Document LpGYM2y3qGmqEvK3pnnGVrZmX

AMERICAN STANDARD INSTRUCTION MANUAL 3P-100-G60 CERTIFIED BY AMERICAN GAS ASSOCIATION NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET MUST BE AFFIXED ON OR ADJACENT TO THE HEATING EQUIPMENT. 02323 G-60 GAS BOILER TC THE OWNER: Tne American-Standard Boiler which has been installed for you is cne neart of your nyaronic heating system. Its design represents advanced engineering and manufacturing techniques to produce a product which will provide you with heating comfort at tne lowest operating and maintenance cost. The sections are made of cast iron which is well known for its long life and corrosion resistant properties. When hot water is used as a heating medium, the entire system is filled with water and an expansion tank provides space for the increased volume as the water in the system expands when it is heated. In a steam system the water is to be maintained at the indicated level. Under no conditions should any boiler be fired unless it is properly filled with water. If a boiler is not'in use during the winter season it must be drained or otherwise protected against freezing temperatures. A gss fired boiler uses gas as a fuel. The chemical composition of natural gas is similar to gasoline which is used as the fuel in an automobile engine. The toxic nature of automobile exhaust fumes is well known. These fumes are toxic because the hydrocarbon fuel is not completely burned. In a properly adjusted and normally operating gas fired appliance such as a kitchen range, boiler, water heater, etc., the hydrocarbon fuel is burned completely, producing harmless combustion by-products, and these products are normally vented to the outside atmosphere. Normal prudence will dictate that the venting system and combustion process of any gas fired appliance be checked periodically to assure that normal operation is taking place. Any abnormalities in combustion or venting of flue products to the outside atmospnere should be promptly corrected. By following the suggestions contained in this manual, you can assume your boiler will function properly for many years. Should any problem arise, contact your nearest American-Standard contractor, whose name can be found in tne "yellow pages" of your telepnone directory. AMERICAN-STANDARD 02324 G-60 GAS BOILER GENERAL DIMENSIONS FOR 6 TO 11 SECTION BOILERS 1 BOILER No. OF No. OF NUMBER SECTIONS BURNERS G-606 G-607 G-608 G-609 G-6010 G-60II 6 7 8 9 10 II 5 6 7 8 9 10 L 27i 31 i 35 f 39 i 43| 47| SIZE GAS CONNECTION NATURAL BUTANE 4. PROPANE MIXED li 2 2 i 2 li 2 li 2 02325 G-60 GAS BOILER GENERAL DIMENSIONS FOR 13 TO 41 SECTION BOILERS 1A AND REAR BOILER No OF No OF No OF No-OF FLUE NUMBER SECTIONS BURNERS drafthoods OUTLETS A B C (APPROX.) L G-6013 G-6015 G-6017 G-6019 G-6021 G-6022 G-6025 G-6028 G-6031 G-6033 G-6037 G-6041 13 15 17 19 21 22 25 28 31 33 37 41 12 14 16 18 20 21 24 27 30 32 36 40 2 2 2 2 2 3 3 3 3 4 4 4 2 31$ -- 6t 62$ 2 35 $ -- TO 71 4 39i -- 8? 79$ 4 43$ -- 8$ 87$ 4 47 i -- 8| 95$ 3 35$ 35& 8| 1061 6 39f 39$ 8$ 119 6 43$ 43g 8$ 131 $ 6 47|| 48$ 8$ 143$ 8 39f 39$ 8$ 158$ 8 43^ 43 if 8$ 175$ 8 47$ 48^ 8$ 191 $ NUMBER AND SIZE GAS CONNECTION NATURAL BUTANE L PROPANE .MIXED 1-2' 1--2$" 1 -2" 1 -2$' 1-2" 1 -3' 1-2$' 1-2$' 1 -3" 1-3' 1-2$' 1-3' 1 d2 1-3' 1-3' 2 -- 2$' 1-3' 2-3" 1-3" 2-3" 1-3' 2-3' 1-3" 2-3" 02326 1109-0 0109 -0 609 -0 809-0 O in 10 r- CO O) 1-- O in <o r*- o> (<oV0J 0 D cK1r ro C (O 6 LEFT END RIGHT END ., L E F T END ARRANGEMENT BOILER OF SECTIONS NUMBER G-606 G-607 LJ cr o in (0 t*- GO at LJ _J RIGHT END BOILER NUMBER G-6013 G-6015 G-6017 ARRANGEMENT OF SECTIONS L E RE 6109-0 G-6021 BOILER NUMBER G-6022 G-6025 G-6028 G-6031 O to <0 a LI - - - - HH - - - - (0 at o 10 ARRANGEMENT OF SECTIONS | -- --- CO O) u 10 - - - - LJ cr G-60 gas boiler tzn o o LinlI cur H z o HZ S-! CO < au 2q: Z li X uLlI HZ gIT (f0O o1 D cxr CVJ C0C\DJ o1 o tuu- m azul h- Ld cr 02327 G -6033 THRU G-6041 BOILER NUMBER G-6033 G-6037 G-6041 - - - LJ -1 O CO o> HH - - - O C- CO at M- -- ARRANGEMENT OF SECTIONS | O t"- co O) t-H - - - O GO o> - - - LJ cr G-60 GAS BOILSK FOR BOILERS EQUIPPED WITH TOP LOCATED DRAFTKOOD NATURAL AND MIXED GASES ONLTf 2A END VIEW (ALU SIZES) FRONT VIEW (13-4! SECTIONS) END VIEW (6*11 SECTIONS) Boiler Number 0-606 0-607 0-606 0-609 0-6010 0-6011 0-6013 0-6015 0-6017 0-6019 G--6021 0-6022 0-6025 0-6028 0-6031 0-6033 0-6037 0-6041 A 31-3/8 35-1/2 39-3/8 43-3/4 47-7/8 35-1/2 39-5/8 43-3/4 47-13/16 39-5/8 43-11/16 47-3/4 B 35-9/16 39-3/4 43-15/16 48-1/8 39-3/4 43-15/16 48-1/6 DIMEHSIOKS - INCHES C D r 6-1/4 16 B 78-5/8 6-1/4 16 R 76-1/8 6-1/4 16 8 78-5/8 6-1/4 16 3 78- 5/8 6-1/4 20 9 80-5/8 6-1/4 20 9 80-6/8 6-1/2 1C ft 78-5/8 8-3/8 16 8 78-5/8 B-3/8 16 3 7C-5/8 8-3/8 20 a 60-5/8 8-3/8 20 5 80- 5/8 8-3/8 16 8 78-5/fl 8-3/8 16 8 78-5/8 8-3/8 20 9 80-5/R 8-3/8 20 9 80-5/8 8-3/8 16 8 78-5/8 8-3/8 20 9 80-5/3 8-3/8 20 9 80-5/8 0 31-3/8 35-9/16 39-3/4 43-15/16 48-l/fi 35-9/16 39-3/4 43-15/16 48-1/8 39-3/4 43-15/16 48-1/8 L 27-1/8 31-1/4 35-3/8 39-1/2 43-5/6 47-3/4 62-3/4 71 79-1/4 87-1/2 95-3/4 106-5/8 119 131-3/8 143-3/4 158-3/4 175-1/4 191-3/4 >o. Of Burners 5 6 7 8 9 10 12 14 16 18 20 21 24 27 30 32 36 40 o. Of Drsftboods 1 1 1 ) 1 1 2 2 2 2 2 3 3 3 3 4 4 4 Ho. Of Flue Outlets 1 1 1 1 1 1 2 2 2 2 2 3 3 3 3 4 4 4 ASSEMBLY OF DRAFTHOOD 1. Assemble base, sections, platcv.ork, burners, manifold(s), jacket(s), and canopy(s) as instructed in the regular Installation Manual. Top jacket panel(s) must be in place before drafthood is connected. 2. Place drafthood firmly on the flue outlet collar of the canopy which projects above the jacket. a. 6 to. 11 section boilers-Draf thood can be pos .;.. >ned co direct the drafthood outlet to front, rear or either s, i ' _>I b-'.-iler. b. 13 to 41 section boilers-Draf thcori must be p.iionod with outlet directed to front or rear of boiler. 3. Install flue pipe connecting drafthood(s). to breeching or chimney. Flue pipe must have adequate support. Do not depend uptn drafthood to support flue pipe or breeching. 02328 G-60 gas boiler TAPPIN G S T A P P IN G S T A P P IN G S T A P P IN G S No O f B A C K N o.O F CNO return R E TU R N Q. 2Ll o ac oD $ h~ UJ -J tr OJ oi Ol OJ OJ OJ OJ OJ OJ OJ OJ OJ OJ OJ OJ 4V OJ OJ o o O o O o - - - - - OJ OJ OJ OJ '1E NNDo F LOOF W Oi a; OJ oj'oj oj 0J Ol OJ 00 00 OJ OJ OJ OJ OJ OJ OJ 1 r o o o ojo o - OJ OJ OJ OJ OF FLOW No TOP in IX 1 zn o t1 1 j r-|jo> o rgjj * p Ol o OJ OJ OJ OJ '' 1 !