PEG-C
GAS FIRED BOILERS
FOR STEAM HEATING
Utica Boilers • P.O. Box 4729 • Utica, NY 13504
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety Symbols
The following defined symbols are used throughout this manual to notify the
reader of potential hazards of varying risk levels.
DANGER
DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
WARNING
WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury
CAUTION
CAUTION - Indicates a potential hazardous situation which, if not avoided, MAY result
in minor or moderate injury. It may also be used to alert against unsafe practices.
IMPORTANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.
WARNING:
1. Keep boiler area clear and free from combustible materials, gasoline and other
flammable vapors and liquids.
2. DO NOT obstruct air openings to the boiler room.
3. Modification, substitution or elimination of factory equipped, supplied or specified
components may result in property damage, personal injury or the loss of life.
4. To the owner: Installation and service of this boiler must be performed by a qualified
installer.
5. To the installer: Leave all instructions with the boiler for future reference.
6. When this product is installed in the Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or Licensed Gas Fitter.
WARNING: ALL INSTALLATIONS OF BOILERS AND VENTING
SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN
ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL.
INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE
WITHIMPROPERMETHODSORMATERIALSMAYRESULTINSERIOUS
INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM
POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS
ODORLESS AND INVISIBLE.
PAGE 1
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION PROCEDURE
WARNING: Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.
1. The installation must conform to the requirements of the authority having jurisdiction
or, in absence of such requirements, to the latest revision of the National Fuel Gas Code,
ANSI Z223.1. (Available from the American Gas Association, Pleasant Valley Road,
Cleveland, Ohio 44134.) Reference should also be made to local gas utility regulations and
other codes in effect in the area that the installation is to be made.
2. Where required by the authority having jurisdiction, the installation must conform to
American Society of Mechanical Engineers Safety Code for Controls and Safety Devices
For Automatically Fired Boilers, No.CSD-1.
3. This boiler is classified as a Category 1 appliance and the vent installation shall be
in accordance with Part 7 & 11 of the latest revision of the National Fuel Gas Code noted
above or applicable provisions of the local building codes. See Vent Installation on page 7.
4. This boiler meets safe lighting and other preference criteria with the gas manifold and
control assembly provided on the boiler per the latest revision of ANSI Z21.13b.
5. This boiler shall be installed such that the gas ignition system components are
protected from water (dripping, spraying, rain, etc.) during appliance operation and service,
(circulator replacement, condensate trap, control replacement, etc.).
6. LOCATE BOILER on level, solid base as near chimney as possible and centrally
located with respect to the heat distribution system as practical.
7. ALLOW 24 inches at the front and right side for servicing and cleaning.
8. When installing in a utility room, the door should be wide enough to allow the largest
boiler part to enter, or to permit replacement of another appliance such as a water heater.
9. FOR INSTALLATION ON NONCOMBUSTIBLE FLOORS ONLY. *The boiler must
not be installed on carpeting. Minimum clearances to combustible construction are:
TOP.................................................................... 24 IN.
FRONT.......................................................... ALCOVE
FLUE COLLECTOR ............................................. 6 IN.
REAR ................................................................... 8 IN.
SIDES .................................................................. 6 IN.
NOTE: GREATER CLEARANCES FOR ACCESS SHOULD SUPERSEDE FIRE
PROTECTION CLEARANCE.
PAGE 2
Download from Www.Somanuals.com. All Manuals Search And Download.
VENTILATION & COMBUSTION AIR
WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT BE
OBSTRUCTED. BY FOLLOWING THE INSTRUCTIONS BELOW, ADEQUATE
COMBUSTION AIR CAN BE MAINTAINED
* Unconfined area: A space whose volume is not less than 50 cubic feet per 1000
BTU per hour of all appliances installed in that space (cubic feet of space = height x
width x length).
** Confined area: A space whose volume is less than 50 cubic feet per 1000 BTU per
hour of all appliances installed in that space (cubic feet of space = height x width x
length).
1. Ventilation of the boiler room must be adequate to provide sufficient air to properly
support combustion per the latest revision of the National Fuel Gas Code, ANSI Z223.1
section 5.3.
2.Whenaboilerislocatedinanunconfinedspaceinabuildingorconventionalconstruction
frame, masonry or metal building, infiltration normally is adequate to provide air for
combustionandventilation.However,iftheequipmentislocatedinabuildingofunusuallytight
construction (See the national Fuel Gas Code, Ansi Z223.1 section 1.7), the boiler area
shouldbeconsideredasaconfinedspace.Inthiscaseairforcombustionandventilationshall
be provided according to part 5 on page 4. If there is any doubt, install air supply provisions
in accordance with the latest revision of the National Fuel Gas Code.
3.Whenaboilerisinstalledinanunconfined
space, in a building of unusually tight
construction,airforcombustionandventilation
must be obtained from outdoors or from
spaces freely communicating with the
outdoors. A permanent opening or openings
having a total free area of not less than 1
square inch per 5,000 BTU per hour of total
inputratingofallappliancesshallbeprovided.
Ducts may be used to convey makeup air
from the outdoors and shall have the same
cross-sectionalareaoftheopeningstowhich
they are connected.
4.Whenairforcombustionandventilation
is from inside buildings, the confined space
shall be provided with two permanent
openings,onestarting12inchesfromthetop
and one 12 inches from the bottom of the
enclosed space. Each opening shall have a
FIGURE 1
minimum free area of 1 square inch per one thousand (1000) BTU per hour of the total input
rating of all appliances in the enclosed space, but must not be less than one hundred (100)
square inches. These openings must freely communicate directly with other spaces of
sufficient volume so that the combined volume of all spaces meets the criteria for an
unconfinedspace.
