Document 6RYDqx2wz4aOXkj64DX8XGOkE

PLAINTIFF'S EXHIBIT ~st- AMERICAN G-2 G STANDARD! BOILER INSTRUCTION MANUAL PACKAGED BOILERS FLUSH OR DELUXE JACKETS Form No. BP-32941-01 DESIGN CERTIFIED BY AMERICAN GAS ASSOCIATION NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET. MUST BE AFFIXED ON OR ADJACENT TO THE HEATING EQUIPMENT. 05116 CAUTION TO INSTALLER AND HOMEOWNER This hydronic heating boiler incorporates the best in engineering and manufacturing techniques and will give years of good service and troublefrep operation. If -properly treated. ] J I ! j The heat transfer surface has been carefully designed to give optimum performance and reliability. However, the presence of contaminants such as scale, sediment and boiler sealing compounds in the section waterways may serve to insulate the heat transfer surface and cause premature failure of the sections. > Scale build-up can be prevented by good installation practices which eliminate addition of makeup water to the system. Sediment which may accumulate in the boiler should b e flushed out on a regular basis in accordance with recommended maintenance practices. Occasionally, leaks will be detected in the system. These leaks are usually of such a nature that they may be prevented or corrected by good workmanship. Every effort should be made to correct them without the use of boiler sealing compounds. If sealing compounds are used, they should be used as sparingly as possible and never in excess of the manufacturer's recommendations. Following their use the boiler must be thoroughly flushed out. Otherwise, serious damage may result. In some special installations, glycol anti-freeze is added to the water in the system to protect against freezing during cold weather when the boiler is not being fired and the system is not drained. Although American Standard cannot recommend this practice, we recognize that glycol anti-freeze will occasionally be used. Heat transfer is poorer with glycol than with water. Therefore, glycol should never be used in greater quantity than 50% in the system; with any quantity, radiator output will be lower than with plain water. It is always better, when possible, to drain the entire system, rather than use anti-freeze: the heating system and house plumbing will not freeze while the heating system is operating; and plumbing is not protected if the heating system is not operating, whether or not anti-freeze is used. , Cast iron is highly resistant to corrosion. However, the propellant used in aerosol cans breaks down into poison gas and corrosive gas at high temperature: if aerosol mixtures are used near boilers, the aerosol will enter the boiler flame and be heated. Continued use of aerosol cans near heating systems will result in severe boiler heating surface corrosion and possible danger to health. 05117 I flush jacket model less controls deluxe jacket model less controls NOTE: These views show typical water and steam boilers with and without controls. Many combinations'of controls and control systems to meet special requirements are possible front new side new deluxe jacket model with controls for steam boiler number G-23 G-24 G-25 G-26 G-27 for Installations from tea level to 2000 ft * A.G.A. rating! net = B = R ratings * * input output water steam steam (Btu/hr) (Btu/hr) (Btu/hr) (Sfl. ft) (Btu/hr) chimney height diameter (inches) above drafthood diet) 60,000 90,000 120,000 150,000 180,000 48.000 72,000 96,000 120,000 144,000 41,700 62,600 83,500 104,300 125,200 150 225 300 375 450 36,000 54,000 72,000 90,000 108,000 4 5 5 6 6 10 10 10 10 10 water content (gallons) water steam boiler boiler 7.6 9.6 11.7 137 15.7 4.9 6.2 7.6 8.9 10.2 (forced hot water only) l=W=H ratings--(gpm)a heater heater heater heater 21B* 222* 226* 232* __ 2Vj _ _ 3 3V -- _ _ _ -- 3Va 4 _ _ _ _ -- For attitudes above 2000 ft., ratings shoutd be reduced at the rate of 4% tor each 1000 ft above sea level. Net I = B = R ratings shown are based on a piping and pick up al* lowence of 1.333 for steam and 1.15 tor water. American-Standard should be consulted before -electing a boiler for installations having unusual piping and pick up requirements A Gallons water per minute heated from 40*F to 140*F with 200*F boiler water temperature. Last two digits designate lineal feet of Tru Fin tubng in heater co>i Domestic hot water connection size is Vj" for all heaters. 