Document 85NoMnzeO0ERgZOgLbE3J4we

riuSU P/KlCAbo boite/L G-2 F PB PACKAGED GAS BOILE by American-e>>tai?dard Installation-Operation AND Maintenance Manual APPROVED BY AMERICAN GAS ASSOCIATION NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET MUST BE AFfIXEDON OR ADJACENT TO THE HEATING EQUIPMENT AMERiCAN-<>taitda*d first in heating ... first in plumbing BP-G-2 FPB KIT. 2-M ' 19307 G-2 GAS BOILER WITH ELIMINAIRE The Eliminaire is a unique built-in air separator which prevents air from being transmitted to the system and directs the air to the compression tank. External air separators such as dip tube or inlined accessories are not required. This important feature on the boiler also allows for considerable simplification of the near boiler piping (See Figure) and assures positive air separation essential to proper system performanc The Eliminaire plus the recommended piping provides for a substantial saving in material and installation cost. 19308 Arcoleader Page 1A BOILER PIPING RECOMMENDATIONS WITH THE ELIMINAIRE PROCEDURE FOR FILLING SERIES LOOP HEATRIM SYSTEM 1. Open 111 valve. 2. Close purge valve. 3. Vent air from boiler by manually opening relief valve. 4. When water appears at relief valve, release lever and allow to close. 5. Continue filling until pressure gauge reads approximately 12 pounds. (Close fill valve) 6. Open purge valve. Note:- Fora single loop heatrlm system no additional vents, cocks, valves, drains, or other accessories are required except: When tankless heater is used and heatrlm is above the boiler outlet. install a flow check valve to prevent gravity circulation. 19309 G-2 - Page 2B; 0-2 GAS BOILER 2-A CAUTION If and when this boiler is used in connection with refrigeration systems, boiler should be so installed that chilled medium is piped parallel with the heating boiler using appropriate valves to prevent the ohilled medium from entering the heating boiler* When hot water heating boilers are connected to heating coils located in air handling units when they may be exposed to refrigerated 'air circulation, such boiler piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle* 19310 G-2 FPB BOILER 1 2 FLOW- TAPPINO FOR'' PRESSURE RELIEF VALVE K I /3J4-- f l/l J TOP VIEW -------A------- RETURN 433- 22 GAS INLET NUOMIL0CCfl* senc*nooMr t *. or UflNCRS A B G-23FPB 3 2 t 1 s'* G-24FPB 4 3 14 'v-4 7VS G-25FPB 5 4 17 '/-j 8H G-26FPB 6 5 20H IOVe G-27FPB 7 6 24 12 C 4 5 5 6 6 0 13 13 V4 13 V4 16 '* 16 E 7 7 7 9 9 * * SIDE VIEW T 5t 81 3 FRONT VIEW Crated Boiler 1. Hails - Top Sc. Sides 2. Side Fasteners .1. Automatic Gas Valve 2 Circulator Pump 3. Transformer U. Junction Box .5. Immersion Limit Control 6 Altitude k. Temperature Gauge . l-Hc i* 19311 G-2 FPB BOILER 2 PIPE DELIVERY SCHEDULE Capacity of Pipes in Cubic Feet of Gas per Hour. Length of Pipe in Feet 3A" Pipe Size 1" 1-1A1 10 212 125 725 20 150 300 510 30 122 252 b25 b0 105 218 370 50 95 195 330 75 77 160 270 100 66 13U 232 Boilers are shipped assembled as completely packaged units except for the drafthood which is shipped as a separate unit. NOTE: Gas connection is 1/2" pipe size art the automatic gas valve. LOCATION Locate the boiler near the chimney or flue and as centralized with respect to the heat distribution system as practicable. If water condition exists in the basement, or if it has been necessary to waterproof the basement floor, the boiler should be mounted on a concrete or hollow tile base, preferably to a height of at least three inches. SERVICE ACCESSIBILITY CLEARANCES Boilers, when equipped with floor pan and radiation shield are approved for installation with minimum permissible clearance to combustible material as shown on the label attached to the boiler jacket. Necessary service accessibility clearances take precedence over these clearances. Minimum clearance of 5" must be maintained between the boiler, including prqjecting drafthood and vent connector, and any combustible material. A minimum front clearance of 2b" must be provided for servicing burners and controls. Allotf 18" for removal of circulator. IMPORTANT: Refer to label on the boiler jacket for the minimum permissible clearance to combustible material as approved by A.G.A. (American Gas