Carrier BS1 Operating instructions

Installation, Start-Up, and Operating Instructions
Gas-Fired
Natural Draft Steam Boilers
Sizes 70,000 through 299,000
BS1 and BS2
Series B
ama
®
ASME
NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler.
This symbol → indicates a change since the last issue.
MODEL BS2
MODEL BS1
Electronic Intermittent Ignition
Continuous Pilot
A95139
A90003
Index
Page
SAFETY CONSIDERATIONS.....................................................................................................................................................................................3
INTRODUCTION..........................................................................................................................................................................................................3
BOILER RATINGS AND CAPACITIES ....................................................................................................................................................................4
Form:
IM-BS1A-05
Cancels:
IM-BS1A-04
Printed in U.S.A.
8-03
Catalog No.
63BS-1A3
LOCATING THE BOILER...........................................................................................................................................................................................4
FRESH AIR FOR COMBUSTION ...........................................................................................................................................................................5-6
Boiler Located in Unconfined Space .......................................................................................................................................................................5
Boiler Located in Confined Space ...........................................................................................................................................................................6
INSTALLATION—SYSTEM PIPING......................................................................................................................................................................6-8
For Use with Cooling Units .....................................................................................................................................................................................8
CHIMNEY AND VENT PIPE CONNECTION .....................................................................................................................................................8-11
Checking Chimney....................................................................................................................................................................................................8
Chimney Sizing.........................................................................................................................................................................................................8
Connecting Vent Damper and Vent Connector..................................................................................................................................................8-10
Minimum Vent Pipe Clearance ..............................................................................................................................................................................10
Removing Existing Boiler from Common Venting System ............................................................................................................................10-11
VENT DAMPER OPERATION..................................................................................................................................................................................11
Automatic Operation of Vent Damper...................................................................................................................................................................12
Manual Operation of Vent Damper .......................................................................................................................................................................12
GAS SUPPLY PIPING ..........................................................................................................................................................................................12-13
Checking Gas Supply ........................................................................................................................................................................................12-13
Connecting Gas Piping ...........................................................................................................................................................................................13
Checking Gas Piping ..............................................................................................................................................................................................13
ELECTRICAL WIRING ........................................................................................................................................................................................13-18
Electric Power Supply ............................................................................................................................................................................................13
Installing Thermostat ..............................................................................................................................................................................................18
Electronic Thermostats ...........................................................................................................................................................................................18
Vent Damper...........................................................................................................................................................................................................18
Wiring Diagrams ...............................................................................................................................................................................................14-17
CONTROLS AND ACCESSORIES ...........................................................................................................................................................................19
Relief Valve ............................................................................................................................................................................................................19
Steam Pressure Gauge ............................................................................................................................................................................................19
Water Level Gauge.................................................................................................................................................................................................19
Steam Pressure Control ..........................................................................................................................................................................................19
Low Water Cut-Off (LWCO).................................................................................................................................................................................19
Water Feeder (Optional).........................................................................................................................................................................................19
Vent Damper...........................................................................................................................................................................................................19
Rollout Switch (Flame Rollout Safety Shutoff) ....................................................................................................................................................19
Spill Switch (Blocked Vent Safety Shutoff)..........................................................................................................................................................19
FOR YOUR SAFETY READ BEFORE OPERATING .......................................................................................................................................19-20
GAS VALVE OPERATING INSTRUCTIONS....................................................................................................................................................20-21
Intermittent Ignition Boiler—VR8204A/VR8304M Gas Valve............................................................................................................................20
Continuous Pilot Boiler—VR8200A/VR8300A Gas Valve ............................................................................................................................20-21
OPERATING BOILER ..........................................................................................................................................................................................21-22
How a Steam System Operates ..............................................................................................................................................................................21
Filling System with Water ................................................................................................................................................................................21-22
Water Level.............................................................................................................................................................................................................22
Automatic Gas Valve..............................................................................................................................................................................................22
Thermostat...............................................................................................................................................................................................................22
CHECKING AND ADJUSTING...........................................................................................................................................................................22-23
Pilot Burner Adjustment.........................................................................................................................................................................................22
Main Burner(s)........................................................................................................................................................................................................22
Gas Valve Safety Shutdown Test ..........................................................................................................................................................................22
Steam Pressure Control Adjustment .................................................................................................................................................................22-23
Checking Controls ..................................................................................................................................................................................................23
CLEANING BOILER.............................................................................................................................................................................................23-24
Skimming ................................................................................................................................................................................................................23
Blowdown ..........................................................................................................................................................................................................23-24
MAINTAINING BOILER......................................................................................................................................................................................24-25
Water Level.............................................................................................................................................................................................................24
Relief Valve ............................................................................................................................................................................................................24
Low Water Cut-Off (LWCO).................................................................................................................................................................................24
Burners ....................................................................................................................................................................................................................24
Boiler Flue Passages...............................................................................................................................................................................................24
Vent Pipe.................................................................................................................................................................................................................24
Cleaning Boiler Flue Passages and Burners.....................................................................................................................................................24-25
Foaming, Priming, or Surging................................................................................................................................................................................25
Boiler Water Treatment (Other Than Cleaners) ....................................................................................................................................................25
Between Heating Seasons.......................................................................................................................................................................................25
SERVICE HINTS ........................................................................................................................................................................................................26
REPAIR PARTS.....................................................................................................................................................................................................27-29
—2—
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should
install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as maintaining water level. All
other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with unit and other safety precautions that may apply.
→ Follow
all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI
Z223.1-2002. Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls.
Recognize safety information. This is the safety-alert symbol . When you see this symbol on unit or in instructions and manuals, be alert to
potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with safety-alert symbol. DANGER identifies
most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or
death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used
to highlight suggestions which will result in enhanced installation, reliability, or operation.
INTRODUCTION
These Gas-Fired Steam Boilers are low-pressure, sectional cast iron boilers design certified by the American Gas Association (A.G.A.) for use with
natural and propane gases. They are constructed and hydrostatically tested for a maximum working pressure of 15 psi in accordance with the
American Society of Mechanical Engineers (A.S.M.E.) Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.
Check to be sure boiler size is correct before starting installation. See rating and capacity tables shown in Fig. 1. Also be sure new boiler is for
the type of gas being used. Check rating plate on right side of boiler.
The boiler must be supplied with correct type of gas, fresh air for combustion, and a suitable electrical supply. Boiler must also be connected to
a suitable chimney and an adequate piping system. Finally, a properly located thermostat is needed for control of heating system. If there are any
doubts as to the various requirements, check with local authorities and obtain professional help where needed. Take time to complete all the steps
for SAFE and PROPER operation of heating system.
If this boiler is installed in a building under construction, special care must be taken to insure a clean combustion air supply during the construction
process. Airborne particulates such as from drywall dust and from fiberglass insulation can clog the burner ports and cause incomplete combustion
and sooting.
These boilers are designed for use in closed heating systems where all of the steam is returned to boiler as condensate and the amount of make-up
water required is minimal. These boilers are not designed for or intended for use in open systems or process applications using 100 percent make-up
water. Damage to boiler resulting from such use shall not be covered under the warranty.
Where required by authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for
Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.
Before installing the boiler in the United States, refer to the current edition of the NFGC. For further information, the NFGC is available from
National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; American Gas Association, 1515 Wilson Boulevard, Arlington,
VA 22209; or from Literature Distribution.
The installation must conform with requirements of the authority having jurisdiction, or in absence of local codes, to the NFGC.
The following steps are all necessary for proper installation and safe operation of boiler.
1. LOCATING THE BOILER
2. FRESH AIR FOR COMBUSTION
3. INSTALLATION—SYSTEM PIPING
4. CHIMNEY AND VENT PIPE CONNECTION
5. GAS SUPPLY PIPING
6. ELECTRICAL WIRING
7. CHECKING AND ADJUSTING
→
WARNING: To prevent fires or explosions, keep boiler area clean and free from combustible materials, gasoline, and
other flammable vapors and liquids.
WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide
poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage.
Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance.
The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this
product. Boilers with cast iron burners are not to be converted to propane gas. Failure to follow this warning could result in
electrical shock, fire, personal injury, or death.
—3—
BOILER RATINGS AND CAPACITIES
VENT
DAMPER
PRESSURE
GAGE
RELIEF
VALVE
26 1⁄2″
4 3⁄4″
2 1⁄2″
TRANSFORMER
GLASS
GAGE
PRESSURE
LIMIT CONTROL
LOW WATER
CUT-OFF
2 1⁄2″ N.P.T.
29″
LOW WATER
CUT-OFF PROBE
36 3⁄8″
12 1⁄4″
WATER
LINE
S86
2 1⁄2″
24″
GAS
VALVE
GAS LINE
A
LEFT SIDE
FRONT
RIGHT SIDE
A90064
Natural Gas-Fired Steam Boilers
BOILER MODEL NUMBER
Intermittent
Ignition
with Vent Damper
Standing
Pilot
with Vent Damper
NO. OF
SECTIONS
AGA
Input
MBH
BS2AAN000075ABAA
BS2AAN000112ABAA
BS2AAN000150ABAA
BS2AAN000187ABAA
BS2AAN000225ABAA
BS2AAN000262ABAA
BS2AAN000299ABAA
BS1AAN000075ABAA
BS1AAN000112ABAA
BS1AAN000150ABAA
BS1AAN000187ABAA
BS1AAN000225ABAA
BS1AAN000262ABAA
BS1AAN000299ABAA
3
4
5
6
7
8
9
75
112
150
187
225
262
299
NATURAL GAS*
Net
Heating
I=B=R
Capacity
Rating
MBH
MBH
62
47
91
68
122
92
153
115
183
137
214
161
245
184
DIMENSIONS (IN.)
Net I=B=R
Rating
Sq Ft
Radiation
196
283
383
479
571
671
767
Flue
Diameter
Width
A
5
6
6
7
7
7
7
11-1/4
14-1/2
17-3/4
21
24-1/4
27-1/2
30-3/4
Fig. 1—Dimensional Drawing and Boiler Ratings and Capacities
The ratings marked "Net I=B=R Rating" indicate the amount of equivalent direct cast iron radiation each boiler will take care of under normal
conditions and thermostatic control. The Net I=B=R Steam Ratings shown are based on an allowance of 1.333 in accordance with the factors in
the I=B=R Code as published by The Hydronics Institute.
Selection of boiler size should be based upon "Net I=B=R Rating" being equal to or greater than installed radiation in sq ft. Consult manufacturer
before selecting a boiler for installations having unusual piping and pickup requirements.
Specifications and dimensions are subject to change without notice.
LOCATING THE BOILER
NOTE: This unit MUST be set on a concrete or other non-combustible material base or floor.
