ECR Olsen OMGB50 Instructions générales

P/N 37615101, Rev. B [07/08]

ECR International, LTD

P.O. Box 900 Wallaceburg, ON N8A5E5

An ISO 9001-2000 Certified Company

OMGB SERIES

Cast Iron Gas Fired Boilers

For Forced Hot Water

INSTALLATION, OPERATION &

MAINTANANCE MANUAL

MODEL NUMBERS:

OMGB50 OMGB75 OMGB100

OMGB125 OMGB150 OMGB175

OMGB200 OMGB250 OMGB300

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

IMPORTANT: Read the following instruc-

tions COMPLETELY before installing!!

TABLE OF CONTENTS

C.S.A. Certied

For Natural Gas Or Propane

Tested For 100 LBS.

ASME

Working Pressure

Indicates an imminently hazardous situation

Which, if not avoided, will result in death, serious

injury or substantial property damage.

DANGER

Indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury

or substantial property damage.

WARNING

All installations of boilers and venting should be

done only by a qualied expert and in accordance

with the appropriate manual. Installing or venting

a boiler or any other gas appliance with improper

methods ormaterialsmayresultinserious injury or

death due to re or to asphyxiation from poisonous

gases such as carbon monoxide which is odorless

and invisible.

WARNING

1. Keepboiler area clear and free from combustible

materials, gasoline and other ammable vapors

and liquids.

2. DO NOT obstruct air openings to the boiler

room.

3. Modication, substitution or elimination of fac-

tory equipped, supplied or specied 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 qualied installer.

5. TO THE INSTALLER - Leave all instructions with

the boiler for future reference.

6. When this product is installed in the Common-

wealth of Massachusetts the installation must be

performed by a Licensed Plumber or Licensed

Gas Fitter.

WARNING

Indicates a potentially hazardous situation which,

if not avoided, could result in minor or moderate

injury or property damage.

CAUTION

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

SAFETY SYMBOLS & WARNINGS

The following dened symbols are used throughout this manual

to notify the reader of potential hazards of varying risk levels.

Ratings & Data - Natural Gas & Propane Gas ...3

Installation Procedure.........................................4

Ventilation & Combustion Air ..............................5

Connecting Supply & Return Piping ...................7

Vent Installation ................................................ 11

Vent System Modication ................................. 11

Vent Damper Installation & Instructions............12

Connecting Gas Service...................................13

Electrical Section..............................................13

Wiring Diagram - 24V Standing Pilot................14

Wiring Diagram - Intermittent Ignition...............15

Lighting Instructions..........................................16

Normal Sequence of Operation........................18

General Instructions .........................................18

Checking Gas Input Rate To Boiler ..................20

Replacement Parts......................................22-27

RATINGS & DATA - NATURAL GAS & PROPANE GAS

Boiler No. Natural Gas

Inlet*

Dimensions Pump size Supply &

Return Tappings

A B C D E F

50 ½" 11⅛" 5½" 4" 30¾" 36¼" 6" 1¼"

75 ½" 15 7½" 5" 30¾" 37¾" 6" 1¼"

100 ½" 15 7½" 6" 30¾" 37¼" 6½" 1¼"

125 ½" 18⅞" 9½" 6" 30¾" 37¼" 6½" 1¼"

150 ½" 18⅞" 9½" 7" 30¾" 37¾" 7" 1¼"

175 ½" 22¾"11½" 7" 30¾" 38¾" 7" 1¼"

200 ½" 22¾"11½" 8" 30¾" 38¾" 8" 1¼"

250 ¾" 265

⁄

16"13¼" 8" 30¾" 40¾" 8" 1¼"

300 ¾" 30½" 15¼" 9" 30¾" 42¾" 10" 1¼"

* Propane gas inlet, all units, 1/2"

Boiler

No.

(1)

A.G.A. Input

Btu/Hr.

(1)

Heating

Capacity Btu/Hr.

(1) **

I=B=R

NetOutput

Btu/Hr

(2)

NetRating

Sq. Ft. HW

@ 170

No.

Burners

(3)

Recommended

Air Cushion

Tank

Water

Content

(Gals.)

