DUNKIRK Boiler Manual L0612044

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STALLATION
These instructions

INST

JCTION

must be affixed on or adjacent to the boiler

Continuous

G s-Fi

d

These Gas-Fired Water Boilers are low pressure, sectional
cast iron boilers Designed Certified by C.S.A. (Canadian
Standards Association) for use with Natural and Propane
Gases. They are constructed and hydrostatically tested for a
maximum working pressure of 50 psi (pounds per square
inch) in accordance with A.S.M.E. (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code
Section IV Standards for cast iron heating boilers.

Warning:
property
installer,

Improper

Pilot

installation,

adjustment,

@
®
MODEL PWB
Electronic
intermittent
alteration,

damage,
Refer to this manual, For assistance
service agency or the gas supplier

service

or maintenance

or additional

information

ignition

can cause injury or
consult a qualified

ASME

RELIEF

TEMPJPRESS.

VENT DAMPER

GAUGE

AQUASTAT

llh " SUPPLY

@

tll

LL
!

11k"NPT

roe

\

DRAIN VALVE

LEFT SIDE

11/4"RETURN

\
ROLLOUT
SWITCH

FRONT

GAS=FIRED

BASIC BOILER UNIT NO.
Continuous Pilot
NO. OF
With
SECTIONS
Vent Damper
PVWB-2D
PVWB-3D
PVWB-4D
PVWB-5D
PVWB-6D
PVWB-7D
PVWB-8D
PVWB-gD

RIGHT SIDE

HOT WATER

Electronic Ignition
With
Vent Damper
PWB-2D
PWB-3D
PWB-4D
PWB-5D
PWB-6D
PWB-7D
PWB-8D
PWB-9D

INT. PILOT CONTROL

GAS
VALVE

2
3
4
5
6
7
8
9

BOILERS

NATURAL AND PROPANE GAS
DIMENSIONS
AGA/CGA
HEATING NET I=B=R
(Inches)
INPUT
CAPACITY
RATING
FLUE
IWAl!
*MBH
*MBH
*MBH
DIAMETER WIDTH
37.5
30
8
26
45
70
57
50
5
11½
105
85
74
6
14½
140
113
98
6
17¾
175
142
123
7
21
210
170
148
7
241/4
245
198
172
7
27½
28O
226
197
7
3O¾

* MBH = 1,0O0 Btuh = British Thermal Unit Per Hour
Boilers are equipped for altitudes
up to 2,000 feet only
U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level.
Canada Only - Boilers may be used at high altitude by using a certified field conversion
kit, resulting
in a 10% derate.
+ Heating Capacity based on D.O.E. (Department
of Energy) test procedure.
Add 5½" to height when vent damper is used.
2 section boilers are equipped
with a 3" diameter flue collar on the draft diverter, and use a furnished
3" x 4" increaser fitting to install
the furnished

4" vent damper.

New York City MEA Number

39-86=E Vol. IV.

The Ratings marked "Net 1=B=R Ratings" indicate the amount
of remaining heat input that can be used to heat the radiation
or terminal units. The Net I=B=R Ratings shown are based on
an allowance of 1.15 in accordance with the factors shown on
the 1=B=R Standard as published by The Hydronics Institute.
Selection of boiler size should be based upon "Net I=B=R
Rating" being equal to or greater than the calculated heat loss
of the building.
The manufacturer should be consulted bet'orcselecting a boiler
for installations having unusual piping and pickup requirements.
These boilers must stand on a non-combustible floor. If in

stalled on a combustible floor, use Combustible
Number 42135-1 or 146-14-031 (2-6 section
42135-2 or 146-14-032 (7-9 section boilers).

BOILERS

Floor Base
boilers) or

FOR USE AT HIGH ALTITUDE

This boiler is factory equipped for use at altitudes of 0-2,000
feet above sea level. For use at altitudes above 2,000 feet
above sea level, the input ratings are reduced by a change in
main burner orifice size.
U.S.A.
Only - For altitudes above 2,000 feet above sea
level, input ratings should be reduced at the rate of 4% for
each 1,000 feet above sea level. Consult the National Fuel

Gas Code (NFPA54/ANSI
Z223.1-1atest edition), or the
manufacturer
for correct orifice sizing information. High
altitude orifices are available from the boiler manufacturer.

Canada

Only - For altitudes in the range of 2,000-4,500

feet above sea level, boilers may be field equipped for use
at high altitude by using a certified field conversion kit. The
change in main burner orifice size results in the boiler's
input rating being reduced by 10%. The conversion shall
be carried
out by a manufacturer's
authorized
representative, in accordance with the requirements of the
manufacturer,
provincial or territorial authorities having
jurisdiction and in accordance with the requirements of the
CSA-B149.1
and CSA-B149.2
Installation
Codes. The
certified field conversion kit includes a conversion data
plate, which must be attached to the boiler adjacent to the
rating plate, indicating that the boiler has been converted
for high altitude use. The conversion data plate must be
filled in with the correct conversion information.

If this boiler is installed in a building under construction,
special care must be taken to insure a clean combustion
air supply during the construction
process. Airborne
particulates such as from drywall dust and from fiberglass
insulation can clog the burner ports and cause incomplete
combustion and sooting.
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, No. CSD-1.
The installation must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI Z223.1latest revision.
In Canada, the boiler shall be installed according to CSA13149.1 and .2, Installation
Code for Gas Burning
Appliances and Equipment.

Check to be sure you have the right size boiler before starting
the installation. _ See rating and capacity table on previous
page. Also be sure the new boiler is or the type of gas you are
using. Check the rating plate on the right side of the boiler.
You must see that the boiler is supplied with the correct type
of gas, fresh air for combustion, and a suitable electrical supply.
Also, the boiler must be connected to a suitable venting system
and an adequate piping system. Finally, a thermostat, properly
located, is needed for control of the heating system. If you
have any doubts as to the various requirements, check with
local authorities and obtain professional help where needed.
Take the time to complete all of the steps for SAFE and
PROPER operation of the heating system.

GASOLINE

AND OTHER

Installers - Follow local regulations
with respect to
installation
of CO detectors.
Follow maintenance
recommendations
in this instruction manual.
Techniciens
Veuillez
vous
conformer
a la
reglementation en vigueur concernant I' installation des
d_tecteurs d'oxyde de carbone. Suivre les consignes
d'entretien

FLAMMABLE

figurant dans le manuel dinstruction

VAPORS

AND LIQUIDS

ci-joint.

1. Select level location as centralized with piping system, and
as near chimney, as possible.
2. Place crated boiler at selected location, remove crate
by pulling crate sides from top and bottom boards.
Combustible floors: When boiler is to be installed on a
combustible floor, a Special Base Plate must be used 146-14-031 (2-6 Section) or 146-14-032 (7-9 Section).
This boiler must not be installed on carpeting.

6. Advise owner to keep air passages free of obstructions.
Ventilating and combustion air must enter boiler room
without restrictions.
7. The boiler shall be installed such that the automatic gas
ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation
and service (condensate trap, control replacement, etc.).

