Carrier BW2 Operating instructions

Installation, Start-Up, and Operating Instructions
Gas-Fired
Natural Draft Hot Water Boilers
Sizes 37,500 through 280,000
Series B
BW1
BW2
ama
CERTIFIED
®
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 BW1
MODEL BW2
Continuous Pilot
Electronic Intermittent Ignition
A03114
A03115
Index
Page
SAFETY CONSIDERATIONS.....................................................................................................................................................................................3
INTRODUCTION ......................................................................................................................................................................................................3-4
BOILER RATINGS AND CAPACITIES ....................................................................................................................................................................4
Boilers for Use at High Altitude .............................................................................................................................................................................4
LOCATING THE BOILER ..........................................................................................................................................................................................5
FRESH AIR FOR COMBUSTION ..............................................................................................................................................................................6
Boiler Located in Unconfined Space.......................................................................................................................................................................6
Boiler Located in Confined Space...........................................................................................................................................................................6
Form:
IM-BW1A-05
Cancels:
IM-BW1A-04
Printed in U.S.A.
8-03
Catalog No.
63BW-1A2
INSTALLATION—SYSTEM PIPING .........................................................................................................................................................................7
For Use with Cooling Units .....................................................................................................................................................................................7
Low Design Water Temperature Systems (Below 140°F)......................................................................................................................................7
CHIMNEY AND VENT PIPE CONNECTION .....................................................................................................................................................7-10
Checking Chimney....................................................................................................................................................................................................8
Chimney Sizing.........................................................................................................................................................................................................8
Connecting Vent Damper and Vent Connector.......................................................................................................................................................8
Minimum Vent Pipe Clearance ................................................................................................................................................................................9
Removing Existing Boiler from Common Venting System ..............................................................................................................................9-10
VENT DAMPER OPERATION ............................................................................................................................................................................10-11
Automatic Operation of Vent Damper...................................................................................................................................................................10
Manual Operation of Vent Damper .......................................................................................................................................................................10
Notes for Canada Only......................................................................................................................................................................................10-11
GAS SUPPLY PIPING................................................................................................................................................................................................11
Checking Gas Supply .............................................................................................................................................................................................11
Connecting Gas Piping ...........................................................................................................................................................................................11
Checking Gas Piping ..............................................................................................................................................................................................11
ELECTRICAL WIRING ........................................................................................................................................................................................11-14
Electric Power Supply ............................................................................................................................................................................................12
Installing Thermostat ..............................................................................................................................................................................................12
Wiring Diagrams ...............................................................................................................................................................................................13-14
Vent Damper Wiring ..............................................................................................................................................................................................12
EQUIPMENT AND OPTIONAL ACCESSORIES ..............................................................................................................................................15-16
Relief Valve ............................................................................................................................................................................................................15
Expansion Tank ......................................................................................................................................................................................................15
Diaphragm-Type Expansion Tank..........................................................................................................................................................................15
Air-Eliminating Fitting (Air Purger) ......................................................................................................................................................................15
Main Air Vent for Downflow Systems or Diaphragm-Type Expansion Tank ....................................................................................................15
Automatic Fill Valve ..............................................................................................................................................................................................15
Drain Valve.............................................................................................................................................................................................................15
Water Temperature Control....................................................................................................................................................................................15
Circulating Pump ....................................................................................................................................................................................................15
Vent Damper...........................................................................................................................................................................................................15
Rollout Switch (Flame Rollout Safety Shutoff) ....................................................................................................................................................15
Spill Switch (Blocked Vent Shutoff System) ........................................................................................................................................................16
STARTING BOILER...................................................................................................................................................................................................16
How a Hot Water System Operates.......................................................................................................................................................................16
Filling System with Water......................................................................................................................................................................................16
FOR YOUR SAFETY READ BEFORE OPERATING ............................................................................................................................................16
GAS VALVE OPERATING INSTRUCTIONS....................................................................................................................................................16-17
Intermittent Ignition Boiler—VR8204A/VR8304M Gas Valve ......................................................................................................................16-17
Continuous Pilot Boiler—VR8200A/VR8300A Gas Valve..................................................................................................................................17
OPERATING BOILER................................................................................................................................................................................................18
Automatic Gas Valve..............................................................................................................................................................................................18
Safety Pilot..............................................................................................................................................................................................................18
Gas Valve Safety Shutdown Test ..........................................................................................................................................................................18
Relight .....................................................................................................................................................................................................................18
Thermostat...............................................................................................................................................................................................................18
CHECKING AND ADJUSTING......................................................................................................................................................................18-19
Pilot Burner Adjustment....................................................................................................................................................................................18
Main Burner Air Adjustment ............................................................................................................................................................................18
Limit Controls Adjustment................................................................................................................................................................................19
MAINTAINING BOILER ................................................................................................................................................................................19-20
Burners...............................................................................................................................................................................................................19
Relief Valve..................................................................................................................................................................................................18-19
Expansion Tank .................................................................................................................................................................................................19
Boiler Flue Passages..........................................................................................................................................................................................19
Vent Pipe ...........................................................................................................................................................................................................19
Water System.....................................................................................................................................................................................................19
Cleaning Boiler and Burners .......................................................................................................................................................................19-20
SERVICE HINTS ...................................................................................................................................................................................................21
REPAIR PARTS................................................................................................................................................................................................22-25
—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. In Canada, refer to the CAN/CGA-B149.1- and .2-M00 National Standard of Canada, Natural Gas and Propane Installation Codes
(NSCNGPIC). 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 Water Boilers are low-pressure, sectional cast iron boilers design certified by CSA International (A.G.A. and C.G.A.) for use with
natural and propane gases. They are constructed and hydrostatically tested for a maximum working pressure of 50 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 table 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 venting system 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.
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 and the NFPA 90B. For copies of the NFGC and NFPA
90B, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American
Gas Association, 400 N. Capitol St., N.W., Washington DC 20001.
Before installing the boiler in Canada, refer to the NSCNGPIC. For a copy of the NSCNGPIC, contact Standard Sales, CSA International, 178
Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3, Canada.
Installation must comply with regulations of serving gas supplier and local building, heating, plumbing or other codes in effect in the area in which
installation is made. In absence of local building codes, installation must comply with NFGC in the United States and the NSCNGPIC in Canada.
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. Failure to follow this warning could result in explosion, fire, personal injury, or death.
