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PLAINTIFF'S EXHIBIT --------------------------------------------------------- ..p - G-4 GAS BOILER by AwiwcAN-c^tandapd Installation - Operation and Maintenance Manual 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 A^RiCAN-tf$tattdai*d[ Flrtt In Hatln ... flrft In pUmklni n 19278 G-4 GAS BOILER / GENERAL DIMENSIONS cmui m r KCTMI A 8 C 0 rL KK M MMKTM *f IMC* Ml* Ul 4M 0-44 0-45 0-44 0-47 0-44 0-44 0-410 0-411 f s 4 7 4 10 11 5 HI 15 ] 5 t 20* i i 4 ' 17 <3] 7 S| ii 5 "I 21 4 t r4 *( IS at < 9 4 toi 2i ..1 MtJ r7 *>1 24 "1 9 Mi M| r4 35 i 10 7 >2l 40* i i :_____ t 4 37 ui 10 7 tj **k >i JZ L10 i_ 41 j 11 _U-j _iii LiU_____ Li_____ ______1______ 1 r t >i >4 u 19279 G-4 GAS BOILER 1 ARRANGEMENT OF FLOW AND RETURN. TAPPINGS eotLCft NUM8CR G-44 G-45 NS. 0* KCTIOMt 4 5 L 16 20 A BC 13 4 Mi 17 isi rv> G-46 6 24 21 22} 13} G-47 7 28 25 26} 14} G-48 8 32 29 30i 14} G-49 9 36 33 34^ 15} G-410 10 40 37 38} 15} G-4II II 44 41 42i 16} MINIMUM PIPING RECOMMENDATIONS FOR G-4 GAS BOILERS Bailer (Number and Six* el Outlet*) Steam Water Boiler Steam Water Six* No. Slie No. Six* Six* No. Six* No. Six* G-44 G-45 G-46 G-47 1 2' 1 1W G-48 1 2H' 1 U4* G-49 1 3' 1 l!i* G-410 1 3' 1 2' G-411 2 2\i' 1 2* 2 2H' 1 2H` 2 3' 1 2H` 2 3' 1 2` Note: Other right or left hand xupply outlet may be u*ed on water boiler* uring drculaton, bat limit control ahould be placed in that (action carrying the upply outlet being u**d. On gravity circulation u*e both outlet* oi ixe* ihown above. 19280 2 G-4 GAS BOILER ERECTING Caution On 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. ,----v "This appliance should be installed in accordance with the lates^GA^) Instructions For Installation of Gas Piping and Gas Appliances'll! Buildings. 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.'' Location. Locate the boiler near the chimney or flue and as centralized with respect to the heat distribution system as practicable. If water condition exists in the basement, or if it has been necessary to water proof the basement floor, the boiler should be mounted on a concrete or hollow tile base, preferably to a height of at least three inches. In utility room installations, the door shall be wide enough to allow the largest boiler part to enter or to permit the replacement of another appliance such as a gas water heater. 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 (1) square inch per (1000) Btu per hour of input rating. (This method should always be used where practicable.) (c) Opening to outdoors, minimum free area of one (1) square inch per (2500) to (3000) Btu per hour of input rating. (This method should only be used where openings to interior spaces axe impracticable.) Chimney 1. Flue or vent connector to chimney must be the ^me size as the outlet of the draft diverter. 2. Where two or more appliances vent into a common flue, the afea of the common flue should at least equal the area of the largest flue of vent connector plus 50 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 wall of the chimney flue. 19281 i to G-4 GAS BOILER Pipe Delivery Schedule Capacity of Pipes in Cubic Feet of Cas per Hour. Length of Pipe in Feet 10 20 30 40 50 75 100 212 150 122 105 95 77 66 SIZE 1' 425 300 252 218 195 160 134 3 lr 725 510 425 370 330 270 232 Assembly of Sections 1. All reference to right or left refer to observer's right or left when facing front of boiler where manifold is attached. 2. Select right end section and place on block' on floor as shown in Fig. 1. Clean nipples and nipple openings with kerosene or gasoline and apply good lubricating oil. Do not use paint or red lead. 3. Drive nipples squarely into section, using block of wood and hammer or preferably an alu minum headed hammer if available. Gage nipples in both directions to insure that they are driven squarely and to proper depth in nipple openings; nipple setting gage is provided for 4" nipples. Cutout in gage should rest on both sides of nipple when legs of gage are touching finished t. RUM End Section 1. Nipple 2. Ground Rib ribs on section. See Fig. 2. Flo. 1--RigHt End Section 19282 4 G-4 GAS BOILER Each 3" nipple must project outside of finished face of sec tion uia inch more than half -1 }a< 1. Nipple Geuqc its length. Use rule to gage 3" nipples to insure that they project outside of opening equally all around. Most nip ple leaks are caused by tilted or cocked nipples. 