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INSTALLATION,OPERATINGAND
SERVICE INSTRUCTIONS FOR
TM
SPACEMASTER
DIRECTVENT
NR AT UR AL GAS -FIRED BOILE
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Br oiler Model NumberBe oiler Serial Numbe Installation Dat
S_ M__ - _____ 6_ _ _ _ _ _
Heating Contractor Phone Number
Address
8140312R13-6/06 Price - $3.00
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IMPORTANT INFORMATION PLEASE READ THIS PAGE CAREFULLY Post instructions near boiler for reference by owner and This boiler has a limited warranty, a copy of which is serviceman. printed on the back page of this manual. Maintain instructions in legible condition. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems WARNING should attempt installation of any boiler. When an existing boiler
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Table of Contents I. General Installation Requirements ................... 4 II. Installation Instructions .....................................7 III. Operating Instructions .......................................13 IV. Service .................................................................23 V. Repair Parts ........................................................26 VI. APPENDIX Low Water Cut Off ............................................. 27 3 MAXIMUM DESIGN WORKING PR
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I. General Installation Requirements d. Exterior wall surface must be fl at to ensure that wall 1 INSPECT SHIPMENT carefully for any signs of fl ange can be mounted without being distorted and damage. All equipment is carefully manufactured, also provide a positive weather-tight seal to prevent inspected and packed. Our responsibility ceases upon water damage. delivery of Boiler to the carrier in good condition. Any claims for damage or shortage in shipment must be fi led If exterior w
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a. Combustion air is provided 100% from the outdoors. Air is pulled in on all four sides of vent terminal cover, through the air intake duct and to the combustion area enclosure. The vent terminal must be mounted on a fl at surface which is fl ush or protrudes outward from the exterior wall. Avoid recesses, niches or areas which might have reduced fresh air circulation. b. Ventilation — When the boiler is installed in an unconfi ned space in a building of normal or unusually tight const
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*NOTE – For all practical purposes, each 90° elbow TABLE I can be considered as the following equivalent in Maximum Capacity of Piping in Cubic Feet length of straight pipe: of Gas Per Hour ½” – 1.6 ft. 1” – 2.6 ft. (Based on a Pressure Drop of 0.3" Water and 0.6 Specific Gravity) ¾” – 2.1 ft. Nominal Iron Pipe Size Length in Feet 14 /2 31 / 12 0 18 3 20 7 52 TABLE III 22 0 9010 9 35 33 0 7215 5 28 Multipliers to be used with Tables I and II for 43 0 6015 3 24 Specific Gravity Ot
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II. Installation Instructions DETERMINE BEST MOUNTING LOCATION for boiler which meets site requirements outlined in Section I, pages 4 through 6. 2 INSTALLING BOILER AND INTERIOR 1 INSTALLING BOILER MOUNTING WALL TELESCOPING INTAKE AIR DUCT BRACKET (See Figure 5). (See Figure 5) a. Locate wall bracket packed in miscellaneous parts a. Separate two halves of telescoping intake air duct. carton. Interior half of duct has a 1” wide rectangular gasket b. Hold wall bracket in
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h. Secure boiler to boiler mounting wall bracket with fi ve (5) ¼”-20 x ¾” long machine screws and washers provided. NOTE: Tools required — 7/16” socket, extension bar(s) and drive ratchet i. Secure interior telescoping intake air duct to back plate of boiler. Pull duct forward until duct and weld studs are engaged through 4½” x 5½” rectangular opening and holes in back plate. Make sure gasket is in place and fl at against back plate. Attach duct with four (4) ¼”-20 brass hex nut
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b. Drill four (4) pilot holes, properly sized for the 6 CONNECT SUPPLY AND RETURN PIPING TO non-corrosive fasteners (stainless steel, brass or heating system. aluminum) to be used to secure the wall fl ange to OXYGEN CORROSION: wall. Oxygen contamination of the boiler water will cause c. Attach four (4) ½” long threaded aluminum spacers corrosion of the iron and steel boiler components, to the outer fl anges of the exterior telescoping which can lead to failure. As such, any system mu
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e. A hot water boiler installed above radiation level If it is required to perform a long term pressure must be provided with a low water cutoff device test of the hydronic system, the boiler should fi rst as part of the installation. be isolated to avoid a pressure loss due to the escape of air trapped in the boiler. If a low water cut-off is required, it must be To perform a long term pressure test including mounted in the system piping above the boiler. the boiler, ALL trapped air mu
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Figure 7 RECOMMENDED PIPING FOR COMBINATION HEATING & COOLING (REFRIGERATION) SYSTEMS Figure 9 EXPLODED JACKET ASSEMBLY 11
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support the removable door. (See Figure 9). Place fi xtures, television, rays of the sun or near a fi replace. jacket top panel over top side panels with ventilation Keep large furniture away from thermostat so there will louvers to the left. Secure top panel with four (4) #8 be free movement of room air around this control. x ½” long sheet metal screws provided. Heat anticipator in thermostat should be set at .4. e. Lift jacket bottom panel up to bottom of side panels 9 ELECTRIC WIRING INST
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III. Operating Instructions Safe lighting and other performance criteria were met with c. Be sure that gas to pilot and main burners has been the gas manifold and control assembly provided on the off for at least fi ve minutes. boiler when the boiler underwent tests specifi ed in ANSI d. Open valve on main gas line at meter. Z21.13. e. PURGE AIR FROM GAS PIPING. During the purge adequate ventilation must be provided and no 1 INSPECT INSTALLATION BEFORE smoking or open fl ame permitted. (Se
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NOTE: YOUR BOILER IS EQUIPPED WITH A HONEYWELL VR8204 OR VR8304 GAS VALVE. PLEASE FOLLOW THESE OPERATING INSTRUCTIONS: 14
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15 Figure 11 SCHEMATIC WIRING DIAGRAM
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Figure 12 LADDER WIRING DIAGRAM 16
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SEQUENCE OF OPERATION Should a loss of fl ame occur, the main valve closes and the spark reoccurs within 0.8 second. The 1. When the thermostat calls for heat, relay coil (1M) ignition module has an internal 100% lockout is energized closing two sets of NO contacts. One function to completely shutdown the system should set (1M2) energizes the 24 volt limit circuit and the the pilot gas fail to ignite with approx. 90 seconds. other set (1M1) completes the 120 volt circulator Five to si
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TROUBLE SHOOTING fl ow (cu. ft.) should be in 3 minutes using formula below: Use the Trouble Shooting Guide (pages 19 to 21) to cu. ft. per = Btuh Input (from Rating Label) assist in locating where a malfunction in the control 3 min. = 20000 system is occurring. Clock gas meter for three (3) minutes using second 4 PROCEDURE FOR MEASURING FAN hand or stop watch. DIFFERENTIAL PRESSURE (See Figure 13). For minor input changes readjust pressure re
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