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. Failure to follow this warning could result in
electrical shock, fire, personal injury, or death.
NOTE: Installers—Follow local regulations with respect to installation of CO detectors. Follow maintenance recommendations in this instruction
manual.
—3—
BOILER RATINGS AND CAPACITIES
ASME
RELIEF
VALVE
1 1⁄4† SUPPLY
TEMPERATURE/
PRESSURE GAGE
VENT
DAMPER
A
AQUASTAT
26 1⁄2†
4 3⁄4†
9†
1 1⁄4†
RETURN
1 1⁄4† NPT
SPILL
SWITCH
31 3⁄8†
23 1⁄4†
12 1⁄4†
5 3⁄8†
DRAIN VALVE
ROLLOUT
SWITCH
LEFT SIDE
GAS
VALVE
FRONT
INT. PILOT
CONTROL
RIGHT SIDE
A02318
Gas-Fired Hot Water Boilers
BOILER MODEL NUMBER
Electronic
Ignition
with Vent Damper
Continuous
Pilot
with Vent Damper
NO. OF
SECTIONS
BW1AAN000037ABAA
BW1AAN000070ABAA
BW1AAN000105ABAA
BW1AAN000140ABAA
BW1AAN000175ABAA
BW1AAN000210ABAA
BW1AAN000245ABAA
BW1AAN000280ABAA
BW2AAN000037ABAA
BW2AAN000070ABAA
BW2AAN000105ABAA
BW2AAN000140ABAA
BW2AAN000175ABAA
BW2AAN000210ABAA
BW2AAN000245ABAA
BW2AAN000280ABAA
2
3
4
5
6
7
8
9
NATURAL AND PROPANE GAS*
Net
A.G.A.
Heating
I=B=R
Input
Capacity
Rating
MBH
MBH
MBH
37.5
30
26
70
57
50
105
85
74
140
113
98
175
142
123
210
170
148
245
198
172
280
226
197
DIMENSIONS (IN.)
Flue
Diameter
Width
A
4†
5
6
6
7
7
7
7
8
11-1/4
14-1/2
17-3/4
21
24-1/4
27-1/2
30-3/4
* Boilers are equipped for altitudes up to 2000 ft only.
U.S.A Only—For altitudes above 2000 ft, ratings should be reduced at the rate of 4 percent for each 1000 ft above sea level.
Canada Only—Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10 percent derate.
Heating Capacity is based on Department of Energy (DOE) test procedure.
† The 2-section boilers are equipped with a 3-in. diameter flue collar on draft diverter and use a factory-supplied 3-in. X 4-in. increaser fitting to install factory-supplied 4-in.
vent damper.
MBH—1000 Btuh (British Thermal Unit Per Hr) NOTE: Add 5-1/2 in. to height for vent damper.
→Fig. 1—Dimensional Drawing and Boiler Ratings and Capacities
The ratings marked "Net I=B=R Rating" indicate the amount of equivalent direct radiation each boiler will take care of under normal conditions
and thermostatic control. The Net I=B=R Ratings shown are based on an allowance of 1.15 in accordance with the factors in the I=B=R Standard
as published by The Hydronics Institute. New York City MEA Number 39-86E.
Selection of boiler size should be based upon "Net I=B=R Rating" being equal to or greater than calculated heat loss of building.
Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements.
These boilers must stand on a noncombustible floor. If installed on a combustible floor, a factory-approved combustible floor base must be used.
BOILERS FOR USE AT HIGH ALTITUDE
This boiler is factory equipped for use at altitudes of 0-2000 ft above sea level. For use at altitudes above 2000 ft above sea level, input ratings
are reduced by a change in main burner orifice size.
U.S.A. Only—For altitudes above 2000 ft above sea level, input ratings should be reduced at the rate of 4 percent for each 1000 ft above sea level.
Consult the NFGC NFPA54/ANSI Z223.1-2002 or the manufacturer for correct orifice sizing information. High-altitude orifices are available from
boiler manufacturer.
Canada Only—For altitudes in the range of 2000-4500 ft above sea level, boilers may be field equipped for use at high altitude by using a certified
field conversion kit. The change in main burner orifice size results in boiler’s input rating being reduced by 10 percent. The conversion shall be
carried out by a manufacturer’s authorized representative in accordance with the requirements of manufacturer, provincial or territorial authorities
having jurisdiction, and in accordance with the requirements of the CAN/CGA-B149.1 and CAN/CGA-B149.2 Installation Codes. The certified
field conversion kit includes a conversion data plate which must be attached to boiler adjacent to rating plate indicating that boiler has been
converted for high-altitude use. The conversion data plate must be filled in with the correct conversion information.
—4—
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. Always comply with the minimum 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.
Table 1—Room Large In Comparsion With Boiler
BOILER SIZE
(SECTIONS)
BOILER VOLUME
(CU FT)
2
3
4
5
6
7
8
9
3.8
5.4
7.0
8.5
10.1
11.7
13.2
14.8
MINIMUM ROOM
VOLUME REQUIRED
TO BE LARGE
ROOM
(CU FT)*
61.6
86.6
111.6
136.6
161.7
186.7
211.7
236.7
* 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.)
2—5 Sections
6
6
8
6
18
6
1
6—9 Sections
6
6
24
24
18
6
1
ROOM LARGE
IN COMPARISON
WITH BOILER (IN.)
2—9 Sections
6
6
6
6
18
6
1
8. Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and
maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with
proper circulation of air. When normal infiltration does not provide necessary air, outside air shall be introduced as described in Fresh Air
for Combustion section.
9. Advise owner to keep air passages free of obstructions. Ventilation and combustion air must enter boiler room without restrictions.
10. The boiler shall be installed such that the automatic gas ignition system components are protected from water (dripping, spraying, rain , etc.)
during appliance operation and service (condensate trap, control replacement, etc.).
—5—
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, of the 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 house to replace oxygen used by 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
performances 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 may cause a 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, 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.
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 combined volume of all spaces meets criteria for an unconfined space. The total input of all gas utilization equipment installed in 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 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 free area of 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 within 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
commmunicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors
and shall have a minumm free area of:
a. 1 sq. inch per 3000 Btu per hour of the 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 confined space.
—6—
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)*
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
Fresh Air
Duct Size (In.)
