Document wdXE8V7VmwnZOxe1459BmVDQ

//^ J/p EMPIRE BOILER by AMERiCAN-<tattda*d PLAINTIFF'S EXHIBIT ASI-665 Installation - Operation and Maintenance Manual FOR TYPE 4-GA GAS FIRED BOILERS 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 AMERiCAN-^tandatfd First In hsatlsf first In plsnblsf i i 19077 EMPIRE BOILER American TYPE 4-GA Q uZ tu-. Ul _l _) n-r** j? ? j? u S o r- r*> u jfl 8 Jnru? 5 UJ CD -ST *e- * 3 n> ;* * 't QL m< UtrJ sj $Zuu o> - ou O< Vo<i 4< (4-GA-l l-E1 1 KHMM 1 1 31lO 1 19078 EMPIRE BOILER Amhucan TYPE 4-GA I ERECTING Caution On hot water systems, expansion tank should not be installed in cold or exposed place. No valve of any type should be installed in piping be tween boiler and expansion tank. Sealing system at any time during operation may cause breakage of boiler or radiators. Location If water condition is encountered in basement, or if it has been nec essary to water-proof the basement floor, boiler should be mounted on concrete or hollow tile base at least 3" above floor level. Testing Before connecting boiler, plug openings, fill boiler with water and subject to not less than 10 lbs. nor more than 30 lbs. pressure. Inspect boiler inside and outside for leakage to insure against breakage from handling and shipping. To safeguard accuracy of gauge supplied with boiler do not install gauge until after test of boiler. This precaution of testing the boiler will simplify handling of any necessary replace ments or adjustments and assist in treating with claims against trans portation companies. After test, drain and remove plugs where re quired. Note: When boiler is used for direct hot water supply, test pres sure should be increased up to 120 lbs. Assembly of Fittings 1. Position boiler section assemblage so that front and both ends are accessible. Loosen all tie rod nuts so that they are finger tight only. 2. Place rear jacket panel in position, then attach flow and return fittings to flow and return nipples projecting through panel. If only 2 19079 2 EMPIRE BOILER American TYPE 4-GA nipples are used, connect to diagonally opposite nip ples as marked (W and W) to insure proper circula tion. Remaining nipples (N and N) should be capped. (See inside of front cover.) It is recommended that a tee be provided in the pip ing near the flow outlet for installation of a relief valve. 3* Install bushing, street elbow, close nip- RIGHT END 1. Flow and Return 2 Connections. 2. Plugged; Operating Control, if used 3. Plugged; Reverse 3 Acting Low Limit Control, if used. 4. Burner Access Door 4 Frame. 5. Tie Rod Nuts. 6. 2xW' Bushing for limit bulb 7. Thermometer and Altitude Gage Tapping llfFT ENO -5 Fig. 1--Section Assemblage pie and drain cock in lower tapping on right end section. For Electric Ignition, the pilot lighter assembly is furnished in separate 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. 4. Burner access door frames are alike. Attach frames to right and left end sections using 14-20 x 114" flat head brass screws at top. 5. Fill putty groove at top of sections with boiler putty and place canopy in position with flange firmly imbedded in putty to make gas seal. Smooth off excess putty. Place flue pipe on canopy. 6. Place burner supports for 9 and 11 section boilers on 3rd section from left and 3rd section from right ends. For 8 section boiler, place burner supports on 3rd section from left end and 2nd section from right end. On 8 section boiler the longer burners go in the left end. Installing Burner and Control Sub-Assemblies 1. Each 4-GA boiler is supplied with four burners which must be installed as shown in Fig. 2. Burner Nos. 2 and 4 are plain without pilot attachments. Burner assemblies Nos. 1 and 3 vary according to type of installation. Identify them as shown on page 3. 19080 EMPIRE BOILER Amibican TYPE 4-GA 3 BURNER NO 2 BURNER NO 3 Fig. 2--Burner Arrangement Electric Ignition No. 1--Burner, pilot bracket, pilot burner, thermocouple, vent tube tip and electric ignition block. No. 3--Burner, pilot bracket and pilot burner. Manual Ignition (Mfd., Nat. and Mixed Gases) No. 1--Burner, pilot bracket, pilot burner, thermocouple and vent tube tip. No. 3--Burner, pilot bracket and pilot burner. Manual Ignition (L.P. and L.P.-Air Gas) No. 1--Burner, pilot bracket, pilot burner and thermocouple (also vent tube tip for L.P.-Air gas). No. 3--Burner, pilot bracket, pilot burner and thermocouple (smaller diam eter. Fit burner assemblies to tapered ends of mixers. (Forked lugs on burner engage lug on mixer.) Place burner and mixer assemblies on burner supports in combustion chamber. Install L.H. burner first. 2. Check orifice spud with drill size specified on tag attached to manifold. Push spud holders into tapered holes in mixers and attach the mani fold (with automatic gas valve) and manifold brackets to left end burner access door frame with Vi" x %" round head brass screws in upper holes and Vi" x IV2" round head brass screws in bottom holes. Attach remaining manifold to right end similarly. 