PAGE 3
Download from Www.Somanuals.com. All Manuals Search And Download.
5.Whentheboilerisinstalledinaconfinedspaceandallairisprovidedfromtheoutdoors
the confined space shall be provided with one or two permanent openings according to
methods A or B. When ducts are used, they shall be of the same cross sectional area as the
free area of the area of the openings to which they connect. The minimum dimension of
rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches.
A. Wheninstallingtwoopenings,onemustcommencewithin12inchesfromthetopand
FIGURE 2
FIGURE 3
the other within 12 inches from the bottom of
the enclosure. The openings shall
communicate directly, or by ducts, with the
outdoors or spaces (crawl or attic) that freely
communicate with the outdoors. One of the
following methods must be used to provide
adequate air for ventilation and combustion.
1. When directly communicating
with the outdoors, each opening shall have a
minimumfreeareaof1squareinchper4,000
BTU per hour of total input rating of all
equipment in the enclosure. See figure 2
above.
2. When communicating with the
outdoors by means of vertical ducts, each
opening shall have a minimum free area 1
FIGURE 4
square inch per 4,000 BTU per hour of total input rating of all appliances in the enclosed
space. See figure 3 above.
3. If horizontal ducts are used, each opening and duct shall have a minimum free
area1squareinchper2,000BTUperhouroftotalinputratingofallappliancesintheenclosed
space. See figure 4 at right.
B. Onepermanentopening,commencingwithin12inchesofthetopoftheenclosure,
shall be permitted where the equipment has clearances of at least 1 inch from the sides, 1
inch from the back, and 6 inches from the front of the boiler. The opening shall directly
communicatewiththeoutdoorsorshallcommunicatethroughaverticalorhorizontalductto
the outdoors or spaces (crawl or attic) that freely communicate with the outdoors. The
openings must have a minimum free area of 1 square inch per 3000 Btu per hour of the total
PAGE 4
Download from Www.Somanuals.com. All Manuals Search And Download.
inputratingofallequipmentlocatedintheenclosure. Thefreeareamustbenolessthanthe
sum of the areas of all vent connectors in the confined space.
6. In calculating free area using louvers, grilles or screens for the above, consideration
shall be given to their blocking effect. Screens used shall not be smaller than 1/4 inch mesh.
If the free area through a design of louver or grill is known, it should be used in calculating
the size opening required to provide the free area specified. If the design and free area is
not known, it may be assumed that wood louvers will have 20-25% free area and metal
louversandgrilleswillhave60-75%freearea.Louversandgrillesshouldbefixedintheopen
position or interlocked with the boiler so they are opened automatically during the boiler
operation.
CONNECTING SUPPLY AND RETURN PIPING
1. Suggested piping for steam heating system can be seen in figure 5 below. Actual
piping may vary based on system design and local conditions.
2. Suggested piping for a modular steam boiler using pumped returns may be seen in
figures 6a and 6b on page 6. Actual piping may vary based on system design and local
conditions.
3. Refer to pages 17 & 18 for procedures on cleaning and skimming off impurities.
4. "Near Boiler Piping" is crucial for proper performance of a replacement steam boiler
and should always be considered as part of the boiler installation. Always be sure to include
cleanoutandskimmingteesinthenearboilerpiping. These"Tees"arenecessaryforproper
cleaning and servicing of the boiler.
5. For further piping information refer to the I=B=R installation piping guide.
SUGGESTED PIPING FOR A SINGLE STEAM
BOILER HEATING SYSTEM
FIGURE 5
PAGE 5
Download from Www.Somanuals.com. All Manuals Search And Download.
SUGGESTED PIPING FOR A MODULAR STEAM BOILERS
PUMPED RETURNS
FIGURE 6a
GRAVITY RETURNS
FIGURE 6b
PAGE 6
Download from Www.Somanuals.com. All Manuals Search And Download.
VENT INSTALLATION
WARNING: Thisboilershallnotbeconnectedtoanyportionofamechanical
draft system operating under positive pressure.
1. The vent pipe must slope upward from the boiler not less than 1/4 inch for every 1 foot
to the vent terminal.
2. Horizontal portions of the venting system shall be supported rigidly every 5 feet and
at elbows. No portion of the vent pipe should have dips or sags.
3. This boiler series is classified as a Category 1 appliance and the vent installation shall
be in accordance with Part 7 & 11 of the latest revision of the National Fuel Gas Code or
applicable provisions of the local building codes.
4. Inspect chimney to make certain it is constructed according to National Board of Fire
Underwriters.
5. Attach draft hood to flue collector at rear of boiler, (See figure 7, below), with sheet
metal screw(s) through hole(s) provided. The vent or vent collector shall be Type B or metal
pipe having resistance to heat and corrosion not less than that of galvanized sheet steel or
aluminum not less than 0.016 inch thick (No. 28 GA).
6. Connectfluepipesameasdrafthoodtochimney. Boltorscrewjointstogethertoavoid
sag. Flue pipe should not extend beyond inside wall of chimney. Do not install manual
damper in flue pipe or reduce size of flue outlet except as provided by the latest revision of
ANSI Z223.1. Protect combustible ceiling and walls near flue pipe with fireproof insulation.
Where two or more appliances vent into a common flue, the area of the common flue must
beatleastequaltotheareaofthelargestflueplus50percentoftheareasofeachadditional
flue.
WARNING:
ALL
INSTALLATIONS OF BOILERS
AND VENTING SHOULD BE
DONE ONLY BY A QUALIFIED
EXPERT AND IN ACCORDANCE
WITH THE APPROPRIATE UTICA
BOILERS MANUAL. INSTALLING
OR VENTING A BOILER OR ANY
OTHER GAS APPLIANCE WITH
IMPROPER
METHODS
OR
MATERIALS MAY RESULT IN
SERIOUS INJURY OR DEATH
DUE
TO
FIRE
OR
TO
ASPHYXIATION
FROM
POISONOUS GASES SUCH AS
CARBON MONOXIDE WHICH IS
ODORLESS AND INVISIBLE.
