Utica | Gas-fired Boiler | Installation manual | Utica Gas-fired Boiler Installation manual

MAGB SERIES
Gas Fired Modu-Pac Multiple
Commercial Boiler System
INSTALLATION, OPERATION &
MAINTANANCE MANUAL
Utica BOILERS
P.O. Box 4729
Utica, NY 13504-4729
An ISO 9001-2000 Certified Company
R
MEMBER: The Hydronics Institute
P/N 37518701, Rev. B [02/09]
MAGB SERIES GAS FIRED BOILERS FOR FORCED HOT WATER
Installation Manual and Operating Instructions
TABLE OF CONTENTS
SAFETY SYMBOLS
The following defined symbols are used throughout this
manual to notify the reader of potential hazards of varying risk levels.
Boiler Ratings & Capacities.......................................2
Typical Layouts For Gas Fired Systems.....................4
Supply And Return Piping.........................................5
Installation Procedure...............................................5
DANGER
Ventilation And Combustion Air..............................6
!
Vent Installation........................................................8
Vent System Modification.........................................9
Connecting Boilers With Refrigeration Systems....10
Indicates an imminently hazardous situation which, if not
avoided, WILL result in death, serious injury or substantial property damage.
WARNING
Connecting Gas Service.......................................... 11
!
Electrical Wiring...................................................... 12
Lighting Instructions.............................................. 14
Indicates an imminently hazardous situation which, if not
avoided, MAY result in death, serious injury or substantial
property damage.
Normal Sequence of Operation............................. 15
General Instructions............................................... 16
CAUTION
!
Checking Gas Input Rates To Boiler....................... 18
Optional Controls & Wiring.................................... 18
Indicates an imminently hazardous situation which, if not
avoided, may result in injury or property damage.
MAGB Series Replacement Parts........................... 20
KEEP THIS MANUAL NEAR BOILER AND RETAIN FOR
REFERENCE.
NOTICE
Read the following instructions COMPLETELY before
installing!
2. To the owner: Installation and service of this boiler must
be performed by a qualified installer.
3. To the installer: Leave all instructions with the boiler for
future reference.
H
2
Boiler Ratings & Capacities
WARNING
!
All installations of boilers and venting should be done only by a qualified expert and in accordance with the appropriate 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.
BOILER dimensions
MAGB GAS FIRED BOILER SERIES engineering and DIMENSIONAL DATA
MODEL
NUMBER
NUMBER
OF
MODULES
SHIPPING
WEIGHT (LBS.)
WATER
CONTENT
(GALLONS)
MAGB500
2
945
MAGB600
2
MAGB750
Dimensions in Inches
A
B
C
17.6
62.250”
26.625”
13.313”
1065
20.8
70.000”
30.500”
15.250”
3
1400
26.4
97.875”
26.625”
13.313”
MAGB900
3
1600
31.2
109.500”
30.500”
15.250”
MAGB1000
4
1890
35.2
133.500”
26.625”
13.313”
MAGB1200
4
2135
41.6
149.000”
30.500”
15.250”
MAGB1500
5
2665
52.0
188.000”
30.500”
15.250”
MAGB1800
6
3200
62.4
228.000”
30.500”
15.250”
MAGB2100
7
3730
72.8
267.500”
30.500”
15.250”
MAGB2400
8
4265
83.2
307.000”
30.500”
15.250”
3
BOILER RATINGS & CAPACITIES
MAGB GAS FIRED BOILER SERIES ENGINEERING DIMENSIONAL DATA
Net I=B=R
Water Ratings
Flue Outlet
Dia. & No.
Common
Vent
Dia.
Chimney
Diameter
& Height
10”
12” X 15’
12”
14” X 15’
12”
14” X 20’
14”
16” X 20’
14”
16” X 20’
4
16”
18” X 20’
7,043
5
16”
20” X 20’
1,268,000
8,452
6
18”
20” X 30’
1,680,000
1,479,000
9,861
7
20”
22” X 30’
1,920,000
1,690,000
11,289
8
22”
24” X 30’
Model
Number
AGA
Input
Btuh
AGA
Output
Btuh
Btuh**
SQ. FT.
8”
MAGB500
500,000
*410,000
356,500
2,377
2
MAGB600
600,000
480,000
423,000
2,817
MAGB750
750,000
*615,000
533,000
3,553
MAGB900
900,000
720,000
634,000
4,226
MAGB1000
1,000,000
*820,000
713,000
4,753
MAGB1200
1,200,000
960,000
845,000
5,635
MAGB1500
1,500,000
1,200,000
1,057,000
MAGB1800
1,800,000
1,440,000
MAGB2100
2,100,000
MAGB2400
2,400,000
9”
2
3
3
4
* DOE HEATING CAPACITY
**For elevations above 2000 feet ratings should be reduced at a rate of 4% for each 1000 feet above sea
level.
**For equivalent square feet of radiation, divide I=B=R output by 150.
COMMON VENT
FLUE OUTLET
FLUE OUTLET
FRONT VIEW
4
Typical Layouts For Gas Fired Systems
ACCESS
27"
TYP
31"
MIN.
