Document VJpKwwjd53ewQmrdQNxZp0MBN

t n -1 u 0.I35&I70 r* a c by i , sr ^ AlMEKICM-#t&teSM Ctt GJ ^" PLAINTIFF'S EXHIBIT ! Installation-Operation AND Maintenance Manual 1 FOR PACKAGED GAS HEATING UNITS APPROVED BY'aMERICAN GAS ASSOCIATION NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET MUST 8E AFFIXED ON OR ADJACENT TO THE HEATING EQUIPMENT rs$ in heaCEeag f 5 r s I r p i w rs b S b Fi EP-7S54 Rev. 1-66 !; C 18824 To the homeovrner: The American-Standard boiler which has been installed for you is the heart of your hyaronic 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, ar.d ncderr. 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--i.e., 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. 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 the "yellow pages" of your telephone directory. AMERICAN-STANDARD 18825 GPH GAS BOILER 18826 GPU - 100 THRU GPH - 170 GF5 GAb BOLUSK /a.: The CBn Gos Boiler 1c shipped la two packages - the teesmbled boiler, r.r. r.nf~.hco:\. The boiler unit Id shipped in three cites, tbs GFH-100, GrH-135 end GT.i-170. IKST.tLLATION This appliance should be installed in accordance with the latest American EtAUdr.rdo Association Interactions, ''Installation of Gas Appliances and Gas Piping," Referercshould also be cude to gas ccnptny regulations and local building, plucbing, or other ccdee that ere in effect. ' Should ..any conflict exist between the A.S.A, er ccdr instructions end the following suggestions, the forcer must take precedence. location Careful consideration cust be given to the location of the boiler in relation to i_ny combustible nateric.1 and to any obstacle which night interfere with mintermco. Thi boiler hs.3 been approved for less than standard clearance as indicated on Fi-urc 2\ Mininuc clearances are censured free the boiler Jacket; however, practical service clearance nust be neacured with external cexponents in nlnd (See Figure l) unites those parts are to be separated from the unit. ACCESSIBILITY CISARANCES rfJSj TA2C PHECEEENCE OVER FIRE PROTECTION CLEARANCES. NOTE: C" clearance on left cide of boiler should be extended to 24" for access to controls if left closet panel is not removable. closet outline Provisions cuet be cade f:r combustion air where r-crr^.l infiltration is not edecu-ts (Full Easenents would normally provide adecue-:.- vantilation); either -f .u; methods ssey be eaplep: incure proper circuit :.: l . Two (2) opr-nir-'v .. near the floor and cr* :c\r r:-' ceiling -- to interior with nomal inf iltru:. e&ch with a nininun : r:- - ;. r:- c? one cqunre inch per LI TO ' r per hour of the irpu'. but with a minimus of ILL square inchee, b. An opening to tir, ._c:r with a cicinua f re-z c.r, c. . square inch per 1*CC0 ~ hour of the input rut:'.:-; , uihiuuu clearance tor CLOtCT I ti STALL AT I OH FIG. 2 NOTE: " cIccxetos required fre-- EterrsGt oomhnctiblc cra.-'ruziiur to barir-cniul run cd zluc pipe. 18827 c a ju 100 T u u u t i i 'ii - 170 JLtoiu:iLS GPH GAS EOiIiR UN PA CKIXCi BO 1 i iL U Loeau* the .. v. 11 -: . fm..l installation _U lure rv moving ib crate. Unpacking should oc accomplished us follows: 1. UnfiSm/i all crciL'ig wire at the corner of the craw. 2. Remove naiis fastening cr'ate sides to top and bottom of crate. 3. Lift oil crate top and unwrap craU c;C.~from crate base. 4. Remove the plastic bag, also box containing accessories. 5. Remove four hex head bolts securing boiler to the crate base. 6. Remo'-e boiler from base. Lifting and handling of the boiler into its final location may be made easier with a convenient length of pipe screwed into the flow tapping on the upper right-hand side. COXPs EC TICKS A drip leg piping arrangement should be Installed between the main gas line and the boiler, as shown in Fig. 3. It is essential that a ground joint union be installed between a tee in the drip leg and the connection at the boiler gas valve. CAUTION -- Before the gas piping system is put into sendee, it must be carefully tasted to insure a gas-tight arrangement; a soap .and water solution, or other accept able material, should be used in testing for leaks. 