4. Paint ground rib, around outside of section only, with Fic. 2--Gaging Nipple red lead. 5. Place center section in position on nipples in end sec tion. Drive sections together with heavy block of wood striking section squarely as possible over nipple ports. 6. Place sections in upright position and support with suitable blocking. Sections should stand approximately in their final position with Front facing correctly. See Fig. 3 (Note Cleanout open ings are at front of boiler). 7. Insert tie rods through lower nipple openings and tappings on end section and through cored hole below upper nipple port. Place 3" C.I. washers on lower rods against tappings. Place assembling blocks on lower rods across nipple ports as shown on Fig. 3 placing nuts and washers on all rods. 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 19283 (0 G-4 GAS BOILR $ joints. Apply oil or grease freely to tie rod threads while assembling sections to prevent stripping of threads on rods. Paint ground ribs of each section with red lead and continue assem bling center sections one at a time. Shift blocking each time so that support is under the last section assembled. 8. Remove tie rods and place Left End in position. Insert lower tie rods through lugs on ends and upper tie rod through hole in sections. Draw sections together as in previous operations until ground joints are tight. Back of! all tie rod nuts until they are finger tight only, to allow for expansion. 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 as a result of breakage from handling and shipping. To safeguard accuracy of gage and controls supplied with boiler, do not install until after test of boiler. This pre caution of testing the boiler will simplify handling of any necessary re placements or adjustments and assist in treating with claims against transportation companies. After test, drain and remove plugs where re quired. Assembly of Platexvork, Main Burners and Manifold 1. Screw short threaded end of brass studs into tapped bosses in recess between sections and attach cleanout cover plates to front of boiler. Putty openings between plates and sections. Putty outside of sections at joints with boiler putty. Place burner support on lugs provided on % end sections. See Fig. 4. 19284 G-4 GAS BOILER 2. Fill space between second and third horizontal ribs from top on back of Front Frame with boiler putty and attach frame to front of boiler with four V' x 1" hex head cap screws. 3. Fill space between hori zontal ribs across top on rear side of Back Frame with boiler putty and attach frame to back of boiler in like manner. 4. 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. 1. Front Frame X Manifold Support Bracket t Manifold 4. Automatic Gas Vain X Gas Pressure Regulator Etc. 5--Manifold and Gas Piping 5. Install control piping (coupled at union) manifold and bracket assembly to front frame with W x 1" Hex Head cap screws. Arrow on automatic gas valve and gas pressure regulator must point in direction of gas flow. 6. See that air shutter is assembled on each mixer tube, then place mixer tubes firmly on orifice holders and burner support. Assejnble main burners on tapered ends of mixer tubes so they are straight and level, and tighten set screws in manifold brackets. Pilot Burners Attach pilot burner and tubing assembly (or assemblies) to main burners with two #10--24 x 1" fillister head screws. Pilot installations for all gases require a tube for venting pressure regulator and automatic valve. Vent tube is provided with tip, tubing connector and dip for installation with the pilot burner: (left pilot in case of 8 to 11 section boilers). See Fig. 7 for pilot burner locations. NOTE--Pressure regulator is not used for Butane and Propane Gases. The vent tube clip is secured with the pilot burner attaching screws. The vent tube is inserted under the dip before tightening the screws, with the tip of the tube approximately level with the top of the main gas burner. See Fig. 8 for manual ignition and Fig. 9 for boilers with electric ignition. See Fig. 5 for boiler with burners, manifold and control piping installed. 