1. Select level location as centralized with piping system and as near chimney as possible.
2. Place crated boiler at selected location. Remove crate by pulling crate sides from top and bottom boards. When boiler is to be installed on
a combustible floor, a combustible floor base must be used.
This boiler must NOT be installed on carpeting.
3. Boiler is to be level. Metal shims may be used under base legs for final leveling.
4. The floor supporting boiler must be non-combustible. If it is combustible, place the boiler on a factory-approved combustible floor base.
We use a 2-in. Cladlite™ pad as a combustible floor base. These are available from your local supplier. Use a minimum 24-in. X 30-in.
pad for 2-5 section boilers and a minimum 30-in. X 30-in. pad for 6-7 section boilers. The boiler must be centered on combustible floor
base.
5. Additional clearances for service may exceed clearances for fire protection clearances shown on the unit. An 18-inch clearance should be
maintained on any side where passage is required to access another side for cleaning, servicing, inspecting, or replacement of any part that
may need attention. An 18-inch clearance is recommended on the control side for servicing.
6. Determine boiler room size. Rooms that are large in comparison with the size of boiler are defined as rooms having a volume equal to or
greater than 16 times the volume of the boiler. Where room ceiling height is greater than 8 ft, volume of room shall be figured on the basis
of 8 ft ceiling height. Determination of room size should be based on total volume of all gas fired equipment installed in that room. (See
Table 1.) Refer to section 6.3 of NFGC, Central Heating Boilers and Furnaces for further information, including approved methods for
reducing clearances in large rooms.
7. Table 2 shows minimum clearances from combustible materials.
—4—
Table 1—Room Large In Comparison With Boiler
BOILER SIZE
(SECTIONS)
BOILER VOLUME
(CU FT)
3
4
5
6
7
8
9
6.3
8.1
9.9
11.7
13.5
15.3
17.2
MINIMUM ROOM
VOLUME REQUIRED
TO BE LARGE
ROOM
(CU FT)*
100.4
129.4
158.4
187.4
216.4
245.4
274.5
* For room with single boiler only.
Table 2—Minimum Clearances From Combustible Materials and For Servicing
PART OF BOILER
Top
Rear
Control Side
Opposite Control Side
Front
Flue/Vent Connector
Boiler Piping
ALCOVE OR ROOM
NOT LARGE
IN COMPARISON
WITH BOILER (IN.)
6
6
7
6
18
6
1
ROOM LARGE
IN COMPARISON
WITH BOILER (IN.)
6
6
6
6
18
6
1
FRESH AIR FOR COMBUSTION
Provision for combustion and ventilation air must be in accordance with Section 5.3 of NFGC, Air for Combustion and Ventilation, or applicable
provisions of local building codes.
Canadian installations must be installed in accordance with NSCNGPIC and all authorities having jurisdiction.
WARNING: Be sure to provide enough fresh air for combustion. Enough air ensures proper combustion and
ASSURES THAT NO HAZARD WILL DEVELOP DUE TO LACK OF OXYGEN. Failure to follow this warning can cause a fire,
personal injury, or death.
You must provide for enough fresh air to assure proper combustion. The fire in the boiler uses oxygen. It must have a continuous supply. The air
in a house contains only enough oxygen to supply the burner for a short time. Outside air must enter the house to replace the oxygen used by the
burner. Study the following examples to determine your fresh air requirements.
CAUTION: Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride,
bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air
fresheners, and other household products. Excessive exposure to contaminated combustion air will result in safety and
performance related problems.
→
CAUTION: If a fireplace or a kitchen or bathroom exhaust fan is used, an outside air intake should be installed. These
devices rob the boiler and water heater of combustion air which can cause fire, personal injury or death.
PROCEDURE 1—BOILER LOCATED IN UNCONFINED SPACE
EXAMPLE 1:
An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (unpartitioned basement) in a conventional house, the air that leaks through cracks around doors and windows
will usually be adequate to provide air for combustion. The doors should not fit tightly. Do not caulk cracks around windows.
Equipment located in buildings of unusually tight construction shall be provided with air for combustion, ventilation, and dilution of flue gases
using methods described in example 2B or shall be specially engineered. The authority having jurisdiction must approve specially engineered
installations.
—5—
PROCEDURE 2—BOILER LOCATED IN CONFINED SPACE
EXAMPLE 2A: ALL AIR FROM INSIDE THE BUILDING
The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so
that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the
combined space shall be considered in making this determination. Each opening shall have a minimum free area of one square inch per 1,000 Btu
per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 100 square inches. One opening shall be
within 12 inches of top and one within 12 inches of bottom of enclosure. The minimum dimension of air openings shall not be less than 3 inches.
EXAMPLE 2B: ALL AIR FROM OUTDOORS
The confined space shall communicate with the outdoors in accordance with examples 1 or 2. The minimum dimension of air openings shall not
be less than 3 in. Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.
1. Two permanent openings, one commencing within 12 inches of top, and one commencing within 12 inches of bottom of enclosure shall
be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate
with the outdoors
a. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have
a minimum free area of 1 sq. in. per 4000 Btu per hour of total input rating of all equipment in enclosure. (See Table 3A.)
b. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 sq. in. per 2000
Btu per hour of total input rating of all equipment in enclosure. (See Table 3B.)
2. One permanent opening commencing with 12 inches of top of enclosure shall be permitted where equipment has clearance of at least 1 inch
from sides and back and 6 inches from front of appliance. The opening shall directly communicate with the outdoors or shall communicate
through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors and shall have a
minimum free area of:
a. 1 sq. inch per 3000 Btu per hour of total input of all equipment located in enclosure (see Table 3C), and
b. Not less than the sum of the areas of all vent connectors in the confined space.
Table 3A—Fresh Air Duct Capacities for Vertical Ducts (Btuh)*
100% FREE AREA
75% FREE AREA
25% FREE AREA
Fresh Air
Duct Size (In.)
1/4-in. Mesh
Screen
Metal
Louvers
Wood
Louvers
3" X 12"
144,000
108,000
36,000
8" X 8"
256,000
192,000
64,000
8" X 12"
384,000
288,000
96,000
8-1/2" X 16"
512,000
384,000
128,000
* 1 Square Inch per 4,000 Btuh
Table 3B—Fresh Air Duct Capacities for Horizontal Ducts (Btuh)*
Fresh Air
Duct Size (In.)
100% FREE AREA
75% FREE AREA
25% FREE AREA
1/4-in. Mesh
Screen
Metal
Louvers
Wood
Louvers
3" X 12"
72,000
54,000
18,000
8" X 8"
128,000
96,000
32,000
8" X 12"
192,000
144,000
48,000
8-1/2" X 16"
256,000
192,000
64,000
* 1 Square Inch per 2,000 Btuh
Table 3C—Fresh Air Duct Capacities for Vertical or Horizontal Ducts (Btuh)*
100% FREE AREA
75% FREE AREA
25% FREE AREA
Fresh Air
Duct Size (In.)
1/4-in. Mesh
Screen
Metal
Louvers
Wood
Louvers
3" X 12"
108,000
81,000
27,000
8" X 8"
192,000
144,000
48,000
8" X 12"
288,000
216,000
72,000
8-1/2" X 16"
384,000
288,000
96,000
* 1 Square Inch per 3,000 Btuh
INSTALLATION—SYSTEM PIPING
The near boiler piping (piping around boiler) must be considered as part of boiler for proper water level control and to produce dry steam. Correct
near boiler piping is crucial to proper operation of boiler and heating system. Follow these recommendations carefully.
1. Place boiler in selected location as near chimney as possible.
2. Install relief valve using factory-supplied 3/4-in. coupling into 3/4-in. pipe nipple on top of boiler. Make a discharge pipe using 3/4-in. pipe
(field supplied) to carry water or steam to a nearby drain. Do not connect discharge pipe directly to drain but leave an air gap. The
downstream end of discharge pipe must be unthreaded. No shutoff of any description shall be placed between relief valve and boiler, or
on discharge pipes between such safety valves and the atmosphere. Installation of relief valve shall conform to requirements of the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for any water damage.
—6—
STEAM
MAINS
15″ MIN.
PIPE FULL SIZE SAME
AS BOILER TAPPING
(2 1/2″)
POP SAFETY VALVE
REDUCING ELL
POINTING DOWN
6″ TO 10″
DRY
RETURN MAIN
24″ MIN.
FLUE COLLAR
MAIN VENT
1 1/2″ MIN.
PIPE SIZE
15″ MIN.
E
R
E
AT
LIN
W
2 1/2″ MIN. TEE
WITH PLUG
FOR SKIMMING
6″
28″ MIN. - DIMENSION A
CLOSE
NIPPLE
24″
WET RETURN
WATER FEED
GATE VALVE
(NOT FURNISED)
1 1/2″ FULL PORT BALL VALVE
FOR BOTTOM BLOW DOWN
AND DRAINING BOILER &
SYSTEM (NOT FURNISHED)
DRAIN VALVE (FURNISHED)
FOR FLUSHING SYSTEM
A95493
Fig. 3—Recommended Near Boiler Piping Using 1 Supply Tapping
3. This boiler is equipped with two 2-1/2-in. supply connections and two 2-1/2-in. return connections, 1 each on both the left and right sides
of boiler. Unused connections must be plugged with factory-supplied 2-1/2-in. plugs.
4. Recommended near boiler piping for gravity return systems is shown in Fig. 3. This configuration uses 1 supply and 1 return tapping. This
setup can be used on any size boiler in this series. The supply and return connections may be piped both into the same side (either left or
right) or 1 into each side of boiler.
5. For installers choosing to use both supply tappings, refer to Fig. 4 for CORRECT way to pipe system. Fig. 5 shows WRONG way to pipe
a header with 2 risers.
a. Headers must be fitted with header offsets or swing joints, or be equipped with expansion joints, so that thermal expansion and
contraction of header will not damage boiler. Headers shall not be welded.
b. System takeoffs from header must be between equalizer and riser to header nearest equalizer. System takeoffs must never be between
2 risers.
6. System takeoffs from header must never be bullheaded. If steam main goes in 2 directions, there must be 2 takeoffs from header, 1 for each
main.
7. All boilers in gravity return systems MUST be equipped with a Hartford Loop as shown in Fig. 4 and 5.
8. When piping vertical risers from boiler to header, bottom of header must be a minimum of 24 in. above water level line on right side of
boiler.
9. Steam riser(s) and header shall be 2-1/2-in. pipe size.
10. Equalizer line shall be a minimum 1-1/2-in. pipe size.
11. The near boiler piping shall include a 2-1/2-in. tee with a plug located on supply line for skimming (surface blowdown). (See Fig. 3 or 4.)