05118 WATER HEATER OR TAPPED COVER PLATE OR SECnON. (SEE PACE 3) i.cj* EXTERNAL - ^ DRAFTHOOO i f G-23D ONLY 11 5 IjI G-2 GAS BOILERS DIMENSIONS 'i DELUXE JACKET i 1 MtLCR or m or NUMiCI* sections UftNCftl A G-23D 3 2 13 '* 3 % C0 4 7P5T CDr G-240 4 3 5 191$ G-250 5 4 <9 H 5 19 G-26D 6 5 22 \ 6 19 G-27D 7 6 26 13 k* 6 19 NOTE-. EXTERNAL DRAFTHOOO IS PROVIDED FOR G-23-0 BOILER SIDE VIEW WATER HEATER OR TAPPED COVER PLATE OR SECTION. (SEE PAGE 3) FRONT VIEW FLUSH JACKET SIDE VIEW TOP VIEW r---------- A----------- .? 4 GAS INLET- oT * 1 Z3 C.iS ._ 0l NUMScr G-23F G-24F G-25F G-26F G-27F No OP no or SECTIONS tU*NCftS 32 43 54 6S ___ I___ 6 A 11 14 V4 17 20 V4 24 B s'* 7'* 8*4 I0*fc 12 C 4 5 5 6 6 0 11 14 14 16^ 16'/$ E 5 7 7 9 9 t FRONT VIEW 05119 G-2 GAS BOILERS NOTE: NO TAPPINGS, BACK OF SECTIONS 5/i6-ibta,ps for fastening canopy NOTE: All Boilers (except G-23) with Cover Plates on left end section will accept tankless heater. See Table, Page 1. Heaters are for use with forced hot water, only. Steam or gravity water boilers may be converted to forced hot water by changing controls and converting piping system. USE OF TAPPINGS SHOWN TAPPING LOCATION SIZE A|. *2 3/4" RECOMMENDED USE Water: High Limit or Combination Control Steam: Optional steam pressure control B i/2" Water: Temp* - Altitude Gauge Steam: Pressure Gauge Tapped on All-Purpose Boilers C 3/4" Only, Optional Use, for circulator (reverse acting) control, standby low limit, etc. Water: Air vent and relief D 3/4" valve. Steam: Pop safety valve. Combination Control or Low E 3/4" Limit, in Heater* Steam: Supply and Blowoff F 3" Water: Gravity Supply; Optional Forced Supply. Water: Forced Supply G 2" Optional Gravity Supply Drain Cock (left end section J 3/4" only) Kl 1 l/2" Forced hot water return k2 2" Steam or water return - L . Section Drain Plug (Right End l/2" Section Only) i i s l/2" j For steam gauge glass with low water cutoff i 05120 G-2 GAS BOILERS 4 INSTALLATION REQUIREMENTS The complete installation should be made per the latest edition of American National Standard Z2L 30, Installation of Gas Appliances and Gas Piping, obtainable from the American Gas Association, 8501 East PleasantiValley Road, Cleveland, Ohio 44131. LOCATING BOILER For basement locations, when floor is not level, or water may stand, build a level concrete base, at least 3" high. Locate boiler near the chimney used. Locate front, back and sides of boiler for clearance and convenience. CLEARANCES FOR SERVICING AND SAFETY All G-2 Boilers are design certified for closet installation, with clearances shown on the boiler jacket and in the table and sketches below. G-2 Boilers, natural gas or propane, are 'designjcertified for use on combustible floors when the Floor Paniand Radiation Shield are used (See Page 6) G-2 boilers approved installation in utility rcon-.s. alcoves clo:<.'; . . . anywhere *11 G-? bollers'are aLg'.A. *det sr ctrfif.ed ior close* in Tests show that temo-r'etures e>4 aojacent comcustibie $ur'ac*will net er;*sw* **># r boiler is -n'-iLi'e.*' .* .t c'a; type erte'esu't with *ne specified mir-njm clearances These clearances (see table, below) apply after considering the teedy accessibility to the unit tor adjustment, repair and replacement of parts. With the cicset door open, there n- jst be a minimum f^on* e'earence of 18 Inches. Note: Area of eech inlet ari vent:it.*g eir ootnir.g -- 1 so `n to* eech 1.000 Btun input w th - ninimjrr. of 10C sq. inches Tor mstaiiat-o'i cn '*corr.bu.,'.ib|e rioors; for combustibie floors only when equipped with floor par, and radiation shield. 05121 G-2 GAS BOILERS 5 CLEARANCES (contl.me u) A MINIMUM of 6" from external drafthood (if used) and all smokepipe (breeching) to any combustible material must be maintained. Clearances for service access must also be maintained, as listed below. MAINTAIN THE LARGER CLEARANCE (safety or service) when two different clearances are listed. Service Clearances: 1. When a circulator is mounted on the boiler return, allow the necessary access and clearance of wrenches, etc. to service or remove the circulator. 2. Allow AT LEAST 18" between any fixed obstruction and the boiler front, to allow installation and service of burners and pilots. 3. DOORWAYS must be wide enough to allow boiler entrance. 