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Boiler Manual

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1. closes until supply lt q 1 19 A COMPLETING THE INSTALLATION 1 20 10 11 12 13 INSTALLATION AND OPERATING INSTRUCTIONS 7 START UP PROCEDURES Confirm that all water gas and electricity are turned off Inspect the boiler combustion chamber for foreign objects and remove if present Check physical condition of burners and pilot Make certain that there are no unusual bends or perforations in the burners or pilot Replace components if necessary Verify that water piping venting gas piping and electrical wiring and components are installed properly Refer back to previous sections of these instructions as well as equipment manufacturer s instructions as necessary Fill the boiler and system with water making certain to vent all air from all points in the system To check water level in the system open and close each vent in the system Water should exit from each vent when it is opened The pressure reducing valve on the fill line will typically allow the system to be filled and pressurized to 12 psi 83 kPa Consult the valve and expansion tank manufacturer for more specific information Check joints and fittings throughout the system for leaks If leaks are found drain the system and repair as required Connect a manometer to the gas valve on the valve outlet gas manifold Use the 1 8 NPT tapping provided Confirm that the gas supply pressure to the boiler is above
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3. ANSI Z223 1 NFPA 54 sections 7 2 7 3 or 7 4 of 5 Insert vent pipe into but not beyond the inside wall CAN CSA B149 1 Natural Gas and Propane of the chimney flue Installation Code or applicable provisions of the local building codes 6 Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical 2 Inspect the existing chimney and lining for structural draft systems operating under positive pressure soundness corrosion and perforations Repair as necessary p p 7 Support horizontal portions of the venting system to prevent sagging by use of metal strapping or 3 Install vent pipe to slope upward at least 1 4 per equivalent means Locate supports at no more than lineal foot 21 mm per meter between the draft 4 foot 1 2 meter intervals hood outlet and the chimney Fournir un support toute portion horizontale du Installer le tuyau d vent avec une pente ascendante syst me d vacuation l aide de courroies de m tal minimum de 21 mm au m tre 1 4 po au pied la ou une m thode quivalente afin de l emp cher de sortie du coupe tirage et la chemin e s affaisser Placer les supports des intervalles ne d passant pas cent vingt deux 122 centim tres 4 po ou en suivant les recommandations d installation du fabricant SLOPE UP BIET VENT TO PER Les CHIMNEY 21mm PER METER VENT DAMPER DRAFT SUPPORT HOOD AS REQUIRED RELIEF OPENING OJ OX DRAFT HOOD
4. SERVICE VALVE JACKET G J UNION SEDIMENT TRAP ae LINE Figure 5 1 Gas Connection to Boiler 8 Disconnect the boiler and its individual shut off valve from the gas supply piping system during any pressure testing of that system at test pressure in excess of 1 2 psig 3 5 kPa CAUTION Do not subject the gas valve to more than 1 2 psi 3 5 kPa pressure Doing so may damage the valve Isolate the boiler from the gas supply piping system by closing its individual service valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1 2 psig 3 5 kPa 9 Minimum permissible supply pressure for purposes of input adjustment Natural Gas 5 0 WC 1 2 kPa LP Gas 11 0 WC 2 7 kPa Maximum permissible supply pressure to the boiler Natural Gas 13 5 WC 3 5 kPa LP Gas 13 5 WC 3 5 kPa INSTALLATION AND OPERATING INSTRUCTIONS Table 5 1 Natural Gas Input Cubic Feet Hour Cubic Meters Hour Table 5 2 LP Gas Input Cubic Feet Hour Cubic Meters Hour Table 5 4 Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour cubic meter per hour with a pressure drop of 0 3 inches of water 75 Pa and specific gravity of 0 60 No al lowance for an ordinary number of fittings is required Pipe Length in Feet Me ters 10 3 0 278 7 9 520
5. NOTICE Indicates special attention is needed but not directly related to potential personal injury or property damage INSTALLATION AND OPERATING INSTRUCTIONS 1 PREINSTALLATION Read carefully study these instructions before beginning work This boiler must be installed by a qualified contractor The boiler warranty can be voided if the boiler is not installed maintained and serviced correctly NOTICE The equipment must be installed in accordance with those installation requirements of the authority having jurisdiction or in the absence of such requirements to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 IMPORTANT In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is i
6. 5 2 1 Y Y Y SYSTEM ZONE BALANCING VALVES X X X CIRCULATOR VALVES FX X eX 1 5 H A m lt a H _ CONNECT CONNECT TO CHECK TO RETURN ASS SUPPLY FROM BYPASS CITY WATER NS N SHUTOFF VALVE a EXPANSION TANK PRESSURE REGULATOR Figure 3 5 Zone Piping with Zone Valves TO SYSTEM FROM SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE 1 2 5 5 2 1 Y Y Y ZONE FLOW CIRCULATORS H H CONTROL FX X KX VALVES H HH A H CHECK VALVE CONNECT CONNECT TO N TO RETURN CITY WATER PN SUPPLY TAPPING SHUTOFF S EXPANSION TANK PRESSURE REGULATOR Figure 3 6 Zone Piping with Circulators INSTALLATION AND OPERATING INSTRUCTIONS D EXPANSION TANK F FREEZE PROTECTION For new or existing systems that must be freeze 1 Consult the tank manufacturer s instructions for protected specific information relating to tank installation Size the expansion tank for the required system volume and capacity See Table 10 2 in Section 10 for boiler VAN WARNING water content Use only inhibited propylene glycol solutions of up to 2 Expansion tanks are available with built in fill valves 50 by volume with water Ethylene glycol is toxic and check valves for reducing supply water pressure and can attack gasket
7. qua itie pour mspecter I apparet n utiliser aucun appareil t l phonique dans l immeuble et remplacer toute pi ce du syst me de r gulation du d bit gazeux toute commande de gaz ayant t Contactez imm diatement votre fournisseur de gaz immerg e partir du t l phone d un voisin Suivre les instructions donn es par votre fournisseur de gaz gt scnvesoeronctonnement ARRETEZ Lisez les consignes de s curit plus haut sur cette tiquette Si la soupage d alimentation en gaz n est pas visible R glez le thermostat ou l appareil de r glage au niveau retirez le panneau d acces le plus bas Si le bouton de commande du gaz n est pas en Coupez toute l alimentation lectrique de l appareil position OFF tournez le bouton dans le sens des NE 4 SM aiguilles d une montre O pour les mettre OFF Cetappareil est muni d un dispositif d allumage automatique de veilleuse tentez pas d allumer la Attendre cing 5 minutes pour que tout le gaz pr sent veilleuse la main puisse s chapper Sentir autour de l appareil pour d tecter toute odeur de gaz incluant pr s du sol Si vous sentez une odeur de gaz ARRETEZ Suivez les consignes de Securite apparaissant plus 6 bi sur cette tiquette Si vous ne d tectez aucune odeur Bouton de Controle du de gaz passez l tape suivante illustr en position d arr t OFF
8. EE ooo sonos D STOP Read the safety information above on this 5 If the gas valve is not visible remove control access label panel Set the thermostat or operating control to lowest If the gas control knob is not in the OFF position setting turn the knob clockwise O to OFF Donottry to light any appliance Turn off all electric power to the appliance Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Turn the gas control knob counterclockwise O to ON Gas Control Knob id shown in OFF Replace control access panel if applicable position gt r Turn on all electrical power to the appliance GAS Set thermostat or operating control to desired setting INLET If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier or cas arruiance DE Set the thermostat or operating control to lowest 4 Turn the gas control knob clockwise U to OFF setting 5 Replace control access panel if applicable Turn off all electric power to the appliance if service is to be performed If the gas valve is not
9. Figure 1 6 Air Openings All Air from Outdoors through One Opening INSTALLATION AND OPERATING INSTRUCTIONS 5 Combination Indoor and Outdoor Combustion Air If the required volume of indoor air exceeds the available indoor air volume outdoor air openings or ducts may be used to supplement the available indoor air provided a The size and location of the indoor openings comply with Subsection 3 The outdoor openings are to be located in accordance with Subsection 4 The size of the outdoor openings are to be sized as follows Vavai freq where Areg minimum area of outdoor openings Ari full size of outdoor openings calculated in accordance with Subsection 4 available indoor air volume Vavail required indoor air volume req 7 6 Engineered Installations Engineered combustion air installations shall provide an adequate supply of combustion ventilation and dilution air and shall be approved by the authority having jurisdiction 7 Mechanical Combustion Air Supply a In installations where all combustion air is provided by a mechanical air supply system the combustion air shall be supplied from the outdoors at the minimum rate of 0 35 ft min per 1000 Btu hr 0 034 m min per 1000 W of the total rated input of all appliances in the space In installations where exhaust fans are installed additional air shall be provided to replace the e