19285 <3-4 GAS BOILER 7 In case of boilers provided with RIBBON BURNERS, the ends of the burners having two #10-24 tappings must be toward the front of the boiler. The installer is to remove and discard the truss head screw which holds the ribbon clamp at the front of the bumer(s) where the pilot is to be installed. Two tappings are then available for the 1" fillister head screws for holding the pilot burner assembly. Install sheet metal baffle at front of boiler on lug cast on leg of each end section. Runner Pilot Ignition The lanced runner pilot assembly is attached to the pilot burner by means of a clip. Attach the jnd with the push button valve to the. manifold with the clamp provided. Fig. 6A ... , method of clamping and ar rangement of piping and tub ing. See Fig. 18 for connection at die shutoff and throttling valve. The flame along the side of the lanced tube should be about long. The flame is regulated by an adjusting screw under die cap on die pilot valve. (Boiler with two pilots)--Install connecting tube from the branch outlet of the tee fitting at the push button valve to the tee fitting on the L.H. Pilot tube. Ftc. 6A--Runner Pilot Tubing ud Clamping Anaageraant for Boiler With One Pilot Then run VI" tubing between the fittings on L.H. and R.H. Pilot tubes. Electric Pilot Ignition Attach electric pilot burner and tubing assembly to the main burner with two #10--24 x 1" fillister head screw's. See Fig. 7 for pilot burner locations. Use left pilot in case of 8 thru 11 section boilers. See page 13 for connecting die thermocouple and Baso ignition leads. V t Chrtrfc lanitar Fic. 6B--Electric Pilot Ignition 19286 I G*4 GAS BOILEH ntennj nNNn<Mj_ mn* mLIS i M.U nnnr LIuj.iIjU. Ip finqn i_: MtKi mi Jjp* Q > tfCO XII mmm DQ^QBxpd^QSQ DS^SitpB^QB \- iur MWI ^ Ut M*4U --^ too*/. tMuTorrPILOT LOCATION HMI ALU *ASC - MANUAL IONITION a*t1vnangrkij in*tnr*inNMp-I inNOn-ONnNUnI m tip Lik^jy *N* tMI uNnCuTa<*-nfIff t uuiaLttui *Ta INMUuKI LAN* 1 ***-- M,t QQ&E3QQQ --*W^*--* -V\*--NT IJU^LttUi QB oil Liwd QQmg UbJU 'H#T PUf LOCATION 0N WTO,NAT U UIJU0 tAttt- MANUAL tONTTIOM. nnn i NON I00%L INWTOTT nnANnNp Dp) iu<m n NON V*UlOTf Fie. 7--Burner and Pilot Locations 19287 ( I GA gas boiler 9 Fla. 9 Canwf and Mot InatallaUon--Manual tuition I I t i I 19288 10 G-4 GAS BOILER Assembly of Jacket, Controls and Wiring 1. Attach canopy hook (or hooks) to front of canopy with Vi" --20 x Vi" washer head machine screws. Place canopy on boiler with canopy hooks engaging lugs cast on sections. Seal between out side of canopy and sections with boiler putty. Refer to Figs. 11 and 12. fcCTMOO OF MXOlNG CANOPY TO BCH-D> Fig. 11--Detail of Canopy Hook 2. Remove knockouts from Front Liner for controls, either for steam or water boilers, as required. Attach terminal block and Baso pilot switch, also Baso ignition switch in case of boilers with electric ignition. Locate ignition switch on right side of Front Liner for 4 and 5 section' toilers and on left side for 6 section and larger boilers using the holes nearest to the center of the panel. Attach Front Liner to boiler with Vi"--20 x H" washer head machine screws in tappings near top, on each end section. 3. Attach lighting instruction plate and the number and series plate to the cleanout door and set cleanout door in place. 1. Baso Automatic 5. Steam Limit Control Pilot Switch (Steam Boilers) 2. Terminal Block or Immersion Op* 3. Low Water Cutoff eratlng Control 4. Front Uner with * (Water Boilers) Cleanout Door 1 Jacket Spacer Studs 7. Canopy Pie. 12.--Boilor with Canopy, Front Liner and Controls 4. Assemble six jacket spacer studs, three on each end section, in %" tapped holes. Refer to Fig. 12. 5. Assemble the left side panel to the three spacer -studs and the Vi"--20 tapping on the section with Vi"--20 x Vi" washer head 19289 t G-4 GAS BOILER II (item 5 cont'd) machine screws after removing knockouts for water column trim in case of steam boilers, also knockout for drain cock from either left or right side panel, which ever side is most convenient to drain. 