> o in j 1 1 ; ' ui in ojolojoiojo i!i1 l OJ OJ OJ OJ ! s 2-w 5 i: :;i .1 _!_L J_ 2m o wz OJ oj OJ ro OJ OJ OJ OJ OJ ft. ru OJ OJ OJ OJ OJ OJ OJ z 111 111 I! 1 1 0F -f o> e < 0 * a> 0 *F J? * * ! 1 1 1 1 1 "F $ d? O) * 0 PF r * 0n oOFl * f r* * c oaf * Jf r~ < * * (VI PF A? o> 0 F irf * pOPJ oo JP Ol r-' f** *n o> -oF ,3 * * . r aOJ JF IOTJ) 0O>J e rO fO O0-) OJ * isP O a g rr- 0 * a* PF >O 0 * p* JF a OJ OJ * j? rm~ 0- oa r O O<0 s|= s o<h o o 12 5 o r* 5 0> o tNOt OOJJ OJ OJ o o o o o 66 666666666 666 66 ! o 6 B O ILE R NUMBER | G -6 0 3 7 | 02329 DRAFT HOOD OUTLET DIM ENSIONS FOR 6 TO 41 SECTION BOILERS G-60 GAS BOILER izn o b uin coIm> I cn 2 O K ain ni in oZ tu-- iLnd o CD in O buin 00 tjib h 30 00 H2 Him O OJ mlo <n(v t"* OJ g 00 o)c -K* g CO -In H* Nm OJ o <0 33 37 00 -|N -|<M OJ H* in OJ CinD <0 OJ ro (O H" ro -|IM o OJ ! 0* OJ HlM co CO 01 i1--n L_dl CD OJ <o -|<M ro -|IM (O ms 0OJ jo OJ <o -)w -HM OJ -+* in OJ OJ 22 25 hDO n <*)[< IS <4 in ro CO o OJ OJ Qo o OJ IS <2 HIM o OJ Hit 0* OJ *)k n o> OJ OJ X uf-. O) -Km ro -!*M <o -Km rOJ Him O<D* c Oj c<e Q Him! Hfyl -1* -k 2!!2j8 <hT*> 8 cr 2- in Vi i CM -! 1 l<7 0- CO zin 2 CM =J' S3i i jm(c !<n OJ <o <0 o izn --flM - OJ <n o OJ 1 r- CO Id 2 o OJ B -JIM CO 1 CO <0 o o> HIM Him OJ OJ 1 -I'M o> ro 00 - r!S 1 - />to in 1 co - ts 2 1 1m a CO H2 O< 1. -w ro Hi P 1 -J* Ow k a. OJ 3 35--Ctu-j Ztu < CD U H o No Of SECTIONS INo OF FLUt OUTLETS 1 02330 G-60 GAS BOILER 5 CAUTION: This appliance should be installed in accordance with the latest A.S.A. instructions for "Installation of Gas Appliances and Gas Piping". Reference should also be made to gas company regulations and local building, plumbing or other codes in effect in the area in which the installation is made. On hot water systems, expansion tank should not be installed in cold or exposed place. If 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 Y/HILE THE BOILER IS IN OPERATION. MINIMUM CLEARANCE Between boiler, vent collector and any combustible material - 6 inches. Front or sides for servicing, cleaning or removal of controls, burners and circulator - 2h inches. Access passage at a side to another side requiring service or cleaning - 18 inches. In utility room installations, the door shall be wide enough to allow the largest part to enter or to permit the replacement of another appliance such as a water heater. LOCATION Locate the boiler near the chimney or flue and as centralized with respect to the heat distribution system as practicable. Provide necessary service accessibility clearance. 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. 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. (b) Opening to interior space, minimum free area of one (l) square inch per (1000) Btu per hour of input rating. (This method should always be used where practicable). (c) Openings to outdoors - minimum free area of 1 square inch per U000 Btu per hour of input rating, or in accordance with the methods outlined in the latest issue of A.S.A. Z21.30 entitled "Installation of Gas Appliances and Gas Piping". (This method should only be used where openings to interior spaces are impracticable). CHIMNEY 1. Flue or vent connection to chimney shall not be smaller than 12" diameter for 6-7-8 section boilers and for larger sizes not smaller than equivalent diameters shown in chart on Page U. 2. './here two or more appliances vent into a common flue, the area of the common flue should at least equal the area of the largest flue of vent connector plus $0 per cent of the areas of the additional flue or vent connectors. 3. Flue or vent connector must be inserted into but not beyond the inside of the chimney flue. It, Horizontal runs of flue pipe should be kept at a minimum and should be installed with a 1/lt" pitch per foot maintained. 02331 G-60 gas boiler 6 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 chilled medium from entering the heating boiler. 17hen hot water heating boilers are connected to heating coils located in air handling units, where 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. RECOMMENDED BOILER PIPING FOR F I G. I COMBINATION HEATING L COOLING UNITS FIG.2-BASE FOR TWO COMBUSTION CHAMBERS SHOWN 02332 G-60 GAS BOILER ASSEMBLY OF BASE Base for 13 through 21 Section Boilers, as shown on preceding page. - Only half of the assembly is required for 6 through 11 section boilers. For 6 through 11 section boilers - Bolt front and rear base frames to right and left hand base side panels with ribs inside. Word ''TOP" is cast on all base panels to indicate correct position. Be sure that corners of base are square, then level base with front in final position with regard to chimney. Attach two end section STOP BLOCKS on end of base from which assembly is started with 5/16" x 1-1/V' bolts, making nuts finger tight only and leaving block in horizontal position temporarily. For 13 through ill section boilers - Select intermediate spacers from boiler parts, two for 13 through 21 sections; four for 22 through 31 sections; and six for 33 through hi section boilers. Bolt two spacers between the flat sides of two side frame panels so that spacers are flush at the bottom. Assemble all spacers and side panels required for the boiler using 1/2" x 3" bolts provided. Assemble front and rear base frames to bolted side panel assemblies, then assemble a base side panel on each end. Draw bolts only moderately tight. Be sure that corners of base are square, then level base with front in final position with regard to chimney and draw all bolts up tight. See Fig. 2. NOTE: All reference to right or left parts refer to observer's right or left when facing front of boiler. ASSEMBIY OF SECTIONS 1. Select either right end section (less 1/2" gauge and trim tappings) or left end section (with 1/2" gauge and trim tappings) and place on base with flat outside face flush with outside of side panel (Cleanout opening to front of boiler). Support with wood prop. Turn stop block up to vertical position and tighten nuts. This operation is important io make sure DRaT-end section does not move off of the base during subsequent section assembly operations. See Fig. 3. 