installation, operating and service instructions

INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
ADVANTAGE DV™ SERIES
CAST IRON GAS-FIRED BOILER
9700609
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Serial Number
Installation Date
Boiler Model Number
AGDV_-H_
Heating Contractor
Address
105248-02 - 9/14
Phone Number
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Advantage DV™ Series Boiler. See the Massachusetts
Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest
Approval Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels, or to important information concerning product life.
DANGER
CAUTION
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
NOTICE
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
TABLE OF CONTENTS
I. Pre-Installation ....................................4
VII. System Start-up and Checkout ..........21
II. Unpack Boiler .....................................4
VIII. Operation ..........................................24
III. Water Piping and Trim ........................5
IX. Service and Maintenance ...................26
IV. Gas Piping ...........................................8
X. Troubleshooting ................................29
V. Venting ................................................9
XI. Repair Parts .......................................31
VI. Electrical............................................19
Table 1A: Ratings
Advantage Gas Ratings
Boiler Model
Input (MBH)
DOE Heating Capacity (MBH)
Net AHRI Rating Water (MBH) (1)
AFUE (%)
AGDV3
AGDV4
AGDV5
AGDV6
60.8
91.2
121.6
152.0
52
78
104
130
45
68
90
113
85.5
85.4
85.3
85.2
(1)
Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15. Consult manufacturer before selecting
boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.
Table 1B: Dimensions and Connections
Boiler Model
Supply NPT
(inch)
AGDV3
AGDV4
AGDV5
AGDV6
1¼
1¼
1¼
1¼
Return NPT
Vent (inch)
(inch)
1¼
1¼
1¼
1¼
3
3
3
3
Air Inlet
(inch)
Gas NPT (inch)
Relief Valve
NPT (inch)
Drain
NPT (inch)
3
3
4
4
½
½
½
½
¾
¾
¾
¾
¾
¾
¾
¾
Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi
relief valve.
2
Figure 1: Minimum Clearance to Combustible Materials
3
I. PRE-INSTALLATION
D. Provide clearance between boiler jacket and
WARNING
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
A. Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of boiler to carrier in good condition. Any claim
for damage or shortage in shipment must be filed
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
B. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas Code, ANSI Z223.1/NFPA 54. Where
required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
combustible material in accordance with local fire
ordinance. Refer to Figure 1 for minimum clearance
from combustible material for closet installation.
Provide 1/2" clearance from water piping to
combustible materials.
E. Provide practical service clearances. A minimum
of 24" from the left side and front jacket panels is
recommended for servicing but may be reduced to
minimums shown in Figure 1.
F. Install on level floor. For basement installation provide
concrete base if floor is not level or if water may be
encountered on floor around boiler.
G. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
H. Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.
C. Appliance is design certified for installation on
combustible flooring. The boiler must not be installed
on carpeting.
II. UNPACk BOILER
CAUTION
Do not drop boiler. Do not bump boiler jacket
against floor.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
4
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
F. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.
III. WATER PIPING AND TRIM
WARNING
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
building.
A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water.
Oxygen contamination sources are system leaks
requiring addition of makeup water, fittings, and
oxygen permeable materials in distribution system.
Eliminate oxygen contamination by repairing system
leaks, repairing fittings, and using non-permeable
materials in distribution system.
B. Install circulator with flanges, gaskets and bolts
provided.
C. Install Safety Relief Valve. See Figure 2. Safety Relief
Valve must be installed with spindle in vertical position.
WARNING
Safety relief valve discharge piping must be piped
near floor to eliminate potential of severe burns.
Do not pipe in any area where freezing could
occur. Do not install any shut-off valves.
D. Connect system supply and return piping to boiler.
Refer to Figures 2, 3, 4 and 5. Maintain minimum ½
inch clearance from hot water piping to combustible
materials.
E. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled medium
piped in parallel with the heating boiler using
appropriate valves to prevent chilled medium from
entering boiler. See Figure 3.
Figure 2: Near Boiler Piping
F. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
flow control valves or other automatic means to prevent
gravity circulation of boiler water during operation of
cooling system.
G. Use a boiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).
Remove circulator and install pipe tee between
circulator and boiler return along with second tee in
supply piping as shown in Figures 4 and 5. Bypass
should be same size as the supply and return lines with
valves located in bypass and supply outlet as illustrated
in Figures 4 and 5 in order to regulate water flow to
maintain higher boiler water temperatures.
Set by-pass and boiler supply valves to half throttle
position to start. Operate boiler until system water
temperature reaches normal operating range.
Adjust valves to provide 180° to 200°F supply water
temperature. Opening the boiler supply valve will raise
system temperature, while opening by-pass valve will
lower system supply temperature.
H. If it is required to perform a long term pressure
test of the hydronic system, the boiler should first be
isolated to avoid a pressure loss due to the escape of air
trapped in the boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must first be removed from the
boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained
trapped air.
Figure 3: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
5
6
Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems
III. Water Piping and Trim (continued)
7
Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems
III. Water Piping and Trim (continued)
IV. GAS PIPING
A. Size gas piping. Design system to provide adequate gas
supply to boiler. Consider these factors:
1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure is listed on rating
label.
2. Maximum gas demand. Consider existing and
expected future gas utilization equipment (i.e. water
heater, cooking equipment).
B. Connect boiler gas valve to gas supply system.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liquefied petroleum gas.
4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, ANSI/NFPA 70.
C. Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonflammable
solution. Do not use matches, candles, open flames,
or other ignition source.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve.
See Figure 6.
Figure 6: Pilot and Gas Piping
8
V. Venting
WARning
Vent this boiler according to the instructions.
