Table of Contents
Troubleshooting
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Summary of Contents for ECR UTICA BOILERS JC Series
- Page 1 JC SERIES Gas-Fired Water BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Utica Boilers 2201 Dwyer Ave Utica, NY 13501 www.ecrinternational.com An ISO 9001-2000 Certified Company P/N# 14683610, Rev. A [06/09]...
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Page 2: Table Of Contents
Table Of COnTenTs Warnings And Safety Symbols ..........................2 Introduction ................................3 Ratings And Capacities ............................4 Installation – Assembly ............................9 Connecting Gas Service ............................11 Wiring And Gas Main Piping ..........................12 Tappings ................................16 Boiler Trim ................................16 Boiler Piping ................................. 17 Piping Diagrams .............................. -
Page 3: Introduction
inTrOduCTiOn Read these instructions carefully before beginning the installation to WARNING be sure all packages have been received. It is recommended that you follow the step-by-step instructions for best assembly results. Before All installations of boilers should be done only by a quali- discarding any packing material carefully examine for loose parts. -
Page 4: Ratings And Capacities
raTings and CaPaCiTies Chart 1 IBR Ratings and Capacities Pressure A.G.A. A.G.A. NET I=B=R Fule Outlet No. Chimney Drop Thru Flue Input (1) Output (1) Ratings (2) & Size Size (6) Boiler Horsepower Water Boiler Collector Model Gross Size to Water Output (4) MBPH... - Page 5 raTings and CaPaCiTies figure 1 - front View figure 3 - left side View Supply Supply Water Line 38” 29” Floor Line figure 2 - Top View Flue Nutlets Return Return Supply Supply Chart 2 Boiler Water Shipping A Jacket Model Content Weight...
- Page 6 VenTilaTiOn and COmbusTiOn air WARNING WARNING Enough air ensures proper combustion and assures that no Air openings to combustion area must not be obstructed. hazard will develop due to the lack of oxygen Follow chart #3 to insure that adequate combustion air can be maintained.
- Page 7 VenTilaTiOn and COmbusTiOn air figure 4 figure 5 Combustion Air Combustion Openings with Motorized Dampers Openings Combustion Air supplied from Combustion Air supplied from outside the building inside the building directly with other spaces of sufficient volume so that the com- NOTICE bined volume of all spaces meets the criteria for an unconfined IMPORTANT: Slope Vent Pipe at least 1/4"...
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Page 8: Ventilation And Combustion Air
VenTilaTiOn and COmbusTiOn air boiler. The opening shall directly communicate with the material to be as listed by pipe manufacturer. outdoors or shall communicate through a vertical or hori- zontal duct to the outdoors or spaces (crawl or attic) that Chart 4 freely communicate with the outdoors. -
Page 9: Installation - Assembly
insTallaTiOn – assembly assembly of bases starting section assembly The 300, 400 and 500 boilers are the basic models. The 300 model The sections may be started from either the left or the right end of has (6) burners, the 400 model has (8) burners and the 500 model the base. - Page 10 insTallaTiOn – assembly attaching the draft hoods figure 8 Attach the draft hoods to the boiler sections after applying boiler putty to the top of the boiler sections where the hoods and the sec- tions meet. Use j-bolts to attach the fronts of the draft hoods to the slots in the section flanges.
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Page 11: Connecting Gas Service
COnneCTing gas serViCe Connecting gas service Chart 5 Connect gas service from meter to the boiler control assembly(s) Minimum Gas Supply Pressure in accordance with ANSI Z223.1-latest revision and local codes or 5.0 inches w.c. utility company. On multiple base boilers, connect gas service with Models 1000 1300... -
Page 12: Wiring And Gas Main Piping
Wiring and gas main PiPing figure 12... - Page 13 insTalling bOiler JaCkeT Panels Attach the upper jacket end panel (left) to the middle jacket end NOTICE panel with the upper behind the middle and lining up the holes. Use (6) #10 x ½” screws. Attach upper jacket end panel to rear Note: Jacket Assembly must be started at the left side of the side of the draft hood.
- Page 14 insTalling bOiler JaCkeT Panels Attach front panel to the boiler after installing the burner door. Attach the upper jacket end panel (right) so the left edge hangs (Figure 17) on bracket on top/front intermediate panel. Attach upper jacket end panel to rear side of draft hood. Use (1) #8 x ¾” screw. On multiple base boilers, all front panels are attached in the (Figure 19) same way (working your way from left to right).