2. Clean nipples and nipple openings with kerosene or gasoline and apply a thin film of good lubricating oil. Do not use paint or red lead. 02333 0-60 GAS BOILER 8 ASSEMBLY OF SECTIONS 3. Drive nipples squarely into end section using block of wood and hammer or preferably an aluminum headed hammer, if available. Gauge nipples in both directions to insure that they are driven squarely and to proper depth in nipple openings; nipple setting gauge is provided for this purpose. Cutout in gauge should rest on both sides of nipple when legs of gauge are touching finished ribs on section. Most nipple leaks are caused by tilted or cocked nipples. See Figs, lj and 5. Fie. 3--Mounting End Section h. Paint ground bead around outside edges of section only with red lead. 5. Place center section on base with cleanout openings to front and engaging nipples in the end section. Drive sections together with heavy block of wood striking sections squarely as possible over nipple ports. Fic. 4--Gaging Nipple 6. For 6 through 11 Section Boilers - Insert one tie rod through each bolt hole above lower nipple ports and one tie rod through upper nipple port. Place assembling blocks on upper rod and assembling washers on lower rods as shown and place nuts and washers on all rods. See Fig. 6. For 13 through Ul Section Boilers - Use Assembling clamps with loose jaws against end section in place of block, nuts and washers. Place clamps on rods with flat side against section. Insert jaws in blocks with serrated end against rod and .draw up on rod from opposite end. Tap jaw lightly to tighten grip on rod. Do not permit jaws to clamp on threads. Place nuts and washers on other end. See Fig. 7. 02334 G-60 GAS BOILER 9 7. All Sizes - Draw up evenly on all tie rods starting with lower tie rods. Tighten nuts alternately and bump sections with heavy block of wood at nipple ports to facilitate assembly. Continue to draw up alternately until sections make contact at ground joints. Apply oil or grease freely to tie rod threads while assembling sections to prevent stripping of threads on rods. Paint ground rib of each section with red lead and continue assembling sections ONE AT A TIME until all center sections are assembled. 1. Assembling Block 2. Tie Rods 3. AnmMing Wtdter Fig. 6--Assembirng Sections 8. For 13 through ill Section Boilers - Continue to assemble sections until ready for intermediate (thick) section, then lengthen tie rods with couplings provided. Repeat this oper ation as each intermediate section is assembled. Soe Fig. 8. 9. Remove upper tie rod and assembling blocks. Remove nuts and washers from lower rods. In case of 13 through hi section, also remove clamps. Place remaining end section in position and insert tie rods through all tie rod holes In sections. Draw sections together as in previous operations until all ground joints are tight. Then back-off all tie rod nuts one half torn. Rods must not project beyond large bosses to avoid interference with jacket. Fic 7--Assembling Clamps Fic. 8--Assembling'Larger Boilers 02335 G-60 GAS BOILER 10 TESTING Before connecting boiler, plug openings, fill boiler with water and subject to not less than 10 lbs. nor more than 3>0 lbs. pressure. Inspect boiler inside and outside for leakage as a result of breakage from handling and shipping. To safeguard accuracy of gauge and controls supplied with boiler do not install until after test of the boiler. This precaution of testing the boiler will simplify handling of any necessary replacements or adjustments and assist in treating with claims against tranportation companies. After test, drain and remove plugs where required. ASSEMBLY OF PLATEITORK, MAIN BURNERS AND MANIFOLD 1. Putty outside of sections at joints with boiler putty. Assemble hook bolts to the cleanout cover plates with washers and nuts started on threads. Place the asbestos wick packing in the groove around each plate press ing it down so that it will adhere to the grooved surface. Assemble the plates to the boiler by placing the lower end of the plate in the recess about 3/U" above the bottom. The upper end of the plate should be held out an inch or more at the top. Push the hook bolt in as far as the nut will permit and turn the hook down. Push the plate down toward the lower end of the recess and at the same time engage the hook on the projecting lugs in the cleanout opening. Hold the plate firmly in the recess and tighten the nut on the hook bolt sufficiently to seal all around each plate. 2. Place burner support in position between lugs provided on inside of base frame side panels. See Fig. 9. 3. Attach manifold support brackets to front base frame with 3/8" cap screws provided. h. See that orifices in ends of orifice holders assembled in manifold are screwed in tight and that orifices are drilled to size specified on tag attached to manifold. Assemble l/li^-SO set screws to the manifold brackets and place manifold in position. Tighten set screws temporarily. 5. Assemble sheet metal locknuts and air shutters on the spud holders. The flatside of the locknuts and boss side of the air shutters should face the manifold. 02336 G-60 GAS BOILER 1] 6. Starting at either end of base, place each mixer tube firmly on its orifice holder and on the burner support. Place burners on mixer tubes. Ends of burners with two tapped holes for pilot brackets should face the front. See that burners are straight and level when assembly is complete. Tighten set screws in manifold brackets. See Fig. 10. 4' For 13 through 41 Section Boilers Couple manifolds at unions as required. See that orifice holders are in straight line before placing manifold assembly in the brackets and tightening the set screws. See Fig. 11. PILOT BURNERS Attach pilot burner assemblies to main burners. When one pilot burner with vent tube assembly is supplied, it should be attached to the third burner from the left end in all cases. If two pilot burner and vent tube assemblies are supplied, the second assembly should be attached to the second burner from the right end, except for six section boilers where it is attached to the first burner from the right end. See Figs. 12, 13, 14, 15, 16, 17, 18 and 19 for pilot installations covering all boiler assemblages for various types of gases. 