4. SMALL ROOMS OR CLOSETS: Boiler and other appliances (gas water heater, etc. ) should be so arranged that one appliance can be removed or serviced without disconnecting or moving the other appliances in the room. 5. TANKLESS WATER HEATER clearance, boiler left side to a wall or other obstruction, must be as follows (minimum): #218 Heater = 15" #222 Heater = 18" #226 Heater = 24" #232 Heater = 31" TESTING Before piping boiler, plug openings, fill boiler with water, and subject to not less than 10 lbs. nor more than 30 lbs. pressure. Inspect boiler inside and outside for leakage as a result of breakage from handling and shipping. To safeguard accuracy of controls supplied with boiler, do not install until after test of boiler. This pre caution of testing the boiler will simplify handling of any necessary replacements or adjustments and assist in treating with claims against transportation companies. After test, drain and remove plugs where required, and continue. INSTALL FLOOR PAN AND RADIATION SHIELD (when used): When the G-2 Boiler is installed on a combustible floor, the floor pan and radiation shield (shown on Page 6) must be installed. The floor pan is inserted, insulation side up, from below the manifold; it rests on lugs on the end sections, in the position illustrated. The radiation shield, with flanges down,'is inserted below the burner access door to rest on lugs on the end sections, as illustrated. 05122 G-2 GAS BOILERS i Mtr* Mcnoa Mil* MCT( (Mil o accTiou sonc rTM T<imK8uPU kctiom aeik.c* aimhoMtMOCOAt kctiom iaui wnm*i.OnT^nCjMMcUaCw* ru Mcnea aica aiTmw.tomTC*uo{Ou*j mjrr mmu UCTIOM Mtfl DBBjjjpB 11 KCTlOa aou.Cft mrtmmuTs>t 4miMmCa*#vl WT Tnf^orfMi H I PILOT BUANCft LOCATION 6 note; radiation shield and floor pan furnished (SPECIAL ORDER) FOR COMBUSTIBLE FLOOR INSTALLATION 05123 G-2 GAS BOILERS 7 GAS PIPING: Install piping from meter per schedule and drawing below. Piping from main to gas valve runs through hole in left side panel of deluxe jacket. Pipe size from main to gas valve is per PIPE SIZE, TEE TO VALVE table, below left. All pipe joints must be made using joint compound resistant to L. P. Gases. GAS PIPE DELIVERY SCHEDULE: Maximum Capacity of Pipe in Cubic Feet of Gas per Hour for Gas Pressure of 0, 5 Psig or less and a Pressure Drop of 0. 3 Inch Water Column Based on a 0. 60 Specific Gravity Gas. Nominal Iron Pipe Size, Inches 10 . 500 . 750 L 000 1.250 1. 500 2.00C 132 278 520 1, 050 1, 600 3, 050 20 92 190 350 730 1,100 2, 100 30 73 152 285 590 890 1, 650 Length of Pipe, Feet 40 63 130 245 500 760 1, 450 50 -------------- 1 56 115 215 440 670 1, 270 60 50 105 195 400 610 1, 150 70 46 96 180 370 560 i. 050 80 90 43 40 90 84 170 160 350 320 530 490 990 930 100 38 79 150 305 460 870 PIFE SIZE, MAIN TEE TO GAS VALVE (Size of gas valve inlet) Boiler Number Natural Gas Propane G-23 1/2 1/2 r* -> 1/2 1/2 G-25 1/2 1/2 G-26 1/2 1/2 G-2 7 1/2 1/2 NOTE: PIPE AND FITTINGS SHOWN ABOVE NOT SUPPLIED WITH BOILER 05124 G-2 GAS BOILERS CONNECT PILOTS: 24 Volt Systems: Connect pilot tubing and thermc.ouple to combination gas vaIve. Self Energizing (S, E. ) Systems: Connect pilot tubing and pilot generator wires to combination gas valve. Combination gas valves are internally vented: A pilot vent tube is not useC. ASSEMBLY OF COMBINATION GAS VALVE* AND MANIFOLD 24 VOLT SYSTEM 24 volt power for valve operation is supplied by power line through a 24 volt, transformer. ASSEMBLY OF COMBINATION GAS VALVE* AND MANIFOLD - SELF ENERGIZING (S. E.) SYSTEM Millivolt power for valve operation is supplied by the pilot generator. ^COMBINATION GAS VALVE (FIVE-FUNCTION VALVE): A pilot safety valve, pressure regulator, ** main manual and pilot shutoff valve and automatic gas valve, combined in one. **The pressure regulator is not used for PROPANE gas (the regulator is installed outside the Boiler) PIPE STEAM OR WATER SYSTEM TO BOILER. See following pages. NOTE: Draft diverter and vent to chimney (See Page 12), and steam or water pipe must be so arranged that there is no interference between vents and piping. 