3 - PILOT FlLTf.R FOR USE WITH MAN'JFAC Tnnr 0 GAS AMD WITH NATURAL GAS WMRr REQUIRED Dy TmL LOCAL UTILITY ______pilot SMUTorr internal FLAME ADJUST ml NT TO PILOT OR GAS VALVE Recommended piping when Aux, manual shutoff valve or separate manual shutoff valve and automatic gas valve are supplied. Flu. 3 18828 G?;i GAS BOILER GPII - 100 .THRU GPH - 170 PIPE DELIVERY SCHEDULE Capacity of Pipes in Cubic Feet of Gas Per Hour Length of Pipe n Feet 3/4" Pipe Size 1" 1-1/ 10 212 425 725 20 150 - 300 510 30 122 252 425 40 105 21o 370 50 95 195 330 75 100 77 loO 270 66 13a 232 The supply to the heating system nvuBt be connected to the boiler at the upper right-hand Bide or top (see Page 9 for recommended hook-ups). The water return is connected to the circulator on the lower left-hand side. Installation of a conventional-type expansion tank is recommended since the GPH boiler Includes the "Elimlnaire Principle" which directs air, released by the heating of water, out the top of tne boiler. No air removing or separating device need be added to the r.satlng system because the released air is directed Into the expansion tank. Tne expansion tank must be installed with its connecting opening aligned vertically with the tapping on top of the boiler. The pressure relief valve must be put in the branch of the pipe tee. In locating the tank, particularly cold or exposed places should not be utilized, to avoid the possible serious damage resulting from freezing. A closed valve in the pipe to the expansion tank during operation of the boiler may cause equal damage. A pre-pressured diaphragm-type tank nay be installed in lieu of the conventional tank. If employed, it is important that an automatic air vent be Installed to relieve air from the system. Recommended and alternate methods of expansion tank hook-ups are shown on Page 9. ~ A gate valve (for purging) should be installed as close as practical to the boiler outlet (see "Pill Procedure" on Page 8). If an automatic fill valve is installed, it is recommended that a bypass (with shut-off valve) be piped around the valve so that full water flow rates may be used to adeauately purge the system of air on initial fill. 30 psi relief valves are standard equipment on GPH boilers; however, the boilers are suitable for use with 50 psi relief valves, If required, 18829 G?H GAS BOILER 5 The draft.", cod must be installed cn top of the boiler, and flue connection race from the drafthood to tne gas vent or chimney with a minimum cl 1/A" pitch per foot of horizontal run. The flue connector s.nould be at least as large as the drafthood outlet. Care should be exercised to avoid blocking the chimney by extending the flue pipe beyond the inside wall of the chimney. When two or more appliances vent into a common flue, the area of the common flue must at least equal the area of the largest flue plus 50 per cent of the areas of the additional flues. An electric service line must be run from a switch to the Junction box, or--v.'ith self-energizing contro!s--to the circulator. For multiple zone Installations, the wiring instructions accompanying a zone control valve set Bhould be followed. Other wiring will have been completed at the factory. At the beginning of the heating season the manual switch in'the electric service line must be closed to start the circulator pump v.-hich will then constantly circulate water of varying temperatures, depending upon the heat requirements. At the end of the heating season, the manual switch should be opened. GPH-60 TiUiU GPH-170 GAS BOILERS 18830 C?K GAS BO GPU 100 TIUIU GPU- 1 7 0- m -5 - ' .`5 I P '=v C c- o ku 18831 GPH BAS BOILER GPH - 100 THRU GPH - 170 8RH 100 THRU 170 CAI OOrt.tR WIRING DIAGRAM FORCIO HOT WAT C R CIRCULATION, 3 L F *CNRCiZinG COxtROLJ 18832 GPH GAS BOILER BALANCIXC CO":S OR lOHt t'U.VCJ 8 Pig. 6 FILLING The following procedure should be used to fill a series loop Heatrim System (See Figure 6). 1. Close all zone valves except the one for the zone to be filled with v.-aoer and purged of air. 2. Open the drain valve on the boiler. 3. Open the fill valve. 4. Close the purge valve. 5. Open the relief valve. 6. 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; out always have one zone open. (Zones are purged and filled when water can be felt in the pipe at the end of the zone). 7. Close the drain valve. 8. When water appears, release the lever on the-relief valve, allowing it to close. 