3. Boiler is to be level. Metal shims may be used under
base legs for final leveling.
4. Additional clearances for service may exceed clearances
for fire protection. Always comply with the minimum fire
protection clearances shown on the boiler. An 18 inch
clearance should be maintained on any side where
passage is required to access another side for cleaning,
servicing, inspection or replacement of any part that may
need attention. An 18-inch clearance is recommended
on the control side for servicing.
Figure 2 shows minimum clearances to combustible
construction. Rooms that are large in comparison with
the size of the boiler are defined as rooms having a
volume equal to or greater than 16 times the volume of
the boiler. Where the actual ceiling height of a room is
greater that 8', the volume of a room shall be figured on
the basis of a ceiling height of 8'. Determination of room
size should be based do the total volume of all gas fired
equipment installed in the room. Consult section 6.3.1
of the National Fuel Gas Code for further information,
including approved methods for reducing clearances in
large rooms.
5. Equipment shall be installed in a location in which the
facilities for ventilation permit satisfactory combustion
of gas, proper venting, and maintenance of ambient
temperature at safe limits under normal conditions of use.
Equipment shall be located so as not to interfere with
proper circulation of air. When normal infiltration does
not provide the necessary
air, outside air shall be
introduced (See Page 4 - "Fresh Air for Combustion").

Alcove, or Room Not
Large in Comparison
With Boiler

Room Large In
Comparison
With Boiler

2-5 SECT.

6-9 SECT.

2-9 SECT.

Top
Rear
Control Side

6"
6"
8"

6"
6"
24"

6"
6"
6"

Opposite Side
Front
Flue/Vent Connector

6"
18"
6"

24"
18"
6"

6"
18"
6"

Near Boiler Piping

1"

1"

1"

Minimum
Boiler
Size
2 sect.
3 sect.
4 sect.
5 sect.
6 sect.
7 sect.
8 sect.
9 sect.
FOR

ROOM

Boiler
Volume
(Cu. Ft.)
3.8
5.4
7.0
8.5
10.1
11.7
13.2
14.8
WITH

SINGLE

BE SET ON A CONCRETE
MATERIAL

BASE

OR

Volume

Room
Required

To Be Large
Room (Cu. Ft)*
61.6
86.6
111.6
136.6
161.7
186.7
211.7
236.7
BOILER

ONLY

OR OTHER

FLOOR.

THIS

UNIT

MUST

NON-COMBUSTIBLE

Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation,
of the National Fuel Gas Code, ANSI Z223.14atest revision, or applicable provisions of the local building codes.

NOTE

WARNING
Be sure to provide enough fresh air for combustion. Enough
air insures proper combustion and assures that no hazard
will develop due to the lack of oxygen.
Youmust providefor enoughfresh air to assure propercombustion.The
fire in the boiler uses oxygen.It musthavea continuoussupply.Theair in
a house containsonly enough oxygen to supply the burner for a short
time.Outsideair mustenterthe houseto replacethat usedby the burner.
_udy followingexamples1 and2 todetermineyourfresh airrequirements.
EXAMPLE1: BoilerLocatedin UnconfinedSpace
An unconfined space is defined as a space whose volume is not less
than 50 cubic feet per 1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (unpartitioned basement) in a
conventionalhouse, the air that leaks throughthe cracks around doors
and windows will usually be adequate to provide air for combustion.
The doors should not fit tightly. Do not caulk the cracks around the
windows.
Equipment located in buildings of unusually tight construction shall be
provided with air for combustion,ventilation, and dilution of flue gases
using the methods described in example 2B or shall be specially
engineered. The authority having jurisdiction must approve specially
engineered installations.
EXAMPLE 2: Boiler Located in Confined Space
A. All Air from Inside the Building: The confined space shall be
providedwith two permanentopeningscommunicatingdirectlywith
an additional room(s) of sufficient volume so that the combined
volume of all spaces meets the criteria for an unconfined space.
The total input of all gas utilization equipment installed in the
combined space shall be considered in making this determination.
Each opening shall have a minimum free area of one square inch
per 1,000 Btu per hour of the total input rating of all gas utilization
equipment in the confined space, but not less that 100 square
inches. One opening shall be within 12 inches of the top and one
within 12 inches of the bottom of the enclosure. The minimum
dimension of air openings shall not be less than 3 inches.
B. All Air from Outdoors: The confined space shall communicate
with the outdoors in accordance with methods 1 or 2. The minimum
dimension of air openings shall not be less than 3 in. Where ducts
are used, they shall be of the same cross-sectional area as the
free area of the openings to which they connect.
1. Two permanent openings, one commencing within 12 inches of
the top. and one commencing within 12 inches of the bottom,
of the enclosure shall be provided. The openings shall
communicate directly, or by the ducts, with the outdoors or
spaces(crawlor attic)that freely communicatewith the outdoors.
a) Where directly communicating with the outdoors or where
communicating to the outdoors through vertical ducts, each
opening shall have a minimum free area of 1 sq. in. per 4000
Btu per hour oftotal inputratingof all equipment inthe enclosure.
(See Figure 3B)
b) Wherecommunicatingwith the outdoorsthrough horizontalducts.
each opening shall have a minimum free area of I sq. in. per
2000 Btu per hour of total input rating of all equipment in the
enclosure.(See Figure 38.)

If you use a fireplace or a kitchen or bathroom exhaust fan,
you should install an outside air intake. These devices will
rob the boiler and water heater of combustion air.
2. One permanent opening commencing with 12 inches of
the top of the enclosure, shall be permitted where the
equipment has clearance of at least 1 inch from the sides
and back and 6 inches from the front of the appliance. The
opening shall directly communicate with the outdoors or
shall communicate through a vertical or horizontal duct to
the outdoors or spaces (crawl or attic) that freely
communicate with the outdoor, and shall have a minimun
free area of:
a) 1 sq. inch per 3000 Btu per hour of the tatal input of all
equipment located in the enclosure ( See Figure 4), and
b) Not less than the sum of the areas of all vent connectors
in theconfined space.

Fresh Air
Duct Size
3" x 12"
8"x 8"
8" 12"
8½" x 16"

1 Square Inch per 4,000 Btuh
100% Free
75% Free
25% Free
Area
Area
Area
¼" Wire
Metal
Wood
Mesh
Louvers
Louvers
144,000
108,000
36,000
256,000
192,000
64,000
384,000
288,000
96,000
512,000
384,000
128,000

Fresh Air
Duct Size

Square Inch _er 2,000 Btuh
100% Free
75% Free
25% Free
Area
Area
Area
¼" Wire
Metal
Wood
Mesh
Louvers
Louvers

3" x 12"
8" x 8"
8" 12"
8½" x 16"

Fresh Air
Duct Size
3" x 12"
8" x 8"
8" 12"
8½" x 16"

72,000
128,000
192,000
256,000

54,000
96,000
144,000
192,000

18,000
32,000
48,000
64,000

Square Inch _er 3,000 Btuh
100% Free
75% Free
25% Free
Area
Area
Area
¼" Wire
Metal
Wood
Mesh
Louvers
Louvers
108,000
81,000
27,000
192,000
144,000
48,000
288,000
216,000
72,000
384,000
288,000
96,000

1.Placeboilerin theselectedlocation(as nearchimneyas The minimum design return water temperature to the boiler to
possible.)
Yourboilerisshippedassembled.
Youneedonly prevent condensation in the boiler and venting is 120 ° F. The
toinstalltheReliefValveanda drainlinetocarryanywater minimum high limit setting is 140 ° F.
or steamtoa drain.
2.InstallReliefValveintothe3/4"pipeonthetopoftheboiler.
CAUTION
SeeFigure5.Use3/4"Pipeandanelbow(notfurnished)
to
carrythewaterorsteamtoa nearbydrain.Donotconnect THE ISOLATION BALL VALVES CONTAIN TEFLON
SEATS AND SEALS, OVERHEATING THIS VALVE MAY
directlyto a drainbut leavean airgap.Noshutoffof any
description
shallbe placedbetweenthesafetyreliefvalve
CAUSE PREMATURE FAILURE.
andtheboiler,or ondischarge
pipesbetweensuchsafety
valvesandtheatmosphere.
Installation
of thesafetyrelief
valveshallconformtotherequirements
oftheANSI/ASME
Boiler and PressureVessel Code, Section IV. The
manufacturer
isnotresponsible
foranywaterdamage.
Install
DrainValveinlowerleftsideofboilerasmarked.
3.ConnectSupplyandReturnLinestoboiler.Theconnections
mayrequirecertainadditionalfittingsandparts,asshown
ondiagram(Figs.5 and6).
4. This boiler is equippedwith 1 1/4"supplyand return
connections
onboththeleftandrightsidesoftheboiler.
In connecting
the coldwatersupplyto thewaterinletvalve,
makesurethata cleanwatersupplyis available.Whenthe
watersupplyisfroma wellorpump,a sandstrainershouldbe
installedatthepump.
A hot waterboilerinstalledaboveradiationlevel mustbe
equipped
witha lowwatercutoffdevice.A periodicinspection
is necessary,as is flushing of float type devices, per
manufacturers
specificinstruction.
FOR USE WITH COOLING