- Page 15 insTalling bOiler JaCkeT Panels Attach the lower jacket end panel (right) to the middle jacket figure 22 end panel with the lower behind the middle and lining up holes. Use (5) #10 x ½” screws. Attach the lower jacket end panel to the two Z-bars on the base end closures through the two slotted holes on the bottom of the jacket end panel.
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Page 16: Tappings
TaPPings Figure 25 shows the end section and the various tappings provided. figure 25 - boiler Tappings Tappings are the same in both right and left end sections, except for the drain valve tapping which is ¾” left end, and 1 ¼” right end. The openings on the end sections and their functions are listed in Chart Chart 7 OPENING... -
Page 17: Boiler Piping
bOiler PiPing boilers used With refrigeration system figure 26 When the boiler is installed in connection with a refrigeration sys- tem, the chilled medium must be piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the heating system. -
Page 18: Piping Diagrams
PiPing diagrams figure 28 Water boiler Piping BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS SHOWN WITH EXCEPTION OF NO. 764 WHICH MOUNTS IN PIPING NO. 764 CITY WATER SUPPLY SUPPLY LINE NO. 63 TO RETURN MINIMUM DIMENSION 29-3/4 McDONNELL LOW-WATER CUT-OFF McDONNELL FEEDER CUT-OFF COMBINATION For All Boilers Up To 50-PSI Relief Valve Setting For Boilers With 30-PSI Relief Valve Setting... -
Page 19: Flue Connection And Venting
flue COnneCTiOn and VenTing figure 29 WARNING This boiler is to be vented by natural draft and shall not be connected into any portion of a mechanical draft system operating under positive pressure. flue Connection and Venting Consult local codes and gas company requirements. Adhere to the following standard practice recommendations for installing the flue pipe: Consult dimensional drawing for number and size of flue pipes... -
Page 20: Removing Existing Boiler From Common Venting System
flue COnneCTiOn and VenTing cannot be maintained, the diameter of the horizontal run must be figure 32 increased one inch for each foot of riser reduction. This procedure will reduce the resistance of the system, and if the chimney is ad- equate the boiler will vent properly. - Page 21 flue COnneCTiOn and VenTing...
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Page 22: Electrical Wiring
eleCTriCal Wiring electrical Wiring thermostat for the final adjustment, checking thermostat operation. When set above temperature indicated on the thermometer, boiler Wiring connections are to be made in accordance with the National burners should ignite. Make certain the thermostat(s) turns off the Electrical Code, ANSI/NFPA 70-2002 and/or local authority having boiler when room temperature reaches the selected setting and starts jurisdiction. -
Page 23: Wiring Diagrams
Wiring diagrams figure 33 - schematic Wiring diagram for s8610u SCHEMATIC WIRING DIAGRAM FOR S8610U figure 34 - honeywell Vr8304m gas Valve Wiring figure 35 - robert shaw 7000 derhC gas Valve Wiring HONEYWELL VR8340M GAS VALVE WIRING ROBERT SHAW 7000 DERHC GAS VALVE WIRING... - Page 24 Wiring diagrams figure 36 - hot Water single base boilers with honeywell intermittent Pilot figure 37 - hot Water single base boiler with honeywell intermittent Pilot - With Thermostat Controlled Circulator Pump...
- Page 25 Wiring diagrams figure 38 - Wiring for boilers With Two or more bases and electronic ignition...
