Document 716vGZzzDb3qkxprZNzjmKYRE

2-GA AND 2-GA-E GAS BOILERS by AMiBiCAN-^taodapd Installation - Operation and Maintenance Manual -<vA1L / k mm APPROVED BY AMERICAN GAS ASSOCIATION Notice to Install* and Operator This Booklet Must Be Affixed to or Placed in Suitable Pocket on the inside of the Access Panel AtfHKCAN-\and8*d flnl la baallafl ... Ilr* la ^laaiblao 17820 2-GA AJfD JGA-E GAS won rn 1) GENERAL DIMENSIONS FOR 2-GA-E BOILER n o-- GAS INLETj F 40 *3j tz^j BOILER NUMBER NO. OF NO. OF SECTIONS BURNERS 2-GA-4-E 4 2 2-GA-5-E 5 2 2-GA-6-E 6 2 2-GA-7-E 7 2 C 6H 8* 9% W/t D BL 5 544* 1 9 Va 5 5434 22'4 6 55 '/z 2514 6 58 2 8'A Caation ERECTING On open hot water systems, expansion tank should not be installed in cold or exposed place. If the pipe leading to or from the tank freezes, senous damage may result. If valve of any description is installed in the piping leading to or from the expansion tank BE SURE THAT IT IS OPEN WHILE THE BOILER IS IN OPERATION. Location If water condition is encountered in basement, or if it has been neces sary to water-proof the basement floor, boiler should be mounted on concrete or tile base at least 3" above floor level. 17821 J-GA AND 2 QA-C GAS BOOTHS X GENERAL DIMENSIONS FOR 2-GA STANDARD BOILER -*j D n1 2 j FLOW - 2^RETURN T FLOOR 1-- 153--| BOILER NO. OF NO. OF NUMBER SECTIONS BURNERS 2-GA-4 4 2 2-GA-5 5 2 2-GA-6 6 2 2-GA-7 7 2 DL B 5 13 H 47% 5 16 % 47!*, 6 19% 48 k 6 22 % 51 !* Testing Before connecting boiler, plug openings, fill boiler with water and subject to not less than 10 lbs. nor more than 30 lbs. pressure. When boiler is used for direct hot water supply, test pressure should be in creased up to 120 lbs. Inspect boiler inside and outside for leakage to insure against breakage from handling and shipping. To safeguard ac curacy of gage supplied with boiler, do not install gage until after test of boiler. This precaution 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. 17822 2 2-GA AND 2-GA-E GAS BOILERS c Assembly of Fitting 1. Position boiler section assem blage so that sides with removable cleanout plates are accessible for pe riodic cleaning. Loosen tie rod nuts so that they are finger tight only. 2. Screw bushing and/or other return fittings into 2Vi" lower tap ping on back section. Provide a drain connection in the return pip ing at the lowest point in the system. 3. Screw flow fittings into back sec tion. It is recommended that a tee be provided in the piping near the flow outlet for installation of a relief valve. 4. Burner access door frames are alike. Attach one to front sec tion using 1W fiat head screws at top. If boiler is Standard model, place front jacket panel in position before attaching door frame. (Fig. 1 shows frame in position for Em pire model) ~ 5. Fill putty groove at top of sec tions with boiler putty and place canopy in position with ribs firmly imbedded in putty to make gas seal. Smooth off excess putty. 1. Burner Access Door Freme 2. Ctnepy 3. Tasting for Limit Control Front Section 4. Teppin? for Reverie Acting Lam Limit Control Fie. 1--Section Auemblage Installing Burners and Control Sub-Assemblies 1. Fit left burner assembly (Fig. 2) including burner, bracket, pilot burner, thermocouple lead, and vent tube tip to tapered end of mixer with forked lugs engaging lug on mixer. (See Fig. 3.) For Electric Ignition, the pilot lighter assembly is furnished in sepa rate container. It should be installed before the burner assembly is placed in the boiler. To install the lighter assembly, place it in position with the end of the thermocouple through the hole and push downward until the spring clip engages the bottom of the pilot body. See Figs. 2 and 3. See that air shutter is assembled on mixer. Install burner assembly an/1 mixer in combustion chamber. Place mixer firmly on burner sup port which should rest on lugs provided on section (See Fig. 4; 2-GA-E model shown). Place right burner and mixer alongside resting on ngh t side of burner support. 17823 2-GA AND 2-GA-E GAS BOILEHS 3 Electric Ignition Manual Ignition Etc. 2--Left Burner Sub-Assembly Electric Ignition Manual Ignition Fie. 3--Cross Section Through Combustion Chamber 2. Attach the control piping assembly at the union on the manifold. Be sure that arrows on automatic gas valve, automatic pilot valve and gas pressure regulator point in direction of the gas flow. Check spuds in end of spud holders to see that they are screwed in tightly and that orifices are drilled to size specified on tag attached to manifold. Assemble manifold, controls and manifold brackets to front burner ac cess frame. Use W round head screws in upper holes and l'V' round head screws in lower holes to hold frame to front section. (See Fig 5 ) Be sure spud holders are fitted firmly into mixer tubes. 