GAS-FIRED STEAM BOILERS INSTALLATION, OPERATION & MAINTENANCE MANUAL Models PEG075DID PEG112DID PEG150DID PEG187DID PEG225DID PEG262DID PEG299DID MODEL PEGDID Electronic Intermittent Ignition Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13504-4729 An ISO 9001-2008 Certified Company web site: www.ecrinternational.com P/N# 240009572, Rev. C [08/2012] DIMENSIONS Figure 1 - Dimensions 25" A Depth C Safety Relief Valve 2" NPT 2" NPT ½" 16⅝" NPT 2" NPT Plug B 29" 2" NPT 12⅜" 5½" 13½" Floor Table 1 - Physical Data Models 075 112 150 187 225 262 299 Width (A) 7 1 3 5 7 1 3 10 /8 14 /8 17 /8 20 /8 23 /8 27 /8 30 /8 Height (B) 7 35 /8 Depth (C) 3 3 3 3 3 3 3 28 /8 28 /8 29 /8 30 /8 30 /8 30 /8 30 /8 Gas Connection Size (G) ½ NPT ½ NPT ½ NPT ¾ NPT ¾ NPT ¾ NPT ¾ NPT Flue Diameter 5" 5" 6" 7" 7" 7" 7" 2 BOILER RATINGS AND CAPACITIES Table 2 Ratings and Capacities Natural Gas & Propane (LP) Heating Net AHRI Rating (2) Boiler Model Input No. of Vent Pipe Capacity AFUE, % Number MBH (1) Steam, Steam, Sections Size MBH (1) MBH Sq. Ft. PEG075DID 75 62 47 195 82.2 3 5" PEG112DID 112 93 70 292 82.4 4 6" PEG150DID 150 125 94 391 82.6 5 6" PEG187DID 187 156 117 488 82.8 6 7" PEG225DID 225 188 141 587 83.0 7 7" PEG262DID 262 219 164 685 83.2 8 7" PEG299DID 299 250 188 782 83.4 9 7" Heating Capacity and AFUE are based on DOE (Department of Energy) test procedures. 1. Input rating for sea level to 2,000 ft. above sea level. Altitudes over 2000 ft. above sea level, reduce input rate 4% for every 1000 ft. 2. Net AHRI steam ratings shown are based on a piping and pickup allowance of 1.333. Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc. 3 TABLE OF CONTENTS Important Safety Information ....................... 5 Introduction Locating the Boiler ...................................... 6 Boiler is designed for use in closed heating systems where all steam is returned as condensate and make-up water is Hydronic Piping .......................................... 7 minimal. Boiler is not designed for or intended for use in Fresh Air for Combustion ............................11 open systems using 100% make-up water. Chimney and Vent Pipe Connection ..............12 Prior to Installation • Verify correct boiler for type of gas being used Vent Damper Operation ..............................14 natural or propane. See Rating Plate. Gas Supply Piping ......................................15 • Verify boiler size and dimensions. See Figure 1 and Electrical Wiring ........................................16 Table 1, page 2. Operating Instructions ................................17 • Verify ratings and capacity data for natural gas. See Table 2. Operating Your Boiler .................................18 Installation Requirements Checking and Adjusting ..............................19 • Supply boiler with correct gas (natural or propane), Start-up Cleaning ......................................21 fresh air for combustion, and suitable electrical supply. General Maintenance .................................22 • Connect boiler to adequate venting and piping systems. Troubleshooting .........................................23 • Provide boiler with properly located and adjusted Wire Diagrams ..........................................24 thermostat. Optional Hydronic Piping .............................27 Installation of boiler in building under construction, use precaution to insure clean combustion air supply during construction process. Airborne particulate from construction materials can clog burner ports and cause incomplete combustion and sooting. Complete all steps for safe and proper heating system operation. KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE GAS FIRED STEAM BOILERS Check our website frequently for updates: www.ecrinternational.com Information and specifi cations outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifi cations or system design at any time without notice and without incurring any obligation, whatsoever. 