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Page 26: Operation And Service
OPeraTiOn and serViCe Make sure all wiring connections are clean and tight. Control (s8610u) functions and Operation Review the control’s normal sequence of operation. The control module performs the following basic functions: Opens and closes the first (pilot) operator of the gas valve. system Troubleshooting Provides a spark for igniting pilot burner. -
Page 27: Starting The Boiler
OPeraTiOn and serViCe Ignition Cable Check - Cable must not run in continuous Check Grounding - A common ground is required for the contact with a metal surface or spark voltage will be greatly re- pilot burner/igniter-sensor mounting bracket, and the GND duced. -
Page 28: Pilot System Troubleshooting Table
PilOT sysTem TrOubleshOOTing Table figure 40 - Pilot system Troubleshooting Table NOTE: Before troubleshooting, familiarize yourself with the startup and check Turn gas supply OFF. Turn thermostat procedure. (controller) to call for heat. Check line voltage power, low voltage transformer, limit controller, thermostat Power to module (24V module) (controller) and wiring. -
Page 29: Checking And Adjusting
CheCking and adJusTing to flush free any sediment that may lodge on the valve seat. Then Check burner input permit the valve to snap shut. Check Boiler for proper BTU input rate. CAUTION burner and Pilot flame Do not exceed the Input rate stamped on the nameplate of We recommend that you make a periodic visual check of the burners the boiler located on the END Jacket Panel. -
Page 30: Venting System
CheCking and adJusTing Venting system The vent system is a very important part of the heating system. No AT LEAST ONCE A MONTH DURING HEATING SEASON check boiler, however efficient its design, can perform satisfactorily if the to see that the sections of vent pipe are secure at all joints and fit- chimney that serves it is inadequate. - Page 31 This Page inTenTiOnally lefT blank...
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Page 32: Complete Boiler Parts List
COmPleTe bOiler ParTs lisT Chart 11 COMPONENT CAR- JACKET SECTIONS WATER ACCES- BASE END TRIM SORY PANEL PANEL MODEL L INNER CARTON CARTON CARTON CARTON WA-1 WA-1 WA-1 WA-1 WA-2 WA-2 WA-2 1000 WA-2 1000 1100 WA-2 1100 1200 WA-3 1200 1300 WA-3... - Page 33 maTerial lisTs Chart 12 WaTer Trim CarTOn maTerial lisT paRtS DESCRIptIon paRt no. UnIt QUantItY pER CaRton Wa-1 Wa-2 Wa-3 Wa-4 Wa-5 41200071 41200072 41200073 41200074 41200075 L4006A Aquastat 240006706 Well for Aquastat 14662804 Water Temperature/Pressure Gauge 1260006 1/2” x 1/4” Bushing 1060001 3/4”...
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Page 34: Electronic Ignition
eleCTrOniC igniTiOn figure 42... - Page 35 eleCTrOniC igniTiOn base maTerial lisT Chart 14- List of Parts Shown in Figure 42 QUANTITY PARTS DESCRIPTION PART NO. UNIT 300 Base 42557123 400 Base 42557124 500 Base 42557125 300 Fire Door 42557133 400 Fire Door 42557134 500 Fire Door 42557135 Orifice 30 Natural JC 14615310...
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Page 36: Accessory Carton
aCCessOry CarTOn Chart 15 aCCessOry CarTOn bOiler mOdel numbers and QuanTiTies ParTs 1000 1100 1200 1300 1400 1500 desCriPTiOn ParT nO. COMPLETE ACCY CRTN # 4” Push Nipples 43300977 5/8” - 11NC x 7 Stud 14695304 5/8” - 11NC Hex Nut 1330005 5/8”... - Page 37 aCCessOry CarTOn - COnTinued Chart 15 - Continued aCCessOry CarTOn continued 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000...
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Page 38: Material Lists
maTerial lisTs Chart 16 fiTTing bags maTerial lisT FB-1 FB-2 FB-3 FB-4 FB-5 FB-6 PARTS DESCRIPTION PART NO. 41200051 41200052 41200053 41200054 41200055 41200056 #10 x 1/2” Self Tap Screws 14695074 #8 x 3/4” Self Tap Screws 14695003 #10-32 x 1/2" Slot Head Screws 14695307 none #10-32 Hex Nuts... -
Page 39: S8610U Universal Intermittent Pilot Gas Ignition Control
s8610u uniVersal inTermiTTenT PilOT gas igniTiOn COnTrOl failed Trial for Pilot ignition The S8610U Control Module provides multiple trials for ignition (TFI). If the pilot is not lit or sensed before the end of the trial for ignition time, the ignition control shuts off the spark and pilot gas (100% shutoff ). - Page 40 s8610u uniVersal inTermiTTenT PilOT gas igniTiOn COnTrOl figure 43 Idle (Not Powered) 'Call For Heat' Received From Thermostat Power To Module And Self Check Damper Switch Damper Damper Switch Check Status Closes in 60 Sec.? Connected ? Opens in 60 Sec.? Damper Switch If Configured Retry Delay...
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