6. Install the controls and the control wiring to accord with the wiring diagram supplied then as semble the right side panel in same manner as left side panel after re moving knockout for safety valve, in case of steam boiler. Place burner access door (or doors) in position on projections cast on front frame. Refer to Fig. 12. 1. Burner Accen Door 3. Junction Boa 2. Lett Hand Side Rant) 4. Right Hand Side Panel Flo. 13--Aesembly of Side Panels 7. Assemble the upper front panel to the side panels with four #10 x 1" sheet metal screws. As semble the bottom cross tie with two #10 x 1" sheet metal screws. Run the electric line to the junc tion box, located on left hand side panel, connect wiring and install the transformer on the junction box. Refer to Figs. 13 and 14. 8. Assemble the upper back panel to the side panels with four #10 x 1" sheet metal screws. 9. Assemble the lower back panel by engaging the lock strip with the upper rear panel and at taching to side panels with four #10 x 1" sheet metal screws and to upper rear panel with two #10 x V4" sheet metal screws. 1. Freni Bottom Croat Tie 2. Vent Tube X Pilot Tube 4. Trantformer V Uooer Front Panel Fig. 14--Jacket Crou Tie and Upper Front Panel 19290 12 G-4 GAS BOILER % i \ 10. Assemble draft hood to canopy with #10 x XJi" sheet metal screws. 11. Assemble top panel (rear) with four #10 x 1" sheet metal screws. 12. Assemble two, back filler pieces to top panel and upper back panel, each with four #10 x 1" sheet metal screws. Refer to Fig. 16 for assembly uf back jacket pieces and drafthood. 13. Assemble top panel (front) with turned down flange on rear edge, engaging lock on rear top panel. Opening at front is to pro vide ventilation for the control compartment. Fic. 16--Rear View--Steam Boiler (~ 19291 v) G-4 GAS BOILER 13 Assembly of Exterior Piping and Pilot Tubing 1. For 10 and 11 section boilers, Manufactured ar.d LP-Air (525 to 800 BTU) gases, install gas pressure regulator outside of the jacket, connecting regulator to automatic gas valve under jacket with long nipple provided. 2. Make up drip leg piping (not supplied by AR & SS Corp.) of suit able height and install the manual shutoff valve assembly. 3. Make suitable connection between tee in drip leg and piping to gas pressure regulator. Be sure to leave sufficient space between pipe cap on bottom of drip leg and floor to allow for drip removal. Place suitable block under drip leg to support control piping in level position. 4. For Boiler with Non 100% Shutoff, Manual or Electric Connect pilot line from manual shutoff valve assembly to the pilot burner tube (left hand in case of two pilot burners) running the tubing through the opening in the jacket along the side of the gas piping. In case of 8 to 11 section boilers, inter-connect the pilot line to the right hand pilot burner. Tubing is to be installed above the orifice holders. See Figs. 14 and 19. See Fig. 6A for runner pilot tubing hookup. UMN SASLtC Connect the thermocouple lead from the pilot burner to the Baso pilot switch. Also con nect the electric ignition lead to the Baso ignition switch for boiler with electric ignition. See Fig. 6B. Fie. IS--Supply Piping--Manual Ignition 19292 I 14 G-4 GAS BOILER 1. Manual ShutaR t. Gat Pressure Regu Valve lator 2. Pilot Valve 7. Vent Line a. Pilot Line I. Manual Control 4. Baso Automatic Pilot Switch 9. Automatic Cas Valve 5. Reset Button 10. Pilot Burners 11. Thermocouple Fic. 19--Control Connections--Manual Ignition-- Nat, Mid., and Mixed Casei Fic. 20--100% Shutoff-Single Tilot foe Mid., Nat., Mixed and LP-Air Casa Fig. 21-100% Shutoff-Single Pilot fa Butane and Propane Casa Fic. 22-100% Shutoff-Dual Pilots la Mfd., Nat. Mixed and LP-Air Casa Fic. 23-100% Shutoff-Dual Pilots fa Butane and Propane Casa 5. For Boiler with 100% Shutoff o 4 thru 7 SECTION BOILERS--Connect Ve" pilot tubing from the manual shutoff valve assembly to the L.H. fitting,on the bottom of the Baso pilot 19293 P G-4 GAS BOILER switch (marked "IN") running the tubing through the manifold opening in the jacket. Connect V" pilot tubing from the pilot burner to the R.H. fitting (marked "OUT) on the bottom of the Baso pilot switch, also connect the thermocouple lead from the pilot burner to the fitting on the bottom of the switch. See Figs. 20 and 21. 