10. GD 318v9 HOSN3S YOLINOI 1 T f N lt 2 OfolQla 5 Z8NIBN 29 0 FINGOW NOILINOI d T Cl A7ddNS N mp ET AdIMLS 1 09 01 p en oe 2 A8 HOLIMS 3LIHM n Ca 5 Lys aasn4 MOVIE M E ud HITIV SNI AS Q3lddns e LO 7 18 38 OL SWALI 3S3HL monte B ZO IHM l z SYIHLO A8 ud a v J LVLSOWNSHL AvZ 3009 1 OOMT M 1 JOMLNOO LINIT NOLLYNIBWOO 0729 LN3A WV49VIQ NOILO3NNOO 18 INSTALLATION AND OPERATING INSTRUCTIONS D SEQUENCE OF OPERATION THERMOSTAT CALLS FOR HEAT B m urners extinguish and vent damper temperature is approx 15 F 8 C below limit setting Circulator continues to run VENT DAMPER OPENS CIRCULATOR STARTS GAS VALVE ENERGIZES Igniter deenergized for 5 min 4 Pilot gas off for 5 min If pilot flame not detected within 90 seconds I IGNITER ON PILOT GAS ON hese If control loses pilot PILOT FLAME DETECTED 594 IGNITER OFF ta MAIN GAS ON MAIN BURNERS ON If supply L temperature reaches limit 7 setting CALL FOR HEAT ENDS MAIN AND PILOT GAS OFF MAIN AND PILOT BURNER OFF VENT DAMPER CLOSES CIRCULATOR OFF Figure 6 4 Intermittent Ignition System Operating Sequence
11. Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in per 2000 Btu hr 22 cm per 2000 W of total rated input for all appliances in the space See Figure 1 5 Z BOILER mm 5 Air Openings All Air from Outdoors through Horizontal Ducts One Permanent Opening Method Provide one permanent opening beginning within 12 inches 305 mm of the top of the space The opening shall communicate directly with the outdoors communicate through a vertical or horizontal duct or communicate with a space that freely communicates with the outdoors The opening shall have a minimum free area of 1 in per 3000 Btu hr of total rated input for all appliances in the space and not less than the sum of the cross sectional areas of all vent connectors in the space The gas fired equipment shall have clearances of at least 1 inch 25 mm from the sides and back and 6 inches 150 mm from the front of the appliance See Figure 1 6 for this arrangement ALTERNATE d LOCATION 305mm max 12 305mm max ONE AIR OPENING Minimum Free Area Each 1 in per 3000 Btuh 22 cm per 3000 and not less than the sum of the areas of all vent connectors MINIMUM CLEARANCES 1 25mm From sides and back 6 150mm from front BOILER
12. Tournez le bouton de commande dans le sens contraire des aiguilles d une montre G pour le mettre en position de marche ON Replacez le panneau d acc s du r gulateur de d bit le cas ch ant 2 10 Remettez en marche toute l alimentation lectrique de ARRIV E l appareil q DE GAZ R glez le thermostat ou l appareil de r glage au niveau d sir Si l appareil ne se met pas en marche suivez les instructions ci dessous Couper l alimentation en gaz de l appareil et appelez votre technicien entretien ou fournisseur de gaz COUPER L ALIMENTATION EN GAZ DE L APPAREIL R glez le thermostat ou l appareil de r glage au niveau 4 Tournez le bouton de commande dans le sens des le plus bas aiguilles d une montre O pour les mettre en position z d arr t OFF Sides travaux d entretien doivent tre effectu s couper Tm i e toute l alimentation lectrique de l appareil 5 Replacez le panneau d acc s du r gulateur de d bit ae A le cas ch ant Sila soupape d alimentation en gaz n est pas visible retirez le panneau d acc s HSP VR8204 VR8304 9414 REV 0 MM AA Figure 7 4 Operating Instructions 22 B CONTROL DESCRIPTIONS INSTALLATION AND OPERATING INSTRUCTIONS See Figure 6 1 in Section 6 Electrical for locations of these devices 1 C ADJ USTMENT OF GAS PRESSURE REGULATOR 1 2 FLAME ROL
13. Operation and Maintenance Manual and User s Information Manual in an E CHECK OUT PROCEDURE accessible position near the boiler 1 After starting the boiler be certain all controls are working properly Check to be sure that the limit will shut off the boiler in the event of excessive water temperature This can be done by lowering the limit setting until the main burners shut down When proper limit function is confirmed return the dial to its previous setting 2 To check operation of the ignition system safety shut off features e Refer to Figure 7 3 Operating Instructions and Figure 6 4 Intermittent Ignition System Operating Sequence 24 INSTALLATION AND OPERATING INSTRUCTIONS 8 TROUBLESHOOTING DANGER When servicing or replacing items that communicate with the boiler water be certain that SHUT DOWN CAUSED BY PILOT OUTAGE BLOCKED VENT SHUT OFF SWITCH OR FLAME ROLL OUT SAFETY SHUT OFF SWITCH There is no pressure on the boiler In the event of a shut down caused by a pilot outage The boiler is not hot action of the blocked vent shut off switch or flame roll The power is off out safety shut off switch effecting a shut down of the ii i main burners When servicing the gas valve or pilot be certain that a Refer to the Operating Instructions in Figure 7 3 to gt The gas is oit properly turn off the gas to the boiler The electricity is off b Turn off all electric powe
14. demeurent raccord s au syst me d vacuation commun se trouvent et le reste de l immeuble Mettre en marche les s cheuses et tout autre appareil non raccord au syst me d vacuation commun Mettre en marche tous les ventilateurs aspirant tels que les hottes de cuisini re et les ventilateurs de salle de bain en les faisant fonctionner vitesse maximum Ne pas faire fonctionner les ventilateurs aspirant d t Fermer les registres de foyers Eni SERVICE chandelle ou encore la fum e d une cigarette d un a Seal any unused openings in the common venting cigare ou d une pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Apr s avoir tabli que les r sidus de combustion de chaque appareil qui demeure raccord au syst me commun sont ad quatement vacu s lorsque soumis au test d crit ci dessus remettre en place les portes fen tres portes int rieures ventilateurs aspirants registres de foyer et appareils fonctionnant au gaz Any improper operation of the common venting system should be corrected so that the installation conforms with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any p
15. 14 7 1050 29 7 1600 45 3 20 6 1 190 5 4 350 9 9 730 20 7 1100 31 1 30 9 1 152 4 3 285 8 1 590 16 7 890 25 2 40 12 2 130 3 7 245 6 9 500 14 2 760 21 5 50 15 2 115 3 3 215 6 1 440 12 5 670 19 0 60 18 3 105 3 0 195 5 5 400 11 3 610 17 3 Maximum Capacity Correction Factors for Specific Gravity other than 0 60 Specific Gravity Correction Factor Specific Gravity Correction Factor Specific Gravity Correction Factor 15 INSTALLATION AND OPERATING INSTRUCTIONS 6 ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code and local requirements NOTICE This unit when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the current edition of the National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code Part 1 CSA C22 1 Electrical Code A WIRING C CONTROLS 1 See Figure 6 1 for location of wiring and controls 1 Use Figures 6 2 and 6 3 to connect the boiler to a power supply and to connect components to the boiler 2 For proper location of controls and accessories refer to Figure 6 1 and Section 11 See the attached control sheets for specific details regarding the ins
16. Make certain that the boiler area has ample air for combustion and ventilation and that there are no obstructions to the free flow of air to and from the boiler 2 Observe general boiler conditions unusual noises vibrations etc 3 Observe operating temperature and pressure on the combination gauge located on the left side of the boiler Boiler pressure should never be higher than 5 psi 35 kPa below the rating shown on the safety relief valve 25 psig 172 kPa maximum for a 30 psig 207 kPa rating 45 psig 310 kPa maximum for a 50 psig 345 kPa rating The valve rating can be found on the top of the safety relief valve see Figure 5 for location of the safety relief valve Boiler temperature should never be higher than 250 F 121 C 4 Check for water leaks in boiler and system piping 5 Smell around the appliance area for gas If you smell gas follow the procedure listed in the Lighting O perating Instructions in Section 7 C WEEKLY WITH BOILER IN USE 1 Flush float type low water cut off if used to remove sediment from the float bowl as stated in the manufacturer s instructions D MONTHLY WITH BOILER IN USE 1 Check boiler room floor drains for proper functioning 2 Check function of the safety relief valve monthly unless specified otherwise by manufacturer by performing the following test a Check valve piping to determine that it is properly installed and supported b Check boiler opera