1. Manifold 2. Manifold Support Bracket J. Canopy 4. Draft- hood Fic. 10--Earners. MmntfatcL Canopy And Draftnocxi Awcmbled Fic. 11--Kaniiold And Canopy Aaeembly--Larger Boilers FOR 100% SHUTOFF - One or two pilot burners with 24" thermoeoaples are, provided as required. One Pilot with 24" thermocouple must be attached to the second burner from the right hand end, except for the G-606 boiler in which case the pilot is attached to the first burner from the right hand end. Refer to Fig. 18, Page 16 for the position of the second pilot burner near to the centrally located pilot switch on G-6028 and larger boilers for Mixed Gas. FOR ELECTRIC IGNITION - Attach electric pilot burner Igniter assemblies to main burners. See Figures 14, 15 and 16. NOTE: - Pilots with electric igniters are to be located only where pilots with thermocouples are designated by symbols in Figures 15 and 16. 02337 G-60 GAS BOILER l; Fig. 12 - Burner Installation - Pilot Burner, Thermocouple and Vent Tube. Fig.. 13 - Burner Installation - Auxiliary (Stand-ByJ Pilot Burner. Fig. H - Burner Installation - Pilot Assembly for Electric Ignition. 02338 G-60 GAS BOILER 13 0(O 1 .. o ft C-O-* 0-0-' o> o <o c--o-* 0-0-* i=^ L. ~/L 0-0 iO F ig . 15 - B u rn e r, P ilo t and C o n tro l In s ta lla tio n fo r N a tu ra l Gas, Non-100% Shutoff o-o' >d aDooo5 CL w a 2 4X 2o w> Dj K 3 a 5 hQ $ vQ < a a o5 Ui ? <n o< @,o,o c .. 6 Ci CKH 02339 coemoo I Oo G-60 GAS BOILER 1' ^5- 0 (O1 o o-o-* 0 <10 ,o --cm o> o <0 -CM \ o> bo (O 6 3> b o (0 6 3' -CM 00 o <0 \ I -CM ' toi o CO > <o to O-CM -CM <o0 to t O -CM *h => (0i b -CM to OJ o (0 > I bo 04 OJ o do $> --Oi --CM CVJ o <0 b --Ov -CM --O--i 3' ro O <0 t b >-Oj --O-i oo OJ o to b* -CM -o, ro 0 (10 o (Hr O-On P ro no 0 to1 O > 2 D ID Ko -J UJ _J QD. ooO 2 C14L XK 0J. D OV o g5 XUJ H X5 3 UJ > >< UJ a> H 2 oa< XCL < a: o<cDOUcJ UtrJ V1DCca4Or) C<O CL 5 o <&#nO Cl 0 o 2 LLl b UJ Oz Od c^o-, ff O -I to- M< oz >" , tt W . ^z O2 OI O J9 P ^' t0o1 O 5 CO rHI B O Z o O C JS s U O nt *-* a 0 1 c T cP t 5 * c l I =3> O--O-J 02340 G-60 GAS BOILER <o 0 ID 1 o 1 W3C oo rVwt O aotPh Q> I 3<*- PQ oc ci PbH a 4- aCO IO* <eo** O o s0 .0) E 3 CP 1 to 4 U< 02341 o> C0CMO0 I oo CO G-606 G- 607 G-608 G-609 G-6010 G-60II n o(O 6 G-60 GAS BOILER 02342 F ig . 18 - B u rn e r, P ilo t and C ontrol In s ta lla tio n fo r M ixe d Gas, 100% Shutoff 16 i G-60 GAS BOILER O ID t O t<W>J 02343 .Fig. 19 - Burner, P ilo t and C ontrol Installation fo r N atural Gas - 100% Shutoff 17 G-60 gas boiler If ASSEMBLY OF JACKET, CONTROLS AND HIRING For 6 through 11 Section Boilers 1. Attach canopy hooks to front of canopy with four l/Un - 20 x 1/2" washer head screws. 2. Place canopy on the boiler with the canopy hooks engaging hook lugs cast in flueways on center sections and seal between outside of canopy and sections with boiler putty. See Fig. 20. 3. Assemble drafthood to canopy with four #10 x 1/2" sheet metal screws. h. Assemble the three pieces of the front liner panel with sheet metal screws. Remove necessary knockouts for controls either for steam or water boiler as required. Attach terminal block, instruction plate, number and series plate and Baso switches to the panels. In case of boilers equipped for electric ignition, attach the Baso igniter switches next to and to the right of the pilot switches. Attach the front liner panel assembly to the tapped bosses on the end sections and install controls. See Fig. 21 Controls for Steam Boilers are shown. Install control wiring to accord with wiring diagram supplied. See following page for pictorial views of wiring installations. .5 Assemble front half of left side jacket panel after removing knockouts for water column trim in case of STEAM BOILERS. 6. Assemble front half of right side jacket panel, 7. Assemble two front cross ties, center and bottom, then place back panel in position. See Fig. 22. 8. Assemble upper front jacket panel. IMPORTANT i The top flange must be inserted under top flange pf the side panels. 9 Assemble rear half of left side jacket panel ormethoo holding canopy TO BOILER Pic. 20--Installation Of Canopy 1. Front Liner with Cleanout Door 2. Steam Limit Control (Steam Boilers) or Immersion Operating Control (Water Boilers) 3. Low Water Cutoff 4. Terminal Block 5. Baso Automatic Pilot Switch Fie. 21--Front Liner And Controls Installed 1. Front Liner with Cleanout Door 2. Front Center Cross Tie 3. Left Hand Side Panel 4. Front Bottom Cross Tie 5. Right Hand Side Panel Fic. 22--Side Panels Installed 02344 TO THERMOSTAT OR OPERATING NCONTROL TO TRANSFORMER 1T?D - PXRFSSURE LIVI'I'"1 fONTRL pT1^ ALL WIRING EXCEPT WIRE TC THERMOSTAT TO BE U.L LABELED LOW VOLTAGE SAFETY CIRCUIT WIRE-I05*C TEMPERATURE RATING Pi ASS GAS PRESSURE/ REGULATOR . ^X TV L pilO^tcH ib: ft" " -.13 li AUTOMATIC' GAS VALVE \ it1 STEAM BOILEH ALL WIRING EXCEPT WIRE TO THERMOSTAT TO BE UL. LABELED LOW VOLTAGE SAFETY CIRCUIT WIRE-I05*C TEMPERATURE RATING -U 02345 G-60 GAS biui-iv 20 10. Assemble rear half of right side jacket, panel. See Fig. 23. 11. Assemble back panel to side panels. Assemble back filler pieces, one on each side of drafthood. 12. Assemble top panel. FOR 13 through ill SECTION BOILERS 1. Attach canopy hooks to front of canopies with four l/Ii" - 20 x 1/2" washer head screws. 2. Place canopies on the boiler with the canopy hooks engaging hook lugs cast in flueways on center sections and seal between outside of canopies and sections with boiler putty. 3. Assemble the three pieces of the fronr t' liner panels with sheet metal screws. Remove necessary knockouts for controls either Fie 23--Assembling Jacket And Controls for steam or water boiler as required. Attach terminal block, instruction plate, number and series plate ana Baso pilot switches to panels. Also attach Baso Igniter switches next '-f Raso Pilot switches in case of boiler equipped for electric ignition. h. Attach the front liner panel assemblies to the t;.pve : and end sections. Liner with terminal block ar.d irs'" i at the left side of the boiler. Install controls. 1 boiler are shown). ' r. the intermediate ' ' - is installed nirois for Steam 5. Assemble front spacer (or spacers) to intermediate section (or sections) against front liners. Offset ends of spacer should be at top. Use 1/Li" - 20 x 1/2" washer head screws. See Fig. 2Lu 6. Assemble back spacer (or spacers) to rear side of intermediate section (or sections). 7. Assemble front and back (narrow) panels to inter mediate panel spacers with 1/Li" - 20 x 1/2" washer head screws. 1. Front Liner vrtth Cleanout Door 2. Front Spacer for Intermediate Section 3. Baso Automatic Pilot Switch 4. Terminal Block 5. Low Water Cutoff $. Steam Limit Control (Steam Boilers) or Immersion Operating Control (Water Blrs) Fic. 24--Starting Jacket Assembly--Larger Boilers 02346 G-GO GAS BOILER REVISED JACKET SPACERS FOR INTERMEDIATE SECTIONS 20A 4-1-4 4! 