* 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
1. Place boiler in selected location (as close to chimney as possible). Boiler is shipped assembled. Only the relief valve, circulator pump, and
a drain line to carry any water or steam to a drain need to be installed.
2. Install relief valve into 3/4-in. pipe on top of boiler. (See Fig. 2.) Use 3/4-in. pipe and field-supplied elbow to carry water or steam to a
nearby drain. Do not connect directly to a drain but leave an air gap. No shutoff of any description shall be placed between safety relief
valve and boiler, or on any discharge pipes between such safety valves and the atmosphere. Installation of safety relief valve shall conform
to the requirements of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for any water
damage. Install drain valve in lower left side of boiler as marked.
3. Connect supply and return lines to boiler. The connections may require certain additional fittings and parts. (See Fig. 2 and 3.)
4. This boiler is equipped with 1-1/4 in. supply and return connections on both the left and right sides of boiler.
→
5. Install factory-supplied circulator pump on supply piping, after expansion tank and before any zone valves. (See Fig. 2.) Route circulator
electrical cable between circulator pump and aquastat and connect cable as shown in Fig. 9 or 10.
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.
A hot water boiler installed above radiation level must be equipped with a low water cut-off device. A periodic inspection is necessary as is flushing
of float-type devices per the manufacturer’s specific instructions.
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. 3.)
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.
PROCEDURE 2—LOW DESIGN WATER TEMPERATURE SYSTEMS (BELOW 140°F)
If boiler is to be used in a heating system where design water temperatures below 140°F are desired (for example radiant floor heating), a 3-way
or 4-way mixing valve or suitable alternative is required to prevent low temperature return water from entering boiler. Follow mixing valve
manufacturer’s Installation Instructions.
The minimum design return water temperature to boiler to prevent condensation in boiler and venting system is 120°F. The minimum high limit
setting is 140°F.
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, in the United
States or Part 7 NFGC, Venting System and Air Supply for Appliances, in Canada, and applicable provisions of local building codes.
—7—
TO SYSTEM
A
CIRCULATOR
B
AIR VENT
COLD WATER
INLET
SUPPLY
MAIN
RELIEF
VALVE
AIR
PURGER
GAUGE
C
FILTROL
TANK
LIMIT
CONTROL
D
WATER
CHILLER
RETURN
LINE
VALVES C & D
CLOSE FOR HEATING;
OPEN FOR COOLING
→
VALVES A & B
OPEN FOR HEATING;
CLOSE FOR COOLING
A03116
A95143
Fig. 3—Chilled Water Piping
Fig. 2—Typical Hot Water Piping
PROCEDURE 1—CHECKING CHIMNEY
The chimney is a very important part of heating system. It must be clean, the right size, properly constructed, and in GOOD CONDITION. No
boiler can function properly with a bad chimney. Table 4 gives typical chimney sizes. Fig. 4 shows 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.
In Canada, follow CAN/CGA B149.1 and B149.2 Installation Codes for Gas Burning Appliances and Equipment.
PROCEDURE 3—CONNECTING VENT DAMPER AND VENT CONNECTOR
Refer to Fig. 1 for size and location of vent (flue opening). Use 28 gauge (minimum) galvanized pipe to connect to chimney.
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, hole MUST be left open. On boilers equipped with intermittent ignition, 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 two sheet metal
screws spaced 180° apart. Make sure damper blade has clearance to operate inside of diverter.
On 2-section boilers equipped with vent damper, the factory-supplied 4-in. vent damper is equipped with a 3-in. to 4-in. adapter so that the
4-in. vent damper may be installed on boiler’s 3-in. flue outlet collar. Fasten all fittings with sheet metal screws.
As An Option (U.S.A. Only): The damper may be installed in any horizontal or vertical position (closer to the flue outlet collar preferred).
Follow diagrams shown in Fig. 5, 7, and 8.
2. Install vent damper to service only the 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.
5. Vent pipe must be same size as flue outlet collar, except 2-section boilers with vent damper as noted above.
6.
7.
8.
9.
Slope pipe up from boiler to chimney not less than 1/4 in. per ft.
Run pipe as directly as possible with as few elbows as possible.
Do not connect to fireplace flue.
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. 4.)
The sections of vent pipe should be fastened with sheet metal screws to make 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.
—8—
2-FT MIN
HT
3-FT MIN
Table 4—Typical Chimney Sizes
BOILER INPUT
(BTUH)
Up
Up
Up
Up
to
to
to
to
100,000
155,000
230,000
350,000
FLUE AREA IN INCHES
Height (HT)*
10-15 ft
15-25 ft
25 ft up
6X6
6X5
5X5
6X7
6X6
6X5
7X8
7X7
6X7
9X9
8X9
8X8
ROOF RIDGE
* HT = top of thimble to top of flue. (See Fig. 4.)
For boiler input, refer to Fig. 1.
For information only — not meant to imply minimum sizes.
3/4 HT MAXIMUM
MUST SLOPE UP
AT LEAST 1/4 IN.
PER FT OF
HORIZONTAL RUN
A95144
Fig. 4—Typical Masonry Chimney Requirements
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, common venting system is likely to be too large for proper venting of
appliances remaining connected to it.
At time of removal of an existing boiler, the following items shall be followed with each appliance remaining connected to common venting system
placed in operation, while other appliances remaining connected to common venting system are not in operation.
1. Seal any unused openings in common venting system.
2. Visually inspect venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion,
and other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between space in which appliances remaining connected to
common venting system are located and other spaces of 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 appliance being inspected. Follow 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 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 ANSI Z223.1-2002. When
resizing any portion of common venting system, common venting system should be resized to approach minimum size as determined using
the appropriate tables in Part 11 of the NFGC in the United States or Appendix B of the NSCNGPIC in Canada.
—9—
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. 5—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. 6—Vent Damper Position Indicator
Fig. 7—Typical Installation for Vent Damper
(Note Caution and Footnotes)
For boilers connected to gas vents or chimneys, vent installations shall be in accordance with Part 7 NFGC, Venting of Equipment, in the United
States or Part 7 NFGCPIC, Venting System and Air Supply for Appliances, in Canada, 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.
VENT DAMPER OPERATION
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 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. 6.)
2. Turn thermostat or controller up to call for heat and check that vent damper indicator points to the OPEN position. (See Fig. 6.)
