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PLAINTIFF'S EXHIBIT
AMERICAN: VP OIL
INSTRUCTION MANUAL
PACKAGED OIL HEATING UNITS
FORM NO. 32425-g^_04
NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET MUST BE AFFIXED ON OR ADJACENT TO THE HEATING EQUIPMENT.
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To the homeowner: The American-Standard boiler which has been installed
for you is the heart of your hydronlc heating system. Since the performance of your system depends upon the boiler, it has been designed to operate at maximum efficiency. Advanced design, precision engineering, and modern manufacturing techniques are combined in this product to provide you with comfort at a low operating cost and with a minimum of maintenance.
The boiler sections are cast in iron--a metal resistant to corrosion, especially in a closed system. If this boiler is part of a new installation, it is Joined in a closed system--l.., normally water is neither lost nor added-- and should not be drained. The replacement of water adds oxygen to the system; corrosive action continues until that oxygen is consumed; but, certainly, the boiler should not be fired without an adequate supply of water. On the other hand, if the boiler is not used during the winter months, it must be drained to prevent damage caused by freezing.
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By following the suggestions contained in this manual, you can assume your boiler will funotion properly for many years. Should any problem arise, contact your nearest American-Standard contractor, whose name can be found in the "yellow pages" of your telephone directory.
AMERICAN-STANDARD
05226
The V? Packaged Boiler comes to you pre-assembled; the installers major responsiiility will be in locating, connecting accessory parts and performing the actual hookup.
1
05227
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.h ailowea at tne front (at least a 2v" clearance; to a...,-.
i or ..1 t.i ... ater. Clear.mg space ^approximately 24") s:\ij.c.
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.v*.; r^.tiev should be mounted on a. concrete or hollow :;j<.
r-A.-.-l
-301LFR
c; n * a r ;t- finai installation site before removing its crate, unp.10 - loiilri be acre r.p..r. as follows: (See Figs. 1 and 2)
l. ret iit crating wire at the corner of the crate.
L. i\C T* wi- .lAi-S" fastening crate sides to top and bottom of crate.
3, in It
. rate top anc unwrap crate side from crate base.
4. a:-.-' .- ;f;m,va. 0: the plastic bag, remove and discard the sr.ort nipple T ns :"i.ou. tapping at top of boiler.
*/ r -o\ .-..-iotaimr.g draft stabilizer, relief valve, and rnisceilar.eou.i
w
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.orating the exoar.sior. tar.K. It should not be set tr. a c-'-l.:
or tixpr.srr. s -
:.-.r tune to or fro.r. the tame were to freeze, serious carnap
con:-. r -i::;. I:
.-eferahie to use a minimum of horizontal run pipint;
to cr.ti e repno.-: or. tat.-: co t&ciiitaie free communication from the boiler to the tank.
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FIG. 1
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Remove four .u.s securing boiler to - .. ooIts on let: s-t.e. oolts on rignc 510. .vhere they v.-iii stay. This is imoor;a removing holier from base.
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frorf' ._
Tilt boile r to rear and to right.
3. Pivot boiler on right rear leg, rotate 90, and lower to floor.
4. Tilt boiler so that crate base can be completely removed.
above p iceoure 15 quite simple and can be very easily accomplished by two . In ar. merger.cy, it can be accomplished oy one man with comparative ease). After :n= 00.-er is removed from the crate base, it can be easily walked to its final location.
05231
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CHECK-OFF PARTS LIST FOR V? PACKAGED 3GILER Although the VP packaged Boiler comes to you assembled, it is necessary to check certain accessory items prior to final hook up.
Accessory Box Draft Stabilizer Relief Valve 3/4" x 7-1/4" Pipe Nipple 3/4" Tee 3/4" Drain Valve Oil Burner Nozzles Circulator Flange Gasket and 3olts Thermostat 3/4" Street Elbow Draft Tube Sleeve Sleeve Insulation Instruction Sheet
Oil Burner Sox DH-F Oil Burner
ELIMINAIRE FEATURE This VP Boiler makes use of a special front section with a 1-1/2" supply tapping incorporating the "Eliminaire" feature (See Figs. 3 and 4). The "Eliminaire" is a unique, built-in air separator which prevents air from being transmitted to the system and oirects the air to the com pression tank or vent. This eliminates the need for external air sepa rators such as dip-tubes or unlined accessories. The "Eliminaire" also assures positive air separation, thereby insuring proper system per formance .