FIGURE 7
PAGE 7
Download from Www.Somanuals.com. All Manuals Search And Download.
VENT SYSTEM MODIFICATION
When an existing boiler is removed from a common venting system, the common venting
system is likely to be too large for the proper venting of the appliances remained connected
to it. If this situation occurs, the following test procedure must be followed:
At the time of removal of an existing boiler, the following steps shall be followed with
each appliance remaining connected to the common venting system placed in operation,
while the other appliances remaining connected to the common venting system are not in
operation.
A. Seal any unused openings in the common venting system.
B. Visuallyinspecttheventingsystemforpropersizeandhorizontalpitchanddetermine
there is no blockage or restriction, leakage, corrosion and other deficiencies which could
cause an unsafe condition.
C. Insofar as is practical, close all building doors and windows and all doors between
the space in which the appliances remaining connected to the common venting system are
located and other spaces in the building. Turn on clothes dryers and any 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 damper.
D. Place in operation the appliance being inspected. Follow the lighting instructions.
Adjust thermostat so appliance 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.
F. Afterithasbeendeterminedthateachapplianceremainingconnectedtothecommon
venting system properly vents when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas burning appliance to their previous
conditions of use.
G. Any improper operation of the common venting system should be corrected so the
installation conforms with the latest revision of the National Fuel Gas Code, ANSI Z223.1.
When resizing any portion of the common venting system, the common venting system
shouldberesizedtoapproachtheminimumsizeasdeterminedusingtheappropriatetables
in appendix G in the latest revision of the National Gas Fuel Code, ANSI Z223.1.
PAGE 8
Download from Www.Somanuals.com. All Manuals Search And Download.
VENT DAMPER INSTALLATION
AND INSTRUCTIONS
INSTALLATION
NOTE: REFER TO FIGURE 8 BELOW FOR STEPS 1-7
1. Place Vent Damper on or as close to vent outlet of boiler as possible.
2. Remove Locknut from connector at the free end of the Damper wire harness.
3.FeedDamperconnectorandDamperwireharnessthroughbracketholeonDamperMotor
frame.
4. Replace and tighten locknut onto Damper wire harness connector.
5. Plug Damper connector into socket on Damper Motor frame.
INSTRUCTIONS
FIGURE 8
FIGURE 9
1. Ensure that only the boiler is serviced by the Vent Damper. See figure 9 above.
2. Clearance of not less than 6 inches between Vent Damper and combustible
construction must be maintained. Additional clearance should be allowed for service
of the Vent Damper.
3. Vent Damper must be in open position when appliance main burners are operating.
4. The Vent Damper position indicator must be in a visible location following installation.
5. The thermostats heat anticipator must be adjusted to match the total current draw of
all controls associated with the boiler during a heating cycle.
6. The Vent Damper wire harness may be removed and installed in flexible metal conduit
if local codes or jurisdiction requires. If this is necessary, the flexible metal conduit
must be mounted to a J-box and all appropriate connections must be made to this J-
box.
PAGE 9
Download from Www.Somanuals.com. All Manuals Search And Download.
CONNECTING GAS SERVICE
Connect gas service meter to control assembly in accordance with the latest revision of
ANSI Z223.1 and local codes or utility. A ground joint union should be installed for easy
removalofgascontrolforservicing. Adriportrapmustbeinstalledatthebottomofavertical
section of piping at the inlet to the gas valve. A pipe compound resistant to the action of
liquefied petroleum gases must be used on all threaded pipe connections. Check with the
local utility for location of manual shutoff valve if required. See figure 10 below.
1. The gas line should be of adequate size to prevent undue pressure drop and never
smaller than the pipe size of the main gas control valve.
2. The boiler and its gas connection must be leak tested before placing the boiler in
operation. To check for leaks in gas piping, use a soap and water solution or other approved
method.
WARNING: DO NOT USE
AN OPEN FLAME.
3. The boiler and its individual shutoff
valve must be disconnected from the gas
supply piping system during any pressure
testing of that system at test pressures in
excess of 1/2 psi (3.5 kPa). The boiler must
beisolatedfromthegassupplypipingsystem
by closing its individual manual shutoff valve
duringanypressuretestingofthegassupply
piping system at test pressures equal to or
less than 1/2 psig (3.5 kPa).
FIGURE 10
ELECTRICAL WIRING
SEE ADDENDUM "A" FOR WIRING DIAGRAMS AND COMPONENT CODING
Electrical wiring must conform with the latest revision of the National Electrical Code, ANSI/
NFPA No. 70 and/or local authority having jurisdiction.
WARNING: 1. The boiler, when installed, MUST BE electrically grounded
in accordance with these requirements.
2. Install a fused disconnect switch between boiler and meter at a convenient location.
PAGE 10
Download from Www.Somanuals.com. All Manuals Search And Download.
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall at least two feet from an uninsulated
or outside wall, approximately four feet above the floor.
2. NEVER install a thermostat on an outside wall.
3. Do not install a thermostat where it will be affected by:
A. Drafts
B. Hot or cold pipes
C. Sun light
D. Lighting fixtures
E. Television
F. Fireplace or chimneys
4. Check thermostat operation by raising and lowering thermostat as required to start
and stop the burners.
5. Instructions for the final adjustment of the thermostat are packaged with the
thermostat ( adjusting heating anticipator, calibration, etc.).
LIGHTING INSTRUCTIONS
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EX-
ACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR LOSS OF LIFE.
