INSTALLATION AND OPERATION MANUAL GAS BOILERS MODELS: CG214 (E) CG314 (E) CG414 (E) CG220 (E) CG320 (E) CG325 (E) southbend A MIDDLEBY COMPANY 1100 Old Honeycutt Road Fuquay-Varina, NC 27526 (919) 552-9161 FAX (919) 552-9798 (800) 348-2558
IMPORTANT NOTES FOR INSTALLATION AND OPERATION WARNING FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPOURS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THAT THE OPERATOR OF THIS APPLIANCE SMELLS GAS MUST BE POSTED IN A PROMINENT LOCATION. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING THE LOCAL GAS SUPPLIER. IMPORTANT DO NOT ATTEMPT TO OPERATE THIS UNIT IN THE EVENT OF POWER FAILURE. ADEQUATE CLEARANCES MUST BE MAINTAINED FOR SAFE AND PROPER OPERATION. THE APPLIANCE AREA MUST BE KEPT FREE AND CLEAR OF COMBUSTIBLES. DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR. WARNING IMPROPER INSTALLATION. ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION. OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT CONTACT THE FACTORY. THE FACTORY REPRESENTATIVE OR A LOCAL SERVICE COMPANY TO PERFORM MAINTENANCE AND REPAIRS SHOULD THE APPLIANCE MALFUNCTION. REFER TO WARRANTY TERMS. -1-
IMPORTANT NOTES FOR INSTALLATION AND OPERATION WARNING: IN THE EVENT OF POWER FAILURE. NO ATTEMPT SHOULD BE MADE TO OPERATE THE APPLIANCE DURING POWER FAILURE. WARNING: IN THE EVENT OF MAIN BURNER IGNITION FAILURE. A 5 MINUTE PURGE PERIOD MUST BE OBSERVED PRIOR TO RE-ESTABLISHING IGNITION SOURCE. WARNING: IN THE EVENT A GAS ODOR IS DETECTED. SHUT DOWN EQUIPMENT AT THE MAIN SHUTOFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE- WARNING DISCONNECT UNIT FROM POWER SUPPLY BEFORE CLEANING OR SERVICING APPLIANCE- WATER QUALITY STATEMENT WATER QUALITY IS THE MAJOR FACTOR AFFECTING WE PERFORMANCE OF YOUR APPLIANCE. IF YOU UNSURE OF WATER QUALITY. CONSULT A LOCAL WATER TREATMENT SPECIALIST AND HAVE WE WATER ANNALYZED. VOW WATER SUPPLY MUST BE TOTAL DISSOLVED SOLIDS LESS THAN 60 PPM TOTAL ALKALINITY LESS THAN 20 PPM SlLICA LESS THAN 13 PPM CHLORINE LESS THAN 30 PPM ph FACTOR 7.0-8.5 WATER WHICH FAILS TO MEET THESE STANDARDS SHOULD BE TREATED BY INSTALLATION OF A WATER CONDITIONER FAILURE OR MALFUNCTION OF THIS APPLIANCE DUE TO POOR WATER QUALITY IS HOT COVERED UNDER WARRANTY. INTENDED FOR COMMERCIAL USE ONLY NOT FOR HOUSEHOLD USE. - 2 -
INSTALLATION AND OPERATION It is recommended that this manual be read thoroughly and that all instructions be followed carefully. This manual should retained for future reference. INDEX DESCRIPTION PAGE IMPORTANT MOTES 1-2 INDEX 3 DIMENSIONS AND SERVICE CONNECTIONS 4 INSTALLATION INSTRUCTIONS 5 OPERATION INSTRUCTIONS 6 PERIODIC MAINTENANCE 7 TROUBLESHOOTING 8 DESCALING INSTRUCTIONS 9 ELECTRONIC IGNITION 10 TROUBLESHOOTING ELECTRONIC IGNITION 11 IMPORTANT NOTES FOR ELECTRONIC IGNITION ELECTRONIC IGNITION 12 WIRING DIAGRAM ELECTRONIC IGNITION 13
DIMENSIONS & SERVICE CONNECTIONS SERVICE CONNECTIONS CW Cold Water. 3/8 copper tube EC Electric Connection: 1/2" (13 mm) conduit connection to controls. 2 Amps per compartment. 120-60-1 or 220-50-1. DR Drain: 2" (51mm) IPS piped to open floor drain. No Solid Connection. ST Steam Take-off Connection: 3/4" (19 mm) optional to operate adjacent equipment. WD Wiring Diagram Location GC Gas Connection: 3/4" (19 mm) IPS. -4-