3. Turn thermostat or controller down again and check that vent damper position indicator returns to CLOSED position.
PROCEDURE 2—MANUAL OPERATION OF VENT DAMPER
The Effikal vent damper may be placed in OPEN position to permit burner operation by using 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 Effikal manual packaged with vent damper.
PROCEDURE 3—NOTES FOR CANADA ONLY
1. Canadian Standard CAN1-2.28-M81 prohibits the use of vent dampers on propane-fired appliances with intermittent ignition.
—10—
2. In Canada, vent damper must be attached directly to flue outlet collar, with the exception of 2-section boiler where the 3-in. to 4-in. adapter
is supplied with vent damper. No other interconnecting pieces are allowed between boiler and vent damper.
3. In Canada, vent dampers are not an option. Boilers are either factory built for use with a vent damper and vent damper is supplied with
boiler, or they are factory built for use without a vent damper. In the second case, a vent damper cannot be installed later.
GAS SUPPLY PIPING
PROCEDURE 1—CHECKING GAS SUPPLY
The gas pipe to boiler must be the correct size for length of run and total Btuh input of all gas utilization equipment connected to it. See Table
5 for proper size. Be sure gas line complies with local codes and gas company requirements.
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 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. 8 for general layout at boiler. It shows 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 ANSI Z223.1-2002. In Canada, follow the CAN/CGA B149.1 and .2 Installation Codes for Gas Burning
Appliances and Equipment.
2. Use pipe joint compound suitable for natural and propane gas on male threads only.
3.
4.
5.
6.
7.
8.
9.
10.
Use ground joint unions.
Install a sediment trap upstream of gas controls.
Use 2 pipe wrenches when making connection to gas valve to keep it from turning.
Install a manual shutoff valve in vertical pipe about 5 ft above floor.
Tighten all joints securely.
Propane gas connections should only be made by a licensed propane installer.
Two-stage regulation should be used by propane installer.
Propane gas piping should be checked by propane installer.
PROCEDURE 3—CHECKING GAS PIPING
Upon completion of piping, check immediately for gas leaks. Open the 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. 9 and 10 for wiring diagrams for the various models.
Table 5—Gas Pipe Sizes
Length
of Pipe
(Ft)
20
40
60
Length
of Pipe
(Ft)
20
40
60
MANUAL
SHUTOFF
VALVE
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
PROPANE 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
GROUND JOINT
UNION
AUTOMATIC
GAS VALVE
MANIFOLD
SEDIMENT TRAP
* Outside diameter.
NOTE: The length of pipe or tubing shown should be measured from gas meter or
propane second-stage regulator.
FLOOR LINE
A95148
Fig. 8—Gas Piping at Boiler
—11—
→ All electrical work must conform to local codes as well as the National Electrical Code (NEC) ANSI/NFPA-70-2002. In Canada, electrical wiring
shall comply with the Canadian Electrical Codes CSA C22.1 and 2.
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.
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 power supply to aquastat terminals L1 (HOT) and
L2.
→ The boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction, or in the absence
of such requirements, with the NEC ANSI/NFPA-70-2002. 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 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 0.2 amps. The 24-v thermostat connects to aquastat terminals T and TV.
PROCEDURE 3—VENT DAMPER WIRING
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.
→ PROCEDURE
4—CIRCULATOR PUMP
The pump does not come pre-installed on boiler. It must be connected to circulator harness in the field according to pump manufacturer’s
instructions and wiring diagrams in this manual.
—12—
L8148E
AQUASTAT
VENT
DAMPER
TR
B
TH-2
TV
C1 C2
L1 L2
B1 B2
LS
B1
BLUE
WHITE
RED
24V
24VGND
PV
PV/MV
MV
GND
PV
MV/PV
MV
VR8204A
OR
VR8304M
5 6
5 6
GREEN
FUSE
B
GREEN
BLUE
9
SPARK
8
SSW
SSW
1 2 3 4
9
8
B2
TO
PILOT
RSW
1 2 34
Z
W
1K
1K2
CIR
120V
60HZ
SUPPLY
UT 1003-620
T
R
TO
PILOT
GND
PV
MV/PV
MV
1K1
DAMPER
R
24V
24VGND
L1
C2 CIR
Z
SPARK
C1
L2
HARNESS
T W TV
RSW
WHITE
PV/MV
PV
RED
MV
VR8204A
OR
VR8304M
UT 1003-620
COMPONENT CODE
TH-1
TH-2
TH-3
TR-1
TR-2
MGV
LGV
LGV-1
PS
MR-PS
SD
THERMOSTAT (MILLIVOLT)
THERMOSTAT (24 VOLD)
THERMOSTAT (LINE VOLTAGE)
TRANSFORMER (120V/24V 40VA)
TRANSFORMER (120V/24V 50VA)
MILLIVOLT GAS VALVE
24 VOLT GAS VALVE
24 VOLT GAS VALVE
PRESSURE SWITCH
MANUAL RESET PRESSURE SW.
STACK DAMPER
CONTROL TERMINAL
NOTES:
1K
1K1
1K2
LS
MS
CIR
ECO
LWCO
EWF
PG
PSC
RELAY COIL
RELAY CONTACTS
RELAY CONTACTS
LIMIT SWITCH
MANUAL SWITCH
CIRCULATOR
ENERGY CUT-OFF
LOW WATER CUT-OFF
ELECTRIC WATER FEEDER
POWER GENERATOR
PILOT SAFETY COIL
WIRE CONNECTION
NOT ALL COMPONENTS LISTED ARE
USED IN ALL CONTROL SYSTEMS
WIRING
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
1) SWITCHES ARE SHOWN IN POSITION TAKEN DURING THE HEATING CYCLE.
2) IF ANY OF THE ORIGINAL WIRING SUPPLIED WITH THE BOILER IS REPLACED, IT MUST BE REPLACED WITH
LIKE WIRE, SIZE, AND TYPE OF INSULATION OR EQUIVALENT.
