Download Weil-McLain CGt Boiler Manual

~ IUEIL·
0
Gas~ Fired
Water Boiler
with Tanldess Heater
o1ler
anual
• Installation • Maintenance
• Startup
• Parts
-
,. -I
I.A...- I
---
us•
-
DO IIOY
IIOILM D~·a, CO.IIIYJIUCTIOII lll~L:u )'tJU pru... ldt:. l'lllirLrlrt:t:. ~· w tilt!
blnl.!r
('Jr !Allow tllll! ~tn!tlli!Si~ Rh'i!P n f1 e 9. Mtll~ TO « unpti)o e(1ltld .,esu11 Jn ~1!
~uA! ii:Jjuty. rhaihaJ ~ Lhl.l pt~prly~
0
oler-
DC
How it works •
CD CoDII'O• module
M;!TE- Tlie COfl.troiliitldule pmv1ds a p~~it~p ~
iJl.S routiDe. It die bo' er ii JiM ~ted liN- 34l d:tys, •the
J:lt!Jiltml module
pO'M!I' the a~ fur 30 leOood~.
*
a.beo rum o1T.
®
The colitm1 module illow,i up fO 15 !SeCOnds to establish P.ilot
fuune.!lffbmets.cJ)t aen!!l!dw.itllln 15 se:::onda, the ro:ntml.J:I:I!OOille
will tum o1frthe ga1valve, flalb tbe !FWne !U,gbt and tb.en errtec a
l 5ooo'll!((tJid pOBpLJ.Il¢. 1.'be c:ontrol module- will then fltLrL a. new
(}'tie.. 'Ib:fsvdll ro:ntinue!ndefiniMyuntiil pilot:flmne:fs establtshed
or power :l:s :lntenupted. On"e pilot fla:nle iJ pmwlll., tbe cuntrol
module opens the 831 w.lvll! t0 aii.orN maio.bucner:fhme.
Wb.en the mom dteJlii.OI>1ll.t iJ wtsfied, the rontrolllliJidJ.iletmm
oil rbe p* v.i1V'I:'o optrwi lbe m.fua.r fur~ l S.B!ood ptxttpurse
;md ...m'tli fl)r the listliet.t ~u.
The a:mlrOI ~ iodlc:itorll&hts !~how l'larmtJ~ ialue~ wht!n
~ l~u are on m ady:. Wlt.en ill problem ~ ~ a:mtro1
modille:flasht!S c.omblcatiom ofl.Jghtll to :lndiarte 1hemi'llil: !ltb!ly
IUjOn lor abe problem (&1!11!! pzse -417).
lf'llie t3tllcleii beo'lte r low Iim it cmtil:.n'lll4!: met 'bol leor wa11!'r
iJ. b:Jo cooLtO pmride dalilil!itk wter from llf.e co:l~ ·the
,_way val'w!! dlw.cta :Ill of the hot water 1l<M' from the
boilt!r ~Mid to tbl!! Rb:m'lo dedimclne; :all o'IVfulahle limt
for dameaic walleor. Tbe 1·wy ~ iJ. &hipped inside
ahe ltiduar cuton. Vau must imtta.ll tliist vallre
and tilting&" aB :shown. See. pages: 21· and
64 fOr dsails
M31o:c mrc the wh-e ~ is in the axm:t pOtitlon D,j
~n on p~~ 3 met F'LiJIR' 3'9~ ~·604. \'aTn:o ~ A•
mJ.Ut. J:lt!Jiil'lect ra booller 1H!fp:Ly plJim:S.- Vilh-e part "'Ji.B•
mu.H tol'll'JI!(t ~ttboiler rerum pJpins- ~epart"'B" must
be used fOI' the fiJ'ilt.ertl return (I)t'ltJ«t:ion. ThiJ. a.llo..n
water to fulw nMinJILy from part "B"' ta port "'AB.. duri~ :a s.pXe beoitDli, Q'de.. Tlie 'li'iil¥t' ~ ~ besatins
dirultllow and &Whche:s~ to full.red:roulitloil. {flaw frm:il
port "'A"' liD part "AS") when !!he L3tlk.'h~ii b~t low 1i:mit
J:lt!J li trol dose~~.
01
The tonlml rr.mdorDiU ~ line \'01•·to 2d, ¥0lu lor the>
p n lve circuit
The ilnduc.erpulbi flu.e gasa~ tbmugb.1b.eboller, ca'tlJI::ng air to be
pu!J~ io thmusJl dii!! 'boiler :Ur0p!llili8;L Tlie iriduo!s ~ 1be
B.'ue gasa~ t~ the "'ellt plpe as well The iodltcer la abtw~
with~t md d, ours Inside ~cattOn loa red iniid.!o the~-~
FiJuR' 35 on ~ 59 fOI' praper irllllilbtlm; or iDdLICII!'r.
@ Tarrld. . . heater
tl.e 13J'lll~t btlilb""!Dt!S lwtbtMierwtltcrto'bett doJild'I:K
w;MI".
@I
WI-.. to • •lentt....peratu.-. switch
lnst.dl the rwitcli u;d 'bracla~uup,l?lied wl1h the bolluon
ahe wlill doseft 10 IIlii!! bolter~ w.ltli1n 5 i.ndk!s ot'the mcloSt~re uili~ Tllit twitdi ~WMs fbeoal'libient ll!!mperodl~U
i ll tb!! bot1~r .:p.xe.. Should 'boiler rOOm lrttiptrtlll:IJ'I:' ri~
ta0 ~b d~to:lnmf&i.ent w.ntnaUoo. ak. tbe sw:ltcb'!"'m
q:t:leo ilie bo i!cr off wlRr~~llie 'teJYtpentture ;at lbi!' iSNrl!d.
ri!sadls l J54'F:
Air pre~:sure twitch
The air p~ *""~ tl~ 1he ~litml ~odule. till:ins; d'teo
tontml .bodule wlieo~ber 1M ln~r li wod:•na eorl'l:'dl.y or die
\oerlot ~~~ bladed.
@ lliQ11 limit
The high lim it t lll:tli oR ~ p;;tS v.a1 ~ lf rbe tnt'~ peli'll.lUn!: in di~
boill!!r 8oei illlove i:u setclnS: (l"lte cin:ubb.x will contin.W!' ro run
a tooS ;U. lbere- iJ. a. call for lieu)
T8nkl8$$ h.-.r row limit contro•
@ 3-Wayva-...
'l'ra11Urformar
@ lnducer
wm
Thii J:lt!Jiltml pn:rvilh dnt~:i~!!itl~ ~ilJ: by divel1ine; all
av.ribbleo he.3it ID d.mi~tlt: w.Ul!'r bi:'(Jjji'J@l ~r it
~ w;Mn- L~pellltDR btdow lti ~en1ng.
igrur.lon tp;trlt.
00
anual
• •
Tl1e contrOl module r.ecpondJ. 1.0 aign~I.J, from llae room
!lhernildraf. lai'tklet: hste:r low limit, ~~.. preUun!! ~w.llcli md
boiler limit dxuiLIID ~ll!! the bolter dn:ularor, pi!ot b11mer~
s;u. v.a1¥'t' iUid induOtt. Wbem roam fbern'IOJUl ctllh for~ d'teo
totttnll module itatti the ~ty~Uili clrmbt:OI' U'ld mdua!.-.
11u~ tomrml ~ ru:J15 1be iod~.~ttr loox emouQ.iliiD ~ d te
beller:fbae~a, b:nopenstbe pii« vil:ve and actbmm pll.ot
@
aller
®
Cordrol RaiQ
@ Boiler circu at.o:r
lbe boiler circul'*toT cireulall!!i Yr.liber rlimue;h the ~ L
(*7Ctan) pipiDS- The drculator Is iliipptd loo~ :md ~nurs:l h
mom:~t;ad on fhr1l baihw n~tuTB piping .ii i'howli..
Othcw boiler C(llllpo~H~nbr:
;(I supply [ 0 if*m
g: te:rl!f valve
b fl!iDtn ri:'Oft'l sytrem
lb alt ~nt oont'JedJOfl.
oQ stadnle~ tre.el bumm.
ii flame rollout thtrmJ1! fW!ll elm:ne:ot (T1FiE)
d
e
f.ll!IB 0lll:kt
gasv.alw!
f
p~peratme:gauge
j bumer holding bndc:et
Ill: piJm bWil.er a-nd. bradc:et
• sas m.mlfold
m cast Iron boiler ~JedJOM
n :fh:1e mllectM
o juncd.o n bo:t
p dralnnl~
q bumershleld
r exptMion ilallk llnie .::onnedion
a
-Fired Water Bolle - -
oller Manual 1!1!ll!lll
CGt: ~Gas~-Fired water Boiler with tanlk less heater
ltelmllur
3-way valve
oonnact'icn&
A
0
DC
a
Ired Water
oler-
aller
anual
Contents
How it 'WOr-ks ··~· ·=-••••=-••••~•••••••••••~~:~~••••••=-••••=-••••• .... ••••••2-s
······-=·····...... 4
Hazard deft nltlons .......,•••••••••••1£11... . . ..... . . .
Please read
bet~ore
procee4i ng .,.......... 1£11· · · · · 1£11· · · · . ... . . 5
l
P l"e-P'a re. boiler Ot:aliODJ ••••••••••1£11... . . ..... . . ... . . . ..1£11 . . ...6-111
2
Pre)pare. boiler.r••=-•••••••••r•••••••••••-=-•~••••••••••=-•••••-=••• t 2-113
3 -niJftli -=••••••••••••=-•••• •••••r•• ••••• ••••-=-•••••••••• • ••••••-=••• 1 4 •i 9
4
W~ pf.pingl ···~··=-·········~···········-=-·~· ·········=-·····-=··· 20·27)
7
·······=-·········~·· .•.•.····-=-······.•.•.······-=·····.•.28
Field wiring ·~ · ··~··=-···· ·····~·· .•.•.····-=-·~· ·········=-·····-=-···· .•. 29
svn-~ .....·······=-····•••••r•• •••••····-=-······.•.•.······-=···30-32
8
Cttec k-out
9
Opera-tion ••
5
6
Gas piping •
p~cedure ••,•••••••••••1£11.,. . . ..... . . . ,. • •• •• 1£11 . . . .....
33
·······=-·········~·· .•.•.····-=-······.•.•.······-=···34·38
10 Service an d maintenance ••••••1£11.,. . . ..... . . .,.• •• •• 1£11 •• 39·43
····-=-······=-··········-=···45·57)
·11
Trct bleslloO'ting •••••·····~·· •••••
12
Replacement parts ................. 1£11. . . . ... ,. ••• •
13
Dim.e11sions andl ratings •••••••••
=-·····-=-··58-65
IDI . . . . .. . , . • • • . , . • • • • • . , . • •
86·67
Hca:a rd definitions
The follGWing del1ililed terms 311! llSI!d throupolll: this manual to b:d:ng attention to the pre~~tmc.e of haz::J.f'lig of
V".triOW N k l.e\'t!b. or 10 imp<IIWU kft~Ji'ft'lll£m eonoemJ
fhe fife of !!he proaDct.
dam.
lndlatei presence
property
~f
har.ards that will csne BIW!'re
~llal iiiJUry~
lridlr.at-es pre.1ence af h~ tlia1 can cause sevell'e penorial
~nJW')'~
de.alh ar Soub rttntial
death or
rub~tlal
property dam•
IACMITIDN~
liD TirE
Indicates pte~llt::e of halaf"ds. that Will ·Oil' CBJli cause milnor pl!l'wlla.i Injury or propert)'
damage.
lndiateup~d~ b:tstrudion!i on :lruta.Datlo~t; oper-ation. or malnte:oance dlat at'l! lmporl::al'lt bw.
oat tdi~ed to persoi:W :lntllry or p~y d~
a
-Fired Water Bolle - -
oller Manual
Please read befo1re proceeding
User
Installer
[AWARNINGI
Read aCI mldrueliiom. bafore fniltSOinQl. Follow alllmt.n:ld:JOM i.n
proper on:Ler
10
preveilt ptmanaJ
Injwy or de3di.
~
Consfdt!fpjpmgand imtallation wll& dl!lem'linlft,g
-~~location.
~
~
ThEa mactua'l ia. tor u:u onLY by your ~ified
heatmg inatalrmta.ervice technician.
P1cilae :refe:r oo the Uasn lnformsliiion ltaJMJEtl f01l'
your refi!'N!flee_
We £eoommend :regular urvf!C,a by a 'q uallfied
service IEichmcian. at leaatamma[Jy.
..
~
A!llydaima. for d11J1189e 'o:r ahortsga in .ahipmectt
must be filed fmmeillatsly~sttbe tlmlspl)rfatio:n
com.pany by th~ oonsdgnee.
:fi.~ mab!f:ial!. U1111 care when handling ths!e
lmirudlons on pll!le 8111 of this: ft'Wl.ba1_1?a1fure to comply mu'ld. res:ult in~
The lboilsf' rontam!l c:e'J'lUDic fiber and
m2ter:l:!!ls:~r
penona!l lfljury.
NDRC£
'When Ol'll'lns or wfitlft abou• th~ bolter- Ple::ue have ·ml!' b<iil~ modell number oom th!!
lboi!lsr rn.tins·!:Jbel md the Cansi!UD_ef Pmtedio:n (CP) number firom the bllllet jadket. Youmq
mist the CP number in th!! spa.c:e p;rovidsd an the hata'llation and aeJVice c Brtificms rout'lt1
on
e3~.
FailUre to adhere to the guidelines on thlt page C3li ltiuft ltl 5le\l'l!rt! ~alllljUI')'~ death
ot whstltulal p~v damage.
WhH
•
•
MI'VIialnsl ..... -
•
Contmual fnllh makeup wme.r will reduce
holler llff!_ MlneraJ bwldup Ln :sealoM reduceS;
hea1 t.raft!:f«, ovetheau ost :Iron~ :and camei
~Sed.~ on fai~ Addlalan of Mf~ .and a.ther
gases ean ause ltltetnat rorrosLon_ Lew In
buller or plplns must be repaired at onee to
•
Do not add mld water to hot bo:Der. 'Ibl!ml:al
sllodt at"J came s:eedom to ctat:k.
Th avoid electric modi:~ dhconnect elect:rlc;;al supply
be&at'l! perfOJ"IYUns ma.i~
Th avoid !i8VeC4! bur:os, allow boiler to cool bef€1:te
petform.ing m~
pt'e\letll R12~p ~et-
Bol•ropwalloll•
•
Do not block :flow of combt151ian €1:r'Wlltilatian ili
to boiler_
Should ovemeatlng O(ru:[" o:r g311 11upply fail to rJJ.Ul
off, do not rurn o ff cw d~nlleer i!lt!dheal wpply
to ciJ:"eUUatot_ fnstead~ 11hnt off the .u supply at a
loeadOCII enernal to dl~ appllaaoe.
•
Do not usa thiS bG:iler ff 3IJY part bu been 1mder
wateL. Immediat.elyC'all.a qlll11ffi.ed ae:rvfceti!dmfdan
to ifltpt!d. the boller and to reptaee any part o ( the
OOI'IlrOI !i)'it~ and any gat OOfit ro'l tNt h ~
uruier w.lla
Bol•rwatet-•
•
Do not IJBe petro]eum-bued d&ming o:r 11liillling
oor»poulktSi ltl boll:er IS)"item_ '!Nat-et seal de~etlora.­
tlon wiJI ocaJt~ ca~ns leabgoe between sec:tions.
Th can rau:l1in wh!tiH\'tlaJ pnlpe:rty oetamas,e.
Do nat ll5l! "".Wim1mlade ruraf" ar "'balle:r patmrt
medldnei": Ser:lom dama&! ro boiJe:r~ ~rtnel
W'td/Ot' pL"CCpp!rlV iliol)'
remit.
Glycol - potential fire hau rd All glyool It flammable when i!IpO!Ot!d 1.0 hjgh
t~ pa-.u.um_ If gl)lcol 1!1 allowed ~ ~rumuJaie!
Ln or around the b oiller a..r any oth~ potentla1
{gn:[tlon !IOurce, a :fin! c:m develop. [n o:rder to
ptt!vent potefltl21 !M!Wte pet.sonal l111jury~ d~lh
M 11ubstanthl property dliiDage from fife mdJo:r
wu.dllt'a1 damase:
• Never store ~1 of any Jrlnd ma:r the '~~oiler
or any port!mla.I(Srutioo source.
• Mond.te:r and inspect the system and boilar
:regularly fur leakage. R.epaJt any leah lJn..
mediately to pl'l!\o;elll pMliblle aawtnJJa.tkm of
gEyooL
• Never U9EI automoti'W! antlfre!ll'oze o:r ethylene
glyool In d\e !0")'\teln. UJing ~ ~ can
(ead 1ohuardaru k.al.a!J! ofgJy-rolln ~ bolkr
tem_
5
0
oler-
DC
la
Instal allons must
Betere locating the boiler,
check tile following.:
"
LocaL atate, proviDcia.L md na.tional
•
National Fuel Gu Code, ANSI .1'221 1latHf etlit ~.
~
StandJ.fdfo.rControls and SafetyDev.l.ca
fur Alllo:ma1iailly Fired Boll6C'!I, ANSi/
ASM!E C:SD-1, wbsn 1Equired..
"
•
National Eb!ctrk:al C~de.
•
ForCm.a.daonly: B149.1 or B14!).2 ImtJ112tion Code, CSA C22.1 C:mlldian Elleru:l.calC~de Part 1 and anylocal mclei.
The CGt b oiler gu manifold arui cantro1s met !W"e
lie:htlns and other performanu t:dterla wh l!ft
~e~ts:
~pedtied:in.ANSI Z21.13-
boner UBderwe1u
1atesl edli.ior).
NOTICE
lb
Check for n_eaiby ronn4!dloD to:
•
CXIde.t, la.w~ regulatiOiU and ordinol:ftCd
liD riCE
anual
Pre1p are boiler location - codes & checklist
follow these codes:
~
~lt1m'l water pJplne:
.. Venting OODD.ediona
.. Gu mpplypipi:ng
.. EJearlcal power
Check llftla. aroLID.d bo:i1er. Renove any canbuatibte r.natariala.
,p .aoli'ne and other Uammabte IJqu:icfa.. ·OT other contami'nan'-.
Fallute to keep batlff ~. deal .uui ft'el! of combunible matari~gaaoineand o1har1'1811111118bi1&
liqulda and vapara can result ~ ieYere poenonal
inJury, d$Jirh or s.ulutuuW property t.:Lttmge..
"
..
BoBet MIJSt be lftstl:lled .so that gas eoni.J:'OI S)'.Sit!n'l OOIDpclftl!iiU are
protected from drlpplng o r .!pr.l)'lng water or ram during operaOOlll
01' s.et'\'M:le..
Ifnew boiler will rep~exlsUnf!: baiJet~cliedc fOr alld carreeuysr.em
prob1~ mdt as:
1. S)'.stem leaks eau:stns OX)'8.I!I'I. rorroslon or &edlon ~from
b atd water depo:sh1
2.. l~dy-slud exput~Loo laAk.
l . Lade. of antlfteezt! 11'1 Miler~ eau$111J s.-ys.tem and boBet to
f~ at~d leak.
Read mdfollowthe ~peciaHnst:ruc:tiom for the C'.omm.ollweia1 ofMa.asac;b.Ulletts,
lo.cat~d on p• 414 ofthls manual.
Install ambient temperature switch
Befo~ pbclft8 boDet In
boiler room~ mount tile smbien11emper.a--
1ure awitc:b on the 'Wall that w.ID be closest h) the holler as s.how.ft a r
tl@:bL Mount 1he 5.wir:cb no nKKe than S indlea hm the ceiling,
wwn. Conoec;t tb_e switch win!!i to tb_e switch after p1.adn,g tlJe
boder In posld.utl.
3!
•~mpenture swlkb ph!\'enas.
o\'erh.ea.ttn of the boller Olmpall.t!ll. U; and
~ombw.tlble nureriab tl'l the ~fciftlry of the
boiler in the e~n• wntllatLon aEr should be
bliocbd.. Fa:llw:i! lO> lruaa!lllh~ S;wikb .as s.hoWft
caWd lli!Wit:ln~ pett~aiiU'I :Injury, d~th or
s.ub_stm.W prape:rtv dalmge..
The amblt!nl
6
aller
a er Bolle - -
a -
1C
oller Manual
Prepare boner location - clearances
Recammebded SERVICE
clearat~.ces
Fiip& 2
Required M1NMUM dearBooeB
(Flg. 1)
L
:2..
Fl.l1h to cclltng
~'O'idl! dear~ for dJ!iifilitg: ut)d servidtl. £he ~fer and fur
lu IOI)flt mb. and ~l!flts.. Sl!l!' PI Ul'@ l fur MOO!Difit!lldaliol'l&,
P.J'ov.idl! ;:U ]e.IW teJreWdr [\'d' deaf;lAU tO jacike:[ fttllll
~J;
fi.'l r retnM•al Bf fmpJ pw~ tOr 11up«I:IM (JJIIjj I:Hdor ~ If
amal:llle pnwidt! ilf l!!a~~t stcrewtitl ~a t:llaar.aoee, lnsanU WiltMt$and
ara1 dos as
O&lt:bll
JWl.ef
••
w
Mlnlmvm
•bwoff Yalve$ In lfltent w boi~r Oft be n •oVI!d OOr setVJd ng.
..~.
'l 'relfl lilllt
I Ide
figure 1
RecorrwneDded
SERVICE
Claarances
l=lootiag
fAwARIIINGI
Ill' lllty~leentrtlce 1111!!11• than fill Flgun 't, prov.lllll
opemlnga fOr comllu.Uom amd vemUiaUon1alii'
loaltldon 111e wall «dt:JtJr lllfiPIMMe Me mtli!N"
FRONT
Rgwe ~J.
'l1l.ese openlft8.5 mwt be k.eated eliM¥IL w FJgwe 2 to provide
proper af:r :flaW 300und tba bo:ile:f. 'fh:e
H"e:a. M' e::u:h ope:Il:ing
(aher deductiog ~ lollVI!rs} m~t b e at le-ast one &qi'J•II'8 Inc h per
1,000 Btu h1 of ooUer Input. If dl.e buildiiiJ is o f Wlmll;i)]y t:Jsht
eomtl'utiJOil {s.e.e
11 fix defioltloD). the air opmfng-s must
t'Ciftoed dln!oCr.l)' to outside or the b uildlng mll.\t have air o~nin s
to the oumide as apedfted oD page 11.
If de.:u--.mct!S aM equal to orgrt=a.ter thu Figure 1~ ~ pages. I 0 and
II lOr lCddoa ancl 5ii2ing c:ombustion aLr ope!'ln8S-Filllllt'l! to comply can :res.Uit In 5.eV'ef1e pa.sooA.IInjury. dead! o r
mbs.tantial property
and redueed boiJer lite.
'I'he CGi baileria appro"¥edf!ll!':f!osta1htlon on romb'IWible
:llo0rlng, but mwt never be mstalled on ~
r--
Do Dot 1mtill boiluon ~ ewn
if fuundatloa It U5lecl Fire ean f'(!Wli,
mlng ~e pei:'SOul lnjury. Mall!
or rubs.umiall property da!nage.
me
pase
or
cbmase
Required MINIMUM clearances
t•
WARIIINGI
·
1. Prov"tde :li sdM:I bfid.o:r mbtlmum 2-weh t1tlck.~
~undaoon pad If 3ilrJI• of thl!' foll.ow"ms lsi U'Ue:
• filoar Glll be roms flooded.
• the bo:ilu mounting :lfi!a is Dot~
2. MJnimum dlmen~om are ~S.. Iong by 18~' widla.
(Fig. 2)
Navar moan the boiler in 8 8p;GB with c1earSftCea 5a;uthan t'he m'inimu:mc1earallcea.'llihewn
in Figure 2. F.alltl:te to comply can t'Mili Jn JSe\'efe
penoul ~njDt'V', death or wb.rtanf~l propeTty
cbmag.e a:nd redU!O!tl boEier life.
l - Hot water pipelli: m least 1h mch from mmhmtH~te maJerlal.
2. Smg~ V8n1 p1pe; at l'eaail:16 inchea fromoombmtUile m.a.:rrl21.
3. T-,pe 8 doUbfe.w.all metal vec111 pipe: refer tovertt manufac::rum's
reoomme~~dailim for dearM'J.:es 10 t::omho5tJ'ble material.
IA
IFou:ndatien
Residential garage lastallatioas
'Thke d'w! b Uow.l !!pedal JilrflCaUtlo:n~ when JMUIIII'I g thebolller In a f61tiefttl.a] gara~ If die boller b: looted 1111 a
:re&identhl swage. per ANSI Z223.1:
..
..
:MOunt tlul boilel aml.nfmum at 1 R inches. above 1fw,
11k>ar ai r:he garag-e to assure tbl!' bwtt~ aDd ig.nltioo
devka will be DO hl!i111hm 1 S :fnchea abava fue floO"J'.
La ate 01! pr;atae11he lboiJer 5lO if caonot b e
by mo.wlng vehicle.
dam.
7
0
oler-
DC
1d
aller
anual
Prepare boiler location - vent system
Failwe t o fOllow all:linstruct£cms GUJ result mflue
p~.sonal ln:IW')' Qt' de:Uh.
gas~
md c;arbon monmde E!lllhaicms. c.mslng !iiEM!r8
IM)!ed. er~tlog d!imney bef4lrte loitillltlg boils. Faihlre tod.eao .or repb«! per.fcw.ru:d pJpe or tile lmms wl!l crus:e
Sl!\rere per.sonll Jn;lury .or de:lih..
DiFac1 ahau:at ¥BI'lliling r(CsfsQIOJY II) -Do not oommon vent (s:idE!waiL wnt om}'} the CGtm a diced: mrhau5t
one appliance oo a dfrect: e:xiban:1st 9j'&tem wiill an~e fl'ue gas spillage
or appiiM!ff: :malfimc:Do.D~ rewUios ltl pOMibfe !Se\!i!l.'l!!! person& InJury. death or !1\ub!iUn&l property damage.
9j'stsm ~Category Ill). Coo!ltec:tfDg more than
When remOVing bolle.- from an
existing common vent sptem:
At the lime of I.'I!!!MOV:1I of an. exlsti~ hal ret, lhe fo:llmori~
stepsw11 be f!lllbW.ed with each app11att.:.e t'I!IUI.itlngroo-
oert!d m dlie eMU\'I.OD wl'iii~ sytti!m pla.ced In OPf!li'atlon.
to ll1e
wlitle lhe other appl'lanees remalllltls eonoeaed
rommon \"e~Ulng il'~ .ate atot Jn op~aJion.
;a_ Seal any u:m~aed opemng• In tht!' eommon \rei'ltlns
5)'ftem.
b. ViwaOy illllpl!d: the venting ap1Bm for ~F l!lm
aofl hor.!Jootll pltdi and dell!:fft'il.nt!'tliel:'l! 1!1 no ~
or :C'Brtl':kltlon. leakage. mfi"'!l<m M other defuimdEII
wftld! rou'Jd ca. e ilift oruafe rondlooo.
Cllimney or vent requ.·re·
melds
1. '1/entlfig mw.a b.! btru.fled aeeordlfig fb Part 7,
Ventlng of Equipment, of NaM:onal Fuel Gas
Cade,.ANSli Z223..1-1ml!iteditlon :m.d app:Jlable
blllildlng rodes. Canadian mstdlation!l must
comply w:lth 8 1.. 9.1 or Bl 9.2 lnstalbtlon
Cades.
2.
Irated cap•:Stibuld exund a1leaat 3 fee1llho\lle
the•hig'hea1 pain1 wbse It~ through a tool
of a bmldins and a1 te.BSt 2 fem higher than
any portion o1 a blllilding wilmn 8 harizontall
diatsnce of 10 fee1. A chmmey or vent mmt
not mend ~~!lsi than the dltt.allo!!!. &tided above..
c. Teat ven1 .ay~~Jm -lnwfa:r
is ~od~ dose a11
buBdlrtg doon. and wl:Ddow.s and ill dOO:f'!l betweM
the sp3iCe In which f.be 3ppllanoe!.l:'m'labtl.ngcoftnected
to the co.mm.aD ventlftg ~are~ :md othet
5p3!Cel!l. of tht!' bolldi:Bg.. 1'um on d~ dJ}oef'll and my
applianee not eonned.ed ro lhecolml'IIOOwnt:llii!J ~
'IW:'J1i O.ft 3iJI}" e:xhaust fa:IU, $uch
hOOd!il and
bathroom exll:l'WU, so they will oper.lU! at l'lu.rlmum
speed. Do not operata a. &wmmu uib.aust fan. Oose
fireplace daJnpeR.
ranee
d. Place• m .er.ailfaD tht!' i.tppJI!ance belt!ii!J iMJW!CIM.
PQ[Iow ll.e Hgtulosfoperatlo,g irutructloll!-.. AdJU!i:t
~ :10 appll~ wltl opt!'rate- erunltluomty.
e. Teat mr aplllage at dt.aft bood re!IB' openmg after 5
mlnuD!!I of :ma1n bumi!f opar:ation.. U!illl tbs flame of a
matd'l M candle..
( Afi~ Jt h!ii been fletermlo.ed that •e ach appliance
fl!fl'lalrtlf18 OOI'IntKtefl IOo lhe COMMOI'I 'W:ftt~ ~m
:prope:tly 'i'eillts wlt@ft ti!s.ted ;&!1\ outlined .abo¥e, retum
ioOft, windOW'S, a:haust fans, ifure:pln.ce dllmpm. :m.d
an.y otber gas-burning appllanee to their [prevlou!l
eoftdltlom oJ liSe.
Any improper ope.r.atlo11. Gf commcm veot'!'l& "}'ttem
lbould be eotrectefl w the l.1mallation confo:f'm.5. wlth
the Natiol13l. Fuel Gu Code. ANSI Z22:U -blest edition..
Co:rmct by :resizing to appr-oach t.b:e mini!lllWll! me IJl
det~I:Mfl. using tbt!' appropr.lilte tabff5! i11.1?.art 11 .of thu
rode. C:m.ad.im frtstal1al1fons must ro:Illp]f with B14.9.1 or
B14.9.2 InstalLltfun Code.
