Document v6EyqLgdpKp6M5v2v6MVGQEE6

2-GA AND 2-GA-Ei GAS BOILERS by American - <$tat?dard Installation - Operation and Maintenance Manual tfy. >'* K r V w')1 APPROVED BY AMERICAN GAS ASSOCIATION Notice to Installer and Operator This Booklet Must Be Affixed to or Placed in Suitable Pocket on the inside of the Access Panel AwERiCAN-c^taitdaiKi First la haatlaf ... first la plsabisi 19190 2-GA AND 2-GA-E GAS BOILERS i GENERAL DIMENSIONS FOR 2-GA-E boiler BOILER NUMBER NO. OF NO. OF SECTIONS BURNERS 2-GA-4-E 4 2 2-GA-5-E 5 2 2-GA-6-E 6 2 2-GA-7-E1 7 2 C 6V8 8/s 9Va ll/e D BL 5 54J4 1 9 4 5 54J4 22'4 6 bbVz 25 4 6 58 4 28 4 ERECTING Caution On open hot water systems, expansion tank should not be installed in cold or exposed place. If the 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 WHILE THE BOILER IS IN OPERATION. Location If water condition is encountered in basement, or if it has been neces sary to water-proof the basement floor, boiler should be mounted on concrete or tile base at least 3" above floor level. 19191 2-GA AND 2*GA*E GAS BOILERS 1 GENERAL DIMENSIONS FOR 2-GA STANDARD BOILER BOILER NO. OF NO. OF NUMBER SECTIONS BURNERS 2-GA-4 4 2 2-GA-5 5 2 2-GA-6 6 2 2-GA-7 7 2 DL B 5 13% 47% 5 16% 47^ 6 19% 48 k 6 22% 5 11* Testing Before connecting boiler, plug openings, fill boiler with water and subject to not less than 10 lbs. nor more than 30 lbs. pressure. When boiler is used for direct hot water supply, test pressure should be in creased up to 120 lbs. Inspect boiler inside and outside for leakage to insure against breakage from handling and shipping. To safeguard ac curacy of gage supplied with boiler, do not install gage until after test of boiler. This precaution of testing the boiler will simplify handling of any necessary replacements or adjustments and assist in treating witr. claims against transportation companies. After test, drain and remove plugs where required. 19192 2 2-GA AND 2-GA-E GAS BOILERS Assembly of Fittings 1. Position boiler section assem blage so that sides with removable cleanout plates are accessible for pe riodic cleaning. Loosen tie rnd nuts so that they are finger tight only. 2. Screw bushing and/or other return fittings into 2W lower tap ping on back section. Provide a drain connection in the return pip ing at the lowest point in the system. 3. Screw flow fittings into back sec tion. It is recommended that a tee be provided in the piping near the flow oudet for installation of a relief valve. 4. Burner access door frames are alike. Attach one to front sec tion using 1W flat head screws at top. If boiler is Standard model, place front jacket panel in position before attaching door frame. (Fig. 1 shows frame in position for Em pire model) ~~ 5. Fill putty groove at top of sec tions with boiler putty and place canopy in position with ribs firmly imbedded in putty to make gas seal. Smooth off excess putty. 1 Burner Access Door Frame 2. Canopy 3. Tapping for Limit Control Fropt Section 4. Tapping for Reverse Acting Low Limit Control Fig. 1--Section Assemblage Installing Burners and Control Sub-Assemblies 1. Fit left burner assembly (Fig. 2) including burner, bracket, pilot burner, thermocouple lead, and vent tube tip to tapered end of mixer with forked lugs engaging lug on mixer. (See Fig. 3.) For Electric Ignition, the pilot lighter assembly is furnished in sepa rate container. It should be installed before the burner assembly is placed in the boiler. To install the lighter assembly, place it in position with the end of the thermocouple through the hole and push downward until the spring clip engages the bottom of the pilot body. See Figs. 2 and 3. See that air shutter is assembled on mixer. Install burner assembly and mixer in combustion chamber. Place mixer firmly on burner sup port which should rest on lugs provided on section (See Fig. 4; 2-GA-E model shown). Place right burner and mixer alongside resting on right side of burner support. 19193 2GA AND 2-GA-E GAS BOILEHS 3 Electric Ignition Manual Ignition Fic. 2--Left Burner Sub-Assembly Ftc. 3--Cross Section Through Combustion Chamber 2. Attach the control piping assembly at the union on the manifold. Be sure that arrows on automatic gas valve, automatic pilot valve and gas pressure regulator point in direction of the gas flow. Check spuds in end of spud holders to see that they are screwed in tightly and that orifices are drilled to size specified on tag attached to manifold. Assemble manifold, controls and manifold brackets to front burner ac cess frame. Use 3A" round head screws in upper holes and l11" round head screws in lower holes to hold frame to front section. (See Fig. 5 i Be sure spud holders are fitted firmly into mixer tubes. 