Association) For utility room installations, the door shall be wide enough to allow the largest boiler part to enter or to permit the replacement of another appliance, such as a gas water heater. AIR FOR COMBUSTION AND VENTILATION Adequate facilities must be available for providing air for combustion and ventilation. Except for installations in large spaces (such as full basements) where infiltration can normally be assumed to provide sufficient air, this will usually necessitate: (a) Two openings, one near the floor, the other near the ceiling installed in the door or a single wall of the heater room. 19312 L. G-2 .a 3 (b) Openings to interior- mr- ce. cirivo." per 1000 Btu per hour of input. (This method should ' .ys ho u-j.m; ~r . am a of o>w (1) square inch a minimum of 100 squareinches. practicable). (c) Openings to outdoors - i-im r. :.v n:-'n .'f l square inch per LOCOBtu per hour of input rating, or in : s -.orda: .t'.i the methods outlined in the latest issue of A.S.A. Z21.30 ertit.'._-s ''7:.s,,. ' : ion of Gas Appliances and Gas Piping". (This method should oaf; be us;-. ' openings to interior spaces are imoracticable). CHIMNEY Flue or vent connector to chimney shall not he smaller than the 3ize of the outlet of the draft diverter. Yfhere two or more appliance* vent into a common flue, the area of the common flue should at least equal the area of the largest flue or vent connector plus fifty percent of the areas of "'h; uvisional fire or vent connectors. Flue or vent connector mu; ns:.-' ad :nto but not beyond the inside wall of the chimney flue. Horizontal z-of flue ripe should be kept at a minimum and should be installed v/ith a 1/L,! ri` " "jr foot maintained. CAUTION The expansion tank should r.-r. h= s-i :'r * cold or an exposed place. If the pipe leading to or from the tank serious damage may result. If valve of any descriDtion is installed _r. Ih ciulng leading to or from the expansion tank BE SURE THAT IT IS OPEN V.l-IiLE IfE 2OILER * IS IN OPERATION. This appliance should be installed in accordance with the latest A.G.A. instructions "For Installation of Gas P: Tv; Appliances in Building." Reference should also be made to gas compa-y - -- .! c v-.:; ard local building, plumbing or other eodes in effect in the area in . *..: :nswallation is made. Bottom pan (Floor Shield) : r radiation shield are provided (on special order) for use if boiler is to be installed on combustible floor or in a closet type enclosure* The bottom pan should be inserted from the front and rest on supports near the bottom cf each end section. The radiation shield should be installed in front of the main burners and rest on projecting rib of each end section. Turned down flanges cn shield should point down r no.vn in cuts on page 5. Place beiler in approximate final location, if possible before removing the shipping crate. TIoor should be level where boiler is installed. 1. Unfasten all crating wire at the corner of the crate. 2. Remove nails fastening crate sides to tep and bottom of crate. Lift off cratft top and unwrap crate side from c-ato bu.ee, 3. Loosen four cap screws tier, hold boiler to the crate base, one at either side of end sections, just under the jacket. Remove both screws at one end section so that the two remaining screws can be slid out of the slots in ths other end section, i.iov.e the boiler off the crate base to the final location, 1 r-> - - k -) c* kii vnovc i r* nl . 19313 '-? FPB BOILER 1* 5. Make up drip leg pining - acrl icd ny `J> 4 S3 C rp.) of suitable height and install the manual ,z \-iva assembly. See page 6. 6. Make suitable connection between tee in the drip leg piping and the Cas Valve, It is advisable to inwall union fitting vihc-n making this connection. 7. For boilers with non-100''! shutoff, install the pilot line from the manual shutoff valve to the plot vr e connection. 8. Connect return piping to th? ;rculator. 3-5 sure that the flange gasket is not damaged ar.d that the bcii.s are prop.rl, tightened. 9. Install the safety relief .