8
~ Ratii'I~JJ 1:able on page67 for minimum mimfll!)' or \~t siza .A chl:m:tln!f or \'elll. with Old 8
3. A lined. chimney Is prefened and.:must b e W!!!ld
whe11. reqwtec:l ~ 1~1. ttate, pt'M'ioda/1 and
l'laJJonal md!s,laws.ft!gU!aJions :md otdlmtl.:.a.
Vlateom tile llo1ogi will! joltlts that pt'e\"'!ll.t
retentlOfi .of moUmte aM Jlfrung!i\ rude or nl)fi('Mf'OsNematerial! lftlbe:rt. AdviO! fM:fl'ue amoed.Joru. and chimney llnilog~ ean be obuilll!d
from IOc:;d gas uilllty. Type D d.oob!e-wall metal
::t ~ or !llftgle-wan ft:ft t plpe may be W!!!ld
1
4..
ColdmasonryohlmruJYB, al!okoown as oi!I.11Ide
cbjntfti!yt ~ typJcally bave ooe 01' m.o:re waUs
exposed. ro ouulde air. When 'Ml'f almMph~lc
ga.&-fifi!d bolli!r with auJ:omatic vent d3.II1pi!F
Is vented tbroogh thii type of ehl.moey. the
pott!Dilal ex,~ts fo:r oooC:ft!Dtatlon to o.ce:ur.
Candmlsa!.loll am damage a masomy dtimney.
We.LI-MeLain recommenda. the following to
p.mrent possible datmage.
a. line d!lmne)•Wiili eort."'!!lon-u~t
mstallloer m.ch aa AL2!1-40' &fDgle-wall
stain leu !1\teel orB-vent. Silt!'
Naltklnal Fwl Gas Code ANSI . .11atest eilllioi'J.
ltzl?rr
b. .Provide drail'l tr.lp to remove any oooflJ!ru:.l~
a
le
-Fired Water Bolle - -
oller Manual
Prepare boi~er locatli on - contamination
.P~ :te'\'W!w the fol1owlng iaformation on
combmtion air motamination pi."'hhem~
IAWARNUIGI
po~tlal
.Refl!l' to TabJa,1 tar producu and at\!.3S whk 'h mii)' cw.se
amtaminated rombustm air.
Th p:r-evenl potentlall of s:evere petilOi'allnjury .or dea1h, check for protluct.s.or oue.as rlited
b elow be.fote lrn.mmns oouer. rr ilDV of t:lli!S~e ooma:m:ill.ti\u a~e taund:
.. :rl!lllaw o:mtamlnaots pe:llllanently
-a... :isolate boiler and provide out!ide oombll5tion aU;. See natiooal. prnvindil! o:r local! codal
fu:r furdi.er b;fottnatlon..
Productfi to avoid
Areas~~
8pi'B)' cans cootalrimg ~hloro"fluorocartlcl!1s
Dly el~ aundry are39; and e918bll9htll1!1118
Permanent wave ~ooe
S~pootg
Chlorirnated ~desners
Metal fabrication plants
Chlorine-based s.wlrm1lng pod dhemlcats
Beauty shops
Calelium chloride I.IBeJd klr &Iawing
R'etrlgerstlon repa1r.shop9;
Sodium ehlorifle used tor water soltenlng
Photo pro<:e9Sing plants
Refiigemnt IBak!l;
Auto body shope
~ nt
Pl8911e msnu1actul'hg plant9:
or vamlsh removets
to ha-ve contamiii'IBfrts
H)'droehlorie: add/nulatle add
Furnttwre reflnlsl!llnQ ar&aa 8Ji1d estBbl shmei!TtB
Cements and i:jlues
New bUidiDg conalructllon
AntiBtatle tablllc soitenets used In dothes: dryers
Remode!h!J areas
Chlorine-type blelsches, det~nts, alld cleanM'Ig
soi'JefliB 1oond In l'loosehotd laundry rooms
Garages With M.'Oik.ebop:g;
A.dheSives used tD fasten btilldlng proclJctB. 8l'ld
c1her' slrDI&r prodl.ld.B
Bullcllng,s under oonstructkfn (wtte~e .air h
contaminated vA1h pBitlculates)
Airborne partlcuiBtes (di)I'Mill dust. fiberg888
psr11!Cies., road cr {11'8\fe1 duEt, IIITI, etc.)
CONSTRuc-11011 DUioT IUZ&ItD - Airbot1k pa..tkub.ae~. su.ch as drywall dlll.t
()~ fibecglDII d'll!t, will C"alllle b:Jod!:age of the CGt bu.m£0, alillltlng:fn Glib on mODOiide
proilurti.on. a fire ihaz mi. a:r bl.l.ildl!ng fme:r.e dam2ga. If the boiler is operated during
oooitruetlon, yoo rnw.t lsolari! rhe boller ro pt'M'ldot! dean a:lr for COft'lbwilon. H you are
una.We to enamtt uncontaminated air in lhe baUer vicinity at a'llltirnea, you muat
inap&et itha baii111TIIIIen1 once weekly'. When inq;ealn~. dean die bUtlleti :tk!f65aJY
lliiftS.tlie ptot:Wl~ :given on page .41. RtiiM!! to f:oll.ow theit! f3111detl11~ MUJd re:st!Jr in
~1.'1! pe:taoMl :lnjuty, dearh cw soubunlbl prope:rlf damage..
•r
9
0
oler-
DC
1f
aller
anual
Prepare boiler location - air openings
Cambu•tian air apening lclcation and ai:mng
requf.rretBama depend on dte clearancM arolfid
dw boiler. Check the b oiler plaGeJlEllt compued
""PJ~ 1,
paae 7.
H a11 daarsncu •e at least equal m FtgUJB 1 f
page 7. applf the il7ios and placemmt of apertlliS'
f3LW!n on pases: 10 and 11.
H ANY clearance La. len 1han FtgUre 1f page 7 ~
you m~£ ptmltde air apen.lngs: stzed and !oealed
!iihown il'l Flguu 2,
e 7. DO NOT apply the
s:l!lns .and location in.furmatlon s:hown on pa~ 10
a~IL
Air open in .s must l'le proVided
£'ad! .. ~~ (JM ..... 1 ....... b:h F'V I PJCIM.ab
OlmbuatlooJ 3I.:r 31ld ventl.1Jl£on openinsTi must romp]f tbe National Fuel
Gu Code ANSIZ223.1-latmt edlli£OD, or applk:ib1e lma.l bw1dJmg codes.
Canadl:m mstallatiom mut c:om:ply with !B14.9.1 or B1t19.2 ]nmllation
Oldm.
t!A.
.....
.
ProvJtie adequate llX!mbus:thrm ;tnd. ver.illa:tlon alt to
as:swe proper combmOOn .u~d reduce the tistar ~te
per.iOna l lftjury~ death or !WMI!.uiJjaJ pmp«l)' Wm3g;e
caual!d by :lllue su ~pillase and catbon mflftetdde
em ilons...
Air open in - opti011s
Two· o.penlnrga - :Air mq~p., from lrt.ade the bulldlne
*
rt:Hh 4tiift'ht ff4ot ~· , . . .,.._,.., I.«(( 91 oh
oflll1uamilly1[ghtcooatructian (IIE!e definitlo~ DI!Xt
page)~ tbebmld'ing nmat ako lbepi'OWc:load with air openings. d'irec:dy
to Hle rautlri~ :Siz&t and laeilld per F"~ 4~ Fi!JUI:'I! 5 or F:l~ 6.
i.. Bolfdlngs of t}'pleal o:lft:W'UaJaD should providea.de:qutlit! combmtion
3I.:rfrom Datu:ral:illfilm1t£oD, ao additioDal air ope;c{Dga to illb:e bulldlng
1. IfthebwldlnJ
~ not required.
l. See Fignte 3. PrM•i.de lworoptmfnp r.hrough llle ifuerlor wal~ wldtln
12 moliss of the ceillmg and the :tl.oor, sized~ F4lure l .
*
'IWo· opening• - :Air auppty dfre~ t-rom outdde
1. Alt opea&t~JS- mw1 be dlredfy tlt~ u ouu:ld.e ~tar Into asp31Ce
1:1ta1 ro~~.DeCJt dl.red.ly tet the ouhlde {Siucb as a \ufila.ted auk a.r crawl
spact., fa.r example).
i.. See Fl;g.l:lu 4- Openinga direcdy1hrough sn oulaide wa'll - prcwltl.e
two opectinga w[thfD 12 md:iell of the c.el.Jl.ng and the fioM, W d pet
Pigute4.
1. See Pigure 5 - Ah supp'Jtad ithmugh ver1i'al clucta - p!tWLde two
opemnga. tumfnm!d witbio 12 fllches of the atlllng and the fto!ltl't &fmd
per FISUft 5.
hor~an1a'l dUJCts. - pt'O'I'lde
lWO opactinga wft!hin 12 mdJa Ol the fioM and the c.elling, sized per
"'" See FISUft 6 - Arr a-uppUed lfmlugh
Pigute6.
10
*
-
RtJUFe 6
IE':.d! .. .,.n'111 ..._ _,_I '"'I· lu:h p..- 1/t(l) llhil
.....
··-
a
-Fired Water Bolle - -
oller Manual
Prepare boi'ler locatii on - air openings
N01lCE
FRiilii AREA of open!~- 1.1\.e r»l.ftlmum a:re:a."'
!l)v.en In lhls m:urual are free a:rea (equals the area.
~~ lifllt!S wJdth of .opening. after dedDc::dM for.
l oU\•et obmDCtlon).
Uae 'the free 3.1'eil infotmat.lon prcwlded by me lo~ ma:nuf-..J.ctllt'e:t.
When md ln!CII'mat.lon ~s not avalbhl~ .wume:
.. W,;,od 1oLWI1!fil- aa!ilUlle free area is 20% oftotal; 110 1ha actual arsa.
af each openmg with "wood loUYefi: ljiiOOuld be 5 liMes the tetlulted
free area.
.. MetaUouvers- aa!ilUlle fme :iH'&li& 60% of acrwl ~ !iiO,:forwood
loo\'t!ts~ 1he a.cmal at"eiJJ of
opmln,g mw.t be 1.67 tLrnes the
tequlred free area.
e.am
linll• air openlr-a1opttoR
*
A slflsl~ eombosiio-1'1 air ~lftg ean be us.ed ~n lleu of the rwo-opMID,g
opdom 0111 pa:ge I o. provided:
C.leemnces lmm kU'M to •~
.. Ths bo:ller must have dearmam of at 1sJat tb.o11e sh0vrn fn Figul'll!' 1 ~
toonrlnue\!JJ
UniiMI 1J tight conatn~ctlon
UJ111SUa1lftight ronmurnon me am (pBf ANSI Z223.1)
bulldift!J!- in wNd'l:
a. WaDs and ceU,I'IIJS apo5!ed to llle outside .umotpb ete have: .a oo.rdln001Uw.ater v.apcwfeUtdet" will!
a r.aJil'l@l of 1 perm or l!!H wlth ~II'IIJ!- ke£.ed.
aM ...
b.
~~Huipplng
has bl!ltfl .added
on openahle
w"lftdolllil9. ililld. doors, and •.•
c;.
Caullring Of aealant!i are applied to ueas sud1. as
Joints ;]J'.QUJLd wil'ld~ and door ~ h.ei:Wl!efi
sole plats~~ and :flooflll, between waU-oollng foin:tB,
be1.we8i 'W"Jill panels. at penetta.tions bt' plwm:l
!~earL 11 an4 :gas I~ and In .otbet" op~.
Foot-web ooMtrucrlo:n ca~ if appllln~ u.s;e ~mlile oW'
fM' ~ n. pr,fWi'da air opemnga i:nt:o tbe bllilding fromoumde.Sde :mil locaie tl~.openin!JS'p.er 1h e
ppropri~ ca51e In Rsme' 4, 5 or Gon ~ge 10.
(Jitge7.
()paning trWS:t be dlteeiJy to (1~
.. Ths opmfng must OJIUJect df:reotlf to 1lhe outdo.m Of to a !!J.)&a that
eom.munkate!ii dltedly to the ootdoon ( not roan :Interior ISplllf.e).
.. The ai..fcanbspnvided through. a df:recr openi.ngottll.:mugb a~
or vmieal dlirt.
~ phlatlmlftl
..
~
..
..
...
Ths top of the ale openmg mut ba wi1:ihln 12 mcltes oftha a!ilfng..
Ths ftee area of the openlng m'll!t be at !Leut equal to the III.IDl af the
3!fe:lJ of all equlpm!nl venr eoiiMeJote. In the !ipe~. af'ld •..
Ths ftee area of the opanmg mut be at least 1 lllqua.fll tncll par 3,1!100
Bru/h:r input r.illl'l@l o f aH .equipment lo~ted in 1he tp.:u:~
lbc.epthm for large.-..
*
No oombustian ad'.t' openlmg!i are needed when tbe baile:r (3Dd otlle.r 3.P'plla~~1':8) are lmiaiJI'ed in a~ wW' a \!Olume m laut 51) 'c ub]c feet per
1~000 Bbih of ;all iuWled appllaillees:, pn:w"ded~
.. lhe l:lllil'dmg m111111 n€1t luwaunuBUaiJy light conatflllCtion (!i!il!B d.efuci'..
tlon. '~:liM. p ~}
an de3f'3Jl.CSii u,;,und! the bo:iler must mliSt be no less than shown in
111pre 1. pase 1.
Th deit!r.mine IT llll! spliCe bt,ge enoutb kJ. quality;
.. Add 1ha total input of all appliances mMBH (1,.001ll"s ofBtub).
.. Multiply tihis numbar 1:imsi 50 t o d.e:ts:tmm_e miDlmlilllll n~om volume.
.. Enmpls: Fo:r a total Input Bf 100 MBH (11!11!1.000 Btuh), mlclml!lm
\OfAwne d 50 1 100 =s.ooo enbie ~t. AI a .::eiHrtg he:.lg_b 1. oi 8 fe&. llll!
spao! flUID b:we 3it least .5,000 + 8 =625 tqll~ f!et (25 f:eet% 25 feet.
for llllstal'lee).
Edlaust tans and ail" movers
The appliance ip3U: must
na~er
~· l!!!.r.en, lrthe apfl]~s)
h.e amdet a n_eeat.ive
:1:fe ~ur.all:ai
.as dl-n:!et
vent. Alw.a)'s prowltftt ;air· .openlnss sl2:ed not .only
to the cllmensuma :r~qul!reod !o:r the firing nts of ail
appll~ bu1 alsoo ro b md!e me air- rn~• r.au.
oT llll! .erlianst fam or al'l" :MO\'t!rs ti!ing air fmm the
bumdrng .or spaM:e.
Motorized air dampers
If tbe air' openfng& are fitti!d! with moto:d'zed dampers,.
e.l ed.:rically lnrerloet llll! damper to:
.. Pfl!vmt the bo:IJu fftlm fuing :if 1M damper is nat
fully opm.
..
Shut the b~ down sh0uld the dampu clo&e
during bolls opemtlon.
Th aocompflih !!his i.nterlo&. wil.'e ai'J tao fated contact
(provltlg the damper open} in~Se'les wltl' dli! ll!t!f'.lnill3tat
~Dpu.t kJ. 1he boU!r. 'fl~ balle:r wiJI not mrl lf this
coniact i!ii opt~ .and will shut down should ' t open
dlltlng operation.
11
0
oler-
DC
2a
aller
anual
Prepare· boiler- placement and setup
Place boiler/crate near
Inspect or1flces and burners
positio:n
1.
Corrli!dly-sfzed mmfia ld O!':ii&es
mwd be um Fa!~ to. do. • wen
lave brltller ro er.ue and 411'1 plJiler uDt.U :IMulhrtloo
site ready.
i. Move l!fttlJie crate at'Jd pallet next 10. S!!leeted location.
3.. J.Wnm.r;e O'at.e..
4. ~ IK!iler from pod fer..
Do not drop boiler o:r bump fadmt
on !lloM o:rpallet. Dam~ to boiler
~3111 li'M\lft.
a. 'J'IIt lefm ~de 4lf boiler up and pbee a 'bo3td
UDder fm l.egs..
b. 1"111 boJf.er the other way~ p~ a boatd
oodet right legs.
of. SBde bullet lhaehtard 4lff p:l!llet and EftiCI pMIliclrL
5. Cbsok lew1.
a. Shim feg!l. if neoe.ssary.
h. Do not altef Jeg,~ .
Install inducer assembly
1. J.Wnmr;e the rorlucer W!!l1l.bly (.md &J-'lket~ fro_m :Its
sb.ipplng ~3.i'klrL
2:. P1.ace ~aslEt on :flue roll.'ectof' as s:how:o in F.Es,nre 36,
p.ase s9. M~ iill'l!! the ~sut is: rn good oo:Mttion.
1. Seeure :In pli11Ce wJih foot· :nul5: provlded ~ a plrnl~
bra :1 Ide 1~ Inducer ~
4.. W:lre :lruiUM" motor ttl ooatrol module by !Jmfling
Mole% (O!ineeto:r iliroup rlglu mo:u jadc.@t top
amdnh opmlng (aee p~ 3 fu11 finished assembly).
Pr:ess: strain relld bmh!Ag into. hole. ID:Sa"f Molex
~ounutor
Into :matins eonoeetor on
m oduls. C1ll1Dectoo;
~Mtrol
keyed and an only be
:1~ on.e'\'l'ay.See ~ 3S,
48, fot foeatlon
of c:ollfieCfot 411'1 .ooatt'OI module..
3.1t!
re!luJt
~n ~v~re
peHoanal ln,jury.
de-arth or l!llllstantfod property damo~~se..
1. JleJI~,re front Jacket door. ltemO¥e buroa- sh ield
(!k'!oi! A~111re 371 ~1em ~ p~ &2).
i.. Verifi;'tbattbs arffice &W! :fs 2.7mm. (Th:e off:fia! liflm
~-
i& &tamped on 1lhe Mifu::e spud bam!Ll)
Re:IM13.1JJ bumer d\.Md.
D o nat apsrats boiler w:lithout
blltnt!r !ih ield lft pb c:e-_ F:Uiuu to
de. so oould roestd1 fn ~ pettoftal
lnjury.~th o.r~tbl propett)'
.t~.
da..ruge..
This prodw:i Is used at .sea Ievell only.
Orifice replacement
precedure tlihlen requrteCI)
~ 1he ~rews ~urlftg the b lll"ftet sb le'ld .arui
remtwe bumer ihle'l fl_
2:. 'U!Ili.Dg a ~~.,.. opeo--eod wreneb~ rent0\\1! the bumet
odti.CSI from the manifold.
3.. Apply a small .amount o f pipe dope to e-JK:h of d\e
new Mifi.a!ll andiD&tallf.n the mmffold uaiicg a ~/""'
open-end wnmcb.Make S1lfl'! tbe Mitia!!l afil alfgJ:led
cott«tl)•1 nof ctMS-ilireaded jn the nwti~rrl tap­
1.
plngs.
Usetllll)•plpe dope mmpaJibl.ewLCh
propue ~. ~ if boBer :Is to be
operJted on mwr;l) P · Falh:tM to
oomplr mulJd r&Utt•n ~per­
sonil injury. deaill or wbsotant~l
property Mm3.8f.
4. Ca:tefullyrepace the bllf[lft' &bield.
5.. filollow the ~herlc:-om pi:'OoOedore of Sec:tJon fl. to
e:n5:Uf'l!! the boller ' :DOW opera6og properly afiet
oritic".al :t1i! !O!plaa!d.
a
2b
-Fired Water Bolle - -
Prepare
boi~er-
pressure test
Hydrostatic pressure test
li'~ rtest boiler ~ Mt.achl:ftgwara or SM plplft
(euepm:lJ n.oted below} 01' electtlcal supply.
Prep_.. bollar for te.a
NPTpipe~.
.Rem~M't! 1 ~"'
nipple. reiucitlg tee and draJn v-.lilve
from. clmlhtor bardwat!!! bag. )mtaJ] in boiler t'!Wrn
roal!leclion as r~Mwo 4lll. page 3 an.d Figure 31 ~
~ 64 lmaaJI dutllatot 4ll'l the retutn side.
3. Re.move 1 ~ .. :n i pple~ 1~ .. x J. IA'" :t 1.. te.e from
dreula.to:r Jwdware b.ag and ph!5.'1UI'dh!mperarure
SliD&! from l:ndlLO!I" otton. PJpe ro b otler rupply
mt"~:MCI.Ioft as shown on~_; 3itd Figure a1. ~
64~.
3. \\'hen wate:r :D.ows from shutoff valves. dose boll'er
drain valve..
4.. aoae slmi:.Bff valve9.
5. Slowmy reop-en. ballet dra.lD 'i'alw utttll tes.i pt"eUW'e
0111 d!e press.ure{ten!feF.d.urega.u:ge l:'l!adtt.s o.o. IDQI:'e
dian~
L !Remow the shipping nd:pple (from CGt lll!lpply
tapplrtg) and remov-e th e ooil~r rel l.ef n lve.
Teq2orari1y< plug ihe rt!llefv.!h "t: tapproi!l with .a.""'"
2.
[U'se pipe oope spa.ri:ngty.)
46 pslg for bo~erswlth SOpdg
ef'¥Bfwe..
10 pslg for boBerswlth SOpdg
ef'¥Bfwe..
6. Tefll. for no mf.M'e thiU'I 10 lllltrtute!li at
~
46 pslg for boaetS with 30 pdg _ ef wt~
~ 16 pslg for boBetSwlth SOpdg _ Jefwt~
•
~
~AWARIIIHGI
A mld. wmrr fill c.ould! apand! 3Ild
7. Mak-e sure comtatu gauge lin'E!!~ has been m.alntalned throughout teat. Ched: fo:r htak9. Rsp:dt if
fol!Dd.
le11b mlm: be repal!ced at artce.
raJJu.re IOo do 5lO c:an t!l~ ooaer~
rerultlos fn rubttil:tllt:l311 property
5. Cmmei!it a.nippl'e andmutoff valYato II)'Biiml llupply
Cflltth!diao o o the! 11\4." lee. This vahre 'WI[] be ~ed
1o bleed ai:f duringtbs:fill (VaM andn[ppl'e ue Dot
lru:hlderl Wild! bo.ller.}
6. Conned a nipple md muto:II valve to symm :retum ronn«:tion (at droulatoc t.lanf'3 :If clrouLltoc
ln.m Ded 011. retut:n). 11tl~ \laM w:IDbe med to bleed
ili dJ.!u:illgthe fill. ( Valve 3Jld rupple a:fe DOt iindJ.lded
with b oiler.)
Ill ...d ........... tQI
~ rnemuroffvall.~s:yoo lnttaDed
h:!lUtf'l eonn edJoi'I.S.
Do not hi~ bo11er um~~ded.
coaw e exe~SS~'W! prasur.e ~ :t'l!fllltl:ttg
fn sew!~ :petSQI'la! injury. d.eath or
Sllbitantloil property d.ama.ge.
4.. Con:ruJ;ct a hose oo bmilsr dJrai.D v.aNe. the otlm eJJd
~ded lo. a :tush \Mi!liet mpply. Make sure hMe
.:=a 31~ be used to dta:l'fl boiler ~ USL
L
oller Manual
damag-e.
Do n ot ll5il pelroteum..b&Md dal1lfn.g ar ~ns: mmpm.tl'lm io boiler
S.) '!Uetn. Sev.eh:! damage to bo.lll!f'
will oerur~ f6u ltln.s in 1Wbua:nrd1
propettv damage_
Drain and remove flttl ngs
l . IHsooncild fill wam.r hose from water !K)ttree.
Dtam boile:r 3:1: drain valve Of o ut llose, wbktteve:r
ptovides bu~ :u::o!SS to dmn. .Remo\~ hrue after
drainins tf wed to dram 'boger_
3. ltan.o\oe nipples and v-a:lves unless tl~ MDrem am
for ~ rfl dlit ~ [plpfng:.
2~
on.s:upplyal'ld
2. Slowty open bolter drail'l ...aJve ai'Jd fte.sll w.at.erw.pply oo :fill boiler whb. wata&
4.
Rem.o\'i:: plug from ~~WI~ ~ppl:ng. ~
page 20
to tepiaee rt!llefvalve..
13
0
oler-
DC
aller
anual
3a Venting -general information
~cat ve~~tin -
options - Chimney draft or DiNe~ ex.llaust
--...o
C*imft., dNft vetrtlftg
Chlmn1Jf dfa:ft vmting l!l!ea tbe Dal:l!l:flll. df3ft p:rovjded
by a ve:rtiCll vmt 0'.1!' dlf:mn8y;.Category I appliance ( DOOJp~!JJJ've wnt Wltle preuUfe aDd vent gas ~rature
That avoids I!X.casl\te oond:eruate prOO.uclli:m r!'l w1n).
See Seciion ,.,, Cbf.m.nq dnfl: mit:alh.ilimll uae:
1. Vent eruu'led.ot· (!ringle or d.oub1ewan) il:z.ed Lo
elfmlnate poalthre pmuru11! m'Wnt ~ Dhmeter
inere:ues f:tmnedbte'l)' at bo:ller.
2. DoublRa!Lm~t:al ...--m~:· (B-wnt) M chfm:ceywlth
1fDer approved by the N311:0na1Fuel!Gas Cod'e, ANSI
Z22J.1-1atestediti0D,o:r m0mad2.B149..1 or Bl-49..2
Jinstalbl:lo:n Code.
3b
Ta'b'le2
Vent coon ector
diameter
Venting
DJt;tC.'t exltaaqt v~g (wdlaal or
Dfru;t ahaUBt vmtmgllll!illli Wide mm~U51ion air with
DO ro:mbunion air cOimectar p:Lplng. AU CGt :flue 8"3!1
V1!r11ts .are pussurizedt :reqwttttg .careful sealinf of an
fomta. CategoryIII appllmce (po11BftM! '\tilt BI:Dl.cpra!li!D~ a:Dd vent p;a!l ~per.tture thu ~ds ~
c.oDdensate proclurno:o mwnt) .See page:s l5-19. D1reDt:
ahamt lm:talla.o om: use:
1. Vmt plpe spedified
2:..
Ve~~.t ~nation ilii:'Oll:tb outSide waD~ roof or Utt-
used d:limn_ey. T~gbt ehTmney a.reas wiDmake vent
j alint am li1::l:'l!ldian very difficult.
- ~chimney ~draft
wnl. connec4or
OOt
5'"
venti1n g
lnspeetexiuln.g d:llmney befoft! lmill:llins boil8. Fdure
to .!lean CJI' teplaee perfotated pipe or·llnln;g will ause
ISI!W!te per.sonll. jnjw-y M deadi.
"'D"' Minimum
Bollar
moC1el
numbar
mthis mama.a.L.
dlam&fer
lfeftt ~ling glwn m'Mile :2 is: only a. :gener.d guidefll'le
The vent eonned.M and .ehlmney m.wi be de.si,-ett..
:!llud and ~ueted in rempllooeew:lih all app'lleahle
.codu. Fat:lure to ror:recdy :tlze ar!'ld iMtaU mh~ vent
IS)'.stem. oould ~rult In set;'eft persoiU! ~n;IW')'t dwtl ot
iSIIb.slutW prop~ &l.ina:W!-
1. Use d.~ !!Wall rn8a! ~~ (B-vet~t) ot ehlmtt~ w'rth liner as requited b)'
, . . . - - - - Tiijhl .....
i..
,.....---- ~min. 1111' rlu.IAI FT.
.3.
4.
.5..
tlbs NatloDal.Fuel GasCod'e. ANSI Z223.1-hm!lit ail1tlon,. orin Qmalh,
BU.U M BU.9.211nstallation Ccl£1.
Th pte'i'eftt do\'mlirafu, d\lmney iboul!d aund atleast.ll feet above the
~lteft pobu wh ete If pa:sses mtoUg11 a roof arftd at lea.!t 2 feet h~gbet
1Jian my pol'tloo of a bwlldlng wil!hm a botl2.:fNit3J ~ of 1•0 feet.
Th vmt with. acot:h:u a.pp]{mce, see Natlonal FL:Wl Gas Ccld'e. ANSI
Z221.1-lateBI: edllii0n ot :In Gmada B149.2 M B149.2 Insta.lla!:iion
C-ode
Do Dot amDect:b:n!ecltlngto anyportfun of a medlank.al dr.rll: 5)'5tem
tltal a n operate Wkle:r po~I.We ~M.Uiitaln mlrtlmum 2"' d~ ft'M.'l ll!flm.busb'b'l~ ma-teti1s ~ vent
pipe.
6. Do not l.lSEI dtimneywith an open fifeplaca.
7. MiLke horiro:1ua.l run~ as short
padl'b]e.. long rum c::an ca~ oon-
det'lsalion.
8.. When lof~SU nuu are u&ed~ mpfi01'l pipe wiJh :a~prlate b ~.1..
9. Th pl:"'!'\!en1 bloctase. d.o :not \tent illtfl. bortom of chlm.DeJ.
l O. Vettt pipe m~E not :go be)"'ftd &u:id~ waU of ddmlley..
1L ~ pllningthmugh ll.ool"5 m- ~linss mwt be ~~d.
l l. See. Hg Ull'lt 7 .md T.t!Je 2 to ammect bai&!s b:J ~ S)'lfem.
a
oller Manual
-Fired Water Bolle - -
3c Venting- direct exhaust- components
L The followiftg speebJ gal: 'Rf'lt ~ oomp.ly will!
UL-1738 amfULC-S~611tndarda and are '"ertffied
byCSA a.a the ODlf S'j'!fmJB suitable f(lt:U!l! wnh CGt
boilet$ (aU .l '' d iameter):
.,
Heat-Fab, IcC', SBf.•:r Vt!ortrl'la
..
..
FJ.u:-:n. Jntun.monal. llntt. S'tiiQ..34
Z--JFJex<l, Jntt. z..vem n
..