UNITS

A. This boiler, when used in connection with chilled water
systems, must be installed so that the chilled water is piped
in parallel with the heating boiler. Appropriate valves must
be used to prevent the chilled water from entering the heating
boiler (Fig. 6).
B. When this boiler is connected to heating coils located in air
handling units where they may be exposed to refrigerated
air circulation, the piping system shall be equipped with flow
control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.

LOW
DESIGN
WATER
SYSTEMS (BELOW 140 °)

TEMPERATURE

If the boiler is to be used in a heating system where design
water temperatures below 140 ° F are desired (e.g. radiant floor
heating), a 3-way or 4-way mixing valve or suitable alternative
is required to prevent low temperature return water from
entering the boiler. Follow the mixing valve manufacturer's
installation instructions.

TO

_/ALVES
A 8_ S
OPEN FOR HEATINGj
CLOSE
FOR COOLING
_/ALVES
C 8_ D
CLOSE
-OR
HEATINGj
OPEN
FOR
COOLING

j_
WATER

CHILLER

SYSTEM

Z223.1=latest

CHECK

revision

and

applicable

provisions

YOUR CHIMNEY

This is a very important part of your heating system. It must be
clean, the right size, properly constructed and in GOOD
CONDITION. No boiler can function properly with a bad
chimney. Fig. 7 gives typical chimney sizes. Fig. 8 gives you
an idea how a boiler might be vented to a chimney. Note that
the height (HT) is measured from the vent pipe to the top.

CHIMNEY

SIZING

Chimney sizing, and all other aspects of the vent installation
must be in accordance with Part 7 of the National Fuel Gas
Code, ANSI Z223.1 latest revision, and applicable provisions
of the local building codes.
In Canada, follow CAN/CGA B149.1 and B149.2, Installation
Codes for Gas Burning Appliances and Equipment.

CONNECTING
CONNECTOR

THE VENT

DAMPER

of the

codes.

The sections of vent pipe should be fastened with sheet metal
screws to make the piping rigid. Horizontal portions of the vent
system must be supported to prevent sagging. Use stovepipe
wires every 5' to support the pipe from above If the vent pipe
must go through a crawl space, double wall vent pipe should
be used Where vent pipe passes through a combustible wall
or partition, use a ventilated metal thimble. The thimble should
be 4 inches larger in diameter than the vent pipe.

AND VENT

IMPORTANT - The damper blade on the furnished vent damper
has a 1/2 square inch hole (approximately3/4 diameter). On
boilers equipped with standing pilot, the hole must be left open.
On boilers equipped with intermittent ignition, the hole should
be plugged by using the plug supplied with the vent damper.
1. Position furnished vent damper on top of flue outlet collar.
Fasten damper securely to flue outlet collar with sheet
metal screws. Make sure damper blade has clearance to
operate inside of diverter.
On 2 section boilers equipped with vent damper, the
supplied 4-inch vent damper is equipped with a 3- to 4inch adapter so that the 4-inch vent damper may be
installed on the boiler's 3-inch flue outlet collar. Fasten all
fittings securely.

(U.S.A.

building

7. Run pipe as directly as possible with as few elbows as
possible.
8. Do not connect to fireplace flue.
9. End of vent pipe must be flush with inside face of chimney
flue. Use a sealed-in thimble for the chimney connection.
10. Horizontal run should not be longer than s/4 the
chimney height (HT) (Fig, 8).

Refer to Fig. 1 flue diagram for the size and location of the vent
(flue opening). Use a 28 gauge (minimum) galvanized pipe to
connect to the chimney.

As An Option

local

Only)

The damper may be installed in any horizontal or vertical
position, closer to the flue outlet collar preferred. Follow
the diagrams - Figures 9, 10 and 11.
2. Install the vent damper to service only the single boiler for
which it is intended. The damper position indicator shall
be in a visible location following installation. Locate the
damper so that it is accessible for servicing.
3. The damper must be in the open position when appliance
main burners are operating.
4. The boiler is equipped with a factory wired harness that
plugs into the vent damper.
5. Vent pipe must be same size as the flue outlet collar, except
2 section boilers with vent damper as noted above.
6. Slope pipe up from boiler to chimney not less than 1/4" per foot.

Boiler Input
Btuh
Up to 100,000
Up to 155,000
Up to 230,000
Up to 350,000

FLUE AREA IN INCHES
*HT.
*HT.
*HT.
10-15 Ft.
10-25Ft.
25Ft. UP
6x6
6x7
7x8
9x9

6x5
6x6
7x7
8x9

5x5
6x5
6x7
8x8

HT = top of thimble to top of flue. See Fig. 8
For boiler input refer to table, page 2.
For information only - not meant to imply minimum sizes.

MiNiMUM

VENT

PiPE CLEARANCE

Wood and other combustible materials must not be closer than
6" from any surface of single wall metal vent pipe. Listed Type
B vent pipe or other listed venting systems shall be installed in
accordance with their listing.

REMOVING
EXiSTiNG
BOILER
COMMON VENTING SYSTEM

FROM

When an existing boiler is removed from a common venting
system, the common venting system is likely to be too large
for proper venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps
shall be followed 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.
1. Seal any unused openings in the common venting system.
2. 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.

3.Insofarasispractical,
closeallbuildingdoorsandwindows
andalldoorsbetweenthespaceinwhichtheappliances
remainingconnected
tothe commonventingsystemare
locatedandotherspacesofthebuilding.Turnonclothes
dryersandanyappliancenotconnected
to thecommon
ventingsystem.Turnonanyexhaustfans,suchasrange
hoodsand bathroomexhausts,so theywill operateat
maximumspeed.Donotoperatea summerexhaustfan.
Closefireplacedampers.
4. Placeinoperation
theappliance
beinginspected.Follow
thelightinginstructions.
Adjustthermostat
soappliance
willoperatecontinuously.
5. Testfor spillageat thedrafthoodreliefopeningafter5
minutes
ofmainburneroperation.
Usetheflameofa match
or candle,or smokefroma cigarette,cigaror pipe.
6.Afterit hasbeendetermined
thateachapplianceremaining connectedto the commonventingsystemproperly
ventswhentestedasoutlined
above,returndoorswindows,
exhaust
fans,fireplace
dampers
andanyothergas-burning
appliance
totheirpreviousconditions
of use.
7.Any improperoperationof thecommonventingsystem
shouldbecorrected
so theinstallation
conforms
withthe
NationalFuelGasCode,ANSIZ223.1-1atest
revision.
Whenresizinganyportionofthecommon
ventingsystem,
thecommon
ventingsystemshouldberesizedtoapproach
the minimumsize as determinedusingthe appropriate
tablesin Part11in the NationalFuelGasCode,ANSI Vent
Z223.l-latestrevision.
shall

//

\MU£T
£/4

SLOPE
UP AT
!qCU
PER FLIBT

LEAST

connectors serving appliances vented by natural draft
not be connected into any portion of mechanical draft
systems operating under positive pressure.