Before any procedures are attempted on this appliance, it is necessary to
determine if the ignition system is intermittent or continuous pilot system. If you are
uncertain, contact the manufacturer before proceeding.
CAUTION: Before operating, make certain steam boiler is full of water
to water line and system is vented of air. See the operating lighting instructions.
LIGHTING PROCEDURE FOR BOILER WITH
INTERMITTENT PILOT SYSTEM.
FOR YOUR SAFETY READ BEFORE OPERATING.
A. Thisapplianceisequippedwithanignitionsystemwhichautomaticallylightsthepilot.
Do not try to light the pilot by hand.
B. Before operating smell all around the appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than air and will settle on the floor.
CAUTION: WHAT TO DO IF YOU SMELL GAS:
* Do not try to light any appliance.
* Do not touch any electrical switch.
* Do not use any phone in your building.
* Immediately call your gas supplier from a neighbor's phone.
* Follow your gas supplier's instructions.
* If you cannot reach your gas supplier, call the fire department.
PAGE 11
Download from Www.Somanuals.com. All Manuals Search And Download.
C. Use only your hand to push in or turn gas control knob. NEVER USE TOOLS. If the
knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a
qualified service technician to inspect the appliance and to replace any part of the control
system and gas control which has been under water.
OPERATING INSTRUCTIONS FOR
INTERMITTENT PILOT SYSTEMS
1. STOP! Read the safety information in the user’s information manual.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which automatically lights the pilot.
DO NOT try to light the pilot by hand. See figure 11, below.
5. Remove access panel (if present)
INTERMITTENT PILOT GAS VALVE
6. Push in gas control knob slightly and
turn clockwise
to "OFF."
7. Wait five (5) minutes to clear out any
gas. Ifyouthensmellgas,STOP,Follow“B”
in the safety information “What To Do IF You
Smell Gas”. If you don’t smell gas, go to the
next step.
8.
counterclockwise
9. Replace control access panel (IF
PRESENT).
10. Turn on all electric power to the
appliance.
Turn gas control knob
to “ON.”
11. Set thermostat to desired setting.
12. If the appliance will not operate,
follow the instructions “To Turn Off Gas To
Appliance” and call a qualified service
technician or your gas supplier.
FIGURE 11
LIGHTING PROCEDURE FOR BOILER WITH
CONTINUOUS PILOT.
FOR YOUR SAFETY READ BEFORE LIGHTING
A. Read warning at the beginning of this instruction.
B. This appliance has a pilot which must be lighted by hand. When lighting the pilot,
follow these instructions exactly.
C. Before lighting, smell all around the appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air and will settle on the floor. Follow “B” in the
lighting instructions for safety information for what to do if you smell gas on page 10.
D. Use only your hand to push in or turn the gas control knob or reset button. Never use
tools. If the knob or reset button will not push in or the knob will not turn by hand, don’t try
to repair it. Call a qualified service technician. Force or attempted repair may result in fire
or explosion. See figure 12, on page 13.
PAGE 12
Download from Www.Somanuals.com. All Manuals Search And Download.
E.Donotusethisapplianceifanyparthas
beenunderwater.Immediatelycallaqualified
service technician to inspect the appliance
and to replace any part of the control system
and any gas control which has been under
water.
CONTINUOUS PILOT GAS VALVE
LIGHTING INSTRUCTIONS FOR
CONTINUOUS PILOT SYSTEM
1. Stop! Read the safety information at
the beginning of this manual.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the
appliance.
4. Remove manifold cover and burner
door, (figures 13 & 15 on pages 14 & 16).
5. Turn gas control knob clockwise
FIGURE 12
to “off” (See Note #1).
NOTE #1: Some gas control knobs cannot be turned from “pilot” to “off” unless knob is
pushed in slightly. Do not force.
6.Wait(5)minutestoclearoutanygas.Ifyousmellgas, stop!Followsafetyinformation
“What to do if you smell gas,” located on page 10 of this manual. If you don’t smell gas, go
to the next step.
7. Find pilot. Follow metal tube from gas control. Depending on the model of the boiler,
pilot is mounted on the base or on one of the burner tubes.
8. Turn gas control knob counterclockwise
to “pilot”.
9. Push in gas control knob, or reset button if so equipped, all the way in and hold.
ImmediatelyLightthepilotwithamatch.Continuetoholdthegascontrolknoborresetbutton
for about one (1) minute after the pilot is lit. Release knob or button and it will pop back up.
Pilot should remain lit. If it goes out, repeat steps 5 through 10.
* If knob or button does not pop up when released, stop and immediately call your
service technician or gas supplier.
* If the pilot will not stay lit after several tries, turn the gas control knob clockwise
to “off” (see note #1 above) and call a service technician or gas supplier.
10. Replace burner door and manifold cover, (figures 13 & 15 on pages 14 & 16).
11. Turn gas control knob counterclockwise
to "on".
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove access panel (if present)
4. Turn gas control knob clockwise
to “off”. (See note #1) in the lighting
instructions. Do not force.
PAGE 13
Download from Www.Somanuals.com. All Manuals Search And Download.
NORMAL SEQUENCE OF OPERATION
On a call for heat:
1.) The thermostat will actuate completing the circuit between T and T.
2.) The damper will then open thus closing the end switch completing the circuit, and
ignition will begin.
3.) In the event that the boiler steam pressure exceeds the pressure control setting,
the pressure control will interrupt the circuit to the boiler ignition system. The power will
remain off until the steam pressure drops below the pressure control setting.
4.) In the event a low water condition occurs, an automatic low water cut-off device
will interrupt the circuit to the ignition system until the low water condition is satisfied,
(i.e., manually restore the water or utilize an electric water feeding device which will
automatically restore boiler water to its normal operating level).