ProTem Syitelm FaaiNSea~ll!l
[AWARMING)
Use only tile vent starter-of tl;e tame
manufa~ oJ:!. the \'t!nt c:ompo.!llsnts. D o D(lt mU: oo:rnpane:mts
from different tystem:s. The- ~fit
sylltam could f~ C3l.Df.tLg :f.ll!le gas
sptlla~, rewltmg lit ~e'\~Ue penou1
:llljW'f Qt' deo\th.
2.
Sef.ec~ veat
method based oo page U l ;Wr!l lmtllla-
tion tequlretnellu..
.3. Refer to nare3 for ma.ximum vem: ftlfi lenphs :ll'ld
nuc:lber 0f elbawa. Do not oree.d dati. :fn Ill lire' 3.
4. Sef.ec~ vmt eompoRI!Itts ftom ntllre 4. AU c:omponen~ lndllfllog tile ventiltllter.mwt be ofthes;:une
vmt ~ Da notmf:x: c:omp0nsnt&.
MiDC. vent
lengftl (fee'Q
Tota~
0
40
CGt
1
numbef" of e[Dows (Nd.e 1)
1
33
2
3
26
1Q
4
112
5
6
5
--
Nde 1: oa oot lrld'lD! ~on IIIIFig'Mlen
cotdng 11:1a!I'UT'b!r al'ellxJAI.
Saf-TVente
$taR-S4
:z.Vent I
~~
~GIS
:sRAWCGI
SYEWMFAm
FSA..wBL..CCiU
7J.WMTERM
-
SYSI!IPXDI!
FSBaS
t:!it 4T&Ifill
.sR'Mo41'!
SVS1'E!XOaGO
FSTIBliO
T4Wr*ldloil TM wllli Sli'Mn
7:!!90TEE
SR'IT.(JJ
SVST1'X09
FS1T9
.f6"E;Jbow
7.t W30
SRSABOa!
S:'llEBN'eC!lWfl
FSELC50!1!
80" Bblow
7U4QOTR
SRBI0091
SVEEWCO!&O
FSELBIIM
&· Pipe
780~00
SBOePOa
~kfl
FSVU!Oa
12" Plpill
7.9102GO
SA11:2PIIa
S\IEP'WCO!~
PSYU2Qa
1 8" Pfpill
'7'a0400
-
S\'E'PWtCQSr11
PSlillteoa
24"' Plpill
7.SO!JQO
SR24POa
S\"EPWOOI
PSIIJ....MOa
Wl'lpl
-
SA!!!POa
S\'EPW(lt[IM
P"S\UIIO!a
Diii!IIHiplln
CGtSIMer'
T«mml''dttltl c;:lm.li*!QI wtlll SiOI'Mn
,..mrrt.uloli Elbow with SM!tfl
-
-
7aQ)IIG0
Sfi'I'DMO!
S'IIBlWOOia
-
S~t4
MW'Pipll
7.907GO
snp Conni!I!Ctor (SM Nl)'ll'E)
732-tGCS
Hortzoot.l S...ppcut
'7JI23GO
Hortzootal l!liteln 'A!&
JOIJwBarid
S'Mtlnt
ltOD• SOp ODrii'IIIICitot
S:R$.M191
-
As Bped11ed bJ ln:ll'l'ldl.EIJvent rApe l'l"BBlUfSCI:Urer
-
FSSH
FSHDTa
Not requf..c!
l!.f» al!P <!10fi~r11:1 .dti)Uii~ fot tu:...~ iltanlliard pfpe. l ~ II'Uil Saf-'IJ"'Ii'iMte Gl'lly;.
l:te!1itJie urmli!don cOIJillltiQ to Ul'mll'iate rur\.
15
0
oler-
DC
3d Venting 1.
anual
direct exhaust - vent starter
Seled. ;a v;ent plpe manufacturer tild
obtain aU ~~ oompo:ftents needed,
baSI!d a n boiller locaiJan. a nd venlins
~
meiliot'L
2~
aller
p1n iti
You must 111.&1! the vent at!lft:e1' m ads
by ~lie ~nt pipe matnl&eturer_ Se:~!!
Ta'hle: ... page IS. \lent IS)'Siem rompa:t.ell.U, fclr put number of i!lllCb oom-
poflem, limd by wilt mmul'aclllfi!r:.
Us.e onl y the: vent
starter of t he u me
maf'lufaetun:r :u the
vent c.omponentB. Do
cot ~ oompolllents:
fromdl&rent ~
BlawH o ut l11t
The ~• $Y!itl!:tn could
fa.U. e;ausing Hue ps:
in
spmJ~g.e. :remlltb tg
:SI!\'t!re pm6f'lal jnjwy
Ot death.
,l_ Follow aU a.ppHc:ablt Datiou 1, s:t.om,
I~ or. prov'1Dcia1l i!Od~ wlteD veniin
the ffitlb0ilu.
4.. Connect vent starter to blower h a'WIing outlet H sliown in the FiiaUrM 8
throos,h 11~ right
a Do nat mil: C()mponeotll foo m
d:llfe:rent vent ma:nufa.dlml'o~..
h. Nbi!'II.Jlin mlltlmum 2:"' d ea.'F.IDCt!
Rg,uFe 10 Ssi-T \tenti2l vent starter
frvm l.'lo m bustlble m.aterlals to
~lpJpe.
c.. Sea1 w.ltlJ. Sll!'31.ant spedfie d by
~~ pJpe maJIDfacwur. w[ftg %~
b e.ad (not fl!ql!tiredl fM FasNSeaJft')_
d.
'JishtM rtf'ap at baf'ld el:l:tnp
Kf."e'W UDail
strap is Sll.Dg arOimd
blows' hbusins.
ll:.and ota.mp :lt'rtii'W
16
_ _ _ __,
RSJ!Fe 11 StaR-34 vel'l1 8t.arter
Tlli!l:llln
p01ifion
a
3e
fAWARIIUIGI
oller Manual
-Fired Water Bolle - -
Venting- direct exbaust- termination
Follo:MJ in.WDctlons on dU~ page wllen d!UrmiBin;'W!nt
location to amid pcma"bEmy of !ilevere perso11a! lDJDf)'~
deadt or w.biWttfal propetty damaae.
1. Locati! rile h61ter aDd ~t peN!trati.oft lhrou~ !!he
wall SO aJl tequiretne~~~IS Oil d\ti; page .artd [n ~IJUI'e
12 wiD be met. Abo follow vet~~t ma~~.llfartl.lUt"'s
ltnti'DCd-ruu..
2. Gasesw:lllfo.rm whltsplum_e mwiDti!f. Plume a:ruld
obeir.ruci. w"mdow Y:l~
~t;'aillnJ w:llld.scould. .:.ruse free2ii'IIJ ofroodmsate
and waterftee build11pao 'W!Oltermlmtlon. bulldlng,.
piU~.ta. or tool.. let!! buJidup on Vl!fl.t ~.l"'atlon cafi
omse holler !Shutdown and bolrdlng fte1!2etJ9.
.4. 'INrf'ldJ ORt" ..0 mph cat'! eau!e rrulai'I.O!! bailer dwtdbwrl.lfboiler ~~~~all Vl!ll.t!d. Thl~ eoold ~rult
in kiSlt of beat to bulld.IIIS•
fll'!!e%leup.
:5-. lbclte or gua.nt ~t term1Mtl:o:!l ta .P~'t!llt rondemate from damagrng e:xUrior swfaees.
3.
eausir.s
6.. lbclte !!he ve:tu r-emtlnadon Wl!!ll M'l:l)' fnlm ~~
mrub~ bftd deeot.aiWe lli!m~
7. :Locate 01' s.uMiJ Vl!fl.t 10 ~otacddema! c:ontad:
by people or peta..
B. Do Dot Wn!lrum! Vi!llt in window well. l!lttirweii.
a!oove., cm.mr.ltd~ CJ:r fliher ~ :areu.
Sl. Do Dot wtap or iDBulm! vmt pipe o.r fittings.
10.. 00 Dat tamlhlab! vmt :ab0Ve ;my doot~ ar window.
Condensate em :fae~ c::auafng ke :futmatlom.
1 L 00 Dot 100IllD1l ct::
.. Any .:rt:bm" applim..:e to wnt pipe.
.. Mrultlple bo:l1ers to a roimDon vent pipe.
U . Canadlm in&tal!lati:OOJ& - See B14SI.1 or B14!11.2,
lmtallation Cod.e. Thrn:J1cab! vmJt DO ls!s tbac 6
fe« fmm a.-Aatlier combll!tloo air lftlei, 3 fe!t from
any a mer building opel'IDg, and l fe!t &om atJY gas
lt!1:'Vic4! ~a.tor.
il.3. See ~ 12!. showing that the veBt mwt lenninate~
~
more than 4 feet btlow ar to !lids oo an d.o01111
•
more than 1 f0ot ab0Ve grade ot m1iiclpa.tad
or wJnc:low!l.
!mOW"f'J e.
~
at least 1 feet :above pLiblic wa.1kway.
3 feet ab0Ve amy furo~d aic:lntake wirtbf.D 10
leei.
141. 'kni. must a1so ierm.lDaJe:
• at len.st 6 feet away &om adjac;mt walla~
•
U(l doaer tbm 5 feet b.WW :ro(lf BVe.l!'bang..
• at least 4 feet hmrlmntally (and :in no GJM
~ or below liDre,~ a ;t foot l10r.lm11tt1
distaDce Is mamtaif'led.J from elec:i.rk melt!~
g.u met.en.l'!eh"'ll:'la.tor&,. :rellt!f WIV!S. and !Mhe.r
~
eqwpmmt.
lS. S-l:t.l!! rol"'dltl01u may dleate ~ dea.r--.lfteeS..
16. D'(J Dot mmdupo!Bd....-.entpl.pa ol!li:Bide ofbllflding.
Condenuts mLil.d ~ md blocll: wet pipe.
A
vent exteod~~~.g through ao
enerl:orwaU iliaD :ooi. r.et'm.lute
~~t ta til~ wall 01' beJlow builldlng
enemlom; :!lid' as eaves. p~t!,.
baleonl.l!!J or ~lcs. rallute 10 COM-
»
ply could l:'el.rult In ISe\'t!te pmou1
i11J'ufy, dmth or·tllh!ta:otlil property
damage.
Figure 12 Vent lennlnatbl n*l:mwn dear:Bnces
17
0
oler-
DC
aller
anual
3f Venting- direct exhaust- vertical or sidewall
L Do n ot mfx types or mmuf3rtltl:mrs of wnt material!.
a
R~PJFe 1
2, Cl&m all jaf:mts bef.arce &ealing. See vent :rrumufilctum"& mmud:l.oos
fo:r deanf.ng md sttaliog jllf.nts.. The thei:r specl.fi.ed sealmt. ])(I not Wll.!
Olrect e:dulust vertJcaJ V8I"J11ng
(!fl
3. Insta11
YeOl
pipe wlth ISetiJU on rop of \!4:!111 horimntal
I.'UI'J~
requiremeno l:ft Secoon 3e., p.t~ge 17 1 for \'Hl UnnlnilioiL
~..rt IT~t
lnmxt.ms b
sa'eW!l.
~ hsYIIILilll
Cf•.~t loll-.n£~III=!Jt,
:i~ t:'ll ~l'litwl1tnNDL
1\ollow
4,_ Mal attain mil'l'lmwn 2.. deara.~ from romlllt.tltilo1e mat:eriab ao Vl!ftt
pipe.
5. Vertical venlilllg-See FJgure 13. Fcllow ve~u nwtufac~:Ute,t"s irunruetlons fw~dng tbroogh roof_
.. "\\m:t pipe Dlll5t o:tend tl!.ro~ roof tJa!ibfng. fad;& 0J' thfmble.
•
"\Wt may p.m througb.:fl.oo:r, :l.nMdt! w.1U or ama!a1ed &pace whml
inLitalled acoord.llts: to vent manuf3!Cttlrer"i lmUurtloM.
Sidewa'll v.lmling- ~ F l~res 14 and 15. Vent must terminate
at l.ea:st ODe foot abow anakl.pated satMNflne.. 'Vellt muit be 1erm._
nared Ml~ wlth:
• The or elbow with :l.nti!gnl saem The m.ust be mounti!d vartic.tlly.
• Elbow and terminat:ioo 011uplingwi1lh !!Cifl!en (not :ilivaiila.ble f111:r
StaR-34).
6. Do not se:al wnt plpe (sUp roJlllli!d0-f!t"o:r Saf-TVe:nt) to inside at' ou1Md.fl
plate..
7. J( passing dltO~ I'IOAOOmbustlble watl, :pnwlde hoile diuneter 'lattge
eaougb to ln9et't the wru ptpe (~lp oomecior fo-r Saf- 'Vmt) .
.8. ID&t11lhorlzoota] df3fnti!e asdoS!i! as possible to boi~:ill!:ti::mhmoot3l
fl1:ll. See F11Jl111! 13.
9. Do !Dot aceed tbs maximum vent system length Biven in Table 4.
page 15.
Rgwe·14
Direct~
sldew81l 'a'el'lmlng
Fcihw Y«<l.
I'Mtll1111Ctin,.., Niudli'I'IS 1Cr
!AW.RIIIGI
!A CAUTION I
Oln.deosate d::rain H:oe- W!tl o:nly a:i.Hc:0ne tlilmg
rated for .:u ll!ilSt ~F for the alftilettSatedr:Un line.
lllfng:my ot:berm:amrlal. collld c:.auae flue gas Jsabge,
potl!tltlally n!iulilins Jn ~W!n!' pew-Jtlmllnjury. detltb
or sa.tbwn1JaJ properry d~
On some imtallatl.ons. tbs rond.emiate d:n:in :fitting
lll3Y be omiued~ provided:
• Vent m:anufacture:r shows th1J option in thti:r
il'l!ltrliCOOOS..
~t
:fa llloped wwml tetlllfDation :as 5hOWD in
dotted Hnes in Plgun! 14.
• The Wilt is iill!talkd pe:r Well-Mdafll and wnt
n'W"IufuctUre:r'S; lmU'UdJOM.
Coruitm&:.lti! dripp;a,ge fi:om auoh V6JltJi !1I13f :a.crumu·
lab! on tbs ground below. Caml.Urtmtlic in the a:ma
to 1\'0I.d lwatd due to Ice ill«llli'l'lubtlim. L~ ooUdup
may also bloclc ven'l
•
1.8
~ i~ llh'ln1lllni,
rn~ng.sipPt, ~ vd
«inti~ ~i'l. '
...r. . . . . . ....
w
+
0
a er Bolle - -
a -
~WARMINGJ
oller Manual
U.!nsl ibl)' •191Dltilidon ~ llan lilni!' ofdlo51!' shown eooJd ea~ nulsanee oubiges and I!Mi of heat, multltt
ill .,Jll:tumtlll! ptllperty &~e..
DblnM ..bel ll!rmlrR!f!an
Dallpilnt Wlfh IICNH!II
1
~ IU\III lltrmiMIIDft
C~~H~Itlintl wtVII liCI'Mrl
1
1
-
,
Bblrw •ltd ll!rmlrR!f!an
,
1
IDOII,... Wlfh IICI'HII
1
!
Jz
=
u:.
19
0
oler-
DC
4a Water piping -
20l!f above Bi!tpoint of:fin.t romroL:Max:hnum ali.<MJbls
r 2W"F.. See Section SD for wlr:lng..
Sl!'l.pOifiE
A low wate~ ,c lftotr ·l:lervlce ts Wtl,Wted wb_en boiler :IJ
lmtaUed ~ r.adia&o leVI!I or by .::s1aln. st:1.te or loeal codes M' lmur-JACJ! oomp:Uill?il. Ute l M~~W3t.er artolf
desdgoed for water lnst1:UatloM.. Sednlde ptobe-t•{pe
Is :rerommmded. PUKbaie ~nd lmUJI m tee in wpp1y
plpiAg: above bo:ller.
T he clreulator h: ililpped loose (wiring pre-.atta.ched
to bo[1er). !Pipe !!he dtm!ator on d\e t'etlltil ll:De only;
.as; :shown 0111 page 3 and pas.e 64. Pipe dLe apamlon
t.HIJc: to dw! met:lon 11Mie of th.e drcul;Nw :H ~Shown :In
Flpn:! 16, ~ 2:1. IMtall an air separaror ro th.e rupply pip.Eng. Always Install the II)ISbml fill ronnectioll at
rb.e :SaMe point ru~ dlie ~pa.n:slon W'lk .ronfieerlon to
the system. Flgun 16 ~ typleaJinear-boliJer plptt'lg
.roonectlmu..
..
owlt!t.utd. run ito a •afepface,a f cfi•poaal. Thr-
If bolller is infl'alled In a doset~ it Is ~od& to
lmWa~ the bo:IW":plpins in tbedo5ltt to lO!l!l'el" tbedo5ltt
airr tempera111.re.
..
P.-essw-e/temperature gauge
IMtl.U ~WlJieitlmpt!l'oilil.fe pttge mtht! tee 0o:t11 dlie
ISU'pf!l)' prpmg ( .ibown 11'1 dt"JIW'Ing on page 3).
Relief valve
InstAl] retlef whre ~ly ' o ~,. tapplq on dde of
Rgwe 16_ ~ :21 • oULd. me
aliadl;ed to
me- teflef va:Jve for mattufaetl~It8's ~marudiou
bo~er. ~
nec:tion th~om •~ etulre: length.
DI!idiarge lHDe mll5t pilch downward from dLe
wlYe :a:nd hmDi:Dats at 1A:ut: fl' above the floOf
dtaln where any discllatgl!' wUI be dearly Wible-..
.. '!be di!dlacge llne sba.1l. 1anninate plain ~ no1
threaded• with am~ ~l"!!ireable fur temper.ttltn!$ of 3759 F ot greater.
• Do nat pipe the diacharge1D .my place where
trumng coutd occur.
3-way valVe
•
Rlgure39.
3.. Ilcstall ciroulato:r, flangE! and gasbtx.
4.. Gmlpleti! by solde:liDg c.oppet fittings 3Jl.d 3-way
valve In the order shown lft F".gure 3St
s.. .Pul'l 3-w-J.)' v-afve Mole:x: aDd ~ through .fac.bt
top left COftdWt opeolilg.
6.. loJett Mole:.: cotU:l.edo:r lnto ruti.Dg ronneclclr on
3-waywl~ Male s.ure that V'Jil'it'l! body [s In rol'f!d
posim~
sho\'tft in Rlgwte 39.
~Jethe dldatge line- ro ellntlna12 po&Si)lfll)'
of seV&!:r'l!' bums shoUld tbe valve disdl~.
DI!idiarge lHDe must be as rhort u poasible and
be the '88mll aize,a.a lhe·valw cfiacharge"ccm-
..
•
1. Apply pipe dope to :fitti.D.ga md imBtill m bollu
s~y aftd ~tum tappii'IIJS mthe-otder ~:In
'fl) a\'Old wa.tei"d~ ot ~aid­
ing due ro reUef v-a.lve o~r.a­
t.ion.:
DIE!tharge line mll5t be c.oDD:ecti!d to 1'8llsf valve
IAWARIIINGI
IIJ:acktlow cl'leck 'lllilve in told water rupply ;;u re-
qutl'!d by local ~-
~Clrct~lator and
1. See pee 64 Figure :w.
anual
general information
~General piping information
J!f f.nstil.l.ln{on fJ to comply whb. As:ME. or C 3llad.im
~ul.reme~W,. an :uidltiooa:l l'llghi tsmp!!mttlre limit ~J
oll!ded. lmull coor.t'C'IIlft wppl)' pip lAg~ boiler
md Isolation vaJve. Set seoo-lld coJurol to mirumwn
~
aller
•
No ah.utoft valve w n ~ i~t~SWlerl be~n the
ttlllef valve and boiJet~ or in the d.l~ UDe.
~ not plug 011' plus any obmuction mtlu!
diJdliaJ:ll! line.
Failure 1o comply with tbe- abtwe gulddlftet
could L"eiuh in fai!Ut"e of rhe- telief v.i'J~ 10 opera•e-.. rewtiliig in po5.3it.lllty of w:vete ~a.l
lftju:t')) death Ol' i!lltJMWttiaJ propetty cbJti • •
Tntlhe operation ,af1Jw,va'lve aftn- filling :md!
pteuutizlng :S)I5tem by mrms th.e le\rer. Make
~ou~ ~~~~freely. If the~ fails
10 opel:'".rte correcdy, rep~ It wirh a new L"!!lef
vatve..
a
4b
-Fired Water Bolle - -
oller Manual
Water piping - system
System water piplng
St'!l! Ftlg.ure 11 B and Tlrb1e 5 fot near-boEiet _pip!Jt arfld
plplns .Or.sln~e-mne ~ ili!s~ned fo-r l."l!tum water
at !eaJt 131)'F.
See pages 22-21 to for mJ.thiple-~t::~n_e pipios for systems
\OAth :li'Wlrn water t.empealll.rt! of at lm.st 13CJI'F. Se:i! ~
24-:25
1.0w-t.empentme syBtem piping; i.e., :l!'adhlnt
M.a6ns tyStenu ot eonwrted St.avll)' systems (la.rgevolwne systems: origluUy detlgned for dtrukslio:ft by
:IWW':l.l ronftetlOil r.all!s than a pwnpJ.
IAWMMIIDI
9.aOer
n.umtler
To
a
em
~Agie-­
l.OIIIe ll)lllletlU designed fOt :rl!'lllfD water at least l~c:fF. For
~with low
rerum waw
tl!ltlp ent ute pM5ilble, such ,u
ronv.erted gra.v'ty s.ys.tems and
tadwu ~~ea~.g 5.Yi~
ro
tlle~aJ piping ~tlomof
paees 2.t-2s. FaiJ.ur.e to ~r
bW :rew.rn watet ~Llt't! 10
till! boll8'rollld ea~ .:ott'081.01l
af tbe bo:lkrsedlons ot bu.rnen.
mf
mo~l
Use Fi gure Ul only for
rmr
~am
mrnltiogrn sfYI!f4! ~l ltlju­
ry. de.atJi Ot sub8r.uttl:ll property
stem
damagl!.
~
•
ChiUeTBi or air hanidli'ng umm ~
Inm11 bfllle:r rudliliaaClhl1l81i me dhm:l. if l.lBI!.t i & pjpedl in p aral.le1! whh
healing boOe:r. USle appropt'la.te 'i'll\leS co pt"t!Wfil
Cibill.'ed me dlW!ll from tmterfng bo:ll.'m'. C<!usult
[ =R=lllimtallatian and Piping Gulde8.
[f b oll'u fa COD.n ected to heating ro.lls locateli in
a:lr harJdJ[ftg unltil wll~ they e.lfi be ~§ltd to
mfriguateil. aff, use fl. ow m ntrol valves or ot:.b:er au'tomatie:meaJ~S to prevenl:gr.t~l)' drat1a.tiofl durl.rtg
mollng cyo1e. Cfn:ulatioiJ oo rold W ih!r rth.roush the
bolle.roCOllad tffillt In dii.m2ge ao the h eat 91!h::ms:er~
Om:lftg ('l?!i:5fu].! 5leWI\t! petsonal 1-n,iurr.. W ffl Ot'
fllb!iitaotiall property damage.
Figure 16
Piping to Bingle-zone systEm using ~
pingm-type er bladder-1.~ .expanelon
mnk. See 'l'l:lble 5 tor piping Slz£19:..
The piping of ths Q;t b o.ilef :requln"!i the e of a bladder-rype or
dbph r::IJM-t}ffll! ~u rank..
us~ of a do~d-type lank. li not
:f'e«<mm.ended.
IA CAlfiiOll l
Uoder&tzed erpanslao rW:tb ..::a.u:se
war~ to be lMr from ~lief
va.I!A:! and l'tlakeup w::.ter to be added
t!hrough :fill valw. Bventwl lll!ctlooJ
:failure can m ult.
L En5iure t!('(pamloo WLk 5d:ll!! wUI har.dle bailer :md
~ waier w lwne :lftd temp.erarw-.!. T:mt muu
be locrted in bolter terum plpl-ng as do5le 10 bolfe:r
po~l.ble~ before l.nlet side of clrcubror. See Wtlt
m.:muf~ ~MIIlldJom filii de..Uis.
2. :rmta!l an aJ!J'Inrrm:trc air venit ~ 11h owo.
•
·
iSfftetD
21
0
oler-
DC
4c
aller
anual
Water piping - multii ple zones
Pi ping mufti,ple zenes
Nping fer radiant healing
Fallaw imuud.iotu fit\ pages. 20 aDd 21 ro luaU n~­
boBet pJpl~ or ~r l'llngle..zoM .i)'Mems.. (Abo 5lel! "Pip.
systems or eoawerted gravity
systems
1ng1il'clr rad1Bili1 h I!Btlng
sy a~m • 'llill'
c alfM!II'ted g:rs.-vJity
ayatema'" ~f ~pplh=able..)
F.a.liW'I! to [pl:'eYI!t'lt low mum w.aJer
r!!:mperatufe u.. the b~l!!!r eould
$ee iFtlg,UIJ'8,1!8orifllgull'8 119tpase n.torompleae lmtidlMJon:.
ca~ cort'Miofl of the bol~r s;e.ct~tu or bU:fflen., remlt:ing
!;eVeft
m
Zoning WJih c1rcua.ton l'guftt 18J
(Nium '"'P .,., 13 .,...
1. su~ each drculatot• iO iru:l.t'i'ldual citmlt
property cbm~
requlre-
:Meflb.
2. Do c _ot inltllll. ciroula.tot on b oiler ( e:m::pt fer v.rimat')'iiOOO:I'Ii:luy bypass plplngl.
l.. lcstrillblolal£on (k1Lmd.ng) v.a'MII to adjuat flow to
dlnrlhot.e b e:at ro 3111roMs..
4. Inua11 and ware a ie,puaie rela:y for each :zone circubtor.
Zoning wJih .._. ulwH ~..... i
(Nturn temp over 13 811' J
pmol'iol!llnjury, death orw.MWiil:all
OJ
1. lcstrillblolal£on (k1Lmd.ng) v.a'MII to adjuat flow to
dlstr:lhot.e b e:at [Q 3111roMS..
2:. .Pro\~de a ~par.aie.2..t-vort u.aru:former to power dw!
zoue w!IVI!!I. Sd~ tlM? tranifwme-to tw-rdle the total
:rated [load of all mnoecUrl :zofle- vahra
Converted
g....,
(or steaM) :QStems
Whenever pot!SI'bfe, ~ tlM? prif'IW1/~d;uy hyp1:!i
21) Ot' Z11 on ~25. The plpng
di!&)gn allows dlmlgicgbolledl.ow uti! vri!hoiJJ: affevtlng
p.rl.mMy drouit fiow !"atE.
prpm shown In IR gu ftll
Radiant hNilna .......
Prefe-ra.b4y. 1Dt ptima.ty}teeondat)' b)'p
iSiwwn LD Frgu rl!!ll 20 or 211 on paee 25.
$
plpl
as
If radiant ~ Whlrtg has n_o o:q,>gen bamer. a herd
wed.
,eJC.Cballl!J4111' must~
.!UdWu he.rtlrtgS)'ISII!I't'l prp!ll_g !dkluld lndude a mW'!s of:regu131Jng lhe botlerrerum wa.tet
ten'tperature.:md dl.e ~)'item ~upplv temperature (su.cll :u.prcwlded b)' :m ll'ljeetioo pumplos
fOI\t rol). BOOs l'f!rum w.ater tempe:raw.rt! will be ~dequ:a re1y com.rolled U!'lln_g dw! medtow
thown In thli manual provided "Ilk! ~.suppi)' ll!ft'lper.illtl'!!! ii relatively fOdStllir..
DO NOT appll)• me methods mlhts. manual If rhe qostern Is ~ulpped will'l an outdcte~rre1181
contrO'J. lrutea.d, provld~ eont.ro and p1p1118 'Willm caa J:1!6U"Iife the bofler :rentrn wa.t!r
tmnperatme at no lsi&than 130"F :regudfe• of !I}'S1:Bm suvply 1:Bln:pM"aturs. Contact yoW"
\r\~11-McLUn r!pt'es.etuiili'v!! fo:r :w.g~tetl plpln:g: and oomrol method!. Fallut.-.! to ~·
eold :ret.un\ Wakr temper";Ulltl! 10 the boller eOuJI e:ulSe ~ion d3tn:18f to di.e iit!Clio:M or
bw-rl.ert, t'e$ult.lng lR pas.ilble s.evere personal lnjw---y. dlath o r subs-tantial ptop!!!tl)' damase.
22
a
4c
-Fired Water Bolle - -
oller Manual
Water piping - multiple zones (ooMintred)
Figure 18
~
Figure 19
With dculators
- return water 1~F or higher.
ZONE2
Zoning Wlth :zane ..,aM:Is
- return water 1~F or h1g1w.
ZONE2
ZONE 'IIi
a
Sym!m .ot :.one dKUbt.or
S Zolile valve
13 Air separator with autom atk vmt :f!f U5l!.ld (Note that the :fill vuhre
must alwa)IS be ronnected. to the expansion tank.}
!AWARNUIGI
~ble low r-etum-water1am:pa-a.tu:J;& {11tJdl .u eon~ pavlt)' i}'iradiant he:lt.lrtg ~~ aod. heat pump systems). refel' to the .!f!«1a1 piping suF~
tioos of Figure! 20 - 21, page 25, ll! appllis. Failun ! ro p.revmt sunain-"'ll low mtw:n watu
tem~ t.o d\e boiler o:ruld eat.HI! oot'tOsdon of~~~~ bo&'let ~ooi'Js, ~suhms
~~~
pet.sonaJ Injury. death (tJ' sub~antial pro~y d~tllase.
FoOt' !ifW!!:lm wJtll
te~.
m
0
oler-
DC
4d
aller
anual
Piping- low temperature systems
Bypass pipittg
..