Failure to do so may cause products of
combustion to enter the building resulting in
severe property damage, personal injury or
death.
CAUtiOn
install this boiler according to this manual and
the national Fuel gas Code, AnSi Z223.1/nFPA
54, or applicable provisions of the local building
codes. Contact local building or fire officials
about restrictions and installation inspection in
your area.
CAUtiOn
Failure to install a condensate drain line could
cause boiler to shutdown unexpectedly.
Direct Vent “Direct vent” is also called “sealed combustion”. All combustion air is drawn from outside the building directly
into the boiler. The boiler vents vertically or horizontally, assisted by a fan in the boiler. Gas vent must resist temperature and
corrosion and be sealed against leakage of flue gases and condensate. Approved materials include AL29-4C stainless steel.
Combustion air provided by a separate PVC or galvanized steel pipe.
Power Vent Similar to Direct Vent, but some or all combustion air is drawn from inside the building. May draw air directly from
the boiler room without the use of a combustion air pipe.
Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems
operating under positive pressure.
a. General
If An exIStIng boILer IS reMoVeD
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 to it.
At the time of removal of an existing boiler, the following
steps 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, and 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
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the 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 (or operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the 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 the 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 the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/nfPA 54. When resizing any portion of
the common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Chapter 13 of the National Fuel Gas Code, ANSI
Z223.1/nfPA 54.
9
V. VENTING (continued)
4. If a non-standard length is required, there are two
options:
WARNING
a. Select adjustable length pipe from Table 2. The
pipe adjusts 7” from 12 ¾” to 19 ¾”. Or,
Do not use this boiler with galvanized, Type 304
or Type 316 stainless steel, non metallic or any
other non AL29-4C® based vent systems.
b. Cut the non-gasketed end of a standard straight
length. Make a square cut and file the end
smooth.
Installing Stainless Steel Vent
5. Remove dirt and grease from the male end of the
joint using an alcohol pad.
AL 29-4C® stainless steel vent systems resist the corrosive
effects of high temperature acidic flue gas condensate and
are leak-tight. Alternate stainless steel venting systems
require special adaptors to connect to the parts supplied
with the boiler. Obtain the adaptors from the supplier of the
alternate manufacturer’s venting system. Approved alternate
brands are:
6. Align weld seams in pipes and use a slight twisting
motion to fully insert the male end into the female
end of the joint.
CAUTION
Do not dislodge, scratch or cut the factory gasket.
(1) Heat-fab Inc – Saf-T- Vent
800-772-0739
(2) Flex –L International Inc. – Star 34
800- 561-1980
7.
Tighten locking band by hand with a 5/16” nut driver,
plus ¼” turn past snug, ensuring that the locking band
fully captures the bead in the pipe.
(3) Z-Flex U.S. Inc. – Z-Vent
800-654-5600
WARNING
(4) Protech Systems, Inc. – FasNSeal
800-766-3473
1. Follow all general warnings and instructions for
Direct Vent systems described in the beginning of
this section. Start at the vent connector on the boiler
and work towards the vent terminal.
2. Select stainless steel vent components from Table 2.
3. Verify that the vent and air intake components
do not exceed the boiler’s maximum allowable
equivalent venting length, and do not fall below the
boiler’s minimum equivalent venting length, using
the worksheet on Page 13.
Part Number
3” Dia. Pipe x 1 Ft
8116296U
3” Dia. Pipe x 3 Ft
8116298U
3” Dia. Pipe x 5 Ft
8116300U
3” Dia. Pipe x Adjustable
8116319U
3” Dia. 90° Elbow
8116294U
3” Dia. 45° Elbow
8116292U
3” Dia. Horizontal Drain Tee
8116302U
3” Dia. Vertical Drain Tee
8116304U
3” Single Wall Thimble
8116116
3” Double Wall Thimble
103877-01
10
Provide Combustion Air
Provide combustion and ventilation air in accordance
with the section "Air for Combustion and Ventilation," of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or
applicable provisions of the local building codes.
Like all fuel-burning appliances, boilers need air to operate
reliably and safely.
1. If equipping for direct vent (sealed combustion),
provide combustion air according to Paragraph B —
Direct Vent.
Table 2: Vent System and Air Intake
System Components
Vent System Component
Insufficient combustion air supply may result
in the production and release of deadly carbon
monoxide (CO) into the home.
2. If not equipping the Advantage DV for direct
vent, provide combustion air from the boiler room
according to Paragraph C — Combustion Air.
V. VENTING (continued)
WARNING
DRAFT HOODS, VENT DAMPERS and other
obstructions or openings in the vent system are
prohibited.
IF USING A CHIMNEY AS A CHASE for the vent,
do not vent any other appliance into the space
between the chimney wall and the vent.
DO NOT REDUCE THE DIAMETER of the vent
pipe.
ELIMINATE LOW SPOTS in the vent where flue
gas condensate may pool.
MOISTURE AND ICE may collect around and
below the vent terminal. keep the area in good
repair.
DO NOT PENETRATE VENT PIPE with holes or
fasteners.
B. Direct Vent
Planning a Direct Vent System
1. Avoid contact with plumbing or electrical wires.
2. Horizontal vent pipe must maintain a minimum ¼
inch per foot slope down towards boiler.
3. Any condensate forming in the vent will return to
the boiler. Provide for a condensate trap or siphon
near the boiler to remove condensate from the vent.
4. Support the piping to maintain vent location, prevent
sag and prevent accumulation of condensate. The
vent and/or air intake piping must be adequately
supported with straps or supports with a maximum
spacing of five (5) feet on horizontal runs.