17. One opening is to begin within 12 inches 305 mm of the top of the space and the other is to begin within 12 inches 305 mm of the floor The openings are to communicate directly or by ducts with the outdoors or with spaces that freely communicate with the outdoors The size of the openings shall be determined as follows i Where communicating directly or through vertical ducts with the outdoors each opening shall have a minimum free area of 1 in per 4000 Btu hr 22 cm per 4000 W of total input rating for all equipment in the space See Figure 1 3 for openings directly communicating with the outdoors or Figure 1 4 for openings connected by ducts to the outdoors TWO AIR OPENINGS Minimum Free Area Each 1 in per 4000 Btuh 22 cm per 4000 W min OY 2 g Figure 1 3 Air Openings All Air Directly from Outdoors EN ETS 12 305mm max ty TWO AIR OPENINGS 3 Minimum 76mm Free Area Each min 1 in per 4000 Btuh 22 cm per 4000 W BOILER 305mm max 76 z 7 7 a 2 4 4 4 p 4 Figure 1 4 Air Openings All Air from Outdoors through Vertical Ducts max AIR OPENINGS Minimum 3 76mm Free Area Each 2 1 in per 2000 Btuh i 22 cm per 2000 W OY 353 3 3 12 305 max Figure 1 12 12 305mm
18. See Figure 1 1 for an illustration of this arrangement 2 12 305 TWO AIR OPENINGS p c4 Minimum tA gt Free Area Each 3 76mm 1 in per 1000 Btuh 2 22 cm per 1000 W T ce ba BUILDING em SPACES ON SAME STORY Must not be under negative pressure 2 3 76mm 2 min BOILER 1 12 305mm max 7 4 a a 4 Figure 1 1 Air Openings All Air from Indoors on the Same Floor b Combining spaces on different floors Provide one or more permanent openings communicating with additional spaces that have a total minimum free area of 2 per 1000 Btu hr 44 cm per 1000 W of total input rating of all equipment See Figure 1 2 for an illustration of this arrangement BUILDING SPACES ON DIFFERENT STORY Must not be under negative pressure ZRNNUZ R ONE OR MORE AIR OPENINGS Minimum Total Free Area 2 in per 1000 Btuh 44 cm per 1000 W BOILER Figure 1 2 Air Openings All Air from Indoors on Different Floors INSTALLATION AND OPERATING INSTRUCTIONS 4 Outdoor Combustion Air Outdoor combustion air is max 12 305mm 3 76mm max 12 305mm 3 76mm 7 min A VA BOILER to be provided through one or two permanent openings The minimum dimension of these air openings is 3 inches 76 mm a Two Permanent Opening Method Provide two permanent openings
19. TANK VALVE PRESSURE REGULATOR EXPANSION CHECK VALVE FETY WATER T NI FILL SHUTOFF VALVE SHUTOFF RETURN H LIEF LVE Ao 2 mo TO DRAIN SS p LE E E SS OS p e _ Figure 3 1 Supply and Return Piping INSTALLATION AND OPERATING INSTRUCTIONS 5 Install this boiler so that the gas ignition system components are protected from water dripping spraying etc during appliance operation and service circulator replacement condensate trap control replacements etc 6 If this boiler and distribution system is used in conjunction with a refrigeration system pipe the chilled medium in parallel with the boiler and install the proper valve to prevent the chilled medium from entering the boiler A drawing illustrating this hook up is provided in Figure 3 2 7 When the boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation install flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 8 If this boiler is installed above radiation level provide a low water cutoff device either as a part of the boiler or at the time of boiler installation B SAFETY RELIEF VALVE 1 Locate safety relief valve and fittings in bag assembly
20. appareil fonctionne sans arr t Au moment de retirer une chaudi re existante il est important de suivre les tapes suivantes pour chaque appareil raccord au syst me d vacuation commun qui sont en service alors que les autres appareils demeurant raccord s au syst me d vacuation commun ne sont pas system Sceller toute ouverture du syst me d vacuation commun non utilis e Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Effectuer un contr le visuel du syst me d vacuation pour v rifier la taille et la pente horizontale et s assurer qu il n existe aucun blocage ou obstruction fuite corrosion ni tout autre probl me pouvant menacer la s curit Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on any clothes dryers and any appliance not connected to common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Dans la mesure du possible fermer toutes les portes et fen tres de l immeuble ainsi que toutes les portes entre l espace dans lequel les appareils qui
21. of gas to be provided to the boiler 3 Use the value obtained above as the basis for piping sizing Size the gas piping in accordance with Table 5 4 Consult the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code for proper sizing options 4 Locate the drop pipe adjacent to but notin front of the boiler 5 Install a sediment trap See Figure 5 1 Locate a tee in the drop pipe at same elevation as the gas inlet connection to the boiler Extend the drop pipe to a pipe cap 6 Install a ground joint union ahead of the gas control assembly to permit servicing of the control Some local codes require an additional service valve when using the combination gas controls If your code requires such a valve a suggested location is shown in Figure 5 1 WARNING Use a pipe joint sealing compound that is resistant to the action of liquefied petroleum gas A non resistant compound may lose sealing ability in the presence of this gas resulting in a gas leak and fire or explosion potential 7 Check piping for leaks Use an approved gas detector a non corrosive leak detection fluid or other leak detection method If leaks are found turn off all gas flow and repair as necessary WARNING When checking for leaks do not use matches candles open flames or other methods that provide a source of ignition This can ignite a gas leak resulting in fire or explosion
22. this appliance is to be installed is unusually tight The air infiltration rate shall be determined b Known Air Infiltration Rate Method Where the air infiltration rate of a structure is known the minimum required volume of indoor air for appliances other than fan assisted and for the boiler shall be determined as follows 218 Required Volumeother ACH xor where lother Input of appliances other than fan assisted in Btu hr ACH air change per hour percent of the volume of the space exchanged per hour expressed as a decimal For fan assisted appliances calculate the required volume of air using the following equation 15 fe I fan Required Volumefan ACH 100094 Input of the fan assisted appliances in Btu hr Note These calculations are not to be used for infiltration rates greater than 0 60 ACH Indoor Air Opening Size and Location Openings connecting indoor spaces shall be sized and located as follows a Combining spaces on the same floor Provide two permanent openings communicating with additional spaces that have a minimum free area of 1 in per 1000 Btu hr 22 cm per 1000 W of the total input rating of all gas fired equipment but not less than 100 in 645 cm One opening is to begin within 12 inches 305 mm from the top of the space and the other is to begin within 12 inches 305 mm from the floor The minimum dimension of either of these openings shall be 3 inches 76 mm
23. workmanship for ten 10 years from the date of installation If upon examination by the Manufacturer the Product is shown to have a defect in material or workmanship during the warranty period the Manufacturer will repair or replace at its option that part of the Product which is shown to be defective Eleventh Year and Above The Manufacturer warrants that the cast iron sections of its residential cast iron water boilers will remain free of defects in material or workmanship under normal usage for the lifetime of the original owner at the original installation site Should any sections be found to be defective the Manufacturer will repair or replace at its option the original cast iron sections upon the payment of a proportionate charge based on the time the defective section was in service The proportionate charge will be equal to the appropriate percentage of the trade price of the section at the time the warranty claim is made determined as follows Year 11 12 13 14 15 16 17 18 19 20 21 22 23 24 258 Above of Trade 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 Price This limited warranty does not apply a if the Product has been subjected to misuse or neglect has been accidentally or intentionally damaged has not been installed maintained or operated in accordance with the furnished written instructions or has been altered or modified in any way to any expenses including labor or material incurred during removal or reinstall
