Document dnkwQMgVwo1xp5aOgop4qvNN6

AP OIL BOILER by American-Standard Installation-Operation AND Maintenance Manual FOR PACKAGED OIL HEATING UNITS vs ATTENTION INSTALLER! THIS MANUAL IS TO BE LEFT WITH BOILER FOR THE HOMEOWNER American-Standard lint la baatlnf first In ^Ivaklaf BP-7S0S-AP - ___, j ll.L) FEB 23 1953 Vw J F a 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--i.., normally water is neither lost nor added-- and shouTd 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 AP OIL BOILER 1 cTV The AP Packaged Boiler comes to you almost completely preassembled; consequently, the installer's major responsibility will be in locating, connecting accessory parts and performing the actual hookup. 10535 GENERAL INFORMATION The APT Packaged Boiler ccir.es pre-assembled, and has been testej and approved by I=B=R as an oi.-iired unrt only. The APT Packaged Bolder cosies w.; .i 4, or 6 sections. Size APT-95 APT-130 APT-165 1=B^R Ratings No. of Sections 4 5 6 I=B=R Gross Output Btuh 95 >000 130.000 165.000 LOCATING BOILER POR INSTALLATION The boiler should be located on a level floor as near the chimney as possible. Be sure that sufficient apace is allowed at the left side (at least a 20" clearance) to allow for removal of the water heater. Cleaning space should also be allowed at the front of the boiler. If a water condition exists in the basement, or it has been necessary to waterproof the basement floor, the boiler should be mounted on a concrete or hollow tile base. APT Pkgd. B lr. i- 4 NOTE: THIS BOILER IS NOT RECOMMENDED FOR INSTALLATION ON COMBUSTIBLE FLOORS. UNPACKING APT PACKAGED BOILER Locate the boiler near its final installation site before removing its crate. Unpacking should be accomplished as follows: (See Figs. 1 and 2) 1. UnfaBten all crating wire at the corner of the crate. 2. Remove nails fastening crate sides to top and bottom of crate. 3. Lift off crate top and unwrap crate side from crate base. 4. Remove the plastic bag. 5. Remove box containing draft stabilizer, relief valve, and miscellaneous parts. 6. Remove boiler from base per instructions on Pig. 2. EXPANSION TANK LOCATION Care should be taken in locating the expansion tank. It should not be set in a cold or exposed apace. If the pipe to or from the tank were to freeze, serious damage could result. 10536 AP OIL BOILER B lr, I ft s 1. Side Fasteners 2. Nails FIG. 1 10537 1. Remove four hex head bolts securing Doiler to me crate base. 2. Tilt boiler to rear and to right. 3. Pivot boiler on right rear corner, rotate 90, and lower to floor. 4. Tilt boiler so that crate base can be completely removed. AFT Pkgd. B lr (The above Drocedure Is quite simple and can be easily accomplished by one man). 5. After the boiler is removed from the crate base, it can be easily walked to Its final location. FIO. 2 10538 AFT Fkgd. Blr, 5 CHECK-OFF PARTS LIST FOR APT PACKAGED BOILER Although the APT Packaged Boiler cornea to you assembled, it is necessary to check certain accessory items prior to final hook up. Accessory Box Draft Stabilizer Relief Valve x 4-1/2" Pipe Nipple 3/4" Tee Oil Burner Nozzle Circulator Plange Casket and Bolts Thermostat Oil Burner Box DH-5R Oil Burner BftTMTMATRg PEATURK This APT Boiler makes use of a special end section with a 2" supply tapping. Incorporating the "Ellmlnalre" feature (See Pigs. 3 and 4). The "Ellmlnalre" is a unique, built-in air separator which prevents air from being transacted to the system and directs the air to the compression tank or vent. This eliminates the need for external air separators such as dip-tubes or lnllned accessories. The "Ellmlnalre" also assures positive air separation, thereby insuring proper system perfonsanoe. <0 10539 6 12-65 AP Pkgd. B lr. SECTION ASSEMBLY SHOWING TAPPINGS FOR FORCED CIRCULATION CONTROL APPLICATION LOCATION SIZE OF ON BOILER TAPPING CONTROLS A < TEMPERATURE AND ALTITUDE GAGE B PRESSURE RELIEF VALVE AND EXPANSION TANK COMBINATION CONTROL, C OPERATING, HIGH LIMIT, CIRCULATOR RELAY ft PRIMARY CONTROL LIMIT CONTROL OR D 3/4 COMBINATION LIMIT AND REVERSE ACTING CONTROL (FOR INSTALLATIONS WITHOUT TANKLESS WATER HEATER) OPTIONAL AUXILIARY E UMIT CONTROL SPECIAL ORDER ONLY FIG. 3 10540 TO CONVENTIONAL EXPANSION TANK OR AIR VENT IF 7 APT t t * i . Blr, AND RELIEF VALVE FXQ. 4 10541 INSTALLING THE APT BOILER After moving the APT Packaged Boiler to the desired location, final Installation procedures should be accomplished as outlined below. 1. Hook up piping. 2. Install relief valve and fittings in top of left-hand end section (See Pig. 4). 3. The upper flange of the circulator should be Installed on the return piping, then bolted to the circulator flange. Be sure the flange gasket is not damaged, and that the flange bolts are drawn up equally. 4. Install the flue pipe and draft stabilizer using instructions provided with stabilizer. Die flue pipe should not extend beyond the Inside wall of the chimney flue. Horizontal runs of flue pipe should be kept at a minimum with approximately 1/4" pitch per foot maintained. 