5. Adhere to the boiler’s maximum and minimum
allowable vent lengths. Vent length is provided
in terms of equivalent length of straight pipe plus
equivalent length of fittings, including both the vent
and the combustion air piping, but not including
vent or intake terminals.
6. Maintain minimum allowable clearances between
the vent pipe and combustible materials as
specified by the vent pipe supplier, this manual, and
applicable building codes.
7. Do not install venting system components on
the exterior of the building except as specifically
required by these instructions.
8. Locate the vent terminal per these restrictions and
Figure 7:
a. Minimum twelve (12) inches above grade plus
normally expected snow accumulation level, or
seven (7) feet above grade, if located adjacent
to public walkway. Do not install over public
walkway where local experience indicates
appliance flue gas vapor or condensate creates a
nuisance or hazard.
b. Minimum three (3) feet above any forced air
intake located within ten (10) feet.
Exception: Combustion air intake of direct vent
system.
c. Minimum 4 ft. horizontally from, and in no case
above or below, unless a 4 ft. horizontal distance
is maintained, from electric meters, gas meters,
regulators and relief equipment.
d. Minimum twelve (12) inches from overhangs or
corners of buildings.
e. If window and/or air inlet is within four (4) feet
of an inside corner, then vent terminal must be
at least six (6) feet from adjoining wall of inside
corner.
f. Minimum one (1) foot below, one (1) foot
horizontally from, or one (1) foot above any
door, window, gravity air inlet, or other air
opening into building.
9. Locate the combustion air terminal on the same face
of the building as the vent termination to prevent
nuisance boiler shutdowns.
However, boiler may be installed with vertical
venting and sidewall combustion air inlet or
visa versa, if installation conditions do not allow
alternate arrangement.
10. If the vent passes through interior spaces in floors
above the boiler room, enclose the vent with
material having a fire resistance rating at least
equal to the rating of the adjoining floor or ceiling.
Maintain minimum clearances to combustible
materials between the enclosure and the vent.
11. Use appropriate designed thimbles when passing
through combustible walls (thimble use is optional
for noncombustible walls). Ensure thimble is sealed
to prevent moisture from entering structure.
12. Protect building materials from degradation from
flue gases or flue gas condensate.
11
V. VENTING (continued)
Figure 7: Approved Terminal Locations
13. Vent-Air Intake system may be installed through
wall 3" - 24" thick.
Planning Vertical Installations —
1. Install fire stop where vent and air intake passes
through floors, ceilings or framed walls. The fire
stop must close the opening between the vent and/or
air intake pipe and the structure.
2. Size roof opening to allow easy insertion of vent
and air intake piping to allow proper installation of
flashing and storm collar to prevent moisture from
entering the structure
3. Use appropriately designed vent flashing
when passing through roofs. Follow flashing
manufacturers’ instructions for procedures.
4. Ensure there is a weather-tight seal between the vent
and/or air intake piping were it penetrates the storm
collar and roof flashing.
5. Extend the vent and air intake pipe to maintain a
minimum vertical and horizontal distance of twelve
(12) inches from the roof surface. Allow additional
vertical distance for expected snow accumulation.
Brace as required.
12
Horizontal Stainless Steel Vent Installations
1. Install vent and intake piping per Figure 8.
2. Where the vent pipe penetrates any combustible
wall (Figure 9):
a. Insert the wall thimble from the outside of the
wall, and secure the outside flange to the wall
using nails or screws.
b. Seal any exterior openings in the wall thimble,
or between the thimble and the wall, using a
weatherproof sealant.
c. Install the inside thimble flange and secure the
flange to the inside wall using screws or nails.
3. Maintain 12" separation between vent and intake
terminals. Where the intake air pipe penetrates the
external wall, seal the opening with weatherproof
sealant (Figure 9).
4. To install a vertical “snorkel” exterior to the
building, refer to Figure 10 or 11.
V. VENTING (continued)
Vent/Combustion Air, Equivalent Length Work Sheet
This sheet is supplied to assist in vent/combustion air, equivalent length calculating
Combustion Air (PVC shown)
90° elbow(s) PVC
Quantity =
90° elbow(s)
x 5’ =
equiv. ft. a.
45° elbow(s) PVC
Quantity =
Quantity =
x 5’ =
equiv. ft. a.
x 5’ =
equiv. ft. b
x1=
equiv. ft. c.
x 2' =
equiv. ft. d.
x 7' =
equiv. ft. e.
45° elbow(s)
x 2.5’ =
equiv. ft. b.
x1=
equiv. ft. c.
Straight pipe PVC
Length ft. =
Vent (stainless special gas vent)
Quantity =
Straight pipe
Length ft. =
Horizontal drain tee
Length ft. =
Vertical drain tee
Length ft. =
Total*
a.+b.+c. =
equiv. ft.
Total*
a.+b.+c.+d.+e.=
equiv. ft.
* Total length cannot exceed 50 equivalent feet length (AGDV3 through AGDV6) .
Vent and combustion air terminals do not count towards total equiv. ft.
Figure 8: Separate Horizontal – Vent/Air Intake Installation
13
V. VENTING (continued)
5. An optional concentric adapter kit (P/N 61106012) is
available for 3” & 4” stainless steel vents to provide
a single exterior wall penetration accommodating
both the intake and exhaust. Refer to the installation
instructions provided with the concentric adapter.
Vertical Stainless Steel Vent Installations
6. Install the intake air terminal supplied with the boiler
onto the outdoor end of the air intake pipe per the
instructions in this manual. See Figures 9 and 10.