9. Continue filling the syBten until the pressure gauge reads 12 psi without heat; close the fill valve, 10. Open the purge valve. 11. For quietest operation, check the gauge pressure with the system at 200 F. Adjust the pressure to 2p psi if a 30 psi relief valve is employed and 40 psi when a 50 psi relief valve is used. If an automatic fill valve is used, it may be necessary to readjust the setting of the valve to allow a higher fill pressure with the system, cold to obtain desired pressure with the system at 200 F. Following the completion of the installation, a thorough check should be made of the entire hydronic system to locate possible leaks. If a diaphragm-type expansion tank is used, it may be necessary to increase the initial air pressure in the tank with the system cold to Insure adequate expansion volume'. These tanks are usually fitted with a tire valve for this purpose. 18833 GPH GAS BOILER EXPANSION TA.\?C GPU - n o THRU GPU - 170 : FCO* ENDED HOOK-UP USING CONVENTIONAL EXPANSION TANK RELIEF >' VALVE WATER SUPPLY i TO DRAIN FILL VALVE It I! {X]--H j_ TO 1 SYSTEM PURGE VALVE (GATE) EXPANSION TANK ALTERNATE HOOK-UPS USING ElAPHRAG'A-7YPE EXPANSION TANAS 18834 GPH GAS 3CILZ?. If this boiler is used in connection with refrigeratioft systems, t e boiler rust be installed so that the chilled medium i* piped parallel vit the boiler, using appropriate valves to prevent the chilled medium fhon enteri S the boiler. RECOMMENDED BOILER = IPING FOR COMBINATION HEATiNC L COOL INC- UNITS Fig. 7 If this boiler is connected to heating coils ir. an air handling unit where coils nay be exposed to refrigerated air, the bailer piping system rust be equipped with flow control valves to prevent gravity circulation of boiler water during the operation of the cooling system. That safeguard will help prevent condensation on the boiler and, there:are, corrosion dar.ge. 18835 G P H -6 0 T fmu GPH-170 GAS BLRS G?H GAS rOILER Pi 8 OPERATION The homeowner should occasionally check the readings on the gauge located on the front of the boiler. The lower scale indicates the water temperature within the boiler; and, should the water exceed 250 F, operation must be discontinued until the system is checked and the fault corrected. The upper scale indicates the pressure within the system and should net exceed 30 lbs (50 lbs with 50-lb relief valve). In a closed system the boiler and piping are entirely filled with water except for a cushion of air in t:ie upper portion of the expansion tank. When the water is heated, it expands, compressing the air. If, for any reason, tr.is air were completely displaced from the tank, there would no longer be a cushion. In that event an increase in water temperatures would cause a corresponding increase in volume and pressure would force the relief valve open to discharge the excess volume. To correct such a condition, the expanr.ion tank must be drained enough to permit the tank to fill 'with air. The boiler is ea.uipped with an adjustable limit control with a mechanical stop at 220 F. This setting can be reduced for lower system design temperatures. 18836 G PII-100 THRU GPH-170 GPH GAS BOILER INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION-NON 100% SHUTOFF SELF-ENERGIZING CONTROLS TO SHUT OFF: ) CLOSE MANUAL SHUTOFF VALVE "A" AND PILOT VALVE "B" MAIN CA3 CINE 1. SET ROOM THERMOSTAT TO LOWEST TEMPERATURE. 2. HE SURE MANUAL SHUTOFF VALVE -A" AND PILOT VALVE '"B" HAVE BEEN SHUT OFF FOR AT LEAST FIVE MINUTES SEFOKE PROCEEDING. 3. OPEN PILOT VALVE "B" AND LIGHT PILOT BURNER (S) 4. OPEN MANUAL SHUTOFF VALVE "A". 5. SET ROOM THERMOSTAT TO DESIRED TEMPERATURE. 1-ST-14388 Rev. B INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION -- 100% SHUTOFF 24 VOLT CONTROLS to shutoff: 1, DEPRESS THE KANUAL GAS COCK KNOB AND TURN TO "orr". TOLrGHT: 1. SET ROOM THERMOSTAT TO LOWEST TEMPERATURE. 