1275085
A03106
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. 9—Wiring Diagram for Hot Water Boilers with Intermittent Ignition
—13—
HARNESS
VENT
DAMPER
TH-2
L1
L2
T W TV
C2
CIR
C1
1K1
Z
TR
DAMPER
B
R
TH-2
CIR
RSW
B1
W
T
TV
C1 C2
L1 L2
1K2
B2
B2
L8148E
AQUASTAT
R
120V
60HZ
SUPPLY
LS
B
B1
FUSE
TH
SSW
Z
1K
LGV
LGV
RSW
SSW
TR
TH
TR
COMPONENT CODE
TH-1
TH-2
TH-3
TR-1
TR-2
MGV
LGV
LGV-1
PS
MR-PS
SD
THERMOSTAT (MILLIVOLT)
THERMOSTAT (24 VOLD)
THERMOSTAT (LINE VOLTAGE)
TRANSFORMER (120V/24V 40VA)
TRANSFORMER (120V/24V 50VA)
MILLIVOLT GAS VALVE
24 VOLT GAS VALVE
24 VOLT GAS VALVE
PRESSURE SWITCH
MANUAL RESET PRESSURE SW.
STACK DAMPER
CONTROL TERMINAL
NOTES:
1K
1K1
1K2
LS
MS
CIR
ECO
LWCO
EWF
PG
PSC
RELAY COIL
RELAY CONTACTS
RELAY CONTACTS
LIMIT SWITCH
MANUAL SWITCH
CIRCULATOR
ENERGY CUT-OFF
LOW WATER CUT-OFF
ELECTRIC WATER FEEDER
POWER GENERATOR
PILOT SAFETY COIL
WIRE CONNECTION
NOT ALL COMPONENTS LISTED ARE
USED IN ALL CONTROL SYSTEMS
WIRING
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
1) SWITCHES ARE SHOWN IN POSITION TAKEN DURING THE HEATING CYCLE.
2) IF ANY OF THE ORIGINAL WIRING SUPPLIED WITH THE BOILER IS REPLACED, IT MUST BE REPLACED WITH
LIKE WIRE, SIZE, AND TYPE OF INSULATION OR EQUIVALENT.
1275086
A03107
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. 10—Wiring Diagram for Hot Water Boilers with Standing Pilot
—14—
EQUIPMENT AND OPTIONAL ACCESSORIES
PROCEDURE 1—RELIEF VALVE
A relief valve must be installed on boiler. Water expands as it is heated. If there is no place for water to expand into, water pressure builds up
inside boiler and system. Should this happen, relief valve automatically opens at a predetermined pressure. This relieves strain on boiler and
system. Run a pipe from relief valve outlet (pipe must be same size as outlet, and open end must not be threaded) to an open drain, tub or sink,
or other suitable drainage point not subject to freezing. Failure to do so may cause water damage or injury should relief valve release.
PROCEDURE 2—EXPANSION TANK
In a properly assembled system, expanding water flows into expansion tank. This tank should be of the correct size.
The tank is filled with air. As water expands, it compresses air in tank to form an air pressure cushion. This "spring-like" cushion serves to maintain
correct operating water pressure regardless of water temperature. This assures a "full measure" of water even in the highest radiation unit of system.
It also prevents blowing off the relief valve.
The air in tank in the beginning (with system filled with cold water) is sufficient for proper operation. The tank also serves as a trap for excess
air in system. This air would cause gurgling in pipes and inefficient circulation in radiators if left in system.
It is possible for a tank to become "water-logged" (filled with water). It can also become overfilled with air. This can happen after filling system
with new water. Fittings are provided on tank and in line to tank for bleeding off excess water or air.
When installing this tank, the following are important:
1. Tank should be higher than boiler top.
2. Pipe to tank should continuously rise up to tank (so that air can "bubble" up to it).
PROCEDURE 3—DIAPHRAGM-TYPE EXPANSION TANK
The diaphragm-type expansion tank (EX-TROL) takes the place of a conventional expansion tank. Read instructions packed with EX-TROL tank
assembly carefully.
The EX-TROL tank comes with a 10-12 psi air charge. This is same as the pressure produced in system by automatic fill valve. When system is
first filled, EX-TROL tank contains little or no water.
As water is heated, its pressure increases. It expands into EX-TROL tank compressing air in tank. This compressed air cushion permits water in
system to expand as temperature changes.
The diaphragm-type tank can be mounted on air purger fitting or at any other convenient place in supply or return line.
PROCEDURE 4—AIR-ELIMINATING FITTING (AIR PURGER)
An air purger is used to remove excess air from system. It is installed in supply line. It eliminates air from water before it reaches radiators and
bleeds off this air.
PROCEDURE 5—MAIN AIR VENT FOR DOWNFLOW SYSTEMS OR DIAPHRAGM-TYPE EXPANSION TANK
Before a system is filled with water, there is air in pipes and radiation units. Some of it will be trapped as system fills. It is possible to eliminate
most of this air through air vents on radiation units. A main air vent speeds and simplifies this process. It should be installed on highest point in
supply main when all radiation is below top of boiler.
PROCEDURE 6—AUTOMATIC FILL VALVE
For safe, efficient operation, a hot water system must be COMPLETELY FILLED with water. Adding new water when needed can be done
manually (by use of a hand valve in water supply line). This requires regular attention to system’s needs. An automatic fill valve accomplishes
this without attention. It is installed in supply line on hot water boilers only. The valve operates through water pressure differentials. It does not
require electrical connection.
PROCEDURE 7—DRAIN VALVE
This manual valve provides a means of draining all water from boiler and system. It is often installed in the 3/4-in. tapping at bottom of end boiler
section. It can also be installed in a tee where return line enters boiler.
PROCEDURE 8—WATER TEMPERATURE CONTROL
The water temperature limit control in relay is adjustable and may be set as necessary. It may be set as low as 140°F or as high as 240°F. Setting
depends on the type and amount of radiation involved and weather conditions.
PROCEDURE 9—CIRCULATING PUMP
→ Every forced hot water system requires a circulating pump. A separate pump or zone valve is required for each zone if there are 2 or more zones.
This pump must have capacity to provide circulation required by system. For optimum system performance, pump is connected to supply piping
AFTER expansion tank and before any zone valves. Connect pump to aquastat using 5 foot of cable supplied with boiler. The pump may also be
connected to return main.
PROCEDURE 10—VENT DAMPER
This is an automatic, motorized stack damper that has been developed to increase efficiency of heating systems by reducing standby losses from
heating apparatus and conditioned air space. The damper closes chimney vent when burner is off and fully opens it when combustion is required.
PROCEDURE 11—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.