5 Install nozzle in oil burner. 6. Install oil burner by hanging on burner plate mounting bracket and guiding gun into combustion chamber. 7. Run electric service line from switch (not furnished by ARMSS) to the control mounted on built-in water heater. 8. Install room thermostat. 9* Make all electric connections according to wiring diagrams (See Pig. 3). 10. The boiler is now ready to be filled-. THE PILLINO PROCEDURE IS AN IMPROVED METHOD, AND SHOULD BE FOLLOWED AS INDICATED ON PIC. 6. 11. Adjust oil flame per instructions in Oil Burner Manual shipped in oil burner box. UNDER NO CONDITIONS SHOULD SMOKE EXCEED NO. 1 ON THE BACHARACH SCALE. CO2 per centage will noraally be between 100 and ll with 0.02 lwc over fire draft. 12. Boiler la now ready for service. 10542 THERMOSTAT 9 APT A g d . Blr, PACKAGED OIL BOILER WITH WATER HEATER WIRING DIAGRAM FOR CONSTANT IGNITION FIO. 5 10543 WIRE COLORS B-BLACK O-ORANGE R-RED W- WHITE HONEYWELL L4080B LIVIT CONTROL SA AP P k g d . B l r . PACKAGED OIL BOILER LESS WATER HEATER WIRING DIAGRAM i.a.ism ' CONSTANT IGNITION - CONTINUOUS CIRCULATION thervostat VS WIRE COLORS PACKAGED OIL BOILER LESS WATER HEATER WIRING DIAGRAM WITH REVERSE ACTING CIRCULATOR CONTROL AND CONSTANT IGNITION 10544 oiiutrOiar c**Lrarntl 10 APT Pkgd. Blr. 3-65 The following procedure should be used to fill a series loop Heatrim system (See Fig. 6). 1. Close all zone valves except the one for the zone to be filled with water and purged of air. 2'. Open the drain valve on the boiler. ?. Open the fill valve. . Close the purge valve. 5. Open the relief valve. 6. Open the valve to the second zone to be purged; then close tne first. Repeat this step until all zones have beei purged of air and filled with water; but 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 system until the pressure gauge reads 12 psi without heat or 25 psi at 200P; close the fill valve. 10. Open the purge valve. Following the completion of the installation, a thorough check should be made of the entire hydronic system to locate possible leaks. NOTE: 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. CAUTION: If a valve of any type is installed in the piping leading to or from the expansion tank, BE SURE THAT IT IS ALWAYS? OPEN WHILE THE BOILER IS IN OPERATION-: 10545 CARE OP EOxLER WHILE IN OPERATION 11 Keep open type system rilled to x/3 of expansi jh im:, . . .. A HOT WATER SYSTEM, THE PRESSURE MUST NOT EXCEED jO LHS., i/ 1. ^OEo, IT MUST' IE RELIEVED IMMEDIATELY AND THE CAUSE uP THE P.-n^hi 0/ ..... RELIEF VALVE INVESTIGATED Ai.D CORRECTED; OTHERWISE, PRESSURE NAY BUILD UP AND CAUSE DAMAGE TO THE HEATING SYSTEM. B lr, The homeowner should periodically cneck the readings on tne gauge, located on the front of the boiler (See Fig-. 7). The lower scale K indicates the water temperature. That temperature should never be allowed to exceed 250F. The boiler is designed to operate With a normal maximum water temperature of 230P; but, during mild weather, the system operates with water temperatures considerably below the maximum. The upper scale Indicates the pressure witnin the system and snouid 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 cuse a corresponding increase ih 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 uBe. When adding water while boiler is in operation, DO NOT OPEN SUPPLY VALVE FULLY. BUT ADD WATER SLOWLY. \ 10546 AFT Pkgd. Blr, 12 CARE OF BOILER WHILE NOT IN OPERATION At end of heating season, clean boiler thoroughly. Lubricate circulator in aceordanoe 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 VINTER, IT MUST BE FULLY DRAINED TO PREVENT DAMAGE CAUSED BY FREEZING. * <0 10547 CONSTRUCTION DETAILS Three different cored section eastings are used to make up the APT Packaged Boiler (See Pig. 8). 1. Left-hand end section with 2" supply tapping, and "Eliminaire." 2. Right-hand end section. 3. Center section. PLATE WORK Burner Plate and Door These are integral components and made of sheet steel with block insulation. CANOPY An aluminized sheet-steel canopy is provided. Smokeplpe sizes are as follows: No. of Sections 4 5 6 Smokeplpe Size 6" 6" 7" INSULATION The Jacket 1b insulated with 1/2" Pibergias, with 1" Plberglas on the top panel. A iT Pkgd. Blr, 10548 PRESSURE RELIEF VALVE *"17* REQUIRED FOR REMOVAL OF WATER HEATER------- v TO ^ ^ THERMOSTAT H3 { RETURN TO EXPANSION TANK OR AIR VENT CLEAN OUT 45f ffl t SIDE VIEW FLOOR tr LINE FRONT VIEW BOILER NUMBER A B c FLUE PIPE OIA APT-95 2i 14? APT-130 24| APT-165 26 20 r 6 6 7 PIQ. 8 10549 pfcid X d v 15 COMBUSTION CHAMBER The APT Boiler has a refractory combustion chamber. OIL BURNER The Model DH-5R oil burner is used with the APT Boiler. CONTROLS The APT Boiler makes use of a light-sensing primary control. Otherwise, controls for the APT Packaged Boiler are conventional. JACKET Jacket design for the APT Packaged Boiler is conventional as with otljer AR&SS boilers. * 10550