ACCESS
27"
TYP
"L"
REAR
"D"
L
FRONT
"D"
"L" FOR 1 BATTERY, (3 BOILERS PER BATTERY), IS
99 ⅞" FOR MAGB 750 AND 111 ½" FOR MAGB 900
"D" FOR 1 BATTERY, (3 BOILERS PER BATTERY), 1S
36 ⅝" FOR MAGB 750 AND 40 ½" FOR MAGB 900
"L" FOR 1 BATTERY, (2 BOILERS PER BATTERY), IS
63 ¼" FOR MAGB 500 AND 71" FOR MAGB 600
31" MIN.
"D" FOR 1 BATTERY, (2 BOILERS PER BATTERY), 1S
36 ⅝" FOR MAGB 500 AND 40 ½" FOR MAGB 600
"L" FOR 1 BATTERY, (5 BOILERS PER BATTERY)
IS 192 ½" FOR MAGB 1500
27"
TYP
27"
TYP
ACCESS
"E"
"D"
ACCESS
ACCESS
"D" FOR 1 BATTERY, (5 BOILERS PER BATTERY)
IS 40 ½" FOR MAGB 1500
*
"L"
FRONT
* "L" FOR 1 BATTERY, (7 BOILERS
PER BATTERY), IS 273 ½"
** "L" FOR 1 BATTERY, (4 BOILERS
PER BATTERY), IS 136 ½" FOR MAGB 1000
AND 152" FOR MAGB 1200.
*
"L"
FRONT
"L"
*
*
"D" FOR 1 BATTERY WITH 4 BOILERS IS 36 ⅝"
FOR MAGB 1000 AND 40½" FOR MAGB 1200.
"E" FOR 1 BATTERY WITH 7 BOILERS IS 40½".
FRONT
"L"
**
27"
TYP
"D"
ACCESS
ACCESS
* "L" FOR 1 BATTERY WITH 5 BOILERS IS 192 ½" FOR MAGB 1500
** "L" FOR 1 BATTERY WITH 7 BOILERS IS 273 ½" FOR MAGB 2100
"D" FOR 1 BATTERY WITH 7 BOILERS IS 40 ½".
NOTE: FOR ACCESS DIMENSION, REFER TO LOCAL CODES OR MAINTAIN
NO LESS THAN 24".
5
ACCESS
Supply And Return Piping
Installation Procedure
1. The installation must conform to the requirements of the
WARNING
authority having jurisdiction or, in the absence of such requirements, to the latest revision of the National Fuel Gas Code,
ANSI Z223. (Available from the American Gas Association,
8501 E. Pleasant Valley Road, Cleveland, Ohio 44134). Reference should also be made to local gas utility regulations and
other codes in effect in the area in which the installation is to be
made.
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.
2. Where required by the authority having jurisdiction, the
4. When this product is installed in the Commonwealth
of Massachusetts the installation must be performed by a
Licensed Plumber or Licensed Gas Fitter.
installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices For
Automatically Fired Boilers, No.CSD-1.
Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage.
3. This boiler series is classified as a Category 1 and the vent
installation shall be in accordance with the latest revision of the
National Fuel Gas Code noted above or applicable provisions of
the local building codes.
4. This boiler has met safe lighting and other performance criteria
with the gas manifold and control assembly on the boiler per
the latest revision of ANSI Z21.13.
5. The 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
6
INSTALLATION PROCEDURE
replacement, condensate trap, control replacement, etc.).
FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY
*. The boiler must not be installed on carpeting. Minimum clearances to combustible construction are:
6. LOCATE BOILER on level, solid base as near the chimney as
possible and centrally located with respect to the heat distribution system as practical.
TOP............................................18 IN.
FRONT................................. ALCOVE
FLUE CONNECTOR ................... 6 IN.
REAR............................................ 4 IN.
CONTROL SIDE........................... 9 IN.
7. Allow 24 inches at the front and right side for servicing and
cleaning.
8. When installed 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.
OTHER SIDE . ............................. 3 IN.
9. The MEA number for this boiler series is 19-79-E.
NOTE: Greater clearances for access should supersede fire protection clearances.
* For installation on combustible flooring special base part no. 3252-8.00 must be used.
Ventilation And Combustion Air
WARNING
!
Air openings to combustion area must not be obstructed.
By following the chart below, adequate combustion air can
be maintained.
Model
Number
Number
Of
Modules
MAGB500
MAGB600
MAGB750
MAGB900
MAGB1000
MAGB1200
MAGB1500
MAGB1800
MAGB2100
MAGB2400
2
2
3
3
4
4
5
6
7
8
COMBUSTION AIR REQUIREMENTS
(Minimum Opening In Square Inches)
*UNCONFINED AREA
**CONFINED AREA
OUTSIDE
COMBUSTION AIR
Outside
Outside
Combustion Air 1
Sq. In./4000 Btuh
(See Figure #2)
Combustion Air 1
Sq. In./1000 Btuh
(See Figure #1)
Vert. Ducts
1 Sq. In.
/4000 Btuh
Horz. Ducts
1 Sq. In.
/2000 Btuh
125
150
188
225
250
300
375
450
525
600
500
600
750
900
1000
1200
1500
1800
2100
2400
125
150
188
225
250
300
375
450
525
600
250
300
375
450
500
600
750
900
1050
1200
* 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).
7
VENTILATION & COMBUSTION continued
Figure #2
Figure #1
1. Ventilation of the boiler room must be adequate to provide suf-
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.
ficient air to properly support combustion per the latest revision
of the National Fuel Gas Code, ANSI Z223.1.