24. 2 If air elimination is not required at the safety relief valve tapping install valve and piping as shown in Figure 3 3 3 For air elimination at the safety relief valve tapping install valve and piping as shown in Figure 3 4 CAUTION Pipe the discharge of safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet la RETURN LINE VI THREE WAY VALVE WATER 1 CHILLER Figure 3 2 Parallel Hook Up with Water Chiller SAFETY RELIEF VALVE SUPPLY 3 4 X 6 NIPPLE TO DRAIN Figure 3 3 Safety Relief Valve Hook Up Installation with Air Elimination in System Piping TO AIR ELIMINATION DEVICE SUPPLY SAFETY RELIEF VALVE 3 4 X 6 NIPPLE 3 4 x 2 NIPPLE TO DRAIN 3 4 STREE ELBOW Figure 3 4 Safety Relief Valve Hook Up with Air Elimination INSTALLATION AND OPERATING INSTRUCTIONS C PIPING FOR ZONED SYSTEMS 1 See Figures 3 5 and 3 6 for basic zoned system layouts 2 Run each zone pipe down then up to zone to prevent air accumulation in piping 3 If required provide means to isolate and drain each zone separately A FROM SYSTEM ZONE ZONE ZONE ZONE ZONE ZONE
25. 4 Orifice Spud 48 Natural Gas 70 4 50894 Orifice Spud 48 Natural Gas 105 6 50894 Orifice Spud 48 Natural Gas 140 8 50894 Orifice Spud 48 Natural Gas 175 10 50894 8 Orifice Spud 49 Natural Gas 195 12 50895 Orifice Spud 56 LP Gas 70 4 50899 Orifice Spud 56 LP Gas 105 6 50899 Orifice Spud 56 LP Gas 140 8 50899 Orifice Spud 56 LP Gas 175 10 50899 Orifice Spud 57 LP Gas 195 12 50900 Honeywell VR8204A 2001 Gas Valve Spark Natural Gas 70 thru 140 50583 Honeywell VR8304M 4002 Gas Valve Spark Natural Gas 175 thru 195 50589 Honeywell VR8204A 2103 Gas Valve Spark LP 70 thru 140 50584 Honeywell VR8304M 4010 Gas Valve Spark LP 175 thru 195 50590 10 Honeywell Q348A 1002 Spark Pilot Natural Gas 70 thru 195 50558 INSTALLATION AND OPERATING INSTRUCTIONS Figure 11 4 Block Draft Hood Figure 11 5 J acket INSTALLATION AND OPERATING INSTRUCTIONS Table 11 3 Block Draft Hood amp J acket Re Quantity ock Assembly 70 ock Assembly 105 ock Assembly 140 ock Assembly 175 ock Assembly 195 ue Collector Draft Hood 70 ue Collector Draft Hood 105 ue Collector Draft Hood 140 ue Collector Draft Hood 175 ue Collector Draft Hood 195 ue Collector Blanket Seal specify length needed Jacket Assembly Complete J acket 70 12 13 nnn 7 7 7 NN x 14 Jacket Assembly Complete J acke
26. ALANCING HOT DOMESTIC f VALVE WATER SUPPLY SUPPLY RE TO TANK gt 2 L DRAIN COLD BALANCING DOMESTIC 3 VALVE I WATER SUPPLY Nc 2 Figure 3 7 Typical Piping with Indirect Fired Water Heater 10 INSTALLATION AND OPERATING INSTRUCTIONS 4 VENTING A INTEGRAL DRAFT HOOD 1 The boiler is equipped with a built in draft hood B VENT DAMPER INSTALLATION GENERAL This device is designed to 1 Do not use one vent damper to control two or more a provide for the ready escape of flue gases from heating appliances See Figure 4 1 the boiler in the event of no draft TE 2 Follow these and the installation instructions that are b prevent a backdraft from entering the boiler included with the vent damper Observe the cautions and warnings that accompany all instructions c control stack draft during operation 3 Make certain that minimum clearances provided in These tasks are accomplished without the extra the vent damper manufacturer s instructions are height requirements of a separate draft hood maintained and that adequate space is available for damper access and service The draft hood relief opening is the large rectangular passage at the front of the boiler Make certain that 4 Orient the damper operator to facilitate connection there are no obstructions to airflow in front of this opening vent safety shut off switch is located with
27. AUSES Burners not functioning 1 2 No power Limit not working Flame rollout switch open Blocked vent switch open Gas off at boiler gas valve 6 Gas off external to boiler 10 Plugged orifice spuds Defective gas valve Improper wiring Vent damper malfunctioning CORRECTIVE ACTIONS 1 Check line voltage wiring and fuses 2 Check wiring and contacts relay temperature setting Clean and adjust as necessary Replace switch Locate cause and correct Reset blocked vent switch Locate cause and correct Start boiler using Lighting O perating Instructions 6 Check any gas valves in the line 10 Check clean and re install Use Figure 8 1 to troubleshoot intermittent ignition gas valve Replace if necessary Check and correct in accordance with wiring diagrams in Section 6 Refer to vent damper manufacturer s instructions Replace if necessary Burners will not shut down Defective gas valve Short circuit Use Figure 8 1 to troubleshoot intermittent ignition gas valve Replace if necessary Check and correct wiring Flashback or burning at orifice spuds RUNKE a Manifold gas pressure too low Improperly sized drilled orifice spuds Leaking gas valve Burrs on orifice Low supply gas pressure Excessive downdraft or draft problems in boiler room WN HR Adjust to proper pressure In
28. Ducts shall terminate in an unobstructed space allowing free movement of combustion air to the appliances Ducts shall serve a single space Ducts shall not serve both upper and lower combustion air openings where both such openings are used The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air Ducts shall not be screened where terminating in an attic space Horizontal upper combustion air ducts shall not slope downward toward the source of the combustion air The remaining space surrounding a chimney liner gas vent special gas vent or plastic piping installed within a masonry metal or factory built chimney shall not be used to supply combustion air Combustion air intake openings located on the exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches 305 mm above grade WARNING Liquefied Petroleum LP is heavier than air and may collect or pool in a low area in the event of a leak from defective equipment This gas may then ignite resulting in a fire or explosion D PLANNING THE LAYOUT Prepare sketches and notes of the layout to minimize the possibility of interferences with new or existing equipment piping venting and wiring INSTALLATION AND OPERATING INSTRUCTIONS 2 BOILER SET UP 1 Provide a sound level foundation Locate boiler as near to the chimney or outside
29. HWX2 213 22 HWX2 HydroTherm Boiler Manual Installation and Operation Instructions WARNING This manual is intended only for use by a qualified heating installer technician Read and follow this manual all supplements and related instructional information provided with the boiler Install start and service the boiler only in the sequence and methods given in these in structions Failure to do so can result in severe personal injury death or substantial property damage I WARNING Do not use the boiler during construction Construction dust and particulate particularly drywall dust will cause contamination of the burner resulting in possible severe personal injury death or substantial property damage The boiler can only be operated with a dust free air supply Follow the instruction manual procedures to duct air to the boiler air intake If the boiler has been contaminated by operation with contaminated air follow the instruction manual guidelines to clean repair or replace the boiler ifnecessary CAUTION these instructions near to the boiler water heater Instruct the building owner to retain the instructions for future use by a qualified service technician and to follow all guidelines in the User s Information Manual INSTALLATION AND OPERATING INSTRUCTIONS TABLE OF CONTENTS USING THIS MANUAL 2 INSTALLATION SEQUENCE 2 B SPECIAL ATTENTION BOXES 2 1 PREINSTALLATION B A ACCE
30. L OUT SAFETY SHUT OFF SWITCH FLAME ROLL OUT SWITCH A thermally activated switch located between the first burner from the left and the manifold bracket The flame roll out safety shut off switch will sense excessive temperature caused by continued flame roll out and shut down main burner gas This is a non recycling switch that must be replaced once it has been activated and the cause of the roll out eliminated VENT SAFETY SHUT OFF SWITCH SPILL SWITCH A thermally activated manually resetable switch located in the draft hood relief opening If venting system becomes partially or totally blocked the vent safety shut off switch will sense excessive temperature caused by flue products exiting the draft hood relief opening and shut down main burner gas LIMIT WITH LOW WATER CUT OFF A Beckett 7600B or Hydrolevel 3200 control incorporate a thermally activated adjustable switch that will shut down main burner gas if the supply water temp exceeds the control setting It will also shut down main burner gas if the water level in the boiler drops below the control s sensing well The temperature switch will automatically reset when the boiler supply water temp drops below the control setpoint The low water cut off switch will automatically reset when the water level is above the control s sensing well LOW WATER CUT OFF FOR GRAVITY SYSTEMS OR HOT WATER BOILERS INSTALLED ABOVE RADIATION LEVEL If limit control does not incorpor
31. ND OPERATING INSTRUCTIONS 10 BOILER DIMENSIONS amp RATINGS Le D VENT 15 11 16 da 1 1 2 NPT SUPPLY Af 3 5 16 SUPPLY E LIMIT TEMPERATURE PRESSURE GAUGE 1 1 4 NPT RETURN i c 12 3 8 Y LEFT SIDE Figure 10 1 Boiler Views Table 10 1 Boiler Dimensions E VENT BOILER DIMENSIONS Rear of J acket Length Depth to of Vent F DIA 2 3 8 SUPPLY DEG VENT a mm INLET 8 3 8 RIGHT SIDE Left of J acket to of Vent pn Vent Size Diame ter inch mm inch mm inch 6 1 4 inch 7 11 16 9 5 8 11 5 16 Table 10 2 Boiler Ratings BOILER RATINGS Heating Capacity Net Ratings Water 13 MBH MBH kW Water Content 1 Net water ratings based on an allowance of 1 15 2 Consult factory before selecting a boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 3 Heating Capacity and Annual Fuel Utilization Efficiency AFUE ratings are based on U S Government test Before purchasing this appliance read important information about its estimated annual energy consumption or energy e
