Document JDx6pK3JVK3M9EK7b20Vq8oZ
08737
ERECTING DIRECTIONS AstESiB GAS BOILER TYPE 4-G
h-D-H
GENERAL DIMENSIONS
FOR 6 TO 11 SECTION BOILERS
6* PLOW L
BOTH ENDS
B
ZpoiL]
T5'RETURN
--1_L4|^ ^BOTH ENDS
No. at Boilor 4-G- 6 4-G- T
4-G- 8 4-G- 9
4-G-10 4-G-ll
No. at Soctiooo
6 7
8 9 10 11
No. at Burner*
10 12 14 16 18
20
B 74 75 77 77% 79 Vi 80
11 12 13 14 15 16
L 27 31 35 39 43 47
08738
ERECTING DIRECTIONS AAOIUS GAS BOILER TYPE 4-G
GENERAL DIMENSIONS
FOR 13 TO 41 SECTION BOILERS
1
5'RETURN BACK ONLY
19 &
t in zME^ZJ 5 RETURN
No. of Boiitr
4-G-13
No. of No. of Section* Burners
13 24
B
75
c Dz T L 30% 12 30% 15% 61%
4-G-15 15 28 77 34% 13 34% 17% 69%
4-G-17 17 32 77% 38% 14 38% 19% 77%
4-G-19 19 36 79% 42% 15 42% 21% 85%
4-G-21 21 40 80 46% 16 46% 23% 93%
4-G-22
22
42
77
34% 13 34% 17% 103%
4-G-25
25
48
77% 38% 14 38% 19% 115%
4-G-28 28 54 79Vi 42% 15 42% 21% 127%
4-G-31 31 60 80 46% 16 46% 23% 139%
4-G-33 33 64 77% 38% 14 38% 19% 153%
4-G-37 37 72 79Vi 42% 15 42% 21% 169%
4-G-41 41 80 80 46% 16 46% 23% 185%
08739
2 ERECTING DIRECTIONS Annie** GAS BOILER TYPE 4-G
ERECTING
CAUTION On hot water systems, expansion tank should not be installed in cold or exposed place. No valves
or any type should be installed in piping between boiler and expansion tank. Sealing system at any time during operation may cause breakage of boiler or radiators.
location
If water condition is encountered in basement, or if it has been necessary to water-proof the base ment floor, boiler should be mounted on concrete or hollow tile base at least 3 inches above floor level.
note
All references to Right or Left parts refer to observer's right or left when facing front of boiler. All sections are stenciled with word "Front" and individual numbers "1", "2", "3', etc. indicating the position which each section is to occupy in the boiler.
ASSEMBLY OF SECTIONS 1. Select right end section (less two 1" trim tappings; stenciled No. 1) and place in approximate
Anal position with front of section facing correctly. Support with wood prop. Clean nipples and nipple openings with kerosene or gasoline and apply good lubricating oiL Do not use paint or red lead.
Layout 01 Flow And Return Tappings
SOILER K M
. ***0G-- -_ ***-0G0G*--*iOi ftt
O- i 3 . 4-G-.T
120ft ./, --
1* * _
443ff2tt /*
_
-- --
ffttO* >
30
34
//*4
3ft'
N
... --
-- __ _
--
NO or SECTIONS
CMOS !MtDIATts!etTf
2 2
1
00
'!
4
s
210
222
1
00 0
'
f?t ft
9
222 111 1 11 420
BOILER
4*0* 19 4-0-21 4*0 22 4-0-25 4-0-2* 4-0-31 4-0-33 4-0-3? 4*A* 4 1
K
*4 /, 9 2*7 102*. I ia*. '2*V. < 3* * ISl ift* i*5
M
4 2'/. 4ft* 1*'. la*
*2'* 4* )*. 4 2'/. 414
N
_
la <. lav. 42* a#'/. 3ft a 42 * 4ft 4a
NO or SECTIONS
ENO*
j INTEA'wcoiatcs:
CENTERSi
2 2
i i
22 22
2'2 22
23 23 23
i ft < ft i ft 2> 2 2? ' 2ft 32 3 ft
08740
ERECTING DIRECTIONS AsDUSU GAS BOILER TYPE 4-G
; nrive nipples squarely into end section using block of wood and hammer. Gage nipples in both [jr=cuons to insure that they are driven squarely and to proper depth in nipple openings; nipple setting jag? a provided for this purpose. Cutout in gage should rest on both sides of nipple when legs of gage afe touching finished pads on section. Most nipple leaks are caused by tilted or cocked nipples. See Fig 1.