2. When a boiler is located in an unconfined space in a building or
conventional construction frame, masonry or metal building,
infiltration normally is adequate to provide air for combustion and ventilation. However, if the equipment is located in a
building of tight construction (See the National Fuel Gas Code,
ANSI Z223.1) the boiler area should be considered as a confined
space. If there is any doubt, install air supply provisions in accordance with the latest revision of the National Fuel Gas Code.
A. When installing two openings, one must commence within
12 inches from the top and 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.
3. When a boiler is installed in an unconfined space, in a building
I. When directly communicating with the outdoors, each
opening shall have a minimum free area of 1 square inch
per 4,000 BTU per hour of total input rating of all equipment in the enclosure. See figure #2.
of tight construction, air for combustion and ventilation 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 input rating of all appliances shall be provided.
Ducts may be used to convey makeup air from the outdoors
and shall have the same cross-sectional area of the openings to
which they are connected.
II. When communicating with the outdoors by means of vertical ducts, each opening shall have a minimum free area 1
square inch per 4,000 BTU per hour of total input rating of
all appliances in the enclosed space.
III.If horizontal ducts are used, each opening and duct shall
have a minimum free area 1 square inch per 2,000 BTU per
hour of total input rating of all appliances in the enclosed
space.
4. When air for combustion and ventilation is from inside build-
ings, the confined space shall be provided with two permanent
openings, one starting 12 inches from the top and one 12 inches
from the bottom of the enclosed space. Each opening shall
have a 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 unconfined
space. See figure #1.
B. One permanent opening, commencing within 12 inches
of the top of the enclosure, 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 communicate with
the outdoors or shall communicate through a vertical or
horizontal duct to 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 input rating of all equipment
located in the enclosure. The free area must be no less than
5. When the boiler is installed in a confined space and all air
is provided from the outdoors the confined space shall be
provided with one or two permanent openings according to
8
VENTILATION & COMBUSTION continued
be assumed that wood louvers will have 20-25% free area and
metal louvers and grilles will have 60-75% free area. Louvers
and grilles should be fixed in the open position or interlocked
with the boiler so they are opened automatically during the
boiler operation.
the 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 ¼ 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
Vent Installation
WARNING
!
This boiler is to be vented by natural draft and shall not be
connected to the mechanical draft system operating under
positive pressure.
1. The vent pipe must slope upward from the boiler not less then
INSTALLATION FOR OPTIONAL VENT DAMPER
2. Horizontal portions of the venting system shall be supported
NOTE: Refer to Figure #3 for steps 1 - 7.
1. Place Vent Damper on or as close to vent outlet of boiler as
possible.
¼ inch for every 1 foot to the vent terminal.
rigidly every 5 feet and at the elbows. No portion of the vent
pipe should have any dips or sags.
2. Remove Vent Damper Motor cover.
3. This boiler series is classified as a Category 1 and the vent instal-
3. Feed Damper and Damper wire harness connectors through
lation shall be in accordance with the National Fuel Gas Code
noted above or applicable provisions of the local building codes.
bracket hole on Damper Motor frame.
4. Tighten locknut onto Damper wire harness connector.
4. Inspect chimney to make certain it is constructed according to
NFPA 211. 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).
5. Plug Damper connector into socket on Damper Motor frame.
6. Replace Damper Motor cover.
7. Wire Damper in accordance with figure #3.
5. Connect flue pipe from draft hood to chimney. Bolt or screw
INSTRUCTIONS
joints together to avoid sags. 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 pip with fireproof insulation. Where two or more
appliances vent into a common flue, the area of the common
flue must be at least equal to the area of the largest flue plus 50
percent of the area of each additional flue.
1. Ensure that only the boiler is serviced by the Vent Damper. See
Figure #4.
2. Clearance of not less than 6 inches between Vent Damper and
combustible material must be maintained. Additional clearance
should be allowed for service of Vent Damper.
3. Vent Damper must be in the open position when appliance
main burners are operating.
4. The Vent Damper position indicator must be in a visible location following installation.
5. The thermostat's heat anticipator must be adjusted to match the
total current draw of all controls associated with the boiler during a heating cycle.
9
Vent Installation
LOCKNUT
Figure #3
HARNESS
CONN.
Figure #4
ACCEPTABLE VENT
DAMPER LOCATIONS
INSTALLER
HOOK-UP
REFER TO DAMPER MANUFACTURER'S
INSTALLATION INSTRUCTIONS FOR
POSITION OF DAMPER CONTROL BOX
DAMPER
MOTOR
DAMPER
CONN.
CHIMNEY
INSTALLER
HOOK-UP
X
VENT
DAMPER
UN-ACCEPTABLE
DAMPER LOCATIONS
X
X
X
VENT
OUTLET
BOILERS
HOT WATER HEATER
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:
REMOVAL OF BOILER FROM VENTING SYSTEM
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.
1. Seal an unused opening in the common venting system.
2. Visually inspect the venting system for proper size and hori-
zontal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deficiencies which could cause an
unsafe condition.
pliance not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom exhausts,
so they operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust thermostat so appliance will operate continuously.
5. 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.
6. After it has been determined that each appliance remaining
connected to a common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans,
fireplace dampers and any other gas burning appliances to their
previous condition of use.
7. 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 re-sizing
any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as
determined using the appropriate tables in the latest revision of
the National Fuel Gas Code, ANSI Z223.