3. Apply Dow Corning Silastic 732 RTV Sealant
between the vent pipe and the storm collar to provide
a watertight and heat-resistant seal.
7. Install the vent terminal supplied with the boiler onto
the outdoor end of the vent pipe per the boiler-specific
instructions in this manual. See Figures 9 and 10.
4. Install the vent terminal per the boiler-specific
instructions in Figure 12 in this manual.
NOTICE
Storm collar, flashing and sealant for roof
penetration, and vertical vent tee for collection of
condensate are required for vertical venting and
are not supplied with the boiler.
1. Install vent and intake piping per Figures 11 thru 13.
2. Install the storm collar onto the vent pipe immediately
above the flashing.
5. Install the air intake terminal per the boiler-specific
instructions in Figure 12 in this manual.
6. An optional concentric adapter kit (P/N 100222-01
(3”) is available to accommodate both intake and
exhaust piping in a single roof penetration. This
kit is compatible only with Saf-T Vent SC gas vent
produced by Heat-Fab. Refer to the installation
instructions included with the kit.
Figure 9: Separate Horizontal Air Intake Terminal Installation
14
V. VENTING (continued)
Figure 10: Optional Separate Horizontal Vent
Terminal Installation
Figure 11: Typical Vertical Stainless Steel Venting
15
V. VENTING (continued)
Figure 12: Vertical Vent/Air Termination Details for Stainless Steel Direct Vent
Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve
(12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.
16
V. VENTING (continued)
Combustion Air
If the boiler is a Direct Vent boiler and exchanges all
combustion air and combustion products directly with the
outdoors, there are no special requirements for providing
combustion, ventilation, and dilution air.
If the boiler is chimney vented, power vented or induced
draft and draws combustion air from within the building,
follow the steps below to determine how to provide air to
the boiler.
Is the boiler located in a confined space?:
1. Calculate the floorspace (in square feet) of the boiler
room and all rooms connected to the boiler room by
passageways not furnished with doors.
___________ floorspace (sq. ft.)
2. Add up the input rates of all the combustion
appliances installed in the same floorspace.
___________
combined appliance
input (BTU/hr)
3. In the table below, find the Minimum Allowable
Floorspace based on the Combined Input Rate from
Step 2 and the ceiling height. If the Combined Input
Rate is between two rates, use the next highest rate.
___________
Figure 13: Vertical Air Intake Piping for Direct Venting
C. Power Vent
Some direct vent boilers are also approved with use of
indoor combustion air. If the boiler you are installing is
approved for use with indoor combustion air, install the vent
according to the instructions in Paragraph B, Direct Venting,
but omit the “optional” indoor air piping and components.
Specific instructions for configuring the boiler for indoor air
appear in the boiler-specific instructions at the front of this
manual.
4. If the Floorspace from Step 1 is less than the
Minimum Floorspace from Step 3, then you must
provide outdoor air to the boiler room. Proceed to
Step 6.
Is the boiler located in a building of unusually tight
construction?
5. If the answer to all of the three questions below
is “yes”, then you must provide outdoor air to the
boiler room.
Minimum Allowable Floorspace in the Boiler Room
and Freely Connected Rooms (sq. ft.)
Locate vent terminal at least 4 ft. below, 4 ft. horizontally
from, or 1 ft above any door, operable window, or gravity
air inlet. Locate at least 10 ft. horizontally from an operable
opening in an adjacent building.
WARNING
Provide enough air to ventilate the boiler room,
dilute the flue gases, and sustain combustion.
Ignition failure, overheating, fire, carbon
monoxide, and spillage of flue gases may result
from poor air supply.
minimum allowable
floorspace (sq. ft.)
Ceiling Height
7’
8’
9’
10’
357
313
278
250
100,000
714
625
556
500
150,000
1071
938
833
750
200,000
1429
1250
1111
1000
250,000
1786
1563
1389
1250
300,000
2143
1875
1667
1500
350,000
2500
2188
1944
1750
400,000
2857
2500
2222
2000
50,000
Combined
Appliance
Input Rate
(see Step 2)
(BTU/hr)
17
V. VENTING (continued)
Do the walls and ceilings exposed to the outside
atmosphere have a continuous water vapor retarder
with a rating of 1 perm or less, with openings gasket
or sealed?
 Yes  No
Are operable windows and doors weatherstripped?
 Yes  No
Are exterior wall joints caulked or sealed?
 Yes  No
6. If you must provide outdoor air to the boiler room,
the top of the permanent opening into the boiler
room must be within 12” of the ceiling, and the free
area of the opening (sq. in.) must be no less than the
Combined Appliance Input (from Step 2) divided by
3000 BTU/hr/sq. in.
18
__________
combined appliance
input (Step 2)
÷
3000
BTU/hr/sq. in.
_____
Minimum Opening Size
(sq. in.)
7. Duct this opening vertically or horizontally
directly to the outdoors, or directly to a space that
communicates directly with the outdoors, such as an
attic or crawlspace.
For more details and options, refer to the National Fuel Gas
Code (ANSI Z223.1/NFPA 54), or applicable provisions of
local building codes.
VI. ELECTRICAL
A. General. Install wiring and electrically bond boiler to
ground in accordance with requirements of authority
having jurisdiction, or in absence of such requirements,
with the National Electrical Code, ANSI/NFPA 70.
D. For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance.
CAUTION
B. Install thermostat. Locate on inside wall
approximately 4 feet above floor. Do not install on
outside wall, near fireplace, or where influenced by
drafts or restricted air flow, hot or cold water pipes,
lighting fixtures, television, or sunlight. Allow free air
movement by avoiding placement of furniture near
thermostat.