Flf!Jli~M 20 anlll 21 , ~ 25, show m~ ·~ a:r-
t'l:l:'lgt!ntenu
wing b)'p3SS plplftJ fot
row U!mpemute
adjust libeva:I'I'I!S
S)ISient."' ~uctl as radlallit l'leatl ng aptema or ,conNerted
ret}ul~
bet=aUSle
water temper:atw'e).
me ~fer dl'Cldator rfiWif l.ruiaU Oft me r.!WID I!fie an.d
be 'Wled to provtdedomes.tit!wara phofi~¥· AdJwtmet~.t
of dte bypu va'kw. LD the boEier cluUJ't wiD rt.ot Cl'IDe a
change in 1hB htlmng cioourit flow rnts 01!' ~tl.lHI
distrlbuli-on.
The
~·pau
val'W!lli
~n Figures. 21!1
and l11 (hems 711
3Jld 7b) provide moons of hot bo!Jer ouilet wa:terwl.th
cooler~~ retnrn waur-- set lo a3-rut'l! a mJn:lmwn
return waaer temper.atute (.at le3!lt ~~~ to the boil~
Set d te valves as apla:ln.ed below.
TeMpeNIUN pug. .
• GMJgS~ 4a :Is w.pted. but o.p&.oal on 36l'f S)'Jteln.
..
Gauge Q Es.optl.oml ortootwetted s.r;avJl)l' if*mS.
bu~ rectwl red on radiant heatl.fts systems- t.o ~­
play dte water wnperoa.wre bein rupplled to dl.e
radiant tubing..
IAWARrHl
sum dlat d1.e bcliler-m.oonled tem-
peratllte/pressoure ~ f'eiJilb oa1 least I~P when
tlM! S)"'tmt rerum 'lftlltls iso cold (appmximat.eJJy~P
·gralltty •-yateom a.
P'"rlmraryiterontiafy bfiPm ptpi.Dg ~.s;
GiiiiUQ9 ~ l.s r equired! em aD ifrtems. lo asstlr'e dl.e
rerum wafer aempe:rature l.!1i ~[)' ~et .Or a l'lllnimum ai 1.30PP.Ifdlisg;tUg!! Is :DOt av;Ulahle however,
'ValweMJ);IIdiDent
(figJ;II'U
1.
:10 an.d 2t
0~
Set dte 'i".l!"W!!II while d te if*m.lscool~sd6ns for dl.e
co!ldellif erped.ed waller temperoaWie (mually 6()Qp
s&u.e the i)'lil:em w.:ll ofiet~. drop lo mom temperature belWeoel'l eyelet).
.2.. Start with valve 7a fUlLy dooed and 7b fully open.
3. Gn.du3lly open val~ 111 wllil~ dlooif'l g val I! 7b W1tU
the remperoawu at:gatlg! 8 reads 130'Fwhen gauge
48 r.!oads ISO" F..
4. Notetbat'i"Jl9e 7a regulates the amalll'liofbot walet
ftom the holler rupplywhkh mixes: wit:h li!tWft water. Val't!e 7\b ~res the amount of i')'ste:m w.aaer
flowing thro~ the bow aero:nduy llo0p,
PABW't! lO pravent low rmum WBIH 1amplnllllura lO d\e boBet oould came c:orro.slon of
libe boil!:r s.ectlonS; o:r limltdt, remh.lng ' o !>evert! per.sonal in)'ury, death or rubswilial
property c:bm:tge..
Radl.mt hearmg s.')'JUm (Jtpmg ~ufd Jndude a mf:3JU o f regUlating lhe boiler retwn
water 1amperatu:re and the aya1am wpply 1eqMJature' (:!Dcli a.s; provided by an injection pumping control).
Bolla' fi!Wt'n warer remp~ wiill bt!' Nt!qua't.tlly oonuolled lt!&ig fhe m~lhot:li shown
In this m;u;ual provl.dc.'!d the 1rptem aupplv temperature i!ii 1relatiM'ty conatanL
DO NOT app·l)' 1.he med!CN& of IIlli. motmw If the S.)'Si~ h equl:pped wlili 361 outdoor
reaal ~rol. l.mtea.d, prcMdle control'a and piping which ean regukle 1he boiler re1um wlll.-1e~e a.t no leu dian 1.30"f regardless of ~tetn supply temperat11re.
Contart your \\ell-Md. aln :r epnlllllltattw for 11ugge!ti!d plping md mntrol method&
Po\Bure ro prevent caJd retum water 1ampel"81ure ro the ballet cauld ea' e rett'Oslan
d~ 1.0 die S«tl.o m O l' bwners. resuhJng lrt poo'ble .se\'Cfe petJO.Ila.l mjury1 death or
Um:mtl31 propetl)' damage.
a
4d
oller Manual
-Fired Water Bolle - -
Piping - low temperatu~e systems
Figure 20
(~ontJnueCI)
By-pa..sg piping
Zanklg Wlth dn::ulators.
Z-ONE2
Z-ONE 2
Z-ONE1
ZONE1
1
12
t
Boaet tsolalioft (balandfl8) 'll'.l!lm
2: Flow/check valve
8 Blend ltmper-.mue gauge
9
Rellef va!V"e
4 System temp~J.tnre ~
5, Zonevl1Ne
11 Fmvalw
6 Dr.l.1o valve
7
Sl'Stem t.emperatureva!VI!$ { ~eehk!truc­
ttonil o~t pt~ge :u fur adjustffls v-~vet)
13 Air !i!ep3ftt0f'and mtomat:ic'¥1Dlt. if l!lSII!!il. (NOU! that the:fiJl wive
m~f ~'S be eoMeeJed rto the e:xp~on tall~ :u item 11-)
:25
0
oler-
DC
4e
anual
Water piping - connect tankless heater
------------------------------
j~
aller
DANGIIER
Hot WGter Can Scald!
~
Conaumet Product Safety C<llll:m.isllion and some states ft!ro:mtrumd
domt11tic llot wat ttr1emperarute of l lO"F or b.
• Wbmimta.lll.ng m mtomltk:mb:fngvalve. aelectl.on and :in5tallat:iOD must
fi:lmply wid! vah!t! manuf~'s ~atloruJ and "~itnKtl.oJu..
• w.ttBr halted to a tempef:ai:WE al.l.it3b1e for dotfu!&w.uhing. dilih washing
300 odler sanltlziniJ neetb wiJI led and came injury
• Cblld:am, el.du]f, infifm 0:1!' phyal.cally bandk;apped! !PI!'f'IIODS a.te more
ll iblyto be f.njured by hot wafiU'.NIM!f laue them un.attended 1n orneu
a bathtub. shower ac sink. Nevel' allow mtall cJill.dnm to U!e a hot water
~f or draw thelr O'il!i'll barh. lf olll.fO:M wl:ftg hot watt!!:' ~n the bulMin.g
fits tbiJ deacript{oD, or if ante hnn or local rode !I :require ..-.ert:ain water
temperatuteJ a:t hot water faucett,. t2ke ~ ~dons::
• Install automatk; mil:fng valYe set arom'Umg to those at:mdafd&
~ Use lowest pnrtiaJ.l t.emperature sett:ing.
• Check water tmnperature :immallittaly a:ft.e.r :fim mating r;;yds :m.d! after
an,adjwmtent.
Protectlon Mli:St BeT~ Against ~'ve Tempetalute .and Prt!.til.lle'! -
IDt Wla.tlan of aThruper-.liUte& Preuure{T&P) teflefwJve l.t required.
To pipe tanlclees heater.
TabJe6
Size ptfJtftiJ flO !lmafl_er dloafi twk]en beatJ!r rfl~t and outle1.
i.. 1'hi! rlll1owin,g tCO:IUf.'flb (fum_WM!d by od!8i!i) MUSI be lmuU&f:
'&lnkl8!l8 haatar rating tabla
L
~-
a. A.o1:ollatlc mmns wJve llt!l! FlanN! 22:. ,See DANGER abov-e.
b. Flow f!!SUbdng valve.. Size ~ft to l.lliter:m:liient draw of
wl'ld~s he.Uer. See 'laJIIJ.e 6.. Fool low VaJve. manufactUJ:'e:f'.s huttuetl!lll!l il> ioKtall.
Add'ti.onal anti-~ drn~ may be ititalll!d. 3i1: e.ad! bot wil.f5 faru:&;
bath ann!) h ower ourlet
-4~.
Jn hard wa~ ateo
wft~
eord domet"dc supply water to
heiltl!r~S to
BDiler
1madel
num'-'
CG.1
HMb!r
numt--
lnwmilblrc dlww
rwting• 'G.P.M)
INola 1
lnlll!t•ndl
aUtllrt lblpping
1!!1!1)92j«:'')
U·
814"
lllc:M 1: Galhn ot~ pulll"tlliiiH: h«Mtd~ 4D"PI'IIII lo41J"I:'
vttbl!OO"P lroiiH'WifiB ~ Tmai ill.~
vtth. I•W•H: Te:ldfiJ llld 1Ru1fiJ S'llllliMd Slt ~
"[)nlteu \\Wiu H - Tested 'l<lllh Boitn.
pl:'eYelil lime OO.l d-up..
To,:s et tanldess heater low ·mit::
L Adjust setpolnt dtll to 190"'1il- :20otF.. The boUet high lrm.l1 diould be
set :2~F h~ber.
!AWARMNGI
Stud1et ftave.~ndlea.ted.lllat ttmgerous haae:r:la ean form
In potable wa1er tllitt:lbuOOn ~If eertaln mmlmum
waw te:m:pentl.lres m1 not mafnt3fcedl. Conta.c;t l!>c.al
NDTICE
b e-a:'llll departmem: for :Milt'e ~nfotmatlofl..
The !ill! single waii.ht!at adL:mgen romplywtth Nalional
St.mdud. Pl'un:ibing G!.de provided! that
• B.o lle:rwaw (fnd'uillng adclli£ves) fa p.ract£C3l.lynon~ having a to~rity r.aJins ~ d~ of 1. ~ l~U!d
m Cllmk.al Toxtrology Gf Cimnn~ !Product&
• B(llle:f'wati!f' preSJWl! :Is limited to maximum 31il p!lig
by ~ \ftt1!11' rellefv;a)V@.
If bo:ll'er Is iMtaOed ~II. a d!!eiel• lr lt l'eCO:lU1lwt'ld «<. to
lnsubte llle.wpplypJplogof c:lomeitlc: bot water 10 lawef
cbet adr temperature..
•im•
I
t
Flwt
r.t~lll
........
l%'
"'ilinl!m
<11•-l
c......
llfffl t<ll
~
a
-Fired Water Bolle - -
oller Manual
4f Water piping- refrigeration systems
Prevent cbDied water fllom entering boi er
l1utaU ooilet&Oothatdtllled med:lnm. piped in par-JIIel w"rtb the 1\.e:acln .iboaer. Ute appro:pfiaje
valves: lo p~nt .chafed medlum from I!!Dtmng boUer. See Figure, 23 for iypkal in~la&n
ofbalandngvatw and dledc: v-.dve..
lfboiler Is e:oo:ned.ed [Q heatl.og e:olb. focaied. ill: air h.lndllog 'W'lii:S were dl.ey Clift be exprued
oo m&ige;rated af:l;. use fi0W rontrol valves ar ~tl:Jer automatic; m«ma mpmwnt gravhydrotila;t:lon duriftg eoolll'lfl cyek
CirCLiki.Or
T
17112'1'
2J
0
oler-
DC
5
~re ~eke~
gas supply pipi. . to boi er
ldentlned by llll! lmtl!r.et_
i.. suppcrr1pi(Jlmg with llan~. Dot by boiL!:r or its aooe5lSOrlei.
;__ PU11Je all B'lr oom p$ :SUp',Plf prpl~
Bef011e pl311:.1n:g b oi.ller ~n o~an, cllll!!l:k boUe:r llnd 11111 gaa.cmnn&ctr.on
flilll' I BBfl:ll.
a. Close manwal ma1n al"'utgU VSI!'..e during any p.res:snte te5tln.g am
less lll an U ~ w.e..
b.. Disconnect bo'ller and! ga11 valtve' rmm ·gaa awv,ply plplng dnring
any pres:mre tettl.ng greater tha.n 13,. w_e._
IDD 1n ot Clleck tor gaa [eakli wl1h
m ·Dpe;n name·-USle
bubllle te.tt_ Pa.Uutt! u. lliie lrubb1l! tl!St fli'" check for 831
lJ!'olb atJ eallSle lt?V!U ~al rnjut)·~death or rub~tla'l prop!:11y d~ge.
Tahte 7 P,ipe capEICity for a.eo specific glm'ity natural gas
G=e
(teet)
2.8
5_
uae p ipe dape 'compaUIIIe wltn propllne ·o •ss.
Ap_ply ~ln:gly only to male threadJI of pipe jolr.o
so that· pjpe dope doai nl!rt block go :ft. ow.
Croat pmd 31id ~ U.ifllgure,24 tCJ pipe gas lb ~ler..
a. 1n11ii:BU drip leg at ~n:let. ai g.u oCO:lltled:lon tCJ bolter_ WJ~~ lo .
utility :requires drip~ to be atended to the floor, Wle app.roprlate ~~ oJ pipe beiWeM cap and 1e:e..
b.. I nsbiU grounfil JDIIIlt u n1on for !iltrV"teln& when requiml
e._ 1nsbiU mamulll B'hutofl' valVe fn
mpply pJpng outside boller
jafket when reqolnd. bf bcal codes or utility ~quirernen11.
d. ln1Call!llilla-~ ~IJlSM~IIUa:l Mlifi ilaUJOfhahre, iEmwwt De•
.ol~.
anual
Gas piping
~connecting
1.
aller
Fa"llure ro ~ply pipe dope as detaU~ above an ~It liD ~.re
_penol'ia.4 lnjnry, dflat.h OI'JSU~taJLtial
.Ptopmy dti'nag.e.
Sizing gas
su~
~ t& 'tllhle·7 !fM pipe lemgtli and db-meter. Rue
on :rated ooUI!t' if1P11l (d.Nid.e bf I ~1)1) 10 ob1ain
cubI l'eet ps-hlrur)_ 'fable1 ~5o on.ly IOrp w"rth spe-cff'tc: !IJ'avlity 0.61. w,itll a pre.sMne drop duough
the< gas piping af0,30i" w..a. Poradditlonat p.plpe
af:z!lnginfoJmatio:nome:rro ANSI Z12J.l (orB149.1
or B14SI.2 fur Canadian imtal.latlom).
i.. Inlet pusmre requited at sas valve inlem~
.. Mmmun:c l:r"w.c.
.. M!fnfmum: 5"'w.c.
.. Mmff~ 83SpNSlll!lr« :33" w.c.
.3. JtnstaiL 100% loclm.p gaspfi!i!Sllfi regulatodn supply
ld!Je If~ pr-ew.are ~~~s ;a• w.c. AilfllSt for
13"w_e._ ma:rlmum.
L
RgJJJiB 24 llss ~ly piping
p.,.
Capacity iiA
tor pipe me of:
(C)apacily in cubic teet 0$$ per hour)
"*""IMII'i'lilll'l.,ub!rll'
, _ ........ 4wh.., ,.qr.u•dJ
'i lk"
'4"'
1"'
11/6'"
1'W'
10
132
27$
s2Q
10W
1600
2(1
92
100
360
130
1100
3(1
7'3
1S2
~5
soo
$611)
4(l
63
130
245
600
700
50
56
115
215
...co
670
75
45
93
175
300
S4.s
100
S8
7'9
100
3(15.
4$)
150
31
64
12(1
25()
3;00
pipiag
Gl"'o.ri\\Q join~ un!Df'l ~.........-tll!!l!!ll
[WMn
r:aquoa~
a
6
oller Manual
-Fired Water Bolle - -
Field wi.,ing
ror }'0111' ~afety. rurn 4lff .electrDI ~r w~y •[
sen'~ et'lb'aJI.m,pmel be6o!;I!!~JclJJglll_)'f~l Ml'int!diOM [i) M'Clld p:mib elec0'1t: it~ hHud. Fal~
to do iO ea.n eause Sew!:fl! pet'!IOI'l~ ifljury o:r dealh.
Tbennestat
1. Coomsrd thermomt as Bb.0WIIi em wiring dfagmn
0111 boBer.
wtrln.g mllll'li belN.E.C. c'ua 1.
:2. rnstaJ 10111 rnarde wallawsy- ifllomJI11111wencea afdratta.
Ifo-tiglnai relloot thermalfuie e'lemmt w.re.as: iuppUed.
wilt! boll'.er :tm.tst be rep]ao!!!t, Wt! only tvJitE! :&!Oit'C w"rre
o:r ~v.a~ena. rf odtS" ~oal wlrins .u; soppllet'l wilt!
OOllir mmt be rep bud~ type 10S"'C· wi.re or ~t
:tm.tst ~ wt!d.
&til\er nunr bl!! e'lec11ilesn~ QII'Olllllded as :required
by Na1il:onal Eiectrlcal Code ANSiiiNFPA 70-btest
edl.tlon..
ha't ·Df ·CCJ~d wate:rp:1pea.
3. Jf thetf'I)Q.Sbt h u .a heat ut.ki~tott se1lleat .at'li.icipator rthermoJtat ro. ma.teh power requirements
Of equl~Dt c:oMed:ed. to ii_Jf COIUi.~ted dlfefdy
m
to ballet'~ set rot 0.1 a-mpi pills
il'l f-J(IJUl'B 2,9• PilSi! 35. Fo:r other
mm.u.fiJ.Gture:r' ap~ns. \V"mng di3gmm on
boiler SbKJSeUlftg ~roomml modu1~Mlrl gas valve.
Abo see lmttu.etloM w"rth the:tmMtaJ.
oom»IY with=
1. Nati0nal meotrlrn Code and :my 0tbar nationA
stajet prov.lnda.JI or kw:all codes or regula I loou..
2~ [D Cma.d~ CSA C22.1 Caoad1an Elecit:lliaJl Code
P"att l t and any local e:flde.s..
Juactio:n Box (fumished)
1. Connect 120 VAC pow8C wiring as shown fn
Agur-e25.
Wiring connections
:2. Fnsed d~nnect or sel:'\!k.e fi't.lidl (1.5; amp. teerunmended) may bl! moun ted. oa tbh boL For
~e imulhtlom wilt! 1~ oode;s; wlilth problb.lt
itl$talbtion of .ftmd! tli!tfJftned.or ~t'Vlce fi't.ltell on
boiler, lmta:JI a 2 :1 d, cover plate on the bo:JI'.er 'unction. box ilad. MO'W'Jt the tet'!Jk,e !M.lld! :l'eiYI£JUiy ;U
by dW! fOOL
B0ile:r :f& shlpj!li!lil. with rontralS romp1.81:E1r wired.. Yol!l
:tm.tstooi'JIWl! thi! ambllem t11m;pera1v:re awiteh wlres
(p• 3·t ~ 10) to dlil! MIC.h tirer the bollet ~1ft pbee.
~ PilSi! 6 for iwlleh loeatlon .and mount.ID.g. The fucat'!!!
~•­
~ s;llown
deviel!'lll, refi!r 10
gas v.al¥e
Se-e lruorm tlon oa wrrlng rllasram
Eleclrical lnstalfation must
tM)'-mf!PI"=d W.re~
wire lf needed.
llg'htlng tn':XibJ11'811 ,tell!!\!lalan.
•-unmy.. CJ:r111!'8praca..
.red
.4-fe.et lollS. Splloe at'lilloof'lal
The a:;1 OOOltfOl. module ;is pohrity-eentitiYB. '!be hot md ~utnl w:i1e& must be mnnerted to
the mm!ct leads. A !fl.tibfng PO'ft'Eit lfght L151Dllyfndirnes :revemad p 0larlty of 12~ VAC 1aa.d
wires.
Rg~e' 2S
Flald Ylfrlng ecmaetflcrts service smrm and thaii'I'I!OStat
(cr end l!flolli.tch)
prmrkted by bltsber
no-,
•
Grwi'MI
I
I
I
I
I
I
I
I
I
I
nt-..lll!i
"" ..... ..ftc
I -.. ~
I
I
)
/
I
J
"
llr.l;
:29
oler-
7a
~ct.ecrc
Fill the system 'W ith water
Befoli! sr.artmg the 'boller. and. dlll'iftg lnitla! operation.
smell n"4!u the filooJ and a.:round the boilerfo~ gas ado.rmt en my unll5Ull odM. Do lll0t proceed with stut-up
If~ Is any lMk.atlon of a gas 1\e.ak. ~any ~k
atOACe.
L Cloise ID11DlL1ll and auro:matk; sir wn'IB ad boUet
drain rod:.
i.. filii! to c:oii'IJ'eCt ·ayBflllm preasure1CofN!ct pm!illllf41
wiD vary wlt'h eac:b a'J'pfltatioll.. 1)'plc.a11oold 1\\aJel'
fill PJ:i!lliwre f!M! a :resldential8)'5tem :fs 12 psi.
;_ IPu~t~e srr £rom syeaem~
Cilnm:ect a !ho!i!EI to the pl.lfge valw! (!BI r1Mht
·~ ltem &. In m~ piping dlagrami
on pasei 2:3 f.b:rough :25~ 1R:g111~ea 16 throUSh
Rg111re 21l}.lloote b f~St 10 an aTea where w:ili!r
eitl d.rJ.in and be 51el!f'l.
b. Close the boilelr OJ! S'j'Stam ~tlao valve
between the pw-ge valve and :fill c.omtectfun oo
dlie !.y.stem..
(;., Cl.o ae mne :i!olaililn valvn.
d . Qpem. qukl::-:fill valve on rold waliU." mmup
line.
a
Determine if water treatment is needed
Do not u.! petm1~u m.b11Bed dl!oSJI'IImg or aeallmg c:am-
pcnnuf• In bol~ i')'!tem.. ~dam e to boller wlll
OCOIJ'• l:tillltlng ill StJMWI.tial property dam~.
Bllim£nate all aystem Jeili. Conti!llll..l.al fresh maksup
'Water will reduce bvJler fife.. Mlfiera]s can build up ln
:SI!lcttom., reductt.g lteou u-.uuter~ overbe-.rtlng CMt rron.
and e.:twrog :Sedllon faihut!.
VHrfr watar ct.emiatrr
e. Open p~ vah't!.
f. Oae zone at li.met open the !Mlbtl.cm val\'t!S...
AI !low wa.ter to :f\lfi dtrou g.b ~roo e. pmhln,g
aut the ai1:. R1UD uct:l111lo noti:csabls air dow
is preMmt. Clolle the mme :fsokman valva and
proceed! wbli the nat m~W. Foil~ lhii p~
dut'l! 'l.tl'lbl aU wna.. are purged.
g. Cl0ae the qllk;k-:fill Wlltef' valve and P'Wl:'J!
v.ali\'t! and rt!:f'GOve the hMe _O_pt!n a11isolatlon
v.aJit.'t!s.. 'WAtdl tlt.al i)'ltem pre.saure rlses to oor11!rt mld-fill. PJ:i!llium.
~the ~ Jw oper.a.1etl. far a wnUet
l!!ll:tnlnate aftl' l'@idnil aJr by usans tlte IJW'IDIIII
alr'W!ftt~ l~ated dtrouS:oont the ~
L 1f pwge valves are not llutallt!d io llfil&llt
O msult local wllm' treatme:ct rompanies for Wll!l.liwilly hMd water aJEas
(shove 7 ,grn1m hardn"4!!i11) ar lCM pH water' oondh£ons {b@aw 7.0). B0ller
watar pH of7.0 to 8.5 is :rK.(IIDmmJded.
(When ~
Use ;anti~ made< especla11y fott hyd:rorak &)'Items. Ifthiblted propjime
Preeze pi"Otection
glyrolls reoomme~~.ded.
Do not
l!l.lie
etll)!teme !JI¥c:ol~ BJlltl:nnotlve a r umifllluted
an'Ull'reeze. ~ ptHQilal rojw:y 01' death
mD
a.
resadl.
1. Dete1mioe snmreeze qua.ntrty: acront&tg to~ wate:roontl!ftt. BoC1et
W'".l.ter'conte:f'lt lsl~d. oi'I.Pase 67. ~ to illdufleapatl!don tank
waiter a=on~l'l•-
i..
opena m;lftuii'J air vent~ Jn ~um one at a timet
begillmingw11h.lowest flou. Clo!i!EI vmt whm1
water~ ow.. Repeat wllh tema.iruns
~low attui&ee2:e maouf.KrtJJer"i 11Uit'lld:i~.
3. A 50% solution of pmpyle:oe glyrollwate:r p:rovldes mui.mum protec~
tlon to abmn -3Q9F.
-4~.
anual
Start-up - preparation
tor gas le·aks
!AWMMIIGI
aller
1~ ood8 may reqllff'e bact n:DW Jlll'elftllrtel'oradml
dht:ooraed. from
dif w.a~er mpply.
5. l'l1:xm L1!i.n,g :mti:fialeze :fn a system with. autam.atlc :fill!, ilm:ill. a Wiler
lD.1!teJr to monioor vrn.te.r CJ3kaup.
Glfrol will leak bafo.rs the W3lU be-
gam to leat. eamins glyoollev.!l 10 drop.. Added li!l'itter will dllllte the
anilll:'ei!Ze, redudns l!he fh!eze pro•edianle;,.'t!l_
~1'1~
+.
0~ st~mmatrc a1rvemt (dlaphl'118m-tvpe or bfladder-rype ~p:l.ltOOI'I rattk i')'!tmls oo!lyl one l1ltl'L
5.. Opetl! olhwvenrs:.:
a. Sta:rtmg OD the lowest flo0r, opm aft 'W!Ilt! one
at a ume 'l.ti'IUIJ water squim OUL
b. Repeaf with remaiftmg Vl!ll.14..
6.. R.e:fiJl to OOil'J:'i!d p.reaSW"e.
a
78
oller Manual
-Fired Water Bolle - -
Start-up - preparation ,_...LIGII)
Inspect system water piping
Inspect base insulatien
After :fil1mg ths bailer and !}'!tLml with water, hTispect ..ruplptn.g
thl'!!'ll.l&h_out ~~~~ !!fitem for lealal. !II f.aUild. repal ~mmerllately.
~t lihi.s lluprKrlun .after dliE! boUe.r h 'bet!ll $W'ted artrl the
~JY~tertll h het!Jed up.
A
LeakS mlfat lie repalll'ed at omce. Fadllw'e 1:0
do :st~o eaJ'J dam• abe bolle,rt resuttlns in
subitat11JaJ property dam~-
t1inJ: md J;l
7b
The boil'u ron mica am1lllk; fibu and :fibe:r~ m:rte.fials... Ole eau when lwldlins these
materials per instrucliol'l~ on page68 of this
manml F3>1JW'I!! tl') comply rould te!!iult ill
I4!Veft pet5lililbllnjuty.
81
Clbeck t 0 mili sure lnaulat:Jc>n ~a. secure agalrut 11 fOur dd~ of
the base.. !II lrua:IJabo.n is damaged or dl~liliC&i. 'liD nat operate
boll~ Rep~ or reposittm. illrubtlon.
Do not IWiiB [p1!11INI'IIUII"'''I-IIaaed ,CJeanlmg <CII"
eeaJingJ.compcuunds l.n IKM~ ~em. S!veft!
~ boiler w ill,oorur, ~uh:ln_g ill t ub-
FallwJe to replace damaserl iMul til')n o.tr
mposh.iiooJ iwll.llaRon em :result ma :fi.tt! haz-
stmtla.ll propert)' dama:ge_
rub~tial
cbmase
:lif't'4 eawlng .severe perw.nal illjury. death o:r
property d:wa~
Start-up - operate boiler
Final cheek bet'cwe starting bolter
..
..
..
Rsa.d mmwl.Seakm g ~ IDdodl the OpemlngJin.tructllllll&l
(Sertl1m lc).
'\Vlfytl:ae b ok and B)'!1mi!l 31'1! lftllll CI1J water.
'\Vlfythe .Starf..,up p_repal'llflon ~ofSedloll 7a ba~
m«:md J;l
:lnlh=up waterw.ID red~ boUt=r life •.Mitiera.ls eat~~ bulld up in ~tloMt reducing
heat tranifer, ovetltealill,g cast troll , ::tnd
eawln,g !lt'!edon .f.tlhJte.
Start tile beller
..
Follow the qp!!m'Ung ~natruc!llona from
dliE! bo~er.
See Section 7c lfbo~er f;ill~ to si::ariL
cbmaee
Ell m'Jnate tllll apmm ~N'ka. C6Dtfnwlfresh
~ fflmpiei~(;L
..
Do n0t USB petro[4!llllm.-1Jaaed cll!!llllfng or
&eallngJcompe~uncre ~n boiler ~rem. Severe
to bolter wlll oemr, resal'ltil'l8
in sub:ru.ntlal property damage.
SeciiM !lie 1o s.tart
Check system amd boiler
l- Cl'leck ayfiem[lllplmg and•c:lfimeatrc lhotwatsrp)JilngJfjJII' rellli:a.
If failllrl, shut doliwll boller .uiD repaa immedia~.
:2. vent str ii'Nm ly&tl!omJllilllg manoa] vmt4. Al:r ~n the ~
will Interfere 1i!i'lth dr.ruboon afld eawe hea,t dHt:tlbutloll
prohl!!tm aDd noise.
3. 1nspect vent •ystem thorooply fur sigM of dl!iei'lo:ra1Jon
from corrosion., phvslotll damas;e or sa.ggJng. In add.lt.kll'l
- Cb!ck for gas-tight seal at ave:ry c.onndon and &e:m:J.
4. Cl'leck a~N~Wndlthe llo[le:r!furp odor foalo\r/11118 ~~~~procedure
of Section 7a of dth manoa1.
5. Verify 'a;p~Jration per Sedian 7b. htform cbedt-out pro-i:edUI:'I!! ln Sedioll :0... and fill :lin the lnamllation a:nd .aBnfice
mntilicat& on ~~~~ S3JW! p• .
[IA.WMIIINGI
G~olM mtifreel!IB leab aroWJdtl:ie bok
maytrerult: in :fi.tt!, rnliBI.ng aevere perBODal.
inJury. death o:r sub.uant.ial property dam-
age.