HORIZONTAL

TO
OR

FI_N&CE
E_LER

_/ENT

INSTALLATION

]_4F_'F3_

_o

CAUT[BNE DD NOT [NSTALL
THE VENT
DAMPER
WITHIN
6 hq, <[52 ram) OF
CBMBUSTA_LE
MATERIAL

OI[NNE(

NO
%

INS_#_L lYE}IT DANPE_ _TH
_CTU_TORTO
_]_
OF VZNT
DNLY, D0 NOT _[]UNT A_O_/E
OR DELO'_ VENT,

V'ERTICAL

INSTALLATION

CHIMNEY

FLB%"

ACTUATOR NAY BE
34_TALL[_ IN _NY F_ZT_N

_01LER

OR _OILER
TO

FUF,_L_CE

[_

TYPICAL

iNSTALLATiON
FOR VENT DAMPER
NOT CAUTION AND FOOTNOTES

1. Install the vent damper to service only the single
appliance for which it is intended. If improperly
installed, a hazardous condition, such as an explosion
or carbon monoxide poisoning, could result.
2. Do not install the vent damper on pipe curve.
3. Do not run wires near high temperature
stand-off brackets if necessary.

surfaces. Use

For safe, efficient operation, the vent damper and all flue product
carrying areas of the appliance must be checked annually by
you, with particular attention given to deterioration from
corrosion or other sources.
If you see corrosion or other
deterioration, contact yourheating contractorfor repairs. Check
vent damper operation as follows:
1.

When the boiler is off, check that the vent damper positions
indicator points to the closed position, Fig. 11.

2.

Turn the thermostat or controller up to call for heat and
check the vent damper indicator points to the open
position, Fig. 11.

3.

located on the damper controller. The thermostat will control
the burner firing as before, while the damper will remain open.
DO NOT turn damper open manually or motor damage will
result. Set switch to "AUTOMATIC OPERATION" to close vent
damper during burner off cycle.
For further information, and for a vent damper troubleshooting
guide, refer to the manual that was packaged with the vent
damper.
The vent damper must be inspected at least once a year
by a trained, experienced service technician. The name of
the person who originally installed your vent damper is
shown on the installation label.

rq

z

Turn the thermostat or controller down again and check
that the damper position indicator returns to the closed
position.

MANUAL

OPERATION

OF THE VENT DAMPER

DANPER

The vent damper may be placed in the open position to permit
burner operation by using the "HOLD DAMPER OPEN" switch,

NOTES FOR CANADA
1.

2.

SHOWING

ONLY

Canadian Standard CAN1-2.28-M81 prohibits the use of
vent dampers on propane fired appliances equipped with
intermittent ignition.
In Canada, the vent damper must be attached directly to
the flue outlet collar, with the exception of the 2 section
boiler, where the 3- to 4-inch adapter is supplied with the
vent damper.

CLOSFD

_AHPER

OPEN AN_

CLBSEB

OPEN

POS[TION

No other interconnectng pieces are allowed between the
boiler and the vent damper.
,

In Canada, vent dampers are not an option. Boilers are
either factory built for use with a vent damper and the vent
damper is supplied with the boiler, or they are factory built
for use without a vent damper. In the second case a vent
damper cannot be installed later.

CHECK GAS SUPPLY
The gas pipe to your boiler must be the correct size for the
length of the run and for the total Btu per hour input of all gas
utilization equipment connected to it. See Fig. 12 for the proper
size. Be sure your gas line complies with local codes and gas
company requirements.

NATURAL
Pipe Capacity
Length

The boiler and its individual shutoff 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 (3.5 kPa).
The boiler must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures
equal to or less than 1/2 psig (3.5 kPa).

CONNECTING

CHECKING

- Btu Per Hour Input

Includes

Fittings

Pipe - Ft.
20

1/2"
92,000

3/4"
190,000

1"
350,000

1¼"
625,000

40

63,000

130,000

245,000

445,000

60

50,000

105,000

195,000

365,000

PROPANE
Pipe Capacity
Length

THE GAS PiPiNG

Refer to Fig. 13 for the general layout at the boiler. It shows
the basic fittings you will need. The gas line enters the boiler
from the right side.
The following rules apply:
1. Use only those piping materials and joining methods listed
as acceptable by the authority having jurisdiction, or in
the absence of such requirements, by the National Fuel
Gas Code, ANSI 223.I-latest revision. In Canada, follow
the CAN/CGA B149.1 and .2 Installation Codes for Gas
Burning Appliances and Equipment.
2. Use pipe joint compound suitable for LP gas on male
threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection to
the gas valve to keep it from turning.
6. Install a manual shut-off valve in vertical pipe about 5
feet above floor.
7. Tighten all joints securely.
8. Propane gas connections should only be made by a
licensed propane installer.
9. Two-stage regulation should be used by the propane
installer.
10. Propane gas piping should be checked out by the
propane installer.

of

GAS

of

GAS
- Btu Per Hour Input

Includes
Copper
5/8"

20
40

131,000
90,000

216,000
145,000

189,000
129,000

393,000
267,000

60

72,000

121,000

103,000

217,000

* Outside

Tubing*
3/4"

Fittings

Pipe - Ft.

Iron Pipe
1/2"
3/4"

diameter

The lenght of pipe or tubing should be measured
meter or propane second stage regulator.

AUTOHATIC

GA3
VALVE_

THE GAS PiPiNG

\\\x

MANIFOLD

Upon completion of piping, check immediately for gas leaks.
Open the manual shut-off valve. Test for leaks by applying soap
suds (or a liquid detergent) to each joint. Bubbles forming indicate
a leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE.

fJ

FLOOR

I0

LINE

f

-_

_

J

from the gas

All electrical work must conform to local codes as well as the
National Electrical Code, ANSI/NFPA-70, latest revision. In
Canada, electrical wiring shall comply with the Canadian Electrical Codes, CSA-C22.1 and.2.

ELECTRIC

POWER

a vertically mounted outlet box. It should be sensing average
room temperature, so avoid the following:
DEAD SPOTS:
Behind doors
Corners and alcoves
HOT SPOTS:
Concealed pipes
Fireplace
TV sets
Radios
Lamps
Direct sunlight
Kitchens
COLD SPOTS:
Concealed pipes or ducts
Stairwells - drafts
Doors - drafts
Unheated rooms on other side of wall

SUPPLY

Run a separate 120 Volt circuit from a separate overcurrent
protective device in the electrical service entrance panel.
This should be a 15 ampere circuit. Locate a shut-off switch
at the boiler. It must be turned offduring any maintenance.
Connect 120 Volt power supply to aquastat terminals L1
(HOT) and L2.
The boiler, 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
National Electrical Code, ANSI/NFPA No. 70-latest revision.
Run a 14 gauge or heavier copper wire from the boiler to a
grounded connection in the service panel or a properly driven
and electrically grounded ground rod.

WARNING
Turn off electric power at fuse box before making any line
voltage connections. Follow local electrical codes.

INSTALL

YOUR

THERMOSTAT

The thermostat location has an important effect on the operation
of your boiler system. BE SURE TO FOLLOW THE
INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT.

Set heat anticipator at .2 amps. 24 Volt thermostat connects
to aquastat terminals T and TV.