50 50,000 42,000 37,000 243 1 15 2.4

75 75,000 63,000 55,000 365 2 15 4.0

100 100,000 83,000 72,000 481 2 30 4.0

125 125,000 104,000 90,000 603 3 30 5.6

150 150,000 124,000 108,000 719 3 30 5.6

175 175,000 143,000 124,000 829 4 30 7.2

200 200,000 165,000 143,000 957 4 30 7.2

250 250,000 205,000 178,000 1189 5 30 8.8

300 299,999 243,000 214,000 1368 6 60 10.4

EXPLANATORY NOTES

--All boilers are design certied for installation on noncombustible oor.

--For installation on combustible oors use combustible oor kit.

--Recommended chimney height 20 feet. In special cases where conditions

permit, chimney height may be reduced to 10 feet. Refer to the latest

revision of NFGC part 11.

--Electric service to be 120 Volts, 15 Amps, 60 Hz.

--The MEA number for the this boiler is 19-79-E.

(1) For elevations above 2000 feet, ratings should be

reduced at a rate of 4% for each 1000 feet above sea

level.

(2) Base on 170° temperature in radiators.

(3) Tank sized for non-ferrous baseboard or radiant panel

systems. Increase size for cast iron baseboard and

radiation.

--Net I=B=R ratings include 15% allowance for normal

piping and pick-up load. Manufacturer should be

consulted on installations having other than normal piping

and pick-up requirements.

** For equivalent square feet of radiation, divide I=B=R

output by 150.

STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler

Battery, High Limit Control, Vent Damper Relay, Theraltimeter

Gauge, Circulator With Return Piping To Boiler, Main Gas

Burners, Combination 24 Volt Gas Control (Includes Automatic

Gas Valve, Gas Pressure Regulator, Automatic Pilot, Safety

Shutoff, Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief

Valve, Drain Cock, Spill Switch, Rollout Switch, Automatic Vent

Damper. Not Shown Are: Wiring Harness, Thermocouple,

Non-linting Safety Pilot.

OPTIONAL EQUIPMENT: Intermittent Electric Ignition

Pilot System.

Improper installation, adjustment, alteration, service or maintenance can cause

injury or property damage.

INSTALLATION PROCEDURE

The installation must conform to the requirements of the

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. When installed

in Canada: The latest revision of the CAN1-B149.1 and/

or B149.2 Installation Codes for Gas-Burning Equipment

and/or local codes.

Where required by the authority having jurisdiction, the

installation must conform to American Society of Me-

chanical Engineers Safety Code for Controls and Safety

Devices For Automatically Fired Boilers, ANSI/ASME

No.CSD-1.

This boiler series is classied as a Category 1 and the

vent installation shall be in accordance with Part 7 of the

National Fuel Gas Code noted above when installed in

the United States. In Canada refer to the CAN1-B149.1

and or B149.2 Installation Codes for Gas-Burning Equip-

ment. Also refer to applicable provisions of the local build-

ing codes.

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/CGA 4.9.

The boiler shall be installed such that the gas ignition

system components are protected from water (drip-

ping, spraying, rain, etc.) during appliance operation and

service, (circulator replacement, condensate trap, control

replacement, etc.).

Locate boiler on level, solid base as near the chimney

as possible and centrally located with respect to the heat

distribution system as practical.

Allow 24 inches at the front and right side for servicing

and cleaning.

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.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY - For installation on combustible ooring

special base must be used. (See Replacement Parts Sec-

tion.) The boiler can not be installed on carpeting. Mini-

mum clearances to combustible construction are:

TOP ........................................................... 18 IN.

FRONT ...............................................ALCOVE *

FLUE CONNECTOR ................................... 6 IN.

REAR........................................................... 4 IN.

CONTROL SIDE.......................................... 9 IN.

OTHER SIDE............................................... 3 IN.

NOTE: Greater clearances for access should supersede

fire protection clearances.

* The denition of an Alcove is a three sided space with no

wall in front of the boiler. The ANSI standard for an alcove is

18 inches from the front of an appliance to the leading edge of

the side walls as shown below.

Minimum Clearances to Combustible Construction (as

seen from above)

BOILER

18"

WARNING

VENTILATION & COMBUSTION AIR

COMBUSTION AIR REQUIREMENTS

(Minimum Square Inches Requirement)

Model

No.

