DUNKIRK Boiler Manual L0612044
User Manual: DUNKIRK DUNKIRK Boiler Manual DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides
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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 _[ I _ I £I:S RE --L _ DE I ER I:,:B[ I I :, I I ' J 17 T ST E _ISL : E ',, )[ A, [ ', I T Aq E ,I I'I /. I)tl I [ ',', I :'_,, £ t I I IJ i r /,,i '!i ,,' ! ',m, i:'! ,I I, i i i¸ _:_, ' i i i c} i i1< I t_ =il i :t o,F _ iJ][,kl ! ' ,_ i] , < L_ ,i: !_E_ ¸ s_, I _:1 :bit: ,v i I if - o_5 J 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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