3. Paint ground ribs around outside edge of sec tion only, with red lead.
4. Place center section in position on nipples in end section. Drive sections together with heavy block of wood, striking sections squarely as possible over nipple ports. Assemble sections in numerical order with fronts (stenciled with position number) :'scmg in same direction.
5. For 6 to II Section Boilers---Insert one tie rod .nrough each bolt hole above lower nipple ports and ar.e tie rod through upper nipple port. Place as sembling block on upper rod and assembling wash ers on lower rods as shown and place nuts and wash ers on all rods. See Fig. 2.
For 13 to 41 Section Boilers--Use assembling clamps with oose jaws against end section in place of nuts and washers. Place :.omps on rods with flat side against section. Insert jaws in blocks with serrated end against rod and draw up on rod from opposite er.d. Tap jaw lightly to tighten grip on rod. Do not permit jaws j damp on threads. Place nuts and washers on other end. See ~:g 3.
All Sites--Draw up evenly on nuts until sections make conac: at ground joints. Bumping sections with heavy block of A'od alternately at nipple ports during drawing up operation 1facilitate assembly. Apply oil or grease freely to tie rod reads while assembling sections to prevent stripping of
reads on rods.
Fic. 2--Assembling Secuoru
08741
f ERECTING DIRECTIONS Ajumcw GAS BOILER TYPE 4-G
0
vrrange for suitable blocking under center section. Paint _.nd rib of each section with red lead and continue assemf b' b ,. :g center sections ONE AT A TIME. Shift blocking each time so '.hat support is under the last section assembled. See Figs. 1
ar.c -
6. For 13 to 41 Section Boilers--Continue to assemble sec tions until ready for intermediate (thick) section. Bolt two - rr.er support brackets to each side of intermediate base and er.gthen tie rods with couplings. Repeat this operation as each .r.'.ermediate section is assembled. See Fig. 4.
7. All Sires--Remove upper tie rod and assembling blocks. Remove nuts and washers from lower rods. Place left end section in position and insert tie rods ..-.rough bolt holes in sections. Draw sections together as in previous operations until all ground joints are tight. 3ack off all tie rod nuts until they are finger tight only.
TESTING
Before connecting boiler, plug openings, fill boiler
* ::h water and subject to not less than 10 lbs. nor more
than 30 lbs. pressure. Inspect boiler inside and out
side for leakage to insure against breakage from han dling and shipping. To safeguard accuracy of gage sup plied with boiler do not install gage until after test of
1, Right End Section i. Intermediate Section 1. Center Sections
Fic. 4--Assembling Larger Boiler
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.
ASSEMBLY OF PLATEWORK 1. Screw short threaded end of brass studs into tapped bosses in recesses between sections
and attach cleanout cover plates to front of boiler. See that asbestos gasket is on each plate and makes gas seal when drawn up tight. See Fig. S.
Attach filler plates in like manner to back of boiler. Putty openings between plates and sections. Putty outside of sections at joints with boiler putty.
08742
ERECTING DIRECTIONS Aaaoas GAS BOILER TYPE 4-G
5
2 place burner supports in pockets provided on end or.s. and in bolted-on supports of intermediate sec^ ; n 13 to 41 section boilers. See Fig. 5.
3. Fill grooves on back of burner access door frames r..r putty and attach frames to sections with hex head 0.r?ws using washers under heads. Attach manifold ^rackets to front and back burner access door frames
..ex head screws. See Fig. 6.
1. Cleanout Cover Plans
l Burner Support
Fie. S--Section Assemblage
assembly of burners and control
PIPING 1. Assemble sub-assemblies of manifold, manifold
piping, automatic gas valve and gas pressure regulator or automatic pilot valve and attach to boiler. See that orifice spuds in ends of burner cocks or spud holders are screwed in tight and that orifices are drilled to size spee ded on tag attached to manifold. (See Figs. 7, 8, 9, 10 ard 11.)
Fie. 6--Assembling Burner Accems Door Frame
Fie. 7--Burner InataUauon--Pilot Burner, Thermocouple and Vent Tube
08743
I ERECTING DIRECTIONS A.mn. GAS BOILER TYPE 4-G
0
2. See that air shutter is assembled on each mixer tube, then place mixer tubes firmly on gas cocks or spud holders and burner support. Assemble main burners on tapered ends of mixer tubes so :hey are straight and level. (See Figs. 7, 8.12, 13, 14 and 15 for proper burner locations).
3. Place front and back secondary air baffles on lugs on end and intermediate sections. The baffle danges should be away from burners and turned downward. See Figs. 7 and 8.
