Green Mountain GMGS, Installation, Operation & Maintenance Manual

Page 1: ...ATION OPERATION MAINTENANCE MANUAL Models GMGS075E GMGS225E GMGS112E GMGS262E GMGS150E GMGS299E GMGS187E Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240009192 REV L 04 30 2019 ...

Page 2: ...50E 6 17 5 3 7 GMGS187E 7 21 6 2 4 7 GMGS225E 7 24 7 4 5 7 GMGS262E 7 27 8 6 6 7 GMGS299E 7 30 9 5 7 7 Add 5 to height for Vent Damper Figure 1 Dimensions LEFT SIDE FRONT RIGHT SIDE Gas Line Rollout Switch Low Water Cutoff Probe Spill Switch Pressure Gauge Water Line Low Water Cutoff Glass Gauge Gas Valve 2 5 OD 2 5 OD Transformer 24 00 36 375 CG400 Pressure Limit Control 26 50 4 75 Vent Damper AS...

Page 3: ... 62 82 7 47 195 1 GMGS112E 4 Natural Gas 112 91 82 0 68 283 1 GMGS150E 5 Natural Gas 150 122 82 0 92 383 1 GMGS187E 6 Natural Gas 187 153 82 0 115 479 1 GMGS225E 7 Natural Gas 225 183 82 0 137 570 1 GMGS262E 8 Natural Gas 262 214 82 0 161 670 1 GMGS299E 9 Natural Gas 299 245 82 0 184 766 MBH 1 000 Btuh Btuh British Thermal Unit Per Hour For altitudes above 2 000 ft reduce input rate 4 for each 1 0...

Page 4: ...ing any obligation whatsoever Introduction Boiler is designed for use in closed heating systems where all steam is returned as condensate and make up water is minimal Boiler is not designed for or intended for use in open systems using 100 make up water Prior to Installation Verify correct boiler for type of gas being used natural or propane See Rating Plate Verify boiler size and dimensions See F...

Page 5: ...ving jurisdiction installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Controls can be added to make this boiler CSD 1 compliant Check with your local codes for requirements Requirements for Commonwealth of Massachusetts Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited ...

Page 6: ...mperature for clothes washing dish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never leave them unattended in bathtub or shower Never allow small children to use a hot water tap or draw their own bath If anyone using hot water in the building fits the abo...

Page 7: ...r normal conditions of use Boiler location should not interfere with proper circulation of air Introduce outside air if normal infiltration does not provide necessary air Fresh Air for Combustion on page 12 6 Notify owner to keep air passages free of obstruction Ventilating and combustion air must enter boiler room without restrictions 7 Install boiler so automatic gas ignition system components a...

Page 8: ...educing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing Allow complete drainage of valve and discharge line Install safety valve with spindle in vertical position Do not install shutoff valve between boiler and safety valve Install union if used cl...

Page 9: ...nd header shall be 2 pipe size 10 Equalizer line shall be minimum 1 pipe size 11 The near boiler piping shall include a 2 tee with a plug located on the supply line as shown for skimming i e surface blowdown 12 The near boiler piping shall include a 1 1 2 ball valve in the return piping as shown for bottom blowdown and draining 13 For gravity return systems the bottom of the lowest steam carrying ...

Page 10: ...10 Figure 3 Recommended Near Boiler Piping Using One Supply Tapping 3 4 Section Sizes SYSTEM PIPING 2 1 2 TEE WITH PLUG FOR SKIMMING PN 240009192 Rev L 04 30 2019 ...

Page 11: ... CLOSE FOR COOLING VALVES C D CLOSE FOR HEATING OPEN FOR COOLING Figure 4 Recommended Near Boiler Piping Using Two Supply Tappings 5 and 9 Sections Figure 5 Chilled Water Piping 2 1 2 TEE WITH PLUG FOR SKIMMING 28 MIN DIMENSION A PN 240009192 Rev L 04 30 2019 ...

Page 12: ...CH greater than 0 60 Room volume shall be greater than 21 cubic feet divided by ACH air changes per hour x Total Input Mbh D Refer to National Fuel Gas Code for opening requirements between connected indoor spaces All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors A Two Permanent Opening Method Provide opening commencing within 12 inches of top and second ...