32. OUTLET BE Figure 4 2 Venting with Vent Damper in Vertical Position SLOPE UP A MINIMUM VENT TO OF 1 4 VENT CHIMNEY PER FOOT DAMPER 21mm PER METER 11 O CLOCK 1 O CLOCK POSITION POSITION DAMPER UN HEAT 47 OPERATOR LA SUPPORT AS ZONE m REQUIRED CONDENSATION 2 ZONE 7 O CLOCK ae O CLOCK POSITION POSITION DO NOT MOUNT DAMPER OPERATOR IN SHADED REGION SECTION Figure 4 3 Venting with Vent Damper in Horizontal Position 12 INSTALLATION AND OPERATING INSTRUCTIONS D BOILER REMOVAL FROM COMMON VENTING SYSTEM At the time of removal of an existing boiler follow these steps with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe V rifier toute fuite l orifice de d charge du coupe tirage apr s que le br leur ait fonctionn pendant 5 minutes Utiliser la flamme d une allumette ou d une d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Mettre en service l appareil inspecter Suivre les instructions concernant l allumage R gler le thermostat afin que l
33. REBY DISCLAIMED AND EXCLUDED FROM THIS LIMITED WARRANTY IN NO EVENT SHALL THE MANUFACTURER BE LIABLE IN ANY WAY FOR ANY CONSEQUENTIAL SPECIAL OR INCIDENTAL DAMAGES OF ANY NATURE WHATSOEVER OR FOR ANY AMOUNTS IN EXCESS OF THE SELLING PRICE OF THE PRODUCT OR ANY PARTS THEREOF FOUND TO BE DEFECTIVE THIS LIMITED WARRANTY GIVES THE ORIGINAL OWNER OF THE PRODUCT SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION IN UNITED STATES IN CANADA HydroTherm 260 NORTH ELM ST 7555 TRANMERE DRIVE WESTFIELD MA 01085 MISSISSAUGA ONT L5S 1L4 www hydrotherm com TEL 413 564 5515 TEL 905 672 2991 FAX 413 568 9613 FAX 905 672 2883 4 SAN ys A MESTEK COMPANY
34. ROL CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE VENT DAMPER END SWITCH IF USED IS MADE PULL IGNITION LEAD AND CHECK SPARK AT MODULE SPARK OK REPLACE MODULE YES CHECK IGNITION CABLE GROUND WIRING CERAMIC INSULATOR AND SPARK GAP ARE CORRECT CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES CHECK THAT ALL MANUAL GAS VALVES ARE OPEN SUPPLY TUBING AND PRESSURES ARE GOOD AND PILOT BURNER ORIFICE IS NOT BLOCKED PILOT GAS FLOWING CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF VOLTAGE IS OKAY REPLACE GAS CONTROL IF NOT REPLACE MODULE NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF PROBLEM PERSISTS REPLACE MODULE CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF NO VOL
35. ROUBLESHOOTING GUIDES 25 9 MAINTENANCE 28 A GENERAL aye bac SOR 29 B DAILY WITH BOILER IN USE 29 C WEEKLY WITH BOILER IN USE 29 D MONTHLY WITH BOILER IN USE 29 E ANNUALLY BEFORE START OF HEATING SEASON st Ka Se be 29 10 BOILER DIMENSIONS amp RATINGS S 11 REPAIR PARTS 32 A BASE COMBUSTIBLE FLOOR PAN 32 B MANIFOLD GAS VALVE amp PILOT 33 C BLOCK DRAFT HOOD amp J 35 D CONTROLS CIRCULATOR VENT amp DAMPER 37 USING THIS MANUAL A INSTALLATION SEQUENCE Follow the installation instructions provided in this manual in the order shown The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation B SPECIAL ATTENTION BOXES Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards DANGER Indicates a condition or hazard which will cause severe personal injury death or major property damage WARNING Indicates a condition or hazard which may cause severe personal injury death or major property damage CAUTION Indicates a condition or hazard which will or can cause minor personal injury or property damage
36. S ANNOYD SJOVTANIY 3413 LNIIVYAIG T9MVddV 139 30 XNVNIDINO SFIGYO S31 00 SVO 31 SNVG 3MIM Ndal NMV M3L 3MIM 81 91 IZIS JOVLIOA MOT NMOHS SV 3MIM G3OVW1d34 38 ISNN LI Q39V 1438 3MIM XZ10 3dAL OMV 81 IZIS 39V110 MOT 38 ISNN 3ONVIIddv JHL 5 Sv TYNIDIMO IHL 40 ANY dl Z SNOILVINDAY S3ONVNIQMO SIAOD 3ONVIIddv ISnW 9NIMIM TV SALON 3MIM WMV MAL NO Ndal ML 3dAL 81 91 3215 JOVLIOA JNN 3MIM WMV M3L YO N44L ML 3dAL 9MV vL 3215 JOVLIOA INN ON3931 WV3OVIG NOILO3NNOO SAG HOLIMS S44 HOLIMS lN3A 100103 INVI SONS JAWA SV9 NOH 3 N Kremer ST d I 1 a Si 51 M 38 MEA i 318vO NOSN3S NOlINDI ME S il 1 43108 015 9 1 TN E MOSN3S 3d0ud A TN o RIZ YILSINYIHL WON rue e 2 lt 1019 a2 TEN oz 20 TINTON NOILINOI X 1 18 SY3HLO A8 DUST E lVISONWM3HL TEE 3 1 3LIHM M oc Cl AlddnS HOVI FT al 1 ae MOTI3A 1 09 01 ML I Aa 8 5 HOLMS S E aoiauas L ii ad 20835 Las
37. SCREW STANDING PILOT ONLY NOTE LOCATIONS ARE SIMILAR FOR STANDING PILOT AND INTERMITTENT IGNITION VALVES Figure 7 2 Valve Tapping and Adjustment Screw Locations INSTALLATION AND OPERATING INSTRUCTIONS or vour sareTy READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device Immediately call your gas supplier from a _ which automatically lights the pilot Do not try to neighbor s phone Follow the gas supplier s light the pilot by hand instructions BEFORE OPERATING smell all around the appliance If you cannot reach your gas supplier area for gas Be sure to smell next to the floor call the fire department because some gas is heavier than air and will settle C Use only your hand to push in or turn the gas control on the floor knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may WHAT TO DO IF YOU DO SMELL GAS result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician e Do not touch any electric switch to inspect the appliance and to replace any part of the do not use any phone in your building control system and any gas control which has been under water
38. SSIBILITY CLEARANCES 3 B CLEARANCE FROM COMBUSTIBLE CONSTRUCTION dod hber ee 3 C AIR FOR COMBUSTION AND VENTILATION 4 D PLANNING THE LAYOUT suis emnes 6 2 BOILER SET UP 7 3 WATER PIPING AND CONTROLS 7 A BOILER SUPPLY AND RETURN 7 SAFETY RELIEF VALVE 8 PIPING FOR ZONED SYSTEMS 9 D EXPANSION TANK 4 aa dates dnce dim tenti e 10 E INDIRECT FIRED WATER HEATER 10 FREEZE PROTECTION 10 4 VENTING 11 A INTEGRAL DRAFT HOOD 11 VENT DAMPER INSTALLATION GENERAL 11 VENT PIPING AND CHIMNEY 12 D BOILER REMOVAL FROM COMMON VENTING SYSTEM us ace hate na die anges 13 5 GAS PIPING 14 6 ELECTRICAL 16 WIRING da bise dee Hage ie data 16 ZONED SYSTEM WIRING 16 C CONTROLS EE hems idee cit 16 D SEQUENCE OF OPERATION ise eme ene 17 7 START UP PROCEDURES 20 A COMPLETING THE INSTALLATION 20 B CONTROL DESCRIPTIONS nier Re eres 23 C ADJ USTMENT OF GAS PRESSURE REGULATOR 23 D CHECKING BURNER INPUT 23 E CHECK OUT PROCEDURE 24 8 TROUBLESHOOTING 25 A SHUT DOWN CAUSED BY PILOT OUTAGE BLOCKED VENT SHUT OFF SWITCH OR FLAME ROLL OUT SAFETY SHUT OFF cs mp 25 B T
39. T Time Seconds the Meter is Read SI Metric Units Input kW 3600 x F x H Tx3 6 Where 3600 2 Seconds per hour 3 6 Megajoule MJ per kilowatt hour kwhr F Cubic Meters of Gas Registered on Meter H Heating Value of Gas in MJ Cubic Meter T Time in Seconds the Meter is Read As an alternative use Table 7 1 a and 7 1 b Use the heating value provided by gas supplier Use a stopwatch to record the time it takes for 2 cubic feet 0 0566 cubic meter of gas to pass through the meter Read across and down to determine rate Table 7 1a Meter Conversion Natural Gas U S Customary Units Burner inputs in Btu hr for various meter timings and heat values Table based on 2 cubic feet of gas through merter Time that meter is read sec Heat Value of Gas Btu cubic foot 1025 295200 246000 210857 184500 164000 147600 134182 123000 113538 105429 98400 92250 86824 82000 77684 73800 70286 67091 64174 61500 59040 288000 240000 205714 180000 160000 144000 130909 120000 110769 102857 96000 90000 84706 80000 75789 72000 68571 65455 62609 60000 57600 302400 252000 216000 189000 168000 151200 137455 126000 116308 108000 100800 94500 88941 84000 79579 75600 72000 68727 65739 63000 60480 23 INSTALLATION AND OPERATING INSTRUCTIONS Table 7 1b Meter Conversion Natural Gas 3 Low Water Cut Off if used Consult the SI Metric Units manufacturer s instr
40. TAGE REPLACE MODULE CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED INTHE CIRCUIT IF OKAY REPLACE GAS CONTROL NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE NOTE IF GROUND IS POOR OR ERRATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE PILOT FLAME MUST NOT BE MOVING AROUND DUE TO OUTSIDE AIR FLOWS ETC ADJUST PILOT FLAME CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER ON AND ALL OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE IF CHECKS ARE OKAY REPLACE MODULE CHECK FOR PROPER THERMOSTAT CONTROLLER OPERATION REMOVE MV LEAD AT MODULE IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL Figure 8 1 Intermittent Ignition System Troubleshooting Sequence 27 INSTALLATION AND OPERATING INSTRUCTIONS 9 MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers RCF Airborne RCF when inhaled have been classified by the International Agency for Research on Cancer IARC as a possible carcinogen to humans After the RCF materials have been exposed to temperatures above 1800F 980 C they can change in