12. The near boiler piping shall include a 1-1/2-in. ball valve in return piping for bottom blowdown and draining. (See Fig. 3 or 4.)
13. For gravity return systems, bottom of lowest steam carrying pipe, be it dry return or end of steam main, must be at least 28 in. above normal
water level line on right side of boiler. This is known as "Dimension A."
—7—
STEAM
MAINS
PIPE FULL SIZE SAME
AS BOILER TAPPING
(2 1/2")
15″ MIN.
POP SAFETY VALVE
CONNECT RISER TO
BOILER WITH 2 1/2″
ELBOW AND NIPPLE
(NOT SHOWN)
REDUCING ELL
POINTING DOWN
6″ TO 10″
DRY
RETURN MAIN
24″ MIN.
FLUE COLLAR
MAIN VENT
1 1/2″ MIN.
PIPE SIZE
15″ MIN.
E
R
E
AT
LIN
W
2 1/2″ TEE
WITH PLUG
FOR SKIMMING
6″
28″ MIN. - DIMENSION A
CLOSE
NIPPLE
24″
WET RETURN
WATER FEED
GATE VALVE
(NOT FURNISED)
1 1/2″ FULL PORT BALL VALVE
FOR BOTTOM BLOW DOWN
AND DRAINING BOILER &
SYSTEM (NOT FURNISHED)
DRAIN VALVE (FURNISHED)
FOR FLUSHING SYSTEM
A95494
Fig. 4—Recommended Near Boiler Piping Using 2 Supply Tappings
14. For pumped return systems, follow condensate pump or boiler feed pump manufacturer’s instructions for proper installation and hookup.
15. In connecting cold water supply to water inlet valve, make sure that a clean water supply is available. When water supply is from a well
or pump, a sand strainer should be installed at pump.
PROCEDURE 1—FOR USE WITH COOLING UNITS
1. This boiler, when used in connection with chilled water systems, must be installed so that chilled water is piped in parallel with the heating
boiler. Appropriate valves must be used to prevent chilled water from entering the heating boiler. (See Fig. 6.)
2. When this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, piping
system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling
cycles.
CHIMNEY AND VENT PIPE CONNECTION
For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7 NFGC, Venting of Equipment and applicable
provisions of local building codes.
PROCEDURE 1—CHECKING CHIMNEY
This is a very important part of the heating system. It must be clean, the right size, properly constructed, and in GOOD CONDITION. No boiler
can function properly with a bad chimney. Inspect chimney and verify that construction and size of chimney meet all applicable provisions of the
NFGC and local building codes. Fig. 7 gives an idea how a boiler might be vented to a chimney. Note that height (HT) is measured from vent
pipe to top.
PROCEDURE 2—CHIMNEY SIZING
Chimney sizing and all other aspects of vent installation must be in accordance with Part 7, NFGC Venting of Equipment and applicable provisions
of local building codes.
PROCEDURE 3—CONNECTING VENT DAMPER AND VENT CONNECTOR
Refer to Fig. 1 flue diagram for size and location of vent (flue opening). Use 28 gauge (minimum) galvanized pipe to connect to chimney.
—8—
THIS PIPING CONFIGURATION IS INCORRECT
TO SHOW COMMON MISTAKES
WRONG WAY
DO NOT BULLHEAD,
USE 2 TAKE OFFS
WRONG WAY
TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER
WRONG WAY
SWING JOINTS ARE MISSING
WRONG WAY
MISSING TEE FOR SKIMMING
E
R
E
AT
LIN
W
A95495
Fig. 5—Common Near Boiler Piping Mistakes
—9—
TO SYSTEM
A
B
C
D
WATER
CHILLER
VALVES C & D
CLOSE FOR HEATING;
OPEN FOR COOLING
VALVES A & B
OPEN FOR HEATING;
CLOSE FOR COOLING
A95143
Fig. 6—Chilled Water Piping
IMPORTANT: The damper blade on factory-supplied vent damper has a 1/2-sq in. hole (approximately 3/4-in. diameter). On boilers equipped
with standing pilot, the hole MUST be left open. On boilers equipped with intermittent ignition, the hole should be plugged using plug supplied
with vent damper.
1. Position factory-supplied vent damper on top of flue outlet collar. Fasten damper securely to flue outlet collar with at least 2 sheet metal
screws. Make sure damper blade has clearance to operate inside of diverter.
As An Option:
The damper may be installed in any horizontal or vertical position, closer to flue outlet collar preferred. Follow diagrams shown in Fig. 8,
9, and 10.
2. Install vent damper to service only single boiler for which it is intended. The damper position indicator shall be in a visible location
following installation. Locate damper so that it is accessible for servicing.
3. The damper must be in open position when appliance main burners are operating.
4. The boiler is equipped with a factory-wired harness that plugs into vent damper. The thermostat must be connected to black wires marked
"24 volt thermostat" on boiler.
5. Vent pipe must be same size as flue outlet collar.
6. Slope pipe up from boiler to chimney not less than 1/4 in. per ft.
7. Run pipe as directly as possible with as few elbows as possible.
8. Do not connect to fireplace flue.
9. End of vent pipe must be flush with inside face of chimney flue. Use a sealed-in thimble for chimney connection.
10. Horizontal run should not be longer than 3/4 the chimney height (HT). (See Fig. 7.)
The sections of vent pipe should be fastened with at least 3 sheet metal screws to make the piping rigid. Horizontal portions of vent system must
be supported to prevent sagging. Use stovepipe wires every 5 ft to support pipe from above. If vent pipe must go through a crawlspace, double-wall
vent pipe should be used. Where vent pipe passes through a combustible wall or partition, use a ventilated metal thimble. The thimble should be
4 in. larger in diameter than vent pipe.
PROCEDURE 4—MINIMUM VENT PIPE CLEARANCE
Wood and other combustible materials must not be closer than 6 in. from any surface of single-wall metal vent pipe. Listed Type-B vent pipe or
other listed venting systems shall be installed in accordance with their listing.
PROCEDURE 5—REMOVING EXISTING BOILER FROM COMMON VENTING SYSTEM
When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of
the appliances remaining connected to it.
—10—
2-FT MIN
HT
3-FT MIN
ROOF RIDGE
3/4 HT MAXIMUM
MUST SLOPE UP
AT LEAST 1/4 IN.
PER FT OF
HORIZONTAL RUN
A95144
Fig. 7—Typical Masonry Chimney Requirements
At the time of removal of an existing boiler, the following items shall be followed with each appliance remaining connected to the common venting
system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion,
or other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space in which appliances remaining connected to
common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to common
venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from
a cigarette, cigar, or pipe.
6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined
above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
7. Any improper operation of common venting system should be corrected so installation conforms with the NFGC. When resizing any portion
of common venting system, common venting system should be resized to approach minimum size as determined using appropriate tables
in Part 11 of the NFGC.
For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7, NFGC Venting of Equipment and applicable
provisions of local building codes.
Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under
positive pressure.
—11—
HORIZONTAL INSTALLATION
FLOW
NO
YES
YES
NO
TO FURNACE VENT
TO CHIMNEY
OR BOILER DAMPER
INSTALL VENT DAMPER WITH
ACTUATOR TO SIDES OF
VENT ONLY. DO NOT MOUNT
ABOVE OR BELOW VENT.
CAUTION: Do not install
the vent damper
within 6 in. (152 mm) of
combustible material.
NOT
HERE
INSTALL
DAMPER
HERE
VERTICAL INSTALLATION
TO CHIMNEY
2
1
VENT
DAMPER
FLOW
ACTUATOR MAY BE
INSTALLED IN
ANY POSITION
TO FURNACE
OR BOILER
CHIMNEY
3
A95145
Fig. 8—Horizontal and Vertical Vent Damper Installation
ROTATION
OPEN
CLOSED
FLUE GAS FLOW
ROTATION
OPEN
CLOSED
FLUE GAS FLOW
DAMPER CLOSED
BOILER
WATER HEATER
1. Install the vent damper to service only the single appliance for
which it is intended. If improperly installed, a hazardous condition,
such as an explosion or carbon monoxide poisoning, could result.
2. Do not install the vent damper on vent pipe curve.
3. Do not run wires near high temperature surfaces. Use stand-off
brackets if necessary.
DAMPER OPEN
A95146
A95147
Fig. 9—Vent Damper Position Indicator
Fig. 10—Typical Installation for Vent Damper
(Note Caution and Footnotes)
VENT DAMPER OPERATION
PROCEDURE 1—AUTOMATIC OPERATION OF VENT DAMPER
For safe, efficient operation, vent damper and all flue product carrying areas of appliance must be checked annually with particular attention given
to deterioration from corrosion or other sources. If corrosion or other deterioration is observed, contact your heating contractor for repairs. Check
vent damper operation as follows:
1. When boiler is off, check that vent damper position indicator points to CLOSED position. (See Fig. 9.)
2. Adjust thermostat or controller up to call for heat and check that vent damper indicator points to OPEN position. (See Fig. 9.)
3. Adjust thermostat or controller down again and check that vent damper position indicator returns to CLOSED position.
4. If system has central air conditioning, set thermostat to COOL and adjust it down to call for cooling. Cooling system should operate.
5. Return thermostat to desired setting.
The vent damper must be inspected at least once a year by a trained, experienced service technician. The name of the person who originally
installed vent damper is shown on installation label.
PROCEDURE 2—MANUAL OPERATION OF VENT DAMPER
The vent damper may be placed in OPEN position to permit burner operation by using the HOLD DAMPER OPEN switch located on damper
controller. The thermostat controls burner firing as before while damper remains open. DO NOT turn damper open manually or motor damage
will result. Set switch to AUTOMATIC OPERATION to close vent damper during burner off cycle.
For further information and for a vent damper troubleshooting guide, refer to the manual packaged with vent damper.
GAS SUPPLY PIPING
PROCEDURE 1—CHECKING GAS SUPPLY
The gas pipe to boiler must be correct size for length of run and Btuh input of all gas utilization equipment connected to it. See Table 4 for proper
size. Be sure gas line complies with local codes and gas company requirements.
—12—
Table 4—Gas Pipe Sizes
Length
of Pipe
(Ft)
20
40
60
Length
of Pipe
(Ft)
20
40
60
NATURAL GAS
Pipe Capacity—Btuh Input
Includes Fittings
1/2 in.
3/4 in.
1 in.
1-1/4 in.
92,000
190,000
350,000
625,000
63,000
130,000
245,000
445,000
50,000
105,000
195,000
365,000
LP GAS
Pipe Capacity—Btuh Input
Includes Fittings
Copper Tubing*
Iron Pipe
5/8 in.
3/4 in.
1/2 in.
3/4 in.