5.) In the event the flow of combustion products through the boiler venting system
becomes blocked, a blocked vent safety switch will shut the main burner gas off (See figure
13 below).
6.) In the event the flow of combustion products through the flueways becomes blocked
a flame rollout switch will shut the main burner gas off (See figure 13 below).
FIGURE 13
PAGE 14
Download from Www.Somanuals.com. All Manuals Search And Download.
CONNECTING SUPPLY AND
RETURN PIPING, WATER CHILLED MEDIUM
1. When the boiler is used in connection with refrigerated system, connect supply and
return piping as suggested in figure 14 below.
A. The chilled medium MUST BE IN PARALLEL with the boiler.
B. Use appropriate valves to prevent the chilled medium from entering the heating
boiler.
a. During heating cycle open valves A and B. Close valves C and D.
b. During cooling cycle open valves C and D. Close valves A and B.
C. Maintain a minimum clearance of one inch between combustible materials and
hot water pipes.
* Reduced pressure backflow preventer must be present under provisions required by
the Environmental Protection Agency, (EPA).
2. When the boiler is connected to heating coils located in air handling units where they
may be exposed to refrigerated air circulation, the boiler piping system MUST be supplied
with flow control valves or other automatic means to prevent gravity circulation of the boiler
water during the cooling cycle.
3. A hot water boiler installed above radiation level must be provided with a low water
cutoff device either as a part of the boiler or at the time of boiler installation.
4. Suggested piping for steam heating system can be seen in figure 5 on page 5. Actual
piping may vary based on system design and local conditions.
FIGURE 14
PAGE 15
Download from Www.Somanuals.com. All Manuals Search And Download.
GENERAL INSTRUCTIONS
Before seasonal start up it is advisable to have a competent service agency check the
boiler for soot and scale in the flues, clean the burners, and check the gas input rate to
maintain high operating efficiency.
On steam boilers make certain the boiler is filled to the water line as indicated in figure
15. The gauge cocks should be normally open. To remove dirt from the gauge glass the
petcock may be opened to flush out the glass.
WARNING: DISCHARGE WILL BE BOILING HOT WATER.
Theradiatorvalvesonaone-pipesteamsystemmustbeeitherwideopenortightlyshut.
Do not attempt to regulate room temperature by partially closing the radiator valve.
Air vents on steam radiators and the supply main release air from the system. If radiators
do not heat satisfactorily, make sure the air vents are clean and operational.
The lever of the safety valve, shown in figure 15 below, on the boiler should be operated
periodically to make sure that it is functioning properly.
WARNING: DISCHARGE WILL BE BOILING HOT WATER AND STEAM.
The safety valve should open before the steam pressure exceeds the 15 lb. reading on the
gauge, (figure 15 to right). If this pressure is
exceeded and the safety valve does not
open, it must be replaced. If the safety valve
leaks steam when the boiler is operating at
normal pressures, it should be immediately
replaced. Corrosion can build up rapidly at
the valve seat and prevent its functioning as
a safety device.
Duringtheheatingseasonthedraincock,
on the bottom rear of the boiler, should be
opened once a month to flush out the boiler
sothedevicewillbefreetofunctionproperly.
Use a pail to catch the discharge.
WARNING: DISCHARGE
FIGURE 15
WILL BE BOILING HOT WATER.
If the water in a steam boiler appears to be dirty or oily, or the water level in the gauge
glass fluctuates considerably, the boiler should be cleaned and skimmed (See page 18 for
instructions). A competent service person will use approved cleaning compounds and
properlycleanandflushouttheboiler.He/sheshouldalsocleanorreplaceairventsandtraps,
clean flue passages and check for proper operation of all controls and safety devices.
The venting system should be inspected at the start of each heating season. Check the
vent pipe from the boiler to the chimney for signs of deterioration by rust or sagging joints.
Repair if necessary. Remove the vent pipe at the base of the chimney or flue and, using
a mirror, check for obstruction.
The boiler flue gas passageways may be inspected by a light and mirror. Remove the
burner access door, (figure 15 above). Place a trouble lamp in the flue collector through the
draft-hood relief opening. With the mirror positioned above the burners, the flue gas
passageways can be checked for soot or scale.
PAGE 16
Download from Www.Somanuals.com. All Manuals Search And Download.
TO CLEAN THE BOILER FLUEWAYS:
1. Remove the burners from the combustion chamber by raising the burners upward
from the manifold orifices and pulling toward the front of the boiler. To remove the burner
with the pilot burner attached, first disconnect the pilot line tubing and thermocouple or pilot
generator leads at the main electric gas valve. Do not remove the pilot line tubing at the pilot
as the pilot burner orifice may drop out and become damaged or lost.
2. Disconnect the vent pipe from the draft hood.
3. Remove the draft hood. The draft hood is attached to the flue collector at the top by
sheet metal screw(s).
4. Remove the top jacket panel. It is attached to the jacket by sheet metal screws.
5. Remove the flue collector from the boiler casting by loosening the nuts on the “J” bolts
at either side of the flue collector.
6. Place a sheet of heavy paper or similar material over the bottom of the combustion
chamberandbrushdownthefluepassageways. Thesootandscalewillcollectonthepaper
and is easily removed with the paper.
7. With the paper still in place in the combustion chamber, clean the top of the boiler
castings of the boiler putty or silicone used to seal between the castings and the flue
collector. Make certain chips are not lodged in the flueways.
When the cleaning process is completed, restore the boiler components to their original
position.UseboilerputtyorGEIS-808siliconetosealaroundthefluecollectorandcastings.
Makecertaintheburnerendsareinsertedintheslotsatthebackofthecombustionchamber
and well down in position over the burner orifices. Follow the lighting instructions on the
boiler to put the burners back in operation.