3. 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 of the building. Turn on clothes dryers and any other ap-
10
Connecting Boilers With Refrigeration Systems
1. Connect supply and return piping as suggested in figure 5,
pipes.
when the boiler is used in connection with refrigerated systems.
D. 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.
2. The chilled medium MUST BE PIPED IN PARALLEL with the
boiler.
3. 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.
4. For further information refer to the I=B=R Installation and
Piping Guide.
B. During cooling cycle, open valves C and D, close valves A
and B.
C. Maintain a minimum clearance of one inch to hot water
Figure #5
CIRCULATOR
A
SUPPLY
PIPING
TO HEATING
AND COOLING
ELEMENT
C
EXPANSION
TANK
WATER
CHILLER
FEED
WATER
D
CHECK
VALVE
B
11
RETURN PIPING
FROM HEATING
AND COOLING
ELEMENT
Connecting Gas Service
1. Connect gas service from meter to control assembly in accor-
dance with ANSI Z223.1 and local codes or utility. A ground
joint union should be installed for easy removal of gas control
for servicing. A drip leg or trap must be installed at the bottom
of a vertical section of piping at the inlet to the boiler. 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 #6.
2. The gas line should be of adequate size to prevent undue pres-
sure drop and never smaller than the pipe size of the main gas
control valve. See chart below.
3. Check all connections using a commercially available soap solution made specifically for leak detection.
!
WARNING
DO NOT USE AN OPEN FLAME!
4. Disconnect the boiler from the gas supply piping system during
any pressure testing of the gas piping. After reconnecting, leak
test the gas connection and boiler piping before placing the
boiler back into operation.
5. See figure #7 for a typical gas line installation, and the table
for pipe sizes.
Figure #6
Figure #7
GAS MAIN
INSTALL MANUAL VALVE WITHIN
6 FEET OF THE BOILER AND
5 FEET ABOVE FLOOR WHERE
REQUIRED BY LOCAL CODES
3/4"
MIN.
SEDIMENT TRAP
FRONT VIEW
PRESSURE
12
GAS
MIN. SUPPLY
NATURAL
5" w.c.
PROPANE
11" w.c.
MAX. SUPPLY
14" w.c.
14" w.c.
MANIFOLD
3.5" w.c.
10.5" w.c.
Connecting Gas Service
Model
Number
500
600
750
900
1000
1200
1500
1800
2100
2400
MAGB PIPE SIZES IN INCHES FOR NATURAL GAS MAIN
Run Length in Feet
20’
30’
40’
50’
60’
80’
1.25”
1.25”
1.50”
1.50”
2.00”
2.00”
1.25”
1.25”
1.50”
1.50”
2.00”
2.00”
1.25”
1.50”
1.50”
2.00”
2.00”
2.00”
1.50”
2.00”
2.00”
2.00”
2.00”
2.00”
1.50”
2.00”
2.00”
2.00”
2.00”
2.50”
2.00”
2.00”
2.00”
2.00”
2.50”
2.50”
2.00”
2.00”
2.50”
2.50”
2.50”
2.50”
2.00”
2.00”
2.50”
2.50”
2.50”
3.00”
2.50”
2.50”
2.50”
3.00”
3.00”
3.00”
2.50”
2.50”
3.00”
3.00”
3.00”
3.00”
100’
2.00”
2.00”
2.00”
2.50”
2.50”
2.50”
3.00”
3.00”
3.00”
3.00”
125’
2.00”
2.00”
2.00”
2.50”
2.50”
2.50”
3.00”
3.00”
4.00”
4.00”
Electrical Wiring
WARNING
!
1. When an external electrical source is utilized, the boiler,
when installed MUST BE electrically grounded in accordance with these requirements.
2. Install a fused disconnect switch between boiler and
electrical panel at a convenient location.
3. The MAGB series requires 120 Volts to operate.
Electrical wiring must conform with the National Electrical Code,
ANSI/NFPA No. 70 when installed in the United states, the CSA
C22.1 Canadian Electrical Code, Part 1, when installed in Canada,
and/or the local authority having jurisdiction.
Things to Avoid when Locating Thermostats
DEAD SPOTS:
Corners and alcoves
Behind doors
COLD SPOTS:
HOT SPOTS:
Concealed pipes
Concealed pipes or ducts
Fireplace or chimney
TV sets
Stairwells - drafts
Radios
Unheated rooms on
Lamps
THERMOSTAT INSTALLATION
1. Thermostat should be installed on an inside wall about four feet
above the floor.
2. Check thermostat operation by raising and lowering thermostat
setting as required to start and stop the burners.
3. Instructions for the final adjustment of the thermostat are
packaged with the thermostat (adjusting heating anticipator,
calibration, etc.)
13
other side of wall
Direct sunlight
outside wall
Kitchens
Electrical Wiring
CAUTION
!
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify
proper operation after service.
24 VOLT GAS CONTROL WIRING WITH LIMIT CONTROL
HOT WATER CONTROL AND INTERMITTENT IGNITION WIRING WITH LIMIT CONTROL
TH-1
THERMOSTAT (MILLIVOLT)
1K
RELAY COIL
TH-2
THERMOSTAT (24V)
1K1
RELAY CONTACTS
NOT ALL COMPONENTS LISTED ARE USED IN ALL CONTROLS SYSTEMS.