131,000
216,000
189,000
393,000
90,000
145,000
129,000
267,000
72,000
121,000
103,000
217,000
MANUAL
SHUTOFF
VALVE
GROUND JOINT
UNION
AUTOMATIC
GAS VALVE
MANIFOLD
* Outside diameter.
NOTE: The length of pipe or tubing shown should be measured from gas meter or
propane second-stage regulator.
SEDIMENT TRAP
FLOOR LINE
A95148
Fig. 11—Gas Piping at Boiler
The boiler and its individual shutoff valve must be disconnected from gas supply piping system during any pressure testing of gas supply piping
system at test pressures in excess of 0.5 psig (3.5 kPa).
The boiler must be isolated from gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas
supply piping system at test pressures equal to or less than 0.5 psig (3.5 kPa).
PROCEDURE 2—CONNECTING GAS PIPING
Refer to Fig. 11 for general layout at boiler. It shows the basic fittings needed. The gas line enters boiler from right side.
The following rules apply:
1. Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction or in the absence of such
requirements, by the NFGC.
2. Use pipe joint compound suitable for LP gas on male threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
5. Use 2 pipe wrenches when making connection to gas valve to keep it from turning.
6. Install a manual shutoff valve in vertical pipe about 5 ft above floor.
7. Tighten all joints securely.
8. Propane gas connections should only be made be a licensed propane installer.
9. Two-stage regulation should be used by propane installer.
10. Propane gas piping should be checked by propane installer.
PROCEDURE 3—CHECKING GAS PIPING
Upon completion of piping, check immediately for gas leaks. Open manual shutoff valve. Test for leaks by applying soap suds (or a liquid
detergent) to each joint. Bubbles forming indicate a leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE.
WARNING: Never use a match or open flame to test for leaks. Use a soap-and-water solution. A failure to follow this
warning could result in fire, explosion, personal injury, or death.
ELECTRICAL WIRING
See Fig. 12-15 for wiring diagrams of the various models.
PROCEDURE 1—ELECTRIC POWER SUPPLY
WARNING: Turn off electric power at fuse box before making any line voltage connections. Follow local electric
codes. Failure to follow this warning could result in electrical shock, personal injury, or death.
All electrical work must conform to local codes as well as the National Electrical Code (NEC) ANSI/NFPA-70-2002.
Run a separate 120-v circuit from a separate overcurrent protective device in electrical service entrance panel. This should be a 15-amp circuit.
Locate a shutoff switch at boiler. It must be turned off during any maintenance. Connect 120-v electrical supply to primary leads on 24-v
transformer. Solder and tape or securely fasten these connections with wire nuts.
—13—
VENT DAMPER
MOLEX PLUG
4
115V/60HZ/1Ø
POWER
SUPPLY
1
BK
2
BR
3
O
Y
O
NEUT
THERMOSTAT
HOT
OVERCURRENT PROTECTED
DISCONNECT
t´
BK
BT
BK
PRESSURE
LIMIT
W
R
H
W
N
G
B
1
2
3
N
H
LOW WATER
CUT OFF
C
W
Y
B
BK
OPTIONAL WF-2U-24
WATER
FEEDER
BK
BLOCKED VENT
SAFETY SHUT OFF
NOTE:
TERMINAL NO. 3 APPEARS ONLY
ON WATER FEEDER MODELS WITH
MANUAL FEED PUSH BUTTON.
J7
BT
FLAME ROLLOUT
SAFETY SHUT OFF
LWCO PROBE
BK
BR
BL
Y
R
BT
W
G
- BLACK
- BROWN
- BLUE
- YELLOW
- RED
- BLACK WITH WHITE TRACER
- WHITE
- GREEN
- WIRE NUT
RGW
(24V)
(GND.)
SPARK
GND.
COLOR CODE
(24V)
MV
MV/PV
PV
UT 1003-620 SERIES
INTERMITTENT PILOT CONTROL
BK BK BT
BL
TO PILOT BURNER
BK
IGNITION CABLE
LINE VOLTAGE
LOW VOLTAGE
GND.
PV
PV/MV
MV
W
G
R
GAS VALVE
VR8204A / VR8304M
4 POLE CONNECTOR
VENT DAMPER CABLE
P1-01
BR
THERMOSTAT
P1-02
B
O
PRESSURE
LIMIT
LWCO
N
TO
VENT
DAMPER
H
P1-04
BK
P1-03
Y
24 V.
SECONDARY
BK
BT
120 V.
PRIMARY
W
NEUTRAL
BK
FLAME ROLLOUT
SAFETY
SHUTOFF
115V/60HZ/1Ø
HOT
OVERCURRENT PROTECTED
DISCONNECT
BLOCKED VENT
SAFETY
SHUTOFF
R GW
BK BK BT
SPARK
(24V)
(GND.)
(24V)
GND.
MV
MV/PV
PV
UT 1003-620 SERIES
INTERMITTENT PILOT CONTROL
BL
TO PILOT BURNER
BK
NOTE:
1) S1A AND S1B ARE THE AUTOMATIC
OPERATION/HOLD DAMPER OPEN SWITCH.
SWITCH SHOWN IN AUTOMATIC POSITION.
S2, S3, AND S4 ARE CAM ACTUATED SNAP SWITCHES.
W
G
R
GND.
PV
PV/MV
MV
GAS VALVE
VR8204A / VR8304M
A03102
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C thermoplastic
wire or its equivalent.
→ Fig. 12—Wiring Diagram for Intermittent Ignition Boilers with PS-802 Probe-Type Low Water Cut-Off
—14—
VENT DAMPER
MOLEX PLUG
4
115V/60HZ/1Ø
POWER
SUPPLY
BK
1
2
3
O
BR
Y
O
NEUT
THERMOSTAT
HOT
OVERCURRENT PROTECTED
DISCONNECT
BT
t´
BK
W
BK
PRESSURE
LIMIT
Y
BK
R
W
H
N
G
B
1
2
3
LOW WATER
CUT OFF
N
H
C
W
B
OPTIONAL WF-2U-24
WATER
FEEDER
BK
J7
BT
NOTE:
LWCO PROBE
TERMINAL NO. 3 APPEARS ONLY
ON WATER FEEDER MODELS WITH
MANUAL FEED PUSH BUTTON.
TR
- WIRE NUT
GAS VALVE
COLOR CODE
BK
BR
0
Y
R
BT
W
G
B
- BLACK
- BROWN
- ORANGE
- YELLOW
- RED
- BLACK WITH TRACER
- WHITE
- GREEN
- BLUE
FLAME ROLLOUT
SAFETY SHUTOFF
TH
BLOCKED VENT
SAFETY SHUT OFF
4 POLE CONNECTOR
VENT DAMPER CABLE
P1-01
BR
P1-02
B
O
PRESSURE
LIMIT
THERMOSTAT
LWCO
N
H
TO
VENT
DAMPER
P1-04
BK
24 V.
SECONDARY
P1-03
Y
BT
BK
TR
FLAME ROLLOUT
SAFETY
SHUTOFF
120 V.
PRIMARY
BK
BLOCKED VENT
SAFETY
SHUTOFF
W
NEUTRAL
HOT
TH
GAS
VALVE
115V/60HZ/1Ø
OVERCURRENT
PROTECTED
DISCONNECT
NOTE:
S1A AND S1B ARE THE AUTOMATIC OPERATION / HOLD DAMPER OPEN SWITCH.
SWITCH SHOWN IN AUTOMATIC POSITION.
S2, S3, AND S4 ARE CAM ACTUATED SNAP SWITCHES.
A03103
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C thermoplastic
wire or its equivalent.
→ Fig. 13—Wiring Diagram for Standing Pilot Boilers with PS-802 Probe-Type Low Water Cut-Off
—15—
VENT DAMPER
MOLEX PLUG
4
24 VOLT
TRANSFORMER
BK
1
2
3
O
BR
Y
115V/60HZ/1Ø
POWER SUPPLY
HOT
- WIRE NUT
O
BK
THERMOSTAT
BK
COLOR CODE
BK - BLACK
BR - BROWN
0 - ORANGE
Y - YELLOW
R - RED
BT - BLACK WITH TRACER
W - WHITE
G - GREEN
PRESSURE LIMIT
BT
Y
BK
4
1
3
LOW WATER
CUT OFF
UT 1003-620 SERIES
INTERMITTENT PILOT CONTROL
BK
(24V)
NOTE:
TERMINAL NO. 3 APPEARS ONLY
ON WATER FEEDER MODELS WITH
MANUAL FEED PUSH BUTTON.
2
MV
MV/PV
PV
OPTIONAL WF-2U-24
WATER FEEDER
RGW
FLAME ROLLOUT
SAFETY SHUTOFF
(24V)
(GND.)
SPARK
2
3
1
GND.
t´
BK
OVERCURRENT PROTECTED
DISCONNECT
W
NEUT
BK BK BT
BL
TO PILOT BURNER
BLOCKED VENT
SAFETY SHUTOFF
BK
GND.
PV
PV/MV
MV
W
G
R
4 POLE CONNECTOR
GAS VALVE
VR8204A / VR8304M
VENT DAMPER CABLE
P1-01
BR
P1-02
O
THERMOSTAT
PRESSURE
LIMIT
TO
VENT
DAMPER
BK
24 V.
SECONDARY
P1-04
Y
BK
P1-03
BT
2
120 V.
PRIMARY
LWCO
1
BLOCKED VENT
SAFETY
SHUTOFF
(24V)
(GND.)
SPARK
(24V)
R GW
GND.
UT 1003-620 SERIES
INTERMITTENT PILOT CONTROL
MV
MV/PV
PV
FLAME ROLLOUT
SAFETY
SHUTOFF
BK BK BT
BL
BK
W
NEUTRAL
115V/60HZ/1Ø
HOT
OVERCURRENT
PROTECTED
DISCONNECT
TO PILOT BURNER
BK
NOTE:
1) S1A AND S1B ARE THE AUTOMATIC
OPERATION / HOLD DAMPER OPEN SWITCH.
SWITCH SHOWN IN AUTOMATIC POSITION.
S2, S3, AND S4 ARE CAM ACTUATED SNAP SWITCHES.
W
G
R
GND.
PV
PV/MV
MV
GAS VALVE
VR8204A / VR8304M
A03104
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C thermoplastic
wire or its equivalent.
