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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
®
SERIES 2 (model B)
GAS - FIRED BOILER
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.
Boiler Model Number Installation Date
Boiler Serial Number
2
Phone Number
Heating Contractor
Address
Price - $3.00
81417032R24-10/08
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NOTE: The equipment shall be installed in accordance with those installation regulations in force in the area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
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WARNING READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE TECHNICIAN. MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION. Dimensions [Inches] Gas Approx. Boiler Water Recommended Connection Shipping Model Content Vent Size For Automatic Weight A B C D E F G Number [gallons] [1] [2] Gas Valve [lb.] 202 18-3/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10 [3] 1/2 2.5 3" dia. x 15 ft. 212 202X 20 12 6 4 45-5/8 8-1/
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I . Installation Instructions C. Save two of the wooden slats from the container 1. INSPECT ShIPMENT carefully for any signs of sleeve for use in Steps D & E. damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon D. Tilt the boiler to one side and slide a wooden slat delivery of Boiler to the carrier in good condition. Any under the two raised feet. claims for damage or shortage in shipment must be filed E. Tilt the boiler to the other si
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e. For boiler located in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. f. For boiler located in building of unusually tight construction, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches (30.5
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Table 1: Maximum Capacity of Schedule 0 Pipe in CFH For Natural Gas Pressures of ½ psig or Less 0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop Length [Feet] ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 118 220 460 90 40 84 160 320 53 110 205 430 100 38 79 15
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Figure : Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems with flow control valves to prevent gravity circulation of boiler water during the operation of the cooling system. h. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.). Figure 3: Recommended Water Piping for Install a pipe tee at the
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To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air. K. OxYGEN CORROSION : Oxygen contamination of the boiler water will cause corrosion of the iron and steel boiler components, which can lead to failure. As such, any system must be designed to prevent oxygen absorption in the first place or prevent i
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Figure : Plug-in Damper Installation WARNING NOTICE Failure to properly install and use this Blocked Provide adequate clearance for servicing. Vent Switch may result in property damage, personal injury or loss of life. WARNING 12. TO MEET FEDERALLY MANDATED Provide " (1.cm) minimum clearance between EFFICIENCIES, ThIS BOILER MUST BE damper and combustible construction. EQUIPPED WITh A vENT DAMPER. OPEN ThE vENT DAMPER CARTON and remove C. Install the 90° BX connector attached to
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boiler is served by the damper device. Installation per paragraph 12 complies with this provision. E. Where two or more appliances vent into a common vent, the area of the common vent should at least equal the area of the largest vent plus 50% of the area in the additional vents. Do not connect the vent of this appliance into any portion of mechanical draft system operating under positive pressure. F. vent pipe should have the greatest possible initial rise above the draft hood consistent
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speed. Do not operate a summer exhaust fan. Close l’espace où les appareils toujours raccordés au fireplace dampers. système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les D. Place in operation the appliance being inspected. sécheuses, tous les appareils non raccordés au Follow the Lighting (or Operating) Instructions. système d’évacuation commun et tous les Adjust thermostat so appliance will operate ventilateurs d’extraction comme les hottes de c
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heat Anticipator in Thermostat should be set to match 17. vENT DAMPER SEQUENCE OF OPERATION. the requirements of the control to which it is connected. See Figure 9. See Table 4. If system tends to overheat above the A. The vent Damper is continuously powered at thermostat's temperature setting, reduce heat anticipator Terminal 1. setting by .1 or .2 amps. If system tends to short cycle B. When there is a call for heat, the damper relay coil is without reaching desired room tempera
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Figure 11: Wiring Diagram, Volt Standing Pilot and Intermittent Circulation 2. Blocked vent Switch SEQUENCE OF OPERATION In the event excessive blockage in the vent system is Normal Operation developed the blocked vent switch will open 1. When the thermostat call for heat, the vent damper interrupting power to the gas valve. The main will open (see paragraphs 17A through 17D). The burners will be extinguished immediately, the circulator is started through a relay and at the same circ
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Figure 1: Wiring Diagram, Electronic Ignition (EI), Intermittent Circulation SEQUENCE OF OPERATION NORMAL OPERATION 1. When the thermostat calls for heat, the relay is 2. Blocked vent Switch: Automatically interrupts energized. The circulator starts and the vent damper main burner operation when excessive vent system opens (see Paragraphs 17A through 17D). When the blockage occurs. Control is a multiple use device. If damper blade reaches the fully open position, the blocked vent sw
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Figure 13: Wiring Diagram, Volt Standing Pilot with Continuous or Gravity Circulation SEQUENCE OF OPERATION 2. Blocked vent Switch: In the event excessive blockage in the vent system is developed the NORMAL OPERATION blocked vent switch will open interrupting power to 1. When the thermostat call for heat, the vent damper the gas valve. The main burners will be extinguished will open (see paragraphs 17A through 17D). The immediately and the vent damper will remain open gas valve is
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Figure 1: Wiring Diagram, Electronic Ignition (EI), Continuous or Gravity Circulation SEQUENCE OF OPERATION NORMAL OPERATION 1. When the thermostat calls for heat the vent damper 2. Blocked vent Switch: Automatically interrupts opens (see Paragraphs 17A through 17D). When the main burner operation when excessive vent system damper blade reaches the fully open position, the blockage occurs. Control is a multiple use device. If ignition module is energized opening the pilot valve bloc
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Figure 1: Wiring Schematic, Zone Valves Figure 1: Wiring Schematic, Zone Circulators 1
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II. Operating Instructions 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 American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13b-1994. 1. MAIN BURNER ChECK - Check main burners to see that they were not dislodged during shipment. Rear of burners should be in the slots in the rear of burner tray and the front of the burners should
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Figure 1: Top View of VR Gas Valves Figure 0: Operating Instructions, VR0 and VR30 Gas Valves 1
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e. Reconnect pilot tubing and check pipe and fittings from meter to combination Gas valve for leaks using soap solution or other approved method. 2. Electronic Ignition Models (Suffix I): a. Turn "ON" electric switch serving boiler. b. Open Manual Shut-off valve upstream of Combination Gas valve. c. Loosen or remove Inlet Pressure Tap Plug in Combination Gas valve and when purging is complete, tighten or replace plug. See Figure 19. d. Check pipe and fittings from meter to Combinatio
