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Series DE
Gas Boilers
Installation,
Operation &
Maintenance
Manual
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TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 1 6. ELECTRICAL 18 A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1 A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .18 C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .18 1. PREINSTALLATION 2 D. SEQUENCE OF OPERATION . . . . . . . . . . . .19 A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 7. START-UP
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USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE DANGER Follow the installation instructions provided in this Indicates a condition or hazard which will cause manual in the order shown. The order of these severe personal injury, death or major property instructions has been set in order to provide the installer damage. with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation. WARNING B. SPECIAL ATTENTION BOXES Indicate
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PREINSTALLATION 1. PREINSTALLATION Read carefully, study these instructions before beginning work. This boiler must be installed by a qualified contractor. The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly. NOTICE The equipment must be installed in accordance with those installation requirements of the authority having jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54
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PREINSTALLATION where: I = Input of the fan assisted appliances in fan Btu/hr ACH = air change per hour (percent of the volume of the space exchanged per hour, expressed as a decimal) For appliances other than fan assisted, calculate the required volume of air using the following equation: ⎝ 3 ⎛ 21 ft I other ⎜ ⎜ Required Volume = other Btu ⎛ ACH 1000 / hr ⎝ I = Input of appliances other than fan other assisted in Btu/hr Note: These calculations are not to be used for infiltration rates greater
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PREINSTALLATION Figure 1.4: Air Openings – All Air from Outdoors through Vertical Ducts Figure 1.6: Air Openings – All Air from Outdoors through One Opening ii. Where communicating with the outdoors through horizontal ducts, each opening shall 5. Combination Indoor and Outdoor Combustion Air: 2 have a minimum free area of 1 in per 2000 If the required volume of indoor air exceeds the 2 Btu/hr (22 cm per 2000 W) of total rated available indoor air volume, outdoor air openings or input for all app
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PREINSTALLATION c. Each of the appliances served shall be f. Horizontal upper combustion air ducts shall not interlocked to the mechanical air supply to slope downward toward the source of the prevent main burner operation where the combustion air. mechanical air supply system is not in operation. g. The remaining space surrounding a chimney d. In buildings where the combustion air is provided liner, gas vent, special gas vent, or plastic piping by the mechanical ventilation system, the system i
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BOILER SET-UP 2. BOILER SET-UP 1. Provide a sound, level foundation. Locate boiler as 4. Separate the wood shipping pallet from the boiler near to the chimney or outside wall as possible and base by removing two (2) hold-down bolts at each centralized with respect to the heating system. end of the boiler base. 2. Locate boiler in front of installation position before 5. Move boiler into final position. If using combustible removing crate. floor pan, install boiler on pan as outlined in the instr
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WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS 3. Supply Piping: A. BOILER SUPPLY AND RETURN Pipe the supply to the 1-1/2 NPT supply tapping at the top of the boiler. 1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1. 4. When system return water temperature will be below Refer also to the I=B=R Guide to Residential 130°F (54°C), pipe the boiler with a bypass Hydronic Heating Installation/Design and the PB arrangement to blend the system
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WATER PIPING AND CONTROLS 6. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacements, etc.). 7. If this boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium in parallel with the boiler and install the proper valve to prevent the chilled medium from entering the boiler. A drawing illus
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WATER PIPING AND CONTROLS C. PIPING FOR ZONED SYSTEMS 1. See Figures 3.5 and 3.6 for basic zoned system layouts. 2. Run each zone pipe down then up to zone to prevent air accumulation in piping. 3. If required, provide means to isolate and drain each zone separately. Figure 3.5: Zone Piping with Zone Valves Figure 3.6: Zone Piping with Circulators 9
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WATER PIPING AND CONTROLS D. EXPANSION TANK F. FREEZE PROTECTION For new or existing systems that must be freeze- 1. Consult the tank manufacturer’s instructions for protected: specific information relating to tank installation. Size the expansion tank for the required system volume and capacity. See Table 10.2 in Section 10 for boiler WARNING water capacity. Use only inhibited propylene glycol solutions of up to 2. Expansion tanks are available with built-in fill valves 50% by volume with water
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VENTING 4. VENTING 2. Horizontal portions of the venting system shall slope A. GENERAL upward at least 1/4” per lineal foot (21 mm per meter) between boiler and chimney. The vent pipe 1. Install vent system in accordance with the "Venting shall be supported to prevent sagging; using metal of Equipment" Chapter of the National Fuel Gas strapping or equivalent means at no more than 4 ft. Code, ANSI Z223.1/NFPA 54, the "Venting Systems (1.2 meter) intervals. and Air Supply for Appliances" Section
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VENTING 2. Refer to Table 4.2 for minimum and maximum vent c. Type vent material approved is AL29-4C, 3 inch length allowed. (76 mm) diameter stainless steel; manufactured ® ® by Heat-Fab (Saf-T-Vent); Z-Flex (Z-Vent); ™ 3. Maintain a minimum 2” (51 mm) clearance between ProTech (FasNSeal ); Flex-L (StaR-34); Metal- vent pipe and combustible construction. Fab (Corr/Guard). 4. When installing vent pipe through a combustible d. Attach the fan adapter to blower outlet flange wall, pipe must pass th
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VENTING Figure 4.2: Direct Exhaust, Sidewall Venting with Vertical Off-Set Figure 4.3: Vent Pipe Adapters 13
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VENTING Figure 4.4: Direct Exhaust; Sidewall Venting 5. Horizontal portions of the vent pipe shall slope up D. DIRECT EXHAUST; VERTICAL VENTING not less than 1/4” per foot (21 mm per meter) from the boiler to the vertical vent. 1. This vent system will operate with a positive pressure in the vent pipe. Follow vent pipe manufacturer’s 6. Provide a horizontal drain tee in the horizontal vent instructions for proper assembly of vent pipe and run. Use silicone drain hose with a 3” (76 mm) fittings.
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VENTING Figure 4.5: Direct Exhaust Vertical Venting d. Place in operation the appliance being inspected. E. BOILER REMOVAL FROM COMMON Follow the lighting instructions. Adjust thermostat so VENTING SYSTEM appliance will operate continuously. At the time of removal of an existing boiler, follow these e. Test for spillage at the draft hood relief opening after steps with each appliance remaining connected to the 5 minutes of main burner operation. Use the flame common venting system placed in oper
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GAS PIPING 5. GAS PIPING 1. Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the meter and the boiler. 2. Determine the volume of gas to be provided to the boiler in cubic feet per hour. To obtain this value, divide the Btu per hour rating (on the boiler rating plate) by the heating value of the gas in Btu per cubic feet. Obtain the heating value of the gas from the gas supplier. As an
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GAS PIPING Table 5.1: Natural Gas Input Input Model (Cubic Ft/Hr) (Cubic Meter/Hr) DE-03 70 2.0 DE-04 105 3.0 DE-05 140 4.0 DE-06 165 4.7 Based on 1000 Btu/Cubic Ft. Table 5.2: LP Gas Input Input Model (Cubic Ft/Hr) (Cubic Meter/Hr) DE-03 28 0.8 DE-04 42 1.2 DE-05 56 1.6 DE-06 66 1.9 Based on 2500 Btu/Cubic Ft. Table 5.3: Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour [cubic meter per hour] with a pressure drop of 0.3 inches of water [75 kPa] and a speci
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ELECTRICAL 6. ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code and local requirements. NOTICE This unit when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical Code, ANSI/NFPA 70 and/or the Canadian Electrical Code, Part 1, CSA C22.1, Electrical Code. A. WIRING C. CONTROLS 1. See Figure 6.1 for location