VENT DAMPER

WIRING

The boiler is equipped with a factory wired harness with 4 pin
molex plug, that plugs into a 4 pin molex receptacle inside the
vent damper operator.
The vent damper must be connected for the boiler to
operate.
Wiring diagrams follow for the various different models.

Locate the thermostat about five feet above the floor on an

CAUTION

inside wall. It may be mounted directly on the wall or on

Label all wires prior to disconnection
when servicing
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.

The pump does not come pre-installed on the boiler. It must
be connected to the circulator harness in the field according to
the pump manufacturer's instructions and the wiring diagrams
in this manual.

11

INTERMITTENT

IGNITION

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vALVE

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE
MUST BE REPLACED,
IT MUST BE REPLACED
WITH TYPE 105°C THERMOPLASTIC
WIRE OR ITS EQUIVALENT.
NOTE: THE CIRCULATOR
HARNESS IS FACTORY WIRED TO THE AQUASTAT. THIS HARNESS
NEEDS TO BE CONNECTED
TO THE CIRCULATOR
IN THE FIELD.
12

STANDING

PILOT

F

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE
MUST BE REPLACED,
IT MUST BE REPLACED
WITH TYPE 105°C THERMOPLASTIC
WIRE OR ITS EQUIVALENT.
NOTE: THE CIRCULATOR
HARNESS IS FACTORY WIRED TO THE AQUASTAT. THIS HARNESS
NEEDS TO BE CONNECTED
TO THE CIRCULATOR
IN THE FIELD.
13

RELIEF

VALVE

AIR ELIMINATING

You must have a relief valve on your boiler. Water expands as
it is heated. If there is no place for the water to expand into,
water pressure wilJ build up inside the boiler and system. Should
this happen, the relief valve will automaticalJy open at a
predetermined pressure. This will relieve the strain on the boiler
and system. Run a pipe from the relief valve outlet (pipe must
be same size as outlet and the open end must not be threaded)
to an open drain, tub or sink, or other suitable drainage point
not subject to freezing. Failure to do so may cause water
damage or injury should relief valve release.

EXPANSION

TANK

In a properly assembled system, the expanding water flows
into a expansion tank. This tank should be of the correct size.
The tank is filled with air. As the water expands it compresses
the air in the tank to form an air pressure cushion. This "springlike" cushion serves to maintain correct operating water
pressure regardless of water temperature. This assures a "full
measure" of a water, even in the highest radiation unit of the
system. It also prevents blowing off of the relief valve.
The air in the tank in the beginning (with system filled with cold
water) is sufficient for proper operation. The tank also serves
as a trap for excess air in the system. The air would cause
gurgling in the pipes and inefficient circulation in the radiators
if left in the system . It is possible for a tank to become
"waterlogged" (filled with water). It can also become overfilled
with air. This can happen after filling the system with new water.
Fittings provided on the tank and in the line to the tank are for
bleeding off excess water or air.
When installing this tank, it is important:
1) That the tank be higher than the boiler top.
2) That the pipe to the tank continuously rises up to the tank
(so that air can "bubble" up to it).

DIAPHRAGM

TYPE EXPANSION

TANK

The diaphragm type expansion tank (EX-TROL) takes the place
of the conventional
expansion tank. Carefully read the
instructions packed with your EX-TROL tank assembly.
The EX-TROL tank comes to you with a 10-12 pounds per square
inch air charge. This is the same as the pressure produced in
the system by the automatic fill valve. When the system is first
filled, the EX TROL tank will contain little or no water.
As the water is heated its pressure increases. It expands into
the EX-TROL tank, compressing the air in the tank. This
compressed air cushion permits the water in the system to
expand as the temperature changes.

FITTING

(AIR PURGER)

An air purger is used to remove excess air from the system. It
is installed in the supply line. It will eliminate air from the water
before it reaches the radiators and bleed off this air.

MAiN AiR VENT
OR DIAPHRAGM

FOR DOWN FLOW SYSTEMS
TYPE EXPANSION
TANK

Before a system is filled with water, there is air in the pipes and
radiation units. Some of it will be trapped as the system is filled.
It is possible to eliminate most of this air through the air vents
on the radiation units. A main air vent will speed and simplify
this. It should be installed on the highest point in the supply
main when all radiation is below top of boiler.

AUTOMATIC

FILL VALVE

For safe, efficient operation, a hot water system must be
completely filled with water. Adding new water, when needed
can be done manually (by use of a hand valve in the water
supply line). This requires regular attention to the system's
needs. An automatic fill valve accomplishes this without
attention. It is installed in the supply line on hot water boilers
only. The valve operates through water pressure differentials.
It does not require an electrical connection.

DRAIN VALVE
This manual valve Provides a means of draining all water from
the boiler and system. It is often installed in the 3/4" tapping at
the bottom of the end boiler section. Or it can be installed in a
tee where the return line enters the boiler.

WATER

TEMPERATURE

CONTROL

The water temperature limit control in the relay is adjustable
and may be set as necessary. It may be set as low as 140°F,
or as high as 240°F. This depends on the type and amount of
radiation involved and weather conditions.

CIRCULATING

PUMP

Every forced hot-water system requires a circulating pump. A
separate pump or zone valve is required for each zone, if you
have a two or more zone system. This pump must have the
capacity to provide the circulation required by your system.

VENT DAMPER
This product is an automatic, motorized stack damper that has
been developed to increase the efficiency of heating system
by reducing standby losses from the heating apparatus and
the conditioned air space. The damper closes the chimney
vent when the burner is off and fully opens it when combustion
is required.

The diaphragm type tank can be mounted on the air purger
fitting or at any convenient place in the supply or return line.

14

ROLLOUT
(FLAME

SWITCH

SPILL SWITCH

ROLLOUT

SAFETY

SHUTOFF)

The rollout switch is a temperature-sensitive fuse link device.
It is located on the boiler base just outside the fire box. In the
event of heat exchanger flueway blockage causing flame to
roll out of the fire box, the fuse will blow, shutting clown the flow
of gas to the main burners. The fuse does not change in
appearance when blown.
If the rollout switch blows, it must be replaced with an exact
replacement. Check heat exchanger flueways for blockage
when restoring system to operating condition. DO NOT operate
system without a rollout switch.

HOW A HOT-WATER

SYSTEM

(BLOCKED

OPERATES

radiation unit in the system (ending up at the highest unit in the
system). If your units have automatic vents, this manual venting
is unnecessary but it will speed up the proper filling of your
system.
If your system is a closed expansion tank system, you may
leave it open to refill the system automatically as needed. Check
the temperature pressure gauge. Not the position of the hand

turn main to the boiler. This provides positive and rapid response
to the thermostat.

SYSTEM

WITH WATER

Close the air vents on all radiation units. Open the valves to

SHUTOFF)

In the event that the spill switch contacts open, the reset button
on the back of the switch will pop up. The spill switch must be
reset manually, after the switch has cooled off, by pushing the
reset button down. Check the venting system and chimney for
blockage when restoring the system to operating condition. DO
NOT operate the boiler without a spill switch.