Page 13: ... as short as possible but not longer than 3 4 the chimney height HT Figure 6 page 14 Vent Pipe Fasten sections of vent pipe with 3 sheet metal screws at each joint to make piping rigid Support horizontal portions of vent system to prevent sagging Use stovepipe wires or metal strapping every 5 to support pipe from above Vent pipe through crawl space use double wall vent pipe Vent pipe passing throu...

Page 14: ...any other gas burning appliance to their previous conditions of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 When re sizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Ch...

Page 15: ...bleshooting guide refer to Appendix A of this manual and literature packaged with vent damper Horizontal Installation To Boiler Vent Damper To Chimney NO NO YES YES Flow Install vent damper with actuator to sides of vent only Do not mount above or below vent To Chimney Flow Vent Damper To Boiler Actuator may be installer in any position Figure 8 Alternate Vent Damper Installation Do Not Install He...

Page 16: ...essive vibrations and prevent strain on gas connection Gas valve will not support piping weight Use thread joint compound pipe dope suitable for natural and liquefied petroleum gas Install field sourced manual main shutoff valve ground joint union and sediment trap upstream of gas valve See Figure 10 DANGER Fire Hazard Do not use matches candles open flames or other methods providing ignition sour...

Page 17: ... wires are black One wire is located on secondary of 24 volt transformer second wire is located on pressure limit control F Boilers with CG400 probe type low water cut off one wire is green and is located on terminal P2 of CG400 second wire is black and located on pressure limit control VENT DAMPER Boiler is equipped with factory wired 4 pin molex harness that plugs into 4 pin molex receptacle ins...

Page 18: ...ly and turn clockwise to OFF Do not force For Your Safety Read Before Operating CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fire department WARNING If you do no...

Page 19: ...e of boiler Determine water level when boiler is off and cold when all water in the system is inside the boiler and return piping below water line and everything above water line is air no steam When boiler is making steam water level drops two to three inches below normal water line WARNING Burn Hazard Never run water into a hot empty boiler Failure to follow these instructions could result in de...

Page 20: ... softer blue outer mantel with no yellow Remain still when observing main burner flames Check main burner orifices burner throat and flame ports for dust and lint obstruction if flame appearance is not correct Remove rollout shield if necessary to observe main burner flames Replace rollout shield after observation Gas Valve Safety Shutdown Test 1 Test ignition system safety shutoff device after pl...

Page 21: ...rn thermostat to call for heat C Gas valve opens for approximately 10 seconds time delay on probe type LWCO gas valve will close and red indicator illuminates on LWCO D When water is restored it waits 30 seconds before reactivating burner circuit Boiler Equipped With Optional WF 2U 24 Water Feeder E Continue thermostat call for heat after low water cut off recognizes low water condition F One minu...

Page 22: ...onnection from boiler drain valve to safe discharge point outside Shut off gas burners open drain valve allow all of water in boiler to drain out Close drain valve Allow boiler to cool slowly refill boiler to water line Repeat this step as many times as necessary until blow down water is clear 7 Following final blow down allow boiler to cool Add fresh water slowly up to normal water line Start bur...

Page 23: ...cover 9 Reassemble all parts 10 Check tightness of pilot connections and condition of burner flames after reassembly See Figures 14 and 15 Boiler Water Treatment Other Than Cleaners In steam systems where system is tight free from leaks and all steam is returned to boiler as condensate amount of make up water is small Water treatment is generally not required In steam systems with less than 90 of ...

Page 24: ...ut switch blown Have your service technician check heat exchanger for blockage Chimney flue is blocked Spill switch contacts open requiring manual reset of spill switch Have your service technician check and correct chimney problem Vent damper not operating Consult troubleshooting guide packaged with vent damper IF BURNER IS NOISY Gas input amount is incorrect Contact your service technician IF WA...

Page 25: ...st be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent Figure 16 Wiring Diagrams For Boilers With CG400 Probe Type Low Water Cut Off Shown CG400 PS802 CG400 N 2 H 1 C P1 W P2 B A Terminals PS802 To CG400 Cross Reference PN 240009192 Rev L 04 30 2019 ...