CHECK SAFETY CONTROL CIRCUIT, after burner adjustments are made, for
satisfactory operation.
CAUTION: Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after service.
1. Pilot: with main burner operating turn the pilot gas adjusting screw clockwise
until pilot gas is turned off. See figures 11 and 12 on pages 12 & 13. Within 90 seconds the
main gas control should close, shutting off the gas to the main burner. After, check pilot
operation. Relight following lighting instructions on pages 10-12.
2. Pressure control - on steam boilers - remove cover and note pressure setting. With
the boiler operating, decrease the setting. When setting is lower than boiler pressure, the
control will open, closing the automatic main gas valve. After checking pressure control,
reset control to original setting.
3. Mechanical Low water cut-off: Operation may checked by opening the blow-off valve
located in the lower portion of the body. This will drain water quickly from the cut-off body
and break circuit to automatic main gas valve. Owner should blow off this control at least
once each month of the heating season.
WARNING:
WATER WILL BE BOILING HOT.
PAGE 17
Download from Www.Somanuals.com. All Manuals Search And Download.
4. Electronic Low Water Cut-off: Operation may be checked by opening the drain valve
inthebacksideoftheboiler. Thiswilldrainthewaterfromtheboilerandbreaktheelectronic
circuit to the automatic gas valve.
IMPURITIESINBOILERWATERofasteamboilermaycausefoamingandanunsteady
water line, or prevent steam generation. They may result in objectionable odors escaping
from the vents on water boilers. This condition is caused by oil, grease, and sediment from
pipe fittings collecting within the boiler and can be remedied only by giving the boiler a
thorough cleaning.
BOILERS CAN BE CLEANED by skimming or blowing down.
CAUTION: The boiler should not be left unattended during the cleaning
process.
SKIMMING OFF IMPURITIES
Some of the impurities in the boiler water will float on the water and must be skimmed off.
With the boiler empty and cool, slowly begin to add water. After water has entered boiler
- never before - turn “on” main gas burners and adjust flame at main manual shut-off valve
so that the water being added is kept just below boiling point. Avoid boiling and turbulence.
Gradually raise hot water level to skimming tee, see figure 5 on page 5, installed at the
supply outlet piping of the boiler being careful not to raise it above the opening of the tee.
Skim until there are no impurities. Repeat the process if necessary.
Water may be checked to make sure it is free from oil by drawing off a sample at the
skimming tee. If the sample is reasonably free from oil, it will not froth when boiled on stove.
This test does not indicate the amount of sediment which may lay in the bottom of the boiler.
It is therefore necessary that the boiler be further cleaned by “blowing down”.
BLOWING DOWN BOILER
Beforeblowingdowntheboiler,fillittothewaterline.Lightburnersandallowfivepounds
of steam pressure to build up. Run a temporary connection from one of the drain valves to
a nearby sewer. Connect to a drain valve on the opposite end of the boiler from feed water
inlet, if possible. Shut off the gas burners, open drain valve and blow down the entire
contents of boiler.
Allowboilertothoroughlycoolandslowlyrefilltowaterline. Repeatstep2asmanytimes
as required until blow off water is clear. Owner should blow down boiler at least once each
month of the heating season.
WARNING: WATER WILL BE BOILING HOT.
USING CLEANING COMPOUND
If an exceptional amount of dirt or sludge seems to be present in the boiler, a boiler
cleaning compound made by a reputable manufacturer may be used according to the
instructions of the manufacturer of the compound. When any type of cleaning compound
is used, care must be taken to thoroughly flush all traces of the compound out of the boiler.
Following blow down allow the boiler to cool. Add fresh water slowly. Be certain to blow
enough times as required to remove compounds from system.
PAGE 18
Download from Www.Somanuals.com. All Manuals Search And Download.
CHECKING AND ADJUSTING THE GAS IGNITION COMPONENTS
The gas input to the boiler can be adjusted by removing the protective cap on the
pressure regulator, see figure 16 on page 19 , and turning screw clockwise
t o
increase input and counterclockwise to decrease input. Natural gas manifold
pressure should be set at approximately 3.5 inches water column. Propane gas manifold
pressureshouldbesetatapproximately10incheswatercolumn.Manifoldpressureistaken
at the pressure tap on the outlet side of the gas valve, see figures 11 and 12 on pages 12
and 13. Burner orifices should be changed if the final manifold pressure varies more than
plus or minus 0.3 inch water column from the specified pressure.
To check for proper flow of natural gas to boiler divide the input rate on the rating plate
by heating value of the gas as obtained from the local gas company. This will determine the
number of cubic feet of gas required per hour. With all other gas appliances off, determine
FIGURE 17
FIGURE 16
the flow of gas through the meter for two minutes and multiply by 30 to get the hourly rate.
Make minor adjustments to the gas input as described above.
Primary air adjustment is not necessary, therefore air shutters are not furnished as
standard equipment. Air shutters can be furnished on request when required by local codes
or conditions.
A visual check of the main burners and pilot flames should be made at the start of the
heating season and again at mid-season.
The main burner flame should have a well defined inner blue mantel with a lighter blue
outer mantel. If the flame does not appear this way, check the burner throats and burner
orifices for lint or dust obstruction. See figure 17 above.
The pilot flame should envelop 3/8 to 1/2 inch of the tip of the pilot sensor. See figure
18 on page 20. To adjust the pilot flame, remove the pilot adjustment screw and turn the
inner adjustment screw clockwise
to decrease or counterclockwise
t o
increasepilotflame.Seefigures11and12onpages12&13.Besuretoreplacecoverscrew
after adjustment to prevent possible gas leakage.