-.live in the 1/V' tapping on top of the boiler at left side. Place the drafthood firmly on the flue outlet collar of the canopy which projects above the jacket -uni connect to chimney. CLEANING BOILER - To cl.ea '>. _ler remove parts in the following crderi Flue Pipe, Drafthood, i'op Pane, and Canopy. IMPORTANT - After cleanir: , r. a fully seal all around the canopy with asbestos packing also remove :! ' dirt from main burners and pilot to insure proper operation when se v co resumed. CANOPY INSTALLATION - Lay tr.-- oestos packing provided against the front edge and across the left end v' the recess on top of the sections. Carefully place the canooy so that it he Ids the packing against the front and end of the recess. Do net PLACE TITS CANOPY ON TOP CF THE PACKING. Hold the canopy firmly in .lace t.-ri lay the remainder of the packing along the rear and -'ight end un-.;e hold-dc?. clip. Insort the canopy screws and tighten to hold the canopy m final position, lock the packing in place around the canopy usi.g a nutty knife or piece of material about 1/16" thick and 1" wide. Br careful not to pu.r the packing under the canopy into the flue ways. CANOPY INSTALLATION G-2 FPB BOILER 5 Manual Ignition Electric Ignition I Runner Pilot Ignition 19315 LIM IT CONTROL U til O iz o D< <o CO CTi i O CO 2 Id f</-> "SfjC* >,_X VATER RMOS E SWI ^ ui z TA 1 T" MOS ...... R HIE T (T 5 i * Ul ?!Q Z Ul Ol Ul CQ* 19316 G-2 FPB BOILER VIALVE NOT SUPPLIED Bf AR. A SS CORP Supply Piping for Boiler Y/ith 100$; and Hon-100# Shutoff. all pipwg Shown below shutoff VALVE NOTSUPPLCO BY ARABS CORP Supply Piping for use on Boiler With Manufactured Gas, Kon-lOO'-J Shutoff \ .`-- A' .f'. tor J Wis/e/ INSTALLATION OF PILOT FILTER FORIOO^ SHUTOFF WHEN REQUIRED Electrical service should be brought to the boiler and connections made to accord with the wiring diagram furnished. Install and connect the roon thermostat according to the wiring diagram. 19317 G-2 FPB BOILER 7 TESTING Before any system of gas piping is finally put into service, it shall be carefullytested to assure that it is gas tight. Soap and water solution, or other material acceptable for the purpose, shall be used in locating gas leaks. FILLING SYSTEM CAUTION: Never start boiler unless it is properly filled. After boiler is in operation, makeup water rhould be added slowly. Fill open system to 1/3 height of expansion tank, remove rim and glass from gauge and set movable point under automatic pointer. Replace rim and glass. Fill closed system until relief valve relieves. This must be less than 30 lbs. pressure. Remove rim and glass Aram gauge and set movable pointer under automatic pointer. Replace rim and glass. Keep system filled. Pointers on gauge should be even. If pressure exceeds 30 Lbs., relieve at once by opening relief valve or drain cock. NORMAL PILOT INPUT FOR BASO PILOT BURNERS Input per Burner Btu/Hr. MFD. 1000 NAT. lUOQ MIKED 1235 LP 1555 LP-AIR 1555 MANIFOLD PRESSURE ADJUSTMENT FOR MAIN BURNER INPUT Light the boiler according to the directions on the Lighting Instruction plate (on front of boiler) and operate for a short period. Then, shut off all other gas appliances connected to gas meter and time consumption. Boiler input should be adjusted at rated input as indicated on nameplate in accordance with procedure outlined below. Gas Consumption (Cubic Feet per Hr.) B HeaiTng"Se~^f^'(BW^er^! Ft.) 1/8" pipe plug is placed in the manifold to provide for checking the gas pressure in the manifold with a manometer or small pressure gauge. The manifold pressure should be set at 3*5 inches of water for natural and mixed gases or 2.5 inches of water for manufactured gas. To adjust the pressure, remove the cap on the gas pressure regulator and screw in the adjusting screw to raise pressure or screw out the adjusting screw to lower pressure. Refer to 7-600 valve instruction sheet for making regulator adjustments. Only small variations in gas flow should be made by means of the gas pressure regulator adjustment. In no case should the final manifold pressure vary more than plus or minus 0.3 inches water column from the above specified pressures. Any necessary major changes in the flow should be made by changing the size of the b irner orifice. MAIN BURNER PRIMARY AIR ADJUSTMENT Adjust burner flame by opening or closing primary shutter. Flame should bum quietly, shear no yellow and should have a noticeable inner blue cons. After adjustment, tighten screw to lock shutter in position. 