C. Wire boiler. Boiler is rated for 120 VAC, 60 hertz,
less than 15 amperes. A separate electrical circuit
must be run from the main electrical service with an
over-current device/disconnect in the circuit. A service
switch is recommended and may be required by some
local jurisdictions. Connect to black and white wires
and green ground screw. See Figures 14 and 15.
This boiler contains controls which may cause
the boiler to shut down and not restart without
service. If damage due to frozen pipes is a
possibility, the heating system should not be
left unattended in cold weather; or appropriate
safeguards and alarms should be installed on the
heating system to prevent damage if the boiler is
inoperative.
Figure 14: Wiring Connection Diagram
19
VI. Electrical (continued)
Figure 15: Schematic Ladder Diagram
20
VII. SYSTEM START-UP AND CHECkOUT
IMPORTANT
This boiler is equipped with a feature that saves energy by reducing the boiler water temperature
as the heating load decreases. This feature is equipped with an override which is provided
primarily to permit the use of an external energy management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING
CONDITIONS IS TRUE:
•
•
•
•
An external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.
This boiler is not used for any space heating.
This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.
This boiler is equipped with a tankless coil.
A. Main Burner Check - Check main burners to see
that they were not dislodged during shipment. Rear
of burners should be in the vertical slots in the rear of
burner tray and the front of the burners should be seated
completely on the orifices.
B. Initial start 1. Fill entire heating system with water and vent
air from system. Use the following procedure on a
System equipped with zone valves.
a. Close isolation valve in boiler supply piping.
b. Isolate all circuits by closing zone valves or
balancing valves.
c. Attach a hose to hose bib located just below
isolation valve in boiler supply piping. (Note
- Terminate hose in five gallon bucket, at a
suitable floor drain, or outdoor area).
d. Starting with one circuit, open zone valve.
e. Open hose bib.
f. Open fill valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping).
g. Allow water to overflow from bucket until
discharge from hose is bubble free for 30
seconds.
h. Open zone valve to the second zone to be
purged, then close the first. Repeat this step until
all zones have been purged, but always have one
zone open. At completion, open all zone valves.
i. Close hose bib, continue filling the system
until the pressure gauge reads 12 psi. Close fill
valve. (Note - If make-up water line is equipped
with pressure reducing valve, system will
automatically fill to 12 psi. Leave globe valve
open).
Figure 16: Top View of Honeywell Gas Valves
j. Open isolation valve in boiler supply piping.
k. Remove hose from hose bib.
2. Turn ROOM THERMOSTAT to lowest setting.
3. Be sure that gas to pilot and main burners has been
off for at least five minutes and vent damper has
been in the open position.
4. Turn "OFF" the electric switch serving boiler.
5. Open valve on main gas line at meter.
6. PURGE AIR FROM GAS PIPING. Adequate
ventilation must be provided and no smoking or
open flame permitted.
7. Turn "ON" electric switch serving boiler.
8. Open Manual Shut-off Valve upstream of
Combination Gas Valve.
9. Loosen or remove Inlet Pressure Tap Plug in
Combination Gas Valve and when purging is
complete, tighten or replace plug. (See Figure 16).
10. Check pipe and fittings from meter to Combination
Gas Valve using soap solution or other approved
methods.
21
VII. System Start-up and Checkout (continued)
CAUTION
11. Test gas piping and connections between
Combination Gas Valve and manifold, orifices, and
pilot piping for leaks after boiler is operating. Use
soap solution or other approved method.
C. Check Gas Input to Boiler
1. Input Rate and Maximum Inlet Pressure shown on
Rating Label must not be exceeded. Inlet pressure
must not be lower than minimum inlet pressure
shown on Rating Label.
2. All Rate checks and all adjustments are to be made
while boiler is firing - all other appliances connected
to the same meter as the boiler must be off.
Figure 17: 1 Inch Main Burner Flame
3. With boiler off, water Manometer or water column
gauge should be connected to a shut-off valve
installed in the 1/8" outlet pressure tap in the gas
valve (See Figure 16). By installing gas valve
upstream of manometer, gas pressure can be
introduced gradually - without shut-off valve; surge
of pressure when boiler is turned on, could blow
liquid out of manometer. Replace plug in gas valve
when rate check is finished.
4. LP Gas Input:
Adjust Regulator on Gas Valve so that manifold
pressure is 10 inches water column. Turning
Regulator Adjusting Screw Clockwise increases
pressure. Counterclockwise rotation decreases
pressure.
5. Natural Gas Input
a. Approx. Input - Adjust regulator on Gas Valve
so that manifold pressure is 3½ inches water
column. Turning Regulator Adjusting Screw
Clockwise increases pressure, Counter-clockwise
rotation decreases pressure.
D. Check Main Burner Flame. See Figure 17. Flame
should have a clearly defined inner cone with no yellow
tipping. Orange-yellow streaks caused by dust should
not be confused with true yellow tipping.
22
Figure 18: Pilot Burner Flame
CAUTION
Avoid operating this boiler in an environment
where saw dust, loose insulation fibers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.
VII. System Start-up and Checkout (continued)
E. Check Pilot Burner Flame.
1. See Figure 18. The pilot burner should be lit only
if thermostat is calling for heat. The pilot burner
produces three (3) flames. The center flame should
be steady, medium hard blue enveloping 3/8 to 1/2
inch of thermocouple.
F. Check Ignition System Safety Shut-off Device.
Remove 3-wire plug from gas valve.