Venting a~em m.llf81i lie neledl ga..tlgtd
to Pfi!Vtm.t :flue gas 11plllage and c:ubon
monaxJd~ mti5;!iOM which will
s~ persoruJ injuty or dead!.
re.wJt ln
If you dEseover 1!'\•ldetiel!' of :my as ~.
slim d.owilthl!' boi.'ler at on ~ F'lrui th.e
ll!ilk ~ue with b ubble test and U!palr
immedlately. Do not start bolleir aga:[n
l.ltlbl oo:rn:!eJed.. F.ailwe to oo:mp'ty could
t'l!'illb. ill severe p ersoMl tojury. death at
subsw.tJaJ properry daruas,e.
31
0
oler-
DC
7b
aller
anual
Start-up - operate boiler (conll....O(i)
Check bumer flames
Vtewpilot mdmaln :flaJma through the impection p0J't
lft lite b~ burn !!I' $hlelt'L
Pilot burnor flamo ( rugul'e' M )
PROPER ,Nfotflllme charsr:isrimt:'B:
1. Blue iflllllls.
2:. Innu rtAJne en&.u lfing pilot flam-e !iim!f!llf.
l. Pilat flmls &l!l!lllor glowing clte.n:y:red.
lltfPIIOPER pilot fl1111le chsractsria:tics:
1. Overifi:fed -lafg:e flame lift:ing o_r blowf:ngi{lii1Eil pilot
:flame &e II! OJ".
1. Und'et:fi:o!d -Small:tl.ime.. Ionu ame em eiJgul.fing
pilot flame liii!DSOL
Pilot
fli1mc
aemor
3. Lack of p.rimll.f)' air- Yeii.ow fLmle tiip..
4.. klrom1!Utlybeateil pilot :D. lUlls aemo:r.
Main bu m or flamo (A.; we .21)
PROPER mm bumMfl&me eharsr:tsrimt:'B:
1. Ye11l.ow-onnge meillka may appear (nused by
dtut).
INPIIOPER main bu'ftsr flame eltsractaristica:
1. Oveffio!d- ~ :flamsa.
1. Undef'fin:d- Sm3ll:flsmea.
3. Laok of pdimaJY :ili' (5;100tl:Dg will fiCOir).
7c
IMWIII:Im•
'\Ellaw tipping on flames
Start-up - it boiler ~doesn't start
• • •
Check.fer.
fuse o:r iervloe sw.l1dt aiP.
1.
~ ooMectlom. blfl!lltltl
2.
Hlih Hmit !M'l.roh. set below boiler watef' t.em:permurel
3.. ~set belOW' I'OOtD ll!fl'lpet"J.~
4.. Gas n.ot.tl!lfileil on it mete:r o:rb oiterl'
5. Iru:o.mlD.g ~s; pteHW"t!! ~ tlkan 5"' w.e.. for oatnral
a.t~
32
6. If DO I'll! of 1:ht!' pl:'e!O!dlng OOI:ftdS the prob~
refer to noublealllaaung. Section il1 of fllis;
:manna4.
NDn&E
I
If the bolleii'WiW!r'tempe:ra~ ~
belo\t.r t.aJ:IkJ'less heater low limit
i!!f!f.Ung. boilet' can be illat<ted
t!VI!Ii li thetmostaf b 5:ef
I:"CCIftl t.emperaWN.
abow
a
8
tl
tl
tl
tl
tl
-Fired Water Bolle - -
oller Manual
Check-out procedure - checklist
Ope!~. mULl~~.'~] main shuiolf 8'11 Ne. Manomaer
mould cmntiml ths.re is DO 8"i!l tlow.
Rolle:r andl beat dist:rlbuMoo WJ{tB :fi.IJ.ed with waterr
Al:LtM'tatl.c: air\'4!flt. if used. open one fitll w:m.!
d.
Air f'W'g&i from S)'Sietn~
Air pW'g&i from p piping? Plplrtg ~ fur leab!
Cocfi!rtly &liz4!d mmlfald orl!fia!a inml!ledl Re:fi?:r t B page 1:2
to cliKk 5I :r.e.
e. Pilot willftlight. :fl.amtJ !llml~cg e1mne:ct will.~~~mSll! pilot
M4il
fti•i1~
- - -··--·-
Com!ctlyummllilfiBldorlficeBmu.st be I:DE'd.
PallutetodoMwllleaDM ~ pemool lnjury. death ot rub italltiaJ propetty damage_
tl FoiJowed L"lpeT.lt:lrtg ri'IUt"UetiUM uta boil~ or rl'l M;)I'Jw!( Seelioo 9•fot propet $1art-ltp!
tl Properbume dl.a.me oblsenedilleferm Cl'leek lbur.metr 111amea.
manual Sedla.ll 71L
tl fut llmllcol'ltrol - 'WI\Jie bumetuJe ~tin& move indl.:ator onllm:ll c:ontrol below aen:tal 'bolla-water ~perarure...
Bums.i should go off wbire clmdator C'Diitlnues to optr:rte..
JUI$t seuift8 on limit c:oJuml ;a~ bo:lle:rw.atet ~tw'e
aDd bwners should telgnire.
tl 'Feit tMJ~ lleat 'low limit ccmttol - Wblfie burnett. are
oper"Jitlng. mm•e indloto:r on low llmlt eonttol :Jho.w! xtual
boiler waJ~ temp~- 1'he :;..way valve sh oWd operate to
byp:w all:liklw aroiJllld the bailef. If:WW limit md wlw operata
mt"rectly. tum seuli'I!J on low flmit back to l'lcwmal. 1be 3-w-ay
''.ahre should retum to aal."mi!U posloon.
tl 'Il!it addl:tio:cal field-installed c.ant:rolli - Itf boiler has a low
wuer ~ addltloi'Ja:l ihlsb "mit or otMr ro.namls, lffi for
ope:r-.ttlon ;as ootllned by manufru turer. Bumers. thou1d be
operating a:nd ~d go off wbert ro.nrro!s are 1ested. Wben
mntto ill't! m tored, bumm iShould relp'tlie. Test ambient
tetnperatu~ !MJieh by dl!mnoetil~~g cmt!' of the wins from
d!.-e SW.tcli. Boaer ~ut dO'Wil 'WU.II wfte ' upl'aeed.
tl 1'm !pioon ~ saft!ry devilc:e-:
a. Gnnnect mmomQ"ter oo Butl'trt side of gas valve.
b.. Start ooa~ allow! for l'lCii'ft'Jal itarr-up eyde to ot.CUr
.and main bumets to !gl'lit:e.
e.. Wlth mail'l burners. on, mam.Wly :shut off Sti mpp'l¥ at
manual rMin sh u.talf as vah~e. Burner.s shoUld. off.
so
~e ~dm~bum~ wm~~
I:J Set ll:mlt ooi:Urol(s) to !il}'St~ •~peratur~ retpll~nts..
Adjwt balancins valW!!. ai'Jd.roi'Juols to prov.lde d!!$1gn ~­
petaWM
to syf[t!m.
I:J Fo:r:mullipls m:ce~, adJUBt fiow a0 It is about the &:aiDS fn eadL
:%01'1 1!'.
I:J Vi!rify dtermomt heat .antid_paiot (if :w.allable) .set propetly~
Refer rto Field wlrl ngJ manu:tl Set:t:lon s. ~ 19~ l!lill!'rmo~
·atat.
I:J Oj'cle boiler with thermB&t31: - Raf.se ro blgbest 98l:tirng ~d
vet"lfy boos goes through l'lutmaJ start-up qdt!<. lm'ft!l' to
~!Mit!St settin :1fid verify boUer snes off.
I:J
M~ ~~~atur.al
input:
a. Oper.ai~ bolfier 10 mlmrtai-..
b. '1\lm off 6ther .appiiJI:illees..
c. At natural gas meter.~ tlnte (in~) requlud m. 'll$t o i'Jf! ruble mat of
d. Cakuhm! gas input:
9600 :.: 1000
=
flluh
number a1 i!I!SCond!l. from step c
e. Bmh eakulaud. shoo!d apprml.mate tl'lput ratl:ftg on
boiler tat:lng bb el.
I:J Olsdl: mmlfold gu pre~we by roDill1!'(;tfng !1Th1Domste:r oo
dowmwatn test UJ!Pns 011 main pva'lve. Milftlfold (lfil'wte
[or ft31U.r.d sas sltould be 1.5"' w.e.
1:J Okerve ~ oper-atlfiS. e)ldes for proper €1fM!t'at lon.
I:J
Set room thetmomt 10 desired room te.mper.alliU.
I:J Fill mltnBtail.a.tion md rmvfce ~me belowl
I:J ltevJI!liri' all IMII'Udlof'l t sh ipped wlth tlil!! bolleli' with owneli'
or :m aln tel'lance persoa Return Jurudla.l'ls to ell'il!lope lfid
gl've to oWDer or pl;ooe In pocbi Jrt!We front ptnel lo boiler.
Installation and service certificate
Bollu model _ _ _ _ _ __
~d.B illh
Serle& _ _
wpw. _ _ _ _ _ __
_
_
CP nrumbu _ _ __
Data :fns1:allHJ! _ _ __
tl lnuaUtadon ln!Fit!tUctl.ons liaw been followt!d.
tl Gbeck out seq,lWlC>@ !h3B been perfo:cmecl
tl Above~ :fnfO!'Iru11ion is Cfttlfied t o be rom!ct.
tl lnfmmatlon rece:lved and feft wJJh ownerlnWilienanee pe:t'tQI'I
ll'lstoiller _ _ _ _ _ _ _ __
(eompany)
(address)
los.t!llei's signaDlt't!': - - - - - - - - - - - - - -
(ph o~)
0
a
DC
9a
Ired Water
oler-
aller
anual
Operation - sequence
I . And ()pl!iraflng l'nsblu c.tl!ona in. Secilon. tc. This
5. Dul'iftg matn bumer ~on:
l.nbl:'m!ltlo.n is ] jQ roca•e::t on :11 label 0111 d te Imide;
of the b0.ilu j:rokst: doc!' pomeL N0tla! that ehbef
a. Control madrue momtoo p.llot iftmne cmrent. n sJgma'lla l aid,
main v.aWe do~. S.pMk generator 3CDvatet and s.equmce returru
rc:utep 4..
h . n power I • l'rttee~~u pted\, control ~~~ ahu'IB afll' pil'm .and main
wh~& and :fl!iWts amrll!p 1 when ~Is~fi. In the; e\~n.t the limit cam'IN• BhLml dDWJ'I Ule lloller - The oon.trol
modUl!!! clMI!i m.l!! ptlot :Hid main ,8U vaJvat) but ~ the i.ndueet
me- room mermmtat 01' the~ heater bwllmlt
ronirol an came :11 call for heaL
2. Ra1li!ll' mom lM:tmostu (or :rals.e &eltlftS o f ~:~n'kllesJ5.
beater low llmWt rorurol) ao oaU ~r beat.
:3. CIII'Culator energl2'8&. ]f li.mlt ciKuif is. dcued , the;
mdut:er &W"I.S.. Afiet ptes;ture s.-wikb Pro\'fl!.prop~
alrll.ow, m rmol madl.lle mi tiate& Ui-serond p:re-
o~.J.tln
pwge.
.t. Col'litm• mactU1e s,pam the pilot o'llld open plio•
valve In main gas valve.
a.. If pilot ·doe a not (ligh t wlthm 1s :!:I!!O:mcb, pBot
vallve ii c~Med and spatk eener.aior ts UttDed
off. Contooimadrule htitfate11 a 15-aerond
J?OstJ>ll.tgt!'t 1hefJ starb a new c:yde.
h. If pllof ·doe a. light and ron.CJol modWt! S~ei'IB­
:fln.m.e Gl1I"ellt, I!,P:aJ!'k gen.emto:r l!l tu.meil off
9. R~pea1 steps; 11 tbroop 6· ~ llml!i to verify operatdon.
1'0. Return the th e;.-molt2t ot t:l.ntle~. healer low l'lm' t •o normal selllflg.
11. Sel fbermomt bl!!.tt :an mW:,paror it!li.ing :a11 ~nsi.ftlc:ted jn Frgure 211',
p :35.
:Ht.d malfi\M~ope:M-
C.l ~
Stwps
li'«Do"""l
oO..p iJ. <'PW IP"~'
SUn~
1.
•
""'*h1ll,: tAr
~r 1:5--.JI!!I:Ond P'MI~
-The; dWJiator co:ru.l1ruet 110 ~
1. II.CJWI!i-r room. rbes•rrrMut s.etitns (or 1\o'Wet' wtklw be-.rter flow llm't
eol'l.tfol •l!ttins) to :siop ea11 ~r be:U. .!Pelot and madn
wl\m dos.e
- fud ucu ape:rati!! fo.E ~5-BX~Dd po«tpUfgtl - C1ra.ilato:r !hntB o:fi.
a. Boller Is now in the an cyde.
l"Jii".AT
II!'(WID
lliH11'
h .o:lo. lio ol<l' 1. )
0
NO
&t~t
!. c.llt.rlh..t
CitaJktuR
Y!S
LJI.P
11
NIE!g
foi.AME
c
CJ
c
()
0
0
Q
0
-
E_
0
0
0
-
0
0
-
0
0
-
~h~ltlllfMdt
il•
.
~~~~ !Do)c~
.
rr.•0
YES
W:"IR (Qfi!Jiru d~
Am lrKnt ~• mp.~T~blq~ dr:N•oi!
4.
Iii.
·
trodour tiii'IIII' c.a.
.
l"tuw.M ~ ICI> n llldl d.....S
'YEISI
llr'Mwr11 cirwh
'YEISI
i'l:tplli'C~ IN 10~
ft
tl
Tlmi...
i1\1411"0H
aRe
E
~
~
-~1.
0
10~cc
P\fa111M'M pi!IWH •
~.
..
c;.,..r.w (lj)~n
~,.:roQIKilll h<e~.~
L.Jmlt "l:.d.
l'.
·
.
•••
ljmo~~,.._
Gti'\ ~
id
0
\'U
F.I~>II!Dl.
1Mil41'~
II. Tllitfii\ottt.t ·~ .... ~ ,.,,• .-. ,
llrw limit Htl•fiM
CinulllilN!illf
.
0
YES
Fllmt iiouUp •
•
16 !IIIC.
VI! I
PilaL .r<:m~~Uu aa.
NO
0
NI!J
0
0
-
0
-
0
,5
0
30 ~K
ill!tt
~
tO. Clfi11ktw Dllnil•• r-tin11
C'..ircul:iiO>T wnu aa. rar ~fl kC!I>n!.I ir
bA~ aot~udtca !IOdm
rt
0
= "ON"
Of
0
0
:::::
"OFF"
" lf.rfJRI Ibm! iiiM'I~ Iil. lli~ ~~ 'lrlJI llll.b r.b.+rrJ&MILk,ill. ~-..ll~DliiiH UtWnl!olr orfilo 1It411JJQ IO'llllh! Q,.,IJII.l.,.l.>wn!l'
'11.•~
~wiliMJ; .kdo:.'!lllll' l
llrt'"'"''-''
.o-..t.Dr>dl
Jl'.ltJI'IIn~""")c"~IJ~M<!iRT~~lHtOJ••har.b.oti]IL'loP~
!Dot. t'NIIl'1IN ~ IH J (~~ ~O.Iblt• ...ulm ~ aln>M~~ ~r lfbn.~ In
If ."'l du~e~
•lbW ~I:t(~
• ~1M ~e "'l thmnWlll *ti.~
:)4,
'f'41uol1
•
~ th!!P. 'Ih~ Mtl!'JMIJ Pf<l' cfw~ ~w
~'ltl:i:G't<A.G~--.r/ww; l~.u~
«HHIIt!
OLD cat
9b
a -Fired Wate Bolle -
la l
ailer Man al
Operation -wiring diagram
FJgure 211 Sehematk :tnd ladder wiring diagram
i
2
i
-
0
anual ~
DC
9c
~Operating i nstructi~onrs
• Spark pilot • Natural or ptQpane gas
• Gas valw: Honeywoll VR82041VR8304
FOR YOUR SAFETY READ BEFORE OPERATING
!.,A
WARNINGI•you do not follow~~- rn•tfuctton• uae11y, a fiN or uplosfon
; ; _=-------'· may rre:sult•C:BUIIng property dam:ag!Lt, penoi!W!I mjuryorlon oflife..
A. This ~ppllar.ce is tq,t~lpptd
an ignitiorl dt•
wl'lleh wtomiti~~ ligl* tile pied. Do .I!!!. II)! tx:l
l;hUbt pl~br l'illlld.
B. BEFORE OPERATING, tmtll d around ·rh.t
ij:~pllance ~ mr gBS~o 8~ 5tl~trw :tmel Ded In lbe
lac~rt.«UII IOml•pl illttnilr than dr ll'ld W
settle on tlltflaor.Set btlow.
' Do DOf11)1 tollt)l~ arJYIIPIIIIa"nu.
• hnmulllttly call fGCJr g.u I'UJII'IItr from 1 ntfslb'boo~s pflol\lt. Fctlow
• Do r~ot ·touch aBJI elaclrlc. tttilch; Ito DOt UM an~
thtgas wppllart't lnltl'Uallons.
_
phl)llaill)!DuriKllk!lniJio
• l~u>Ce~~not~Qchyour1JQ &uppller., ~tlleifire lle~rtment.
OPERATING INSTRUtnONS
t. STOPI R:udttJuar.ty lr*rmatiollallovtOII lhki hbtL
t 5etftwt11mn.o!ltltito lo¥1Ht5i11lng.
3. Tum oft'II drrl~ pD'ftl tolbe q~pllltlct.
4. RelrJOII'i ont pant~.
$. Th.is .a~ Is t«pJipped h Ill ignltiocl clt¥a Whk:h
wt41ma.tlcal}llgtu the plat Do .llaltiJ to llgM tlle pilot b~
l'lllr.il
S. Tumt~tco'Onlnllkoob do~, ~ ttl "Off,•
l. \\!ait fiWJ fS) mii'II.IM to dau auta~ <Q~I.li!M! .amal for Ql
lnd!.ldin' n11 tht~r. l)'lXI 1II'KIIIgD, STOPIF.n "S." Ill
1fltufltylnfcrmdon lbovt.l)'~ don't 1m11 go.. go lot'M
ntXtltl!).
& Tumgu®ntrVillm®~QillnWKbt;;~ r-. to"'N,"
9. Tum on dtiKIItc powwto lhlt appllaDct.
10. iettlletmor;tat~ detired•etmlg.
11. Htlltapplilnct
not Dpll'ltt. loloW' 1!111 lnstrucll!llls ll'fo
Tllm Ott Gas To l ltt Apt:J~v allid call VCJUI' IC\IICjl
~hlllqwp' Mlpplier.
12. Rq~llct l'raa!~ paDtl.
TO TURN OFF GAS TO THE · PPLIANCE
p.ana
1. S11 th.t1111Hmo!Jtltto lo-we!ltMUing,
3, ~move from
:2. Twn off ill •cllk PD'ft1 ta IM ;applilnce: I s.tl\llet II to bt 4. 'Tumps C(lntJ'oiM<Ib elo
perftlrmad,
5, R-eplacifmRtpilliiL
·a,
(il,
to llQFf."'Do DOUCiftt..
5~1
a
9c
-Fired Water Bolle - -
Operatiing instructions
oller Manual 1!1!ll!lll
• Nab.ral or propaneo gas
• Gas valvo: Whito-Rodgon 36E
• Spark plot
FOR YOUR SAFETY READ BEFORE OPERATING
IAWARNIKGIIf you do nat f"llow f1ase lnllrud.klns auctly, a fLl'8•or aplo:sion
=-----'_J.
=·
may r-esult causing proj:K:l"ly damage, pe!'$01111 lnjur:y or ion ofl[fc..
A. Thh 1ppilafl(l(l If eqglpped wltll U1 lg Jon de-Wet
which IU aml.1lcaly llr.J}Ibi lbt pilot. Do m! lly ~
(1htlho plbtby hand.
B. BEFOR£ OPERAT G, 1mel d iri)UIId lht
q~p11anc• am for ga_s. Bl run lo smd nut to tflt·
IDOII' t.cauatso!DII gas is hmlar'llumairand wll
~tQntlu~fb.u.&ee be law.
WHAT TO DO IF YOU SMELL GAS
• D" Doi.D)t follglfl aeya;p~lmct.
• bunrulately cal !fOW gas IUPII fttOD'I a n , bof'l prhoRIL Ft:ln
• Do not tc;u;u;h rm)' ek~ R'ltdl; do not ~.~tt 4111)'
flleps UJppiter"' inMctic~~J~o
pfiDI'Ieln)'ourlla~lns.
• lyou.c DOl r-.I!Chyourg ss.!JPFIIr, c:alth.tfirt dtparlm~r~l
OPERATING I STRUCTIONS
t. ITO PI R.lld'ltlt·Sifttyln.fcnna11onabove onlbls lib&
t
SetlJJBtluaimt~&tattx:J krwasls-etti~.
3. TtlmodfiltteGtriCII poe"totlutiPflilncle.
4. RtmiWt ftoat pan.&
!5. Thi' appli(l110e hl· eql,llpped with Bfl ignition de'iioe wiDeh
w ocnatl~ llgllts the pllol Do om try to ltbt ~1\e pllo1 by
han!I.
S. Tumga&I;IOnttalblotu::bc:kwfs.e r., lo""OfF.u
F\Jaitio;~"
in.J"' ~I;MI'
~~·
Ga11
r;Qfllld
~- ~~ .~;;~.
kncb
7. Walt Dv• (5) mlrwCifllto dNrout iU!Y ps.l'Mrllmal for ps,
ln.dudlng Marlbe ft.wr.lfyou smalga&1 STCPI FtliOoW ua,n In
lthe tB!tlJ fnfoo:ndiQIIl a.bl1t't.lfyau ti011't smel en, ;otot111
Mitstep.
8. Tum ga&cootrolknob C!llunferclochise .j:"\ ID "'N."
9. Tum ond.. tdrlcpOMrfotha app11ance.
10. Stt'ttlamtcmatlod•lrad ..uing.
11. If ttlle •I'll
fl'iii1QA oper1te, JoliN' tile ifl1.1R!~Ofl!l "'To
Ttlm Oft' Gas To Tbe AppliiDCc" 11M11 cal )IIWr serwlae
ill'du'Jjcf.tn O'I!IU.SLIJIIIIir.
12. Repaemmt pwu:L
-
TO TURN OF GAS TO HE APPLIANCE
t. S.. llw'lll. osl'attolbw.cttutlln;.
3-. RemtlnfrontpUicl
t Tum off 111&1ectric p!OWH lCi tli& tJlc:laru:a if servl~ la.lo b. 4. Tumga-s tt~n.1tcl kt!tlb~OoCkwisa nt ttl uoFF.ItDo DO&fclfte.
perklrmed.
$. Rej!IKI.'hntpaMI.
~2 o
0
oler-
DC
9c
~Operating i nstructi~onrs
aller
anual
• Spark pilot • Natural or ptQpane gas
• Gas valw: White-Rodgers 36C
FOR YOUR SAFETY READ BEFORE OPERATING
you do not follow thn.e R11trvdfons euctly. a fire or explo1lon
IAWARNINGIHmay
nsuh causing property damage, per$onaflnjury or lo•.s ofltre.
=·
; ; ; ; . . . . __ ___,_
~
Thll appliaMDII tqiJI~ with ill! Ignition dfticl'l! C. UM orfyyDAnrhand l.o drapn~n·or rum lbfl Slati C(JD\Jid bl.ab.. Nratm use
wlliefl aulllll\ali c:aly II !Jl1 5 U'le pilaf. Do not by to
tueb.lf th.e blab wil notd~& ottum by hand, doo'f ~ b:l ~r it,
Q11 qlllllfied •mice ·technfdll\ F~~: w attempted
nsQ
ighUhe pl~bJ hind.
ru~ ln.dl'loll'nploslon.
B. BEFORE OPERATING, smtl al arott.nd lha,
iJfiFiiatu::ili Bte"A gaJo Be I IIi's ttl ltfi1el nnt'kl '1119 [). om turt uu tlii'i appliaooe f iJI'iy pa11t tia:s been ufildat watPJ.
IQIQr becJWitiOrDe gail hmoiarth~~r~:alrarMI wl
I
diltm Cllllllcp~aiJled Mr¥h:.eteclulidl11to ~!IJieclthe appliaMt
dCJan theft:~«. Set below.
.and lo replace· any Plrt or the control sys~cm 1ndl an~ g111 c:ol'11rcl.
which has baaaulllllarwa11r.
repm
rm
HAT TO DO IF YOU S ELL GAS
•
•
Do not!ry!oll!lhl BI'IY
311ct.
Do not taucb illf llltWit l'"l¥1tth; do not uu .any
pllo.ne inyoutbui~i"!J.
tnmed ilrMI~ eal ytiJJ' gas St:lPIJ fulm .a
bor's. pllon-e.. Folow
Uwgas wpplltftl'rlstnJdlons.
• Jyau eat~"«!< r&aehyoull'gas SuPtJit1, r.rAIIBeul! departmHIL
•
OPERATING INSTRUCT IO S
1. STQPr ~dthe-Jifetyi~o-n~bQ/lle oniiJlilll.libd.
2. S.Ubl fhntoslltto low11h.Wng.
1. TUm oft d•ctrlal po to'thuppla~
t RIJIIl0¥1,1 r11011t po~na
S. Tb11 applllnca Is equipped wltll 1r1 lg Jon dcvka which
automi11lal}l lglt1J Utt plloL De .aat,IJy fD llgtrt lhll plol by
han~L
l Dtp.rusps CC~1111Jd blobt(QbttJandwmcloc~ n. ~o
"CIFF." N~ Krlob ta!Miot btl tt.nN to "CIFP' unhu blob
!hp-ren~ alig~lly.lla noUor~
Gn1
7. Will flllt (<5~ mi~e~ 1o ~rcwt PI~ 91'·1~ 5melr01 gn,
lnd!Ming DtarU'It ftoar.tfyousmal gas, sro Foi!YII "B" In
111ua!at)' ln[on:n~Jcnatuwt.tfyou dDill't :Kntl gu, gD'Io tllt
nut step.
8. Tum ga.sc011II"'O kDOI:I OOilnltrcloelwlst vf'"\ t.o "'N."
V. T1.111 an.alflleclrh::powerfDtf'l&llJ!ftlmc..
1(II. Settflermostatto r.lnlred seUint~.
11. HtiiUPSJiiaiiCI dl DOl Gpllratt, fclw 111• IM1nlc1JI)lls "Tao
Tum l)ff Gas la The' Appili!noel' and d )!IIlii ~h;:e
tedtrlldlnor au lllppler.
1.1. lla(llact &ont pwl.
~tr(ll
mob
TO TURN OFF GAS TO THE AJ PLIANCE
1
S!'tf!U!thannrntatla bwsiil tiitftitig.
3. RemouftontpmiiL
Tum Qff • electric powa to ~tlppllll~:t if samce is ft be ~ Depren ga cr:llllbol blob lll,gtrtl)' .arMI tum drxllwile r.... to
parfom18d.
l\OFF."Do no•fflr'C*.
5 Re cefnml
5~
a
-Fired Water Bolle - -
oller Manual
lOa Service and maintenance - schedule
(
VERIFY PROPER OPERATION AFTeR SERVICING
TaiJfe 6
)
Senke and maintenance sdledules
......."''C:. Mel"~
(111M fciii!:I!Wfn.g pages f« linstnll:lllons)
• Reported problems
~--~
~-- CGt USefi"& l rrfon'nation iMINIIIII foil' fttinJD~
• Oheck Blr opemlngs
• Ohec'k bollell" preaa.~I'Bf
terrpecra:t111re QEllliiJ9
• Bollef Blll!B
• Air opernlrgs
• FI!Je gas vent 81J.9tem
• Oheck bollell" Interior piping
• Pilot Bllld 1maJ111 b111mecr names
• Oheck venting system
• Water p lplmg
• Ol"'edc Blrventa
• Bollef lh eatlng
aul'fBDes
• eumera B1"KK oomer St1eld
• Condensste di"BBn syst&m
• Ol'ledk condensate drain B)!Stem
• Oheck al.ilt<lmatlc Blr \I80t.!!, {If
u:aed)
a.M-=•=
• Olled-basrlng ClK:I!JIBtolra
Stut~:
• Operate relief valVe
Ch~
• Gaa piping
• Cdl:il 1111 Bllld opE!f"Btlng pi'E'IBSIJII'Q!I
• Air vemta Bllld Bill" el m lnatloo
• Umlti controls. end cuto'll'a
• E'lqlan!!lon 1Brlk
• Bollef l l!llefvBflr.e
R'AMdew:
lrollo\t.r d te Servloo andl matnmnan~e procedures @:l'W!n throt13hout this m.urual and !In compo:ru!ftt f11e:r.allih! !ilbfpped w:llllthi! bol~ F'ailnre to perbrm lite senlr~! 311d mainimanEI!
c»U1d t'8Uit 1111 d~ r.o lite bolli!r or ~Jfflt!ln. F;k!luttt!! ro ~llow the ttirKrlo:1u In litis Maflua]
at'! d.mmpooent llt.er:rtute oouW. temlt in severe ~I :Injury.. d_eath or euhfWl.tla!l property
damase-
0
oler-
DC
1 Ob
aller
anual
Service and maintenance - annual start-up
AlropanJ....The boiJ~ shouJid be ~ lnd Mal"tied anftUr
ally~ af lite beg.I.Mms of the heaLing :SI!a10o, IOftl¥
by .a qua:Jiifiad •wvice tsclmician. In add.ltlon.
dlol! maintaiaD«! .and ate oftht= boiler d~d
in Table page' .39t a.:nd dplainetl. on the followIng pag.e.s mmt. be performed to w~ nu:xlmum
bow efficlamcy and celiablli~ FailJ.l1E to liBrVic"e
a.ftd mainlain the boller and i}'ill:m .:nuld rewlf in
a.
~ulpme•u fai~
lAWAR. .]