8 thru 11 SECTION BOILERS--Connect Vs" pilot tubing from the manual shutoff valve assembly to the "INLET" end of the Baso pilot valve running the tubing through the manifold opening in the jacket. Connect W pilot tubing from the pilot burner nearest to the left end of the boiler to the branch connection on the Base pilot valve. See Figs. 22 and 23. Connect Vi" tubing from the "OUTLET* end of the pilot valve to the L.H. fitting on the bottom of the Baso pilot switch (marked "IN"). Connect Vi" pilot tubing from the pilot burner nearest to the right end of the boiler to the R.H. fitting (marked "OUT) on the bottom of the Baso Pilot switch, also connect the thermocouple lead from this pilot burner to the fitting on the bottom of the Baso switch. 6. Install drain cock in end section where jacket knockout was previously removed. 7. Place lower front panel in position and turn handle (or handles) to lock after completion of piping and wiring. Steam Boilers Install steam gauge and water column trimmings in left end section. Install safety valve piping and safety valve in right end section. Fig 15 shows front view of complete steam boiler (6 sections) Fig. 16 shows rear view of complete steam boiler. (6 sections). 19294 16 G-4 GAS BOILER Water Boilers Install combination altitude gauge and thermometer in left end sec tion. Install relief valve in 2" tapping near top of right end section. Fig. 17 shows front view of complete water boiler. (6 sections). Filling System 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 midway up gage glass between try cocks. Fill open hot water system to Vs height of expansion tank, remove rim and glass from gage and set movable pointer under automatic pointer. Replace rim and glass. Fill closed hot water systems until relief valve opens. This should be at a pressure not greater than 30 lbs. per square inch. If necessary adjust relief valve setting. 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 alti tude of approximately 69 feet represents a pressure of 30 lbs. per sq. in.) Note that the altitude-temperature gauge is calibrated both in feet of altitude and in lbs. per sq. in. Replace rim and glass and reduce pres sure by draining out water until the indicating pointer lines up with the movable pointer. Keep system filled. Pointers on gauge 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 over top of burner. Pilot rate can be adjusted with screw underneath cap on pilot throttling cock. G-4 GAS BOILER 17 Normal Pilot Input for Baso Pilot Burners Input per Pilot Burner Btu/Hr. Mfd. 1000 Gas Nat. Mixed 1400 1200 LP. LP-Air 1000 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. Gas Consumption (Cubic Feet Per Hr.) Input Rating (Btu per Hr.) Heating Value of Gas (Btu per Cu. Ft) A 1/8" pipe plug is placed in the top of the manifold to provide for check ing 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 or 2.5 inches of water for manufactured gas. 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 mani fold 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. 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. 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 l*evel is above centerline of low water cutoff. Automatic gas valve should open. 19296 IS G-4 GAS BOILER INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION - NON 100% SHUTOFF To Shut Off: 1. Close manual shutoff valve "A" and pilot valve "B." To Light: 1. Set thermostat (or operating control) at 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. Open pilot valve "B" and light all pilot burners. 4. Wait two minutes. 5. Press reset button(s) on all automatic pilot switches. 6. Open manual shutoff valve "A." MAIN GAS LINE 7. Set thermostat (or operating control) at desired tempera ture. 19297 G-4 GAS BOILER 19 INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION - 100% SHUTOFF (BOILERS WITH ONE PILOT) 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 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. Open pilot valve "B." 4. Press plunger "C" on Baso automatic pilot switch and light pilot "D." Hold plunger "C" for one minute. 