If burners do not shut down determine cause of
malfunction. Replace necessary items and check
operation.
G. Check High Limit Control.
Jumper Thermostat connections 'T' and 'TV' in
HydroStat Control. See Figure 14 and 15. Allow
burners to operate until shutdown by limit. REMOVE
JUMPER.
I. Combustion Chamber Burn-off
1. The mineral wool combustion chamber panels
may contain a cornstarch based binder that must be
burned out at installation to prevent odors during
subsequent boiler operation.
2. Ventilate the boiler room, set the high limit to its
maximum setting, set the thermostat to call for heat.
Allow the boiler to fire for at least an hour or until
the odor from the cornstarch has dissipated.
3. Return the high limit and thermostat to their desired
settings.
J. Review User's Information Manual and system
operation with owner or operator.
K. Post instructions near boiler for reference by owner
and service personnel.
H. Check Thermostat Operation. Raise and lower
temperature setting to start and stop boiler operation.
Adjust thermostat to normal setting.
23
VIII. OPERATION
A. Temperature Limit/LWCO Control
Refer to the HydroStat 3200 Installation Instructions
and Operating Manual included with these instructions.
B. Electronic Ignition Module
See Figure 19 for electronic ignition (EI). Electronic
Ignition Modules with LED indicators. Table 3 crossreferences the ignition module terminal designations
to the ignition terminal numbers in the wiring ladder
diagrams. Table 4 provides green LED status codes
and recommended service action where applicable..
See Figure 19 for Location of LED. See Figure 22 for
Troubleshooting Guide.
Figure 20: Measuring Pilot Flame Current
with Micro-ammeter
b.
Flame current must be measured with pilot
valve open/pilot lit but the main valve
closed.
c.
Disconnect MV lead wire from the module
before measuring flame current. Trying to
measure the pilot flame current in series
with the wiring will not yield the accurate
reading.
d.
The minimum steady pilot flame signal
must be 1 μAmp (microampere) DC (direct
current).
e.
For reliable operation the flame current
should be 2 μAmp or greater.
f.
To ensure adequate flame current:
Figure 19: Location of LED
Table 3: Ignition Module Terminal CrossReference
Ignition Module
Terminal Designation
Wiring Ladder Diagram
Terminal Number
MV
1
MV/PV
2
PV
3
GND
4
24V (GND)
5
24V
6
SPARK
SPARK
1. Flame Current Measurement Procedure. See
Figure 20 “Measuring pilot flame current with
micro-ammeter”
a.
24
Pilot flame current in micro amps can be
measured using any standard micro-ammeter
by inserting the meter probes into the
module holes labeled FLAME CURRENT
as shown in Figure 20.
i. Turn off boiler power at circuit breaker
or fuse box
ii. Clean the flame rod with emery cloth if
required
iii. Make sure electrical connections are
clean and tight, and wiring not damaged,
repair/replace as needed
iv. Check for igniter/sensor cracked ceramic
insulator, replace if needed
VIII. Operation (continued)
g.
v. Check the pilot flame. It must be blue,
steady and envelop the flame sensing rod
3/8” to ½”.
vi. If needed, adjust pilot flame by
turning the gas valve pilot adjustment
screw clockwise to decrease or
counterclockwise to increase pilot
flame. Always reinstall pilot adjustment
screw cover and tighten securely upon
completion to assure proper gas valve
operation.
Reconnect MV lead wire to the module
upon satisfactory completion of pilot flame
current measurement.
h.
Check the pilot burner operation/ignition
sequence during ignition cycle:
i. Restore boiler power at circuit breaker or
fuse box.
ii. Set thermostat to call for heat.
iii. Watch ignition sequence at burner.
iv. If spark does not stop after pilot lights,
replace ignition module.
v. If main burners do not light or if main
burners light but system locks out, check
the module ground wire and gas control
as described in Figure 22 “ Honeywell
Electronic Ignition Troubleshooting
Guide”.
Table 4: Green LED Flame Codes
Green LED
Flash
Codea
OFF
Next System Action
Recommended Service Action
No “Call for Heat”
N/A
None
Flash Fast
Power up - internal check
N/A
None
Heartbeat
Normal startup - ignition sequence
started (including prepurge)
N/A
None
Device in run mode.
“x” = flame current to the nearest µA.
N/A
None
4 Seconds ON
then “x” flashes
a
Indicates
2
5 minute Retry Delay
- Pilot flame not detected during trial for
ignition
Initiate new trial for ignition after retry
delay completed.
If system fails to light on next trial for ignition
check gas supply, pilot burner, spark and
flame sense wiring, flame rod contamination or
out of position, burner ground connection.
3
Recycle
- Flame failed during run
Initiate new trial for ignition. Flash code
will remain through the ignition trial until
flame is proved.
If system fails to light on next trial for ignition,
check gas supply, pilot burner, flame sense
wiring, contamination of flame rod, burner
ground connection.
4
Flame sensed out of sequence
If situation self corrects within 10
seconds, control returns to normal
sequence. If flame out of sequence
remains longer than 10 seconds, control
will resume normal operation 1 hour
after error is corrected.
Check for pilot flame. Replace gas valve if pilot flame present. If no pilot flame, cycle “Call
for Heat.” If error repeats, replace control.
6
Control Internal Error
Control remains in wait mode. When
the fault corrects, control resumes
normal operation.
Cycle “Call for Heat”. If error repeats, replace
control.
7
Flame rod shorted to ground
Control remains in wait mode. When
the fault corrects, control resumes
normal operation.
Check flame sense lead wire for damage or
shorting. Check that flame rod is in proper
position. Check flame rod ceramic for cracks,
damage or tracking.