1. Verify that rombwtlon aDd vem.ibt.loo air openllip
to the boller mom and/or bulld&~~s .u-e Of!en ;U~d
u n(kb!ltJU'dedl.
i. Verify dliat boiler \Ui. ~ha.fse Is dean and fteo
~ l()b~JUdOM.
llllue e-• VMd .,..t4Uft
1. ViMJa1ty iRSJJeCt enitim 1'1ua gas venting &yatern
fur blc:lcb~. de~riOI'J.lion or leakage. Repair all)'
jo,no dliat sh&Ws'smofle·a.Jic:a&e I'll acrol:'danrewlth
writ imtlufacllll'i!!r"s iftSift:l.ctlom.
Blmlrull:e • syt.tem 01 holler leah.. Continual
fresh m:akeup watet w.ID rt!duee bolller II~ Minet-abean buikf up l.n &eetlons, rt!dud~~S twsu tr.uufer.
M~tms CMt &on, .md causlns 5«tlon fail.ure.
laklft8: wa~er may od!ilO cawe W!vete propet1y dam-
Fa1Jure to btspeat fof' tnl'! above
oondlllolli and tuwe dw!m repaired
c::;m resuh ifi Sl!"\"e~ penoullnjW')'
or dea.th.
e..
Do not
UJe petlaltum~
aleenlng or Haling
I'll bolle!r :q•Soteto. Seven!! d2to• to
co~~und't:
bolf.e:r will O«W",
rerufLing in rubitarii.ial propmy
dama~
El eetrical .shock hil7il.fd - Tum oft ~ to the
baler before •1'1¥ seiVIce operatiM on the bolmer
e:roept :u noted od!erwls! in thl!l instru:tlon tll3nual.
Failure to tum oJf elecrrkal pcw;oer mu1d res.ult In
~euiell diode;. ~lng iSe\'eti!' petiOMI ii'IJ\Jty or
d.eath.
0 Inspect .
Pilot and main bumor flamos
1. VimaJiy iMpet:t /llot b ulfl.er and main burner
flll:mm as d!f:mru under $'tart41p, See.t.ior. 7b of
tltl!l lt'J;Jilllllill
Water plpbtg
L Cbe.":k:thebolle:rinteriorpfp:i.ng and aU 9jl!tem piping fi:Jr filsn~ .aJ leaks.
;t l.lepa'f any le-aks: bek.re f!ro.oeedlng.
Boll.. "-linl•rf.ao•
--
Reported problem•
lnsped. any prohienu reporuti by OWIH!t aM rol'f."ect
bek.rep~
L Dfaoonnecittbe vmtpipe at theboilerindu.c:u outlet
amnedlon ;ali~ rum i ng .off pow~ &o dlie boil~.
;t Uae a. bfi8ht llgbt to fn!!JM!d the :fil u! p£:1!'8 inteclar
~tid indue~
l.. Ifi!iped. the b or'lervsu oudel area and heaJing wrfac::es by looldn:g: dlrol~Sh the opening.
4~.
If tlie \•ent pif!e or i.ndooer mredor shOIA' evldi!llee
af 80ot~ foUow cteaning boUar heating surlacea
io this mmual Bitlon to !IEJlOYB the fii.Je rollecto1!'
and. de-.lft dl.e bo~er ~ afll:r dOte ' nspee'tlon of boiler·lteaeing mr~t. Jf theft!. l!i evidi!llee
af rwry ae dep!Mits. dl.eck th!! water ptp.lng .and
oontrol . .em ro male sure tlie boliler returll w.ateli' rempera.ture b f!roperl.y madnwned (per dtis
ma.nual).
•r
Bollara,..
l. Verlfy mat bolleli' arti!i11 :1!1 ~of oU1f combustible
m~rteriah,. g:u:mlline and 0thell' flammable vapofli
acd liquids.
;t Verify ·mat botf.e:r an:! a (and ad- intdc:e} ~free of any
of 1.111! contaminants liJied Jn Table! 1 on page! 9 of
thl!l manual. IT all.f of these are present :In theboiler
:lnttke air vicmlty, thl!)' musm be temowd. If thl!)'
ttaf!Mt be :1\"!lt'JOWid. :liOJate dl.e IKJd~ and rl'lWid.e
ouuide oombunlon. air. See Ralio-nal. provtndal or
loeil md8 for furths mformablln.
liuer:lor.
5
·
leoonnecl vent to :lnduO!I' oudet at~~d r!pace ill
bo:lla OOI'IIIf!Oiru'!nts before~ 10 :~ervire.
6. Cbeok:budde and around boiler forev:iden.Cl! of m.y
leaks: fro-m dl.e boiler.lf~und, loeaJe.soureeofle-..b
and.~r.
a
10 b
Sewice and maintenance - annual start-up (mnt)
0 lnspeet
- ..
1. Ifany portis nat rompl~.elycl~, run :~~vacuum at the bumer
~ntet while dean!
the bumer poliS with a wrre bntSII. 1-Je
'V:lrullll'l 'Wi ll bdp to draw 'Mi'f al'l'bonle matt!r:la!l out of the
bumer.
4.. .Reln:stlfl .oompo:n~ iWtiftg wllh the btlmao R-.If. diM di_e
pi10t bt'll.di.et asaembly. but1cet b~ and :Ur inkt top and
Tlh:e boiler canta.im Qlf3.J'Ilic: fiber md
fi.be:rg13Jsll:1Jb!ria1J. Uae w:e when hmldi~ ft'l.3tuJah pet> irun.rucllofl!'l
on pa..P' 68 of drli ft'l;li)Uat Failure to
comply oould resultln ~e:re pet5:0:1W
injwy.
dl'ns
lAWAR.:;]
oller Manual
-Fired Water Bolle - -
lfl:mu:ltttlon lsdttm~ or tlliplaood, do
not ~t~ the boiJet. ~bu or repo~ltlon imU!ailon .M ll!eOI!IJW"f. Failure to
repboe d~ JMUialion ean ~ult
in a.fue huM(i. c;al.!l.Sfng5llM!Cepefli!OlJal
inJury~ d~di or rub!aan_.al pi."'perty
tbmttge.
s..
front pme!li.
~!Ow dw! itart-up ptoeedure Ia the bol1er ma.nual
Conde,_.• drain SJ'&Ieftll
L Inspect ronde:csab! dtain fit'llns11 and tublog. Verlfytbat oond'eomte aw ftow fteelyto dWn.
0 Service
--.
Inducer motor
l- Afier 1Dm&.g off powet to the boll'er.l'eMO\'e the b;Ht! bumer
sb~Eid
( lflgure :JT~ ~•em ~ ptge 60).
2. Jl'iput bumera. .ttnd
.am
Mhet
oompof'l~u
bll the bo4f.e;
L W:IJII 'boil.!t :power oft. pb oe 31 fl!\lol di:'Ofl" of S-A. E. 20 motor
o:ll in l!!aiCb of the lWO otl cupt.
A ~UanuMGI
AnNllnl
l
base_
3. lfbW"ns,s mwi becle;;med seeBumsreJaaning irudruGtlcm
bl!law.
Oiled-baa,.... cl'n::ulators
4. l'.lupeemthe slotted jadc.et c:ooll.ng openlnp in die bottom left
;md rig.ht oft~ bas;.e pan {AgJ;ure u . item 7, pag.e 60).
5.
U.!!P! only .S.A.E. 20,.,.,. o'll 10 luhr:leatf! t:he
:fnd.uce:r moto:r:. Do !llo1i l!ISe tmh'mial! l!Lousebold ollt. Motor a:..uld. be damaged, resultlng
in ptiOI'bP.e IS!!Vt'!re property damage.
lmpelrt dieba5le ~ru.ulaiJOIL Pay a.ti.en'tlOII.IOtbe Wi\RI\IIING on
e Iii$ teprillftS WOI'ildriJ with :liM!lbtlo:ft m.ater:lah. \~rU)'
ih:it the mrubtlon is :Intact and semre .ttpmt .all foot iSides
ofthebd:se.
WI fibe:tglaBa and
are preulli 4DF.1 oon!Itrurt!M anti
fl!modoe'lift!J. '.l"h.ese ma.t!tia'l (at~ be drawn :In
wldi tbeoombustlon ailrand obmuct bomer
porta,. ~:In Olfbon m.oooDde pmduc:t:i.0n,a fife haza.fd.. Qfbuild!fng:ireezs
age.
Read and f~llow the WARNING on p=~~ge '!)_
F=allutt kl in~C:l and dear BM butner polls
could resadt fn ltMi't! penaru! Injury~ dead\
or wbstWJal prope;ty damag.e.
A.Itbome :mJ.t:e:rWB. sud!.
1. 'Ibs drouhtor ab£pped w.itb.tlle CGiibllilsr:f! wat.er-lllbrlc~ted..
No oilfng is :ftlqui.fe&
2. Cbedl: ot1Jef' d:roulamn in tbs systa:c. Oil any r;;iraJbtoni :re~g OIJ~ foflowlftg dKUbtOt' ftW'IUfac:WM"'!l in!rtmctlom..
O~otl.ing wUI c:Wria:ge the c::it'rula.tor.
0
Start-up ...
du~t,
l- .l?etf€lftfl aU d3ti.-up p~ in ~on 7 o f 1his: l'llaJ'IWII.
2:. Ver!Iy cord nn pl!'e&aw re:Is ~and tbat ifillll}'!tmn :f! wofk-
arm
l.
2.
Rml~ bume:ra~ldand tbs base pan af:tibaffie. Nextmn0Vi!
the J~llot bradc:et owemblf. 'Then :remcwe die fOUt' ~ ~­
I!'DfillS die bum.er fr.lr 10 dw! mattlfuld at'ld sf! de the bumer
D"ay ou1 und~ die nufti.Oid.
~m
opell.
eadt bmnao to iMUte dl.ar ewtty port
oompP.e~l~
~
properly.
l. Ver!Iy antifreeze 1evem (lf wed) Is at the ti ht ~D'aJJon
and thttt ~fihlbi[Ot' 1~) ~$ OOI:":f'ed..
4.. Chedr: gaa p1p1111g per manual Sect!om 5, anti 7a, Rrlfyktg nt~o
:lndlatlom of 1
e .and dl piping ;md tolu tectlons. ~ in
good roatb'tl.oll.
s..
.IWtd meOJP8rstlngJIn.atnJctJon• (S«ticc Sic of dih m3r:111ual or
oft bolfier lttbel) applyins 10 lhe ballet.
6.. SUtt
me
bolDer fulllowlntJ tile appropr:latf! •Operating lnatrucUoma (Semoo 9c ofthls manual or on boiler label)-
.u
0
oler-
DC
lOb
aller
anual
Service and main1
tenance - annual start-up toonm.)
0 Cheek/test
. --
•qMMiontan
1. Sn1ffnear:lia01' and aoound b Bilm' n:n!afuf myfn-
dteadon of a g~ leak.
2:. Teat pa pfping uamg bubbfe itnl, per- Sed.io~ 5
of dlis manual. ~f thete Is any indication of a ~e-ak.
1. ~Lon tanb f!roVtde spa«! br ~ lo MOW!
Jn an out as lh! h.eattns: system ~expands due
to rempera.Dtt'l!' ii!CI1:!ase ot eontf':ld:s .u the w.uer
cook Onl~ dbph~m-type or bladd.et-ty~ tallb
should be ued with CGt bolle:rB. See Secooo 4 of
thl!i millftual w ~ed beltloeatlo.o oierparuJ!on
tat'Jb a~~.d air ~1im1iwors...
2:.
Cold fill and oporatlng prossuros
1. While dlte sysum Is ooldt flotethe prenure read'i ng
on tM'ooller .P-~.Jillft gau~ Vetifythar
c.old fillptes:9llftl :l.s oo:JHtt
2:. Watch ilhe pMaaure as: the boUer and ~'\~ beat
Uf! to et'lmt't!! ~UN r.ISlt! Ji Ml'ft'lal. Too hi W! a r.IU!
woulld i:ndieale aw.aJetlosged C)J"undel:'912edexpa~­
siofl unk.
Air nnta •I'KI•ir elimination
1.
J~speet
a.utoonatlc air vents.(Jf used.). Also mnspect
air jj!paratof,s to et'lmre they are oper;Wo11aL
2:. 'The cap mwt be lll'l«rewerl one tum to allow aft to
eseape.
l.. ~ Rgure 31. Tf Itt~ ililr vent Js l~fi8• re:MOVe tap
A and ib:rleO:ypum valve B ;tnd dl_8i te1e.ue to dean
the \rahoe 5:eal
4.. Repla-ce tap A bf IW!ruftS all the- W"a)' onm ~ B
and then W'lsc:rewi~g one tum.
~-
D~hnlgm.. or b faddaretypa expansion tanka
Theil!' tanb 3.'f'e' lf!.l<i!!ded sas tight wlrh a. rubber
membrane to separate the tank ~air.and
the~ Maybe l~ar a:nypol:nt ~n tM ~~
but mMt ofim fouod :nea.t dlte bol:'ler.
.. SyB1:e:lm with thlstype ofE!qlami:ontm:cequire
at least cme autamSii.c air wntj. Pftfenbl)' lo.::ated .on 1op of an lr ellmil'latoJ", as dlOWft Ln
~es: In manual Seer~ 4.
If m~ v.alve ]w; tended to li!ll8ep (~oendy. dlte
e:xparaslon W1k. may be damaset'J. or uod.eniz.ed.
• Flrslt meek tank me iO be :JUlie it Is l;uge
I!DOU!Jh for rhe sysrem.
.. Jf s1u iiB to0 small a.d d a.dd!ItiOIJal rtmik(a) u
nea!&!I:H')'"to provide mffidsnt II!X!p-.msi.an.
.. If tank me :{g large mo~ :remaw tmk from
~ and eh.ed:: chaiJI!< ~ (uruall)'
11 f!il8 br l:'elldenlJal appllatlom}.
'" If tank WOIII't h 0ld prt!l!mre,. :memb.mce lJw
heen datmged. Replaee tank.
Bollar Nllef aln
1. Iospeet the relief v~ ~ lift the lever w ve:rU)'
:fi.aw u fD the f!lllowing wsminga, excupted from
a reflefvah-e manufacturer'S; WM1'11DS llabel!Before
operaliog any relief val...e, enmu tbat Ji l!i pJped
wid! ~d~ :In a ufe area ro avo-.:1 se:\oere iard
~~l Read! manual Seellon 4 befote p:rooeedii'IS
2:. Afl'l!r follflllii•lng the abo~ 'WlU't'li ng dlrecOOI'Ii, :If dlte
relief Yal\'e li!ll8epi fit' will not ~ properfvj, 1'e'J'l 31Ce
the relief valve. :EI'ISW'e thAt tbe rea.5li:iB lor ~lief mM
we-ep:ln:g l9-lh.e valve- .:md not ~p:l.'el.'lmti!ai.ion of
the ~m dlle! apanfion tant ~lng or
Uf'J~I:'Ig.
Limit contra~• .mt outoa.
1. Jns.pee1 and te.st the bol.r.et limit oonuel 'krlfy oper.ttlon bf tumi:ng oooarol set poiJu below boUer
temperawre. Bllller dtou1d qlcl.e off. htum diaJI to
OFiglullseilil'lg.
2. Jotped: and test addlliortail. llmh t:nntro1i
~ .rutoffi!. in!l1:alled <m ~
M'
low
•o
a er Bolle - -
a -
10b
Service and maintenance - annual start-up (mnt)
S:lfl!l;y JE!id'\l!llv6 Jbi:ruf.d 'b~ ralnapacEd AT
LEAST ONCE EVERt THREE YEARS, by a
llce:ihal ~mnb:h
RgureMRalle:t wlw
·~
!C'Otllhltul(
Cleaning boiler
heating eurfaces
or audmriurl
!AWADIIIGI
ow. tLmu • .~db-dn lhe ,,a) e •nopet11tlve_
Sutl! .;:.oad lttu~l .1111e nul ~IIKUbl~ l:1ft len
fM \'3We .od ht (d'mronenas IW1!' ~hytk.ally
~t!u•ow .uml ~nsp«:tecl Thb JMpM.Iollrmwt
Ellll)' b.! llJJIJdUded by a. piU111bttJ8 ..oo.Lracror
nrJl111hnrl4'tl into-pedio~:~ ~llq'- om by lhe
ow~- F-'• ure to rel~a die boiJe" relief
L
In uq, rlea.ll' ur ~hstiutb'l
pro~)' d;~ll'$~
:FtJIIowtll~ in!ll.iDabfiln, rho! wlq lliMJciii'IIAt
be operated AT LEAST ONCE A YEAR
to ensure that wne:rways ue dea£ Cari:Jlm
natuuiJy oteUtrlll.(!: m~nt!fa1 dep.cults may
:ldh~ ra me vah'i!, tendft"mg ia lno~ve..
When rnuua.lly opetatlng tnt!' levtr, ~t'
wl"ll d.ls.clwge and preaWions mun be l2hn
to a\'Old contact with hot water oill.d to .wold
wili!t damase- 8ef0h'! operating l~r. dl.eik
tc. tee rh;rt a dlsc.ha.rge lwe 15 col'l.neCted IJ) dUi
val¥~~ dtr«;t{ng the flow ofh.ot water from the
v.al'!.'e ro .a proper pla.2 of d~pos:al ofhet"W~
~ peNlfla.l mj1111' D13f result. H no waar
ftawa, valve l& inoperative. Shuadown boiler
artUil at nf!'W rt!lief vah•t!' has been ~mulled.
0 Review with owner
2. Emphametheneed ro pefio:rmthe mafntimamt! schedule speclfied
Jn the UB8J"'a lntcmna'ticm Mmwlll (and in thl!i manual as '!A'ell).
.l. Remind theO'W'nliel'of the need to call Ill a'lioen$ed mtiJI-.ldor should
tl~ booer or-~·~ exhibit Ml' unusual b ellav"ur.
~nd
0
~JJSped.itt"'a~cy. It) l!ml,lft ~1 1h.! pn>ciw::t
lw. outhew atT~ b)' ¢1Yt'O$L'i: water cut'"ld.IUa:oj ~ lfl o(9'1wte~ the lve omd tlJsdmge
line ltaw 11,0t bt!~n. Wtes>ed I!JI' tant~ w:Uh
m~~rany. Certai.n m.1Jwrall1 11mJ.t'ltiug c.ondid~J!J uuyCQrro& me v-,UV~ O:t ht oompo~eoti
~i'w;s:a dJ~~;;ak!W ~h h! LUI~ pressute
bullduttt wtlklt an re.ult In 11&!\'1!1'.! per.sonal
4.
oller Manual
dw! OWI'It!f' tc. fallow tile pro:per :shutdown pmO!d.ure :a~~d
ro Khedn'le an an.l'IU3J swr-up .u thebegmfirns of the :neon beaJif:\8
se-.uon.
The b o:ilef rontafns Q?famk; fiber and
:fibtiglass matef'ials. Use ClJ!fe wheJJ
handling tMse ma.teria~ per los.1ructioru e>n paga,68of this mt3.0113L Fa:llu.re to £.'0Dlflly oould result in seo.~
penou1I11:fury.
Shut dawn
..
"'
boi~
Follow ""'1b1lon Oft! Gn to AJ:Ipl~ lru.1rucoon5i .Qii boner :ltlld (lpe!Ming lnstHJtldon$.
D{l DOt dn1o bG:Ilet liilleS'II itw.illlbe 11DipO!ii8d
to fh!l!zio8 ~mpuaJmn.lfusans antlfreez.e In
~do.ootdmn.
2.
3.
4.
5.
Foll_o.w ihu.td~WI:l procetiure..
R.emi!WI! Yentlng system C'.flllftedion to boilu.
R.emi!WI! top 1ad:et panel. Thtn bad: rllil11a.'tl0ft.
!llemove a~Ilei:itot bH/t:mW:tiOJilaB!imDbly. Qean lil!alarDtl from ~y and sediou
0.. ~ r;~d~a&o :p'aiei llaogl hetweJ!n s:ecrlom..
7. ,R.snow bumen. from M!e. Brush and.vacuo:m born~ to.l:'fmO\'i! all dtut and llflta. ~If diat aU bume:r
po:JU iltil! he of debrJs.
8.. Piau llle!\fip.apl!l'.s Jn bas!e ofboJkr to rolled. sooL
9. Clam b!iltween secrums whh wke :llils bru&
10. ~ ~apet' and SOCII. Vaeuum Qr brwh Mse
a:nd i!ll lft'OW'Hling ~]I. ~IUtall r;uil:liJon _pl:N&..
]2. .R.ep1:1ce coU!edor bm1tr-JJI:Sitlo:a ~- Se.al wllh
ae:ilmt. Obtain gas-tight sealto pnvmt flue gas !!pillage and. arbon mon!Wde emlt!f>lons, l'e!5UltJng Ill
~ pi!f'Ot'la.l rnjut1r or dealih.
n. ~aft! !mobtloo and ~ildet top paneL
~4- SiMi. "P boiler fallowlfig SectiCJil 7 of lhlt m mul
art~td. the boJf.er Operating III.SirUcttans., Sectloft Sic.
~lvei5Uii.ill8 !ru:Lkat~Mimproper as ~fi­
JI rounct dliedc: !Or p~ oombus.tJon ud mah al'ly
neces:sary adjUJLtne:nts.
0
DC
oler-
aller
anual
lnstr;uction fo1r the·Commonwealth of Massachrusetts
(a) For al l d dewaJI borlmrtta!ly Ydred gas fuelled ~lulptnent lmialled
in~ dwelllllg. bull~ or ttruch1r.e u:sed in whale or mpart
fi!J:r MSMieoi.lai J!'W'pcl5li!!St mdudlftg those fMf!ed or C).P~•et'l. bf
tha Commonwealth and where tbe a£dsw:allexbaust wm tmmfnatlfllll Is less than~ (7) fe!at above :Jiuls:bed grade m1:!be 3.tl!a of
t1M! vet:H.IflS, ind udins bm not limited to dew alld poreb et, the
following :requimline:mtB man be satimed!
L INSTALLATION OF CARBON MONOODE DEflECTORS. At
the t.lme 4)fll'lt tal13i.loll. of lile sMte w.all horiz.ontall ~llltt!d sas
:fil.fled! equl.pmmt. the installlng plumbef M ~ fittu &1n.a.ll
observe that a hard wired caroon monaDde deertor w"rth a.n
alamland batt:BJybadk-up fll bmaiied on the ftoorJsvel wl:me
the ~ e-t~ulpmenr is 10 be iMtaUed.. In add.lt:lon, the lnstaDms·p!umiei Of' gu fi.tl:sf shall Bbllll!fVe that a bal:tm'f opera.tad
or hti'd wlud orbon moMxMe dt!•edoi' with n alafft'l ~s
iruiraDI!d o.n .eam addi tioftal ll.e\~1 of tbe dweDlti!. building or
itruci.W't! iS!!t'\'ed bf the .!Ide wall 1\o:rdoma.l rwmted 83S fueled
l!llulpntent. It shalf be die l.tif'OI'I!ilbillry C)f t1\e pt'i?pt!!'ty o:t.-mei
to aecwe the aenrices of qtii1i.fied 1ki!JilJed p;m:fe&tionall! f!MI
the lruiidlatlo-Jl ofbtsrd wlred carbon m.o-~e dete.ctors
a. Jn die t!W!tlmdtu lile side w.all hotifollta.Uy ~toed sas
fueled equipment is; lmta11led rl'l a era'Wt s_pat!i! or an am
&.
lile br i w.IIM C31oon mono.dde ~w.IJh aiarm oMJti
ba.tte:ry bock-up may be mmDed 4)11. the nen adj:11eet'lt
fulo:r 1e9eL
b. .In die event thai die ~~ts of this .sal.bdMsLo-Jl can
not be fll4!t amthe Ume of OMriP'Jeiloll of ~mliilla1llon, the
owner shaU have a _,period of diirty {.3ll) days to OMWply
with the abaw:r~ll1mlleots; p:rcm&d.~ t:hatdurmg saiid dlirty (30) da.}' ~r.lod. a hauety operated earbon
mort.Orlde detedo:r w•llh om alum 5;hall be Iruu!led.
2. APPROVED CARBON MONOXIDE DETECTORS. ~ch
~ :tnOftODdedeted.Mas requlroed In ac4.."0:1'daMe wJdi di!
;~bow ~ona !hail romplywith NFPA 110 and be ANSIJ
UL 2014 :listed and IAS ~
~-
SIGNAGE. A mllrt31 M plastic :£dEJti1lc.ation p13:ts shall be
petnW'!Mt1)' mounUd ro t1\e reD.erloll' of the bull~ at a
minimum hedS-h t of eJsJu (8.) ~~ abcw.e ;RHde dln!dJy m flne
with the ~bawt v;ent terml~~~a1 for tbe"'horilonta1-r v;el'lled
gas ~ ed h.eat.l:Dg ;a~W:u:e Of' ~pm.ent. The :s~go dlidl
read, ln rriot size 11.0 l.a u fban one-6alf (J.I2) iot'.h In !112:1!.,
"'GAS V9NT Dm.ECTI.Y BKLOW. KEEP Cil!.AR OF ALL
OBSTIUJCTIONS."'
(b) EXIENPTIOHS: The followlns equipm-ent Is: .exempt ftom
248 CMR.S.£18{2)(~ 1 tbrough 4:
1. The equipm6IItllsted hJJ Chapter 10 entitled "'E.qlllpm.ent Not
Required Th Be Vmtail"' in tbe most Cl.lf.fSJllt edlitton Bf NFPA
54 e adopted bytbe Boa.tl:t and
~.
2. Prodlld..A_eprow!d ~wall borlzonllallyvemed ~
fueled eqmpmemlrutailled In a mom or !O'I:ructUre
s.e,pua~.e from the dweiHns. bmfdl
or !rttDCtwe
used in 'W'I!Oie or in part ~r retld.enila.lpurpo51eS..
(!':!}
MlANUF~TURER REQUREIIENTS- GAS EQUIPMENT VENTING SYSTEM PROVIDED. Whl!tl the
nwulf~ of Produc1 Approved stdt! w.aD borimntrlly Vl!ll.ted g;:t!i equlp.mt!fltprov"tdeso 31 Ydlil'lS il'~
d.e!lg.n or V!lrtlng llj'item mmptoll.eii.U with die .equipmenrr. me IDs;t.I'IKtlruu pi"''Yiffed. b)' t1\e ma.nufamlft!l'
for tmiall31ioo of the equipmet'llat'ld l!he \o;enlift,g:s.ytr.em
shall ~nd~
1. Detailed instructions :for tae fnstallat£0:m. of the
ventlil,K li)'Siem ~gn or t1M! ~mlng if*m romp0MDUG and
2. A rompl~ par1s I ~ for the ~l'l lmj!liS)'SII!It'l desip
or Vl!lltiDg system.
( d) MlANUfACTURER REQUIREMENTS- GAS EQUIP-
MEHTVENTINO SYSTEM NOTPROVIDED. '!;\Ibm d!.e
m3itluftseJlJI.et.'of a .Ji'roduet.Approwd side waD:hotdotltaUyvented p fueled equipment ~ not pmv:lde the
parts fur wnting 1he fl'ue gues, but iidmtifi.al "&pedal
~l'l bt'lj!l syttemi": die follMII'm,g r.equi~u sha.ll be
sa11.sfied by the mmllfil.citt.l!e:
I. The referenc-ed "iipedal 'Rt'ltillJ~I!m" liut rucIJons ihaJl b.e ~ndw:l.ed with
.a la:neeor equi~
me
mi!nt Instailat£on ~"1iorul; m
2.. The 41 Sf!L!!CL:a.l \~n tlos s.)\ltemt" sh31U be Produe:t
Approwrl by the BOOrd, aod the ~l'tSUildJol'ls for
dlat system shall ~ndud! a pa.tU lih.t al'ld detail!d.
1
ltutalla.llon iMU'UCOOfU..
(~) A .ropy of all L1lStaillatl.oft &urt:tDctlom for .all Pmdnct
Ap(IJO\~d ~de w.all 1\.orlzonraiJiy vented j!l3S fueled
equ!pmen~t aJI Vl!ll.tla:~& lmt:ructlcm~ aU paru llu for
\'f!ll.;f'l l!l if'ltU'IKtlmu. aftdJor all \'4!tliln8 design ~mtrue­
UoM mail tema.in wlih !!he *.PRlla:Dee or ~ulpment at
the oompletl:oa of the iom D:ilicliL
a
11 a
-Fired Water Bolle - -
oller Manual
Troubleshooting - procedure
IA:WAR. .l
Labt!l all w.ir.?S ptkw to di~enon wheD se.v.lclns eol'lirok. Wir.lng
l!i'1'0r1i ean ~a.use lmprapet ;and dangerous C~petabllD.
IAWU. .l
Nevu jumpet" (bypua) rollout the:acal fwle el.mlm 01' any Btbe1'
devioe e.x.cept fot :tno:tnt=nW')' 1!1StiniJ CJutHnt!d Jn Troobteahao1ing
Charta. Severe penollil mjw;\ d~ or substantia] propertyd~
o n resuJa.
Befere t ruubleshoollng:
1. Haw the following items::
a. Voltmnar that em meek 1Xl VAC and 24 VAC.
h. Mkroammeur with a minimum .sale mnge .of 0-25.
c. Cantim:wty cbscl::e:r:.
d. U-tube R'laMil'u!ter.
2. Cb.eck fo.r 121) VAC (:mlolmum 102 VAC to m:uimum B2 VAC) to bolle.f.
3. 1\hh !!lure £bermo~Ui£ is ~alllog fur bea£ and (OJ)r:adJ (:lndudlns .appropt.late :zo:oe
ront:rol.!l) are dolled. Ched: fur 24 VAC ibetwefm tht!rmostat wire nut! and gooUDd.
