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

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P/N

240009268

, Rev. A [03/2012]

MGC SERIES

GAS-FIRED

HOT WATER BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com

Models

MGC-8D

MGC-8DP

MGC-9D

MGC-9DP

C.S.A. Certifi ed for

Natural gas or

Propane

Tested for

50 psi.

ASME Working

Pressure

Summary of Contents for MGC-8D

Page 1: ...RATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models MGC 8D MGC 8DP MGC 9D MGC 9DP C S A Certified for Natural gas or Propane Tested for 50 psi ASME Working Pressure ...

Page 2: ...2 1 DIMENSIONS Table 1 Dimensions BOILER MODEL NUMBER DIMENSIONS INCH FLUE DIAMETER A WIDTH MGC 8 7 27 MGC 9 7 30 Add 5 to height for vent Damper Figure 1 Dimensions ...

Page 3: ...ensive piping systems etc 3 MBH 1 000 Btuh British Thermal Unit Per Hour Ratings marked Net AHRI Ratings indicate amount of remaining heat input used to heat radiation or terminal units Net AHRI Ratings shown are based on allowance of 1 15 in accordance with factors shown on AHRI Standard as published by The Hydronics Institute Selection of boiler size should be based upon Net AHRI Rating being eq...

Page 4: ...y Read this manual and understand all requirements before beginning installation SAFETY SYMBOLS WARNINGS The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels NOTICE Used to address practices not related to personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury WA...

Page 5: ...ence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 Where required by the authority having 2 jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically fired Boilers ANSI ASME CSD 1 Boiler series is classified as a Category I Vent 3 installation shall be in accordance with Venting of Equipment of the National Fuel Gas Code A...

Page 6: ...ultiple appliances Do not use an air infiltration rate ACH greater than 0 60 Volume 21 ft3 ACH x Total Input Mbh Refer to National Fuel Gas Code for opening C requirements between connected indoor spaces All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors Two Permanent Opening Method Provide A opening commencing within 12 inches of top and second opening co...

Page 7: ... of the relief valve outlet over the entire length of discharge line have no intervening shutoff valve between safety relief valve and discharge to atmosphere do not plug or place any obstruction in discharge line terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing allow complete drainage of the valve and the discharge line be independently support...

Page 8: ...heating boiler Appropriate valves must be used to prevent chilled medium from entering heating boiler See Figure 5 page 9 B Boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle LOW ...

Page 9: ...9 Figure 5 Chilled Water Piping Figure 4 Typical Hot Water Piping 6 CONNECTING SUPPLY AND RETURN PIPING ...

Page 10: ...10 Figure 6 BYPASS PIPING CIRCULATOR ON SUPPLY Figure 7 BYPASS PIPING CIRCULATOR ON RETURN Bypass Piping Required For High Mass Large Water Content Systems 6 CONNECTING SUPPLY AND RETURN PIPING ...

Page 11: ...d by using plug supplied with vent damper Position furnished vent damper on top of flue 1 outlet collar Fasten damper securely to flue outlet collar with sheet metal screws Verify damper blade has clearance to operate inside of diverter Do not modify either draft diverter or vent damper during installation As An Option Damper may be installed in any horizontal or vertical position closer to flue o...

Page 12: ...ny appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 7 CHIMNEY AND VENT PIPE CONNECTION Place in operation the appliance being inspected 4 Follow the lighting instructions Adjust thermostat so appliance will operate continuously Tes...

Page 13: ...er indicator points to open position Turn thermostat or controller down again and check damper position indicator returns to closed position Vent Damper Manual Operation Vent damper may be placed in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller Thermostat will control burner firing as before while damper will remain open DO NOT turn damper o...

Page 14: ...aller Two stage regulation should be used by propane installer Propane gas piping should be checked out by propane installer CHECKING GAS PIPING DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition source Failure to comply will result in death or serious injury Pressure test boiler and gas connection before placing boiler in operation Pressure test over 1 2...

Page 15: ...tures televisions a fireplace or a chimney Check thermostat operation by raising and 4 lowering thermostat setting as required to start and stop the burners Instructions for the final adjustment of the 5 thermostat are packaged with the thermostat adjusting heating anticipator calibration etc Set heat anticipator at 2 amps 24 volt thermostat connects to aquastat terminals T and TV WARNING Electric...

Page 16: ...Integrated High Limit Electronic Ignition Control 240008781 I Inducer is not an option WARNING Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life ...

Page 17: ...17 11 WIRING DIAGRAMS Figure 13 Integrated High Limit Electronic Ignition Control 240008781 ...

Page 18: ...18 11 WIRING DIAGRAMS Figure 14 Integrated High Limit Electronic Ignition Control 240008781 ...

