ECR Olsen OMGB50 Instructions générales
P/N 37615101, Rev. B [07/08]
ECR International, LTD
P.O. Box 900 Wallaceburg, ON N8A5E5
R
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
2
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
IMPORTANT: Read the following instruc-
tions COMPLETELY before installing!!
TABLE OF CONTENTS
C.S.A. Certied
For Natural Gas Or Propane
Tested For 100 LBS.
ASME
Working Pressure
H
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 qualied 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. Modication, substitution or elimination of fac-
tory equipped, supplied or specied 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 qualied 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 dened 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 Modication ................................. 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
3
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
13
⁄
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
o
No.
of
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 certied 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.
4
Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage.
INSTALLATION PROCEDURE
The installation must conform to the requirements of the
1.
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
2.
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 classied as a Category 1 and the
3.
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
4.
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
5.
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
6.
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
7.
and cleaning.
When installed in a utility room, the door should be wide
8.
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
9.
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 denition 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)
3"
4"
BOILER
18"
9"
WARNING
!
5
VENTILATION & COMBUSTION AIR
COMBUSTION AIR REQUIREMENTS
(Minimum Square Inches Requirement)
Model
No.
Unconned Area* Conned 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
1.
sufcient 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 unconned space in a
2.
building or conventional construction frame, masonry or
metal building, inltration 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 conned 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 unconned space in a
3.
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
4.
buildings, the conned 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 sufcient
volume so that the combined volume of all spaces meets
the criteria for an unconned space. (Figure #1)
When the boiler is installed in a conned space and all air
5.
is provided from the outdoors the conned 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.
6
VENTILATION AND COMBUSTION AIR
When directly communicating with the outdoors, each
1.
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
2.
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
3.
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 conned space.
In calculating free area using louvers, grilles or screens
4.
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 specied. 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.
7
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
B
D
FEED
WATER
C
RETURN PIPING
FROM HEATING
AND COOLING
ELEMENT
WATER
CHILLER
SUPPLY PIPING
TO HEATING
AND COOLING
ELEMENT
CIRCULATOR
A
PRESSURE
REDUCING
VALVE
PROPER
BACKFLOW
PROTECTION
DEVICE
GATE
VALVE
PURGE
VALVE
Figure #5
Connect supply and return piping as suggested in Figure
1.
#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
2.
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
3.
provided with a low water cut-off device.
When a boiler is connected to a heating system that
4.
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
5.
and maintained to a minimum pressure of 12 pounds per
square inch.
8
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
6.
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.
9
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
10
ZONE 3
ZONE 2
ZONE 1 (PRIORITY ZONE)
BOILER
WATER INLET
ZONE 4
*USE FULL PORT ZONE
VALVE.
DHW
CIRCULATOR
CH
CIRCULATOR
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
8
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