1. Gil Suooly Line 2. Manual Shut-Off Valve
Assembly 2. Sis Pressure Regulator L Automatic Gas Valves i. Dresser Couoling t. Manifold Pipe T. Spud Holden t. Union For IS Section
1. Gas Supply Lines 2. Manual Shut-Off Valve
Assemblies 2. Gas Pressure Regulators 4. Automatic Gas valves I. Manifold Pipe ! Spud Holden
'/
Manifold Piping for Mid-, Nat, Mixed and LP-Air Gases
Fie. 9-A--Mid. and LP-Air (S through 13 sec Fie. 9-B--Mid. and LP-Air (13 through IT sections)
tions) Nat. and Mixed (6 through 11 sections)
}[sc and Mixed (13 through ^sections)
08744
ERECTING DIRECTIONS A*TMTM GAS BOILER TYPE 4-G
i. .as Supply Lines
l< Spud Holden
; Manual Shut-Off Valve
25 Section Boilers
AssemBlies
T. Caps For 1? And 21
j. jit Pressure Regulators
Section Boilers.
i. Automatic Gas valves
Coupling For 22 And
i. Manifold Pipe
7
Fic. 10-A--Mid. and LP-Air (19 through 2S secuona)
Fic. 10-B--Mid. and LP-Air (28 through 41 sections) Nat. and Mixed (22 through 41 sections)
I. Gas Supply Lines
1. Automatic Gas Valves
2< BASO 500 Series Automatic 4. Manifold Pipe
1- Gas Supply Line 2- 3AS0 500 Senes Automatic
Pilot valves
2. Automatic Gas Valves 4. Manifold Pipe I. Spud Holders
Maniioid Piping for Liquefied Petroleum Gases
Fic. 11-A--4 Through 22 Section Boiler*
Fit. 11-B--25 Through 41 Section Boilers
/
08745
8 ERECTING DIRECTIONS Asaisas GAS BOILER TYPE 4-G
sC3 -e
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mi
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i
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-e -gs1
Pic 12-O u in e r am i P ilo t In sta lla tio n For M id. Gas
rg-i
a He
an
08746
ERECTING DIRECTIONS AaOlStf GAS BOILER TYPE 4-G
9
T --J V
u
fh
I! I
til
i! 5 *ti
i*1
f ?; 5 l I
Q ISIS
Ze S 8
wc *
* *
*
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Fic. 13 B u llitt and Pilot Installation For Nat. and Miaed Gases
08747
t ic H IJiirn cr and P ilu t in M u lla lio n 'F u r LP G *
ERECTING DIRECTIONS A01S4B GAS BOILER TYPE 4-G 08748
ERECTING DIRECTIONS ABBIfiU GAS BOILER TYPE 4-G
w -SgS?-
j! C3
fe
Hte
11
mm DC3|i *0 Orf*
/bfl
Flo li- H u u u r nmt Pilot Installation For I.P -A ir Gas
08749
12 ERECTING DIRECTIONS AsOtSU GAS BOILER TYPE 4-G
34S /.nc
I. Manual Shut-Off Vslve
J. Main Gat Lint 1. Gum Filter L Pilot Cock I. Pilot Gas Pressure
Regulator L To Pilou T. Tee I. Pipe To Appliance I. Drip Leg II Pipe Cap It. Block At Least
1" Thick To Allow For Drip Removal
1. Manual Shut-Off Valve
2. Main Gas Lint 1. Gum Filter 4. Pilot Cock I. Pilot Gas Pressure
Regulator I. To Pilots 1. Tee I. Pipe To Appliance 1. Orip Leg II. Pipe Cap II. Block At Least
1" Thick To Allow For Drip Removal
Note: All Pioing Shown Below Manual Shut-Off Valve Not Supplies By ARASS Corp.
Note: All Piping Shown Below Manual Shut-Off Valve Not Supplied By ARASS Corp.
Supply Piping Arrangement
Fie. 16-A--Where one manual shutoff valve is supplied at end of boiler
Fie. 1S-B--Where two manual shutoff valves are supplied at end of boiler
4. Install manual shutoff valve assembly as shown in Fig. 16.
ASSEMBLY OF JACKET 1. Fill putty grooves at top of sections
with boiler putty and place canopy or canopies in position so that turned down edges are firmly imbedded in the putty to make gas seal. Smooth off excess putty.
1. Limit Bulb Tube 2. Canopy L Left End Jacket Panel,
Front Half 4i Left End Jacket Panel,
Rear Half I. Left Front Jacket Panel I. Right Front Jacket Panel 1. Draft Hood
Fic. IT--Jacket Assembly; U through 21 section water boiler shown
08750
ERECTING DIRECTIONS Ab&OSU GAS BOILER TYPE 4-G
13
2. Place rear half of left end jacket panel in position, then place front half in position. Fasten -wo halves together having washer head screws pass through front half o: panel into caged nuts at tached to rear half of panel; attach panels to boiler section with washer head screws. On Water Boilers put temperature bulb tubing under jacket panel comer.