→
Fig. 14—Wiring Diagrams for Intermittent Ignition Boilers with Float-Type Low Water Cut-Off
—16—
VENT DAMPER
MOLEX PLUG
4
24 VOLT
TRANSFORMER
BK
1
2
3
O
BR
Y
115V/60HZ/1Ø
POWER SUPPLY
HOT
- WIRE NUT
O
BK
THERMOSTAT
2
3
1
t´
BK
OVERCURRENT PROTECTED
DISCONNECT
W
NEUT
BK
PRESSURE LIMIT
BT
Y
BK
OPTIONAL WF-2U-24
WATER FEEDER
NOTE:
TERMINAL NO. 3 APPEARS ONLY
ON WATER FEEDER MODELS WITH
MANUAL FEED PUSH BUTTON.
2
4
LOW WATER
CUT OFF
1
3
TR
GAS VALVE
TH
BT
BK
COLOR CODE
BK - BLACK
BR - BROWN
0 - ORANGE
Y - YELLOW
R - RED
BT - BLACK WITH TRACER
W - WHITE
G - GREEN
BK
FLAME ROLLOUT
SAFETY SHUTOFF
BLOCKED VENT
SAFETY SHUTOFF
4 POLE CONNECTOR
VENT DAMPER CABLE
P1-01
BR
P1-02
O
PRESSURE
LIMIT
THERMOSTAT
TO
VENT
DAMPER
BK
24 V.
SECONDARY
P1-04
Y
BK
BT
P1-03
2
TR
LWCO
120 V.
PRIMARY
1
BK
FLAME ROLLOUT
SAFETY
SHUTOFF
TH
GAS
VALVE
BLOCKED VENT
SAFETY
SHUTOFF
W
NEUTRAL
115V/60HZ/1Ø
HOT
OVERCURRENT
PROTECTED
DISCONNECT
NOTE:
1) S1A AND S1B ARE THE AUTOMATIC
OPERATION / HOLD DAMPER OPEN SWITCH.
SWITCH SHOWN IN AUTOMATIC POSITION.
S2, S3, AND S4 ARE CAM ACTUATED SNAP SWITCHES.
A03105
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 105°C thermoplastic
wire or its equivalent.
→
Fig. 15—Wiring Diagrams for Standing Pilot Boilers with Float-Type Low Water Cut-Off
—17—
VENT DAMPER
4 PIN
MOLEX PLUG
VENT DAMPER
4 PIN
MOLEX PLUG
4
1
BL BR
2
O
ISOLATION RELAY 24V
SPST N.O. HONEYWELL
R8222A OR EQUIVALENT
3
Y
24 VOLT
TRANSFORMER
4
1
2
BK BR
O
3
ISOLATION RELAY 24V
SPST N.O. HONEYWELL
R8222A OR EQUIVALENT
Y
24 VOLT
TRANSFORMER
O
O
BL
BK
PRESSURE
LIMIT
PRESSURE
LIMIT
BT
ELECTRONIC
THERMOSTAT
W BT
t°
t°
G
B TERMINAL B
OF LWCO
ELECTRONIC
THERMOSTAT
TO LWCO &
IGNITION SYSTEM
TO LWCO &
IGNITION SYSTEM
FIELD WIRING
FIELD WIRING
A96054
A96055
Fig. 16—Isolation Relay Wiring for Steam Boilers
Fig. 17—Isolation Relay Wiring for Steam Boilers
with 67D-1 Float-Type Low Water Cut-Off
with PS-802 Probe-Type Low Water Cut-Off
and Using Electronic Thermostat
and Using Electronic Thermostat
The boiler, when installed, must be electrically grounded in accordance with requirements of the authority having jurisdiction, or in the absence
of such requirements, with the NEC. Run a 14 gauge or heavier copper wire from boiler to a grounded connection in service panel or a properly
driven and electrically grounded ground rod.
PROCEDURE 2—INSTALLING THERMOSTAT
The thermostat location has an important effect on the operation of boiler system. BE SURE TO FOLLOW INSTRUCTIONS INCLUDED WITH
THERMOSTAT.
Locate thermostat about 5 ft above floor on an inside wall. It may be mounted directly on wall or on a vertically mounted outlet box. It should
be sensing average room temperature so avoid the following:
DEAD SPOTS:
Behind doors
Corners and alcoves
HOT SPOTS:
Concealed pipes
Fireplace
TV sets
Radios
Lamps
Direct sunlight
Kitchens
COLD SPOTS:
Concealed pipes or ducts
Stairwells—drafts
Doors—drafts
Unheated rooms on other side of wall
Set heat anticipator at 0.7 amps for boilers equipped with standing pilot and at 0.9 amps for boilers equipped with intermittent ignition. The 24-v
thermostat leads shall be connected to the 2 wires tagged "24 volt thermostat" on boiler. For boilers with 67D-1 float-type low water cut-off, both
wires are black. One wire is located on secondary of 24-v transformer. The second wire is located on pressure limit control. For boilers with PS-802
probe-type low water cut-off, 1 wire is green and is located on terminal B of the PS-802. The second wire is black and is located on pressure limit
control.
PROCEDURE 3—ELECTRONIC THERMOSTATS
Certain types of electronic thermostats may lose their memory or shut down. With PS-802 probe-type low water cut-offs, this may occur each time
the low water cut-off detects a low water condition. With 67D-1 float-type low water cut-offs, this may occur each time thermostat calls for heat,
due to the internal circuit in vent damper. If this is the case, an isolation relay is required for thermostat circuit. A 24-v single-pole single-throw
(SPST) normally open (N.O.) relay is required such as Honeywell R8222A or equivalent. See Fig. 16 or 17 and wire as shown.
PROCEDURE 4—VENT DAMPER
The boiler is equipped with a factory-wired harness with a 4-pin Molex plug which plugs into 4-pin Molex receptacle inside vent damper operator.
The vent damper must be connected for boiler to operate.
CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after servicing.
—18—
CONTROLS AND ACCESSORIES
PROCEDURE 1—RELIEF VALVE
The relief valve should open automatically if boiler steam pressure exceeds pressure rating of valve (15 psig). Should it ever fail to open under
this condition, shut down boiler. If valve discharge occurs or valve fails to open as described above, contact an authorized contractor or qualified
service technician to replace relief valve and inspect heating system to determine the cause as this may indicate an equipment malfunction.
Run a pipe from safety valve outlet (pipe must be same size as outlet, and open end must not be threaded) to an open drain, tub, sink, or other
suitable drainage point not subject to freezing.
→
CAUTION: Failure to do so may cause water damage or injury should relief valve release. Do not cap off drain line from
this valve!
PROCEDURE 2—STEAM PRESSURE GAUGE
Every system should have a pressure gauge installed in boiler. This gauge enables monitoring of pressure in system. If safety devices fail to shut
off boiler at proper settings, notify service technician immediately.
PROCEDURE 3—WATER LEVEL GAUGE
The water level in boiler can be seen through glass tube in water level gauge at side of boiler. Correct cold boiler water level is stamped on side
jacket panel. The water level should be checked regularly for proper level.
PROCEDURE 4—STEAM PRESSURE CONTROL
The steam pressure limit control (pressuretrol) shuts off gas to main burners when steam pressure in boiler reaches cut-off setpoint (the sum of
cut-in and differential set points). Burners refire when stream pressure drops to cut-in setpoint. System pressure requirements are based on size
and condition of pipes and load.
PROCEDURE 5—LOW WATER CUT-OFF (LWCO)
On right side jacket panel of boiler, there are 3 holes for glass water level gauge. The top hole is common for both types of LWCOs and is used
for upper gauge glass fitting. The middle hole (9 in. down from top hole) is used for bottom gauge glass fitting for the Model 67D-1 float-type
LWCO. The lowest hole (12-1/4 in. down from top hole) is used for bottom gauge glass fitting for the Model PS-802 probe-type LWCO. The hole
that is not being used is covered with a sheet metal knockout.
A. Model 67D-1
This is a float-operated switch which shuts down gas burners if water falls below visible bottom of gauge glass.
B. Model PS-802
This is an electronic probe-type LWCO. The probe is located inside boiler. The LWCO shuts down burners if water loses contact with probe for
a period of 10 sec.
Refer to manufacturer’s instructions (enclosed) for more information.
PROCEDURE 6—WATER FEEDER (OPTIONAL)
The model WF-2U-24 water feeder may be used with either of the available low water cut-offs. The water feeder’s job is to maintain a safe
minimum water level. It is used to keep boiler running by compensating for minor evaporative steam leaks and to prevent freeze-ups if the
homeowners are away and a return line springs a leak.
McDonnell and Miller Model 101 water feeders may be used; however, the water feed rates are too high and need to be regulated or throttled,
and wiring must be revised. Consult boiler manufacturer before using these or any other non-standard types of controls.
The automatic water feeder is a safety device not a convenience item. It is not designed to maintain a "normal" water line. The water feeder does
not take the place of a responsible person monitoring and maintaining normal water line. Steam boilers require personal attention.
PROCEDURE 7—VENT DAMPER
This is an automatic, motorized stack damper developed to increase efficiency of heating systems by reducing standby losses from boiler and
conditioned air space. The damper closes chimney vent when burner is off and fully opens it when combustion is required.
PROCEDURE 8—ROLLOUT SWITCH (FLAME ROLLOUT SAFETY SHUTOFF)
The rollout switch is a temperature-sensitive fuse link device. It is located on boiler base just outside fire box. In the event of heat exchanger
flueway blockage causing flame to roll out of fire box, the fuse blows shutting down flow of gas to main burners. The fuse does not change in
appearance when blown.
If rollout switch blows, it must be replaced with an exact replacement. Check heat exchanger flueways for blockage when restoring system to
operating condition. Do not operate system without a rollout switch.
PROCEDURE 9—SPILL SWITCH (BLOCKED VENT SAFETY SHUTOFF)
The spill switch is a manual-reset disc thermostat with a fixed setpoint (280°F) and normally-closed contacts. It is located at relief opening of draft
diverter. In the event of chimney or venting system blockage causing products of combustion to spill out of relief opening, the spill switch disc
heats up and spill switch contacts open shutting down flow of gas to main burners by removing power to gas valve.
In the event that spill switch contacts open, the reset button on back of switch pops up. The spill switch must be reset manually, after the switch
has cooled off, by pushing the reset button down. Check venting system and chimney for blockage when restoring system to operating condition.
DO NOT operate system without a spill switch.
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage,
personal injury, or death.
A. Some boilers are equipped with an intermittent ignition device which automatically lights the pilot. Do NOT try to light pilot by hand.
Some boilers are equipped with a continuous pilot and must be lit manually. See lighting instructions in Continuous Pilot Boiler section. A match
holder is included in parts bag.
—19—
B. BEFORE OPERATING, smell all around appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and
will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to turn gas control knob. Never use tools. If knob will not turn by hand, do not try to repair it. Call a qualified service
technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace
any part of control system and any gas control which has been under water.