19194 4 2-GA AND 2-GA-E GAS BOILERS - +r ra 3. Tighten the set screws in manifold brackets. (See Fig. 5). n 'itr 4. For 2-GA-E model place front insulation panel in position and hold till temperature bulb is attached. Insert the temperature bulb element of the automatic gas valve in the upper center tapping on the front using the split nut and gland fittings provided. Refer to page 9 for assembly of parts. well before installing. Attach number and series plate to front insulation panel, also terminal block and pilot ignition transformer for boilers having electric ignition. Two H" control tappings are provided on the right side of the Front Section (See Fig. 1). No. 3 indicates tapping for limit con trol. No. 4 indicates tapping for reverse acting low limit control. Cj7 Fic. 4--Burner Installation Fig. 5--Control Sub-Assembly Lnstaiiea Standard Model Shown 19195 Z-GA AND 2-GA-E GAS BOILERS s~ 0r---(t3 ly/nry^____ j ^ --rim iS0S= -E3 m. a tn 'jj.u. mu fc iga o.-- =H& E3 jMMu.gpppM* .0' <*r''j**mp.,.'--.tAvMI--o. Fig. 6--Wiring Diagrams Electric Ignition Fic. 7--Supply Piping Manual Ignition 19196 6 2-GA AND 2-GA-E GAS BOILERS 1. Manual Shutoff Valve 5. Vent Tube 2. Pilot Cock 6. Pilot Line 3. Push Sutton Lighter S*'tch 7. 8AS0 Automatic Pilot Valve 4. Gas Pressure Regulator 8. Pilot Ignition Transformer 9. Automatic Gas Valve Tic R-T.icket \ssemhlv and Control Connections for 2-GA-E Mode! with Electric fen 19197 2-GA AND 2-GA-E GAS BOILERS 5. 2-GA-E Model--Install combination thermometer and altitude gauge piping in tapping on right side of face of front section and install gauge. See Fig. S. In Case of 2-GA Standard Model install v*" x 4" bushing and gauce in this tapping. See Fig. 5. Assembly of Jacket of 2-GA-E Model 1. Place rear jacket panel in position. Hold in place and attach rear burner access door frame with lVs" flat head screws at top and 1' ' round head screws at bottom. 2. Place side jacket panels in position with grooved edges engaging flanges of rear panel. Attach side panels to rear panel at top and bottom with screws and nuts. Connecting Controls 1. Connect thermocouple element from pilot burner to BASO auto matic pilot valve. (See Fig. 8). Discard protective cap covering threads on BASO valve. 2. Connect pilot line to manual shutoff valve (Fig. 7 for Mfd.. Nat. and Mixed Gases) and to BASO automatic pilot valve for LP and Butane-air gases. (See Figs. 15 and 16). For electric ignition, connect pilot line from burner assembly (Fig. 2) to Manual Valve (Fig. 7) as shown in Fig. 8. 3. Connect vent tube from pilot burner bracket to gas pressure regu lator. Be sure stainless steel tip is screwed in securely; and that flame check is in place in vent tube connection on regulator. (See Fig. 10 ) 19198 8 2-GA AND 2-GA-E GAS BOILERS 1 Pilot Cock 2. Manual Shutoff Valve 3. Gas Pressure Regulator 4 Automatic Gas Valve 5 Oil** i_,.. 6. Vent Tube 7 3AS0 Automatic Pilot Valve Fic. 9--Jacket Assembly and Control Connections for 2-GA Standard Model *ith Mann Ignition --- 19199 2-GA AND 2-GA-E GAS BOILEHS 9 4. Make wiring connections according to wiring diagram applying to controls used. (See Fig. 6). Install thermostat and connect as indi cated. 5. Install front and rear burner access doors. COMPRESSION MALE ELBOW FITTING material 40 MESH MONEL OR BRASS SCREENING HERE IN REGULATOR FLAME CHECK Fro. 10--Flame Check SPLIT NUT AND PACKING GLAND - ASSBtHLT ORDER OF PARTS For core seneitire operation, cut off well hare and diacard before inntailing. 1. Packing Gland with Well 2. Steel Half Washers 3. Packing Washer h. Split Nut 19200 10 2-GA AND 2-GA-E GAS BOILERS Completing Jacket Assembly for 2-GA-E Model 1. Place front jacket panel in position so that flanges engage grooves of side panels. Fasten at top and bottom with screws and nuts. (See Fig. 11). Install Lighting Instructions Plate by placing it on "Z" clips located inside the control access door and bending down six tabs to secure. Attach control access door. 2. Place top jacket panel over flue outlet with perforations to front over controls. 3. Place draft hood in position with bottom through top jacket panel and on flue outlet of canopy. Front Frc, II--2-GA-E Boiler Assembly Rear 19201 2-GA AHD 2-GA-E GAS BOILERS Assembly of Jacket for 2-GA Standard Model 1. Fit rear jacket panel in position. Hold in place and attach rear burner access door frame with lVa" flat head screws at top and 1' i" round head screws at bottom. See Fig. 12. 