3. In similar manner attach two halves of right end jacket panel to boiler section.
Fie. 19--Jacket Auambly: Right Rear Vttw
08751
ERECTING DIRECTIONS Aumom GAS BOILER TYPE 4-Gf
4. Place front jacket panel in position. Flanges of front jacket panei to lap over end jacket panels and boitom to lap over cast iron burner access door frame, /attach jacket panel to burner access door frame with I washer head screws.
5. For IS to 41 Sections--Attach individual panels together with washer head screws for making up com plete front or rear panels. Refer to Figs. IS and 19. Place key strips between front and rear burner access door frames and attach with washer head screws.
6. Attach rear jacket panel in similar manner.
t. Key L Wisher Held Screw
7. Place four short vertical keys in position at ends
Flc- 2-AlUchu' Comer K**`
of front and rear burner access door frames, inserting top of keys under flanges of front and rear jacket
panels. Attach keys to cast iron burner access door frame with washer head jacket screws. See Fig. 20.
8. Place canopy frame in position. See that frame is down tight over top edges of jacket panels.
9. Seat flue pipe firmly on flue outlet of canopy with protrusions on pipe at upper end, then place draft hood on flue pipe.
STEAM BOILERS 1. Remove and discard plug and dowel at top and bottom of low water cut-off. Assemble low
water cut-off and water column piping as shown in Fig. 21 and attach to boiler as shown in Fig. 22. Make steam gage connection with nipple and tee to 5 i inch tapping on upper part of low water cut-off. Connect steam control element on automatic gas valve with steam gage tee using copper tubing and con nectors. Fill tubing with water and screw steam gage into tee.
2. For 6 to 11 section boilers, connect safety valve to 2'-i inch tapping on right end section using nipple and elbow provided.
08752
ERECTING DIRECTIONS AltlBSU GAS BOILER TYPE 4-G
15
Ftc. 21--Sum Trim
Tic. 22--Sftffl Trim Ammbitd
& %tUT Caw 1i -v,iTtf7Cm*r tat Umm m ii**mfc t*-M a i/lfc" T*. fc *'M i/u" T.
Fic. 23--Right End Connections for Su*m Boilers having 4 Automatic
Gas Valves
For 13 to 41 section boilers, insert bushings and connect safety valves into 3 inch tappings on intermediate sections. Plug unused tappings with plug (or on right end, 2 Vi x V\ inch bushing when 4 automatic gas valves are supplied). Limit controls of right end gas valves should be connected to 2\i x V* inch bushing with V* inch copper tubing, tee, plug and nipple. See Fig. 23.
WATER BOILERS 1. Insert temperature bulbs in upper tappings under jacket knockouts on left end section, see Fig.
17. For more sensitive operation, discard well before installing split nut and gland. Tube leading to bulb should be installed under jacket at corners.
2. Connect combination thermometer and altitude gage to upper one inch tapping on left end sec tion with nipple and reducing coupling.
3. Plug 2 Vi inch tapping in right end near top unless relief valve is installed.
4. For boilers having 4 automatic gas valves, the bulbs from the valves on the right end should be installed similarly in the upper tappings under jacket knockouts on right end section.
5. If reverse acting low limit control is to be used, install it in lower V* inch tapping on rear of left end section.
08753
ERECTING DIRECTIONS AafiOS&S 'GAS BOILER TYPE 4-G
^ BOILERS 1. Install drain cock in lower ? inch tapping on right end section.
2. Plug all tappings not used.
3. Be sure flame check is in gas pressure regulator as shown in
maTCMiac 4|0UmUCS*JO<tfXMliCo*
ig. 24.
Fte. 24--Flam* Check
CONNECTING CONTROLS (MFD., NAT. AND MIXED GASES)
A__For 6 through 17 sections for Mfd. gas and for 6 through 21 sections for Nat and Mixed Gases:
1. Connect pilot line from manual shutoff valve assembly (See Fig. 16) to front pilot burner tubings. Tnctali on top of spud holders. Connect a similar line to the rear pilot burners.
2. Connect thermocouple leads, attached to pilot burners, to BASO 850 automatic pilot switches and attach these switches to bracket with two 10-24 x Vi inch screws and nuts which are then attached to the lower left corner of the front and rear jacket panels with two No. 10 sheet metal screws each. See Figs. 12 and 13 for location of BASO switches. There should be a thermocouple attached to the left pilot burner in each combustion chamber in front and in back.