05125 C.'2 CAS BOILERS 9 PIPING WATER. BOILERS (Sor d "av/ings cod tables, page 10 and below) Gravity Circulation Systemc A new boiler is usually ir.r'.c.iled an a replacement in an existing gravity piping system: connect suppry an' return mains to boiler as for boiler being replaced. See table below fcr pipe lz::K connections. Use TWO returns, as suggested in table, for G-208 and jaryer If existir.g expansion tank is not serviceable, install compression lank (dlapi vain) or n<ui-diaphragm) per drawings. Page 10. Forced Circulation Systems Residential boilers often have the circulator (pump) on the boiler return (see Page 1) or the pum*, m. be or. the supply (pumping away from the boiler). Either position is sg.tiifactory for normal residential use. WHEN HIGH HEAD PUMPS are used, or -vh?n RADIATORS SEVERAL STORIES ABOVE THE BOILER are served, the , unvAM should be installed on the supply: this will keep piping presided and v ill prevent excessive pressure change in the boiler itself. Sec Page 10 fo - porn; and compression tank locations and suggestions. Pipe sizes for norit.^i design conditions are shown below. Boiler Size G-23 G-24 G-25 G-26 G-27 wr^vity CircutS: lev. Pipe Size - i..'l. |i ' s FORCED HOT WATER FLOW RATES AND PIPE SIZES FOR STANDARD CONDITIONS Supply Main R HU."'. Main Approximate Flow Supply &t Return Pipe Rr.te 121 2b F, drop, to Diameter to obtain flow deliver boiler heat rate shown, at normal output water velocity -> 2 5 GPM 2c 7 GPM 2 i 10 GPM 2 2 12 GPM 2 2 15 GPM 3/4" 1" 1" 1 1/4" 1 1/4" 05126 G-2 GAS BOILERS 10 PIPING WATER BOILERS PUMP AUTOMATIC AIR VENT 1. Locate tank near boiler as illustrated (locate on suction side of pump, if pump is mounted on supply main), 2. Use second or larger diaphragm tank to control expansion of water in large piping system. DO NOT ADD A NON DIAPHRAGM TANK. 3. A functioning automatic air vent is re quired. Install as shown, tc venc air off top of boiler at Eliminaire. External air control devices are not needed. 4. If bypass piping is used, add automatic air vents in piping system as needed; pump should be mounted in supply main. NON-DIAPHRAM COMPRESSION TANK Systems using non-diaphragm tank 1. Locate tank above boiler as shown. A second tank at the same level, connected to the SINGLE pipe to the boiler, may be added (if needed) to control expansion of water in a large piping system.* 2. USE NO AUTOMATIC AIR VENTS with non-diaphragm tank system. All air in the system after initial venting collects in the tank, to control expansion of water, 3. Avoid piping systems which bypass water around the boiler, when r.ondiaphrecm tanks are used: for reliable operation, aiv must return to the tank and must not be lost through valve packings, etc. *If more tank capacity is needed, a DIAPHRAGM tank can be added, preferably at pump inlet (suction). TANK STEM MUST BE UP, as illustrated, top left Air must collect in the non-diaphragm tank, only. The system remains NON-DIAPHRAGM: use no automatic air vents. 05127 G-2 C-AS BOILERS - PACKAGED MINIMUM RECOMMENDED STEAM PIPING SIZES BOILER PIPE DIAMETER-INCUES ij HORIZONTAL RETURN EQUAL-I OUTLET AND IZING | RISER LOOP G-23 G-24 G-25 G-26 G-27 1 1/2 2 2 1/2 1 1 1/2 1 1 1/2 1 1 1/2. | RISER SHOULD RISE AT LEAST 18" FROM HORIZONTAL BOILER OUTLET PIPE TO HORIZONTAL OVER HEAD PIPE. 11 --RISER The center of the Hartford loop tee should be 241 below the normal water line of the boiler, or 21" above a level floor under the boiler. (B) The pipe connecting the horizontal steam outlet to the boiler return tapping is usually called the equalizing RECOMMENDED PIPING FOR G-2* or G -24 ILLUSTRATED. NOTE' Larger pipe sizes moy be used, i* desired. Also see Nate , below. loop. The portion of the loop under the Hartford tee A is full of water and is sometimes considered part of the wet return; boiler performance will not be affected if this piping (below A) is the same size as the wet return. However, small diameter pipe v/ill more quickly fill with sediment than larger pipe -- see C below. Tees with nipples and caps (rather than elbows) are illustrated and recommended to allow easy cleaning of the wet return and boiler return horizontal pipes. These pipes (and the bottom of the boiler) collect all scale and sediment from the system. Capped nipples are easier to remove than plugs. Refer to CLEANING STEAM BOILERS in this '.oiler manual, for rec ommendations, blowoff, flushing, eve. Blow-off vaJ ve and piping should be a minimum of 1 1/4" diameter. Once the system has been thoroughly cleaned, the blowoff valve may be left in place; or it may be removed and the outlet pipe capped or plugged. 05128 G-2 GAS BOILERS INSTALL DRAFT DIVERTER HORIZONTAL DIVERTER 12 EXTERNAL (VERTICAL) DIVERTER Slide diverter over collar above jacket, and secure with screws \ IT NT DIVER TER TO CHIMNEY, using vent pipe the full diameter of diverter cutlet. ->\v rccomi;..mentions of American Nation Standard Z2 1. 