19318 G-2 FPB BOILER 8 PILOT GOES OUT If the pilot flame is extinguished the automatic gas valve will shutoff the gas. If boiler is operating correctly, relight as directed on the lighting instruction plate. If boiler is not operating correctly, call heating contractor or gas company service man. 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 snail cup under air vent (located near top of radiator), open vent until water escapes and then close. li. 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 gauge 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. 5. If much water is added to system, it is advisable to heat system to a high temp erature and vent again. This will make less venting necessary during the winter. 6. Where an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed to freezing temperature. If valve of any description is installed in piping leading to or from the expansion tank, DE SURE THAT IT IS OPEN WHTT.E THE BOILER IS IN OPERATION. CARE OF BOILER WHILE IN OPERATION Check water level regularly and add water slowly when needed. This boiler is fired automatically. IN WINTER '.RULE NOT IN OPERATION Drain entire system to prevent damage from freezing. Drain boiler through drain cock, located at left side. Also remove drain plug located on front edrre of right end section. Be sure boiler is completely drained. IN SUMMER WHILE NOT IN OPERATION Fill system as during heating season. Have boiler inspected by service man before the start of the heating season. The surface between the toiler sections can be cleaned from the top of the boiler. If the top jacket panel is to beranoved, it is advisable to place blocks or strips under the sides of the jacket to facilitate re-assembly of the panel. 19319 I m 0-2 GAS BOIL21 TOR BOILER HeOTPPKD WITH V-^31 or V-60} VALVS. EMERGENCY INSTRUCTIONS FOR OPERATION DURING FAILURE OF ELECTRIC POWER SUPPLY In the event of failuro of electric power supply the gas burner operating this boiler will automatically shut off. It is possible to operate this burner manually by following the directions given below. CAUTION -- THE BURNER SHOULD BE OPERATED MANUALLY ONLY AS AN EMERGENCY MEASURE. THE AUTOMATIC SAFETY CONTROLS WHICH PROTECT THE BOILER DURING NORMAL OPERATION ARE NOT OPERATIVE. CONSTANT SUPERVISION IS REQUIRED TO PREVENT THE POSSIBILITY OF DAMAGE TO THE BOILER BECAUSE OF LOW WATER OR OVERHEATING. NEVER LEAVE THE BURNER OPERATING MANUALLY IF IT IS TO BE UNSUPERVISED FOR ANY LENGTH OF TIME. IN SUPPLYING THESE BRIEF DIRECTIONS FOR MANUAL OPERATION OF THE BURNER, THE MANUFACTURER CAN ASSUME NO RESPONSIBILITY FOR THE SAFE OPERATION OF THE BURNER, BOILER AND OTHER EQUIPMENT. SAFETY DEPENDS UPON THE CARE AND JUDGMENT EXERCISED BY THE OPERATOR. ALL POSSIBILITIES CANNOT BE COVERED IN THESE BRIEF DIRECTIONS. BASIC STEPS IN MANUAL OPERATION 1. Be sure the burner pilot is burning properly. If so, then: 2. Turn off electric power switch controlling the burner. LEAVE THIS SWITCH OFF UNTIL POWER HAS BEEN RESTORED. 3. Burner may now be operated manually by opening the automatic gas control valve in accordance with instructions printed on the valve cover. 4. If the boiler operated by the gas burner is installed on a forced circulation hot water heating system (incorporating electric circulating pump) OPEN FLOW CON* TROL VALVE OR VALVES IF PROVIDED IN THE WATER LINES. (Nf: It is suggested that the original position of these valves be carofully observed and these observations recorded, to permit restoring these valves to their original posi tion when automatic operation is resumed.) Also, REDUCE THE MAIN BURNER FLAME TO A MINIMUM ADJUSTMENT (approximately 1/3 or 1/4 normal size) BY PARTIALLY CLOSING THE MANUAL GAS SHUT OFF VALVE. TO RESTORE BURNER TO AUTOMATIC OPERATION UPON RESUMPTION OF SUPPLY OF ELECTRIC CURRENT 1. Return automatic gas control valve to its original "automatic'' setting, in accord* once with instructions on volve cover. 2. Turn on electric power supply switch. 3. On forced circulation hot water heating systems, return flow control valves. If pro vided, to their normal operating positions. 4. Turn manual gas shut off valve to its wide open position. 19320