2. BE SURE MANUAL GAS COCK KHOD KA3 BEEN TURNED TO "err" POSITION FOR AT LEAST FIYE (5) MINUTES BEFORE PROCEEDING, 3. DEPRESS KNOB AND TURN TO "PIIjOT''. LIGHT PILOT BURNER HOLDING KNOB DOWN APPROXIMATELY ONE MINUTE, A. TURN KN09 TO "ON" AND SET THERMOSTAT TO DESIRED TEMPERATURE. PG-1000-64 Rev. A 18837 GPU GO TH1UJ GPU 170 BOILER- GPH GAS .u_ Norma 1 Pilot In rut /,Per burner Btu/hr.) Natural Mixed Liquid Petroleum (LP) 1, -100 1,200 1,000 Manifold Pressure Adjustment for Main Burner After the boiler has been in operation for fifteen minutes, all other gas appliances (including pilots) should be shut off and the consumption .should be timed. The boiler input should be adjusted to the rated input, indicated on the nameplate attached to the boiler jacket, in accordance with the follovir. r procedure. Input Rating (Stu/Hr,) Gas Consumption (Cubic Feet per Hour) - Heating Value of Gas (3tu/Cu. Ft) to The manifold gas pressure should be checked with a manometer or pressure gage connected to the 1/8 pipe pressure tapping located either on the manifold or bottom of automatic gas valve. The pressure should be set at 3.5 iwc for natural and mixed gas, in no case, should the final manifold pressure vary more than 0.3 iwc either way. To adjust the pressure, the protective cap on the regulator should be removed and the adjusting screw should be turned clockwise to raise the pressure or counterclockwise to lower the pressure. The protective cap should be returned to its forcer position. Only small adjustments in gas flow cay be made with this regulator; major changes in the flow must be made through mo ;ification of the burner orific BURNER AIR ADI MEET The- burner flame should be adjusted, cy opening or closing the primary shutter, so that it burns quietly and so that it shows no yellow but has a noticeable blue inner ccr.e. Following the adjustment, the screw should be tightened carefully to lock the shutter in the correct position. OPERATION DURING ELECTRICAL POWER FAILURE The GPH Boiler equipped with self-energizing controls will continue to provide heat without electrical power if the boiler is located below the heating system such as in a basement insta.lation. THE BURNER FLAME SHOULD 3E REDUCED DURING ELECTRICAL POWER RAIL'REC TO 1/3 or 1/4 ITS NORMAL SIZE through a partial closing of the manual shutoff valve. Although the burne equipped with self-energizing controls will continue to operate without adjustment and without damage to the boiler, the reduction in flame size will help offset the loss of the circulating action in maintaining an even but reduced heat. The shutoff valve should be returned to its normal position immediately upon the re-establishment of electric power if the most efficient ar.d effective operation is to be obtained. Flow control valves should be opened during power failure operation. Upon resumption of pi.ver, return flow valves to original position. 18838 GAS BOILER BOILER CARS Cleaning The following diagrams show the flue openings through the boiler sections. If necessary, the flue passages should be cleaned with a stiff brush. The circumstance which makes that necessary would probably make a cleaning of the burners advisable also. The burner should always be removed prior to cleaning the sections. Access to the sections is gained through the top of the boiler following the removal of the flue pipe, drafthood, jacket top, canopy and baffle. In reversing the procedure for reassembly, care should be given to seating the baffle over the pins on the top section so chat it falls into its proper position. (Baffle not required on GPE-r'O). To remove the burners for changing spuds, cleaning, or repairs, the following procedure should be followed. 1. Close the manual shutoff and pilot valves. 2. Remove the manifold cover on the front of the boiler. 3. Remove the burner access door. h. Remove the burners by lifting them at the rear. The reassembly of the burner-pilot section is the reverse of the above procedure. PERIODS OF NON-USE When the boiler is out of operation for periods of any considerable length, the electricity and all gas connections may be shut off, although no damage would occur and very little operating ccs~ would be involved if not shut off. Under normal conditions IRE HEATING SYSTEM SHOULD NEVER BE DRAINED, however, if the boiler is not used during the winter months, and, if adequate protection is not supplied to avoid the possibility of freezing anywhere in the system, the entire system should be drained. 18839 G?H GAS BOILER 15 18840 f' PH GAS BOILER u 16 CE > UJ _J cd 5 CD 5 < UJ (/) <3 tn < z o cr Uu I- 2 co cr n3 CD CD 2 OO O cr o x^ 1- 0. zo 22 h- > oo UJ x CO CO GPU 100 THRU GPU - 1 7 0- F IG 10 18841