INSTALLATION INSTRUCTIONS Appliance location should have an exhaust system provided directly above the appliance to exhaust combustion generated by the Gas Boiler. FOR USE ON NONCOMBUSTIBLE FLOORS. MINIMUM CLEARANCE FROM COMBUSTIBLE AND NONCOMBUSTIBLE CONSTRUCTION, 3" ON SIDES AND FROM THE BACK. Ascertain that adequate clearance on right side of appliance is available for servicing components contained in Steamer Control Enclosure. AN OPEN GAP FLOOR DRAIN IS REQUIRES IMMEDIATELY BELOW THE APPLIANCE DRAIN. Set Appliance is place and level using spirit level. SERVICE CONNECTIONS Make service connections as indicated in Legend (Page 4). GAS INSTALLATION TO CONFORM TO LOCAL CODES OR IN THE ABSENCE 0. LOCAL CODES TO NATIONAL FUEL GAS CODE - ANSI Z223.1 - LATEST EDITION IN CANADA INSTALLATION IN ACCORDANCE WITH CAN/CGA B 149.1 OR.2 OR CURRENT CODE. 1. The appliance and it's individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.45 kpa). 2. The appliance must be isolated from the gas supply piping system by closing it's individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.45 kpa). ELECTRICAL GROUNDING MUST BE PROVIDED IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES WITH THE NATIONAL ELECTRIC CODE. ANSI NFPA 70 - LATEST EDITION IN CANADA INSTALLATION IN ACCORDANCE WITH C.S.A. C22.1 CANADIAN ELECTRIC CODE. PART 1.
OPERATION INSTRUCTIONS Open manual gas shut off supply valve and if the appliance has a manual Blow Down Valve, close it. Open cabinet door and turn ON power switch located on left side. Pilot light will come on (green) and water will begin to enter Boiler and required water level will be reached in about 3 minutes. Observe water gauge glass to verify. The Dial on the gas combination control valve has 3 positions (ON-PILOT-OFF) for manual gas control of main burners and pilot. Turn DIAL on gas combination valve to PILOT. Depress Dial and light Pilot Burner located on centre main burner of Boiler. Maintain Dial in depressed position for about 30 seconds and release. Observe the Pilot Burner flame stays on. If at any time the flame should become extinguished, a 5 minute period for complete shut off Gas Supply is required before relighting. Turn DIAL to ON and burners will ignite. Steam generation will now commence and be completed in about 15 minutes. Observe that Boiler Pressure Gauge indicates steam pressure in range of 10-12 psi. DAILY SHUTDOWN PROCEDURE Turn OFF power switch. Observe that Burners go off and if the appliance is equipped with Automatic Blow Down Solenoid Valve the Boiler contents water and steam will be blown out and exhausted through the appliance Drain. The Cold Water Solenoid Valve will now be activated as well. If the appliance is equipped with a manual Blow Down Valve, open it. The Gas Boiler is designed to ASME Code and approved as a steam heating boiler restricted to operate at pressures not to exceed 15 psi. DAILY STARTING PROCEDURE 1. If Boiler has a Manual Blowdown drain valve, close it. 2. Examine that pilot burner flame is on. If flame is out, a 5 minute period of complete shut off gas supply is required before relighting. 3. Turn power switch ON. COMPLETE SHUT DOWN If the appliance is not intended to be operational for a length period of time then shut it down completely. 1. If Boiler has a Manual Blowdown drain valve open it. 2. Shut OFF all power, gas and water supplies to appliance.
PERIODIC MAINTENANCE NOTICE: As a safety precaution, disconnect the power supply during cleaning or servicing. CLEANING 1. Keep exposed cleanable areas of unit clean at all times. 2. If water in water gauge glass is not clear and appears murky, this indicates poor water quality and will cause control failures. 3. Safety Valve should be tripped during operation once a week to assure that it functions properly. 4. If burner equipped with pressure regulator twice a year remove hex plug located at bottom of regulator remove and clean strainer. 5. Clean around burner air mixer and orifice if lint has accumulated. 6. Visually assure carry over ports are unobstructed. 7. Rinse entire unit and dry. DO NOT GET WATER in- electrical box or any electrical component.
