY...

  • Page 8: Step 5: Hydrotesting The System

    STEP 4: HYDRONIC COMPONENTS (CONTINUED) Follow manufacturer’s installation instructions. MOTORIZED VALVE: Commonly used on combination space/volume water heating systems to ensure a pri- EXPANSION TANK : Locate on suction side of pump ority for domestic hot water over space heating. (2" (where it will protect all modules under all operating globe valve with motor for MC2 heat exchanger) (2- conditions).
  • Page 9 TYPICAL PIPING FOR FLOW CHECK SPACE HEATING SYSTEM VALVE CIRCULATOR Figure 3.4 AIR ELIMINATOR (AIR VENT) City Water Supply SEPARATOR EXPANSION MANUAL RESET TANK HI-LIMIT LOW WATER CUTOFF To Potable Water System BACKFLOW PRESSURE PREVENTER REDUCING (FILL) VALVE SHUT-OFF MAKE-UP VALVE WATER METER BASKET TYPE...
  • Page 10 TYPICAL PIPING FOR VOLUME WATER HEATING ONLY (INSTANTANEOUS RECOVERY) AIR ELIMINATOR (AIR VENT) Service Hot THERMOMETER Water Supply MIXING VALVE MANUAL RESET SHUT-OFF VALVE HI-LIMIT BRONZE CIRCULATOR FLOW CHECK VALVE Service Recirculating LOW WATER Hot Water CUTOFF BACKFLOW PREVENTER City Water Supply PRESSURE...

  • Page 11: Section 4: Venting The Heating Plant

    SECTION 4: VENTING THE HEATING PLANT STEP 1: PLANNING AHEAD IMPORTANT TO NOTE the larger dimension of the rectangle must be in the vertical. Breaching should be constructed of sheet metal 1. Breaching runs must be as short as possible. with smooth interior surfaces.

  • Page 12: Step 2: Draft Regulators, Vent Connectors & Slip Joints

    STEP 2: DRAFT REGULATORS, VENT CONNECTORS & SLIP JOINTS DANGER: Flue outlet and draft regulator as supplied must not be altered as proper module operation would be jeopardized. Fire or carbon monoxide poisoning will result. 1. Mount each module’s factory-supplied draft regulator available head room.

  • Page 13: Step 3: Breeching Runs

    STEP 3: BREACHING RUNS FIGURE 4.5 1. Breaching can be full size for an entire bank of boil- mension of the rectangle must be in the vertical. ers (Figure 4.5 left) or may be tapered (Figure 4.5 4. ALL BREACHING RUNS MUST BE PITCHED 1/4” right), using one tapered division within a bank of six PER FOOT OF LENGTH UPWARDS TOWARD THE modules.

  • Page 14: Section 5: Installing Jackets

    SECTION 5: INSTALLING JACKETS NOTE: Remember, “A” jacket sets are for enclosing gether in one continuous line; just omit one side panel two modules and “B” jacket sets are for enclosing (left panel) in between jacket sets. Fasten front and three modules.

  • Page 15: Section 6: Installing Burner

    SECTION 6: INSTALLING BURNER Install each module’s burner, following manufacturer’s installation instructions packaged with the burner. SECTION 7: INSTALLING GAS PIPING STEP 1: GAS MAIN & GAS HEADERS 1. Gas main and gas headers must be sized to provide a 2.

  • Page 16: Step 2: Test Gas Piping

    STEP 2: TEST GAS PIPING DANGER: Before placing gas piping into service, carefully test it to assure every joint is gas tight. Bubble test all joints with a soap solution. NEVER TEST WITH AN OPEN FLAME AS FIRE OR EXPLOSION WILL RESULT.

  • Page 17: Section 9: Heating Plant Start-Up

    SECTION 9: HEATING PLANT START-UP STEP 1: PLANNING AHEAD 1. Check flow direction arrows imprinted on water system 3. Check all fittings and components for visible signs of components are pointing in the proper direction. leakage, including each module's (and header's) supply and return water connections.