TH-3
THERMOSTAT (LINE VOLTAGE)
1K2
RELAY CONTACTS
LINE VOLTAGE BY FACTORY
TR-1
TRANSFORMER (120V/24V 40VA
LS
LIMIT SWITCH
LOW VOLTAGE BY FACTORY
TR-2
TRANSFORMER (120V/24V 50VA)
MS
MANUAL SWITCH
LINE VOLTAGE BY INSTALLER
MGV
MILLIVOLT GAS VALVE
CIR
CIRCULATOR
LOW VOLTAGE BY FACTORY
LGV
24V GAS VALVE
ECO
ENERGY CUT OFF
LGV-1
24V GAS VALVE
LWCO
LOW WATER CUT OFF
NOTES:
PS
PRESSURE SWITCH
ESF
ELECTRIC WATER FEEDER
1. SWITCHES ARE SHOWN IN POSITION TAKEN DURING THE HEATING CYCLE.
MR-PS
MANUAL RESET PRESSURE SWITCH
PG
POWER GENERATOR
2. IF ANY OF THE ORIGINAL WIRING SUPPLIED WITH THE BOILER IS REPLACED,
SD
STACK DAMPER
PSC
PILOT SAFETY COIL
CONTROL TERMINAL
IT MUST BE REPLACED WITH LIKE WIRE SIZE AND TYPE OF INSULATION OR EQUIVALENT.
WIRE CONNECTION
14
Lighting Instructions
WARNING
!
CAUTION
If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal
injury or loss of life.
Before lighting any type of pilot burner (standing or intermittent), make certain the hot water boiler and system
are full of water to minimum pressure of 12 lbs. per square
inch in the system, and also make certain that the system
is vented of air. Set the operating control of thermostat to a
“below” normal setting. Refer to the following appropriate
lighting instruction.
!
Before any procedures are attempted on this appliance, it is
necessary to determine if the ignition system is electric or
standing pilot. If you are uncertain, contact the manufacturer before proceeding.
DANGER
1. This appliance is equipped with an ignition device
•Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
which automatically lights the pilot. Do not try to
light the pilot by hand.
•If you cannot reach your gas supplier, call the fire department.
2. BEFORE OPERATING smell all around the appli-
!
ance area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle on
the floor.
3. Use only your hand to move the gas control knob. Never use
tools. If the knob will not move by hand, don’t try to repair it,
call a qualified service technician. Force or attempted repair
may result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
4. Do not use this appliance if any part has been under water.
•Do not try to light any appliance.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and any
gas control which has been under water.
• Do not touch any electrical switch; do not use any phone
in your building.
LIGHTING INSTRUCTIONS FOR INTERMITTENT PILOT
SYSTEMS
9. Replace front jacket panel.
1. STOP! Read the safety information above on this label.
11. Set the thermostat to desired setting.
2. Set thermostat to lowest setting.
12. If the appliance will not operate, follow the instructions “To
10. Turn on all electrical power to the appliance.
Turn Off Gas To Appliance” and call your service technician or
gas supplier.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by
hand.
5. Remove the front jacket panel.
6. Turn the gas control knob clockwise
Figure #8)
to “OFF”. (See
7. Wait five (5) minutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas, STOP! Follow “What
To Do If You Smell Gas” section. If you don’t smell gas, go on
to the next step.
8. Turn the gas control knob counterclockwise
TO TURN OFF GAS TO APPLIANCE
13. Set the thermostat to lowest setting.
14. Turn off all electric power to the appliance if service is to be
preformed.
15. Remove the front jacket panel.
16. Turn gas control knob clockwise
17. Replace the front jacket panel. to “ON”.
15
to “OFF”.
Lighting Instructions
LIGHTING INSTRUCTIONS FOR CONTINUOUS PILOT
Figure #9
18. STOP! Read the safety information at the beginning of these
instructions.
INLET
PRESSURE
TAP
19. Set the thermostat to the lowest setting.
PRESSURE REGULATOR
ADJUSTMENT BENEATH
COVER SCREW
20. Turn off all electric power to the appliance.
OUTLET
PRESSURE
TAP
21. Remove access panel and burner door.
22. Turn gas control knob clockwise
to "OFF" See Figure
#9. NOTE #1: Some gas control knobs cannot be turned from
TH/TR
GAS
ON
"PILOT" to "OFF" unless knob is pushed in slightly. DO NOT
FORCE.
OFF
PILOT
PILOT FLOW ADJ. SCREW
BENEATH COVER SCREW
23. Wait (5) minutes to clear out any gas. If you then smell gas,
STOP! Follow “What To Do If You Smell Gas”, section. If you
don't smell gas, go to the next step.
24. Find pilot. Follow metal tube from gas control. Depending on
the model of the boiler, pilot is either mounted on the base or
on one of the burner tubes.
25. Turn gas control knob counterclockwise
to "PILOT".
26. Push in gas control knob or reset button if so equipped, all the
way in and hold. Immediately light the pilot with a match. Continue to hold the gas control knob or reset button in for about
1 minute after the pilot is lit. Release knob or button, and it will
pop up back up. Pilot should remain lit. If it goes out, repeat
steps 5 through 9.
• If knob or button does not pop up when released, stop
and immediately call a qualified service technician or
your gas supplier.
• If the pilot will not stay lit after several tries, turn the
gas control knob clockwise
to "OFF". (See note
#1), and call a qualified service technician or your gas
supplier.