Your entire heating system (boiler, piping and radiation units)is
filled with water. As the water in the boiler is heated, it is pumped
from the top of the boiler through the supply main to the radiation units. The cooler water in them flows back through the re-

FILLING

VENT SAFETY

The spill switch isa manual reset disc thermostat with a fixed setpoint
(340° F), and normally closed contacts. It is located at the relief
opening of the integral draft diverter. In the event of chimney or
venting system blockage causing products of combustion to spill
out of the relief opening, the spill switch disc heats up and the spill
switch contacts open, shutting down the flow of gas to the main
burners by removing power to the gas valve.

indicating pressure. This should be between 10 and 15 Ibs.
Any lowering of this movable hand below 10 Ibs. Will indicate
loss of water due to leakage. The automatic fill valve should
compensate for this. Instructions are packages with the valve.

these units. Make sure the boiler and expansion tank drain
cocks are closed. The air bleed screw on the tank drain fitting
should be closed. Open the valve in the line from the boiler to
the expansion tank. Open the water inlet to your boiler and

WARNING

leave it open. Start with the lowest radiation unit. Open the air
vent on this unit. When all the air has escaped and water starts
to flow from the vent, close it. Go to the next radiation unit, and
repeat this process. Repeat until you have covered every

Never

15

run water into a hot empty boiler.

WARNING:

If you do not follow

may result

causing

property

these

instructions

damage,

personal

exactly,

a fire or explosion

injury or loss of life.

* Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.

A. Some boilers are equipped with an intermittent ignition
device which automatically lights the pilot. Do not try to
light the pilot by hand.
Some boilers are equipped with a continuous pilot and must
be manually lighted. (See operating instructions on page
16-18.) A match holder is included in the parts bag.

C.

Use only your hand to push in or turn the gas control 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 result in a fire or explosion.

D.

Do not use this appliance if any part has been underwater.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system
and any gas control which has been under water.

B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone
in your building.

1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.

7. 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 on page 19 If you don't smell
gas, go to next step.
8. Rotate the gas control knob counterclockwise
to "ON."
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions "To
Turn Off Gas To Appliance" and call your service technician
or gas supplier.

TO TURN OFF GAS TO APPLIANCE
[NLE i I_

1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
GAS
SHOWN

IN

CiqNTRDL
"E]N"

KNDB

3. Push in gas control knob slightly and turn clockwise_
to "OFF" Do not force.

PDS_TIDN

5. Remove lower front panel.
6. Rotate the gas control knob clockwise,,_
to"OFF"

16

9.

1.STOP!Readthesafetyinformation
onpage16.
2.Setthethermostat
tolowestsetting.
3.Turnoffallelectricpowertotheappliance.
4. Removelowerfrontpanel.
5.Rotategascontrolknobslightlyandturnclockwise
to"OFF"

you light pilot burner with a match.
After about one minute, release reset button. Pilot should
remain lit. If it goes out, turn gas control knob clockwise
to OFF To relight, repeat steps 5-9.
• If button does not pop up when released, stop and
immediately call your service technician or gas supplier.

--GAS CONTROL KNOB
SHOWN IN "Oil
_ POSZT[DN

GAS
--_
INLET

Rotate the gas control knob counterclockwise
to "PILOT" Push down and hold the red reset button while

• If the pilot will not stay lit after several tries, turn the gas
control knob to "OFF" and call your service technician or
gas supplier.
10. After pilot remains lit when red reset button is released,
turn gas control knob counterclockwise to "ON."
11. Replace lower front panel.

_J!]!

12. Turn on all electric power to the appliance.
13. Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE
6. 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 on page 19 If you don't smell
gas, go to next step.
7. Find pilot - follow metal tube from gas control. The pilot is
between two burner tubes as shown in Fig. 14 on page 18.
8. Turn knob on gas control counterclockwise to f"_--,
"PILOT"

1.
2.

AUTOMATIC

RELIGHT

to "OFF" Do not force.

GAS VALVE

The Automatic Gas Valve opens or closes according to the
heat requirements of the thermostat and temperature limit
control. It closes if the pilot goes out. Each individual control
must be operating correctly before any gas can pass to the
burners. Any one control can hold the gas supply from burner
regardless of the demand of any other control.

SAFETY

3.

The electric and gas shall be offfor 5 minutes before relighting.

THERMOSTAT
Keep it set at a desired room temperature. If windows are to
be opened or heat is not needed, move thermostat pointer to a
lower setting.

PILOT
NOTE

Safety Pilot prevents the flow of gas to burner if the pilot goes
out, or will not ignite.

GAS VALVE

SAFETY

SHUTDOWN

OFF

ELECTRIC

POWER

In the event of failure of any component, the system will not
operate or will go into safety lockout. The system is
completely self-checking. On every call for heat, each
component must be functioning properly to permit operation.
On safety lockout the system has to be reset by turning the
thermostat to the lowest setting for one minute, then back
to the normal setting.

TEST

1. For boilers equipped with continuous pilot, with main burners
firing, disconnect the thermocouple from the gas valve. The
gas valve should immediately shut off the main burners and
the pilot.
2. For boilers equipped with intermittent ignition, with main
burners firing, disconnect the ignition cable from the
intermittent pilot control box. The gas valve should shut off
the main burners.

TURN

Set the thermostat to lowest setting.
Turn off all electric power to the appliance if service is to
be performed.
Push in gas control knob slightly and turn clockwise

to boiler before

reconnecting ignition cable, to prevent electric shock.

Safe lighting and other performance criteria were met with
the gas manifold and control assembly provided on the boiler
when the boiler underwent tests specified in ANSI Z21.13 latest revision.
17

PRESSURE
(UNDER

/J

REGULATOR

CBNVEN_NCE
TERMINAIS
(OPTIONAL)

ADJUSTHENT
CAP
¸SCREW)
\
\
\

(2)

(2>

INLFT
PRESStJR_

TAP

[NLETI_i

I_DUTLET

CUTLET
\PiLDI

ADJUS[MENI

CONNECTION
(UNDER
RED

RESET
BUTTON

CAR

SCREW)

GAS CONTROL
KNOB

m

/- OUTER MANTEL

/

INLET

ADJUST

I_

PILOT BURNER

idea how the system works. Example: If your system does not
give quite enough heat in very cold weather, you can raise the
limit setting to 220 ° F Use the boiler gauge to check your
settings. Make the adjustments according to its readings. Check
thermostat operation. When set above temperature indicated
on the thermometer, boiler should ignite. Make certain the
thermostat turns off the boiler when room temperature reaches
the selected setting and starts the boiler operating when room
temperature falls a few degrees.
After setting limit control to limit setting, check to see if it shuts
off the gas supply to the burners. Turn your thermostat up to call
for heat and let your boiler run until the temperature of the water
reaches the limit setting. The gas valve should shut off and the
circulator keep running until the thermostat is satisfied, or the
water cools enough to restart the burners through the limit control.
Finally, set the thermostat for the desired temperature. Special
conditions in your home and the location of the thermostat will
govern this setting.

Pilot flame should surround 3/8" to 1/2" of the pilot sensor.
Refer to Fig. 18. If flame needs adjusting, do it as follows:
1. Remove screw cover over pilot adjusting screw.
2. Insert small screwdriver and adjust flame as needed. Turn screw
counterclockwise to increase flame, clock-wise to decrease.
3. Replace screw cover over pilot adjusting screw.

MAiN BURNER(S)
The main burners do not require primary air adjustment and
are not equipped with primary air shutters. Main burner flames
should form sharp blue inner cones in a softer blue outer mantel,
with no yellow. Puffs of air from blowing on the flame or
stamping on the floor will cause the flames to turn orange
momentarily. This is not unusual. Remain still when observing
the main burner flames. If the flame appearance is not correct,
check main burner orifices and the burner throat and flame
ports for dust and lint obstruction. It may be necessary to
remove the rollout shield to observe the main burner flames.
Replace rollout shield after observation. Refer to Figure 17.