  • Page 18: A: Breeching/Chimney Sizing

    1-ft minimum vent connector height. The recommendations in Figure A3 are not to be used for any other configuration; for non-stan- dard configurations, consult Hydrotherm factory directly.) Example: Let’s assume a MG-2310A heating plant. MG-1925 HEATING PLANT 1.
  • Page 19 must be 15" in diameter. For Section B size, go down to CHIMNEY SIZING (MINIMUM) 3 modules, where you’ll find that Section B must be 12" Circular Rectangular in diameter. Where the two breeching sections are con- Dia. x Ht. Linear x Ht.

  • Page 20: B: Gas Pipe Sizing

    APPENDIX B: GAS PIPE SIZING For accurate gas pipe sizing, be sure to use total equiv- 2. Determine length of the header, which is typically de- alent pipe length: Add the equivalent foot-length of all fit- pendent on length of the bank of modules which it serv- tings, such as elbows, tees and valves, used in the gas es.
  • Page 21 TABLE B2 Maximum Capacity of Pipe in Thousands of Btu per Hour of Undiluted Liquified Petroleum Gases (at 11 Inches Water Column Inlet Pressure) (Based on a Pressure Drop of 0.5 Inch Water Column) Nominal Length of Pipe, Feet Iron Pipe Size, Inches 1/2"...

  • Page 22: C: Control Guidelines

    & tive, low cost control system for small to medium heating size. Hydrotherm has developed three basic control lev- plants (2-6 modules) where it is desired to modulate sup- els which meet most operating methods encountered.
  • Page 23 For additional temperature. Is also used as a heat starter to automati- information, contact your local Hydrotherm sales repre- cally switch on system power to start heating plant. It is sentative or the Hydrotherm factory directly.
  • Page 24 OUTDOOR BULB SUNSHIELD (LOCATED ON NORTH WALL) MANUAL RESET HI-LIMIT CIRCULATOR ELECTRONIC LOW WATER CUTOFF SUPPLY SAFETY OUTDOOR THERMOSTAT HI-LIMIT (SYSTEM STARTER) DUAL AQUASTAT (#1 SET AT 170F, #2 SET AT 175F) 115V DISTRIBUTION PANEL RETURN SINGLE POLE RELAY w/ 115V COIL POWER GAS BURNER SINGLE AQUASTAT (#3 SET AT 180F)
  • Page 25 MODEL "S" CONTROL FOR WIRING CONNECTIONS, OUTDOOR FOLLOW INSTRUCTIONS TEMP. SENSOR IN S2 INSTALLATION MANUAL PACKAGED WITH CONTROL TO "S" CONTROL TO "S" CONTROL 115V SUPPLY WATER TEMP. SENSOR ELECTRONIC MANUAL RESET LOW WATER 3 POLE HI-LIMIT CUTOFF RELAY w/ 115V COIL SUPPLY CIRCULATOR...
  • Page 26 OUTSIDE REQUIRED: SUPPLY WATER SENSOR AIR SENSOR OUTSIDE AIR SENSOR AA HEAT STARTER DISPLAY MODULE EQUIV. AUTOMATIC (OPTIONAL) CONTROL (T6031A) SUPPLY D.A. SENSOR SENSOR SENSOR PRESS FOR SETPOINT MANUAL SWITCH (TO AVOID BOILERS HEAT STARTER RESET TRANSFORMER STAGE STAGE DISPLAY FIRING WITHOUT NO C IN COM COM 24...

  • Page 27: Replacement Parts

    Double-swing Barometric Draft Control BM-5298 Base Assembly w/combustion chamber BM-3303 Combustion Chamber BM-8192 Gas Burner (Refer to Hydrotherm Commercial Trade Price Book) T/P Indicator (For 30# R.V.) MO Only 20-1015 Temp./Press. Indicator (For 50# R.V.) 20-1003 Temp./Press. Indicator (For 75/100# R.V.) 20-1011 Press Relief Valve –...
  • Page 28 10 (MO ONLY) FIGURE 1: GENERAL ASSEMBLY FIGURE 1: MO GENERAL ASSEMBLY...

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