8
Low secondary voltage supply- (below
15.5 Vac)
Control remains in wait mode. When
the fault corrects, control resumes
normal operation.
Check transformer and AC line for proper input
voltage to the control. Check with full system
load on the transformer.
Flash Code Descriptions:
-
Flash Fast: rapid blinking
-
Heartbeat: Constant ½ second bright, ½ second dim cycles.
-
4 second solid on pulse followed by “x” 1 second flashes indicates flame current to the nearest µA. This is only available in run mode.
-
A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats the sequence.
25
IX. SERVICE AND MAINTENANCE
Important Product Safety Information
Refractory Ceramic Fiber Product
Warning:
The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures above 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
•
•
•
•
Take steps to assure adequate ventilation.
Wash all exposed body areas gently with soap and water after contact.
Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
•
•
•
•
26
If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
IX. Service and Maintenance (continued)
Figure 21: Operating Instructions
27
IX. Service and Maintenance (continued)
WARNING
SERVICE on this boiler should be undertaken
only by trained and skilled personnel from a
qualified service agency. Inspections should be
performed at intervals specified in this manual.
Maintain manual in a legible condition.
LABEL ALL WIRES prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation
FAILURE TO MAINTAIN THE BOILER in proper
working condition may lead to fire, explosion,
personal injury or death, and extensive property
damage.
A. General. Inspection and service should be conducted
annually. Turn off electrical power and gas supply
while conducting service or maintenance. Follow
instructions TO TURN OFF GAS TO APPLIANCE.
See Figure 21.
TURN OFF ALL GAS AND ELECTRIC power
supplies to the boiler before servicing. Contact
with or release of dangerous flammable gas,
electrical voltage, moving parts, and very
hot water under pressure may cause serious
personal injury, property damage, or death.
LOCk ELECTRICAL BOXES AND GAS VALVES
CLOSED to prevent someone from inadvertently
restoring power or gas before the heating system
is safe to operate.
6. Remove and clean main burners:
a. Remove jacket front panel.
b. Remove air box door.
c. Disconnect pilot tubing at gas valve.
d. Disconnect pilot lead wires at gas valve.
Equipment you will need:
q Soft bristle brush
q Bristle flue brush
e. Remove wires from flame rollout switch.
f. Remove burner access panel.
q Vacuum with brush attachment
g. Mark location of the pilot main burner on the
manifold if the marking on manifold is missing
or obliterated.
B. Perform these tasks each year.
h. Hold burner at throat. Lift front of burner
1. Clean low water cutoff probe (if applicable).
2. Inspect vent for obstruction and signs of
condensation, distortion, overheating or gas leakage.
3. Clean vent terminal and air intake screens.
to clear orifice. The burner that holds the pilot
can only be removed by first lifting the burner
adjacent to its right.
C. Perform Startup Checks and Adjustments.
4. Clean condensate collection and disposal system.
1. Check operation of airflow sensing switches.
5. Inspect boiler flue passages:
2. Check for water leaks on the boiler or water
pooling around boiler.
a. Remove vent pipe.
b. Remove top panel and hood.
c. Remove canopy.
d. Examine all flue passageways. Using bristle
flue brush and vacuum, remove any soot or
obstructions.
e. Use installation procedure to reassemble and
reseal air intake system and vent pipe.
3. Manually operate the relief valve. If the water
is grey or black, there is excessive oxygen in
the system. Oxygen is corrosive to boilers.
Eliminate any source of oxygen.
4. Verify proper operation after servicing. Follow
Paragraphs C through J from Section VII
"System Start-Up and Checkout".
D. Lubrication. There are no parts requiring lubrication
by service technician or owner.
28
X. TROUBLESHOOTING
A. Temperature Limit/LWCO Control
Refer to the HydroStat 3200 Installation Instructions
and Operating Manual included with these instructions.
B. Electronic Ignition Module (see Figure 22)
29
X. Troubleshooting (continued)
"CALL FOR HEAT."
POWER TO
MODULE? (24 V
NOMINAL)
NO
CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO,
CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED)
IS MADE.
YES
30 SECOND
PREPURGE
DELAY?(S8670
ONLY)
NO
REPLACE S8670
YES
PULL IGNITION LEAD AND
CHECK SPARK AT MODULE.
SPARK
ACROSS IGNITOR/
SENSOR
GAP?
SPARK OK?
NO
REPLACE MODULE
NO
YES
CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP AND CORRECT.
CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING. TAKE PROTECTIVE ACTION TO SHIELD CABLE
AND BOOT FROM EXCESSIVE TEMPERATURES.
YES
TURN GAS SUPPLY ON AND
RECYCLE "CALL FOR HEAT."
CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER
ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING).
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE, IF VOLTAGE IS OK, REPLACE GAS CONTROL. IF NOT,
REPLACE MODULE.
NOTE: IT MAY BE NECESSARY TO RECYCLE THE "CALL FOR HEAT" MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR.
NO
PILOT BURNER
LIGHTS?
YES
SPARK
STOPS WHEN
PILOT IS
LIT?
NO
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
CLEAN FLAME ROD.
CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.
CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF PROBLEM PERSISTS, REPLACE MODULE.
NO
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT. IF
OKAY, REPLACE GAS CONTROL.
NO
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
AT THE TIME OF CHECKOUT.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. PILOT FLAME MUST NOT BE MOVING AROUND DUE TO
OUTSIDE AIR FLOWS, ETC.
ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER IS ON AND ALL
OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE.
IF CHECKS ARE OKAY, REPLACE MODULE.