19081 empire boiler American TYPE 4-GA AA3* fcWFOLP SPUO HOLCA Fig. 4--Sectional View (Manual Ignition; Mfd., Nat. and Mixed Gases) 19082 EMPIRE BOILER Amebicax TYPE 4-GA 5 3. Join lower union joint on left manifold to union joint on right manifold with connecting pipe across rear. Attach control piping assembly with union elbow to left manifold at top union joint and to gas supply pipe with union. (See Fig. 2.) Be sure arrows on Automatic Gas Valve, BASO Valve and Gas Pressure Regulator point in direction of gas flow. Tighten manifold bracket at taching screws and set screws in manifold brackets. 4. Attach number and series plate to left end insulation plate also terminal block and pilot ignition transformer on boilers having electric ignition. Place left end insulation plate in position with bottom edge in back of burner access door frame and hold until temperature bulb is in stalled. Insert the temperature bulb element of the automatic gas valve in the upper center tapping on the left end using the split nut and gland fitting provided. For more sensitive operation, discard well before in stalling. Place right end insulation plate (plain) in position. 5. Install combination thermometer and altitude gage in upper tapping on face of left end of section assemblage (See Fig. 5). Two %" tappings for the application of a reverse acting aquastat and a limit control have been provided on the left end section (See Fig. 1). 1. Temperature Bulb Element 2. Left End Insulation Panel 3. Combination Ther mometer and Al titude Gage .4 Pilot Ignition Trans former 5. Automatic Gas Valve 6. Terminal Block Fic. 5--Installing Gage and Temperature Bulb 19083 6 EMPIRE BOILER American i TYPE 4-GA Connecting Controls 1. For all gases, connect thermocouple from pilot burner to series 500 BASO automatic pilot valve at left end of unit. For liquefied petroleum and liquefied petroleum-air gases mount an 808 type BASO pilot valve and bracket with sheet metal screws in holes provided on right end insulation panel and connect thermocouple (smaller diam eter) from pilot burner to pilot valve. 2. Connect pilot line from pilot burners to manual shut-off valve. See Figures 6 and 8 for Mfd. Nat. and Mixed gases, Manual Ignition, and Figures 6 and 7 for Mfd. Nat. and Mixed gases, Electric Ignition. Connect pilot line to Baso Automatic Pilot Valve for L.P. and L.P. Air gases. See Figure 13. 1. Manual Shut-ofF Valve 2. Gas Pressure Regulator 3. Baso Automatic Pilot Valve Fic. 6--Controls for Manual Ignition Mfd., Nat and Mixed Gases 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. 9). 19084 EMPIRE BOILER WAIN GAS LINE American TYPE 4-GA 7 WAIN GAS LNE VALVE NOT SUPPLIED Bv ARASS CORP Fig. 7--Supply Piping Arrangement (Electric Ignition) VALVE NOT SUPPLIED BY ARAS-S CORP Fic. 8--Supply Piping Arrangement (Manual Ignition; Mfd., Nat. and Mixed Gases) 4. Make wiring connections according to wiring diagram ap plying to controls used. (See Fig. 10.) Install thermostat and connect as indicated. COMPRESSION MALE ELBOW FITTING 5 5. Install burner access doors, MATERIAL 40 MESH MONEL OR FLAME CHECK one on left end frame and one on BRASS SCREENING HERE IN REGULATOR \ right end frame. / Fig. 9--Flame Check Jacket Assembly 1. Place front jacket panel in position. 19085 8 EMPIRE BOILER American I TYPE 4-GA OCT*Oit vv[y ACTIMO LIMIT coro. OCTROIT THERMOSTAT OCTROIT THERMOSTAT JUNHCTiION I . pctroit , , tukvwici rc, ciacuiato* :t*oit automatic WtmiC. MAfcAAM fQR ACL CAMS MAHIMIOA RUNNCW >*-OT ICwOTON WIT* MtCHAUCAL UNIT wm* (aaqaam row All t*Ki MANCHA OR MC* WlOT CHiDON WITH MtCMANCAl LIMIT Fig. 10--Wiring Diagrams 2. Place left end jacket panel in position with flanges engaging slip joints of rear and front jacket panels and attach at top and bottom with jacket screws. 3. Place right end jacket panel in position with flanges engaging slip joints of rear and front jacket panels and attach at top and bottom with jacket screws. 4. Place top jacket panel in position with flue pipe projecting through flue opening and grille over left end. 5. Place draft hood on flue pipe. 6. Attach control access door (with louvers) to left end jacket panel and plain door to right end jacket panel. 19086 EMPIRE BOILER Amemcan TYPE 4-GA 9 Filling System Caution: Never start boiler unless it is properly filled. (After boiler is in operation, make up water should be added slowly.) Fill open system to Ys 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 pounds 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 system 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 the top of the burner. Pilot rate can be adjusted with the screw underneath the cap on the pilot cock or by adjusting throttling cock, if provided in pilot line. Normal Pilot Input for BASO Pilot Burners Mfd. Nat. Mixed L.P. Input Per Burner 1000 1400 1200 1000 LP-Air 1000 Input Adjustment After boiler is warmed up, shut off all other gas appliances connected to gas meter and time gas consumption. Adjust gas pressure regulator to give rated input indicated on nameplate. Gas Consumption (Cubic Feet Per Hr.)