30. Refer to Z.21. *. if orhf-r appliances are vented to the same chimney. NOTE: 1. Vent pipe must not project past inside diameter of chimney. 2. Horizontal pine should be short (boiler near chimney) and should pitch up toward chimney at least 1/4" per foot. INST/. 1.L CONTROLS Boilers may be ordered fc1" u-e with many different control types and control sv = te:T.. Only the mos' frequently used controls and control systems can be described in this manual. See following pages. 05129 G-2 GAS BOILERS 13 Typical wire location '.id wiring diagrams (basic), steam and water, are shown below and on pages 14, 15 and l6. It is suggested that the installer MARK THE WIRING DIAGRAM USED, at the time of installation. If the system design requires a special wiring diagram, a copy of the diagram used should be attached to this manual for later reference. General Recommendations - CONTROLS STEAM BOILERS (see Pages 1, 3, 11, and below). NOTE: Packaged steam boilers are factory assembled and wired as shown. Install gauge glass and low water cutoff with high limit (pressure) control, pressure gauge and pop safety valve, on tappings and in positions shown. Pop safety valve may also be installed on highest point on steam header, at boiler. 21 1. 24 volt transformer and junction box 2. Pop safety valve 3. Pressure high limit control 4. Syphon connection 5. Low water cutoff 6. Gauge glass assembly WATER BOILERS (see pages 1, 3, 14) NOTE: Packaged forced circulation boilers are shipped with controls installed and wired. Special controls may be added as required. Install High Limit or Combination Control, other limit controls (if used), temperature-altitude gauge and relief valve in positions shown or suggested. WATER OR STEAM BOILERS If a pressure limit control is specified IN ADDITION TO the basic controls, that control should be installed on or near the top of the boiler. A syphon connection should be used. See Tappings A (Page 3). FIELD WIRING Packaged boilers with controls mounted are factory prewired at the boiler. Listed low voltage table is supplied for wiring at the boiler when controls are not factory mounted. Lew voltage wiring from boiler to remote thermostat, zone valves, etc. , and all line voltage wiring should follow the National Electric Code and local codes or special codes that may apply, using specified wire types (not supplied). 05130 G-2 GAS BOILERS ComHMATTOH Co-rmo*. C O N TR O L LO C ATIO N , W IRE ROUTING. See page 13 fo r ty p ic a l ste a m b o ile r 14 t/3 BS w o Q fii w H < 5 w J O c: H 2: o o < a H 05131 G-2 GAS BOILERS 15 05132  & hi 44V* Oh3i X m b 5 a ** * CJ CO * * d E*4*t 5 a ' <^Ci J W "i is oM l* e as -s -3 a. ffl ifW 2 2 o 5X *0 hi i4*j > S' H J*9 xm ^ 2 c h a O a 25 o 3 d > Q u e a 2 *3 sO fi s g C B SflO B 5B 9 hi *> s i5 J iBdO o S > < a u H O 2 >h0i J33 (BCO C U ^I *Q* G ioo- .-q2-o ^ 1* Q O ^O L ^rg C G-2 GAS BOILERS oo' 3j B J. c > _*"? 4*J >* ? d s 2B O 60 o X y J5 - Is * ^ 00 X >l jj X jr * s B @2 5 60 8 H oc <d U E *^ 2u 2 u S a 4-i *0co. *V0Bd <ow B g Ihdi Jd3 B * ** h moo 5y o Qu hi oH 2 tAJ 16 05133 G-2 GAS BOILERS 17 AIR FOR COMBUSTION AND VENTILATION Air must be supplied to the boiler area at a rate to give satisfactory combustion and venting, and enough ventilation to keep surrounding air temperature within safe limits. The following MINIMUM recommendations to meet AVERA.GE conditions are based upon American National Standards Z21. 30, Installation of Gas Appliances and Gas Piping. The boiler (and other appliances, such as a gas fired water heater) will probably be installed in one of the three general locations described below. It must be understood that the total amount of air required by appliances, for combustion and ventilation, is THE SAME for all three locations. The differences shown in the minimum size of air openings in the boiler room walls is due to the effect of air infiltration into LARGE rooms, through cracks around doors and windows, etc. ALL AIR FOR COMBUSTION MUST COME FROM OUTSIDE. Buildings tightly sealed and weatherstripped allow least infiltration. In such buildings, positive openings from the boiler room direct to the outside are recommended. 