41. aks in gas piping or fittings Leaks in gas service line or meter Obstructed chimney Obstructed flueways or vent Undersized chimney or vent high draft loss in vent Draft problem in boiler room Overfiring Vent damper malfunctioning WN HL Oo Locate and repair or replace Shut down boiler and notify gas provider Check repair and or clean chimney Clean flueways or vent and remove obstructions Check National Fuel Gas Code and vent manufacturer s recommendations Check air supply ventilation and venting system Reduce rate to input on rating label Refer to vent damper manufacturer s instructions Replace if necessary START BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLLER TO CALL FOR HEAT POWER TO MODULE 24V NOMINAL YES NO SPARK ACROSS IGNITER SENSOR GAP YES TURN GAS SUPPLY ON AND RECYCLE CALL FOR HEAT PILOT BURNER LIGHTS YES SPARK STOPS WHEN PILOT IS LIT YES MAIN BURNER LIGHTS YES SYSTEM FOR HEAT ENDS CALL FOR HEAT ENDS YES REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED INSTALLATION AND OPERATING INSTRUCTIONS NOTE CALL FOR HEAT 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONT
42. ate a low water cut off feature then install a level sensing device float or probe located in supply piping near the boiler Using the manometer setup installed in part 7A set manifold pressure as follows for various gases a Natural Gas 3 5 Water Column 0 9 kPa b LP Gas 10 0 Water Column 2 5 kPa To adjust gas pressure turn adjusting screw of gas pressure regulator counterclockwise to decrease pressure clockwise to increase pressure Refer to Figure 7 2 for location of gas pressure regulator Replace the cap screw when adjustment is complete In no case should the final manifold pressure vary more than 0 3 inches water column 0 07 kPa from the above specified pressures Any necessary major changes in the flow should be made by changing the size of the burner orifice spuds When adjustment is complete turn off boiler gas flow and electricity to boiler Remove manometer connection from valve and plug tapping with plug provided Turn utilities back on and resume checkout D CHECKING BURNER INPUT 1 3 Refer to rating label mounted on the jacket top panel to obtain the rated BTU per hour input In no case shall the input to the boiler exceed the value shown on the rating label Check input by use of the following formulas U S Customary Units Input BTU Hr 3600 x F x Where 3600 Seconds per hour F Cubic Feet of Gas Registered on Meter H Heat Value of Gas in BTU Cubic Feet
43. ation of the Product or parts thereof to any other cast iron parts of the boiler to burners jackets controls and other auxiliary equipment furnished by the Manufacturer but manufactured by others Any warranties for such items shall be limited to those warranties offered by the original equipment manufacturer to damage as a result of settlement distortion collapse or cracking of any foundation area beams or pipes surrounding the Product to any workmanship of any installer of the Product or to Products installed outside the continental United States or Canada This limited warranty is conditional upon a shipment to the Manufacturer of that part of the Product thought to be defective Goods can only be returned with prior written approval from the Manufacturer All returns must be freight prepaid b determination in the reasonable opinion of the Manufacturer that there exists a defect in material or workmanship c the residential water boiler having been installed in a single family or two family residential dwelling Repair or replacement of any part under this Limited Warranty shall not extend the duration of the warranty with respect to such repaired or replaced part beyond the stated warranty period THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EITHER EXPRESS OR IMPLIED AND ALL SUCH OTHER WARRANTIES INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE HE
44. fficiency rating that is available from your retailer 31 INSTALLATION AND OPERATING INSTRUCTIONS 11 REPAIR PARTS REPAIR PARTS Note Remember to include boiler model number and serial number when ordering parts Figure 11 1 Base Combustible Floor Pan Table 11 1 Base Combustible Floor Pan Base Assembly 105 1 Base Assembly 140 2 Observation Cover Door 3 Base Blanket Seal Re Quantity Base Assembly 175 Combustible Floor Pan Assembly 70 Base Assembly 70 Base Assembly 195 Combustible Floor Pan Assembly 105 4 Combustible Floor Pan Assembly 140 Combustible Floor Pan Assembly 175 ible Floor Pan Assembly 195 Combusti 32 INSTALLATION AND OPERATING INSTRUCTIONS Figure 11 2 Manifold Figure 11 3 Gas Valve and Pilot Intermittent Ignition 33 INSTALLATION AND OPERATING INSTRUCTIONS Table 11 2 Manifold Gas Valve and Pilot Steel Burner 70 Required 3 5 7 9 Steel Burner 105 51537 5 Steel Burner 140 51537 Steel Burner 175 51537 Steel Burner 195 11 51537 6 Steel Burner w Spark amp SV Pilot Bracket 1 51539 Gas Manifold 70 50978 Gas Manifold 105 Gas Manifold 140 34 Honeywell Q348A 1358 Spark Pilot LP 70 thru 195 Gas Manifold 175 50981 Gas Manifold 195 5095
45. in the draft relief opening to shut off the boiler in case of a blocked vent condition See Section 7B for details regarding this device See Figure 6 1 in Section 6 Electrical for spill switch location The vent damper can be mounted directly onto the round draft hood outlet vent connector on top of the boiler or in vent piping close to the boiler See the Vent Damper Installation Instructions below DAMPER D INCORRECT Figure 4 1 Venting Multiple Appliances of the harness with the vent damper and boiler Note flue gas flow arrow on vent damper and orient as required For installation with damper mounted in vertical position see Figure 4 2 For installation with damper mounted in horizontal position mount the unit as shown in Figure 4 3 to avoid excessive heat on the operator or condensation drips into the operator OTHER HEATING PPLIANCE E CORRECT 11 INSTALLATION AND OPERATING INSTRUCTIONS C VENT PIPING AND CHIMNEY 1 Install vent piping in accordance with Venting of Equipment part of the National Fuel Gas Code 4 Before connection of joints inspect the vent pipe interior for foreign objects such as tools equipment rags etc and remove if present
46. nstalled that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil A ACCESSIBILITY CLEARANCES VN WARNING Install boiler not less than 24 610 mm between the left side top and front of the boiler and adjacent wall or Do not install this boiler on combustible flooring other appliance when access is required for servicing unless it is installed on a special combustible floor pan Boiler installation on combustible flooring without the special pan is a fire hazard E To order combustible floor pan use the 5 digit stock codes listed in Table 11 1 of this manual The design of this boiler is certified for alcove installation with the following clearances 1 6 152 mm between sides and combustible VN WARNING construction 2 24 610 mm between top of jacket and Do not install this boiler on carpeting Boiler combustible construction installation on carpeting is a fire hazard Install this 3 6 152 mm between draft hood and combustible construction 4 6 152 mm between vent pipe and combustible construction 5 10 254 mm between rear of jacket and combustible construction boiler on non combustible flooring or use a combustible floor
47. ortion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Tout fonctionnement inad quat du syst me d vacuation commun doit tre corrig de mani re respecter les normes du National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou des Codes d installation CAN ACG B149 Lorsqu il est n cessaire de modifier les dimensions de toute portion du syst me d vacuation commun ces derni res doivent tre modifi es de mani re respecter les dimensions minimums indiqu es dans les tableaux du chapitre Sizing of Category Venting Systems du National Fuel Gas Code ANSI Z223 1 NFPA 54 ou des Codes d installation CAN ACG B149 13 INSTALLATION AND OPERATING INSTRUCTIONS 5 GAS PIPING 1 Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the meter and the boiler 2 Determine the volume of gas to be provided to the boiler in cubic feet per hour To obtain this value divide the Btu per hour rating on the boiler rating plate by the heating value of the gas in Btu per cubic feet Obtain the heating value of the gas from the gas supplier As an alternative use Table 5 1 5 2 or 5 3 on the next page to obtain the volume
48. pan to install this boiler on other non carpeted flooring INSTALLATION AND OPERATING INSTRUCTIONS AIR FOR COMBUSTION AND VENTILATION 1 Adequate combustion air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled Air for Combustion and Ventilation or applicable provisions of the local building code Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements Required Combustion Air Volume The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space Rooms communicating directly with the space in which the appliances are installed and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume The required volume of indoor air is to be determined by one of two methods a Standard Method The minimum required volume of indoor air room volume shall be 50 cubic feet per 1000 BTU Hr 4 8 m3 kW This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0 6 air changes per hour As an option this method may be used if the air infiltration rate is known to be between 0 6 and 0 4 air changes per hour If the air infiltration rate is known to be below 0 4 then the Known Air Infiltration Rate Method must be used If the building in which