= Input Rating (Btu 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-clock wise. 19087 10 EMPIRE BOILER American TYPE 4-GA Main Burner Primary Air Adjustment Adjust burner flame by opening or closing primary air shutter. Flame should burn quietly, show no yellow and should have a notice able 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 cocks. 2. Turn off switch in electric line to appliance. 1. Manual Shutoff Valve 2. Push Button Lighter Switch 3. Baso Automatic Pilot Valve .4 Left End Pilot Cock 5. Right End Pilot Cock 6. Left End Pilot Burner T. Right End Pilot Burner Fic. 11--Controls for Electric Ignition EMPIRE BOILER Amhhcan TYPE 4-GA 11 Re-Lighting (Electric Ignition) 1. Set thermostat at lowest temperature. 2. Close manual shutoff valve and pilot cocks. 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 to left end pilot burner. 7. Press button on lighter switch until left end pilot burner lights. 8. Wait 2 minutes. 9. Press plunger on automatic pilot valve. 10. Open manual shutoff valve. 11. Set thermostat above room temperature. (Main burners should light.) 12. Open pilot cock to right end pilot burner. (Pilot should light.) 13. Set thermostat at desired temperature. 19089 12 EMPIRE BOILER American TYPE 4-GA 1. Manual Shut-off Valve 2. Baso Automatic Pilot Valve 3. Left End Pilot Cock 4. Right End Pilot Cock 5. Left End Pilot Burner 6. Right End Pilot Burner Fig. 12--Controls for Manual Ignition; Mfd., Nat. and Mixed Gases Re-Lighting (Manual Ignition; Mfd., Nat. & Mixed Gases) 1. Set thermostat at lowest temperature. 2. Close manual shut-off valve and pilot cocks. 3. Turn off switch in electric line to appliance. 4. Wait 5 minutes. 5. Open left end pilot cock and light left end pilot burner. 6. Open right end pilot cock and light right end pilot burner. 7. Wait 2 minutes. 8. Press plunger on automatic pilot valve. 9. Open manual shut-off valve. 10. Turn on switch in electric line to appliance. 11. Set thermostat at desired temperature. EMPIRE BOILER American TYPE 4-GA 13 1. Manual Shut-off Valve 2. Gas Pressure Regulator (LP-Air Only) 3. Baso Automatic Pilot Valve 4. Right End Baso Auto matic Pilot Valve 5. Right End Pilot Burner 6. Right End Pilot Cock 1. Left End Pilot Cock 8. Left End Pilot Burner Fic. 13--Controls for Manual Ignition; Liquefied Petroleum and LP--Air Gases Re-Lighting (Manual Ignition; Liquefied Petroleum Gases) 1. Set thermostat at lowest temperature. 2. Close manual shut-off valve and pilot cocks. 3. Turn off switch in electric line to appliance. 4. Wait 5 minutes. 5. Open left end pilot cock, press plunger on automatic pilot valve and light pilot. Hold plunger for 2 minutes. 6. Open right end pilot cock, press plunger on right end automatic pilot valve and light pilot. Hold plunger for 2 minutes. 7. Open manual shut-off valve. 8. Turn on switch in electric line to appliance. 9. Set thermostat at desired temperature. 19091 14 EMPIRE BOILER American 0 TYPE 4-GA 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 automati cally shut off. Boiler will not operate automatically while electric power is off; however, boilers equipped with Detroit V-574-FW automatic gas valve may be operated manually as follows: 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 operate 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. 19092 EMPIRE BOILER American TYPE 4-GA 15 CARE AND ATTENTION 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. While In Operation 1. Check water level regularly and add water slowly when needed. 2. This boiler is fired automatically. In Winter While Not in Operation Drain entire system to prevent damage from freezing. Drain 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, remove jacket front and side panels so that cleanout coverplates are accessible. These may be removed from either side of the boiler for cleaning be tween 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. 19093 16 EMPIRE BOILER American TYPE 4-GA 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. 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 neces sary during the winter. 6. Where an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed to freezing temperatures. Never place valves in piping leading to or from expansion tank. 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 ma terial thoroughly. If part cannot be found, report shortage to your dealer, giving boiler size, series number, date, in spector's number and packer's number. GIVE BOILER SIZE AND SERIES NUMBER WHEN ORDERING REPAIR PARTS. Boiler Size................................................... Series No. ( See Series Plate on Boiler) Date............................................................... 19094 o i i I ii Plumbing and Heating Division AMERICAN RADIATOR & STANDARD SANITARY CORPORATION 40 W. 40th STREET. NEW YORK 1 8. N.Y. ARSS 8811 R8V. (1-87) 19095