Page 26: ...inal wire as supplied with this appliance must be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent Figure 17 Wiring Diagrams For Boilers With 67D 1 Float Type Low Water Cut Off PN 240009192 Rev L 04 30 2019 ...

Page 27: ...4 water feeder maybe used with either of the low water cutoffs listed Water feeder maintains safe minimum water level Keeps boiler running by compensating for minor evaporative steam leaks and prevents freeze ups if homeowners are away and return line leaks McDonnell and Miller Model 101 water feeders may be used however water feed rates are too high and need to be regulated or throttled and wirin...

Page 28: ...volts should be present i IF NOT source of the problem is not in damper check line voltage and 24 volt supply ii If 24 volts is present across brown and black continue to step iii iii Reconnect thermostat wires and turn up heat setting iv Check voltage across black and orange wires in Molex plug 24 volts AC should be present IF NOT source problem is not the damper If 24 volts is present continue o...

Page 29: ...nded Solution NO POWER Between 4 1 1 Off on limit 120VAC 2 Bad transformer 3 Loose or broken connections 4 Blown fuse or circuit breaker 5 Disconnect switch off 6 Harness not plugged into receptacle 1 turn limit on 2 Replace transformer 3 Tighten repair or replace connection 4 Replace fuse or reset circuit breaker 5 Turn switch on 6 Plug harness in NO POWER Between 4 2 POWER Between 4 1 When calli...

Page 30: ...on 2 Restore to damper pipe to round verify not binding 3 Correct the condition Damper Rotates Continuously 1 Defective damper motor assembly 1 Replace damper motor assembly Note For troubleshooting only Verify damper is in open position Use service switch to keep damper in open position Place jumper between 2 3 If appliance fires remove jumper and plug receptacle back into damper controller plug ...

Page 31: ... 42500817 42500818 42500819AD 13 Jacket Front Panel 42500811 42500804 42500805 42500806AD 42500807 42500808 42500809AD 14 Tie Rod Nut 14605001 14605002 14605051 14605053 14605055 14605007 14605009 15 Boiler Section Left 41000013 16 Boiler Section Middle 41500015 17 Jacket Top Panel 109006276AD 109006277AD 109006278AD 109006279AD 109006280AD 109006281AD 1090062821AD 18 Draft Diverter 42500673 42500...

Page 32: ...4695301 4 Gas Manifold 14616033 14616034 14616035 14616013 14616014 14616015 14616016 5 Main Burner Orifice 14615031 14615031 14615031 14615035 14615035 14615035 14615035 6 Main Burner Regular 14615532 6A Main Burner Pilot Mount 14615531 7 Pilot Burner 240011102 N S Rollout Shield 42500933 42500934 42500935 42500936 42500937 42500938 42500939 Quantitiy is 1 unless otherwise noted Requires 1 less t...

Page 33: ... PART NO PART NO PART NO PART NO PART NO PART NO CONVERSION KITS NATURAL GAS TO PROPANE 43300723 43300724 43300725 43300726 43300727 43300728 43300729 CONVERSION KITS PROPANE TO NATURAL GAS 43300632 43300632 43300633 43300634 43300635 43300636 43300637 NATURAL GAS AND PROPANE CONVERSION KITS PN 240009192 Rev L 04 30 2019 ...

Page 34: ...ith probe 43300522 9B Probe only for Hydrolevel Cycle Guard 240010925 10 Intermittent Pilot Control 14662070 11 NPT x 4 Nipple PF 033 02 12 x x Brass Tee PS 802 only 14693051 13 Brass Coupling PS 802 only 14693052 14 x 3 Brass Nipple PS 802 only 14607024 N S Drain Valve 240009323 N S WF 2U 24 Water Feeder Optional 1630001 N S Rollout Switch 14629002 N S Spill Switch 36TX16 6282 280F 1500009 N S 5 ...

Page 35: ...35 Date Service Performed Company Name Tech Initials Company Address Phone PN 240009192 Rev L 04 30 2019 ...

Page 36: ...All specifications subject to change without notice 2018 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com BDR THERMEA GROUP ...