1. BOILER IN LARGE OPEN ROOM (basement without partitions, etc. ): Normal air infiltration MAY provide enough air for combustion and ventilation. If the large open room is weatherstripped and sealed from other large rooms by tight doors and windows, a permanent opening or openings direct to outside must be provided. Opening(s) must have a minimum of one square inch free area* per 5000 Btuh input to ALL appliances in the large room. 2. BOILER IN CONFINED SPACE WITHIN A LARGER ROOM (utility room, closet, etc.) See Page 4 - UTILITY ROOM; Two openings to the larger room are required, each opening of one square inch (minimum) net free area* per 1000 Btuh input to all appliances in the confined space, with 100 square inches per opening a minimum, 3. BOILER IN CONFINED SPACE, NOT OPEN TO LARGER ROOM (closed small boiler room in a basement or laundry room, etc.): Provide two openings direct to outside, one within 12" of the ceiling, and one within 12" of the floor, EACH opening with minimum net free area* ol one square inch pet 4000 Btuh inpu. to all appliances in the room. ____________ ________________________ If the room is not on an outside wall, ducts must be run to outside wall openings: OUTSIDE OPENINGS MUST BE DOUBLED to one square inch per 2000 Btuh to all I appliances in the room. Ducts must be full size of openings. In a basement below grade, the opening for air supply should be ducted to within 12" of the floor. The second opening provides ventilation at tne ceiling. * Net free area is always less than total area, if grilles or screens are used (DO NOT USE fine mesh screen). When metal grilleB or large mesh screen is used, add 50% to the net free area calculated. If wooden grilles are used, add 150% to net free area calculated. EXAMPLES: Boiler and other gas appliance in confined space, not open to lar/er root:-,. Total input to both appliances is 175, 000 Btuh. Metcl g.iliji over openings will be used. (1) Net free area, EACH opening = 175, 000/4, 000 = 44 sq. in. Actual grilled opening should be 44 x 150% = 66 sq. in. Two 8" x 10" openings direct through &r. outside wall will meet minimum requirements. (2) IF ROOM IS INTERIOR, DUCTS MUST BE RUN TO OUTSIDE WALL. Net free area and actual area of each opening must be doubled: 132 sq. in, actual area of each duct and outside opening with metal grille must be provided. Ducts and openings 12" x 12" or 8" x 18" would provide this area. TAKE PR. EC A UT IONS AGAINST BLOCKING AIR OPENINGS with snow, debris, etc. 05134 G-2 GAS BOILERS 18 FILLING SYSTEM (do not fire boiler until filled) STEAM SYSTEMS;| Fill to approximately half way up the gauge glass. During normal operation, SLOWLY add any necessary makeupwater. Cleaning is recommended after first filling: see CLEANING STEAM SYSTEMS, Page 27. WATER SYSTEMS: (a) Existing open-expansion-tank (tank at high elevation) systems Fill system, to fill expansion rank 1/ 3 full. Set Boiler pressure gauge stationary indicator under movable ind cator aL this indicated pressure. (b) Standard closed hot water systems - Fill entire system with water; vent or purge air according to the air control system installed. Add water to obtain desired gauge pressure for the system design. Set boiler pressure gauge stationary indicator to that design pressure. CAUTION; After steam or water system is filled, the boiler should be fired and the system vented to remove oxygen from the fresh water. CHECK BEFORE STARTING (Gas valve knob in OFF position): Do not turn main gas valve knob to ON or place system in automatic operation until these items are checked: 1. Is boiler or system filled with water? 2. Is all wiring completed, per the wiring diagram that applies? 3. Is the draft diverter piped to the chimney? Is the chimney unobstructed ? 4. Is air for combustion and ventilation provided for? 5. Has all combustible materia: beer, removed from the area? 6. If boiler is on a wooden floor, has floor shield been installed ? LIGHTING INSTRUCTIONS (See printed lighting instructions plate on boiler and following: TO SHUT OFF: 1. Depress the Manual Gas Cod' Knob and Turn tc OFF MAIN GAS VALVE TO LIGHT: 1. Set Room 'thermostat to lowest temperature,2. Be sure Manual Gas Cock Knob has been turned ;o OFF. position for at least(5) minutes before proceeding. 3. Depress Knob and turn to PILOT. Light Pilot. Hold Knob down approximately one minute and release. 4. Turn Knob to ON and set Thermostat to desired temperature. GAS COCK KNOB 05135 G-2 GAS BOILERS 19 MAIN MANIFOLD. PILOT PRESSURE, AND PILOT FLAME ADJUSTMENT MAIN MANIFOLD - PRESSURE AND INPUT ADJUSTMENT 1. Fire boiler for approximately '.5 min. or until at operating temperature or pressure. 