NO
CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.
REMOVE MV LEAD AT MODULE. IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
GAS CONTROL.
YES
MAIN BURNER
LIGHTS?
YES
SYSTEM
RUNS UNTIL "CALL
FOR HEAT"
ENDS?
YES
"CALL FOR HEAT" ENDS
SYSTEM
SHUTS OFF?
Figure 22: Troubleshooting Guide, Honeywell Electronic Ignition (EI)
30
XI. REPAIR PARTS
All Advantage Repair Parts may be obtained through F.W. Webb Company, 1 Bon
Terrain Drive, Amherst, NH 03031 or any other F.W. Webb Company location.
Key
No.
1A
1B
Description
[Quantity] Part Number
AGDV3
AGDV4
AGDV5
AGDV6
Block Assembly
102287-03
102287-04
102287-05
102287-06
Flue Baffle
[2]
71107002
[3]
71107002
[4] 71107002
[5] 71107002
31
XI. Repair Parts (continued)
Key
No.
Description
2A
Canopy Assembly - Sea Level
2B
Canopy Gasket Kit
2C
Fan Gasket
2D
Fan
32
AGDV3
105168-03
[Quantity] Part Number
AGDV4
AGDV5
105168-04
105168-05
6206001
8206085
102706-01
AGDV6
105168-06
XI. Repair Parts (continued)
Key
No.
3A
Description
AGDV3
[Quantity] Part Number
AGDV4
AGDV5
AGDV6
Base Wrapper
71807031
71807041
71807051
71807061
3B
Base Tray
102543-03
102543-04
102543-05
102543-06
3C
Burner Tray Assembly
61807031
61807041
61807051
61807061
3D
Base Front Panel
102705-03
102705-04
102705-05
102705-06
3E
Burner Access Panel
102707-03
102707-04
102707-05
102707-06
3F
Base Gasket Kit
6206002
3G
Base Side Insulation
3H
Base Rear Insulation
72007031
72007041
72007051
72007061
72007032
72007042
72007052
72007062
3J
Base Front Insulation
3K
Base Leg Assembly
3L
Flame Rollout Switch
[2] 72007001
[4] 6186001
80160044
33
XI. Repair Parts (continued)
Key
No.
4A
4B
Description
4E
4F
[Quantity] Part Number
AGDV4
AGDV5
Gas Valve (Natural Gas), Honeywell
VR8204P1171
81660282
Gas Valve (LP Gas), Honeywell
VR8204C3015
81660146
½" Gas Manifold
82207041
82207051
82207061
Burner Orifices - Natural Gas #49
[4]
822709
[6]
822709
[8]
822709
[10] 822709
Burner Orifices - LP Gas #56
[4]
822707
[6]
822707
[8]
822707
[10]
822707
[7] 100146-01
[9] 100146-01
Pilot Burner
100147-01
Pilot Assembly - Natural Gas
8236163
Pilot Assembly - LP Gas
Main Burner
8236164
[3] 100146-01
[5] 100146-01
4G
Pilot Tubing
4H
Gas Valve Hose Barb Fitting
104635-01
8236122
4J
Plastic Hole T
104636-01
4K
24" Lg. Black Silicone Hose
104658-01
4L
6" Black Silicone Hose
104654-01
34
AGDV6
82207031
4C
4D
AGDV3
XI. Repair Parts (continued)
Key
No.
Description
AGDV3
[Quantity] Part Number
AGDV4
AGDV5
AGDV6
5A
Air Box Assembly
61807032
61807042
61807052
5B
Air Box Door
71807034
71807044
71807054
61807062
71807064
5C
Combustion Air Diffuser
N/A
71807049
71807059
71807069
5D
Pilot Tube Gasket Cover Plate
5E
Pilot Tube Gasket
5F
Window Plug
7096002
8206038
102202-01
35
XI. Repair Parts (continued)
Key
No.
AGDV3
[Quantity] Part Number
AGDV4
AGDV5
6A
Honeywell S8670E EI Module
100959-01
6B
HydroStat 3200 w/Sensor
105161-01
6C
Honeywell Relay Module
6D
36
Description
AGDV6
80160096
Differential Pressure Switch (Natural Gas)
80160762
Differential Pressure Switch (LP Gas)
104576-01
104604-01
80160760
XI. Repair Parts (continued)
Key
No.
Description
[Quantity] Part Number
AGDV4
AGDV5
AGDV3
AGDV6
7A
Jacket Left Side Panel
104249-01
7B
Jacket Right Side Panel
104250-01
7C
Jacket Rear Panel
102569-03
102569-04
102569-05
102569-06
7D
Jacket Vestibule Panel
104246-03
104246-04
104246-05
104246-06
7E
Jacket Top Panel
104247-03
104247-04
104247-05
104247-06
7F
Jacket Front Door
104248-03
104248-04
104248-05
104248-06
7G
Jacket Control Panel
102549-03
102549-04
102549-05
7H
Air Intake Collar Assembly
102644-01
102549-06
102644-02
37
XI. Repair Parts (continued)
Key
No.
Description
[Quantity] Part Number
AGDV4
AGDV5
AGDV3
8A
Water Manifold
80607001
8B
Temperature/Pressure Gauge
100282-01
8C
30 PSI Relief Valve
81660363
8D
Drain Valve
8E
Vent Terminal
8F
Vent Connector
8G
Vent Terminal
Air Intake Terminal (not shown)
Taco 0015 Circulator (not shown)
38
AGDV6
102802-01
8110701
N/A
8110703
N/A
8116310
6116045
6116044
104130-01
39
40