1. Manual Shut-Off Valw 8. BASO 850 Automatic
Assemblies
Pilot Switches
L Pilot Lines
I. Thermocouples
S. (Us Pressure Regulators 1. Pilot Burner Brackets
4. Vent Tubes
Fie. 2S--Connecting Controls
3. Connect vent tube from gas pressure regulator to union leading to vent tube tip on pilot burner bracket. When one gas pressure regulator is supplied, vent tube tip should be attached to left front pilot burner bracket. If two gas pressure regulators are supplied at the same end, one vent tube should be connected to the left front pilot burner bracket and the other vent tube to the left rear pilot burner bracket. See Fig. 7, 12, 13 and 25.
4. Wire according to wiring diagram supplied.
5. Install burner access doors.
08754
ERECTING DIRECTIONS AbooSU GAS BOILER TYPE 4-G
17
.Tor 19 through 41 sections for Mfd. gas and for 22 through 41 sections for Nat. and Mixed Gases:
1. Connect pilot line from manual shutoff valve assembly (Fig. 16) to front pilot burner tubx.gs. Install on top of spud holders. Connect a similar line to left rear pilot burners. Connect sim ilar pilot lines to right front and right rear pilot burners.
2. Connect thermocouple leads (attached to pilot burners) to BASO 850 automatic pilot switches and attach these switches to bracket with two 10-24 x V4 inch screws and nuts which are then attached to the front jacket panel with two sheet metal screws each. The location of the BASO switches and the pilot burners having thermo couples is indicated on Figs. 12 and 13.
3. Connect vent tube from gas pressure regula tor to union leading to nearest vent tube tip on pilot burner bracket. The locations of pilot burner brackets having vent tube tips are shown on Figs. 7, 12, 13 and 26.
4. Wire according to wiring diagram supplied.
5. T"cta11 burner access doors.
1. Minual Shut-Off Vlv* Assemblies I, Pilot Lines
CONNECTING CONTROLS (LIQUEFIED PETROLEUM GASES)
A--For 6 through 22 sections:
1. Connect pilot line from the pilot cock on front BASO 500 Series automatic pilot valve in main gas line to BASO 808 series automatic pilot valve (See Figs. 14 and 27). Connect line from Vs inch tee at outlet of BASO 808 series valve to front pilot burners. If more than 2 front pilot burners are installed, there should be an addi tional BASO 808 series valve attached in series with the first, (use Vi inch close nipple) one for each additional pilot burner. The outlet tee is taken from the outlet of the last BASO valve in the series. (For the 22 section boiler, the last two BASO 808 series automatic pilot valves are located adjacent to the right combustion chamber with an aluminum extension tube connecting them to the first two. See Fig. 28). Connect a bypass line from the tee in the main gas line to the push button valve which is attached to the outlet of the last BASO 808. Attach BASO 808 valve to bracket with two 10-24 screws and at tach brackets to jacket with two sheet metal screws each. See Fig. 14 for the location. Connect a similar pilot line to the rear pilot burners. -
08755
ERECTING DIRECTIONS AaatHB GAS BOILER TYPE 4-G
t
J
2. Connect a No. 50 thermocouple from the left front pilot burner to the BASO 500 series valve in the main gas line. Connect a No. 80 thermo couple (smaller diameter tube than No. 50) from each remaining front pilot burner to a BASO 808 series automatic pilot valve. Connect rear thermo couples similarly.
When finished, there should be a thermocouple from each pilot burner to one of the automatic pilot valves in the pilot line leading to that particular pilot burner. See Figs. 7 and 14.
3. Wire according to wiring diagrams supplied.
la BASO 500 Strle Automatic Pilot Valves I# BASO SOS Strict Automatic Pilot Valvct S. Pilot Lint 4a Bypass Lint I. Thermocouples I. Brackets Ta Tee In Main Gas Line
Fie. 27--Connecting BASO Automatic Pilot Valves
1. BASO 808 Series Automatic 1. Extension Line
Pilot Valves
4. Thermocouples
2a Pilot Line
L Bypass Line
4. Install burner access doors.
Fie. 711 Frtensinn Line
B--For 25 through 41 sections:
1. Connect pilot line from the pilot cock on the left front BASO 500 series automatic pilot valve in main gas line to inlet of BASO 808 series automatic pilot valves which should be con nected in series with Vi inch close nipples (See Fig. 14). Attach to the lower right corner of the left front jacket panel with two No. 10 sheet metal screws. Connect pilot line from Vi inch tee at outlet of BASO 808 valves to left half of front pilot burners. Connect a bypass line from the tee in the main gas line to the push button valve attached to the Vi" tee at the outlet of the BASO 808 valves (See Fig. 27). Connect a timilar pilot line to the left rear pilot burners. Connect sim ilar pilot lines to the right (front and rear) pilot burners from the right end BASO 500 series automatic pilot valves. The brackets containing the BASO 808 valves should be attached to the jacket as indicated in Fig. 27 with two No. 10 sheet metal screws each.