2. Place side jacket panels in position with ends overlapping front and rear panels. Attach to front and rear panels near bottom with jacket screws. Attach number and series plate and lighting instruc tions plate to front jacket panel. 3. Place top jacket panel in position with flanges down tight over front, rear and side jacket panels. 4. Place draft hood firmly on flue outlet of canopy. Front Rear Fig. 12--Standard Boiler Assembly 19202 12 2-GA AND 2-GA-E GAS BOILERS Filling System (~*aution * stsr^ boiler uCSS it is prepe .i.. , tj an.j lUiGU. is in operation, makeup water should be added slowly.) Fill open system to V3 height of expansion tank, remove rim and glass from gage and set movable pointer under automatic pointer. Re place rim and glass. Fill closed system until relief valve relieves. This must be less than 30 lbs. pressure. If necessary, adjust relief valve setting. Remove rim and glass from gage and set movable pointer under automatic pointer. Replace rim and glass. Keep systems filled. Pointers on gage should be even. If pressure exceeds 30 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 just over top of burner. Pilot rate can be adjusted with screw underneath cap on pilot cock or by adjusting t hrottling cock in pilot line if provided. Normal Pilot Input for BASO Pilot Burners | Mfd. | Nat. | Mixed | LP | LP-Air: 'Input per Burner Btu/Hr.| 1000 j 1400 j 1200 j 1000 j 1000 19203 I 2-GA AND 2-GA-E GAS BOILERS 13 Main Burner Input Adjustment After boiler is warmed up, shut off all other gas appliances connected to gas meter and time gas consumption. Adjust gas pressure regulate to give rated input indicated on nameplate. Gas Consumption (Cubic Feet Per Hr.) = Input Rating (Btu Per Hr I Heating Value of Gas (Btu per Cu. Ft.) To increase consumption, turn adjustment screw (beneath cap on pressure regulator) clockwise; to decrease, turn screw counterclock wise. Main Burner Primary Air Adjustment Adjust burner flame by opening or closing primary air shutter. Flame should bum quietly, show no yellow and should have a noticeable inner blue cone. After adjustment, tighten screw to lock shutter in position. OPERATING Shutting Off (For All Gases) 1. Close manual shutoff valve and pilot cock. 2. Turn off switch in electric line to appliance. 19204 U 2-GA AND 2-GA-E GAS BOILERS Re-Lighting (Electric Ignition) 1. Set thermostat at lowest temperature. 2. Close manual shutoff valve and pilot cock. 3. Turn off switch in electric line to appliance. 4. Wait 5 minutes. 5. Turn on switch in electric line to appliance. 6. Open pilot cock. 7. Press button on lighter switch until pilot burner lights. 1. Manual Shutoff Valve 2. Pilot Cock 3. Push Button Lighter SwHth 4. BASO Automatic Pilot Valve 5. Pilot Burner Fig. 13--Controls for Electric Ignition 8. Wait 2 minutes. 9. Press plunger on automatic pilot valve. 10. Open manual shutoff valve. 11. Set thermostat at desired temperature. 19205 1 2 GA AND 2-GA-E GAS BOILERS 15 Re-Lighting (Manual Ignition; Mfd., Nat. & Mixed Gases) 1. Set thermostat at temperature. 2. Close manual shutoff valve and pilot cock. 3. Turn off switch in electric line to appliance. 4. Wait 5 minutes. 5. Open burner access door. 6. Light taper and hold to pi lot burner. 7. Open pilot cock. (Pilot should light). 8. Close burner access door. 1. Manual Shutoff Valve 2. Pilot Cock 3. 8AS0 Automatic Pilot Valve 4. Pilot Burner 9. Wait 2 minutes. Fig. 14--Controls for Manual Ignition Mfd., Nat- and Mixed Case; 10. Press plunger on automatic pilot valve. 11. Open manual shutoff valve. 12. Turn on switch in electric line to appliance. 13. Set thermostat at desired temperature. 19206 16 2-GA AND 2-GA-E GAS BOILEHS 1 Re-Lighting (Manual Ignition; Liquefied Petroleum and LP__Air Gases) 1. Set thermostat at lowest temperature. 2. Close manual shutoff valve and pilot cock. 3. Turn off switch in electric 1 3 line to appliance. 4. Wait 5 minutes. 5. Open burner access door. 6. Open pilot cock. 7. Light taper and hold to pi lot burner. 8. Press plunger on auto matic pilot valve (Pilot should light). Hold 2 minutes. 1. 8AS0 Automatic Pilot Valv 2. Pilot Cock 3. Manual Shutoff Valve 4. Pilot Burner Fig. 15--Controls for LP Gases ;See Fig. 16 for LP-Air) 9. Close burner access door. 10. Open manual shutoff valve. 