The burners and pilot should be checked for signs of corrosion, rust or scale build-up.
Theareaaroundtheboilershouldbekeptclearand freeofcombustiblematerials, gasoline
and other flammable vapors and liquids.
PAGE 19
Download from Www.Somanuals.com. All Manuals Search And Download.
The free flow of combustion and
ventilation air to the boiler and boiler room
should not be restricted or blocked.
It is suggested that a qualified service
agency be employed to make an annual
inspection of the boiler and heating system.
They are experienced in making the
inspections outlined above and, in the event
repairs or corrections are necessary, can
make the proper changes for safe operation
of the boiler.
Optional parts
WC-001.00
WC-004.01
WC-005.00
# 67 - U LWCO
# 101 Water Feeder
# 47-2 LWCO & Feeder
FIGURE 18
PEG-C REPLACEMENT PARTS - PILOT
24VOLT
SPARK
ITEM # PART #
DESCRIPTION
OTY. ITEM # PART #
DESCRIPTION
OTY.
1
2
3
4
PB01301
HW-024.01
MS-003.05
1520001
PILOT-Q350A 24 VOLT
SCREW#10-32X3/16
PILOTTUBE1/4"X24.1/4"
THERMOCOUPLEQ309A
1
2
1
1
2
3
4
PB-001.02
HW-024.01
MS-003.05
PB00702
PILOT-Q345A SPARK
SCREW#10-32X3/16
PILOTTUBE1/4"X24.1/4"
PILOTIGNITIONCABLE
1
2
1
1
FIGURE 19
FIGURE 20
PAGE 20
Download from Www.Somanuals.com. All Manuals Search And Download.
PEG-C REPLACEMENT PARTS - BASE
ITEM # PART #
DESCRIPTION
OTY.
1
ITEM # PART #
DESCRIPTION
OTY.
1
1
3542202
3542203
3542204
3542205
3542206
3542207
MANIFOLDPEG112C
MANIFOLD PEG150C
MANIFOLD PEG187C
MANIFOLD PEG225C
MANIFOLD PEG262C
MANIFOLD PEG300C
32425304
32425305
32425306
BASEPLATEPEG225C
BASEPLATEPEG262C
BASEPLATEPEG300C
5
5612501
5612502
BASEWITHINSULPEG112C
BASE WITH INSULPEG150C
5612503 BASE WITH INSUL PEG187C
5612504 BASE WITH INSUL PEG225C
5612505 BASE WITH INSUL PEG262C
5612506 BASE WITH INSUL PEG300C
2
VG-008.07 GAS VALVE VR8200H-3000
PEG112 & 150 24V
1
VG01102
VG01103
VG01201
GAS VALVE VR8204-3010
PEG112&150SPARK
GAS VALVE VR8304H4206
PEG187 - 300 SPARK
VR8300H4006 PEG262C
PEG187 - 300 24V
6
7
3342701
BURNER ASSY. W/ PILOT
BRACKET & SHUTTER
BURNERASSY.W/SHUTTER
PEG150 - (7), PEG187 - (9),
PEG262 - (13), PEG300 - (15)
1
3342601
PEG112C - (5),
PEG 225 -(11),
3
4
352-1-1.03 GAS ORIFICE #47-NATURAL
352-1-1.04 GAS ORIFICE #56-LP
PEG112C - (6), PEG150 - (8), PEG187 - (10),
PEG 225 -(12), PEG262 - (14), PEG300 - (16)
8
32411302 BRN ACCESS DOOR PEG112C 1
32411303 BRN ACCESS DOOR PEG150C
32411304 BRN ACCESS DOOR PEG187C
32411305 BRN ACCESS DOOR PEG225C
32411306 BRN ACCESS DOOR PEG262C
32411307 BRN ACCESS DOOR PEG300C
32425301
32425302
32425303
BASE PLATE PEG112C
BASEPLATEPEG150C
BASEPLATEPEG187C
9HW-005.01
SCREW 1/4-20X1/2 SELF TAP
FIGURE 21
PAGE 21
32425303
BASEPLATEPEG187C
Download from Www.Somanuals.com. All Manuals Search And Download.
PEG-C REPLACEMENT PARTS - JACKETS
ITEM
PART
ITEM
PART
#
NUMBER
DESCRIPTION
OTY.
#
NUMBER
DESCRIPTION
OTY.
1
1
2
31423001
31422802
31422803
31422804
31422805
31422806
31422807
SIDE PANEL LEFT (ALL)
FRONT PANEL PEG112C
FRONT PANEL PEG150C
FRONT PANEL PEG187C
FRONT PANEL PEG225C
FRONT PANEL PEG262C
FRONT PANEL PEG300C
1
1
6
7
8
344-2-1.02
344-2-1.03
344-2-1.04
344-2-1.05
344-2-1.06
344-2-1.07
31423302
31423303
31423304
31423305
31423306
31423307
1182005
DRAFT HOOD PEG112C
DRAFT HOOD PEG150C
DRAFT HOOD PEG187C
DRAFT HOOD PEG225C
DRAFT HOOD PEG262C
DRAFT HOOD PEG300C
REAR PANEL PEG112C
REAR PANEL PEG150C
REAR PANEL PEG187C
REAR PANEL PEG225C
REAR PANEL PEG262C
REAR PANEL PEG300C
DAMPERPEG112C5"
DAMPERPEG150C6"
DAMPERPEG187C7"
DAMPERPEG225C&262C8"
DAMPERPEG300C9"
TOPPANELPEG112C
TOP PANEL PEG150C
TOP PANEL PEG187C
TOP PANEL PEG225C
TOP PANEL PEG262C
TOP PANEL PEG300C
1
3
31421002 MANIFOLD COVER PEG112C 1
31421003 MANIFOLD COVER PEG150C
31421004 MANIFOLD COVER PEG187C
31421005 MANIFOLD COVER PEG225C
31421006 MANIFOLD COVER PEG262C
31421007 MANIFOLD COVER PEG300C
1
1
4
5
31423002
SIDE PANEL RIGHT (ALL)
1
1
1182006
1182007
1182008
1182009
3442702 FLUE COLLECTOR PEG112C
3442703 FLUE COLLECTOR PEG150C
3442704 FLUE COLLECTOR PEG187C
3442705 FLUE COLLECTOR PEG225C
3442706 FLUE COLLECTOR PEG262C
3442707 FLUE COLLECTOR PEG300C
931423502
31423503
31423504
31423505
31423506
31423507
FIGURE 22
PAGE 22
Download from Www.Somanuals.com. All Manuals Search And Download.