08756
t I /_________________________________________
ERECTING DIRECTIONS AheB&B GAS BOILER TYPE 4-G
19
2. Connect a No. SO thermocouple from the left -ront pilot burner to the BASO 500 series auto matic pilot valve in the main gas line. Connect a No. 80 thermocouple (smaller diameter tube than No. SO) from each remaining pilot burner of the left front pilot burners (See Fig. 29), to one of the BASO 808 series automatic pilot valves.
Connect left rear and right (front and rear) thermocouples similarly.
When finished, there should be a thermocouple from each pilot burner to one of the automatic pilot valves in the pilot line leading to that particular pilot burner. See Figs. 7 and 14.
3. Wire according to wiring diagram supplied.
4. Install burner access doors.
Fie. 29--Pilot Connection*
CONNECTING CONTROLS (FOR LIQUEFIED PETROLEUM-AIR GASES)
A--For 6 through 17 sections:
1. Connect a pilot line from the left front manual
shutoff valve assembly (for the 6 through the 13 sec
tion boilers, the pilot line will come from the left manual shutoff valve assembly) to the inlet of an
i
MH V-167 electric pilot valve, which should be at tached to a bracket as shown in Fig. 30. This bracket should then be attached to the lower left corner of the front jacket panel with three No. 10 sheet metal screws. Two BASO 850 automatic pilot switches should be attached to this bracket and for
t x*
1. Br*cUt (S) 2. BASO BSO Automatic
Pilot Switch**
1. M-H V-167 Electric Pilot Valve
4. Three Sheet Metal Screw*
the 10 and 11 section boilers a second bracket con Ftc. 30--BASO Automatic Pilot Switches M-H Electric
Pilot Valve
taining a third BASO 850 switch should be attached
with two of the same screws.
08757
20 ERECTING DIRECTIONS &TM-T GAS BOILER TYPE 4-G
I
Connect the pilot line from the outlet of the MH V-1S7 electric pilot valve to the front pilot burners (See Fig. 15).
Attach a similar bracket to the rear comer of the jacket and connect a similar pilot line to the rear pilot burners.
I* 54SG 850 Automatic Pi at $v.i:n?s
2* Thermocouoies
2. Pilot Linos
4. M-rt V-167 Electric Pilot Valve ! Vent Tube
2. On the 13, 15 and 17 section boilers, attach another bracket containing two BASO 850 auto matic pilot switches to the lower left* comer of the right front jacket panel. Attach a similar bracket to the rear of the boiler.
Connect a thermocouple from each front pilot burner to a nearby BASO 850 automatic pilot FlC. 31--Connecting pilot Linas. For larger boilers there
art similar connections on the right end
switch. When finished, there should be a thermo couple from each front pilot burner to a front BASO 850 switch which will be wired to the front automatic gas valve supplying gas to the main front burners that are lighted by that particular pilot. Connect rear thermocouples similarly (See Fig. 31).
3. Connect vent tube from gas pressure regulator to union leading to vent tube tip on pilot burner bracket. When one gas pressure regulator is supplied, vent tube tip should be attached to left front pilot burner bracket. If two gas pressure regulators are supplied, one should be con nected to the left front pilot burner bracket and one to the left rear pilot burner bracket. See Figs. 7 and 15.
4. Wire according to wiring diagram supplied.
5. Install burner access doors.
^ B--For 19 through 41 sections:
1. Connect a pilot line from the left front manual shutoff valve assembly (for the 19 through 25 section boilers, the pilot line will come from the left manual shutoff valve assembly) to the inlet of an MH V-167 electric pilot valve which is attached to a bracket as shown in Fig. 30. This bracket should then be attached to the lower left comer of the left front jacket panel with three No. 10 sheet metal screws. Two BASO 850 automatic pilot switches should be attached to this bracket and for the 19, 21, 28, 31, 37 and 41 section boilers a second bracket containing a third BASO 850 switch should be attached with two of the same screws.
08758
ERECTING DIRECTIONS AHIBSAfi GAS BOILER TYPE 4-G
21
Connect the pilot line from the outlet of the
V-16T electric pilot valve to the left front
pilot burners (See Fig. 15).
Attach a similar bracket to the left rear corner of the jacket and connect a similar pilot line to the left rear pilot burners.
2. On the 22 to 41 section boilers, attach (to the lower right comer of the left front jacket panel) another bracket for the 22 and 25 section boilers containing one BASO 850 switch; for the 28, 31, and 33, two BASO 850 switches; for the 37 and 41, three BASO 850 switches.