—15—
PROCEDURE 12—SPILL SWITCH (BLOCKED VENT SHUTOFF SYSTEM)
The spill switch is a manual-reset disc thermostat with a fixed set point (340°F) and normally closed contacts. It is located at relief opening of
integral 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 the spill switch contacts open, reset button on back of switch pops up. The spill switch must be reset manually after switch has
cooled off by pushing reset button down. Check venting system and chimney for blockage when restoring system to operating condition. DO NOT
operate system without a spill switch.
STARTING BOILER
PROCEDURE 1—HOW A HOT WATER SYSTEM OPERATES
The entire heating system (boiler, piping, and radiation units) is filled with water. As water in boiler is heated, it is pumped from top of boiler
through supply main to radiation units. The cooler water in them flows back through return main to boiler. This provides positive and rapid
response to thermostat.
PROCEDURE 2—FILLING SYSTEM WITH WATER
To fill:
1. Close air vents on all radiation units. Open valves to these units.
2. Make sure boiler and expansion tank drain cocks are closed. The air bleed screw on tank drain fitting should be closed.
3. Open valve in line from boiler to expansion tank. Refer to Maintaining Boiler section for additional information.
4. Open water inlet to boiler and leave it open.
5. Start with the LOWEST radiation unit. Open the air vent on this radiation unit. When all air has escaped and water starts to flow from vent,
close air vent.
6. Proceed to next lowest radiation unit and repeat process outlined in item 5. Repeat until every radiation unit in system has been covered.
End with the highest unit in system.
If units have automatic vents, this manual venting is unnecessary but speeds up proper filling of system.
If system is a closed expansion tank system, there may be an automatic fill valve. It may be left open to refill system automatically as needed.
Check temperature-pressure gauge. Note position of hand indicating pressure. This should be between 10 and 15 lb. Any lowering of this movable
hand below 10 lb indicates loss of water due to leakage. The automatic fill valve should compensate for this. Instructions are packaged with valve.
→
CAUTION: Never run water into a hot, empty boiler or thermal shock may crack boiler components (sections).
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.
B. BEFORE OPERATING, smell all around the 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.
—16—
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. 11—VR8204A/VR8304M Intermittent Ignition Gas Valve
6. Turn gas control knob clockwise to OFF position. (See Fig. 11.)
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. 11.)
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. 11.)
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.
4. Remove lower front panel.
5. Turn gas control knob clockwise to OFF position. (See Fig. 12.)
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. 14.)
8. Turn knob on gas control counterclockwise to PILOT position. (See Fig. 12.)
9. Push down and hold red reset button while you light pilot burner with a match. (See Fig. 13.) 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 button is released, turn gas control knob counterclockwise to ON position. (See Fig. 12.)
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. 12.)
—17—
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
A99181
Fig. 13—Lighting Pilot
Fig. 12—VR8200A/VR8300A Continuous Pilot Gas Valve
OPERATING BOILER
PROCEDURE 1—AUTOMATIC GAS VALVE
The automatic gas valve opens or closes according to heat requirements of thermostat and temperature 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 burner regardless of
demand of any other control.
PROCEDURE 2—SAFETY PILOT
The safety pilot prevents flow of gas to burner if pilot goes out or will not ignite.
PROCEDURE 3—GAS VALVE SAFETY SHUTDOWN TEST
A. Boilers Equipped with Continuous Pilot
With main burners firing, disconnect thermocouple from gas valve. 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—RELIGHT
The electric and gas shall be off for 5 minutes before relighting.
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 adjusting
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-latest revision.
CHECKING AND ADJUSTING
PROCEDURE 1—PILOT BURNER ADJUSTMENT
Pilot flame should surround 3/8 to 1/2 in. of pilot sensor. (See Fig. 14.) 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 AIR ADJUSTMENT
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 outer mantel, with no yellow. Puffs of air from blowing on flame or stamping on floor will cause flames to turn
orange momentarily. This is not unusual. Remain still when observing main burner flames. If flame appearance is not correct, check main burner
orifices and burner throat and flame ports for dust and lint obstruction. It may be necessary to remove rollout shield to observe main buner flames.
Replace rollout shield after observation. (See Fig. 15.)
—18—
3⁄8″
to 1⁄2″
OUTER MANTEL
FLAME
ON SENSOR
SHARP INNER CONES
A95160
A99182
Fig. 15—Main Burner Flame
Fig. 14—Pilot Flame and Sensor
PROCEDURE 3—LIMIT CONTROLS ADJUSTMENT
Instructions for each control are included with controls.
Table 6 shows recommended boiler water temperatures. These settings can be changed after becoming familiar with system operation. For
example, if system is not giving quite enough heat in very cold weather, the limit setting can be raised to 220°F. Use boiler gage to check settings.
Make adjustments according to its readings.
Table 6—Recommended Boiler Water Temperatures
TYPE OF HEATING UNIT
Standing Radiators
Baseboard and Convector Radiators
LIMIT CONTROL SETTING
180°F
200°F
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.
After setting limit control to limit setting, check to see if it shuts off gas supply to burners. Set thermostat to call for heat and let boiler run until
temperature of water reaches limit setting. Gas valve should shut off, and circulator should keep running until thermostat is satisfied or water cools
enough to restart burners through limit control.
Finally, set thermostat for desired temperature. Special conditions in home and location of thermostat govern this setting.
MAINTAINING BOILER
PROCEDURE 1—BURNERS
A visual check of pilot and main burner flames should be made at least once each year, preferably at beginning of heating season. See Checking
and Adjusting section.
PROCEDURE 2—RELIEF VALVE
This valve should open automatically when system pressure exceeds pressure rating (usually 30 psi) of relief valve. Should it ever fail to open under
this condition, shut down system. Drain system until pressure is reduced below relief valve pressure rating. If valve discharge occurs or if 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.
This valve should be tested every month during periods of boiler operation, and at the beginning and end of any extended non-service period. Prior
to testing, make certain discharge pipe is properly connected to valve outlet and arranged so as to contain and safely dispose of boiler discharge.
Test at normal system operating pressure. Hold trip lever fully open for at least 5 sec in order to flush free any sediment that may lodge on valve
seat, then permit valve to snap shut.
PROCEDURE 3—EXPANSION TANK
As previously noted, this tank may become waterlogged or may receive an excess of air. Frequent automatic opening of relief valve indicates
waterlogging. A high boiler temperature accompanied by unusually low radiation unit temperature (and "knocking") indicates excess air in tank.