GAS VALVE OPERATING INSTRUCTIONS
PROCEDURE 1—INTERMITTENT IGNITION BOILER—VR8204A/VR8304M GAS VALVE
A.
To Turn On Gas To Appliance
1. STOP! Read safety information in For Your Safety Read Before Operating section.
2. Set thermostat to lowest setting.
3. Turn off all electrical power to appliance.
4. This appliance is equipped with an ignition device which automatically lights the pilot. Do NOT try to light pilot by hand.
5. Remove lower front panel.
6. Turn gas control knob clockwise to OFF position. (See Fig. 18.)
7. Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in safety information
in For Your Safety Read Before Operating section.
8. Turn gas control knob counterclockwise to ON position. (See Fig. 18.)
9. Replace lower front panel.
10. Turn on all electrical power to appliance.
11. Set thermostat to desired setting.
12. If appliance will not operate, follow instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.
B.
To Turn Off Gas To Appliance
1. Set thermostat to lowest setting.
2. Turn off all electric power to appliance if service is to be performed.
3. Turn gas control knob clockwise to OFF position. (See Fig. 18.) Do not force.
PROCEDURE 2—CONTINUOUS PILOT BOILER—VR8200A/VR8300A GAS VALVE
A.
To Turn On Gas To Appliance
1. STOP! Read safety information in For Your Safety Read Before Operating section.
2. Set thermostat to lowest setting.
3. Turn off all electrical power to appliance.
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
WIRING
TERMINALS (3)
INLET
PRESSURE
TAP
GAS
INLET
ON
OUTLET
PRESSURE
TAP
GROUND
TERMINALS (2)
GAS
OUTLET
OFF
GAS CONTROL
KNOB SHOWN
IN "ON" POSITION
PILOT
ADJUSTMENT
(UNDER CAP
SCREW)
PILOT
OUTLET
A95520
Fig. 18—VR8204A/VR8304M Intermittent Ignition Gas Valve
—20—
PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)
WIRING
TERMINALS (2)
INLET
PRESSURE
TAP
OUTLET
PRESSURE
TAP
CONVENIENCE
TERMINALS (2)
(OPTIONAL)
GAS
INLET
ON
GAS
OUTLET
MATCH HOLDER
OFF
PILOT
THERMOCOUPLE
CONNECTION
RED RESET
BUTTON
PILOT
ADJUSTMENT
(UNDER CAP
SCREW)
PILOT
OUTLET
GAS CONTROL
KNOB SHOWN
IN "ON" POSITION
A95521
Fig. 19—VR8200A/VR8300A Continuous Pilot Gas Valve
A99181
Fig. 20—Lighting Pilot
4. Remove lower front panel.
5. Turn gas control knob clockwise to OFF position. (See Fig. 19.)
6. Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in safety information
in For Your Safety Read Before Operating section.
7. Find pilot. Follow metal tube from gas control. The pilot is between 2 burner tubes. (See Fig. 20.)
8. Turn knob on gas control counterclockwise to PILOT position. (See Fig. 19.)
9. Push down and hold red reset button while you light pilot burner with a match. After about 1 minute, release reset button. Pilot should
remain lit. If it goes out, turn gas control knob clockwise to OFF position. To relight, repeat items 5-9.
• If button does not pop up when released, stop and immediately call your service technician or gas supplier.
• If pilot will not stay lit after several tries, turn gas control knob to OFF position and call your service technician or gas supplier.
10. After pilot remains lit when red reset button is released, turn gas control knob counterclockwise to ON position. (See Fig. 19.)
11. Replace lower front panel.
12. Turn on all electrical power to appliance.
13. Set thermostat to desired setting.
B.
To Turn Off Gas To Appliance
1. Set thermostat to lowest setting.
2. Turn off all electrical power to appliance if service is to be performed.
3. Turn gas control knob clockwise to OFF position. (See Fig. 19.) Do not force.
OPERATING BOILER
PROCEDURE 1—HOW A STEAM SYSTEM OPERATES
The water in boiler is heated until it reaches boiling point. As water boils, it turns into steam. The steam rises from top of water through supply
main to radiation units. As it passes through radiators, it releases its heat and condenses into water. The water returns to boiler through return main.
Most residential systems operate at less than 1 lb steam pressure.
PROCEDURE 2—FILLING SYSTEM WITH WATER
On steam heating systems, boiler is partially filled with water. It is very important to proper operation of entire system that boiler be filled to proper
level. The correct water level is about halfway up glass water level gauge as marked on boiler jacket. To fill:
1. Close boiler drain valve.
2. Open valves at top and bottom of glass water level gauge. Also open drain valve at bottom of gauge.
3. Open fill valve and allow water to run into boiler.
→
CAUTION: Never run water into a hot, empty boiler or thermal shock may crack boiler components (sections).
—21—
4. Allow boiler to fill until water runs out gauge drain valve, then close gauge drain valve.
5. Continue to fill boiler until water reaches indicated water line. This is about halfway up glass tube.
PROCEDURE 3—WATER LEVEL
The normal water level is shown on right side of boiler and is 24 in. above the floor. The normal water level is determined when boiler is off and
cold (when all of the water in system is inside boiler and return piping below water line) and everything above water line is air, no steam. When
boiler is making steam, the water level drops 2-3 in. below normal water line.
PROCEDURE 4—AUTOMATIC GAS VALVE
The automatic gas valve opens or closes according to heat requirements of thermostat and pressure limit control. It closes if pilot goes out. Each
individual control must be operating correctly before any gas can pass to burners. Any 1 control can hold gas supply from burners regardless of
demand of any other control.
PROCEDURE 5—THERMOSTAT
Keep thermostat set at desired room temperature. If windows are to be opened or heat is not needed, set thermostat to a lower setting.
NOTE: In the event of failure of any component, system will not operate or will go into safety lockout. The system is completely self-checking.
On every call for heat, each component must be functioning properly to permit operation. On safety lockout, system has to be reset by setting
thermostat to lowest setting for 1 minute, then back to normal setting.
Safe lighting and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests
specified in ANSI Z21.13.
CHECKING AND ADJUSTING
PROCEDURE 1—PILOT BURNER ADJUSTMENT
Pilot flame should surround 3/8- to 1/2-in. of pilot sensor. (See Fig. 21.) If flame needs adjusting, proceed as follows:
1. Remove screw cover over pilot adjusting screw.
2. Insert small screwdriver and adjust flame as needed. Turn screw counterclockwise to increase flame and clockwise to decrease flame.
3. Replace screw cover over pilot adjusting screw.
PROCEDURE 2—MAIN BURNER(S)
The main burners do not require primary air adjustment and are not equipped with primary air shutters. Main burner flames should form sharp
blue inner cones in a softer blue out mantel, with no yellow. Puffs of air from blowing on the flame or stamping on the floor will cause the flames
to turn orange momentarily. This is not unusual. Remain still when observing the main burner flames. If the flame appearance is not correct, check
main burner orifices and the burner throat and flame ports for dust and lint obstruction. It may be necessary to remove the rollout shield to observe
the main burner flames. Replace rollout shield after observation. (See Fig. 22.)
PROCEDURE 3—GAS VALVE SAFETY SHUTDOWN TEST
A. Boilers Equipped with Continuous Pilot
With main burners firing, disconnect thermocouple from gas valve. (See Fig. 19.) Gas valve should immediately shut off main burners and pilot.
B. Boilers Equipped with Intermittent Ignition
With main burners firing, disconnect ignition cable from intermittent pilot control box. Gas valve should shut off main burners. TURN OFF
ELECTRIC POWER to boiler before reconnecting ignition cable to prevent electric shock.
PROCEDURE 4—STEAM PRESSURE CONTROL ADJUSTMENT
The steam pressure limit control (pressuretrol) shuts off gas to main burners when steam pressure in boiler reaches cut-off setpoint (the sum of
cut-in and differential set points). Burners refire when steam pressure drops to cut-in setpoint. System pressure requirements are based on size and
condition of pipes and load.
For good system operation, the cut-in setting of pressuretrol should never be less than twice the system pressure drop. In a typical single family
residence with a clean 1-pipe heating system and cast iron radiation, this means that cut-in will usually be set at the minimum setting of 0.5 psi.
Steam radiation is usually sized based on sq ft of equivalent direct radiation (EDR). This is based on a steam pressure in radiator of just less than
1 psi. Therefore, in example system from above, the differential adjustment would be set at 1 psi (the steam pressure required in radiators). This
gives a cut-off setpoint of 1.5 psi.
3⁄8″
to 1⁄2″
OUTER MANTEL
FLAME
ON SENSOR
SHARP INNER CONES
A95160
A99182
Fig. 22—Main Burner Flame
Fig. 21—Pilot Flame and Sensor
—22—
The above is an example of a typical 1-pipe system. For larger systems or other types of systems such as 2-pipe systems or systems with convectors
or fan coil units, pressuretrol settings need to be determined on a system-by-system basis.
The cut-in setpoint is determined by system pressure drop to furthest radiator or terminal unit. Double the system pressure drop as a safety factor,
resulting in the rule that cut-in setting should never be less than twice the system pressure drop.
The differential setpoint is the steam pressure required at terminal heating units.
Boiler now operates in correct pressure range. It maintains enough steam pressure to send steam out to furthest radiator, and not go over optimum
steam pressure required at radiators.
PROCEDURE 5—CHECKING CONTROLS
A. Low Water Cut-Off (LWCO)
To check LWCO, turn power off to boiler or adjust thermostat to lowest setting. Drain water to below visible bottom of water gauge glass. Turn
power on and adjust thermostat to call for heat. Gas valve should not open on a call for heat when water is low.
If boiler is equipped with optional WF-2U-24 water feeder, keep thermostat calling for heat after LWCO recognizes low water condition. After
a 1-minute time delay, water feeder should start feeding water to boiler. The feeder should feed for 1 minute and then go into another 1-minute
waiting period. This cycle of alternately waiting and feeding should repeat until:
MODEL 67D-1 FLOAT-TYPE LOW WATER CUT-OFFS
As water level raises the float above burner cut-off switch level, burners should ignite. The water feeder remains powered until water level raises
the float to water feeder switch level satisfying water feeder.
MODEL PS-802 PROBE-TYPE LOW WATER CUT-OFFS
The water level rises until water in boiler makes contact with probe satisfying water feeder and igniting burners.
In either case, there should be between 1 and 2 in. of water visible in gauge glass when both the water feeder is satisfied and the burners are allowed
to ignite.
The time delays in feed cycles are designed to prevent boiler from flooding due to slow return lines.
B. Pressure Limit
To check pressure limit, run boiler until pressure reaches system demand. Then turn pressure screw and drop pressure setting until boiler shuts
down. This shows that pressure limit is operating properly.