Connect a thermocouple from each pilot burner of the left front pilot burners to a nearby BASO 850 switch. Connect similar switches and pilot lines to the left rear and right front and rear quarters of the boiler.
When finished, there should be a thermocouple from.each pilot burner to a BASO 850 switch which will be wired to the automatic gas valve supplying gas to the main burners which are lighted by that particular pilot burner. (See Fig. 31).
3. Connect vent tube from gas pressure regulator to union leading to nearest vent tube tip on pilot burner bracket The location of pilot burner brackets having vent tube tips are shown on Figs. 7 and 15.
4. Wire according to wiring diagram supplied.
5. Install burner access doors.
filling system
Caution: Never start boiler unless it is properly filled. (After boiler is in operation make up water should be added slowly).
Steam boilers should be filled until water is visible midway up gage glass between try cocks. Fill open hot water system to % height of expansion tank, remove rim and glass from gage and set movable pointer under automatic pointer. Replace rim and glass. Fill closed hot water system until relief valve relieves. This must be less than 30 pounds 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 system filled. Pointers on gage should be even. If pressure exceeds 30 lbs. relieve at once by opening relief valve or drain cock.
08759
ERECTING DIRECTIONS A*TM-., GAS BOILER TYPE 4-G
13 Section Boiitr Completely Assembled
Fjs. 32-A--Left Front View
Fic 32-B--Left Resr View
PILOT ADJUSTMENT
Light boiler as directed in operating instructions and check for gas leaks. Adjust pilot flame to extend over top of burner. Pilot rate can be adjusted with screw underneath cap on pilot gas pres sure regulator.
NORMAL PILOT INPUT FOR BASO PILOT BURNERS
Input Per Pilot Burner Btu Hr.
Mfd. 1000
Nat.
r 1400
Gas Mixed
1200
UP. 1000
LP-Air 1000
MAIN BURNERS INPUT ADJUSTMENT
After boiler is warmed up, shut ofl all 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 Feet Per Hr.) =
Input Rating (Btu Per Hr.)
Heating Value of Gas (Btu Per Cu. Ft)
To increase consumption, turn adjustment screw (beneath cap on pressure regulator) clockwise; to decrease, turn screw counter-clockwise.
08760
ERECTING DIRECTIONS A*TM*. GAS BOILER TYPE 4-G
23
[AIN BURNER PRIMARY AIR ADJUSTMENT
Adjust burner flame by opening or closing primary air shutter. Flame should burn quietlv. ;how no yellow and should have a noticeable inner blue cone. After adjustment, tighten screw to ock shutter in position.
OPERATING
SHUTTING OFF: (MANUAL IGNITION; MFD., NAT. AND MIXED GASES) 1. Close manual shutoff valve(s) and pilot cock(s). 2. Turn off switch in electric line to appliance.
RELIGHTING: (MANUAL IGNITION; MFD., NAT. AND MIXED GASES)
1. Set thermostat (or operating control) at lowest temperature.
2. Close manual shutoff valve(s) and pilot cock(s). 3. Turn off switch in electric line to appliance. 4. Wait 3 minutes. 5. Open burner access doors.
I. Manual Shut-Off Valve l Pilot Cock
J. Pilot Burners
4. BASO 850 Automatic
2 Pilot Switches
t. Reset Button (On B50 Switcn) W I. Automatic Gas Valves
{] 7. Manual Control Lever || I. Hand Resetting Button
s
6. Open pilot cock(s) and light all pilot burners (front and back).
7. Close burner access doors. 8. Wait 2 minutes.
Fis. 33--Operating Controls Mid, Nil and Mixed Cases
9. Press reset buttons on all BASO automatic pilot switches.
10. Open manual shutoff valve(s).
11. Turn on switch in electric line to appliance.
12. Set thermostat (or operating control) at desired temperature.
08761
24 ERECTING DIRECTIONS AuBSAB GAS BOILER TYPE 4-G
SHUTTING OFF (MANUAL IGNITION; LIQUEFIED PETROLEUM GASES) 1. Close pilot cock(s) and hand shutoff wheels on top of automatic gas valves. 2. Turn off switch in electric line to appliance.