27. Replace burner door.
GAS
OUTLET
INLET
GAS CONTROL KNOB
28. Turn gas control knob counterclockwise
to "ON".
29. Replace access panel.
30. Turn on all electric power to the appliance.
31. Set thermostat to desired setting.
TO TURN OFF GAS TO APPLIANCE
32. Set the thermostat to lowest setting.
33. Turn off all electric power to the appliance if service is to be
performed.
34. Push in gas control knob slightly and turn clockwise
"OFF", DO NOT FORCE.
to
35. Call a qualified service technician.
Normal Sequence of Operation
For a single module the thermostat will actuate, completing the
circuit to the aquastat. The completed circuit to the aquastat will first
activate the circulator and damper. When the damper is fully open it
will complete the circuit to the ignition system and ignition will take
place.
In the event the boiler water temperature exceeds the high limit
setting on the boiler mounted aquastat, power will be interrupted
between the aquastat and the ignition system. The power will remain
off until the boiler water temperature drops below the high limit
setting. The circulator will continue to operate under this condition
until the thermostat is satisfied.
In the event the flow of combustion products through the boiler
venting system becomes blocked, the blocked vent safety switch
will shut the main burner gas off or, if the boiler flueway becomes
blocked, the flame rollout safety switch will shut the main burner
gas off. See Figure #11. If either of these conditions occur, do not
attempt to place the boiler back into operation. Contact a qualified
service agency.
16
General Instructions
Before seasonal start-up, 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.
! CAUTION
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation.
Verify proper operation after service.
The service agency or owner should make certain the system is filled
with water to minimum pressure and open air vents, if used, to expel
any air that may have accumulated in the system. Check the entire
piping system and if any leaks appear, have them repaired.
Circulators must be checked and maintained. Refer to the circulator
manufacturer's instructions.
When the cleaning process is complete, restore the boiler components to their original position. Use IS-808 GE silicone, available
from a distributor, to seal around the flue collector and boiler castings.
A visual check of the main burner and pilot flames should be made
at the start of the heating season and again in mid-season. The main
burner flame should have a well defined inner blue mantel with a
lighter blue outer mantel. Check the burner throats and burner orifices for lint or dust obstruction. See figures #12 and #13.
The pilot flame should envelop ⅜ to ½ inch of the tip of the pilot
thermocouple, ignition/sensing electrode or mercury sensor. See
figure #14. To adjust the pilot flame, remove the pilot adjustment
cover screw (figures #8, & #9), and turn the inner adjustment
screw counterclockwise
to increase or clockwise
to decrease pilot flame. Be sure to replace cover screw after adjustment to
prevent possible gas leakage.
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 vent for obstruction and make certain the vent is in
good working order.
The burners and pilot should be checked for signs of corrosion, rust or scale buildup. The area around the boiler must
The boiler flue gas passageways may be inspected by a light and mirror.
Remove the burner door, figure #11 Place a trouble lamp in the flue
collector through the draft relief opening. With the mirror positioned above the burners, the flue gas passageways can be checked
for soot or scale.
It is recommended 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, trained technicians
can make the proper changes for safe operation of the boiler.
be kept clear and free of combustible materials, gasoline and other
flammable vapors and liquids.
The free flow of combustion and ventilating air to the boiler and
boiler room must not be restricted or blocked.
The following procedure should be followed to clean
the flue gas passageways:
1. Remove the burners from the combustion chamber by raising
the burners up from the manifold orifices and pulling toward
the front of the boiler. See figure #11.
Figure #12
2. Disconnect the vent pipe from the draft hood.
3. Remove the top jacket panel.
4. Remove the combination flue collector and draft hood from the
boiler castings by loosening the nuts on the hold down bolts
located on each side of the collector. See figure #11.
5. Place a sheet of heavy paper or similar material over the bottom
of the base and brush down the flue passageways. The soot and
scale will collect on the paper and is easily removed with the
paper.
With the paper still in place in the base, clean the top of the boiler
castings of the boiler putty or silicone used to seal between the castings and flue collector. Make certain that chips are not lodged in the
flue passageways.
The main burner flame should form a
sharp blue inner mantel with no yellow.
17
General Instructions
Figure #11
INTEGRAL DRAFT
HOOD
HOLD DOWN
BOLT
BLOCKED VENT
SAFETY SWITCH
BLOCKED VENT
SAFETY SWITCH
BURNER DOOR
BASE
BURNERS
MANIFOLD
JACKET BASE
PANEL
ROLL-OUT SAFETY
SWITCH
ORIFICES
GAS VALVE
Figure #13
Figure #14
3/8” TO 1/2”
IN FLAME
BURNERS
ORIFICES
GAS VALVE
KNOB
18
IGNITION ELECTRODE
Checking Gas Input Rates To Boiler
Figure #15
HIGH LIMIT AND
OPERATING CONTROL
TRANSFORMER
BURNER
ACCESS DOOR
SPARK CONTROL
GAS VALVE
1/8" TAPPING
ON MANIFOLD
Gas input to the boiler can be adjusted by removing the protective
cap on the pressure regulator, (See figures #8 & #9), and turning the
to increase input and counterclockwise
screw clockwise
to decrease input. Natural gas manifold pressure should be set at
approximately 3.5 inches water column. Propane gas manifold pressure should be set at approximately 10.5 inches water column. These
manifold pressures are taken at the outlet side of the gas valve. (See
figures #8 & #9)
divide the input rate shown on the rating plate by the
heating value of the gas 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 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.