PEG-C REPLACEMENT PARTS - HEAT EXCHANGER
ITEM
#
PART
NUMBER
ITEM
#
PART
NUMBER
DESCRIPTION
OTY.
DESCRIPTION
OTY.
1 100-2-15.01
2 100-2-14.01
PEG112C - (2),
PEG 225 -(5),
E-Left Hand Section
E-Center Section
1
13 HW-003.02
14 HW-008.01 WASH 5/16 FLAT STL ZP
NUT-1/4-20 HEX SLT
4
2
PEG150 - (3),
PEG187 - (4),
PEG262 - (6),
PEG300 - (7)
3 100-2-13.02 E-Right Hand Section
HW06901 NUT-5/16-18 WISLOCK
1
4
4
(Fully assembled heat exchangers.)
5 HW-011.10TIE ROD 1/4X10.25 PEG112 2
HW-011.02 TIE ROD 1/4X13 PEG150
HW-011.04 TIE ROD 1/4X17 PEG187
HW-011.05 TIE ROD 1/4X19 PEG225
HW-011.07 TIE ROD 1/4X23 PEG262
HW-011.08 TIE ROD 1/4X25 PEG300
10022802
10022803
10022804
10022805
10022806
10022807
4 SECTION PEG112C
5 SECTION PEG150C
6 SECTION PEG187C
7 SECTION PEG225C
8 SECTION PEG262C
9 SECTION PEG300C
1
1
1
1
1
1
6
PF-007.02
7 251-1-2.00
43300976
PIPE FIT PLG 2"
J-BOLT 1/4-20X3.5/16
NIPPLE 2" MACH.
1
2
8
PEG112C - (4),
PEG 225 -(10),
9 HW-016.02
PEG150 - (6),
PEG262 - (12), PEG300 - (14)
PEG187 - (8),
DRAIN LONG
1
10 1570001 VALVE, POP SAFETY 3/4" 1
11 1150001
12 PF-005.10
COUPLING3/4"
PIPE FIT NPL 3/4"X 6"
1
1
FIGURE 23
PAGE 23
Download from Www.Somanuals.com. All Manuals Search And Download.
PEG-C REPLACEMENT PARTS
FRONT PANEL CONTROLS
ITEM
#
PART
NUMBER
ITEM
#
PART
NUMBER
DESCRIPTION
OTY.
DESCRIPTION
OTY.
1
2
3
GA-004.00
PF-033.02
WCO1901
GAUGE WTR LEVEL
PIPE FIT NPL 1/2"X4"
ELWCOPS-802U-24
WITH PROBE
1
1
1
9 753-1-3.00
10 PF-025.01
11 PF-026.05
12 GA-003.00
13 PF-027.01
14 SS-001.01
15 PF-026.01 CLOSE NIPPLE 1/4" NPL
16 PF05601 PIPE FIT NPL 1/2"X3"
17 PF-034.01 1/2"BRASSCOUPLING
90°SYPHON
1/4" TEE
1/4" X 3" NIPPLE
PRESSUREGAUGE
1/4" ELBOW 90°
PRESSURESWITCH
1
1
1
1
1
1
1
1
2
4 HW-006.02 POP RIVIT FLUE 3/16"
5
6
2
1
2
32421901
AQ02101
SENSORBRACKET
CONTROLFIXEDTEMP
(ONEONDRAFTHOOD)
WIRE - ROLL OUT
7
8
37513301
HW06501
1
2
SCR 6X1/4" SLOT
FIGURE 24
PAGE 24
Download from Www.Somanuals.com. All Manuals Search And Download.
PEG-C REPLACEMENT PARTS - ELECTRICAL
ITEM
PART
NUMBERNUMBER
IPTDIOENSCR
OTY.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
EF-013.01
37414401
37424501
PB00702
37413602
PB00604
37413201
37413801
EF03601
37413002
37413001
3641601
ELEC. J-BOX 4X4X1/2
WIRE PRES. SWITCH TO J-BOX 34"
HARNESS-ELWCO TO J-BOX 18"
IGN WIRE 30" CIDE MODELS ONLY
HARNESS IGN. MOD. TO GAS VALVE 12"
SPKCTLS8600M1013
2
1
1
1
1
1
1
1
1
1
1
1
1
1
WIRE SPILL SWITCH 47"
WIRE J-BOX TO CONTROLS 27"
WIRE CLAMP #3600 WHITE
WIRE TRANSFORMER(WHITE)15"
WIRE TRANSFORMER(BROWN)15"
TRANSFORMER ASSEMBLY 24V
DAMPER CABLE 53"
37413101
3641501
ELEC 4"X4" COVER/TERM STRIP
FIGURE 25
PAGE 25
Download from Www.Somanuals.com. All Manuals Search And Download.
3741801
PAGE26
REV: 15, July 2003
Download from Www.Somanuals.com. All Manuals Search And Download.
|