Page 19: ...d repeat this process Repeat until you have covered every radiation units in the system ending up at highest unit in system If your units have automatic vents manual venting is unnecessary but it will speed up the proper filling of your system If your system is closed expansion tank system you may leave it open to refill system automatically as needed Check temperature pressure gauge Not position ...

Page 20: ...lockwise to OFF Do not force WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which automatically lights burner Do NOT try to light this burner by hand Before operating smell all around appliance area for gas Be sure to smell next to floor because some ga...

Page 21: ...t be functioning properly to permit operation Safety lockout system has to be reset by turning thermostat to lowest setting for one minute then back to normal setting ADJUST PILOT BURNER Pilot flame should surround 3 8 to 1 2 of the pilot sensor See Figure 16 If flame needs adjusting do it as follows Remove screw cover over pilot adjusting screw 1 Insert small screwdriver and adjust flame as 2 nee...

Page 22: ...w degrees After setting limit control to limit setting C check to see if it shuts off gas supply to burners Turn your thermostat up to call for heat and let boiler run until temperature of water reaches limit setting Gas valve should shut off and circulator running until thermostat is satisfied or water cools enough to restart burners through limit control Set thermostat for desired temperature D ...

Page 23: ...NT PIPE Venting and piping should be checked at least once a season If vent piping shows any sign of leaking replace immediately WATER SYSTEM If system is to remain out of service during freezing weather always drain it completely water left in to freeze will crack pipes and or boiler CLEANING YOUR BOILER AND BURNERS Flue passages between sections should be examined yearly and cleaned if necessary...

Page 24: ...minals and wire joints Rollout switch blown Have your service agent check heat exchanged for blockage Replace rollout switch with exact replacement Spill switch blown Have your service agent check venting system and chimney for blockage or down draft condition Reset spill switch Vent damper not operating Consult troubleshooting guide in Effikal manual packaged with vent damper Possible Cause What ...

Page 25: ...nstalled in supply line It will eliminate air from water before it reaches radiators and bleed off this air MAIN AIR VENT FOR DOWN FLOW SYSTEMS OR DIAPHRAGM TYPE EXPANSION TANK Before system is filled with water there is air in pipes and radiation units Some of it will be trapped as system is filled It is possible to eliminate most of this air through air vent on radiation units Main air vent will...

Page 26: ...l switch must be reset manually after switch has cooled off by pushing reset button down Check venting system and chimney for blockage when restoring system to operating condition DO NOT operate boiler without spill switch 17 EQUIPMENT AND OPTIONAL ACCESSORIES ROLLOUT SWITCH FLAME ROLLOUT SAFETY SHUTOFF Rollout switch is temperature sensitive fuse link device Located on boiler base just outside fi...

Page 27: ... Check sensing bulb is fully inserted in well and is not loose Refer to enclosed addendum for wiring instructions when using indirect hot water heater A 3 Adjusting Settings To discourage unauthorized changing of settings pro cedure to enter adjustment mode is required To enter adjustment mode press UP DOWN and I buttons simultaneously for three seconds Press and release I button until parameter r...

Page 28: ...ore retry Flame signal was lost during state 7 or 8 and delay is called before retry 32 second delay 13 Soft lock out Soft lockout duration is one hour may override with manual reset 14 Hard lock out Manual reset is required for hard lockout 15 Wait for limit to close Possible thermostat call for heat limit switch is open 16 Flame out of sequence Flame signal sensed before trial for ignition Appro...

Page 29: ...and display On retry models wait for retry or reset at thermostat Check for correct installation and wiring before replacing any component Control module cannot be repaired If it malfunctions it must be replaced Use only qualified service agent to service ignition systems Perform checkout as first step in troubleshooting 1 Check troubleshooting guide to pinpoint cause of problem See Table 7 page 3...

Page 30: ...lockout is reset after one hour if alarm reason disappears 63 Soft lockout maximum number of recycles exceeded Soft lockout 64 Soft Lockout electronics failure On board self diagnostics detected error Soft lockout 65 Over temperature error Sensor measured temperature in excess of maximum allowable limit Soft lockout Note Soft lockout time is 1 hour or manual reset Hard lockout requires manual rese...

Page 31: ... damaged wire Check for cracked ceramic insulator which can cause short to ground and replace igniter sensor if necessary At gas valve disconnect main valve wire from MV terminal Turn on power and set thermostat to call for heat Pilot should light main burner will remain off because main valve actuator is disconnected Check pilot flame Verify it is blue steady and envelops 3 8 to 1 2 in 10 to 13 m...

Page 32: ...UTICA BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

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