If the proper rate cannot be obtained, contact the manufacturer.
CHECK SAFETY CONTROL CIRCUIT
after burner adjustments are made, for satisfactory operation.
1. Pilot: With main burner operating, turn the pilot gas
adjusting screw clockwise
until pilot gas is turned
off. (Refer figures #8 & #9 ) Within 90 seconds the main
gas control should close, shutting off the gas to the main
burner.
2. High limit control (figure #15) Remove cover and
note temperature setting. Decrease this setting to the
minimum and operate boiler. When the boiler water
temperature exceeds the control temperature setting, the
control will open the circuit, closing the automatic main
gas valve.
To check for proper flow of natural gas to the boiler,
Optional Controls & Wiring
The following descriptions outline control options for
MAGB modular systems.
AMB4A and AMB8A Multiple Boiler Sequencers
The AMB4A and AMB8A multiple boiler sequencers are capable
of sequentially step firing up to 4 (AMB4A) or 8 (AMB8A) heating
boilers. The number of boilers fired is adjusted by the AMB control
depending on the system heating load and outdoor temperature.
The AMB control will adjust the control point of the system water
temperature based on the temperature that the outdoor air sensor
is reading. The number of hours on each boiler in the system is recorded and each day the AMB control will choose the boiler with the
fewest hours to be the lead boiler for the day to attempt to run each
boiler equally and extend boiler life. Setpoint, reset ratio, rotation
and many other features are easily programmed in the filed through
the four button user interface.
Operation
When used in a continuous application the AMB will regulate the
water temperature in the system through the use of the water sensor and it will always keep the water warm. The AMB will monitor
the water temperature until the temperature drops the number of
degrees below the control point that the temperature differential
feature is set to. The control will then bring on the lead boiler. The
AMB will monitor the boiler temperature and if it has not reached
the control point it will bring on the next boiler. Boilers will be
phased on or off based on how close the water temperature is to the
control point. If at any point the water temperature is 10°F above the
control point, all boilers will turn off
19
Optional Controls & Wiring
Wiring on ARGO AMB Control to Multiple MAGB Boilers
Figure #16
AMB-4
WATER SENSOR
OUTSIDE SENSOR
IF USING EXTERNAL DAY/NIGHT FEATURE
CONNECT HERE (DRY CONTACT)
IF USING REQ/ACK CONNECT HERE
(TT/THERMOSTAT DRY CONTACT)
TO PRIORITY IF USING
(DRY CONTACT)
Yellow
24VAC 40 VA
TRANSFORMER
Yellow
BOILER
3
Black
White
*SUPPLIED WITH
AMB CONTROL
120 V
WHITE
BLACK
MAGB
MAGB
Consult the ARGO AMB installation manual for additional information on the ARGO AMB control.
20
MAGB
BOILER
2
BOILER
1
MAGB Series Replacement Parts
BASE
1
2
3
7
4
6
5
Item
#
1
2
3
4
5
Description
BURNER TUBE 1 1/2" - 250
BURNER TUBE 1 1/2" - 300
Part #
240005543
BASE W/INSUL - 250
5611605
BASE W/INSUL - 300
5611606
BURNER DOOR - 250
32621002
BURNER DOOR - 300
32621003
MANIFOLD - 250
356-2-1.05
MANIFOLD - 300
356-2-1.06
SCREW ¼ - 20 X ½ SELF TAP
HW-005.01
Item
#
Qty.
5
6
6
1
1
7
1
4
21
Description
Part #
GAS VALVE VR8200H - 50 - 300 24V LP
VG00307
GAS VALVE VR8304H4 - 175-300 SPARK NAT
VG01103
GAS VALVE VR8304 - 50-300 SPARK LP
VG01104
GAS VALVE VR8300H4 - 250 & 300 24V NAT
VG01201
ORIFICE 3.2mm NAT - 250 BASE
240007406
ORIFICE 3.2mm NAT - 300 BASE
240007406
ORIFICE #47 LP - 250 BASE
355-1-5.04
ORIFICE #47 LP - 300 BASE
355-1-5.04
COMBUSTIBLE BASE FLOORING - 250
325-2-8.05
COMBUSTIBLE BASE FLOORING - 300
325-2-8.06
Qty.
1
5
6
5
6
1
MAGB Series Replacement Parts
JACKET
9
10
1
2
3
8
4
7
6
5
Item #
1
2
3
4
5
6
7
8
9
10
Description
PANEL - TOP MAGB 250
PANEL - TOP MAGB 300
PANEL - LEFT MAGB 250 & 300
DRAFT DEFLECTOR MAGB 250
DRAFT DEFLECTOR MAGB 300
PNL LWR ACCES MAGB 250
PNL LWR ACCES MAGB 300
PANEL - BASE MAGB 250
PANEL - BASE MAGB 300
PANEL - RIGHT MAGB 250 & 300
PANEL - REAR MAGB 250
PANEL - REAR MAGB 300
FLUE COL MAGB 250
FLUE COL MAGB 300
DAMPER 8" MAGB 250
DAMPER 9" MAGB 300
PNL- UPPER ACCESS MAGB 250
PNL- UPPER ACCESS MAGB 300
22
Part #
31621506
31621507
3162704
3162505
3162506
3161105
3161106
3161205
3161206
3162703
3162605
3162606
3462105
3462106
240006940
240006941
31621206
31621207
Qty.