49. properly turn off the gas to the boiler b Turn off all electrical power to the boiler 29 30 INSTALLATION AND OPERATING INSTRUCTIONS c Remove burners and brush orifice spuds lightly using a soft bristle brush d Remove the vent pipe vent damper top jacket panels and flue collector draft diverter e Brush flueways with wire brush f To the extent possible inspect inside of vent pipe and vent damper for obstructions in flow or vent damper movement Remove or replace as necessary g When replacing the flue collector draft hood be certain that the blanket seal between the flue collector and top section makes a tight seal to prevent leakage of the products of combustion h Re install the top of the jacket vent damper and vent pipe i Re install burners Inspect entire venting system for corrosion support and joint integrity Repair as necessary Check the pilot and main burner flame See Figure 9 1 The pilot should provide a steady flame enveloping 3 8 to 1 2 1 cm to 1 2 cm of the flame sensor If required adjust the pilot as stated in the gas valve manufacturer s instructions The main burner flame inner cone should be approximately 1 1 2 4 cm high and should have a very sharp blue color characteristic OUTER CONE IS DARK BLUE IN COLOR PILOT INNER CONE IS FLAMES BLUE IN COLOR Figure 9 1 Intermittent Pilot and Main Burner Flame INSTALLATION A
50. r to the boiler c Call a qualified heating service organization or local gas company and have the cause of the shut down VN WARNING investigated and corrected d Refer to Lighting O perating Instructions to Do not use this appliance if any part has been under re start boiler water Improper or dangerous operation may result Immediately call a qualified service technician to inspect the boiler and to replace any part of the B TROUBLESHOOTING GUIDES control system and any gas control which has been under water Use Table 8 1 to assist in determining causes and providing corrective actions to boiler problems Refer also to Figure 8 1 to troubleshoot the Intermittent Ignition System Control These guides must be used only by qualified service technicians These individuals must VAN CAUTION follow all applicable codes and regulations in repair of any boiler problems Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing CAUTION Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump This may aggravate the problem and increase the likelihood of boiler damage Instead shut off the gas supply at a location external to the appliance 25 INSTALLATION AND OPERATING INSTRUCTIONS Table 8 1 Boiler Troubleshooting Guide PROBLEM POSSIBLE C
51. rom the gas supply piping during any pressure testing of the gas system 2 Check pipes adjacent to cold walls or in unheated spaces Insulate and tape them if necessary to be sure they can t freeze up Keeping the water moving at all times will reduce the likelihood of freezing See Section 3 for glycol instructions 3 If there is considerable foreign matter in the boiler water the boiler should be shut down and allowed to cool then drained and thoroughly flushed out Use the drain valve at the bottom of the return connection to drain the boiler Pipe the drain cock to a suitable drain or containment device if a glycol solution is used Flush the system to remove remaining matter If there is evidence that hard scale has formed on the internal surfaces the boiler should be cleaned by chemical means as prescribed by a qualified water treatment specialist 4 There must not be signs of continuous wetness at the chimney If signs of continuous wetness are observed a qualified service agency must be consulted to modify the vent configuration to prevent the formation of condensate B DAILY WITH BOILER IN USE Daily boiler observation can be performed by the owner If any potential problems are found a qualified installer or service technician agency must be notified 1 Remove any combustible materials gasoline and other flammable liquids and substances that generate flammable vapors from the area where the boiler is contained
52. s and seals used in hydronic and maintaining minimum system pressure Check systems the design features of the tank and provide valves as necessary Refer back to Figure 3 1 for typical expansion tank piping 1 Glycol in hydronic applications is specially formulated for this purpose It includes inhibitors which prevent the glycol from attacking metallic E INDIRECT FIRED WATER HEATER system components Make certain that the system If the boiler is to be used in conjunction with an indirect ATA Decore gyen fired water heater refer to Figure 3 7 for typical piping j Follow the instructions provided by the water heater 2 The glycol solution should be tested at least once a manufacturer Pipe the water heater asa separate zone year and as recommended by the glycol manufacturer 3 Glycol solutions expand more than water For example a 50 by volume solution expands 4 8 in volume for a temperature increase from 32 F 0 C to 180 F 82 C while water expands 3 with the same temperature rise Allowance must be made for this expansion in system design SYSTEM CHECK CIRCULATOR VALVE PRESSURE E REGULATOR SYSTEM gt lt T n COLD ZONE VALVES gt ERAN h A DJ WATER A FILL RETURN FROM T SYSTEM SHUTOFF X il VALVE SHUTOFF INDIRECT FIRED WATER VALVE MES HEATER B
53. stall correct spuds Replace valve Remove burrs Contact gas supplier if natural gas Adjust regulator if LP gas Check air supply ventilation and venting system Delayed ignition WN HL Insufficient pilot flame Pilot burner orifice clogged Overfiring Misaligned burners or pilot Draft problem in boiler room WN HR Increase pilot gas flow Clean pilot burner and orifice Reduce rate to input on rating label Realign burners or pilot Check air supply ventilation and venting system Excessive condensation in vent PWN Underfiring Limit Aquastat set too low Vent pipe too long Inadequate chimney or venting system PWN Hn Increase rate to input on rating label Reset Aquastat to higher setting Reposition boiler to reduce length Check chimney and venting recommendations Boiler not heating properly WN oH a Underfiring Limit set too low Air in system Circulator malfunctioning Circulation system clogged Incorrect thermostat heat anticipator setting WN H a Increase rate to input on rating label Reset Aquastat to higher setting Vent air from all points in system Check circulator replace if necessary Shut down and cool boiler drain and flush system Adjust heat anticipator Fumes or gas odors 26 WN H a Le
54. t 105 16 J acket Assembly Complete J acket 140 Jacket Assembly Complete J acket 175 J acket Assembly Complete J acket 195 Complete J acket Consists of 16A Left Side Pane 16B Right Side Panel 16C Rear Panel 16D Top Upper Front Panel 16E Inner Front Baffle Panel Removable Front Panel 36 INSTALLATION AND OPERATING INSTRUCTIONS Figure 11 6 Controls Circulator Vent Damper INSTALLATION AND OPERATING INSTRUCTIONS Table 11 4 Controls Circulator Vent Damper 38 Limit Beckett 7600B Well Beckett 7600TW03B 50341 23 Sensor Beckett 7600P06B 50339 Limit w Sensor H ydrolevel 3200 50334 Well ydrolevel 48 201 50723 24 Temperature Pressure G auge 51324 25 Safety Relief Valve 30 PSI Conbraco 10 408 05 50501 Safety Relief Valve 50 PSI Watts 350 99950 26 Flame Roll O ut Safety Shut Off Switch 51587 27 Blocked Vent Shut Off Spill Switch 90592 Vent Damper 70 105 1 90608 28 Vent Damper 140 175 1 90609 Vent Damper 195 1 INSTALLATION AND OPERATING INSTRUCTIONS 39 LIFETIME LIMITED WARRANTY Residential Cast Iron Water Boilers First Through Tenth Year The Manufacturer warrants to the original owner at the original installation site that the cast iron sections of the Residential Cast Iron Water Boilers the Product will be free from defects in material or
55. tallation of the various controls 2 Connect the boiler by a separate permanently live electrical supply line with a fused switch 3 This boiler is supplied with safety devices in addition to the limit For a description of these devices and 3 Connect the vent damper harness to the damper how they work to ensure the safe operation of the motor as shown in Figure 6 1 boiler see Section 7B 4 Adjust the thermostat heat anticipator to 0 2 Amp 4 Ifthe circulator is mounted in the supply piping provide longer wiring harness as required B ZONED SYSTEM WIRING Refer to Limit Control Instructions for details on Zone Wiring When wiring a zoned heating system follow all applicable codes ordinances and regulations NOTICE Do not power zone valves directly from the boiler limit Doing so will greatly reduce the life of the transformer Use a separate transformer sized to handle the total of all zone valve electrical loads SAFETY RELIEF VALVE 77 AUTOMATIC TEMPERATURE PRESSURE VENT DAMPER GAUGE TO THERMOSTAT TO LINE VOLTAGE POWER SUPPLY _ 7 GAS VALVE SRO BLOCKED VENT SWITCH BURNER OBSERVATION COVER FLAME ROLLOUT SWITCH Figure 6 1 Wiring Controls and Safety Devices 16 INSTALLATION AND OPERATING INSTRUCTIONS 1013U09 90094 uoniub BUHIM z 9 e4n614 U SJULSNTI xn3o 3ND STIL 3813 LNSAIOG SONVHOSY SAIGYO SJN 009 5945 SMV 81 91 IZI