11. Turn on switch in electric line to appliance. 12. Set thermostat at desired temperature. 19207  /J t it*. % 2-GA AND 2-GA-E GAS BOILERS 1. BASO Automatic Pilot Valve 2. Pilot Cock 3. Manual Shutoff Valve 4. Pilot Burner Fic. 16--Control Arrangement for Liquefied Petroleum-Air Gases Pilot Goes Out If the pilot flame is extinguished, the automatic pilot will shut off the automatic gas valve, rendering the boiler inoperative. Relight ac cording to applicable instructions. If boiler is not operating correctly, call Heating Contractor or Gas Company Service man. Operation During Failure of Electric Power Supply In case of failure of supply of electric current, boiler will automat ically shut off. Boiler will not operate automatically while electric power is off; however, boilers equipped with Detroit V-575-FW auto matic gas valve may be operated manually as follows; 1 19208 IS 2 GA AND 2-GA-E GAS BOILERS 1. If pilot is out, relight as directed for manual ignition. 2. Remove rectangular housing from top of valve. 3. Pull up knob located on top. (Burners should light). 4. Caution--Shut off boiler by pressing reset lever, located next to knob, before water temperature becomes excessive. Bear in mind that operating the boiler manually is an emergency condition and that constant supervision is required to prevent the pos sibility of damage due to overheating. Never allow the boiler to oper ate under this emergency condition if it is to be left unsupervised for any length of time. 5. Valve is fully recycling and will return to automatic operation when electric power returns. MAINTENANCE In Fall Before Starting Boiler Drain system sufficiently to remove sludge in bottom of boiler. Do not drain more water than necessary to remove sludge. Then refill to proper level as directed above. Care of Boiler While in Operation 1. Check water level regularly and add water slowly when needed. 2. This boiler is fired automatically. 19209 2-GA and 2-GA-E GAS BOILERS 19 In Winter While Not in Operation Drain entire system to prevent damage from freezing. Dram through drain cock, located at lowest point in system. Be sure boiler is completely drained. In Summer While Not in Operation Fill system as during heating season. Have boiler inspected by service man before the start of the heating season. If necessary, re move jacket front and side panels so that cleanout cover plates are ac cessible. These may be removed from either side of the boiler for cleaning between the sections. General Care of Heating System 1. Keep radiators and convectors clean. 2. Keep system in good repair. It is advisable to have it inspected by your heating contractor at least once a year. 3. If a hot water radiator is hot at the bottom, but not at the top. it indicates that air has 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. 4. Fill hot water systems as follows: Open all radiator valves, but keep vents at top of radiator closed. Fill open systems till hands on altitude gage are even. If it is a closed system the water filling will stop automatically when proper pressure is reached. (Pressure should not exceed 30 pounds.) Then, beginning with ground floor, vent each radiator as directed above. It may be necessary to add water during this operation to expel air from higher radiators. 19210 20 2-GA AND 2-GA-E GAS BOILERS i 5. 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 during tH? winter 5. Where an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed to freezing temperatures. If the pipe leading to or from the tank freezes, serious damage may result. If salve of any description is installed in the piping leading to or from the expansion tank BE SURE THAT IT IS OPEN WHILE THE BOILER IS IN OPERATION. Note: All parts of this boiler have been carefully inspected and packed. See Packing and Parts List sheet for details. In case of shortage, make sure that all parts have been re moved from shipping container and examine packing material thoroughly. If part cannot be found, report shortage to your dealer, giving boiler size, series number, date, inspector's num ber and packer's number. GIVE BOILER SIZE AND SERIES NUMBER WHEN ORDERING REPAIR PARTS Boiler Size..................................................... Series No. (See Series Plate on Boiler) Date ................................................................. 19211 Plumbing and Haaling Division AMERICAN RADIATOR ft STANDARD SANITARY CORPORATION 40 WEST 40th STREET. NEW YORK 18. N Y. ( t't 19212