CheCk tile tollowiiiSP
1. Wlreoonll.ectoH tooon110l modnle are ~y plugsed In at module aAd otlgln:nlJIS
eoillrOL
2. ~tomS;Ul'f! swlreh bMeS al'l!! ptopedy and serurely plugged In aJ'Id are no£ dam-
3. Gas pte!liiiiJlFe&::
a.. Wieh baUet CJff- ll" w.l!. m 3!dmwn llatlltal or prop:lfte S*i p~ upsm.am of gas vafve..
b. WJCh baUer CJn:
•
5"'w..c.. ml:ni:mum n::ttwalgasp:re11sure or 11"'-w:.c~ p:ropa.ne ~raspn~~5UCS
upweam of g.u va!Jve.
•
3 ~"'w.c;. mfnfmum rununl ,g;iiJ pn!IIIWI! or 11)" w.c. propa.Dl! gas prm!iUCS
dowmtm:mJ ofgu vllw - Cm lbe adjl.lBb!d byregubtor on ~valve.
0
oler-
DC
llb
aller
anual
Troubleshooting - components
Troubleslaoeting air pressure
reading
~Cfteck. pressure switcft
setting
See F1gm'e 3l.
2. .llei'DO'IIe both adr prestS;ure i\f'Jteh hoJe5. ftom. .air
pMHim' awUth
3.. Jn1taR rees: and tuMos .u tb M~n~. lD Plprre 31 to
:ll'ldlfied Mlt'l€1metet'.
4.. 'fum oW psv:dveomd 5lel dlie.mtosr.at to ea:ll ~r hm
JodDOer will i'W'I. but bltmel:'!l will n ot iglllte..
5.. Cbeokfot2d. VACbe:tween both :af:rp:ce&aure switclh
1.
Wmina:Ji.
6.. If f:'IWiometer teadlng is ahorwe the ~nt flf dl.e
sw!mh. bnt tbers l& not 24 VAC betw~n beth alr
pi.'I!I.1~Ul'e
~ltdL
p,__.....
L
S\tllrffi temtlult ~
:replao!! .air
~
MIPOint
Thi! air pl:"eS1W'e Mllltch d!.oo.1d drop out wllm the
PMH~m' :liel'Oft ~JWI.tm ~rats
L U maoomei~ ~lng ~s 1 ~ r.b;]JII tbe ~erpoilfll of
the tw:lfdl.- diect fOr _pos$ble c.ausa:
•
blocb,ge In liMe~
•
ollstruetiao In Jlldueer 'bowing ou.tf.et
•
loose IMucer wheel on moror L'lllaft
•
lntlocet' moror n ot in [pfflpel' rpm
•
jntlu.e~ bad: pla~e not
•
b!lockage .m block 85Sellib!y
•
bl0cka.ge :£n flue pipe o:r 'l:e:mlfulation
•
iru::orreer pressure Mllltch
5Jealed _propet:iy
di;Ul 1 .53. I:DChes: WL
Return to ltOI'naal operation
~'ihen _p~ ratUng tltiXil'fl!lCI: ;]JIId alr pRM;l11"t!!iiW!Ub
l.sopetaling pro_petly- rentfM le!es.and reimiaU hooei
to air _pte~~Sllt'e :s.wltdl.
wm
Tile b oilernot operate co:rt'eelly Uf'lle.ti IPI:'e$Slbi!' sw.lfdl. llioles
ah! corrt!W.' ~located. The red hos:e
coor.ed~ from llle fight side ( t'li?Satiw) llao!ii!lbafb tao the flue a~ 11«itof.
The wlllte ll.ose eonnects fro m d1.e
left :side (pooltl ~e) bos:e barb of d1ie
sw:ltth to the m:nrteciM bQI: (between :fl'ue collector :.m.d iod'tK'e~
;as shown lo FlglllfO a
Ambi e- nt te-mpe- ratuMB.
. . ..... swit~
_ ch
The .ambit!rtt •empe:rarure i\'ftrc.b w:IU!i &no the holler
limit dremf.lf the tempe.ratwte jn me vidltity o f die
M¥11dl ~s: U59 1l. the !Witch will d!ut down the
b oBer.
If die i\'fttch dluts.down tbe boller~ehed tbe :rea1011. klr
the blg.h 1em~l'l! lB tlle spu:e.. I~ tbe sW! of
me \~Jibtlon air o_perunss jf f'leo!Bll')'-
a
llb
-Fired Water Bolle - -
oller Manual
Troubleshooting - components
<canii.-.,Je(J)
Contn)l medule
I(J'R&f
Make ~ure ground w ldn;g is lru~lled pet wlrlatg
dlfagram. Goad groundl!ng is mmnely hnportant fu:r
~ oper;rtiM.
ContNI Indicator llaltla LOCKOUT mo*•
See ct.d.. 't thmugtJ 1
d!aoling pcoc:rdwes..
m this Hrtiqn f'w debil.ed lroubl~·
'lb n!M!t .::octm1J attu~:Ltl:x<lrmut. tu:tc cff~ at 1b~ l l!Q "'..C
savii::'l! $Witcb oc turn down all tbsmastn~s. Wail.tS S«<jnds.
'l:h.e.l restwe Jr""''iRR" o:r w l t'oc but.
POWm light flashing alone
tlAL111y·lcdtcil:~• ~ pDhr.ity of l20'VAC powervri'r.&
POWM and 'HU.ilT OIRC [girts fl!Jahin9
t,:lswfy iocfialles strwr"'~~llll¥ oc edl!mal th.ennosbt circuit
vi~
(cs!UIIf d~~e to m iswWd. 3-wire lOIIe v.d\oe)..
a-wavvatve
The ~way valve miUrerts waterftaw :In tbe d.roult.
Nancallytbe valve~ water to :ll.crR tll:mugb tbl!
t.,pm 10 malfitdin !lie liMt in itlll!' boi:lt!r for th.eo tanll!!!Si
hl!u~. Tlie 3-way' YoiiYII!! le-ift' is up in dil!' :rwwmal
pacitioo.. 'Wben the beatingllfil!l'mostat tidls for list,
dil!' 3·w;Jy vut..~ ~r l~r droplli which allows 'Wl\U.r
to :lkJw oo tbe ~ heiltlng &'j'81ETh Check fur proper
3·'1Ry wJi..e Oft!DtiMI a.t follows:
Tanllr:ss optr'l\t ffis. limit cal lor be~r. bo:iler f1lrti.S <rn
POWER and MESS SWifCHiighta flstlhing
t)su.JIIy i.n.dictts p.ressure swild! is ci!Ued 'llfl~c iJ. sfmu&d
not he.or pHSII1I"I! switrb li1kdl to dose wilhic 5 miiXIles of
iodmoer mrtins.
P0W£R .an-d FUNl! liyhts tl:Jshlng
tlAL111y mcdlcates iiD.Is.e &me 119Sll! or &me II!I!.D- i ...men Lt
d u:ruldn•t be t.h.en!.
Control Indicator llaMa. NOIILOCKOUT mod••
POWM light on end nAMe light flaming
~· iodlmts IJnb &me w.uo :oot ed.1i.hed witblc 1:5
r«<Dds W:m 11,p,piX:uti:on of~. Co:utrol will illub ~hi. but
will co:utii:me tm ~Le ~o.d.e:fioltd'y u11til itune is eltilb'II~dor
problem u mrm:ted..
POWER {iglrt on and PRESS SWH"CH {ight flsshin.g
Usw.lly in d icles pre15tUe .-ltd! o p emed. dmicg the
qde.
ri1Jl
Tn;wbk•t.ootlbg theo oOIIII'ol moe~•
mr
See IFJguare ,5, page 48.
loc.uioc ofbameu plug rccq~ •
mcb s =.d pi!~J~~Im abe a:mbtll module..
wlien t~pemhm! dropi ~ro.Uiiliitdy 10 ~
bdtJ.w tln1'kleu limit R!ttinS; (differential.). Boil er iib ul!i
oR ..men temperii.IJu'e :re;;diet; tm kleu limit ISeUin&- '11'11!'
3·'1Rf vah-e lever &tay.S up aJl dwjn8 domeitic h.mtiag
q-dL
Sp.ace 'beatinfSilhslil!M'tat at!ls lb. lH51t. 3·w.ay Ylih-e le!fer
dTBJlG and boli.Kfir619 pco'¥J.d1ng ~ hGJ:.
NarB : [fthe 'OOllet't~nre dmps below mrildets
limit IW!tting :nUmu 10 d~ difJ'erQtial. dlil!! 3·way
v.tl'lll!' le-\w w:iU mil!' 10 refil!'il1 bailer- to tiJlkless limit ~~~et­
tintrr Tben the 3-w-o~.y v.al¥e le-\-er wJU drep at~d b oilu w:iU
:rtJui'lie providing s~ 111!5l.ting untJ1 thu.moulil U. satitfied,IOOJler Umlt lll!ttlcg b !f.'e'Jl(ibed, oi tempemtwl! :fn
boiler drops 'bc!ltrw tmklw l.lmit s.e~ting minw 10 ~
di~ L 'lkrify YoiiYII!! c lrustilled and wi:red ccwret::tL
1TafildeiS lbw Lir'itlt t31 .frlr he3t. but bul.ler doe!: M l
turn on - Cl:tea pmwr oo 3-way '¥-alve and Vlll.ve md
S!A':Itdl.
Ta:nkles$ Low limit ealh fur heat, boilet llll':iUon, but ther@!
is nm mougb d.omestk. w ltEt s111ptiy - Cbedl: 1-way
valve. It MAf be iSU1dc: In iM IJP~ heati.n' poi!ltion.
l1'1ermOUIII. cals ior ~boiler lllr:ri:i 01'1, but t1Jerl! a 1'10
:!low 0flooot water to t!be ~pace beatl:ng sy&tml - Cb«.k
w.'belher- 3-W'o~.y v.tl~ U. stw::k In domestic: ~ter be at~
.,OOtiorL Verify d¥1! is insttl~ and wi.n!d awrcctL1-
Fir d Wat
llb
Troubleshoot~ing
r
aller-
j 0 + - - - - - R.AME
J! 0
PBI!.SS SWimH
~ 0
UMIT
~
anual
- components (OOitlinued>
Fegw. 3!i Oonlml module ec~J"'fttidlons
l
aller
=RCIHC
H itP1 'I'Obgl ia spclllllllild:lodll
UIVACto~-
a
oller Manual
-Fired Water Bolle - -
llc Troubleshooting -
control module nghts
CHART 1- Troubleshooting POWER light status
-
U:sually i n~ ~ 1:20 VAC pafiarity if POV'IIIER li~ flashes lhy itself -
EJecbrical !:Mat hazard - Whel'eli'ei')!Dtlsee .& TURNOFF POWER.1o.. ful low iheins'lructi.ans... Failure ito fellow
insbuclions roukl rest£1: in sera'e personal if9JIIY. dSafu or substamtial property damage.
Is POWER fi;Iht o/P.
..
Yes
No
,~
Fla!:lling
alone
Is P<MElJi¢! - ·
Aa!:llihg \with
anotlner light
On steady
(noC ffasllling)
• Mak_e swe '5e1'Vice ~
or circu:l: ~is on or
fuses are good.
• Rel'll'lllle 1120 VAC IN plug ~fili!JJre 35. Item 3, page -48)
on CJfltn:li111'Dd e.
• lkimg
meier, dledk acmss top and boftom pims of
1:20 VAC IN pi~
Doe.5 '!A71!mefef li'nficate 120 VAC?
1-
Yes
No
~
TSTATCIRC
Chart
19tt fla!sflimg
2
,
PRESS SWITCH
19tt fla51li111Q
Chart
Chart
3
5
RAME
Chart
Chart
4
6
19tt fl.a51timg
Prnlllem is wTI:h inr:oming
electricity. 1-hve ooeused
electrician repair circuit.
1
For instlffiaBrt heat or no he.al prOOIBm.. go tiJ
Chart 1. pageo 55. if POWER light L5 on steady.
wi1h no other ligN Da!hng.
~
• ReoonBI!!rlt 1L0 VAC IN p1Jg.
• Rel'll'lllle 1120 VAC IN bansfmmer PRIMARY pkJg
(JF"~gure 35. lfem 2. page 48) en oontro:l module.
• Usimg !a~C~trneier, died aa"'5S top and boftom pims of
PRIMARY ~le..
Doe.5 '!A71!mefef li'n:licate 120 VAC?
Yes
No
• USually fidicates pcmrit)' ·on iJICO!Iliog 120 VAC JX1M!I'
line iis wroog.
• .& TURN OPf POWER• a.ti sel'llioe Slo'ritch or J:ue.ak.er.
tl!len reverse e HOT and NEUTRAL r.oiJres Etlfeting the
bOC.er imllhe J-bmc.
• Resi:«e POWER at service swTI:o::h a beaker.
Is POINER ligllt lashing now?
Yes
No
*
RepE:e OOfil'lro) mod!te.
Ret:!st.
,
• ReiJISI:all1120 VAC tr.msfnrmer PRIMARY p lug.
• Rel'mlle 2,.t. VAC transformer plug (Figure 35:. tfem 5.
page 48) on 00111trol rrnodule.
• IJsirlg laiOitmeter. dlect pins of p\lg.
llbe.s~~.UVAC?
Yes
No
Boiler sl!lould now
opera'le ooJm~-
I
~ sysitem r.ltedfed by a
lioensed e)ecbicien.. If
prdllem persists. call yoor
local WeiJ..McLan sales
~l:afive..
~
Replace r.ans-bmer.
Re1est: .and dleot far baclt
feedl d vcltage
systEIIl \oriring.
rrom
Replar:e oonfrol mcdllle.
Retest.
0
oler-
DC
11 C
aller
anual
Ttoubleshooting - control module lights 1oont1
,CHART 2 - TSTAT CIRC & POWER lights flashing
Eledrical :siloell hazard - \'Uilerever rou see- '!il URJ\1 OFF POVt'ERs, IOIID'III' tile illS1ructioos.. Faiklre to W aill
instructions could restdl in sev ere persooal injllry, death or sll'bs1arrlial propl!'rt)' da:mage.
• OisCOIIne.cl: '!he- two external wires 0011~ to til e bcler
1nemmstat lead!:. (two blad ID'III' YDitlige fead's, in J-box).
• If a woltaiJI!' does ocror 111tder iii"'Y' oooditiDIII, chl!d ai'Mf
correct tile external m~
• Cooned a orottmeter acros,s, ~se ~w o inooming nes.
Clos.e each lilennostlt, ;mne va1we aJld rel:if ~ 'IRe e-xtern~
c:irou ooe at a fime. and cbed tile \lnltmeter rslfil g
across, 1he wires..
•
exlerTEI tllenno!:k" eire: Wirill!J is cheeked aoo
if nece-s:saJY. recormect e e.Jrtemal tRemlosta1
circt!it wires to the bailer lilermosW wires, and aiiD'III' ~
boier to cycle.
0~ ~lie
co~
• There shoold 1'4EVER be a vdHage reading.
• leon•e e.Jrtemal boilertllE!IITlost al: COIIflecti:on wires
discoolledl!d ·rom bailer.
• Troobleshlld 1fle external lile~~ cin::uit until ,.au find
1he soun:e of lhe siray \IOita.ge. {Pil)' dose irltentioo to
the Rinll cmmeclians to 3-wire zooe valves.)
• Com!ct he prnblem and rej)eBI: fue \'lllltmeW ~~ abclve,
'Veri}Wlg til ere is. oo lon!;E!r a 'l(lfl:a~Je readi'n!J Wlder aJ'IY'
cooditioo ~ lhe external tt.ermostat ciraJil
• An
isol~ing
rela,y may be requirEd
• Boiler s.floidd nail/ opera1e per e nonnal s.equeoce ci
operaman shCtKll ~ FigurE! 28, page 34.
• If no wolt:age is faund under aB)' co ltd ilion of !:be external
fhemlosta1 cireuil coiUlect the 1wo biller tllermosk"
oooned.ion lead's l:o!Jeltler (or~ mper • e l10ler a!F'astat
T-T terminals).
• TIEl off pcwerto e bo:lerfur 1 mirru~.
• Tum on pcwer iilld alkM bcliler 1D cyc1e.
--~_____N
_o______~l ~~-----Y~es------~
a
11 C
oller Manual
-Fired Water Bolle - -
Troubleshooting - control module lights (oontj
CHART 3 - PRESS SWITCH & POWER lights flashing
-
Usual(¥ indi.:ates pressure swftdl stuEk closed or f.ailedl to rnake·wiDiin 5 11Untde5 -
B earical shock hazan::l - Y.~e~ynu see .6TURN OfF POWEIU., fcCcw 1be instruclims. Fa3'ure to fdllow
._____ ___. in5'tructions. ooUd lreSlllt in severe persooal injwy, dealt! or substantial prqlE!rly damaue-
. Reset boiler oootrol b,y rurnlg oif JIO'Yer at service 5'Witm a turning c:bm
. TheJmo:sliil: shotldl
~tit for at least 45 seconds.
for heat and ~priale znne valves. cpen.
Doe:; iJooU;oer mOO:;v- opera!e?
Yes
No
. 'Wait 45 secoorl'!i.
~
~ irDlcer rmkf:qJE!ta.fe?
Yes
No
.
.
•
Rermve INI:IOCER pklg (FtgLU<e 35:. Item 6,. page 48)
from pii!J{I recep'lacle of con'lrol rmdtte_
Place vo'lt:mets leads aaoss th.e 1L0 VAC N amd
t20 VAC H ~ of the INlUCER rreoeptade (11:!11 c:Diumn
center and r9lll ooluJm bo'ltom pns).
. Wail 5
!
rrirruii~s-
Is PRESS SWITCH fight~
Yes
No
Does the w.Qmeter indicate 120 VAC?
No
Yes
. Try reseatilgl plug in
.
.
rmdt6! re::eptade .amd
restart
If indooer stil does not
\mrk. n:place irlducer
assei'OOiy_
Retest
. Rermve one ,cf the wires oonnecled iD the pressure
. swlch.
Check oontirUty aaoss the switdw 1BrrniRals.
. Boiler shotd'd be im
.
notmal operamng
sequence.
Observe cperafioll'l n l
themnslat is satisfied
amtl indooer has
c:xxqMeted ik ~r.ge
cyde_
Are w;nf or ~ air
~b.!Ooked?
No
II
Yes
Doe.s .t he ohmmeter mdicafe the .s.mm is do.sed?
No
!
. Replace oon!R:ll
.
~-
Retest
Yes
. Cbeck :;D
.
.
l
~ swildl
per IJIIaiU3I Secfxxn 11 •
page46_
Rep'laoe tit neoe55ary.
Retes;t
. Clear passages and
recycle
. Redleak
boiler cpemlliL
tx:Qrr_
51
a
11C
-Fired
ater
oler-
aller
anual
Troubleshooting - control module lights 1oont1
4 - FLAME & POWER hgh1s flashi ng
~CHART
Ele~cal s1Ttook hillaRI - fttl~ )IDU see ,.lURN OFF POWER.A. lrolrow the ins1ructions. F.alu~ to kCi
....___ __, in!itn.Jdims rould n!S'Uit in severe pers~Jnid ~ry. dead~ ar substantial pcpeJtv damage..
Are mar:n;al main s~Ud!Yaw and gas~ c:p!ll?
I
Na
•
. l.ea.'i'-e miDI
.. Tum flffpower i4D txaer atvalve obsed.
sw3ch or
miDJal ~gas
'Sel'll)ce
Yes
.
pxrwerto Die bliler at setrTi.ce
a- beakEr.
. T atoffreast
45 seccnds.
.. T oo powerto bo:ilef.
Restart bailer. follow:ng Operating in!itructions imt1i5
mamual (Sec£10111 9::).
. look hmtdl 'lhe p:iloli inspection polft to see 1he pilot is
~-
m1
. Tum ,on p!WE!F o lxiier.
mting OJIH!I'Ifing ill!ibuctians in lhis
manuall {Seclioo Qc).
(b FlAME
buning dumg he prepurg~ period (fi~ 10 s.ecoodsof
oper.r{IOO ).
and POWER fghf.s stif lash?
Nil
gWdJ
m1
Wai~
~Vail: a~. least 45 seoomds..
. ResiJalt boifer.
~
Is pilaf fii:JmfJg dt:Jnng~ peiod'!
Yes
'
II
No
. Replace aom1ml nvJdule•
. Re1est.
. AIJ'ow boiler
~o
oontinue c:yalmg .
AlP RAilE & PGMiERlights~?
No
Yes
+
+
may maw be . Replace oorrbtil
. • llliRN<Ff POWSU . Boiler
oper.tilg
modu le.
to boilEr a11: !iE!IliiDe smb::b
11001181y.
breaker.
. Retest.
. orOpem
main rrarruaJ gas
.
varve.
procedures in
. Tum
an
lD txaer
lloi ler llliD.Ia.l to
,~
Perfatms~
powe1r
at senlioe swi ch or
.
.
breai:etr.
Rest<ifi OOfer per I~
insbudioms..
PEifcrm staJrt-up
p:rooedlr;es in ~ f
manual liD verify pcper
operalioo.
52
'IIEI'ify proper
oper.ticm.
. RepiBce gas 'IMiNa
. Retest boiler•
Yes
'
Ale R.AtiE and POWER tiffis ~
No
Yes
~
.
. REplace+oomb:dl
maw
cper:crie I"'CCTTliilly.
module.
.
. Re'lest.
EDler ~
Original~
FLAME ght
caused by ~gas
vaNe not
cper.ating properly.
. See normal
5eq!Ent:e of
cper.atim,.
F"~gure
28.
page 34.
a
11 C
Troubleshooting - control module lights 100111~
CHART 5· -
-
oller Manual
-Fired Water Bolle - -
PRESS SWITCH light flashing and POWER light on steady
llJISUi10y mr::fic:aJE!s JIR!iSUil! S.Wllc:h opened during nm &yEfe May·11M be eau!i!ed by wind IJIS'ts. in excess of 40 mph fer n.on-din!ct ¥en~: sidewa'll->t-ented boilss -
Bec1rical stwdk hazalrd - \f\.'hefelter you see .A. TURN OFF POWER .A.. fujJbw llhe instructions. Fail~ to follow
instrucf:ans IXlt.lld ll!S!.Jit in setae per901!1al injury. dea1h ar SUbsl:antial property damage.
. Reset lriler oontrol by IBiing off at senrice switch orluming down 0ie1mostat for ali least 45 seaonds.
. Thetrmostrt shm*l c:all b hea and appropriate wne valves •open.
piJWI!tl'
Dbes' ~ower ll'Jt\!or opeJa~?
No
Yes
l
l
. Remo\le INDUCER plug
35. Item 6, page 48)
from plug receptaa::e of aoofrol madtE.
. Place w:1metetr leads at:rnss tl!le 1201 VAC N and
(fi~
1t20 VAC H p3l.s ofth_e INIIlUCER ~tlde (left column
cents- and r~ c:dlJJmrJ tdlnm pD5).
. w.w 5 mnutes.
1.s P.FU:SS SWITCH light ffa.Wrtj?
Does the~~ ~2D VAC?
No
I
Yes
. Replace i111ducer
. ~·
Retest
I
No
l
Yes
. Boiler should be in
normal aperating
. Observe operation until
5eCVJEncE!.
. Remo\le one ofthe wU5 coonected tiJ the
p.ressu~
switch
. Chedk
ocn'fiooiy .aao:ss 1he switch terminals.
Doe5 the ohrlrmeter i1dioafe the .s.wmh ;,s clooed?
No
l
I
lbenrnos1at 1s satisfi ed
and inducer has
oorf1lleted its postpurge cycle..
Yes
. Inspect ald check Mre
.
.
harness from OOIII'lml
I'Tllld11le to pre!SSI!Jil! switdL
Resea: OOOIIledCI' in cootrol
IIT"'Idllle Jreeeptacle..
If harness is · jacl: and
propedy seated. but
problem persi~ rep!aoe
oontrolmc dl.l!e.
. Re1est.
#.s vent bloclcecP.
No
I
I
Yes
I
,
. Check ai'
swttm per manua'l Section 11 b,
pageo46..
. Replace if necessaliY- Ret!st.
JlfieSS!.Jil!
.. aear 'tlem and recyde boB .
Ret:hecl; bailer •opera[Xlfl..
53
a
11C
-Fired
ater
oler-
aller
anual
Troubleshooting - control module lights 1oont1
~CHART
6 - FLAME
l ~ght
flashing and POWER light on steady
ALSO- TroublesJlooting failure to establish main flame
Eledli~ shock ~-\i\berever you see .A TURN OfF POWERA., fOllow ire in~1ruclicns... Fa ill.ft 1D
ins:ructilliJS ooul:d resl!lft in 'seYECE! person ti¥J:y. death or stmstantial prq:M!rly damage..
. Are
rnalll mam&l ~...aM! .allll boiJoi!r gas v-al\!l!'tipa~~?
Nil
I
I
I
.. •
EiEMce
qRn main man!B si'Rrlolr
!Pfi
lnafrudlam lnlhrli mam.rat). \\'al1
. TUm
.al! a:!IVIce
AJGW
T et>
1-
rl•
.
.
.
I
~ ,6flollld be In
. \ieftfy InlEf:
~·
ga& jl'eQ!Ure
.
ali ga&.
pa - SJJ" w..c.. nmr14R
w.c:. rrm:
t5 gas ~{at gas IVa.~ kJ1e1 and
Nabnl
c:tl6eJve apetiilon
unll rther!ms,.tJI: 16
!ii!Sned arulllla6'el'
po&t-purge c.yt:Je.
.
at
llreaker.
. Rsna\!1!' oomer
Yes
I
.
Yes
I I
~ottU:e
•
~
(&ee
~ cg_ham~ page 0'0,
b~).
i
qa6-IJ1e'IIO not
lt!BI. ctJslr:l\dBil cr
~ iWII6 oonedly
wre- 9tJUldl wre
mOOJTbol n:ooule l'l'lCJUnll ng
.screw.
No
'~e Wklng D'00111te
!
.
oori'Jal ll'IOI1le ~ !J36 .
wl\ll!' Is ll'flild. ~Ute
oori'.roll mol1le.
ReiBst.
I+-
~
Olleck 1ne \~ aoJQ55.
1Emtn.:m MV and PVJMV or
1hega&~
1.5 U VACpm5aitVIel'co'?
Nl:l
Ye6
I I
!
1f
. Oorti.aci: ga&
ts gas ~J( atga.s rar.'lll? tft'et arid fl\mlfll! abof.oeo ~?
~ &! oorii'E.'d
~Iii' ;a& &IJlpfy.
.
kJ
a; .semce
or llreakt!r.
. R.Emc:J\Ie tuner :etrerd tsee
&.l'URN OFF POWEIU.
6Widl
~ ST_Imm 4,
page M, 1tl'
~~anlltipk
it.tadl.ec:J 1D J11Dt llracle'l, ~et
+ &eanfV
. '~Jr!a'fplilt ~ ~ . Vert!J pilot oomerlls
R!p!ajng~Df:ll"tuner 17
Retlslillllltmer ~1D
~boiS' tu ref.eot.arter
<Ill)' dli~f9Soroom!C'Joos.
mE <"lil2 iDJI.'E! OOftEoCis
Jm'blemll, then~ ile
mrttral rn::D.1e iiM ~
16- &eCUR!I)' ~ b:ll:llt& lf.e.
ami there 16 no OOil'OEib1 oo 1he
parts !olltllch would aii'Ed: ~
!J(Il.lnd pathfOf ISme &ef18E!.
. \leJtiY ttat pilot
1bne> rod. C<ll1l2
riXil tlE!IilliJc and feadJ r.Ce 1'tool
cmira:1 mole 1o·ll8me llld are lin
. 9000 W1dJIJoo.
a1\f aiXli.!e> JXOl'fSilS.
OCn'e.U
~ng ~ lltlmerCf'~
16-Bnaged.
f4-
Te&
NO
. ..t..lU!ia\1 Ofif POWER.a. b:l boller
. OhBk 1\ame! Slgnal - De1iHlh
IDler
lcca'too~
.
. lo\H"g 161Bnag!!d.
ga& ~ ai: ga& 'lo'a1'te:
NBhlral gas.- S..D'" w.c. 1'11h'14..D'" w.c. max
~.arneo bJ ~ an:l ga&
Wiltrote..
leiid'L'tfiE!ttumcmhll <11!! In
goadcadtkn Sp.:D gap
SfloUdllle~~ 116"'.
CCIN!a arrt iiiJolll!' prct~Em;,
I
'IEmt'riaiiS ~'l'iEtefled
J\!iUVAC~~?
. venry Inlet
1\10
I
!
A TURNOff PCJWfiU. fo
boiS 5eMDe ~or
.r
.
QhBk 1ru:! 'WI~ acms&
l:fmfl:lals. Pl.#'.ilfilj PVI'MII or
~ abO\'eraJi.~Je ?
has~aas.
. \i'el:l'YIDf;
-
r-
~
normal cp:>...Iil".flgi
.
Yes
I
•
Ye&
I
lhe i!JiiS~
Doe\5' fl.AIWE N'f/!'lt :aam oow?
INO
IS. J:(lot bne 'I16IJJe ~ lnlijleCI!on port?
NO
6.1URN OFf POlliBU. ~bal er ill:
Bll'ttcll ar tweaker•
~ and bcll:r
Yalre {P=r
~g
~ ~~ ~ ~r;m
Eel jpi:M'Ef
.fi'Mtl:h €II' ~r:
l:o:J.Hlr ID C)-de
ow
!
at~ s.t11Isl Cl' llreetEr.
&ef18E! leai:!l ifram I!J1llon oontrol
f1f
(R!J'tlr& ~ illBm "' page 48).
COfV"'E!d ne,gatlwl< lead cr MICROiii.WElER ~ oortrn1 sen&e
.
(RgU111·.3'6..llMI>B;
Cl:c1nei::t po6l1ve
MJCRO.AMMETffi ta
lo\1re..
.
r&d
cmneel:ed 1o
a1'1he
~~
IEm1llal
feadl
ar
&enSe
DISCX»>NECT
~ MV
wt'e
ga&
wl\ll!'.
. n.moo
~r to baler iiJldl iiilkJw iiD c.yt:Je. As~IDI as pilot 16OOI'I1l'l9, 'lhe ~R(),f!,_\UI.ETER&llt:Xm read a11ea&t UJ
~·
-
.
fS l?ame #Jl'lel at leimf 1.0 rn'i:mal'lfl?