Unconned Area* Conned Area**

Inside

Combustion Air

Outside

Combustion Air Outside Combustion Air

1 Sq. In./1000

Btu/Hr.

(Fig. #3)

1 Sq. In./5000

Btu/Hr.

(Fig. #4)

Vertical Ducts

1 Sq. In./4000

BTU/Hr.

Horizontal Ducts

1 Sq. In./2000

BTU/Hr.

50 100 10 13 25

75 100 15 19 38

100 100 20 25 50

125 125 25 32 63

150 150 30 38 75

175 175 35 44 88

200 200 40 50 100

250 250 50 63 125

300 300 60 75 150

* 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)

** 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)

Air openings to combustion area must not be obstructed. By following the instructions below,

adequate combustion air can be maintained.

WARNING

Ventilation of the boiler room must be adequate to provide

sufcient air to properly support combustion per the latest

revision of the National Fuel Gas Code, ANSI Z223.1.

Figure #1

CHIMNEY OR

TYPE B VENT PIPE

When a boiler is located in an unconned space in a

building or conventional construction frame, masonry or

metal building, inltration normally is adequate to provide

air for combustion and ventilation. However, if the equip-

ment is located in a building of tight construction (See the

National Fuel Gas Code, ANSI Z223.1 latest revision), the

boiler area should be considered as a conned space.

In this case air for combustion and ventilation shall be

provided according to Step 5. If there is any doubt, install

air supply provisions in accordance with the latest revision

of the National Fuel Gas Code.

When a boiler is installed in an unconned space in a

building of tight construction, air for combustion and ven-

tilation 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 5000 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.

When air for combustion and ventilation is from inside

buildings, the conned 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 1000 Btu per hour of the total input

rating of all appliances in the enclosed space, but must

not be less than 100 square inches. These openings must

freely communicate directly with other spaces of sufcient

volume so that the combined volume of all spaces meets

the criteria for an unconned space. (Figure #1)

When the boiler is installed in a conned space and all air

is provided from the outdoors the conned 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.

When installing two openings, one must commence with-A.

in 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.

VENTILATION AND COMBUSTION AIR

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 equip-

ment in the enclosure. (Figure #2)

Figure #2

CHIMNEY OR

TYPE B VENT

PIPE

When communicating with the outdoors by means of

vertical ducts, each opening shall have a minimum free

area of 1 square inch per 4,000 Btu per hour of total input

rating of all appliances in the enclosed space. (Figure #3)

Figure #3

(DUCT ENDS 1 FT.

ABOVE THE FLOOR)

CHIMNEY OR

TYPE B VENT

PIPE

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 en-

closed space. (Figure #4)

Figure #4

CHIMNEY OR

TYPE B VENT

PIPE

One permanent opening, commencing within 12 inches A.

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 verti-

cal 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 the sum of the areas of all vent connec-

tors in the conned space.

In calculating free area using louvers, grilles or screens

for the above, consideration shall be given to their block-

ing 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 specied. If the design

and free area is not known, it may 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 xed in the open position or interlocked with the

boiler so they are opened automatically during the boiler

operation.

IMPORTANT: Circulators in the following illustrations are mounted on the system supply side, but

mounting on the system return side is also acceptable practice.

CONNECTING SUPPLY & RETURN PIPING

EXPANSION

TANK

CHECK

VALVE

FEED

WATER

RETURN PIPING

FROM HEATING

AND COOLING

ELEMENT

WATER

CHILLER

SUPPLY PIPING

TO HEATING

AND COOLING

ELEMENT

CIRCULATOR

PRESSURE

REDUCING

VALVE

PROPER

BACKFLOW

PROTECTION

DEVICE

GATE

VALVE

PURGE

VALVE

Figure #5

Connect supply and return piping as suggested in Figure

#5 when the boiler is used in connection with refrigerated

systems.

The chilled medium MUST BE PIPED IN PARALLEL A.

with the boiler.

Use appropriate valves to prevent the chilled medium B.

from entering the heating boiler.

- During heating cycle open valves A and B, close

valves C and D.

- During cooling cycle, open valves C and D, close

valves A and B.

Maintain a minimum clearance of one inch to hot water C.

pipes.