4 FRONT SPACER-LOWER Part No. 23198 ~T --I<si -ti 6A j REAR SPACER Part No. 23194, Upper & Lower Separate upper and lower spacer brackets replace the box type intermediate section spacer shown on page 20, Fig. 24. Spacers are to be attached with 1/4"-20 x 1/2" washer head screws same as directed for assembling the box type spacers. 02347 G-60 GAS BOILER 21 e. Assemble top (narrow) panels to front and back intermediate panels with #10 x lw sheet metal screws. 9. .10 .11 .12 Assemble front half of left side jacket panels after removing knockouts for water column trim in case of STEAM BOILERS. Assemble front half of right side jacket panel. Assemble front cross ties, center and bottom. See Fig. 25. Install control wiring to accord with wiring diagram supplied. See also Page 19 for pictorial views of wiring installation. Assemble upper front jacket panels. IM PORTANT i The top flange must be inserted irnder top flange of the side panels. See Fig. 25. t. Left Hand Side Panel 2. Upper Front Panel 3. Intermediate Section Front Panel A. Right Hand Side Panel 5. Front Center Cross Tie 6. Front Bottom Cross Tie 7. Pilot Tube 8. Vent Tube 9. Automatic Gas Valve 10. Gas Pressure Regulator Pic. 25--Assembling Jacket And Controls Larger Boilers 13. Assemble rear half of left side jacket panel also rear half of right side jacket panel. Hi. Assemble back panels to narrow back panels and side panels. Assemble back filler pieces one at each upper corner of jacket. 15. Assemble drafthood to canopies with four #10 x 1/2" sheet metal screws. See Fig. 26. 16. Assemble top panels. ASSEMBLY OF MANIFOLD PIPING AND PILOT TUBING Fjc. Zt--Jacket Assembly--Rear View 1. For 6 through 11 Section Boilers - Hold manifold securely with wrench and assemble elbow, then assemble nipple with seat half of union so that they are level and face to back of boiler. Also assemble a nipple with remaining half of union in automatic gas valve. 2. Make up drip leg piping (not supplied by AR & SS Corp.) of suitable height and install the manual shutoff valve assembly. See Figs. 27 and 28. "P J' J I 3. Make suitable connection between the tee in drip leg piping and the gas pressure regulator. Be sure to leave sufficient space between pipe cap on bottom of drip leg and floor to allow for drip removal. NOTE: See Instructions at back of Manual, if boiler is provided with Dual gas equipment. Fig. 27--Assembled Steam Boiler 02348 - "IF 4. Connect the piping am -v . the manifold piping at the unit.-., u,: block imder drip leg to insure inn ir.ot.iILiuc:: is square and level. 5. For Boiler with NON-100*; Shutn;"., M and ELECTRIC Ignition connect pi?ot l-;--manual shutoff valve assembly to the left pilot burne: tube running the tubing through the r...mi:old epv.uing in the jacket. Inter-connect p;int vine to the rerunning pilot burners. Tubing is to be installed above orifice holders. 6. For Boiler with it- . Vag 11 for installation of pilot burners, .Itt-ic'. the rviir.t switch at the R.H. side of the Front Li;.- : Panel vclth two #10 x 1/2" sheet metal screws. For boilers witn more than one combustion chamber, locate the pilot switch to serve the pilot nearest to the right end of the entire boiler. Two switches are provide--; for .j-tlou- Tfr boilers for Mixed Gas. See Fig. IB for location of pilot switches on these boilers. 22 Connect pilot line ir -m me jautef: vuiva nearest to the L.H. end of ihr bo:lor m-miar dr: ta. jacket. Tubing is to m; awvuiuivV u-noerr In case of G-6028 and * arc. o'" boiler.' tor Mixeo Gan manual shutoff valve asser-hl; -t m.-= bon., valve near the center of tne I: Per. .bee Fig is. The pilot line (or lines) should he assembled for the lengths shown in Fig. 17. 18 and .8 "i-i'.hrvis applicable VALVES ARE ASSEMBLED SO TJIaT j OF. PLY laLO "IN". t.tA. ccordd.u to the coded . TV.' :.L PILOT 'Hr. v i\ i A r MA PKED The pilot line i set.1''-: >. - . *. . F. provided. On G-609 and mr-PV- >-r- *-, *> . J `....vp. l, up (or dumps) ' - ' . ; - * coupling at the pilot valve. Refer to Pigs. 17, io arid ly for approximate location of clamp (or clamps). Pilot line connecting tubing should be installed above the main bu. ner o> nice holders if not supported by clamp (or Oa'^pm. Connect the pilot supply tub*; iron: each pilot burner tu us respect* .* puot valve. Make connectio- f*-....... . * r r tr.- rv'ttn-- : marked "OUT" to the Jas-. ';).>! hn*>-- Hv the pilot 'in'' < Connect the last pi!o< '/'d'..............' - iVt 1 r.e- (o* V bottom of the pilot swiloh (r with i -i" O.L. tv bins.. ` ' ,L , v.L itches i /4" O, D T>tg. ..... udet fitting on Inc CAUTION: - Before any system of gas piping is finally put into service, it shall be carefully tested to assure that it is gat; total Soap and wv-t -a ' other materia! acceptcb!'" v - u 02349 G-60 GAS BOILER DIRECTION OF GAS FLOW^ i| ______ ) __L_ DIRECTION OF GAS FLOW ;' 6 r 7 (C 1. --1 --- < n)!l gr6 ie 9 1 3" SHUTOFF VALVE 2 3" SPECIAL' NIPPLE 3 PILOT SUPPLY TAPPING A. FILTER- S PILOT PIPING ASSEMBLY 5 PILOT COCK ' 5/16" OR l/A" TUBING CONNECTOR NOTE: - FILTER FURNISHED ON SPECIAL ORDER ONLY 2 FIG. B A 3" MAIN GAS LINE SHUTOFF VALVES AND PILOT SUPPLY LINE CONNECTIONS FOR LARGER BOILERS. BOILER SIZES AFFECTED 28, 31, 33, 37 and 41 Section 17, 19, 21, 22, 25 31, 33, 37 and 41 REFERENCE IN MANUAL PAGE FIG. 13 15 17 19 14 16 16 18 GASES Natural Gas, Non-100% Shutoff. Natural Gas, 100% Shutoff. Mixed, Non-100% Shutoff. Mixed, 100% Shutoff. B 28, 31, 33, 37 and 15 17 Butane and Propane, 100% Shutoff. 41 Section NOTE: - All of the above section assemblages have one 3" shutoff valve installed at the L. H. Bide of the boiler, EXCEPT for 31, 33, 37 and 41 Section boilers for Mixed Gas. These have two 3" shutoff valves, one at L.H. side and one at R.H. side of boiler. 