1
1
1
1
1
1
1
1
1
1
MAGB Series Replacement Parts
HEAT EXCHANGER
9
8
1
2
3
7
5
4
Item
1
2
Part No.
HW06901
Description
5
Nut /16 - 18 Wislock
HW-011.07
Tie Rod - ¼” x 23” (250)
HW-011.09
Tie Rod - ¼” x 27” (300)
6
Qty.
Item
6
7
8
2
Part No.
Description
100-2-2.01 Left Hand Section
43300976
10
Push Nipple 2” Mach. (300)
12
Fully Assembled Heat Exchangers
HW-003.02
HW-008.01
Nut ¼”-20 Hex
Washer - 5/16” Flat
2
4
4
100-2-7.04
Heat Exchanger (6 Section)
5
100-2-3.01
Right Hand Section
1
100-2-7.05
Heat Exchanger (7 Section)
Center Section (250)
4
Center Section (300)
6
100-2-1.01
23
1
Push Nipple 2” Mach. (250)
3
6
Qty.
MAGB Series Replacement Parts
PILOTS
2
1
3
SPARK PILOT
4
Item
Part No.
1
109007296
PILOT BRACKET ASSEMBLY
1
2
HW-005.01
BRACKET SCREW
2
3
240007093
SPARK CABLE
1
4
14615005
PILOT TUBING, 1/8" x 24"
1
PB-001.02
Natural Gas Q345A PILOT
240007096
LP Q345A Pilot
5
Description
Qty.
1
* Included with #3 - Pilot Tube Assembly Kit (above)
5
2
1
CONTINUOUS PILOT
Item
5
Part No.
Description
1
109007296
PILOT BRACKET ASSEMBLY
1
2
HW-005.01
BRACKET SCREW
2
3
1520001
THERMOCOUPLE Q309
1
4
14615005
PILOT TUBING, 1/8" x 24"
1
14662098
Natural Gas Q314A PILOT
240007285
LP Q314A Pilot
5
* Included with #3 - Pilot Tube Assembly Kit (above)
3
4
24
Qty.
1
MAGB Series Replacement Parts
ELECTRICAL
(NOTE: quantities are per module)
1
11
14
2
13
12
3
4
10
5
7
8
9
6
ITEM
1
2
3
4
5
CABLE - DAMPER 60”
JCT BOX 4X4X1-1/2
ELEC 4”X4” COVER/TERM STRIP
WIRE ASSY ROLLOUT/SPILL SWITCH 28”
HARNESS IGNITION TO GAS VALVE
P/N
37413101
EF-013.01
EF04401
37513301
37413602
QTY.
1
2
1
2
1
6
PILOT IGNITION CABLE 30” (FOR SPARK ONLY)
240007093
1
7
8
9
10
PLT SPARK CTRL HW (FOR SPARK ONLY)
WIRE - J-BOX TO CONTROLS 27”
HARNESS TRANSFORMER 30”
CONTROL L4006-1827 HW
WIRE JUMPER TO “TT”, 8” (LOCATED UNDER TERM
STRIP)
WIRE TRANSFORMER BROWN 15”
WIRE TRANSFORMER WHITE 15”
TRANSFORMER 125V-24V 50VA
14662070
37413801
272-1-3.00
AQ-008.00
1
1
1
1
37519001
1
37413001
37413002
14662305
1
1
1
11
12
13
14
DESCRIPTION
25
MAGB Series Replacement Parts
PIPING
10
(NOTE: quantities are per module)
12
11
13
16
14
15
17
1
8
7
9
6
2
4
5
3
ITEM
DESCRIPTION
P/N
QTY.
1
WIRE ROLLOUT/SPILL 28"
37513301
2
2
HARNESS IGN TO G/V 18"
37413602
1
3
PILOT IGNITION CABLE 30"
240007093
1
4
PIPE - NPL 1.1/4X4.1/2 NPT
5
DRAIN - SHORT
6
PIPE - TEE 1.1/4X3/4X1.1/4
7
1310002
1
HW-016.03
1
1510002
1
PIPE - 1.1/4" CLOSE NPL
PF-006.01
1
8
WIRE LOW VOLTAGE/DAMPER
375-1-14.01
1
240005480
1
1010002
1
9
HARNESS CIRCULATOR 72"
10
CONTROL L8148E1257 (AQUASTAT)
11
RELIEF VALVE 30#
VR-001.01
1
12
WELL 3/4"X3"
AQ-020.01
1
13
GAUGE - THERALTIMETER
1260006
1
14
PIPE - NPL 3/4"X4"
1310001
1
15
PIPE - ELBOW 3/4" 90°
1190001
1
16
CLAMP #3600 WHITE
EF03601
2
17
PLT SPARK CTRL
14662070
1
26
MAGB Series Replacement Parts
ROLLOUT & SPILL SWITCH
1
Item #
Description
Part #
Qty.
1
TEMP. SENSOR BRACKET
3262001
1
2
CONTROL-FIXED TEMPERATURE
THERMO (ROLLOUT SWITCH)
AQ02101
1
3
SCREW - #6 X ¼ HEX HD
HW06501
2
2
The rollout switch is located on the base and flue collector.
NOTE: The quantities above are for each switch.
3
27
P.O. Box 4729
Utica, NY 13504-4729
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