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D E S I G N E D T O L E A D
Series 16
Gas-Fired Natural Draft Water Boilers
INSTALLATION AND OPERATING INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler.
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury, or loss of life. For
assistance or additional information,
consult a qualified installer, service
agency or the gas supplier. Read
these instructions care
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Table of Contents I. Product Description . . . . . . . . . . . . . . . . . . . 1 II. Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 III. Before Installing . . . . . . . . . . . . . . . . . . . . . . 3 IV. Locating the Boiler . . . . . . . . . . . . . . . . . . . . 3 V. Knockdown Boiler Assembly Instructions 6 A. Prior To Assembly . . . . . . . . . . . . . . . 6 B. Boiler Assembly, Installation & Leak Testing . . . . . . . . . . . . . . . . . . 6 C. Jacket Assembly . . . . . . .
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II Specifications 4 2
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III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the latest edition of the National Fuel Gas Code, ANSI Z223.13. • Where required by the authority having jurisdiction, this installation must conform to the latest
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All Models - The following service clearances are recommended from the top and front of the boilers: 16-325, 16-390 – 24 inches 16-455, 16-520, 16-585 – 48 inches These clearances may be reduced to those shown in Table 2, however servicing the boiler will become increas- ingly difficult as these service clearances are reduced. 3) The boiler must be installed on a hard level surface. 4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or
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Ove r A ll Minimum Ove r A ll Ove r A ll He ight Bo ile r Bo ile r Ro om Le ngth De pth Floor To Volum e M ode l Volum e Jack e t Jack e t Top Of (Ft3) (Ft3) Jack e t 16-325 23 3/4 32 7/16 32 1/2 14.5 231.8 16-390 27 1/2 32 7/16 32 1/2 16.8 268.4 16-455 31 1/4 32 7/16 32 1/2 19.1 305.0 16-520 35 32 7/16 32 1/2 21.4 341.6 16-585 38 3/4 32 7/16 32 1/2 23.6 378.2 Table 3: Minimum Room Volumes Based On Sixteen Times Boiler Volume By Model Size 7 5
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V Knockdown Boiler Assembly Instructions A. Prior To Assembly 1) Thoroughly inspect the cast iron heat exchanger for any shipping damage, i.e. cracks in the castings, broken lugs or punctures due to mishandling. 2) Do not use a damaged heat exchanger. 3) All joints between sections have been factory sealed. Inspect the joints between the sections for openings due as a result of shipping and handling. Reseal any openings with furnace cement. 4) All joints between the base and the heat exchang
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8) Slide or walk the assembly into its permanent position. DO NOT DROP. 9) The assembly must be level in both directions and supported around the entire base bottom. Shim and grout under base if necessary. 10) The flame roll-out switch has been mounted to the burner access panel at the factory. On boilers with two access panels the panel with the mounted flame roll-out switch should be located on the right. See Figure 4. The flame roll-out switch is a single use device - do not test with
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Figure 5: Installation of Combustible Flooring Base C. Jacket Assembly NOTE Before installing the jacket, make sure to plug any tappings which are not going to be used. Also make sure that no tappings are plugged which will be needed later for piping the boiler. See Section VIII for system piping. 1) Align the left jacket side panel with the screw holes located on the upper flange of the left base end panel and loosely attach the left jacket side panel with two #10 x 1/2” sheet metal screws
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5) Lay the jacket top panel on top of the jacket side and rear panels. Locate the top of the rear jacket panel to the inside of the jacket top panel. Align the sides of the jacket top panel to be flush with the outside of the jacket side panels. Loosely attach the rear flange of the jacket top panel to the jacket rear panel using three #10 x 1/2” sheet metal screws. On the inside front of the boiler, attach the jacket top panel to the jacket side panels with two #10 x 1/2” sheet metal screws
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12 10 Figure 6: Jacket Assembly
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Figure 7: Gas Train - Standard Build Figure 8: Gas Train - CSD-1 Build, 16-455, 16-520,& 16-585 13 11
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F. Control & Trim Installation 1) Table 4 shows the use of all tappings on Series 16 boilers. The tapping letter designations referenced are shown in Figure 4. Control and trim components are as follows: a. 4 x 4 Junction Box - Install the supplied junction box on the inside of right jacket side panel with two 8-32 x 1/2” machine screws and nuts. See Figure 6. b. R8285D Control Center is to be mounted to the 4 x 4 junction box. Refer to Section X for complete wiring instructions. c. Tempe
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VI Air For Combustion and Ventilation Sufficient fresh air must be supplied for combustion, ventilation and flue gas dilution. Provisions for combustion, ventilation and flue gas dilution air for gas utilization equipment vented by natural draft must be made in accordance with local building codes or, in absence of such codes, in accordance with the National Fuel Gas Code, NFPA 54/ANSI Z223.1. Warning An adequate supply of combustion and ventilation air must be provided to assure prop
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Figure 10: Boiler Installed In Confined Space, All Air From Inside • If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought into the boiler room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”. B. For Buildings Of Unusually Tight Construction 1) Provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely exchanging air with th
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Figure 11: All Air From Outdoors, Ventilated Crawl Space & Attic Figure 12: All Air From Outdoors, Via Ventilated Attic Figure 13: All Air From Outdoors, Using Openings Into Boiler Room 17 15
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Figure 14: All Air From Outdoors, Using Horizontal Ducts Into The Boiler Room 18 16
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VII Venting Vent installation must be in accordance with local building codes, or the authority having jurisdiction, or Chapters 7 and 10 of the National Fuel Gas Code, NFPA 54/ANSI Z223.1. A typical vent installation is shown in Figure 15. The components of a vent installation are the draft hood, vent damper (optional), vent connector and chimney. 1) Acceptable Chimneys - The following chimneys may be used to vent Series 16 boilers: • Listed Type B or L gas vent - Install in accordance with t
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9) Series 16 boilers are supplied with an external draft hood which must be installed as shown in Figure 15 without alteration. Before installing the draft hood, verify that the model number marked on the draft hood matches that of the boiler being installed. Prior to securing the draft hood verify that the distance from the top of the jacket to the bottom of the draft hood skirt matches dimension ‘E’ in Figure 1. Secure the draft hood to the boiler with at least three screws. 10) Vent pipe s