17824 4 2-GA AHD 2-GA-E GAS BOELEHS T7- 3. Tighten the set screws in manifold brackets. (See Fig. 5). 4. For 2-GA-E model place front insulation panel in position and hold till temperature bulb is attached. Insert the temperature bulb element of the automatic gas valve in the upper center tapping on the front using the split nut and gland fittings provided. Refer to page 9 for assembly of parts, well before installing. Attach number and series plate to front insulation panel, also terminal block and pilot ignition transformer for boilers having electric ignition. Two control tappings are provided on the right side of the Front Section (See Fig. 1). No. 3 indicates tapping for limit con trol. No. 4 indicates tapping for reverse acting low limit control. Fie. 4--Burner Installation Fig. S--Control Sub-Assembly Installed-- Standard Model Shown 17825 2-GA AMD 2-GA-E GAS BOtLEBS , ** W` a--^E3 Ui- a*l Ic O'* *nrc -W'iiiw* *N.<t ,I l- -03 r*? -- ''. Mr o*f1*<il* 6S*HT1 Srtar____P 3 MtMiaix* -4- _ _2T, [&_P_ ~ -um-^ 37m ( 4.v . *=Jtt=3 r * ** 'tv "S iUir*. hu'm* -r" i l--* l t*<* <*'' r Tf <1 s> * fM?- 11] fM* avrMM*"* =StB=-^ O Fic. 6--Wiring DUrms Electric Ignition Fic. 7--Supply Piping Manual Ignition 17826 6 2GA AMD 2-GAE GAS BOILERS I. Manual Shutoff Valve l. Pilot Cock J. Push Button lighter Switch 4. Gat Pressure Regulator S. Autorr 5. Vent Tube (. Pilot Line 7. BASO Automatic Pilot Valve S. Pilot Ignition Transformer ic Gas Valve / Fm. A--Jacket Assembly and Control Connections forJ-GA-E Model with Electric Ignition 17827 2 GA AND 2-GA-E GAS BOILERS 1/ 5. 2-CA-E Model--Install combination thermometer and altitude gauge piping in tapping on right side of face of front seetion and install gauge. See Fig. 8. In Case of 2-GA Standard Model install v" x 4" bushing and gauge in this tapping. See Fig. 5. / Assembly of Jacket of 2-GA-E Model 1. Place rear jacket panel in position. Hold in place and attach rear burner access door frame with lVa" flat head screws at top and 11 -T' round head screws at bottom. 2. Place side jacket panels in position with grooved edges engaging flanges of rear panel. Attach side panels to rear panel at top and bottom with screws and nuts. Connecting Controls 1. Connect thermocouple element from pilot burner to BASO auto matic pilot valve. (See Fig. 8). Discard protective cap covering threads on BASO valve. 2. Connect pilot line to manual shutoff valve (Fig. 7 for Mfd., Nat. and Mixed Gases) and to BASO automatic pilot valve for LP and Butane-air gases. (See Figs. 15 and 16). For electric ignition, connect pilot line from burner assembly (Fig. 2) to Manual Valve (Fig. 7) as shown in Fig. 8. 3. Connect vent tube from pilot burner bracket to gas pressure regu lator. Be sure stainless steel tip is screwed in securely; and that flame check is in place in vent tube connection on regulator. (See Fig. 10) 17828 8 2-GA AND J-GA-E GAS BOILERS t 1. Pilot Cock 2. Manual Shutoff Valve 3 Gas Pasture Reqcnaior 4 Automatic Gas Valve 5. Pilot Line 6 Vent Tude 7 BASO Automatic Pilot Valve Ftc. 9-Jacket Assembly and Control Connections for 2-CA Standard Model tth Manun IgmOon -- 17829 2-GA AXD 2-GA-E GAS BOILERS 9 4. Make wiring connections according to wiring diagram applying to controls used. (See Fig. 6). Install thermostat and connect as indi cated. 5. Install front and rear burner access doors. COMPRESSION MALE ELBOW PITTING material 40 MESH MONEL OR BRASS SCREENING HERE IN REGULATOR FLAME CHECK Ftc. 10--Flame Check SPLIT NUT U PACE3G GUNS - ASSBCBLT ORDER OP PARTS Per cere sensitive operation, eat off cell here ead diecard betore leetall Inf. 1. Packin* Gland with Wall 2. Steel Half Washers 3. Paekinc Vastier L. Split Nat 17830 10 2-CX AND 2-GA-E GAS BOILERS Completing Jacket Assembly for 2*CA-_E Model 1. Place front jacket panel in position so that flanges engage grooves of side panels. Fasten at top and bottom with screjvs and nuts. (See Fig. 11). Install Lighting Instructions Plate by placing it on "Z" clips located inside the control access door and bending down six tabs to secure. Attach control access door. 2. Place top jacket panel over flue outlet with perforations to front over controls. 