2. Shut off gas to all other appliances from the gas mater serving the boiler. 3. Read the rated input in Btuh on the boiler rating plate. Adjust gas pressure regulator to obtain that input, as follows. Rated input is normally obtained at a pressure of 3-1/2 inches of w?ter (natural gas) or 11 inches (Propane) measured at the 1 /8,: tapping or the manifold. * INPUT, 3TUF. = CU, FT. IN 2 MIN. (on gas meter) x 20 x BTU/CU. FT. OF GAS USED FOR NATURAL GAS OF 1000 BTU/CU. FT.: INPUT, BTUH = CU. FT. (Meter) in 3 MIN X 20, 000 FOR PROPANE OF 2500 BTU/CU. FT. : INPUT, BTUH =CU. FT. (Meter) in 3 MIN X 50, 000 TO ADJUST PRESSURE: NATURAL GAS - Adjust regulator in combination gas valve. See instructions furnished with valve. PROPANE GAS - Adjust regulator on gas line external to boiler room. *NOTE: If pressure considerably different from normal is required, larger or smaller burner orifices should be used. PILOT FLAME ADJUSTMENT Normally, no pilot gas pressure adjustment is required to obtain proper pilot flame. Pilot gas pressure cr.n be adjusted at the combination gas valve. Normal input to each pilot is approximately 1000 to 1500 Btuh, 05136 G-2 GAS BOILERS 20 MAIN BURNER AIR ADJUSTMENT DRILLED PORT burners are normally used with natural gas. To adjust the air setting, allow 5 minutes for the burners to heat up; open the air shutter until the flame lifts off the burner (too much ait), then close until the flame returns to the burner. There should be no yellow in the l'lame. (Orange appearance, is caused by lint and dust particles in air and does not affect normal performance). RIBBON BURNERS TSLLOV TIPS (CAUSES CAR30H FOBKATIOHS U BOILER FLOSS) LAZT, GREET XHHEB FLA1C EOT Bi'OOGE PRIMARY ALE n ?, 3LES, HAHD L*. F1A1IE {OTTRITLVL3 D12UCHRS) TOO OUCH I I ur-fiar.? ms SOFT, HLOZ-CSZEX UUS FLAME WRQKG USIiO HIGSI RIBBON BURNERS - NATURAL GAS Adjust air shutter to give sharp blue flame with no yellow. For natural gas, good performance is usually obtained with air shutter set to maximum open position. RIBBON BURNERS - PROPANE GAS Burner flames must be adjusted properly to prevent excessive burner temperatures. Adjust the air shutter to a blue-green inner flame without yellow in flame. (See illustrations). CARE AND MAINTENANCE - ANNUAL THE BOILER AND SYSTEM SHOULD BE INSPECTED AT LEAST ONCE EACH YEAR BY A COMPETENT SERVICEMAN TO INSURE CONTINUED RELIABLE, SAFE OPERATION. 1. CHECK FLUEWAYS, BURNERS AND PILOT for normal combustion and proper alignment. Clean heating surfaces, port? ar.d orifices, if coatedor plugged. See following PROCEDURE-INSPECTION : CLEANING section. 2. CHECK CONTROLS AND CONTROL SYSTEMS foi proper settings, operation of safety controls, and operation of the complete automatic control system. 3. AIR SUPPLY AND VENTING OF FLUE GAS: Make sure of ample supply of air for cortibustion and ventilation and con-plele venting of flue gas. Visually inspect air supply openings and chimney for obstructions. 4. PIPING SYSTEM: Check water or steam piping and gas piping for leaks. Check and service such auxiliary equipment as c ircuh.tlno pomps, control valves, etc. 5. HOT WATER SYSTEM: Check for proper system pressure and control of air. 6. STEAM SYSTEM: Blow down and check low water cutoff; check pop safety valve. Drain off any accumulated sludge, and refill to proper level. Do not drain more water than necessary. Fire bciler to rerr.ov.: oxygen, if fresh water is added. 7. RECHECK GAS INPUT AND BURNER AN- PILOT ADJUSTMENT. (See Page 19) 05137 G-2 GAS BOILERS 21 MAINTENANCE DURING OPERATION 1. Check water level or pressure regularly. Add water (slowly) as needed. If water must be added frequently, call a competent serviceman for advice and service. 2. STEAM BOILERS: At least once a month, check the Pop safety valve and low water cutoff. With steam pressure on the boiler POP SAFETY VALVE: Fasten long wire or cord to handle, and (from a safe distance) pull the handle to release steam. If valve does not release steam, shut off all gas and call for service. LOW WATER CUTOFF: Blow sludge from body of cutoff, as covered in instruc tions furnished with cutoff used. See Page 23 for checking operation of cutoff. MISC ELLA NEOUS-IMPORTANT 1. Do not drain water from either steam or water systems except to remove sludge, or if there is danger of freezing (long unfired periods during winter), or to perform service. See caution, inside back cover. 