5
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1^3 FLOW
(WATER HEATER HEAD)
B - (B._iND FLANGE)
CONTROL TAPd!NGS
.CCATICN -APPlSsS
CONTROL USED
A___ *4
B\
c %, D_~' >4 E /\
RELIEF VALVE
iMIT CONTROL OR
COMBINATION _M/T ANO REVERSE ACTING CONTROL (TOR INSTALLATIONS without TANKLESS WATER .HEATER)
_ IMMERSION CONTROL C0U6LE THROW SWITCH
IMMERSION CONTROL RELAY COMBINATION____
GAUG|lANCK*HEliMOM^ER
AUXILIARY liMI" CONTROL * (WHEN REQUIRED)
A \ .i
D
FIGURE 3
FRONT VIEW-SHOWING CONTROL TAPPINGS
FLOW PIPE--------
--V &
TO CONVENTIONAL EXPANSION TANK OR AJR VENT IF OlAPHRAGM TANK IS USED
RELIEF VALVE
BAFFLE
li .t -
INSIDE
OF
NIPPLE
-E RETURN
ELIMNAiRE ANO PIPING FOR FLOW PIPE
ANO RELIEF VAUT
FIGURE 4
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7.M-LINC THE V? BOILER r moving the VP Packaged Boiler to the desired location, final installation o .-cures snouia oe accomplished as outlined below. 1, Hook up piping. If jacket extension is to be used, make sure
that piping connected with the hot water heater and the boiler return piping to tiie circulator is arranged to pass through the opening m either the top or sides of the jacket extension (follow assembly instructions accompanying same). (See Fig. 5). 2. Screw drain valve into tee at lower right front of boiler. 1. Install relief valve and fittings in top of front section (See Fig. 4), making sure the direction of the discharge is away from controls. 4. The upper flange of the circulator should be installed on the return p.pmg, then ooitea to the circulator flange. Be sure that flange gasket is not damaged, and that the flange bolts are drawn up equally tight. 5. Install the flue pipe and draft staoilizer using instructions provided with stabilizer. The flue pipe should not extend beyond the inside wail of the c.unney flue. Horizontal runs of flue pipe should be kept at a minimum with approximately 1/4" pitch per foot maintained. 6. Run electric service line from switch (not furnished by A-S) to the control mounted on built-in water heater, or for boilers without water heater, on water heater opening cover plate. 7. The Cad Ceil lead should be taped to the conduit assembly extending from control to burner to prevent snagging or damage. (See ?g. H. S. Install room, thermostat. 9, Make all electric connections according to wiring diagram. (See Fig. 6). 0. The boiler is now ready to be filled. THE FILLING PROCEDURE IS AN IMPROVED METHOD, AND SHOULD BE FOLLOWED AS INDICATED ON FIG. 7. 1. Boiier is now ready for service.
05234
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FIGURE 5 Space P.eouirements For Boiler Pipine
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9
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WIRE COLORS
nO. S - SLACK
-IMS
fdotted limes
not furnished
hoT-1 \: <i
;0 6
!. 2
0 Oi I
W-WhTE
HIGr i_IMiT CONTROL
HONEYWEi__ PRIE2D
COMBINATION CONTROL
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fit cf c,
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SETTING APPROX. 210")
; LOW LIMIT CONTROL SETTING ArpROX. 190*)
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NUTS 'ilRiMSKF.O
CIRCULATOR
LOW VOLTAGE
______________ A ______________ L
OiL BURNER
general schematic showing wiring to components
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INTERNAL .rNFMATiC A*C r'y^CTlONS fC* RM*20 CONTROL
PACKAGED Oil. 3OILER WITH WATER HEATER WIRING OI AGP. A.MS FOR CONSTANT IGNITION
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WITH REVERSE ACTING CIRCULATOR CONTROL AND CONSTANT
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'5 v. 60 Cr
'C C l suRner IMC'-'R ANC iCNltiOR
'0 WATER
CIRCULATOR
INTERNAL SCHEMATIC and CONNECTIONS FOR R8182E CONTROL
INTERNAL SCHEMATIC AND CONNECTIONS FOR R8I82F CONTROL
PACKAGED OIL BOILER LESS WATER HEATER WIRING DIAGRAMS WITH REVERSE ACTING CIRCULATOR CONTROL AND CONSTANT IGNITION Figure 6
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T NO.5-Z iDO ON* ZONE CONTROL SET FOR USE WITH HONEYWELL R-8182 0 CONTROL
05240
'\9 diaphragm type expansion tan;; ;s USED AUTOMATIC VENT VALVs SHOULD 8E INSTALLED IN THIS LOCATION
TUPN^
u .ATOP
5 A A \ C. N
'-OCXS 0 =
ZONE VA..