3. Place draft hood in position with bottom through top jacket panel and on flue outlet of canopy. Fie. 11-2-GA-E Boiler Assembly 17831 2GA AKD 2-GAE GAS BOILERS Assembly of Jacket for 2-CA Standard Model 1. Fit rear jacket panel in position. Hold in place and attach rear burner access door frame with l'-s" flat head screws at top and l1 i" round head screws at bottom. See Fig. 12. 2. Place side jacket panels in position with ends overlapping front and rear panels. Attach to front and rear panels near bottom with jacket screws. Attach number and series plate and lighting instruc tions plate to front jacket panel. 3. Place top jacket panel in position with flanges down tight over front, rear and side jacket panels. 4. Place draft hood firmly on flue outlet of canopy. Front Rear F:c. 12--Standard Boiler Assembly 17832 12 2-GA AND 2-GA-E GAS BOILERS Filling System Caution: Never start boiler unless it is properly filled. (After boiler is in operation, makeup water should be added slowly.) Fill open system to % height of expansion tank, remove rim and glass from gage and set movable pointer under automatic pointer. Re place rim and glass. Fill closed system until relief valve relieves. This must be less than 30 lbs. pressure. If necessary, adjust relief valve setting. Remove rim and glass from gage and set movable pointer under automatic pointer. Replace rim and glass. Keep systems filled. Pointers on gage should be even. If pressure exceeds 30 lbs., relieve at once by opening relief valve or drain cock. Pilot Adjustment Light boiler as directed in operating instructions and check for gas leaks. Adjust pilot flame to extend just over top of burner. Pilot rate can be adjusted with screw underneath cap on pilot cock or by adjusting throttling cock in pilot line if provided. Normal Pilot Input for BASO Pilot Burners | Mfd. [Input per Burner Btu/Hr. 1000 Nat Mixed | LP | LP-Airi 1400 1200 | 1000 1 1000 17833 I 2-GA AlfD 2-GAE GAS BOOXHS i3 Main Burner Input Adjustment After boiler is warmed up, shut off ail other gas appliances connected to gas meter and time gas consumption. Adjust gas pressure regulator to give rated input indicated on nameplate. Gas Consumption (Cubic Fwt Per Hr.) = Input Rating (Btu Per Hr ) Heating Value of Gas (Btu per Cu Ft. i To increase consumption, turn adjustment screw (beneath cap on pressure regulator) clockwise; to decrease, turn screw counterclock wise. Main Burner Primary Air Adjustment Adjust burner flame by opening or closing primary air shutter. Flame should burn quietly, show no yellow and should have a noticeable inner blue cone. After adjustment, tighten screw to lock shutter in position. OPERATING Shutting Off (For All Gases) 1. Close manual shutoff valve and pilot cock. 2. Turn off switch in electric line to appliance. 17834 14 2-GA AND 2GAE GAS BOILERS Re-Lighting (Electric Ignition) 1. Set thermostat at lowest temperature. 2. Close manual shutoff valve and pilot cock. 3. Turn off switch in electric line to appliance. 4. Wait 5 minutes. 5. Turn on switch in electric line to appliance. 6. Open pilot cock. 7. Press button on lighter switch until pilot burner lights. 1. Manual Shutoff Valve 2. Pitot Cock 3. Push Button Lighter Switch 4. 8A$0 Automatic Pilot Valve 5. P'lOt Burner Fig. 13 --Controls for Electric Ignition 8. Wait 2 minutes. 9. Press plunger on automatic pilot valve. 10. Open manual shutofl valve. 11. Set thermostat at desired temperature. 17835 J GA AND 2-GA-E GAS BOILERS :s Re-Lighting (Manual Ignition; Mfd.t Nat. & Mixed Gases) 1. Set thermostat at l,,west temperature. 2. Close manual nliutoff valve and pilot cork 3. Turn off switch in eWtric line to appliance. 4. Wait 5 minutes. 5. Open burner access -Jo,,r 6. Light taper and hold v, j,,. lot burner. 7. Open pilot cock. ' Mm should light). 8. Close burner access t. Manual Shutoff Valre 2. Pilot Cock 3. BASO Automatic Pilot Valve 4. Pilot Burner 9. Wait 2 minutes. Fig. 14--Controls for Manual Ignition Mfd.. Nat. and Mixed Gases 10. Press plunger on auv/-.-.^.;c piiot vajva 11. Open manual shutoff 12. Turn on switch in eieev t0 appliance. 13. Set thermostat at des..**^ temperature. 17836 16 2-GA AND 2-GAE GAS BOILERS Re-Lighting (Manual Ignition; Liquefied Petroleum and LP--Air Gases) 1. Set thermostat at lowest temperature. 2. Close manual shutoff valve and pilot cock. 3. Turn off switch in electric 1 3 line to appliance. 4. Wait 5 minutes. 5. Open burner access door. 6. Open pilot cock. 7. Light taper and hold to pi lot burner. 8. Press plunger on auto matic pilot valve (Pilot should light). Hold 2 minutes. 1. BASO Automatic Pilot Value 2. Pilot Cock 2. Manual Shutoff Valve 4. Pilot Burner Fic. IS--Controls for LP Gases (See Fig 16 for LP-Air) 9. Close burner access door. 10. Open manual shutoff valve. 