Refer to control manufacturer’s instructions (enclosed) for more information.
C. Thermostat
Check thermostat operation. When set above temperature indicated on thermometer, boiler should ignite. Make certain thermostat turns boiler off
when room temperature reaches selected setting and starts boiler operating when room temperature falls a few degrees.
Finally, set thermostat for desired temperature. Special conditions in home and location of thermostat govern this setting.
CLEANING BOILER
It is very important to clean a new steam boiler after it has been installed and put into continuous operation. This must be done to remove any
accumulation of oil, grease, sludge, etc. that may be present in system. These substances may cause boiler water to foam and surge, producing
a very unsteady water line, throwing water into steam header, and possibly preventing steam generation. Follow the procedures below in order to
remove these contaminants:
PROCEDURE 1—SKIMMING
New boilers must be skimmed at the time of installation to remove threading oil and other impurities that float on surface of water.
1. Remove plug from skimmer tapping and pipe to a floor drain or bucket.
2. Raise water level to skimmer tapping.
3. Fire boiler to maintain a water temperature of 180-200°F.
4. Feed water to boiler to maintain water level. Adjust water feed rate to keep water continuously flowing out of skimmer tapping without
water level going above or falling below tapping. Cycle burners to prevent boiling.
5. Continue skimming until water runs clear. This may take several hours.
PROCEDURE 2—BLOWDOWN
1. Float-type low water cut-offs must be blown down after skimming. The float chamber of the low water cut-off must be flushed clean and
maintained clear of sediment to allow free movement of float. This must be done frequently during initial operation of boiler and at least
once a week thereafter. Follow instructions on tag attached to control.
Probe-type low water cut-offs require no maintenance at this time.
2. After blowing down low water cut-off and before blowing down boiler, fill boiler to water line. Fire burners and allow normal steam
pressure to build up. Run a connection from boiler blowdown valve to a nearby sewer or floor drain or to a safe discharge point outside.
SHUT OFF GAS BURNERS, open blowdown valve, and allow all water in boiler to drain out. Close blowdown valve. Allow boiler to cool
thoroughly, then slowly refill boiler to water line. Repeat this item as many times as necessary until blowdown water is clear.
3. Following final blowdown, allow boiler to thoroughly cool, then add fresh water slowly up to normal water line. Start burners and maintain
at least 180°F for 15 minutes to remove dissolved gases from fresh water. Shut off burners.
Now let boiler steam for a few days to give the majority of the system dirt a chance to work its way back to boiler. Check water in gauge glass.
The gauge glass should be dry above water line. The water line should not bounce more than 1 in. when boiler is steaming. If water droplets carry
over from top of gauge glass or excessive bouncing of water line occurs, boiler needs further cleaning. Take a water sample and boil it on stove
to see if it foams. If it does, this also indicates boiler needs to be cleaned.
—23—
If cleaning is necessary, repeat skimming and blowdown procedures above. Usually a long skim is sufficient to clean boiler.
In more troublesome cases, it may be desirable to flush the system as well. This is accomplished by closing gate valve in the Hartford Loop and
opening drain(s) at end of wet return(s). Run a hose from drain valve on wet return to a nearby floor drain or bucket. Run boiler at 2 lb. of steam
pressure. Feed just enough water to compensate for waste condensate going down drain and to keep boiler from going off on low water cut-off.
Run boiler until all waste condensate runs clear.
NOTE: Boiler cleaners and chemical cleaning additives are not recommended. If used and not rinsed properly, they will do more harm than good.
The cleaning procedures laid out above clean out typical oils and impurities found in new boilers and in residential heating systems. The best thing
for boiler and heating system is clean water with no additives.
In very extreme cases, it may be necessary to chemically clean and flush heating system. Consult boiler manufacturer before introducing any
chemicals into boiler.
MAINTAINING BOILER
PROCEDURE 1—WATER LEVEL
Check water level every day or two. Verify water line shown by operating drain valve on gage. BE SURE TOP AND BOTTOM VALVES ON
GAUGE ARE ALWAYS OPEN SO THAT ACTUAL WATER LEVEL IS SHOWN AT ALL TIMES.
The gauge glass should be dry above water line. The water line should not bounce more than about 1 in. when boiler is steaming. If water droplets
carry over through top of gauge glass or excessive bouncing of water line occurs, boiler needs to be cleaned. Follow instructions in Cleaning Boiler
section.
PROCEDURE 2—RELIEF VALVE
Before testing, make certain discharge pipe is properly connected to valve outlet and arranged to contain and safely dispose of boiler discharge.
Under normal operating conditions, a "try lever test" must be performed every month. A "try lever test" must also be performed at the end of any
non-service period. Test at normal system operating pressure by holding test lever fully open for at least 5 sec to flush valve seat free of sediment
and debris. Then release lever and permit valve to snap shut. If lift lever does not activate or there is no evidence of discharge, turn boiler off
immediately and contact a licensed contractor or qualified service personnel.
PROCEDURE 3—LOW WATER CUT-OFF (LWCO)
The low water cut-off interrupts electrical current to burner when water line in boiler drops to a low level.
A. Float-Type Low Water Cut-Offs
It is very important to keep float chamber free of sediment, a condition essential to dependability. To keep any accumulation from interfering with
float action, "blow down" or flush out control regularly. This must be down 2-3 times during the first week after installation and once a week
thereafter during heating season. Do it while boiler is in operation.
1. Note water level in gauge glass.
2. Open blow-off valve at bottom of control. Water will pour out flushing away sediment.
3. Drain until water is clear (about a pailful), then close valve.
4. If water level in gauge glass has dropped, add water to boiler to restore level.
Consult LWCO manufacturer’s instructions included with boiler.
NOTE: Opening blow-off valve checks cut-off operation too. As float drops with falling water level, burners shut off. After valve is closed and
normal operating conditions are restored, burners resume firing.
B. Probe-Type Low Water Cut-Offs
Check action of LWCO monthly to make sure it is providing proper protection. See Checking and Adjusting section. LWCO remote probes must
be removed for periodic inspection and cleaning, preferably at beginning of each heating season. More frequent cleaning may be required on boilers
requiring constant or very frequent additions of water.
PROCEDURE 4—BURNERS
A visual check of pilot and main burner flames should be made at least once each year, preferably at beginning of each heating season. See
Checking and Adjusting section.
PROCEDURE 5—BOILER FLUE PASSAGES
Under normal operating conditions with burners properly adjusted, it should not be necessary to clean boiler flue gas passages. However, to assure
trouble-free operation, we recommend that flue passages, burner adjustment, and operation of controls be checked ONCE EACH YEAR by a
competent service technician.
BEFORE THE START OF EACH SEASON (or whenever system has been shut down for some time), recheck whole system for leaks and recheck
boiler and vent pipe for leaks.
PROCEDURE 6—VENT PIPE
The venting of this unit is very important. Piping should be checked at least once a season. If vent piping shows any signs of leaking, replace it
immediately.
PROCEDURE 7—CLEANING BOILER FLUE PASSAGES AND BURNERS
Flue passages between sections should be examined yearly and cleaned if necessary. To clean:
1. Remove burners, pilot, and vent pipe.
2. Remove top and front jacket panels.
—24—
3. Remove 2 screws attaching intermediate front panel to left and right side jacket panels.
4. Remove draft diverter and intermediate front panel as 1 unit.
5. Carefully remove cerafelt gasket strips.
6. Clean passageways between sections with a flexible handle wire brush. Remove dirt from bottom of boiler and between sections by
vacuuming.
7. Make sure all flame ports in burners are open and clear. Shake out or blow out all loose dirt in burners.
8. Reseal seams between adjacent sections as necessary with 400°F RTV silicone sealant.
9. Reassemble all parts. Be sure to check tightness of pilot connections and condition of burner flames after reassembly. (See Fig. 21 and 22.)
10. Be sure vent pipe connections to chimney are secure and no obstructions are present.
PROCEDURE 8—FOAMING, PRIMING, OR SURGING
These terms are used to describe a fluctuating water line—when water leaves boiler with steam.
It is caused by any combination of the following:
1. Threading oil and organic matter in boiler water. (Mineral oil or core sand does not cause surging.) Follow instructions in Cleaning Boiler
section.
2. Faulty quick vents that do not release air until a sizeable pressure is built up. If old style, replace. If dirty, clean so it is easy to blow through
valve.
3. Improper header design—when steam flows in opposite direction of equalizer line on "Hartford Loop." Generally, a 15-in. horizontal run
between riser and main takeoff allows entrained water to fall out of steam vapor so it can return to boiler. (See Fig. 3, 4, and 5.)
4. Adjustment of steam limit control to a wide differential increases difficulty if quick vents are old style, slow-releasing type, or dirty. Always
set steam limit control differential as low as possible.
5. Soap and detergents in boiler water cause extreme surging. Boiler cleaners and chemical cleaning additives are not recommended. If used
and not rinsed properly, they will do more harm than good. The cleaning procedures laid out in these instructions clean out typical oils and
impurities found in new boilers and in residential heating systems. The best thing for boiler and heating system is clean water with no
additives.
→
CAUTION: Never refill a hot boiler with cold water or thermal shock may crack boiler components (sections).
PROCEDURE 9—BOILER WATER TREATMENT (OTHER THAN CLEANERS)
In steam systems where system is tight, free from leaks, and all steam is returned to boiler as condensate, the amount of make-up water is small.
Water treatment is generally not required.
In steam systems where less than 90 percent of steam is returned as condensate, or with very hard or corrosive make-up water, treatment may be
desirable. Follow recommendations of local boiler water treatment specialist.
PROCEDURE 10—BETWEEN HEATING SEASONS
Boilers should not be drained between heating seasons. Steam boilers should be entirely filled with water during summer months to exclude air.
—25—
SERVICE HINTS
You may avoid inconvenience and service calls by checking these points before you call for service.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
1.
2.
3.
4.
Do not try to light any appliance.
Do not touch any electric switch; do not use the phone.
Leave the building immediately, then call your gas supplier.
If you cannot reach the gas supplier, call the fire department.
IF SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT. . .
What To Do
Reset thermostat above room temperature.
Check flame. If it is yellow, burner is not getting enough air. If flame is blue and noisy and seems to lift off
Burner is not operating properly
burner, burner is getting too much air. Contact your service technician.
No electric power to boiler
Check overcurrent protection. Check to be sure electric power supply circuit is on.
Controls out of adjustment
Reset according to instructions.
Radiators not heating properly
Steam air vents are not operating properly. Check flow control valve (if used). It may be in closed position.
Poor electrical contact
Check all control terminals and wire joints.
Have your service technician check heat exchanger for blockage. Replace rollout switch with exact replaceRollout switch blown
ment.