I LUNG
FIG. 7
he following procedure should be used to fill a series loop Heatrim System (See Fig. '
Close all zone valves except the one for the zone to be filled with water and purged of air. . Open the drain valve on the boiler. . Open the fill valve. . Close the purge valve. . Open the relief valve. . Open the valve to the second zone to be purged; then close the first. Repeat this step until all zones have been purged of air and filled with water; but always have one zone open. (Zones are purged and filled when water car. be felt in the pipe at the end of the zone). . Close the drain valve. When water appears, release the lever on the relief valve, allowing it to close. Continue filling the system until the pressure gauge reads 12 psi without heat or 25 psi at 200F. ; close the fill valve. Open the purge valve.
ollowing the completion of the installation, a thorough check should be made of the ntire hydronic system to locate possible leaks.
OTE: For a single loop heatrim system no additional vents, cocks, valves or other accessories are required except: When tankless heater is used and heatrim is above the boiler outlet, install a flow-check valve to prevent gravity circulation.
A'JTION: If a valve of any type is installed in the piping leading to or from the
expansion tank, EE snpg THAT IT IS ALWAYS OPEN WHILE THE EOIIZE IS TN OPrRArnM
05241
^RZ OF 3OILER WHILE IN OFERATION 3X CLOSED HOT WATER SYSTEM, THE PRESSURE MUST NOT EXCEED 30LBS. -r IT DOES, IT MUST BE RELIEVED IMMEDIATELY AND THE CAUSE OF THE FAILUR N'v THE THE RELIEF VALVE INVESTIGATED AND CORRECTED: OTHERWISE, "R-SSURE MAY BUILD UP AND CAUSE DAMAGE TO THE HEATING SYSTEM.
FIG. 8 The homeowner should periodically check the readings on the gauge, located on the iront of the boiler (See Fig. S). The lower scale indicates the water temperature. That temperature should never be allowed to exceed 250 F. The boiler is designed to operate with a normal maximum water temperature of 230 F; but during mild weather, the system operates with water temperatures considerably below the maximum. The upper scale indicates the pressure within the system and should not exceed 30 lbs. In a closed system, the boiler and piping are entirely filled with water except for a cushion of air in the upper portion of the expansion tank. When the water is heated, it expands, compressing the air in the expansion tank. If, for any reason, this air were completely displaced from the tank, there would no longer be a cushion; an increase in water temperature would cause a corresponding increase in volume; pressure would force the relief valve open to discharge the excess volume. To correct such a condition, the expansion tank must be drained enough to permit the tank to fill with air. Clean boiler surfaces at regular intervals. Do not draw water from boiler while in use. When adding water while boiler is in operation, DO NOT OPEN SUPPLY VALVE FULLY, BUT ADD WATER SLOWLY.
05242
CARE OF BOILER At end of heating season, clean boiler thoroughly and spray flue surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners. When replacing cleanout door, boiler putty is necessary for sealing. Lubricate circulator in accordance with lubrication instructions on decal. Clean and remove flue pipe where feasible. Keep system filled with water; in other words, DO NOT DRAIN BOILER. IF BOILER IS NOT USED DURING WINTER, IT MUST BE FULLY DRAINED TO PREVENT DAMAGE CAUSED BY FREEZING.
05243
r.ir-'tc cm' rr.n^ *
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'-!** ia^c o .vikc ud lac Y - -- *
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.b': ' ion c.v
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ncccs.-ir;. vair-r concent * ;d:^
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at
':. - ;; .;*.*.
.ir.f ^ncr.ia And made ol steel. A refractory rao.aric :.
J c_rv:.--rc the
.er tst.'r <:' i.'om heat.
i~ .1 AOP
:- .v.r :-reo:--;:_1 cc-nop-, is provided. Smoke pipe size*: ore -a
! =..-.
.\o. ~,i Sec::ci'.r
Srnokepipe Sir..'
7"
8"
.or.V," * g ui Ate cl with 1/?." j. iberglas. An acicitional t " oi insuia,;o.-.
he canopy.
05244
A R -2! -i7ttF1 l.OW
i
-'T'- 3
-- 6"-------
riON THRU BOILER
cROF
DIMENSIONS ;
--4--&
'P-i
3
4 2f
6~| 15a i
5
FIGURE G
05245
' to
2li
PACKAGED BOILER
FIGURE 10 Although the basic boiler remains the same, the differences e;<:. = : in the wiring procedure with or without water heater (fee 7i.z '
05246
combust:on c:-;.. The VP Boiler has a or.e-piece precast Reiractory Combustion target waii -pecially designed for maximum performance and efficiency. 01L BURNER The Model DH-F oil burner is used with the VP boiler. This burner is especially cesigned with a conventional flame-retention head to give maximum performance ur.d efficiency in the VP boiler. CONTR.OLS Controls lor the VP Packaged Boiler are conventional. ACKET Jacket design for the VP Ehckaged Boiler is conventional as with other A-S boilers.
20
05247
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 trouble-free operation if properly treated. 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 be 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 manufacturers' recommendations. Following their use, the boiler must be thoroughly flushed out. Otherwise, serious damage may result.
05248