2. If fresh water is added, especially complete filling of an empty system, the boiler should be fired immediately to heat the water and drive corrosive oxygen and other gases from the fresh water. Vent and add water as needed. 3. Save all instruction sheets furnished with controls and accessories. Follow these instructions. Keep copies of any special wiring or piping diagrams for the installed heating system, for ready reference. PROCEDURE FOR INSPECTING AND CLEANING BOILER For maximum efficiency and safe operation, burners and boiler flue passages should be inspected at leact once a year, and cleaned if necessary. Inspection Procedure: 1. Turn knob on combination gas valve to OFF. 2. Remove lower front jacket panel (deluxe jacket) from boiler. 3. Remove burner access door. 4. Remove burners, lift at the rear, rotate and drop rear between supports, slide toward the back of the boiler until free of the spuds, and remove from beneath the manifold (disconnect pilot gas tubing as necessary). 5. Check burner gas ports or ribbons for lint and dirt. 6. Section cleanliness can be checked with a mirror and light inserted in the opening where the burners have been removed. 05138 G-2 GAS BOILERS 22 BURNER CLEANING If burner inspection reveals rust, scale or lint is present, clean as follows: 1, | Drilled Port Burner Pass a drill of same size as port diameter through the ports, and shake any dislodged material out through the mixing tube. 2. | Ribbon Burner~| Remove ribbon hold down clamps and then remove ribbons. Separate ribbons by fanning out, and clean with wire brush. Reassemble to burner. SECTION CLEANING If section inspection reveals soot or scale, clean as follows: 1. IMPORTANT - BE SURE BURNERS ARE OUT OF BOILER BEFORE PROCEEDING. 2. Remove jacket top and canopy. 3. Clean sections with a wire flue brush. 4. Reassemble, carefully locating all parts. 5. Install burners and connect pilot. 6. Follow startup and adjustment procedures given in this manual. CLEANING STEAM SYSTEMS The grease used to lubricate the cutting tools during erection of a new piping Bystem (or a neyrboiler on an existing piping system) serv^. as a carrier for dirt, with the result th^.t a scum of fine part^fl^s and gr eas.^a^^mulates on the surface of the water in'all new boilers, while'heavier dislbdgpd..^rticle5 settle to the bottom of the -bpiljsr^ ;. These irjipiirjtie? tend to cause fojajiiyjg. prevent the generation of steam, and cause an unsteady water line.' -^h^g'ijiiavoidable accumulation of oil, grease fmcl' sediment should be,removed by'blowing off and cleaning the boiler as follow? (refer o Page 14 and sketch below). Install blowoff pipe with valve of at least 1-1/.4 inch nominal pipe size, with outlet extended to w-ithin 18 inches of the floor, or to drain (see sketch below). Bring boiler water line to center of outlet, raise steam pressure and, while burners are operating, open blowoff valve. When pressure drops, close valve and repeal process, adding water at intervals, to maintain proper level. Asa final operation, close blowoff valve, bring the pressure in the boiler to about 10 lbs., close main gas valve, ?nn open boiler cJ^aLin valve to flush out sediment. After, boiler has cooled, fill and flush out boiler several times, before filling to proper water level for normal service. Fire boiler -vith final fill of water, to drive out oxygen. *See CAUTION, inside ba ck cover^j 05139 G-2 GAS BOILERS 23 LOW WATER CUTOFF-SERVICEABILITY CHECK CAUTION: An operating Low Water Cutoff is vital to protect the boiler against being fired dry. After boiler has been cleaned, a check should be made of the Low Water Cutoff as follows. NOTE: Combination gas valve has built-in delay in opening and closing. 1. Light pilot as indicated in Lighting Instructions. Turn thermostat or operating control to highest temperature. Automatic gas valve should open and main burners light. 2. Open boiler drain cock, and drain water until water level is below center line of Low Water Cutoff. Automatic gas valve should close, as Cutoff switch opens. 3. Refill until water level is above centerline of Low Water Cutoff. Automatic gas valve should open, as cutoff switch closes. 4. Se MAINTENANCE DURING OPERATION section. Page 21, for cleaning and maintenance of cutoff. 05140