7. Remove vent fitting from regulator (not used for L. P. gas) and see that flame check is in place,. See Fig. 30. Replace vent fitting and install tube between pressure regulator and gas valve, using tee connector, also between tee connector and vent tube connector inside of the boiler jacket. See Fig. 23. Fig. 30--Flame Check 02350 G-60 GAS BOILER 24 8. For 100% shutoff connect the thermocouple lead (or leads, attached to pilot burners) each to its respective pilot valve . Also connect the thermocouple lead of the last pilot burner (s) to the switch (or switches) located on the front liner panel. For Non-100% shutoff installation thermocouple leads attach to Baso Pilot switch (or switches). For assembly of manifold piping and pilot tubing, refer to Figs. 12, 13, 14, 15, 16, 17, 18 and 19 whichever is applicable. For 13 through 37 Section Boilers - Follow instructions as directed for 6 through 11 section boilers as piping arrangement and controls, except for size, are essentially the same where gas supply to manifold is on the left side. 1. Manual Shutoff Valve 2. Pilot Cock 3. Pilot Line 4. Gas Pressure Regulator 5. Vent Line 6. Pilot Burner 7. Baao AuteaMttc PUot Switch 8. Reset Button 9. Thermocouple 10. Automatic Gas Valve 1L. Manual Control Lever Fig. 31 - Controls-Manual Ignition- 31 8nrtfc**JIiJ(edGas__ i 28 SECTION AND LARGER BOILERS FOR MIXED GAS - the gas supply to the manifolds is from both right and left sides. For Non-100% shutoff piping and control arrangement, See Fig. 31. For 100% shutoff piping and control arrange ment, See Fig. 32. Pilot tubing hookup to the pilot burners for 28 section and larger boilers is assembled from each side of the boiler. Pilot tubing hookup for all other boiler sizes is assembled from the left side. See Fig. 33 for piping arrangement of 19 section and Fig. 33A for 21 through 25 section boilers. 1. Manual Shutoff Valve 7. Thermocouple 2. PilotCock 6. Baso Safety Pilot Switch 3. Pilot Line 9. Plunger Button 4. Gas Pressure Regulator 10. Automatic Pilot Valve ft. Vent Line 11. Automatic Gas Valve ft. Pilot Burner 12. Manual Control Lever Fig. 32 - Controls-Manual Ignition 100% Shutoff, 31 Section, Mixed Gas FIG. 33 02351 G-60 GAS BOILER 24A TO VENT CONNECTING COUPLING FIG. 33C FIG. 33B 6 thru 33 Section Natural, And 6 thru 17 Section, Mixed Gas FIG. 33C 6 thru 33 Section Butane & Propane Gases FIG. 33D 28, 31 & 33 Section Mixed ( FIG. 33E 37 SECTION MIXED GAS 02352 G--60 GAS BOILER 24B Piping Arrangement for 37 & 41 Sectic Natural, Butane & Propane Gases Description Of Parts Natural Butane Propane (1) 3" Manifold 1 Req'd. (2) 3" Elbow 3" (3) 3" x 3" Nipple 11 " (4) 3" Union 3" (5) 3" Gas Valve 2 " (6) 3" Tee 2" (7) 3" Regulator 1 M 1 Req'd 3" 10 " 3" 2" 2" 0" FIG. 33F JL 41 Section Mixed Gas (1) 3" Manifold (2) 3" Elbow (3) 3" x 3" Nipple (4) 3" Union (5) 3" Tee (6) 3" Gas Valve (7) 3" x 20" Nipple (8) 3" Regulator (9) 3" x 4" Nipple FIG. 33G 02353 G-60 GAS BOILER 21 ALL BOILERS Install drain cock in each end section. Assemble front jacket panel cleanout doors and burner access doors. CAUTION Steam boiler safety valve or water boiler relief valve must be installed in tapping equal to or larger than the inlet pipe size of the valve. STEAM BOILERS Install steam gauge and water col umn trimings in left end section. Install safety valve piping and safety valve in right end section. Bushing is provided on 15 thru hi section boilers for installing safety valve in upper 6" tapping on right end. Plug all unused tappings. Fig. 3h shows front view of complete steam boiler (8 sections). Fig. 35 shows rear view of complete steam boiler (8 sections). Fig. 36 shows front view of complete steam boiler (22 sections). Fig. 37 shows rear view of complete steam boiler (22 sections). Fic. 36--22 Section Steam Boiler Flu. 37--22 Section Steam Boiler --Front View --Rear View WATER BOILERS Install combination altitude gauge and thermometer in left end section. Install relief valve in 1-1/2" tapping near top of R.H. end section for all except hi section boiler in which case the valve is to be installed in 6" tapping with bushing. Fig. 33 shows front view of complete water FILLING SYSTEM boiler (8 sections). 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 approximately,3-l/h" in the gauge glass. Fill open hot water system to 1/3 height of expansion tank, remove rim and glass from gauge and set movable pointer under automatic pointer. Replace rim and glass. Fic. 3o--8 Section Water Boiler-- Front View 02354 G-60 GAS BOILER 26 Fill closed hot water systems until relief valve opens. This should be at a pressure not greater than 50 Lbs. per square inch. Remove the rim and glass from the gauge and set the movable pointer at a point which will represent an altitude slightly higher than the highest point in the heating system. (An altitude approximately 115 feet represents a pressure of 50 Lbs. per sq. inch). Note that the altitude temperature gauge is calibrated both in feet of altitude and lbs per square inch. Replace rim and glass and reduce pressure by draining out water until the indicating pointer lines up with the movable pointer. See also Page 32. Keep system filled. Pointers on gauge should be even. If pressure exceeds 50 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 over top of burner. Pilot rate can be adjusted with screw underneath cap on pilot throttling cock. NORliAL PILOT INPUT FOR BASO PILOT BURNERS Nat._________ Mixed Input per Pilot Burner 3tu/Hr. 1400 1200 L.P. 1000 MANIFOLD PRESSURE ADJUSTMENT FOR MAIN BURNER INPUT After boiler is warmed up, shut off all other gas appliances connected to gas meter and time gas consumption. Adjust pressure regulator to give rated input indicated on nameplate. Input Rating (3tu Per Hr.) Gas Consumption (Cubic Feet 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. A 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. 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. 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 burner orifice. 02355 G-60 GAS BOILER 26A MAIN BURNER AIR ADJUSTMENT Drill 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 air), then close until the flame returns to the burner. There should be no yellow in the flame. (Orange appearance is caused by lint and dust particles in air and does not affect normal performance.) Ribbon burners - L-P gas L-P 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). WRONG WRONG RIGHT Ribbon burners - Natural and mixed gases. 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. For mixed gas, the setting is usually 1/2 to 3/^ open. 02356 G-60 gas boiler 2' CHECKUP OF LOW WATER CUTOFF 1. Light pilot as indicated in Operating Instructions. Turn thermostat to highest temperature. Automatic gas valve should open. 2. Open drain cock and drain water until water level is below centerline of low water cutoff. Automatic gas valve should close. 