ADJUST

LIMIT CONTROLS

Instructions for each control are included with the controls.
These settings can be changed after you have had some
RECOMMENDED BOILER WATER TEM P ERATU RES
Type of Heating Unit
Limit Control Setting
Standing Radiators ................................... 180 ° F.
Baseboard and Convector Radiators ........ 200 ° F.
18

BURNERS
A visual check of the pilot end main burner flames should be
made at least once each year, preferably at the beginning of
the heating season. See page 21

RELIEF

VALVE

This valve should open automatically if the system pressure
exceeds the pressure rating (usually 30 psi) of the relief valve.
Should it ever fail to open under this condition, shut down your
system. Drain the system until system pressure is reduced
below the relief valve pressure rating. If valve discharge occurs, or if valve fails to open as described above, contact an
authorized contractor or qualified service technician to replace
the relief valve and inspect the heating system to determine
the cause, as this may indicate an equipment malfunction.
This valve should be tested every month during periods of boiler
operation, and at the beginning and end of any extended nonservice period. Prior to testing, make certain discharge pipe is
properly connected to valve outlet and arranged so as to contain and safely dispose of boiler discharge. Test at normal system operating pressure. Hold the trip lever fully open for at
least five seconds in order to flush free any sediment that may
lodge on the valve seat. Then permit the valve to snap shut.

EXPANSION

TANK

As previously noted, this tank may become waterlogged, or
may receive an excess of air. Frequent automatic opening of
the relief valve indicates water logging. A high boiler temperature accompanied by unusually low radiation unit temperature
(and "knocking") indicates excess air in tank.
To correct either condition, close the valve between the boiler
and the tank. Drain the tank until it is empty. Check all the tank
plugs and fittings. Tighten as necessary. Open the valve between the boiler and tank. Water will rise to the normal height
in the tank if you have an automatic fill valve (otherwise, manually refill the system).

BOILER

FLUE PASSAGES

Under normal operating conditions, with the burners properly
adjusted, it should not be necessary to clean the boiler flue
gas passages. However, to assure trouble-flee operation, we

recommend
that you have the flue passages,
burner
adjustment, and operation of the controls checked once each
year by a competent Service Technician.
Before the start of each season (or whenever system has
been shut down for some time) recheck the whole system for
leaks.., and recheck the boiler and vent pipe for leaks. Replace
or patch any boiler seals that are faulty.

VENT PIPE
The venting of this unit is very important and the piping
should be checked at least once a season, if the vent piping
shows any sign of leaking, replace it immediately.

WATER

SYSTEM

If system is to remain out of service during freezing weather,
always drain it completely (water left in to freeze will crack the
pipes and/or boiler).

CLEANING

YOUR

BOILER

AND BURNERS

Flue passages between sections should be examined yearly
and cleaned if necessary. To clean, remove burners, pilot, and
vent pipe, Remove top and front jacket panels. Remove the
two screws attaching the intermediate front panel to the left
and right side jacket panels. Remove the draft diverter and
intermediate front panel as a unit. Carefully remove the cerafelt
gasket strips. Clean passageways between sections with a
flexible handle wire brush. Remove dirt from bottom of boiler
and from between sections by vacuuming. Make sure all flame
ports in burners are open and clear. Shake out or blow out all
loose dirt in burners. Reseal seams between adjacent sections
as necessary with 400 F RTV silicone sealant. Reassemble
all parts. Be sure to check tightness of pilot connections and
condition of burner flames after reassembly (see Figures 17
and 18). Be sure vent pipe connections to chimney are secure
and no obstructions are present.

CIRCULATOR

PUMP ISOLATION

VALVES

The isolation valves in the circulator pump flanges should be
operated manually once or twice per year to prevent the valves
from becoming stuck in the open position Rotate the valves
from the open position to the closed position and back to the
open position.

19

You may avoid inconvenience and service calls by checking

these points before you call for service.

FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
1. Do Not try to light any appliance.
2. Do not touch any electric switch, do not use the phone.
3. Leave the building
immediately, then call your gas supplier.
4. If you cannot

Possible

Cause

Thermostat

Controls

is not set correctly
properly

power to boiler

out of adjustment

Radiators

not heating

Circulating

call the fire department.

What to do

Burner is not operating

No electric

reach the gas supplier,

Reset thermostat

above room temperature

Check flame. If it is yellow, the burner is not getting enough air.
Or, if flame is blue and noisy and seems to lift off the burner, the
burner is getting too mush air. Contact your service technician.
Check overcurrent protection.
supply circuit is "ON".
Reset according

Check to be sure electric

to instructions.

Open radiator vents to excess air. Check flow control valve (if
used). It may be in closed position.

pump not running

Check overcurrent

protection.

Check relay operation.

Poor electrical

contact

Check all control terminals

Rollout

blown

Have your service technician check heat exchanged
Replace rollout switch with exact replacement.

switch

power

and wire joints.
for blockage.

Spill switch blown

Have your service technician check venting system and chimney
for blockage, or down draft condition. Reset spill switch.

Vent damper

Consult troubleshooting
vent damper.

Possible

not operating

Cause

Gas input amount

is incorrect

Water logged expansion
YOUR

packaged

with

What to do

Possible Cause
Dirt on seat

HAVE

guide in Effikal manual,

SERVICE

Contact your service technician.

What to do
tank

Open valve manually. Allow water to run and clear valve seat.
Drain tank, see instructions.

TECHNICIAN

CHECK

ANY

2O

PROBLEM

YOU ARE

UNABLE

TO CORRECT.

GAS = FIRED HOT WATER

READ THESE

BOILERS

- IMPORTANTINSTRUCTIONS
BEFORE

17_

ORDERING
19

All parts are listed in the following Parts List may be
ordered through your nearest supplier.

2O

When ordering parts, first obtain the Model Number from the
data plate on your boiler, than determine the Part No. (not
the Key No.) and the Description
of each part from the
following
illustrations
and list. Be sure to give us all this
information:

t3\
12_

\

The Part No. - The Part Description - The Boiler Model No.

\

7

JACKET-

SECTION

1

AND BASE PARTS

THIS IS A REPAIR PARTS LIST - NOT A PACKAGING LIST
KEY
NO.

3 SECTION

4 SECTION

5 SECTION

6 SECTION

7 SECTION

8 SECTION

PaN No.

Part No.

PaN No.

Part No.

Part No.

PaN No.

Part No.

Part No,

425-00-901

425-00-901

425-00-901

425-00-901

425-00-901

425-00-901

425-00-901

425-00-901

2

Jacket, Right Side Panel
#10 x 1/2 Sheet Metal Screw

146-95-074

146-95-074

146-95-074

146-95-074

146-95-074

146-95-074

146-95-074

146-95-074

3

Rating Plate

146-80-901

146-80-901

146-80-901

146-80-901

146-80-901

146-80-901

146-80-901

146-80-901

4

Base Insulation - Base Sides (2)
- Base Front

146-14-020

146-14-130

146-14-130

146-14-130

146-14-130

146-14-130

146-14-130

146-14-130

146-14-112

146-14-113

146-14-114

146-14-115

146-14-116

146-14-117

146-14-118

146-14-119

146-14-122

146-14-123

146-14-124

146-14-125

146-14-126

146-14-127

146-14-128

146-14-129

1

DESCRIPTION

- Base Rear

2SECTION

9 SECTION

5

Base Baffle

425-00-642

425-00-643

425-00-644

425-00-645

425-00-646

425-00-647

425-00-648

425-00-649

6

Base

425-00-662

425-00-663

425-00-664

425-00-665

425-00-666

425-00-667

425-00-668

425-00-669

7

Jacket Tie Bar

425-00-652

425-00-653

425-00-654

425-00-655

425-00-656

425-00-657

425-00-658

425-00-659

8

Push Nipple

433-00-976

433-00-976

433-00-976

433-00-976

433-00-976

433-00-976

433-00-976

433-00-976

9

Jacket, Left Side Panel

425-45-900

425-45-900

425-45-900

425-45-900

425-45-900

425-45-900

425-45-900

425-45-900

10

Knob, Service Door (Pair)