5. Open manual shutoff valve "A." 6. Turn on switch in electric line to appliance. 7. Set thermostat to desired temperature. i i 19298 20 G GAS BOILER 9 INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION - 100% SHUTOFF (BOILERS WITH TWO PILOTS) To Shut OH: 1. Close manual shutoff valve "A" and pilot valve "B." 2. Turn off switch in electric line to appliance. To Light: 1. Set thermostat 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. Open pilot valve "B." 4. Press plunger "C" on Baso automatic pilot valve and light pilot "D." Hold plunger "C" for one minute. For additional valves repeat. 5. Press plunger "E" on Baso automatic pilot switch and light pilot "F." Hold plunger "E" for one minute. 6. Open manual shutoff valve "A." 7. Turn on switch in electric line to appliance. 8. Set thermostat to desired temperature. MAM NOTC^OUM FILTER MOT U3C0 WITH 19299 <0 G-4 GAS BOILER 21 INSTRUCTIONS FOR SHUTTINC OFF AND LICHTING ELECTRIC IGNITION - NON 100% SHUTOFF 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 6ve minutes before proceeding. 3. Tum on switch in electric line to appliance. 4. Open pilot valve "B." 5. Press red electric igniter button *C" until pilot burner lights. 6. Press plunger "D" on Baso automatic pilot switch. 7. Open manual shutoff valve "A." 8. Light main burners by setting thermostat (or operating control) to high est temperature. Wait for approx. 3 seconds, then return to lowest setting. Be sure that all auxiliary pilots have lit 9. Set thermostat (or operating control) to desired temperature. MAIN OAS LINC Ftc. 24 19300 22 G-4 GAS BOILER INSTRUCTIONS FOR SHUTTING OFF AND LICHTING RUNNER PILOT IGNITION - NON 100% SHUTOFF To Shut Off: 1. Close manual shutoff valve "A" and pilot valve "B." 2. Tum 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. Open pilot valve "B." 4. Push and hold red button "C." Light runner pilot. Re lease button "C." When pilot burner lights. 5. Wait one minute. 0. Press plunger "D" on Baso automatic pilot switch. 7. Open manual shutoff valve "A." 8. Turn on switch in electric line to appliance. 0. Light main burners by setting thermostat (or operating control) to highest temperature. Wait for approx. 30 seconds, then return to lowest setting. Be sure that all auxiliary pilots have lit 10. Set thermostat (or operating control) to desired tempera ture. MAIN OAS LINC $ 19301 -- e G ire. avc Re* "a all era- o G-4 GAS BOILER 23 Pilot Goes Out If the pilot flame is extinguished, the automatic pilot will shutoff the automatic gas valve. If boiler is not operating correctly, call Heating Contractor or Gas Company service man. If boiler is operating cor rectly, relight as directed on Pages 18 thru 22. EMERGENCY INSTRUCTIONS FOR OPERATION DURING FAILURE OF ELECTRIC POWER SUPPLY In lh event si failurs of electric powsr supply the gat burnsr operating this boiler will automatically shut off. It it pottible to operate tbit burner manually by following the directions given below. CAUTION -- THE BURNER SHOULD BE OPERATED MANUALLY ONLY AS AN EMERGENCY MEASURE. THE AUTOMATIC SAFETY CONTROLS WHICH PROTECT THE BOILER DURING NORMAL OPERATION ARE NOT OPERATIVE. CONSTANT SUPERVISION IS REQUIRED TO PREVENT THE POSSIBILITY OF DAMAGE TO THE BOILER BECAUSE OF LOW WATER OR OVERHEATING. NEVER LEAVE THE BURNER OPERATING MANUALLY IF IT IS TO BE UNSUPERVISEO FOR ANY LENGTH OF TIME. IN SUPPLYING THESE BRIEF DIRECTIONS FOR MANUAL OPERATION OF THE BURNER, THE MANUFACTURER CAN ASSUME NO RESPONSIBILITY FOR THE SAFE OPERATION OF THE BURNER, BOILER AND OTHER EQUIPMENT. SAFETY DEPENDS UPON THE CARE AND JUDGMENT EXERCISED BY THE OPERATOR. ALL POSSIBILITIES CANNOT BE COVERED IN THESE BRIEF DIRECTIONS. BASIC STEPS IN MANUAL OPERATION 1. Be ture the burnet pilot it burning proporly. If to, then: -- 2. Turn off electric power twitch controlling the burner. LEAVE THIS SWITCH OFF UNTIL POWER HAS BEEN RESTORED. 3. Burner may now be operated manually by opening the automatic gat control valve In accordance with inttructiont printed on the valve cover. 