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 sup-

plied with ow control valves or other automatic means

to prevent gravity circulation of the boiler water during the

cooling cycle.

Hot water boilers installed above radiation level must be

provided with a low water cut-off device.

When a boiler is connected to a heating system that

utilizes multiple zoned circulators, each circulator must

be supplied with a ow control valve to prevent gravity

circulation.

Hot water boilers and system must be lled with water

and maintained to a minimum pressure of 12 pounds per

square inch.

CONNECTING SUPPLY AND RETURN PIPING

BOILER

WATER INLET

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM FROM SYSTEM

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE

3 WAY MIXING

VALVE

AIR SEPARATOR

HOSE BIB

EXPANSION

TANK

BOILER ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM FROM SYSTEM

V2V1

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE AIR SEPARATOR

ZONE VALVE

EXPANSION

TANK

WATER INLET

SYSTEM

CIRCULATOR

BYPASS PIPING -

AUTOMATIC MIXING VALVE

BYPASS PIPING -

FIXED LOW TEMP ONLY

Figure #6

Bypass piping is an option which gives the ability to adjust

the supply boiler water temperature to t the system or

the condition of the installation. This method of piping,

however, is not typically required for baseboard heat-

ing systems. Typical installations where bypass piping is

used are as follows:

This method is used to protect boilers from condensation A.

forming due to low temperature return water. Generally

noticed in large converted gravity systems or other large

water volume systems. (Figure #6)

These methods are used to protect systems using radi-B.

ant panels and the material they are encased in from

high temperature supply water from the boiler and pro-

tect the boiler from condensation.

NOTE#1: When using bypass piping, adjust

valves V1 & V2 until desired system temperature

is obtained.

NOTE#2: Bypass loop must be same size piping

as the supply and return piping.

7. Installation using circulators and zone valves are shown

in Figures #7-#10. For further piping information refer

to the I=B=R Installation and Piping Guide.

ZONE 3

ZONE 2

ZONE 1 (PRIORITY ZONE)

BOILER

ZONE 4

DHW CIRCULATOR

WATER INLET

CIRC 2

CIRC 3

CIRC 4

CIRCULATOR

SHUT-OFF

VA LV E

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE AIR SEPARATOR

ZONE VALVE HOSE BIB FLOW CONTROL

VA LV E

EXPANSION

TANK

BOILER

DHW

CIRCULATOR

CH CIRCULATOR

PRIORITY ZONE

CIRCULATOR

EXPANSION

TANK

WATER INLET

FLOW CONTROL

VAV L E SHUT-OFF

VA LV E

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE

AIR SEPARATOR

ZONE VALVE

HOSE BIB

SINGLE ZONE SYSTEM WITH

DHW PRIORITY

MULTIZONE SYSTEM WITH CIRCU-

LATORS AND DHW PRIORITY

CONNECTING SUPPLY AND RETURN PIPING

Figure #7

Figure #8

ZONE 3

ZONE 2

ZONE 1 (PRIORITY ZONE)

BOILER

WATER INLET

ZONE 4

*USE FULL PORT ZONE

VALVE.

DHW

CIRCULATOR

FLOW CONTROL

VALVE

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE AIR SEPARATOR

ZONE VALVE HOSE BIB

EXPANSION

TANK

ZONE 3

ZONE 2

ZONE 1 (PRIORITY ZONE)

BOILER

WATER INLET

CH & DHW

SYSTEM

CIRCULATOR

*USE FULL PORT ZONE

VALVE. FOR OPTIMUM TANK

PERFORMANCE, CONSIDER

USING ZONE CIRCULATOR

(SEE FIGURE 5)

ZONE 4

CIRCULATOR

SHUT-OFF

VA LV E

PRESSURE

REDUCER VALVE

CHECK VALVE

EXPANSION

TANK

AIR SEPARATOR

ZONE VALVE HOSE BIB

FLOW CONTROL

VA LV E

Figure #9

Figure #10

CONNECTING SUPPLY AND RETURN PIPING

MULTIZONE SYSTEM WITH

ZONE VALVES AND DHW PRIORITY

(WITH CIRCULATOR)

MULTIZONE SYSTEM WITH

ZONE VALVES AND DHW PRIORITY

(WITH ZONE VALVE)

Ce manuel convient aux modèles suivants

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