To correct either condition, close valve between boiler and tank. Drain tank until it is empty. Check all tank plugs and fittings. Tighten as necessary.
Open valve between boiler and tank. Water will rise to normal height in tank if automatic fill valve is installed, otherwise, manually refill system.
PROCEDURE 4—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. Replace or patch any boiler seals that are faulty.
PROCEDURE 5—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 6—WATER SYSTEM
If system is to remain out of service during freezing weather, always DRAIN IT completely. Water left in to freeze will crack pipes and/or boiler.
PROCEDURE 7—CLEANING BOILER 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.
—19—
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. 14 and 15.)
10. Be sure vent pipe connections to chimney are secure and no obstructions are present.
—20—
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.
Possible Cause
Thermostat is not set correctly
Burner is not operating properly
No electric power to boiler
Controls out of adjustment
Radiators not heating
Circulator pump not running
Poor electrical contact
Rollout switch blown
Spill switch opened
Vent damper not operating
Possible Cause
Gas input amount is incorrect
Possible Cause
Dirt on seat
Waterlogged expansion tank
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
the burner, burner is getting too much air. Contact your service technician.
Check overcurrent protection. Check to be sure electric power supply circuit is on.
Reset according to instructions.
Open radiator vents to vent excess air. Check flow control valve (if used). It may be in closed position.
Check overcurrent protection. Check relay operation.
Check all control terminals and wire joints.
Have your service technician check heat exchanger for blockage. Replace rollout switch with exact replacement.
Have your service technician check venting system and chimney for blockage or down draft condition. Reset
spill switch.
Consult troubleshooting guide in Effikal manual, packaged with vent damper.
IF BURNER IS NOISY. . .
What To Do
Contact your service technician.
RELIEF VALVE LEAKING. . .
What To Do
Open valve manually. Allow water to run and clear valve seat.
Drain tank. See instructions.
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.
—21—
REPAIR PARTS
GAS-FIRED HOT WATER BOILERS
yy
;;
;;
yy
;;;yyy
yy
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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 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
2
4
6
11
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 and Nut
Boiler Section, Left End
Boiler Section, Middle
Jacket, Top Panel
Draft Diverter
Boiler Section, Right End
Jacket, Back Panel
Jacket Complete
Block Assembly
(8, 14, 15, 16, 19)
Combustible Floor Plate
Cerafelt Gasket
Vent Damper
Base Assembly (4, 5, 6)
2 Section
425-00-901
3 Section
425-00-901
4 Section
425-00-901
PART NO.
5 Section
6 Section
425-00-901 425-00-901
7 Section
425-00-901
8 Section
425-00-901
9 Section
425-00-901
146-95-074
146-95-074
146-95-074
146-95-074
146-95-074
146-95-074
146-95-074
146-95-074
146-94-016
146-14-020
146-14-112
146-14-122
425-00-642
425-00-662
425-00-652
433-00-976
425-00-900
137-02-153
425-00-912
425-00-812
425-00-810
146-05-008
410-00-020
410-00-022
425-00-842
425-00-672
410-00-021
425-00-902
425-70-992
146-94-016
146-14-130
146-14-113
146-14-123
425-00-643
425-00-663
425-00-653
433-00-976
425-00-900
137-02-153
425-00-913
425-00-813
425-00-811
146-05-001
410-00-020
410-00-022
425-00-843
425-00-673
410-00-021
425-00-903
425-70-993
146-94-016
146-14-130
146-14-114
146-14-124
425-00-644
425-00-664
425-00-654
433-00-976
425-00-900
137-02-153
425-00-914
425-00-814
425-00-804
146-05-002
410-00-020
410-00-022
425-00-844
425-00-674
410-00-021
425-00-904
425-70-994
146-94-016
146-14-130
146-14-115
146-14-125
425-00-645
425-00-665
425-00-655
433-00-976
425-00-900
137-02-153
425-00-915
425-00-815
425-00-805
146-05-051
410-00-020
410-00-022
425-00-845
425-00-675
410-00-021
425-00-905
425-70-995
146-94-016
146-14-130
146-14-116
146-14-126
425-00-646
425-00-666
425-00-656
433-00-976
425-00-900
137-02-153
425-00-916
425-00-816
425-00-806
146-05-053
410-00-020
410-00-022
425-00-846
425-00-676
410-00-021
425-00-906
425-70-996
146-94-016
146-14-130
146-14-117
146-14-127
425-00-647
425-00-667
425-00-657
433-00-976
425-00-900
137-02-153
425-00-917
425-00-817
425-00-807
146-05-005
410-00-020
410-00-022
425-00-847
425-00-677
410-00-021
425-00-907
425-70-997
146-94-016
146-14-130
146-14-118
146-14-128
425-00-648
425-00-668
425-00-658
433-00-976
425-00-900
137-02-153
425-00-918
425-00-818
425-00-808
146-05-007
410-00-020
410-00-022
425-00-848
425-00-678
410-00-021
425-00-908
425-70-998
146-94-016
146-14-130
146-14-119
146-14-129
425-00-649
425-00-669
425-00-659
433-00-976
425-00-900
137-02-153
425-00-919
425-00-819
425-00-809
146-05-009
410-00-020
410-00-022
425-00-849
425-00-679
410-00-021
425-00-909
425-70-990
410-00-213
410-00-313
410-00-413
410-00-513
410-00-613
410-00-713
410-00-813
410-00-913
146-14-031
146-14-018
118-20-04
433-00-662
146-14-031
146-14-018
118-20-05
433-00-663
146-14-031
146-14-018
118-20-06
433-00-664
146-14-031
146-14-018
118-20-06
433-00-665
146-14-031
146-14-018
118-20-07
433-00-666
146-14-032
146-14-018
118-20-07
433-00-667
146-14-032
146-14-018
118-20-07
433-00-668
146-14-032
146-14-018
118-20-07
433-00-669
* Not illustrated.
—22—
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
8
DESCRIPTION
24-v Gas Valve,
Electronic Intermittent Ignition
Pilot Tube
10-32 X 1/2-in. Hex Head Screw
Gas Manifold
Main Burner Orifice*
Main Burner†
Main Burner with Pilot Bracket
Pilot Burner
Rollout Shield
PART NO.