TROUBLESHOOTING BURNER DOES NOT COME ON 1. Gas supply to unit is "OFF". 2. Manual shut off valve is "OFF". 3. Pilot is "OUT". 4. Power Supply is "OFF". BURNERS PRODUCE CARBON DEPOSITS 1. Wrong size orifices 2. Burner air not adjusted properly. 3. Wrong gas supply. 4. Incorrect pressure at supply. SAFETY RELIEF VALVE BLOWS 1. Defective Valve 2. Pressure too high, pressure switch require adjustment. (lower) or may be defective. WATER MOT BEING SUPPLIED TO BOILER 1. Water supply is "OFF". 2. Defective water fill Solenoid Valve. 3. Water level control clogged or defective, unable to operate fill valve. 4. Check that drain valve is closed. 5. Supply water pressure too low. ADJUSTMENTS WARNING: AT LEAST TWICE A YEAR HAVE AN AUTHORIZED SERVICE PERSON CLEAN AND ADJUST THE UNIT FOR MAXIMUM PERFORMANCE -8-
GAS BOILER DESCALING INSTRUCTIONS It is recommended that the boiler should be checked every 90 120 day's for scale build up. Regular maintenance should Be carried out at this time. If the boiler has been descaled a new Anode should be replaced in the boiler to help extend its life. 1. With Boiler empty, close manual blowdown valve. If appliance is equipped with Automatic Blowdown, turn water supply OFF to appliance. Turn power switch ON, this will energize and close Blowdown valve. 2. Remove 3/4" pipe plug from fitting on left front of boiler. 3. Insert appropriate hose or tube through fitting and pour in (1/2) half gallon (U.S) of CLR Descaling solution. Or use the Optional Deliming assembly DPA-1 available from your dealer. 4. Replace 3/4" pipe plug securely. 5. Open water supply to appliance allowing water to fill boiler to required level. 6. Let appliance cycle, allow two hours for descaling and cleaning. DO NOT TURN STEAM ON. 7. Open both the blowdown and low water level control valves for complete drainage and close both valves. Appliance equipped with Automatic Blowdown, turn OFF power switch and open low water control valve, this will allow complete drainage. Once drained close water level control valve. 8. Turn appliance switch ON. When boiler is completely filled, turn power switch OFF, this will rinse and drain boiler. Appliance with Manual blowdown valve must be opened to drain. 9. Complete Step 8 twice to assure boiler is completely rinsed. 10. Appliance is now ready for use. -9-
ELECTRONIC IGNITION LIGHTING INSTRUCTION Open manual gas shut off supply valve and if appliance has a manual blow down valve, close it. Open cabinet door and turn on power switch located on left side. Pilot light will come on and water will begin to enter boiler. required water level will be reached in approximately 3 minutes. Observe water gauge glass to verify. The Dial on the gas combination control valve has 2 positions, OFF - prevents pilot and main burners gas flow. ON - permits gas to flow into the control body. Under control of power switch and intermittent pilot module, pilot and main burner gas flow is permitted. NOTE: Units are shipped with the gas control knob in the "ON" position. Gas control knob if rotated counter-clockwise is ON. To turn "OFF" turn knob clockwise. With power switch "ON" and water entering the boiler* gas will flow to pilot, spark will begin in approximately 2-3 seconds. If the pilot fails to light in 90 seconds the module will provide 100% lockout. Should this occur wait 5 minutes then turn power switch off for one minute. Turn power switch on. Once pilot is lit and the required water level has been reached the main burners will ignite. Burners will cycle to meet the steam pressure required. Daily Shut Down Procedure 1. Turn power switch OFF. 2. If unit has manual blow down valve - open it. Complete Shut Down If appliance is not intended to be operated for a lengthy period of time - shut down completely. 1. Turn off all power, gas and water supplies to appliance. 2. If unit has manual blow down valve - open it. -10-
TROUBLESHOOTING Pilot does not light 1. Gas supply to unit is OFF. 2. Power supply is OFF. 3. Gas control knob is OFF. 4. Dirty or loose wire connection to module - clean and/or tighten. 5. Ignitor cable, shorting out - check that not in contact with metal or damaged; may require replacement. 6. Defective control or module. 7. Unit goes into 100% lock out - turn off and try again in 5 minutes. 8. Dirty flame sensor - clean with emery cloth. 9. Cracked ceramic insulator - replace pilot burner/ ignitor sensor. 10. Too much draft. Burner does not come on 1. Pilot out. 2. Pilot may require flame adjustment. 3. Water level has not been reached in boiler. Check water supply is on, check water level control. 4. If water at proper level check relay, which energizes pressure switch and gas control. 5. Pressure switch may need to be replaced if relay is operating. 6. Gas control may also require replacement if energized but not operating.
WARNING Do not force the gas control knob. Use only your hand to turn the gas control knob. Never use any tool. If the gas control knob will not operate by hand the gas control should be replaced by a qualified service technician. WARNING Do not disassemble the gas control; it contains no replaceable components. Attempted disassembly or repair may damage the gas control. CAUTION Do not apply a jumper across or short the valve coil terminals. Doing so may damage the heat anticipator or electronic module. -12-