3. Refill until water level is above centerline of low water cutoff. Automatic gas valve should open. OPERATING INSTRUCTIONS FOR SHUTTING OFF AND RELIGHTING MANUAL IGNITION - NON-IOC# SHUTOFF TO SHUT OFF: 1. Close Manual shutoff valve(s) ''l" and pilot valve(s) ,,2". TO LIGHT: 1. Set thermostat (or operating control) at lowest temperature. 2. Be sure Manual shutoff valve(s) "l" and pilot valve(s) n2f' have been shut off for at least five minutes before proceeding. 3. Open pilot valve(s) *2n and light all pilot burners. ii. Wait two minutes. 5. Press reset button(s) on all automatic pilot switches. 6. Open Manual shutoff valve(s) wl". 7. Set thermostat (or operating control) at desired temperature. t. Manual Shutoff Vah* C. Base Automatic Pitot SwKdi 2. Pilot Cock 7. Reset Button X Pitot Line 4. Gas Pressure Regulator 8. Thermocouple 8. Pilot Burner &. Vent Line 10. Automatic Gas Vatot 11. Manual Control Lever 1. Manual Shutoff Valve 2. Pilot Cock 3. Pilot Line 4. & 5. Pilot Burners 6. Baso Safety Pilot Switch 7. Plunger Button 8. Thermocouple 9. Automatic Pilot Valve 10. Vent lne 11. Automatic Gas Valve 12. Manual Control Lever Fig. 40--Controls--Manual Ignition---100% . Shutoff--Butane and Propane Gmn 02357 G-60 GAS BOILER 21 SHUTTING OFF AND RELIGHTING MANUAL IGNITION - 100* SHUTOFF See Fig. hi TO SHUT OFF: 1. Close manual shutoff valve nln and pilot valve n2n. 2. Turn off switch in electric line to appliance. TO LIGHT: 1. Set thermostat to lowest temperature. 2. Be sure manual shutoff valve "1" and pilot valve "2n have been shut off for at least five minutes before proceeding. 3. Open pilot valve "2n. h. Press plunger on Baso automatic pilot valve M9" and light pilot "h". Hold plunger for one minute. For addition al valves repeat. 5. Press plunger "7" on Baso automatic pilot switch "6" and light pilot n5". Hold plunger "7" for one minute. 6. Open manual shutoff valve "1". 7. Turn on switch in electric line to appliance 1. Manual Shutoff Valve 2. Pilot Cock 3. Pilot Line 4. & 5. Pilot Burners 6. Baso Safety Pilot Switch 7. Plunger Button 8. Thermocouple 9. Automatic Pilot Valve 10. Vent Line 11. Automatic Gas Valve 12. Manual Control Lever 13. Gas Pressure Regulator Fic. 41--Controls--Manual Ignition--100% Shutoff 8. Set thermostat to desired temperature. SHUTTING OFF AND RELIGHTING ELECTRIC IGNITION - N0N-100* SHUTOFF See Fig. h2 TO SHUT OFF: 1. Close manual shutoff valve "A" and pilot valve "B" 2. Turn off switch in electric line to appliance. TO LIGHT: 1. Set thermostat (or operating control) to lowest temperature. 2. Be sure manual shutoff valve "A" and pilot valve "B" have been shut off for at least five minutes before proceeding. 3. Turn on switch in electric line to appliance. h. Open pilot valve nB". 5. Press red electric igniter button "C" until pilot burner lights. 6. Press plunger "Dn on Baso automatic pilot switch. (For additional combustion chambers, repeat steps 5 and 6). 7 Open manual shutoff valve nAn. 8 Light main burners by setting thermostat (or operating control) to highest temperature. Y.rait for approximately 30 seconds, then return to lowest setting. Be sure that all auxiliary pilots have lit. MAIN GAS LINE c <> 9. Set thermostat (or operating control) to desired temperature. Fic. 42--Electric Ignition 02358 G-f.0 GA3 anTIER 29 PILOT GOES OUT If the pilot flame is extinguisher!, tn<- automatic pi'Loi will shut off the automatic gas valve. If boiler is not operating correctly, call Heatirr Contractor or Gas Company service man. If boiler is operati.y; sc;: ectly, relight as directed on pages 27 and 28. EMERGENCY INSYP.UCTICNo FOR OPERATION DURING FAILURE OF ELECTRIC P0VfIE SUPPLY In the event of failure of electric power supply tre gas burner operating this boiler will automatically snub oil. It is r.rcsiule to operate thus burner manually by following the directions given below. CAUTION - The BURNER SHOULD BE OPERATED MANUALLY ONLY AS AN EMERGENCY MEASURE. THE AUTOMATIC SAFETY CONTROLS Lnir.-: K.'CTEC* T"." ROLLER DURING NORMAL OPERATION ARE MOT OPERATIVE. CONSTANT SUPER ISION 7" ' FRET- "'0 -REYFIT THE POSSIBILITY OF DAMAGE TO THE BOILER BECAUSE OF LOT _;.J. MUZ?. LEAVE THE BURNER OPERATING MANUALLY IF IT IS TO BE UNSUPERVISED FOR ANY LENGTH OF TEE. IN SUPPLYING THESE BRIEF DIRECTIONS FOR MANUAL OPEI.ATJCN OF TiiF. BURNER, THE MANUFACTURER CAN ASSUME NC RESPONSIBILITY FOR THE SAFE OPERATION OF THE EURNER, BOILER AND OTHER EQUIPMENT. SAFETY DEPENDS UPON THE CARE AND JUDGMENT EXERCISED BY THE OPERATOR. ALL POSSIBILITIES CANNOT 3E COVERED IN THESE BRIEF DIRECTIONS. BASIC STEPS IV. MANUAL CFZRAT.ON 1. Be sure the burner pilot re burn.nr properly. If **-. 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 instruction? n-4 "tei-* on the valve -over, Iu If the boiler operated by tre gar 'urr.er :s installed or. a forced circulation hot water heating system (incorporating --lmetric circulating pump) OPEN FLQYf CONTROL VALVE OR VALVES IF PR' VIDEO . V ' "mET LMDO. Note: - It is suggested that the original position of these valves cars fully :v served ar.d these observations recorded, to permit restorer.- thesp v-lves to their criminal position when auto matic operation is resumed). Also, REDUCE THE MAIN Ul'SJEri FLAX: TC A MINIMUM A jJUGTMEf'T (Approximately 1/3 or 1/h normal size) BY' PARTIALLY CLOSING TriE MANUAL GAS SiiUT OF?' VALVE. TO RESTORE SLTJ'EP TO AUTOMATIC OPERATION UPON RESUMPTION OF OUFFLY OF ELECTRIC CURRENT 1. Return automatic gas control valve sc its original "automatic'' setting in accordance with instructions or valve ''over. 2. Turn on electric power supply switch. 