Spill switch contacts are open requiring manual reset of spill switch. Have your service technician check and
Chimney flue is blocked
correct chimney problem.
Vent damper not operating
Consult troubleshooting guide in manual, packaged with vent damper.
IF BURNER IS NOISY. . .
Possible Cause
What To Do
Gas input amount is incorrect
Contact your service technician.
IF WALLS OR WINDOWS SWEAT. . .
Possible Cause
What To Do
Not enough ventilation
Contact your service technician.
Chimney flue is blocked
Have your service technician check and correct, if necessary.
IF RADIATORS ARE NOISY. . .
Possible Cause
What To Do
Air in system
Refer to "Radiators Not Heating Properly" above.
RELIEF VALVE LEAKING. . .
Possible Cause
What To Do
Dirt on seat
Open valve manually. Allow steam to blow and clear valve seat.
Possible Cause
Thermostat is not set correctly
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.
—26—
REPAIR PARTS
GAS-FIRED STEAM BOILERS
yy
;;
;;
yy
;;
yy
;;
;yyy
21
—IMPORTANT— READ THESE INSTRUCTIONS BEFORE
ORDERING
All parts listed in the following Parts List may be ordered through
your nearest supplier.
When ordering parts, first obtain Model No. from data plate on boiler,
then determine Part No. (not the Key No.) and Description of each
part from the following illustrations and lists. Be sure to give all this
information:
Part No. — Part Description — Boiler Model No.
17
18
16
19
15
20
14
13
12
3
8
9
10
11
2
4
6
5
7
1
A95161
Jacket—Section and Base Parts
This is a Repair Parts List—Not a Packing List
KEY
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
*
*
*
*
21
*
*
DESCRIPTION
Jacket, Right Side Panel
No. 10 X 1/2-in. Sheet Metal Screw
Rating Plate
Base Sides (2)
Base Insulation
Base Front
Base Rear
Base Baffle
Base
Jacket Tie Bar
Push Nipple
Jacket, Left Side Panel
Knob, Service Door (Pair)
Jacket, Service Door
Jacket, Intermediate Panel
Jacket, Front Panel
1/4-in. Tie Rod, Nut
Boiler Section, Left
Boiler Section, Middle
Jacket, Top Panel
Draft Diverter
Boiler Section, Right
Jacket, Back Panel
Jacket Complete
Block Assembly (8, 14, 15, 16, 19)
Combustible Floor Plate
Cerafelt Gasket
Vent Damper
Base Assembly (4, 5, 6)
Rollout Switch Bracket (Nat. Gas Only)
3 Section
425-00-802
146-95-074
146-94-001
146-14-130
146-14-113
146-14-123
425-00-643
425-00-663
425-00-653
433-00-976
425-00-801
137-02-153
425-00-823
425-00-813
425-00-803
146-05-001
410-00-013
410-00-015
425-00-843
425-00-673
410-00-014
425-00-833
425-70-873
410-00-330
146-14-031
146-14-018
118-20-05
433-00-663
425-00-604
4 Section
425-00-802
146-95-074
146-94-016
146-14-130
146-14-114
146-14-124
425-00-644
425-00-664
425-00-654
433-00-976
425-00-801
137-02-153
425-00-824
425-00-814
425-00-804
146-05-002
410-00-013
410-01-015
425-00-844
425-00-674
410-01-014
425-00-834
425-70-874
410-01-430
146-14-031
146-14-018
118-20-06
433-00-664
425-00-604
* Not illustrated.
—27—
5 Section
425-00-802
146-95-074
146-94-016
146-14-130
146-14-115
146-14-125
425-00-645
425-00-665
425-00-655
433-00-976
425-00-801
137-02-153
425-00-825
425-00-815
425-00-805
146-05-051
410-00-013
410-01-015
425-00-845
425-00-675
410-01-014
425-00-835
425-70-875
410-01-530
146-14-031
146-14-018
118-20-06
433-00-665
425-00-604
PART NO.
6 Section
425-00-802
146-95-074
146-94-016
146-14-130
146-14-116
146-14-126
425-00-646
425-00-666
425-00-656
433-00-976
425-00-801
137-02-153
425-00-826
425-00-816
425-00-806
146-05-053
410-00-013
410-01-015
425-00-846
425-00-676
410-01-014
425-00-836
425-70-876
410-01-630
146-14-031
146-14-018
118-20-07
433-00-666
425-00-604
7 Section
425-00-802
146-95-074
146-94-016
146-14-130
146-14-117
146-14-127
425-00-647
425-00-667
425-00-657
433-00-976
425-00-801
137-02-153
425-00-827
425-00-817
425-00-807
146-05-005
410-00-013
410-01-015
425-00-847
425-00-677
410-01-014
425-00-837
425-70-877
410-01-730
146-14-032
146-14-018
118-20-07
433-00-667
425-00-604
8 Section
425-00-802
146-95-074
146-94-016
146-14-130
146-14-118
146-14-128
425-00-648
425-00-668
425-00-658
433-00-976
425-00-801
137-02-153
425-00-828
425-00-818
425-00-808
146-05-007
410-00-013
410-01-015
425-00-848
425-00-678
410-01-014
425-00-838
425-70-878
410-01-830
146-14-032
146-14-018
118-20-07
433-00-668
425-00-604
9 Section
425-00-802
146-95-074
146-94-016
146-14-130
146-14-119
146-14-129
425-00-649
425-00-669
425-00-659
433-00-976
425-00-801
137-02-153
425-00-829
425-00-819
425-00-809
146-05-009
410-00-013
410-01-015
425-00-849
425-00-679
410-01-014
425-00-839
425-70-879
410-01-930
146-14-032
146-14-018
118-20-07
433-00-669
425-00-604
REPAIR PARTS
FOR USE WITH NATURAL GAS ONLY
3
6
4
5
6A
2
1
A98238
Gas Burners and Manifold Parts
This is a Repair Parts List—Not a Packing List
KEY
NO.
1
2
3
4
5
6
6A
7
‡
1
3
7
‡
PART NO.
3 Section
4 Section
5 Section
6 Section
ELECTRONIC INTERMITTENT IGNITION (Shown)
24-v Gas Valve, Elect. Inter. Ignition
146-62-052
146-62-052
146-62-052
146-62-058
Pilot Tube
146-15-005
146-15-005
146-15-005
146-15-005
10-32 X 1/2 Hex Head Screw
146-95-307
146-95-307
146-95-307
146-95-307
Gas Manifold
146-16-033
146-16-034
146-16-035
146-16-013
Main Burner Orifice*
146-15-031
146-15-031
146-15-031
146-15-035
Main Burner, Regular†
146-15-532
146-15-532
146-15-532
146-15-532
Main Burner, Pilot Mount
146-15-531
146-15-531
146-15-531
146-15-531
Pilot Burner
146-62-092
146-62-092
146-62-092
146-62-092
Rollout Shield
42500933
934
935
936
ALTERNATE PARTS FOR CONTINUOUS PILOT — 24V
24-v Gas Valve, Continuous Pilot
146-62-051
146-62-051
146-62-051
146-62-060
10-32 X 1/2 Hex Head Screw (2 req’d)
146-95-307
146-95-307
146-95-307
146-95-307
Pilot Burner
146-62-053
146-62-053
146-62-053
146-62-053
Thermocouple
146-62-037
146-62-039
146-62-039
146-62-039
DESCRIPTION
Quantity is 1 unless otherwise noted.
* Requires 1 less than the number of sections.
† Requires 2 less than the number of sections.
‡ Not illustrated.
—28—
7 Section
8 Section
9 Section
146-62-058
146-15-005
146-95-307
146-16-014
146-15-035
146-15-532
146-15-531
146-62-092
937
146-62-058
146-15-006
146-95-307
146-16-015
146-15-035
146-15-532
146-15-531
146-62-092
938
146-62-058
146-15-006
146-95-307
146-16-016
146-15-035
146-15-532
146-15-531
146-62-092
939
146-62-060
146-95-307
146-62-053
146-62-039
146-62-060
146-95-307
146-62-053
146-62-036
146-62-060
146-95-307
146-62-053
146-62-036
REPAIR PARTS
→
BOILER CONTROLS AND PIPING
1
4
2
6
3
8
11
5
7
13
9
12
14
10
A03137
KEY NO.
1
2
3
4
5
6
7
8
9
*
10
*
11
*
12
*
13
14
15
16
*
*
*
*
*
*
*
*
*
DESCRIPTION
3/4-in. Relief Valve
3/4-in. Coupling
3/4-in. X 6-1/2-in. Nipple
Steam Pressure Gauge
1/4-in. Coupling
1/4-in. X 3-in. Nipple
AT-140D Transformer, 24v
PA-404A Pressuretrol
Glass Water Gauge Set (Used with PS-802 LWCO)
Glass Water Gauge Set (Used with 67D-1 LWCO)
90° Pigtail (Used with PS-802 LWCO)
180° Pigtail (Used with 67D-1 LWCO)
PS-802 Low Water Cut-Off
67D-1 Low Water Cut-Off
Control, Intermittent Pilot UT 1003-620
S8600M Intermittent Pilot Control, Liquified Petroleum Gas
1/2-in. X 3-in. Brass Nipple (PS-802 only)
1/2-in. X 1/2-in. X 1/4-in. Brass Tee (PS-802 only)
1/2-in. Brass Coupling (PS-802 only)
1/2-in. X 3 1/2-in. Brass Nipple (PS-802 only)
3/4-in. Drain Valve
WF-2U-24 Water Feeder (Optional)
Rollout Switch
Spill Switch (36TX16-6282) 280°F
5-in. Vent Damper (3 Section Boilers)
6-in. Vent Damper (4, 5 Section Boilers)
7-in. Vent Damper (6, 7, 8, 9 Section Boilers)
400°F Black Silicone Rubber Adhesive Sealant (10.3 oz cartridge)
Vent Damper Operator (Motor)
* Not illustrated.
—29—
PART NO.
157-00-01
115-00-01
146-07-002
146-23-005
146-93-054
146-07-001
146-62-045
146-62-015
146-22-005
146-22-010
146-43-004
146-43-005
128-00-01
146-26-042
146-62-070
146-62-071
131-00-03
146-93-051
146-93-052
146-07-024
146-22-000
163-00-01
146-29-002
146-60-002
118-20-05
118-20-06
118-20-07
146-06-024
114-00-02
—30—
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization • Maintenance
• Installation Overview • Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-644-5544
[ ] Packaged Service Training [ ] Classroom Service Training
A94328
—31—
© 2003 CAC/BDP
7310 W. Morris St., Indianapolis, IN 46231
imbs1a05 —32—
Catalog No. 63BS-1A3