137-02-513

137-02-513

137-02-513

137-02-513

137-02-513

137-02-513

137-02-513

137-02-513

11

Jacket, Service Door

425-00-912

425-00-913

425-00-914

425-00-915

425-00-916

425-00-917

425-00-918

425-00-919

12

Jacket, Int'd. Panel

425-00-812

425-00-813

425-00-814

425-00-815

425-00-816

425-00-817

425-00-818

425-00-819

13

Jacket, Front Panel

425-00-810

425-00-811

425-00-804

425-00-805

425-00-806

425-00-807

425-00-808

425-00-809

14

1/4" Tie Rod, Nat

146-05-008

146-05-001

146-05-002

146-05-051

146-05-053

146-05-005

146-05-007

146-05-009

15

Boiler Section, Left

410-00-020

410-00-020

410-00-020

410-00-020

410-00-020

410-00-020

410-00-020

410-00-020

16

Boiler Section, Middle

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

17
18

Jacket, Top Panel
Draft Diverter

425-45-842

425-45-843

425-45-844

425-45-845

425-45-846

425-45-847

425-45-848

425-45-849

425-00-672

425-00-673

425-00-674

425-00-675

425-00-676

425-00-677

425-00-678

425-00-679

19

Boiler Section, Right

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

410-00-021

20

Jacket, Back Panel

425-00-902

425-00-903

425-00-904

425-00-905

425-00-906

425-00-907

425-00-908

425-00-909

$

Jacket Complete

425-00-922

425-00-923

425-00-924

425-00-925

425-00-926

425-00-927

425-00-928

425-00-929

$

Btock Assembty (19, 16, 15, 14, 8)

410-00-213

410-00-313

410-00-413

410-00-513

410-00-613

410-00-713

410-00-813

410-00-913

$

Combustabte Floor Plate

146-14-031

146-14-031

146-14-031

146-14-031

146-14-031

146-14-032

146-14-032

146-14-032

$

Cerafelt Gasket

146-14-018

146-14-018

146-14-018

146-14-018

146-14-018

146-14-018

146-14-018

146-14-018

21

Vent Damper

118-20-04

118-20-05

118-20-06

118-20-06

118-20-07

118-20-07

118-20-07

118-20-07

$

Base Assembly (6, 5, 4)

433-00-662

433-00-663

433-00-664

433-00-665

433-00-666

433-00-667

433-00-668

433-00-669

:l: Not illustrated

21

GAS BURNERS

AND MANIFOLD

(FOR USE WiTH NATURAL

4

PARTS

GAS AND PROPANE)

5

2

NOTE:

Actual

gas valve

may look different

than gas valve

shown.

1

24 V Gas Valve, Elect. Ignition-Nat.
24VGasVatve,
Elect. Ignition-LP

146-62-052
146-62-062

146-82-052
146-82-062

146-82-052
146-82-062

146-82-052
148-82-062

!46-62-058
!46-62-059

146-62-058
148-62-059

146-62-058
!46-62-059

!46-62-058
146-62-059

2
3

Pilot Tube w/Fittings
10-32½HexHd.
Screw(2)
Gas Manifold-Nat.

433-00-201
146-95-307
146-16-032

433-00-201
146-95-307
146-16-033

433-00-201
146-95-307
146-16-034

433-00-201
146-95-307
146-16-035

433-00-201
146-95-307
146-16-013

433-00-20!
146-95-307
146-16-0!4

433-00-200
146-95-307
146-!6-015

433-00-200
!46-95-307
!46-16-0!6

Gas Manifold-LP

146-16-009

146-16-010

146-16-01!

146-16-012

!46-16-0!3

!46-!6-0!4

!46-!6-0!5

!46-!6-016

Main Burner Orifice - Nat.*
Main BumerOrifice-LP*

!46-!5-041
146-16-043

!46-15-041
146-16-043

146-15-041
146-16-043

146-15-041
146-16-043

146-15-042
146-16-043

146-15-042
146-16-043

146-15-042
146-16-043

146-15-042
146-16-043

Main Bumer**
Main Burner with Pilot Bracket**

--!46-15-531

146-15-532
146-15-531

146-15-532
146-15-531

146-15-532
146-15-531

!46-15-532
146-15-531

!46-!5-532
146-15-53!

!46-!5-532
146-15-531

!46-15-532
146-15-531

7

Pilot BurnerPilot Burner-

146-62-095
!46-62-093

!46-62-092
!46-62-094

146-62-092
146-62-094

146-62-092
146-62-094

146-62-092
146-62-094

146-62-092
146-62-094

146-62-092
146-62-094

146-62-092
146-62-094

+

Rollout Shield

425-00-932

425-00-933

425-00-934

425-00-935

425-00-936

425-00-937

425-00-938

425-00-939

4
5
6
6A

Nat.
LP

_'Ill:
1
7
+

NOTE:

;,]_r-,Aud
=li#-,I ;;uuF,.I: o] ;,][o,][o]
_ idl_il[o].lJ.'-Ruin[o]

24 V Gas Valve, Continuous

Pilot - Nat.

146-62-05!

146-62-051

146-62-05!

146-62-051

!46-62-060

!46-62-060

_ _ECTI_
146-62-060

_ _ECT!_N
!46-62-060

24 V Gas Valve, Continuous
Pilot Burner- Nat.

Pilot - LP

--146-62-098

146-95-30!
!46-62-098

146-95-30!
146-62-098

146-95-301
146-62-098

!46-95-301
146-62-098

!46-95-301
146-62-098

!46-95-301
146-62-098

!46-95-301
146-62-098

Pilot Burner - LP

---

!46-62-096

146-62-096

146-62-096

146-62-096

146-62-096

146-62-096

146-62-096

Thermocouple-Nat.
Thermocouple-LP

146-62-037
---

146-62-037
146-62-037

146-62-039
146-62-039

146-62-039
146-62-039

!46-62-039
!46-62-039

!46-62-039
146-62-039

146-62-036
!46-62-036

!46-62-036
146-62-036

* Requires 1 less than the number of sections.
•* Requires 2 less than the number of sections.
+ Not Illustrated

22

BOILER CONTROLS

AND PiPiNG

Key
No.

Part
No.

Description

1

¾" ASME Relief Valve

146-22-011

2

¾" x 7½" Nipple

146-07-041

3

Temperature

146-23-009

6

11A,,x ¾,, x 11A,, Tee

151-00-01

7

Aquastat

101-00-02

8

Pessure Gauge - 5" Stem

Relay

Isolation Ball Valve

146-26-043

Grundfos UP15-42F Circulator

Cl-006.01

9

Taco 007 Circulator

Cl-001.03

10

1!/4'' x 2½" Nipple

146-07-044

11

11A'' Bent Return Nipple

146-07-003

12

Intermittent

Pilot Control

Spill Switch (36TX16-6281)340

146-62-070
146-60-002

° F

Rollout Switch

146-29-002

4" Vent Damper (w 3" Adapter)

118-20-04

5" Vent Damper

118-20-05

6" Vent Damper

118-20-06

7" Vent Damper

118-20-07

Vent Damper Operator (Motor)

114-00-02

400 ° F Black Silicone Rubber Adhesive

146-06-020

Sealant (10.3 oz. Cartridge)
:l: Not illustrated

Note:

23

the circulator
pre-installed."

and ball valves

do not come

14683002

Rev.3,November
2004



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