3. On forced circulation v.atar ..ng ayetens, return flow control valves, if pro vided, to their normal operating positions. h. Turn manual gas shut off. valve to its wide open position. MINIMUM RECOMMENDATIONS FOR SYSTEM PIPING Figs. U3 and kii illustrate minimum recommended system piping arrangements for both water.an steam boilers. .These suggestions ar tr> be regarded as the minimum size and number of connections for satisfactory boiler :..,er. sis;,. The return connections to steam boilers should always be connected through a Hartford Loop which will include a properly sized equalizing connection between she steam supply and the Hartford Return. For the G-60 Boiler this connection should be a minimum cf 3" pipe. 02359 G-60 gas boiler GS-606-- 4 RISER GS-607-- 4" RISER GS-608---- 5" RISER GS-609-- 5" RISER GS- 6010-- 5" RISER GS-60II -- 5' RISER GS-6013-- 6" RISER GS-6015-- 6" RISER 3C GS-606 TO GS-60II {------------ ^------------ X \ 1n I \ GS-6033 -- 6 RISERS GS-6037--6'RISERS GS-6041 --6' RISERS GS-6033 TO GS-6041 GS-6033--6* RISERS GS-6037-- 6 RISERS GS-6041 -- 6 RISERS ALL BOILERS SHOW FRONT VIEW Fig. 1*3 - Minimum Piping Recommendations - Steam Boilers 02360 V*J G-60 GAS BOILER GW-606 --2'/2; RISER GW-607-2^2 RISER GW-608-3" RISER GW- 609--3* RISER GW-6010-4" RISER GW-60II-4' RISER GW-6013--4* RISER GW-6015--4 RISER GW-6017--5 RISER GW-6019--5" RISER GW-6021-- 5 RISER \ GW-6022GW-6025' GW- 6028GW-6031 - 5" GW-6022GW-6025- GW-606 TO GW-6011 Y GW-6013 TO GW-6021 GW-6033 -- 51 RISERS GW-6037-- 5^ RISERS GW-6041 -- 5'RISERS GW-6033-- 5* RISERS GW-6037-- 5* RISERS GW-6041 -- 5* RISERS Fig. Uh - Minimum Piping Recommendations - Water Boilers 02361 G-60 gas boiler 32 MAINTENANCE GENERAL IT IS IMPORTANT THAT THIS BOILER BE INSPECTED ONCE A YEAR BY A COMPETENT SERVICEMAN TO INSURE CONTINUED RELIABLE, SAFE OPERATION. This inspection should include checking of all boiler safety controls, pilot(s), section flueways and burners. See next page for instructions on burner and section Inspection and cleaning. 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 in this manual. MAINTENANCE OF BOILER WHILE IN OPERATION Check water level regularly and add water slowly when needed. This boiler is fired automatically. 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 cocks located at lowest point in system. Be sure boiler is completely drained. IN SUMMER WHILE NOT IN OPERATION Keep the system filled as during the heating season. This is the recommended time to have a periodic check up of all safety controls and a close inspection of the burners, flue passageways, and flue pipe. It is also good practice to recheck the input firing rate and the gas air mixture on the burners to see that the boiler is operating at normal efficiency. GENERAL MAINTENANCE OF HEATING SYSTEM Keep radiators and convectors clean. 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. Fill steam boilers and hot water systems only as directed in this manual. See Caution note. 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. 02362 G-60 GAS BOILER 33 CAUTION: On hot water systems, the expansion tank snould not be set ir. a cold or an exposed place. If the pipe leading to or from tne tank freezes, serious damage may result. If valve of any description is installed in tne piping leading to or from trie expansion tank BE SURE THAT IT IS OPEN WHILE THE BOILER IS IN OPERATION. INSPECTION AND CLEANING OF BOILER BURNERS AND FLUEWAYS To assure maximum efficiency and safe operation, burners and boiler flues should be inspected once a year and cleaned, if necessary. Inspection Procedure: 1. Turn manual shutoff valve (s) and pilot shutoff valve (s)to off positions. 2. Remove lower front panel (s). 3. Lift burners off mixer tuoe and remove. (On large boilers it is not necessary to remove all burners; only a sufficient number to determine the degree of cleanliness.) 4. Remove mixer tube by lifting and sliding back to clear tne spuds. 5. Check burner gas ports for lint and dirt. 6. Section cleanliness can be checked with a mirror and light inserted in the opening where the burners and mixer tubes have been removed. BURNER CLEANING: 1. Drilled Port Burner - Pass a #36 or #37 drill through ports and then shake the dislodged foreign material out. 2. Ribbon Burners - Remove end and center ribbon clamps and then the ribbon assembly from the burner head. Ribbons are riveted at one end to insure proper assembly. "Fan" ribbons and clean with a brush. Reassemble to burner head. SECTION CLEANING: 1. Important - Make sure all burners and mixer tubes have been removed from boiler. 2. Remove upper front access door (s). ).3. Remove cleanout access door (s) from the front liner (see Figure 22 4. Remove cleanout cover plates (see Figure 9). 5. Clean sections with a wire flue brush starting at the top and working down one row at a time. 6. Replace cleanout cover plate and seal where necessary. 7. Reassemble all other parts including burners and light pilots. 8. Check burner air adjustment as directed in this manual. 02363 G-60 gas boiler 31 CLEANING BOILERS The grease used tc aubriaate the cutting tools during erection of new piring systems serves as a carrier- for cirt, with the result that ;i scum of fine particles and grease accumulates on the surface of the water in all new boilers, while heavier particles may settle to the rcttom of the boiler and form slinige. These impurities tend to cause foaming, preventing the generation of steam .'md causing an unsteady water line. This unavoidable arrumulaoion of oil and grease shr,uid be removed by blowing off the boiler as follows: If not already presided, install a surface flow connection of at least 1-1/1 inch nominal pipe size with outlet extended to within If; inches of the floor or to sewer, inserting a valve in line close to boiler, Bring water line to center of outlet, raise steam pressure, and while burners are operating open valve in blow-off line. Tfhen pressure recenes, close valve and repeat process, adding waaer at intervals to maintain proper level. As a final operation bring the pressure in the bealer to about 10 Lbs., close blow-off and manual, valves, then open drain valve. After boil-- has cooled, partly fill and flush out seveval times before filling it to proper water level for normal service. The use of soda or any alkali, vinegar or any acid is not recommended for cleaning heating boilers because of the difficulty of complete removal and the possibility of subsequent injury after the cleaning process has been completed. Suggested Piping Arrangement for Blowing-Off Steam Bailer CAUTION After the blow off operation, a checkup should be ~,,;de 0f the Low V.'ater Cutoff as directed on Page Z~. NOTE: All parts af this boiler have been carefu_.^ inspected and packed. See Packing and Parts Least sheet for details. In case of shortage, make sure that all parts have -,oen removed from shirping container and examine packan;g material thoroughly. If par*, cannot be found, report shortage to your dealer, ga ing boiler size, series number; -;ate, inspector's number and packer's number. (Refer tc Packing and Parts List) GIVE BOILER SIZE AND SERIES ''/.lye V/HEN ORDERING REPAIR PART'. i.: her size........................................... ZLPJES NO. (See Series Plate on V.;ier). . Z^TE. . . .(pn.pqdfiijg.aijd.pfin:.. ,3^). . , 02364