Te&
NO
·none or 111e ~ 5IEpa
~ repladng J:(lot)
Cl:lR'ed;s pldlllem.llen ~
111e am1m1 modUle. rel\5tal
oome.r ~ .aoo re!e.&t
.
"'
lrthe Ytfmgifnlm fhe
cxmlrol rrui\Jteo to gas
vaJwe 11s litact. replace h!o
OOJTbol rm::lule iDII reiEst
OLD
a
11 C
oller Manual
-Fired Water Bolle - -
Troubleshooting - control module lights 100111~
CHART 7 - Insufficient heat or no heat to system (POWER light on steady)
Electrical shock hi1Zard - \VhE'l'E!Yer )"''U see ~ TURM OFF POWER .A., fulcw lhe instru~ioos... Failure to fullow
instructions cooh:l ~su in severe pel'!:iooal injury. d~ or suils~lfal property damage.
. Har;_nbeen a11ea&1 s mlnu!e$. since setung lt.-err-..o,shi1D call1iir
• not. wall5 mlnut€5. to. sy.&'l:m 1Leatt9?
. teat?
• lt..en:: 5'\al:5et to ea11 or eat? Rem
erma&1at lo\'ler; .at
I:!: ool\:or sysam
r-t'
boiS .artd d".edi oontlrtctty aoross Ute lin wm. If circuit ~so'!:
do sell, Cheek exlemal•hermalil:at (ZoJie t~al'te. I"E4i1!J, Ek..]
.
w.mg. OIIIU!Ill pro'blemr;
. Reoonned
e.JtEm;;IJit..Ef11100!a1 wlrtng,.1 barer.
and~··
I:!: ii:!Jennlmilf ~ c.!ru"l?d tc;tma'lu.YV .ac;ros.s: IA'Ao:ssJ?
No
Yes
I
No
+
I
ar;tat
Yes
v~
•
I
(31f1Mr h~;;~~
*
Re~lace oontrol modufe.
Relit
•
*
•
•
1!~t
.a ID'IIIng water lkl re m lkl
lboDcr D:o m the &J'Stfa. tr rtdi
refliee .J.IN.ay actualrlf.
re 1.:.
lio l ~ room temp
~DO~ Check air
<q>er. n;s.. Add alldiUIIflaJI
oper. ng.s tr nee:Sell to E£il
IDOOl tempera re Wllllln
mftFi.
•
~epa.el!> eonmJI
*
*
Retest
moo.u:e.
m mnr ~~'lB~
'Anl!d?
No
I
.
Yes
+
. lll&a Ched; .r;e1illlg21,oo mltallm
allav.e 14D'IF.).
Cbfdi IT 3--Wa!f ¥al\'e E.
:e.wfim. tr millh ~n,
·r ID""er
l!cden r.ster ile::TI%1ellllure etmee:le:l 21Dng on
m ~ !>ilotlch w lh Ill~ .;~~ U ~ 1/;lr htl!t
Boili:r i!. OK 4S&e rtllm-al ~ Cl'
~ llli:m, till~ AI
t
•· Ched amtrsrl:temperat.J"e>
•· Ched; 1:1: Filo\~oor~:.
wllll oonl:lnuii:'J m eeker.
Are n:mr ~ mr:Ltaa:s Q'Osfd?
I
Yes
...
.
Uen ter-tJera1llre :se1 em lim I ::cw l:ta.
Slo\
...
1'40
•· Ched hea1 b=..s ea.llllllat.oJl
't€fliUFi boGer SIZe.•
Clock gas ut
• 'lr.U 10r I)Q]er water _to eooJ to ~l!mlfERtl» :m ta JO
.
No
rs LIMn figM an?
Yes
• correct oonmaanr; an.CD
~Ch~k opel'iibnn.
see flU Oil! n . page 34, 11lr
00
e.equen ce all
G!llera'IOO.
. Re111ace It: '
. utes...
I
1'4o
!
'" ~ete w11fn!IJ-
R~.
Retesi.
I:!: ~p.Q""Jg ~ DftA'Gdagl??
.
r. Retest
Ye-s
21, pag2 ~-)
yoo ha.Y.e ler;r; ~han sumcsrt h.ea1, 11ITit Ched; J-'lliiY vatre lkl
be &'!Ire 1 rs nol a:mr~ 1'low ro ~ankless. coli. IT :J,-wa;/ t~al\'e Is.
suppJjlniJ ~ oo ehed; tar. ler;r; mtt to 1!112 ml'l!' It set
~- If 3--ratfliaJ\le .arull Bl'l~ h~r 11M lmlt a.re set
311d cp€fil!ln!J1 ~ -
I'W
•
~liee
(3'
Is FLAME l¥jht oo?
F~u re
.
.,
m~
• 11)'0'11 ha.Ye r;lllm:Srl: h.I!G1 - Il<lli!r mnul:llbl!' In oonnal
Of!i!r.. 5equer-Ce. (Se~ ool"r.lal ~noe oa opera1oo,
.
Yes
R~etXi:tml
. \Vait 5
i
Yes
Yes
~m~We> CIRCULA10R l&n.ess. p(ugl'nlm
CIRC'IJLAiOR p[U!JI recepbde (R:gwa !5, ilfBm 1.
~ 4<1).. Cbelll wltll t,!llrt:neta' acro:,s. plrts o; oodral
collule receptacle.
lJro!!.s ~ NxiW i20 VJjC amw: pJ.'lS?
Gf
Are aJ lli!i:l ghts o:E
I
y
1'4o
operdc!n, fiUllnl! 2S.
p3gi!'M.
Wii Jill .ae:ooll Fi.
No
t-
.. EklJEr ts ln lil:anQ)'.
s.e11h erm
ro
anll reltlect opera,'lml.
. ssqusace
Are aJIIi!i:l gh.ti o:t?
mJI.fa1nr o,peraii!J,g?
No
!We
[II. ~ - ~
[&h.~ be
II
Yes
I
CJ:Jea I'OI'ftlut :swK"" c:nr...'"llt\'l!f
1
Repla.cl!' rolloo~ S'tri!ch.
rt-.n!1'ntt~:l
II mlknrl: thermaJJ'ItSe ~nth~
opened~ o:e1ermt.e caUiiie .and cmed
oo rtdlla IlL FaJ lure nrd o so I cause
se~tere per;;;ooal ~ry. deaJn o:r
r;u~tait.l prolfer rdamage.
rs m~m ~I'~Med?
No
.
.
II
r
Y~s
ctA!cl: <illY o1h er lmlt
centro 1:. wlli!d lntc
the mit ernul!. tr aJI
are OK, 1Jteo repllel!>
control madul'l!'_
Re12&1.
0
anual ~
DC
11 d
Troubleshooting - common problems
eo................
C...•on C.....
Rapid eydlng - Wl'l"'i&f
Tnermostat in:stalled where
Lo~tat'& ltlerrnostat on lrwner walll
dralls or 1\era.t affect reading_ away from heal soorees: or eool
draft$-
turns, on Qnd off
k"equenUy_
PHelbl• eon.otlont
Heal anticipator In
1helmostat adjusted
lncorree11y_
AdjiJSl neat a~tor 10 maten
eul'll'em ct'aw_ Refer to boiler
lnoorrect ni!Jh Omit selling.
Have quaUfled SEJI'llfce
tee~Ydctan nerease lrmtt setting
to decreQse eydlng_Maximum
~ diagram_
setting 220"F.
Need 10 frequenlly add
Leaks In boiler or plprl'lg_
Have, qualified service
teel1nictan repair leaks at once
to avoid constant use of makeup
water.
M neral deposits rn sections
due to oonstant U&e of
Have quaUfled SEJI'llfce
teciYdclan repair leaks at oncze
to avoid COII'I$tant use of makoop
water and c:he<:;k pH (betw&en
7_0 and Et§).
~water_
PcJt:lping or peroolatll'lg
noise neard rn boOeli"-
ma.ke~
pH_
water, or rn~t
Btack waler oondldon.
Olcygen Q0(1'061on due to
leaks n piping_
Have qualified service
teciTIIcla.n repair leaks at once
to avoid constant use of makeup
water and cheek pH (betw&en
7_0 and 8-Sl·
Frequent release of
water tihrougn reDef
ExpartSfon lank :slz.ed too
small or water-loggecL
Have, quaUfled SEJrvfce
teeMJctan eneek e:q~ans1on
tank operation_
VSIIV&-
a
11 d
-Fired Water Bolle - -
oller Manual 1!1!ll!lll
Troubleshooting - common problems toonllnua~~)
Common Prob"'
Common c...-
Metal Hakes foul"iddln
fluewa.y.
Contaminated combustion aJr
s~·-
Po..... ~
Remove~& of
nydroca~ns In or near boller
area (Biaacn&S. d&anars,
d'lemloaJs. sprays. fatn::
softeners, pafnt remover·, ete.)
Condensation o1 QOI"'''busdon Have qualified service l:edvllc:lan
check boiler opera1ion.
oasesSome~or
...,,ts
baseboard
do not
heat 01 are noisy.
Air In system.
Bleed arr from system tnrougn air
vents In radiators or basetloard
units.
Low system pressure.
Have ~iRed service l:edvllc:lan
d'leck leaks In boller or p1plng
at once.
High limit set 1.00 low.
Have quaUJied sewice tedmlc:lan
adjust limit to hlgner se.tllng.
Domeslic waJ:er from
Mineral deposits h$1Aate
lntemal waterways of lleater _
tankless heat.ali 1$ !lot
then :suddenly nJms cord
Boiler :stop-leak compound
OR
has been ~ lo bo11er
wat.er and f$1nsulaJfng
Domestic waJ:er from
outsade of ooll.
ta.nkless heat.er I& always
lukewann.
hc:orrect mixing valve setting
for lankless healer.
Have qualified service l:edvllc:lan
dellme ·Or replace coiL
Have quaiiUed .seNice ted'lnl\can
remove and clean 0011AND dralln
and flush boUerto remove stop-
leak.
Have qual flied service tedV'IIc:lan
adjust mb:lng vahle &emng.
Domestfe ftow rate too hlgn_
Hav~ qualified sewice tedmlc:lan
f.n$ta.ll now cneck valve set to
ratil\9 ol tank~$$ heater.
hc:orrect setting on tanlde$s
l'ieal:er low lil'lit
Have qual flied service tedV'IIc:lan
raise lankle$$ low limit $el&g.
a.w·ery vatv.e ~s not work.
Have qualllled s.arrvice tedmlc:lan
~ the
valve wtrlrig,.
acb.Jator and
.. Check
a:!(,
·operation ·o1 valVe. If aCIJJaiOr
·dMS not mc:we vmen 1he bdler is
shut on a:l"iddltlell'(ti Is a call for
domestic wateli' replace valve
and a.duator.
57
0
DC
a
Ired Water
oler-
aller
anual
12a Replacemen1t parts
Sect1o:n assembly ••••••.••• '"'.................. ·~~~····'"'····-=-·,···~· 58
llaus~ ······~···--····~--··········~····--·····~···········~····--····· It~
~~I(~ ···~···--····~--··········~····~······~···········--···--····· ~Jt
~~~~ ······~·····~····~--··········~····························--····· 1141
Co~ls ·--····=-····~
lAWWIMGI
. . ····--·····-=·····....................................... tss
R~plaeemeru
parts mwt be pu.rrll
ed dlroll811 a l..x.d ~11-Melaln
di:sttlburor. Wlten otdulft& s.pedfy bolter fOOdel aDd stu and Include
de~poon .and part number of rt!p~ll.t part.. ~s.ults from 'Wine;
modi.tied or ot:bet Jll3Dufactured pa.ft! will not be OO'YIBtlld byw3.flr.mt'{
and rnay dam~ baiter or impilit operation.
Well-Mclain part numbi!H aJ'e folllld In Wail-McLain Boilan • d
ColiiRIJ• Repair JWtw. Ltata.
!A;WWUIGI
Tbe lbollr1" rootams oo:o:ok; ifi.'bl!l' md ifi.'betgla.&am:ateria.l& u~ .;::uewhm
handling these maw-lab. pet instrliCiioru; on pt1g11 68 of lllis manual.
Pail~ 10 romply ooufd MU.It in lie~ ~ill injury.
a -
12b
a er Bolle - -
oller Manual
Replacement parts - section assembly
••
Hem
number
D~eription
Weii-M~:Lain
rtem
part nlmlber
numbetr
Dese~n
Weii-Mcn..atn
part: nmnbef"
1
Eml5eciiDA. le:l: hiill.d, 5112Ai
311-1oo-.BQO
g
T<Ullil~ heater
5~21-9:2[]
2
Eml ~ecllml. 11gtrt hand, 51123
311-103-321
10
Ga&k.et. 1atlltle55 hea.~er
591)-317-534
3
lniEmielllate
5ec&n, 51125
3 11-1~18
11
SUI andl nut as&eRU)' lt'8"' X 1-115•,
56(}-3411-577
-4
lniEmielllate
5ec&n ·ror tant~S6
311-1oo-.8([)
12
HI~ lknlt. 3tll' I1Cererltt'al. 'Ailtl wei
meywell: L.'1100[)-11lJ6
Whl~dgaa.: 11B.a1-3
510-312-2:5[]
13
TI!.rlk l~ heater Ia&' nrrat.
~'Nil! weD
510-312 -152
rd~~
RetJiacemel\t secttcn i1515ernllty
321- 11 ~-355
rd~1l
secttan replacemenJ kit. lncJude'S
fie.als ami fie.ala:nJ for 1 jOD1t
381--354-52.7
5a
5b
fl
7
8
56D-234~3&9
7116• X 6.7 'S (Qly:3,
56D-234-;5gi5
~. 7/ 16. { 1 pes1le rod)
Racua1Joo pia!-!!' { 1 per j'*lt)
a·
Hmeywell: LJCOa!J[)-11!144
lie llXI. '6'lthout nut
7fl 6'" J: JUJll" (Qtr...3)
\"'asher, 7/ 16. { 1 p1!'11le rod)
Ql:r-10
562-243-68~
14
450-0ZJ-.497
assembly
15
IOOi.JoeJ 1'iin asseml:i)'
kit. lrdllde:s:
381-3s=-5a7
lnlilueerfan afi&~. gasket and
nuts
561-923-Z35
~[)-[]{)3- 7()[]
CoUI!cioJ tvJoo ami tran&lllan
16
Ga& ket, lnllkl oer
590-317-627
59
t
12c
a
-Fired
Replacem~ent
ater
o ler -
parts - base
aller
anual ~
a
12c
Repllacement parts - b·a se
litem
oller Manual
-Fired Water Bolle - -
<conllr..Je<Jl
·w eii-McLain
part number
Description
null'lber
Base assembty kil (InClUdes base panel items 1.2.3.4.5 .16 iiliTld 7)
381--354-339
1
Base side panel (in Ba.s e assembly)
2
Base fllllll acss-fie assembly (in Base assembty)
3
Base back cro5s-lie assembly (in Base a55embry)
4
Boner shield [111 Base assemllly)
5
Base pan angle. left: side fmt Base assembly)
6
Base pan anl:Jie. righmside (in Base assenilay)
7
Base pan
f., Base .assembly)'
7a
Base pan
~r
8a
Burner mounting pia e
450-0D3-fl92
8IJ
Rear SP'acing strip
550-3.20-162
8c
Nut. hex 5 mm Zp
550-3.20-170
9
Base in stJiation kit
381-354-332
10
Boiler leg kit
550-320-219
11
Ma:niful'd
591-126-737
12
Ma5n burner orifice -
13
Bumer
5 12-2(]0-076
14
Screw, 10-32 x 0.38 STP Type 23 Hex.. Washer Hd S lot
562-135-7 10
15
Rollout lhermal fuse etemem
5 12-050-230
baffle (in Ba.s e assembly)
Natura l gas. 2.7mm
560-52Q..077
61
t
12d
a
-Fired
ater
o ler -
anual ~
aller
parts - j acket
Replacem~ent
®
G
®
, .
.
-
.
I
~ ~rr.
a\J
0. ~·
li&' ®
62
••
@
~
a
12d
-Fired Water Bolle - -
oller Manual
Repllacement parts - jacket (OOdtitluecl)
litem
·w eii-McLain
part number
Description
null'lber
1
J unction box. 2 x -4 x 1.5
2
J acket panel. left side. wifh
3
Jacket pane1. right side. wifh in5Uiation
381-355-793
4
Jacket panel. top front, wifh insulation
381-356-420
5
Jacket pane1. top rear. wf1h insutafion
381-355-7-42
6
Jacket pane1. door
381-355-744
7
Jacket cross-tie. bottom fron~
431--223-327
a
Jacket panel. rear. wifh insulation
431-223-302.
9
Jacket pane1. inferior. with insL.dsficn
.381-355-7-43
Geld touch--up paint, spc-ay can
592-000-000
NS
Avaaab!e localty
inst.~lation
381-355-7-41
a
®
-Fired
:-~
1
ater
oler-
aller
~ ~
DMctipltOGJ
Qanbcilctl
llf1lirl v,atvt, '"'" I'IIPT191bb
"'-"DIM! Vl\1..
Miiili>Noroa
wa~
2
3
4
"
e;
7
•
®
•I
'\'1"., 1%- l( ~IL II: 1%"
NIJlplit,. ·1w· ~~: ~· NPT
N~ 114l" Dl ZONPT
r,
~e,
Jllu8, ~ .ltt'.ltlld)
Ctrndllor viiiiiNl u~ {2 l*lxilll)
Clm&JIIitJor wtiif!g l'iBiiiOH kit
(1VaiJR Jot~ Mal ~itd .i:mlt)
e u .12~ (lo.f23
:2!liSF~
St1-.MW~
'710
1!![)4('J
Uilfl wlitt lhufiiWI iii!JillltMii ttl t!Uidula.
......
3-Wt¥ .....
St1~~
15t1ol246.0~
""'_--oo?_
se;..-.e•
=~~=~~
WllliiN.4tl.iliil'l
S~f7~
WG~o~Mctmn
St1~1'-$~
~
11
H1
2.0
:21
3-1'-&0$-01
Adaf*r, ~PT. 1• :~~:1•
.~
1$
,..
~h~H~~~~
10
1$
117
w.IMai.Jal•
pl1!t !Ui'll!M'
Sft~(t1
Nlpplt. Qi!ljlp!i!lt, 1• x QUi: tQ ill
13
pM: tllltllbllt
S6i...S.C1'-2q:
t
9
,,
anual
S$).7~
~
~
:--......,--
i$1;:;2
~
t:mHtf
!~~1'.,$$0
(nil lloW:VIJi1 ~ lm'~J
!b:rw,c~ t·
S&irt
11411111, 1' K 1 • X '1·. NI"T
~---"""
~450
ButltlnQ. 1" :11: W NPT
~lflliiJa'l pcMiiUrU.tlim.J*ii.UW ~6,
aw iflll:nollat, lii'D't t~~lrlk
~ tWOe
3~
WdoiMc~
Nlppl6, 1• d:llfl(j
'llilil, t l'• X 11fl• J: ·~ • NP'II"
15&1~
N~ '1 14l" ~~. s-
$$1·928-4125
~
5$1..s;c ~
IDI!oe ....... iSM!. 30 PSIG, .... ~
IIW!!
~ JQI!oe nMt. iSM!. 30 PSIG, ..,t.nlilali*t
~ithtiwnki\Wl ~(In ilillillllr.J
<:;:mntiuco
10>-401-10
'Wa~
M3S(I
~tid40
; lf)-t(l$.05
'Wa~
1511 ~50
1511~
:338
:!22
!b:rw, ~ NPT. ~
S6i r1 '~ ~
~
, Nijlplil,.'MI" ,pt'~
~·
:u
NIIJC)I6, ·1• :11: c*- NPT
2S Qlll, 1" K t • I(~· NPT
not
~IDW!mg 'l.f<itwit/.t
ihown Kit SBI'Mca VaNe 9 WfJJ C~e
se;~
15&1..s;c1;.211 IS
A~laoernent
~
AY '10t Q..US-11 et1~~ o-tse
51 '1 -246499
a er Bolle - -
a -
oller Manual
12f Replacement parts- controls
®
G)
·•
@
'rtsm
'"
DBB~boo
II :11 nllfileturec''8
part nuii'Dir'
"N811-M£:1!...a In
~I
VR321MA2D[)1
5111-[144-361
Wlllfle-Rodgen;
J6E35-26fi
5111-1::144-361
MamJtachlr.e:r
n~
1
Ga5. \liit~ %" X K'
Wltl11'.!:2 & aliJmiJI:.D1n plOt gas tl1tllrlg
...
pari I'Ullb8r
weii-Mlialn
511 ~330-08[]
c.ootmf modLJie
Un!IE:d Techll~ 1107-1
51 tl-3»09lll
4
AJr ~e 6W1tCtl. 1 .53'" w.c.
1"11-0elta
511~824-5412
5
conlmiJ ir.msrr:amer
Honeywell
AT140B12fn
51 1J-B42-370
6
.Aimle!ilt tE!rnp!!fiilll.!lre swt1rm (llracket oot
Thefm-0-Disc
60T21 314367
540-130-4{] 1
COOimlii'E!.Iay CP'OT 2'4 V
Hl:lfleyNell
IR822201 []14
51 0-.311-019
TLilllllg.. a lr pr.e&&UJ'e &W..1Cin. ill 12 L D. :&II leone
reel, hJ eollect« hOOd
LydBII
2
PrOt
3
~};: 135" f:
7
not
EihDN1
automauc reset
wMe. to 1Iansman
590-317-650
590-317-651
a
-Fired
ater
oler-
aller
anual
13a Dimensions
~
41
Olmensiatal drawing
CJ) Supply ~o AOe\iOn, 1 \4" NP1" tnote~
IJ) Rcwm ~nnfitiD-n,
e Dreln
'~
1~ NYY inm1111]
VfiMl
•
Gn !llu pply ell'itrllinee [rop or ddsl
(I Rllllef Wtl\11&, ~· 'II PT
Cl
PrN:surehampl!r.srurll gaug11
3) 'h" NPT lo exp•nala n l antl.a r Villnt
-
3-woly v;l\ttli
e 3" DIIImetM vent eonnedlon
_
® uu ~upply p iping
E~pa nrion
lank line COI'II'Ieetlon, lh " NM'
11Qia1: e..•r lUJ~t~N"fP!nt~IIQ .. (li1t') 1rW t." • Rlrtwn
t!OnMt lkn 1hl hmJ ¥1111 ~rt) ls 1" KPT rt~ptr
b.ibt.
B~;•r
drt IJIIIr, '.);UJTo
pt;t"' .,II itrim olrt
sl;jPJf!G l;;on• rar nrl IDI!mlilf. a~Lidi:lr must
u ltdu nll.lml ttHhllMlintN..m.nu&
Al:..t.. PIME;NSION"S IN INCt-n;s
•
LIEFT l!ICIE
BaUer
model
numbM
CG1
~tap,Ji!ng
( ntfte:g, N )
Rllturn:mng
Uncfte.9 N
1 114.
,
,_,1e 3:: Gas piping •rom
me~r 10
o. coJmectiDn d'ZB
0.. m..-dfold •lze
Note3
[Inches NPT)
YJ
*
Note 9
(hwhes. NPT~
boller 10 be~ per loc8lutlllty rsqulreln!l!fll.9:_
I!
a
13b
BOiler
modal
DJD'Iber
-Fired Water Bolle - -
oller Manual
Ratings
DOE
ltealing
capacity
(Btub)
lilplt
Ouiput
(lltufl)
(llbllt
Net.I=B=A
~01
~
Boiler
watf!t'
content
(98Dona}
DOE
vvnt Size
SAaaonlll
efliciancy
{%AFU£)
- Din!Ot
rS Xhau:lil:
(Not.1)
COl-PIN
Notes
108.000
(Note:!!)
133,000
108.000
94,000
-
~
Chimney
draft
-
(NoM I!)
3.1
81.0
3"
5 "'
1. Ba9ad oo &tsndald teet prooedure:!l; pra!!OI'IIbed by 1he Unitad Sisters Oepamrient a1 Energy.
Bl'8 based on net installed radiation of autficient ~tty fur the requirarnerrts of 1m
bullcang and no1Nr1g need be added 1or normal piping and pllckup. Ratings are bassd on a piping and
pickt.p aii0W81"1C!e e11.15. An addltlonal B11Dw.anc& should be made lor L.II1U8U8I plpklg and pldwp ~ada.
2. Net I=B::::Fl ratings
:3. Direcl &'JChau!t OGt bolltYB l'iB!qUile speclBl 'olelltlng, oonalstent \W1h Oatagary Ill i:lcllef"a. Uae oofy 1tte vent
f'lllsterisla end methods specified in ttl!& manuBL Chimney draft wnted CGt boilers may use type B vent or
o'lher materiat!l BUlt8ble fa venllng Category I boilers.
NO fleE
CGtbo.ilmi for ft!sidmtialndiant p-.mel system.s. romrertedgn:Yttyh.&ltl.ng 9j!tmJs or other lew watutemperarure .af!Pilcatl.om .slwruld be lmtaJr.ed with ba1ancl.tlg Vl1.1ws and bJ,rpa:ss: ptpmg equal to d te supply aftd teiutn
&i7.e tB avoid e:m!lliiw ftlli! 8"2!1 COOJdenat:ion dns to lower ~ntlngw.ttu tm:lpt!flii:W"e&.. FM altemartil piping.
cantact your Well-Md.aln sala o:ffiaa..
CSA ds!ign Ctit:ifu!d far :i:ruta1lation on c:ombumble :flooring.
Test-ed for 50 psi working press11re..
67
GOLD
CGt OAS-ARED w.a.TEA BOI'=FA -
Boiler Manual
Handli ng ceramic fi ber and fi berglass materials
MMDVAL o• co.-uariiON CH,..•
u•110 OR..._ PAMIIUJ
Thec.Ylft'lbtbi:loo clwnb4!1.' lltilil,g or bil.ii!
..,-aLA.'I'ION 0111111-RQI • • WOOL,
lmulatlon F.ek Jn lhis _pi'Oduet contUn ctriiDl.c fiber mater:i.ala. Ceramk;
fibara em bs c.onwrted to aistobaH-m
\~ high letnpet'.aul.tt! applicatioM..
CO'Z....JION OHA'Za LIIMG 011
IIAUNI"a-
m
'J"h.e
lnaemationaf Agency for Resean:h on
Gmac (!ARC) lw conduded. "''yBtalll.ne !dllo mhaled In the fotm of qtw'U!
Thisprodu.drr.ontains :fi.baglua ja.drst
:fn.all.ation md cenmicfibe:rmaterl.ak l.n c::ombustion dlambe.r ~or
b ua p:mela:fn p finld prodw::tJ.. Afrborne :fi.bem fmm il:bale IilllJti!rialahaYB
been li!ted by the State of C:ilifoflltia
ou; .a pcmihle calb!e of <:.a.b.O!r lhroush
lnbalailo:ni ..
or erlstobal~ from OC!OlJ:."iUOI'Ial50l.U'O!!I
is c;arc;Jn~ to. hnmana (Group 1)!":
~IIIIUIUNS
0
Avoid bft!athing:fibe:rglus dust and contact whh &kin Of'
~yes.
..
..
Uae NIOSH c:.ertified dUBt :reltpfraroc (N95).
Thlt ~ of l:'elip~.nor ls lw.ed on the
OSHA requfft!ment! far :fibergbaa wool at the
tJ~ th~ document. was. writtm .. Olha t)'~ of
~lr.u.on ~ be llel!ded depelldill8 on ~
job llite condJtiOns. OJ.:mmt NIOSH nro:m:mendltiom em be found on the NIOSH web Bite
at http:/{Www..ak..gcwJnJilMomepageJ mnL
NIOSH app:rowd :napiralM'B:. liWluf3.Citi.U'erB,. md
phone rmmbers .an abo l~eil on thJi web slit!.
\'ku long-&h!e'W!d, !looas :fittmg dotbfng, gloW!a,
and e.ye protedlon..
0
Apply enough d ter to the tX:Iftl..busOOn dl.amb er lining
or bal.e iru.ulat lon .a ~'lent a.irborik dusL
0
R~ combwtion clwrlber llning or bilk aru.ulatJoo
from~ bollt!r and plaee It rll a. plank bag ford~
0
'.Vasil potenldJiy COI\'I:amlna.ud. doth.es W!p31'41~ from
olha dolhiftg.. Rlns.e elotbes: washa ~hly..
NIOSH ftBied FJm Ald.
0
0
Eye: lff!J~ :lmA'If!dlauly.
Bteathlng! Fmh ak
~meest.SW
0
Awld bce:dhlns·fibe:t:ghm dUBt and rontad whh &k1n
or eya.
.. Uas NIOSH certtiiied dust ft!apjrii:O£ (N9 5).
This type of ~or i$ based on ~
OSHA teqWmme:ota fot fiberglua wool! at the
lime thJi dOOI:Mellll '1!\W. wr.ltten.. Other ~of
respirators. may be needed depending on the
jo b afle rr.onditiom . Curcent NIOSH .ecQJlllllPDdatiom can be foiiDd on the MOSH web lliti!
at h ltpjJwww...edt¥V/ft10!Siilbolnep~.. ha..ml ..
..
0
0
NIOsti approved ceapkaton. mmufactu.mra.
and ph:rne numbers :l1'f! ai!IIO ll!iil'.c!d on this web
!Jte..
VWar long-el.am!d.looae fitting dothlng, ~.
and eye prorect5on ..
O p en.tlons. web as :sawing. b lowing, tear out , and
sp:rayfug may geDt!:[lJ.ts afibarne !fibet C::ODG!Ilt:ration
rt=quit:lng add(tJoml pi."Cltet:;tlon..
W.ash po~lltlaJiy .:.oota..ml..ftate.d clothes. .51epa..r.uety
from od!i!r dothlftg.. R:IMe dothes; washer thorough ly..
NIOSH s:r.fed Fhf' Nd.
0 Eye!~ Irrigate alllllk!di.al~..
0 Brealhing: Fresh .air.