56. the minimum and below the maximum values for the gas being used See the end of Section 5 for these values If a supply pressure check is required isolate the boiler and gas valve before performing the pressure check If the supply pressure is too high or too low contact the gas supplier Turn on electricity and gas to boiler Light the boiler by following the Lighting O perating Instructions label mounted to the jacket panel The initial ignition may require several tries as the piping is purged of air Use the sequence descriptions in Figures 6 2 6 3 and 6 4 in Section 6 Electrical to follow light off and shutdown sequences and to assist in diagnosing problems If the boiler does not function properly consult Section 8 Troubleshooting The gas manifold and control assembly are made of gas tight completely factory assembled and installed components of the base assembly See Figure 7 1 STEEL BURNER GAS VALVE PILOT ORIFICE PILOT TUBING LE les SECTION A A TEST TAPPING Figure 7 1 Gas Valve Manifold and Burner Assem bly Intermittent Ignition GAS PRESSURE REGULATOR ADJUSTMENT SCREW rel UNDER CAP SCREW PRESSURE TAP OUTLET PRESSURE TAP OUTLET PILOT GAS OUTLET THERMOCOUPLE PILOT ADJUSTMENT SCREW CONNECTION UNDER CAP
57. ting temperature and pressure c Liftthe try lever on the safety relief valve to the full open position and hold it for at least five seconds or until clean water is discharged d Release the try lever and allow the valve to close If the valve leaks operate the lever two or three times to clear the valve seat of foreign matter It may take some time to determine if the valve has shut completely e Ifthe valve continues to leak it must be replaced before the boiler is returned to operation f Check that operating pressure and temperature have returned to normal g Check again to confirm that valve has closed completely and is not leaking 3 Test low water cut off if used as described by the manufacturer 4 Testlimit as described in Section 7E Check Out Procedure 5 Test function of gas safety shut off features as described by gas valve and ignition control manufacturer 6 Cycle the boiler at least once and check operation of the vent damper E ANNUALLY BEFORE START OF HEATING SEASON DANGER When servicing or replacing components be absolutely certain that the following conditions are met Water gas and electricity are off The boiler is at room temperature There is no pressure in the boiler 1 Check flueways and burners for cleanliness and clean if necessary Use the following procedure if cleaning is required a Refer to the Lighting O perating Instructions in Figure 7 3 to
58. to crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airborne during service or repair inhalation of these particles may be hazardous to your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken when handling these materials Precautionary Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention 28 INSTALLATION AND OPERATING INSTRUCTIONS A GENERAL 1 Disconnect this boiler f
59. uctions for the low water cut off Burner inputs in kW for for various meter timings and operational check procedure heat values Table based on 0 0566 cubic meter of gas through meter 4 Check the system to make sure there are no leaks or overfilling problems which might cause excessive Time that Heat Value of Gas make up water to be added Make up water causes meter is MJ cubic meter liming in the boiler and brings in oxygen Oxygen read sec 38 19 can cause severe damage to the boiler though oxygen corrosion pitting 5 Check the expansion tank and automatic fill valve if used to confirm that they are operating correctly If either of these components causes high pressure in the system the boiler relief valve will weep or open allowing fresh water to enter the system 6 Do not allow the system controls to subject the boiler to excessively low water temperatures which would cause condensation of flue gases and corrosion of the boiler Operate the boiler at a temperature above 130 F 54 C Adjust the boiler limit as required to maintain boiler temperature above this level 7 Check the general condition of the system including piping support joints etc Check cleanliness of the radiators baseboard units and or convectors Clean them to the extent possible If radiators do not heat evenly vent any remaining air from them 8 Review operation and User s Information Manual with end user 9 Hang the Installation
60. visible remove the control access panel HSP VR8204 VR8304 9181R REV 2 MM YY Figure 7 3 Operating Instructions 21 INSTALLATION AND OPERATING INSTRUCTIONS our VOTRE S CURIT LISEZ AVANT L ALLUMAGE MESSE MISE EN GARDE N gliger de suivre ces instructions la lettre pourrait provoquer un incendie ou une explosion causant des d g ts mat riels des blessures ou la mort A Cet appareil est muni d un dispositif d allumage S il est impossible de rejoinder le fournisseur automatique de la veilleuse Ne tentez pas d allumer la de gaz appeler le service des incendies veilleuse la main C N utilisez que votre main pour appuyer ou tourner le bouton B AVANT DE METTRE EN MARCHE sentez autour de de commande du gaz Ne jamais utiliser d outils S il est l appareil pour d tecter toute odeur de gaz Etant donn impossible d enfoncer ou de tourner le bouton la main ne que certains gaz sont plus lourds que l air et se d posent tentez pas de le r parer Appelez un technicien d entretien sur le sol s assurer de bien sentir pr s du plancher qualifi Une force excessive ou une tentative de r paration QUE FAIRE SI VOUS D TECTEZ UNE ODEUR DE GAZ peut provoquer un incendie ou une explosion N utilisez pas cet apparel ni aucune de ses pi ces si elles Ne pas tenter d allumer l appareil ont t immerg es ontactez imm diatement un Ne toucher aucun interrupteur lectrique ecnnicien a
61. wall as possible and centralized with respect to the heating system Locate boiler in front of installation position before removing crate If using combustible floor pan position pan on foundation or flooring A BOILER SUPPLY AND RETURN 1 Size the supply and return to suit the system A typical piping arrangement is shown in Figure 3 1 Refer also to the Guide Residential Hydronic H eating Installation Design for additional guidance during water piping installation Return Piping Pipe the drain valve to a tee provided and the 1 1 4 NPT return tapping near the bottom of the left section Pipe the return to the tee Pipe the drain valve nipples and tee to the 1 1 4 NPT return tapping as shown in Figure 3 1 CIRCULATOR 4 Separate the wood shipping pallet from the boiler base by removing two 2 hold down bolts at each end of the boiler base Move boiler into final position If using combustible floor pan install boiler on pan as outlined in the instructions included with the pan 3 WATER PIPING AND CONTROLS 3 Supply Piping Pipe the supply to the 1 1 2 NPT supply tapping at the top and rear of the boiler When system return water temperature will be below 130 F 54 C pipe the boiler with a bypass arrangement to blend the system return and hot supply to obtain at least 130 F 54 C entering the boiler AIR VENT AIR ELIMINATOR SUPPLY COLD
62. xhaust air Each of the appliances served shall be interlocked to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation In buildings where the combustion air is provided by the mechanical ventilation system the system shall provide the specified combustion air rate in addition to the required ventilation air 8 Louvers amp Grills a The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening i Where the free area through a louver or grille is known it shall be used in calculating the opening size required to provide the free area specified ii Where the free area through a louver or grille is not known it shall be assumed that wooden louvers will have 2596 free area and metal louvers and grilles will have 75 free area b iii Nonmotorized dampers shall be fixed in the open position Motorized dampers shall be interlocked with the equipment so that they are proven in the full open position prior to ignition and during operation of the main burner i The interlock shall prevent the main burner from igniting if the damper fails to open during burner startup ii The interlock shall shut down the burner if the damper closes during burner operation 9 Combustion Air Ducts a Ducts shall be constructed of galvanized steel or an equivalent corrosion resistant material

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