RELIGHTING (MANUAL IGNITION; LIQUEFIED PETROLEUM GASES)
1. Set thermostat (or operating control) at lowest temperature.
2. Close pilot cock(s) and hand shutoff wheels on top of automatic gas valves.
3. Turn off switch in electric line to appliance.
4. Wait 5 minutes. 5. Open burner access doors.
t
I. Pilot Cocks
Z. Automatic Gas Valvti
1. Hand Shut-Off Whis
8. Manual Control
Ltvar
*
l. Hand Rtscttm? Button
* Push Button
Vaivts
. '
BASO 500 Sents Automatic Pilot Valves
BASO 808 Seres Automatic Pilot Valves
6. Open pilot cock(s).
7. Light match and insert in lighting rod.
Fie. 34--Operating Controls Liquefied Petroleum Cases
8. Press left front push button valve, hold and light all pilot burners on this pilot line.
9. Hold 2 minutes.
10. Press reset buttons on all left front BASO automatic pilot valves, then release push button valve.
11. Repeat steps 8, 9 and 10 for left rear of boiler. Repeat for right (front and rear) pilot burners on boilers having 4 automatic gas valves.
12. Close burner access doors.
13. Open hand shutoff wheels on top of automatic gas valves.
14. Turn on switch in electric line to appliance.
15. Set thermostat (or operating control) at desired temperature.
08762
ERECTING DIRECTIONS AafiHGM GAS BOILER TYPE 4-G
HUTTING OFF (MANUAL IGNITION; LIQUEFIED PETROLEUM-AIR GASES) 1. Close manual shutoff valve(s) and pilot cock(s). 2. Turn off switch in electric line to appliance.
25
RELIGHTING (MANUAL IGNITION; LIQUEFIED PETROLEUM--AIR GASES)
1. Set thermostat (or operating control) at lowest temperature.
2. Close manual shutoff valve(s) and pilot cock(s).
3. Turn off switch in electric line to appliance.
1. Manual Shut-Off Valva 2. Pilot Cock 1. Electric Pilot Volvo 4. BASO (50 Automatic
Pilot Switches I. Automatic Gas Valves (. Manual Control Lever T. Hand Resetting Button
4. Wait 5 minutes.
5. Open burner access doors.
6. Open pilot cock(s).
7. Turn knob on left front electric pilot valve to "Manual" and light all pilot burners in this pilot line.
8. Repeat for left rear of boiler. Repeat for right (front and rear) pilot burners on boilers hav ing 4 automatic gas valves.
9. Close burner access doors.
10. Wait 2 minutes.
11. Press reset buttons on all BASO automatic pilot switches.
12. Open manual shutoff valve(s).
13. Turn on switch in electric line to appliance.
14. Set thermostat (or operating control) at desired temperature.
08763
16
ERECTING DIRECTIONS
GAS BOILER TYPE 4-G
PILOT GOES OUT
If the pilot Same is extinguished, the automatic pilot will shut off the automatic gas valve. If boiler is not operating correctly, call Heating Contractor or Gas Company service man. If boiler is operating correctly, relight as directed on page 25.
ELECTRIC POWER FAILURE
Boilers equipped with "Detroit" 569 VS (or VW) valves may be operated manually during electric power failure. Proceed as follows:
1. If pilot burners are out, relight as directed for "Re-Lighting (Manual Ignition)" for the appro priate gas. Follow instructions completely so boiler will resume automatic operation when power returns.
2. When pilot burners are lighted, press down on manual control lever on automatic gas valve; main burners should light; press in hand resetting button to hold lever down, burners will remain lighted.
The 569 automatic gas valve has a mechanical limit control which protects the boiler from exces sive temperature or pressure.
3. Valve is 100% recycling and will resume automatic operation when electric power returns.
CARE AND ATTENTION
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.
08764
ERECTING DIRECTIONS AfilSSU GAS BOILER TYPE 4-G
27
3 Test safety valve on steam boiler at beginning of season and once a month thereafter:
a) Fasten cord or wire to valve lever. b) When pressure is up, stand safe distance away and pull cord. (Steam should be released)
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 by service man before the start of the heating season. If necessary, remove front jacket and cleanout cover plates and clean heating element.
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 accumu lated 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 steam boilers only as directed. (See Caution.)
5. 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 nec essary to add water during this operation to expel air from higher radia tors.
08765
ERECTING DIRECTIONS Ajutcw <SAS BOILER TYRE 4-G
6. 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 necessary during the winter.
7. Where an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed o freezing temperatures. Never place valves in piping leading to or from expansion tank
r
:Note All parts of this boiler have been carefully inspected and packed. In case of shortage, make
sure that all parts have been removed from shipping container and examine packing material thor-
- *.
i
ougiy. If part cannot be found, report shortage to your dealer, giving boiler size, series number,
date, inspector's number and packer's number. (See Parts List and Packer's Check Tickets).
Give boiler size and series number when ordering repair parts.
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BOILER SIZE ............................................................ SERIES NO. (SEE SERIES PLATE ON BOILER) DATE ............................................................................
08766