4 IMPORTANT SAFETY INFORMATION General Installation shall conform to requirements of Boiler and venting installation shall be completed by authority having jurisdiction or in absence of such qualifi ed agency. requirements to the National Fuel Gas Code, ANSI Z223.1/NFPA 54. ! WARNING Fire, explosion, asphyxiation and electrical shock Where required by authority having hazard. Improper installation could result in death jurisdiction, installation shall conform to or serious injury. Read this manual and understand Standard for Controls and Safety Devices for all requirements before beginning installation. Automatically Fired Boilers, ANSI/ASME CSD-1. Controls can be added to make this boiler CSD- 1 compliant. Check with your local codes for BBecomeecome ffamiliaramiliar wwithith ssymbolsymbols iidentifyingdentifying ppotentialotential hhazards.azards. requirements. Requirements for Commonwealth of Massachusetts: Boiler installation must conform to Commonwealth of TThishis isis thethe ssafetyafety aalertlert ssymbol.ymbol. SSymbolymbol aalertslerts yyouou ttoo Massachusetts code 248 CMR which includes but is ppotentialotential ppersonalersonal iinjurynjury hhazards.azards. OObeybey aallll ssafetyafety mmessagesessages not limited to installation by licensed plumber or gas ffollowingollowing thisthis symbolsymbol toto avoidavoid ppossibleossible iinnjjuryury oorr ddeath.eath. fi tter. ! DANGER Indicates a hazardous situation which, if not avoided, ! WARNING WILL result in death or serious injury. Installing or venting a boiler or any other gas ! WARNING appliance with improper methods or materials could result in death or serious injury due to fi re or to Indicates a hazardous situation which, if not avoided, asphyxiation from poisonous gases such as carbon could result in death or serious injury. monoxide which is odorless and invisible. ! CAUTION Indicates a hazardous situation which, if not avoided, ! WARNING may result in minor or moderate injury. Fire, explosion, asphyxiation hazard. Keep boiler area clear and free from combustible materials, gasoline NOTICE and other fl ammable vapors and liquids. Used to address practices not related to personal injury. Modifi cation, substitution or elimination of factory equipped, supplied or specifi ed components could result in death or serious injury. 5 LOCATING THE BOILER Locating the Boiler 1. Select level location as centralized with piping system, Figure 2 - Minimum Clearances To Combustible Construction and as near chimney as possible. 6” 2. Place crated boiler at selected location. Remove all crate material. Please recycle responsibly. ! WARNING Fire hazard. Do not install boiler on combustible fl ooring or carpeting. Failure to follow these Rear instructions could result in death or serious injury. 3. Do not install boiler on carpeting. For installation 7” 6” on non-combustible fl oors only. For installation on Boiler combustible fl ooring, special base must be used. (See Replacement Parts Manual.) 4. Use metal shims under boiler base legs for fi nal leveling Control Side Opposite Side if needed. 5. Install boiler in location that permits satisfactory Front combustion of gas, proper venting, and maintenance of ambient temperature at safe limits under normal conditions of use. Boiler location should not interfere with proper circulation of air. Introduce outside air if normal infi ltration does not provide necessary ALCOVE air. “Fresh Air for Combustion” on page 11. 6. Notify owner to keep air passages free of obstruction. Figure 3 - Draft Hood Installation Ventilating and combustion air must enter boiler room without restrictions. Table 3 - Minimum Clearance Dimensions Front Panel Lift Up Top 6" Then Off Rear 6" Control Side 7" Opposite Side 6" Screws Front Alcove Flue/Vent 6" Connector Near Boiler Piping 1/2" 7. Install boiler so automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and Draft Hood service. Draft Hood Installation ! WARNING Asphyxiation, carbon monoxide hazard. Failure to 1. Lift up then off to remove front panel. follow these instructions could result in improper combustion and possible leakage of combustion 2. Remove top jacket panel (4 screws). products into the living space. 3. Slide draft hood over fl ue collector. 4. Secure with 1 or 2 screws, based on boiler size. Follow directions given in Figure 3. Attach draft diverter, and blocked vent switch. Mount vent damper. See 5. Replace top jacket panel (4 screws). "Connecting Vent Damper and Vent Connector" page 12. 6. Replace front panel. See Wiring Diagrams pages 24 and 25. 6 HYDRONIC PIPING ! WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: • Connect to safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum distance from fl oor or allowable safe point of discharge. • Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line. • Have no intervening shutoff valve between safety 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.