11. Turn on switch in electric line to appliance. 12. Set thermostat at desired temperature. 17837 2-GA A1CD 2-GAE GAS BOILERS .7 1. BASO Automatic Pilot Val 2. Pilot Cock 3. Manual Skuioff Vaic 4. Pilot Bumor Fic. 16--Control Arrangement for Liquefied Petroleum-Air Gases Pilot Goes Out If the pilot flame is extinguished, the automatic pilot will shut off the automatic gas valve, rendering the boiler inoperative. Relight ac cording to applicable instructions. If boiler is not operating correctly, call Heating Contractor or Gas Company Service man. Operation During Failure of Electric Power Supply In case of failure of supply of electric current, boiler will automat ically shut off. Boiler will not operate automatically while electric power is off; however, boilers equipped with Detroit V-575-FW auto matic gas valve may be operated manually as follows: 17838 =t 18 2-GA AJfD I flA E GAS BOILERS 1. If pilot is out, relight as directed for manual ignition. 2. Remove rectangular housing from top of valve. 3. Pull up knob located on top. (Burners should light). 4. Caution--Shut off boiler by pressing reset lever, located next to knob, before water temperature becomes excessive. Bear in mind that operating the boiler manually is an emergency condition and that constant supervision is required to prevent the pos sibility of damage due to overheating. Never allow the boiler to oper ate under this emergency condition if it is to be left unsupervised for any length of time. 5. Valve is fully recycling and will return to automatic operation when electric power returns. MAINTENANCE In Fall Before Starting Boiler Drain system sufficiently to remove sludge in bottom of boiler. Do not drain more water than necessary to remove sludge. Then refill to proper level as directed above. Care of Boiler While in Operation 1. Check water level regularly and add water slowly when needed. 2. This boiler is fired automatically. 17839 J-GA AND 2-GA-E GAS BOILERS 19 In Winter While Not in Operation Drain entire system to prevent damage from 'freezing. Drain through drain cock, located at lowest point in system. Be sure boiler is completely drained. In Summer While Not in Operation Fill system as during heating season. Have boiler inspected byservice man before the start of the heating season. If necessary, re move jacket front and side panels so that cleanout cover plates are ac cessible. These may be removed from either side of the boiler for cleaning between the sections. General Care of Heating System 1. Keep radiators and convectors clean. 2. Keep system in good repair. It is advisable to have it inspected by your heating contractor at least once a year. 3. If a hot water radiator is hot at the bottom, but not at the top, it indicates that air has accumulated inside and should be vented. To vent radiator: Hold small cup under air vent (located near top of radiator), open vent until water escapes and then close. 4. Fill hot water systems as follows: Open all radiator valves, but keep vents at top of radiator closed. Fill open systems till hands on altitude gage are even. If it is a closed system the water filling will stop automatically when proper pressure is reached. (Pressure should not exceed 30 pounds.) Then, beginning with ground floor, vent each radiator as directed above. It may be necessary to add water during this operation to expel air from higher radiators. 17840 20 2-GA AND 2-GA-E GAS BOILEHS 5. If much water is added to system, it is advisable to heat system to a high temperature and vent again. This will make less venting ecessary during the winter. ftiere an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed to freezing temperatures. If the pipe leading to or from the tank freezes, serious damage may result. If valve of any description is installed in the piping leading to or from the expansion tank BE SURE THAT IT IS OPEN WHILE THE BOILER IS IN OPERATION. Note: All parts of this boiler have been carefully inspected and packed. See Packing and Parts List sheet for details. In case of shortage, make sure that all parts have been re moved from shipping container and examine packing material thoroughly. If part cannot be found, report shortage to your dealer, giving boiler size, series number, date, inspector's num ber and packer's number. GIVE BOILER SIZE AND SERIES NUMBER WHEN ORDERING REPAIR PARTS Boiler Size ................................................ Series No. (See Series Plate on Boiler) Date ............................................................ 17841