2 Section
3 Section
4 Section
5 Section
6 Section
ELECTRONIC INTERMITTENT IGNITION (Shown)
7 Section
8 Section
9 Section
146-62-052 146-62-052 146-62-052 146-62-052 146-62-058 146-62-058 146-62-058 146-62-058
146-15-005 146-15-005 146-15-005 146-15-005 146-15-005
146-95-307 146-95-307 146-95-307 146-95-307 146-95-307
146-16-032 146-16-033 146-16-034 146-16-035 146-16-013
146-15-031 146-15-031 146-15-031 146-15-031 146-15-035
—
146-15-532 146-15-532 146-15-532 146-15-532
146-15-531 146-15-531 146-15-531 146-15-531 146-15-531
146-62-095 146-62-092 146-62-092 146-62-092 146-62-092
425-00-932 425-00-933 425-00-934 425-00-935 425-00-936
ALTERNATE PARTS FOR CONTINUOUS PILOT — 24V
24-v Gas Valve, Continuous Pilot
146-62-051 146-62-051 146-62-051 146-62-051 146-62-060
10-32 X 1/2-in. Hex Head Screw (2 req’d) 146-95-307 146-95-307 146-95-307 146-95-307 146-95-307
Pilot Burner
146-62-053 146-62-053 146-62-053 146-62-053 146-62-053
Thermocouple
146-62-037 146-62-037 146-62-039 146-62-039 146-62-039
Quantity is 1 unless otherwise noted.
* Requires 1 less than the number of sections.
† Requires 2 less than the number of sections.
‡ Not illustrated.
—23—
146-15-005
146-95-307
146-16-014
146-15-035
146-15-532
146-15-531
146-62-092
425-00-937
146-15-006
146-95-307
146-16-015
146-15-035
146-15-532
146-15-531
146-62-092
425-00-938
146-15-006
146-95-307
146-16-016
146-15-035
146-15-532
146-15-531
146-62-092
425-00-939
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
FOR USE WITH LIQUIFIED PETROLEUM GAS ONLY
3
6
4
5
6A
2
1
A98238
Liquified Petroleum 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
8
DESCRIPTION
24-v Gas Valve,
Electronic Intermittent Ignition
Pilot Tube
10-32 X 3/16-in Hex Head Screw
Gas Manifold
Main Burner Orifice*
Main Burner†
Main Burner with Pilot Bracket
Pilot Burner
Rollout Shield
24-v Gas Valve, Continuous Pilot
10-32 X 3/16-in. Hex Head Screw (2
req’d)
Pilot Burner
Thermocouple
PART NO.
2 Section
3 Section
4 Section
5 Section
6 Section
ELECTRONIC INTERMITTENT IGNITION (Shown)
146-62-062
146-62-062
146-62-062
146-62-062
146-15-005 146-15-005 146-15-005 146-15-005
146-95-301 146-95-301 146-95-301 146-95-301
146-16-009 146-16-010 146-16-011 146-16-012
146-15-036 146-15-036 146-15-036 146-15-036
—
146-15-532 146-15-532 146-15-532
146-15-529 146-15-529 146-15-529 146-15-529
146-62-093 146-62-094 146-62-094 146-62-094
425-00-932 425-00-933 425-00-934 425-00-935
ALTERNATE PARTS FOR CONTINUOUS PILOT
—
146-62-061 146-62-061 146-62-061
7 Section
8 Section
9 Section
146-62-059
146-62-059
146-62-059
146-62-059
146-15-005
146-95-301
146-16-013
146-15-036
146-15-532
146-15-529
146-62-094
425-00-936
— 24V
146-62-061
146-15-005
146-95-301
146-16-014
146-15-036
146-15-532
146-15-529
146-62-094
425-00-937
146-15-006
146-95-301
146-16-015
146-15-036
146-15-532
146-15-529
146-62-094
425-00-938
146-15-006
146-95-301
146-16-016
146-15-036
146-15-532
146-15-529
146-62-094
425-00-939
146-62-061
146-62-061
146-62-061
146-95-301
146-95-301
146-95-301
146-95-301
146-95-301
146-95-301
146-95-301
146-95-301
—
—
146-62-096
146-62-037
146-62-096
146-62-039
146-62-096
146-62-039
146-62-096
146-62-039
146-62-096
146-62-039
146-62-096
146-62-036
146-62-096
146-62-036
Quantity is 1 unless otherwise noted.
* Requires 1 less than the number of sections.
† Requires 2 less than the number of sections.
‡ Not illustrated.
—24—
REPAIR PARTS
→
BOILER CONTROLS AND PIPING
7
1
8
3
2
5
4
6
9
10
→
A03108
KEY NO.
1
2
3
4
5
6
*
*
7
*
8
*
9
10
*
*
*
*
*
*
*
*
DESCRIPTION
3/4-in. ASME Relief Valve
3/4-in. X 7-1/2-in. Nipple
Temperature Pressure Gage—5-in. Stem
1-1/4-in. X 2-1/2-in. Nipple
1-1/4-in. X 3/4-in. X 1-1/4-in Tee
Aquastat Relay
Isolation Valve Set—Taco
Isolation Valve Set—Grundfos
Cast Iron Flange Set—Taco
Cast Iron Flange Set—Grundfos
Taco 007 Circulator-Field Installed
Grundfos UP15-42F Circulator- (Optional)**
1-1/4-in. Bent Return Nipple
Intermittent Pilot Control
Rollout Switch
Spill Switch (36TX16-6281) 340°F
4-in. Vent Damper (with 3-in. Adaptor)
5-in Vent Damper
6-in. Vent Damper
7-in. Vent Damper
400°F Black Silicone Rubber Adhesive Sealant (10.3 oz cartridge)
Vent Damper Operator (Motor)
* Not illustrated.
** Available as a service part only
—25—
PART NO.
146-22-011
146-07-041
146-23-009
146-07-044
146-93-049
433-00-522
146-26-048
146-26-046
146-26-049
146-26-050
CI-001.03
CI-006.01
146-07-003
146-62-071
146-29-002
146-60-001
146-28-011
146-28-001
146-28-002
146-28-003
146-06-020
114-00-02
—26—
—27—
© 2003 CAC/BDP
7310 W. Morris St., Indianapolis, IN 46231
imbw1a05 —28—
Catalog No. 63BW-1A2