4. If the boilar operated by the gat burner it inttalled on a forced circulation hot wafer heating tyttem (incorporating electric circulating pump) OPEN FLOW CON TROL VALYE OR VALVES IF PROVIDED IN THE WATER LINES. (Note: It it tuggettad that tha original petition of thoie valvet be carefully obtervod and thato obiarvatiem rocordad, ta permit rottoring that# valvet to their original peti tion whan automatic operation it returned.) Alto, REDUCE THE MAIN BURNER FLAME TO A MINIMUM ADJUSTMENT (approeimatoly 1/3 or 1/4 normal tite) BY PARTIALLY CLOSING THE MANUAL GAS SHUT OFF VALVE. TO RESTORE BURNER TO AUTOMATIC OPERATION UPON RESUMPTION OF SUPPLY OF ELECTRIC CURRENT 1. Return automatic got control valve to itl original ''automatic" totting, in accord ance with inttructiont on valve cover. 2. Turn on electric power tupply twitch. 3. On forced circulation hat water heating tytlemt, return flew central velvet, if pro vided, to their normal operating poiitiont. 4. Turn manual got thut off valve to Itt wide open petition. i i 19302 24 G-4 GAS BOILR 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. Maintenance of Boiler While in Operation 1. Check water level regularly and add water slowly when needed. 2. This boiler is fired automatically. 3. 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 cock, located at lowest point in system. Be sure boiler is com* pletely drained. In Summer While Not in Operation Keep the system filled as during the heating season. Each boiler should have a periodic check up of all safety controls and a close inspec tion of the burners, mixing tubes, flue passageways, draft hoods 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. This inspection should be made by your heating contractor or a competent service man before the start of each heating season. If necessary, remove the cleanout jacket panel and the cleanout cover plates and clean pin fin surfaces of the boiler sections. The above inspection should include the testing of all safety pilots, limit controls, safety relief valves, and low water cutoff on steam boilers. General Maintenance 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 w. indicates that a: radiator: Hold; open vent until 4. Fill steam Note. 5. Fill hot w Open all rad open systems t the water fill reached. (Pres ground floor, to add water d 6. If much v. a high temper sary during th 7. Where ar its drain pipe page 2. The grease piping systems fine particles a boilers, while form sludge, eration of stea This unavi blowing-off th blow conuccti to within 18 ii boiler, bring 19303 n of boiler. Do Then refill to when needed. eason and once and pull cord. Drain through boiler is com- n. Each boiler 1 a close inspec- raft hoods and firing rate and is operating at 1 your heating of each heating nd the cleanout ions. The above , limit controls, rs. it inspected by G-4 GAS BOILEB 2$ 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 steam boilers only as directed (on page 16.) See CAUTION Note. 5. Fill hot water system as follows: Open all radiator valves, but keep vents at top of radiator dosed. 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. 6. 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. 7. Where an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed to freezing temperatures. See caution note on page 2. CLEANING BOILERS The grease used to lubricate the cutting tools during erection of new piping systems serves as a carrier for dirt, with the result that a scum of fine particles and grease accumulates on the surface of the water in all new boilers, while heavier particles may settle to the bottom of the boiler and form sludge. These impurities tend to cause foaming, preventing the gen eration of steam and causing an unsteady water line. This unavoidable accumulation of oil and grease should be removed by blowing-off the boiler as follows: If not already provided, install a surface blow connection of at least 1V4 inch nominal pipe size with outlet extended to within 18 inches of the floor or to sewer, inserting a valve in line olose to lioiler. Bring the water line to center of outlet, raise steam pressure, and 19304 26 G-4 GAS BOILER r* while burners are operating open valve in blow-off line. When pressure recedes, close valve and repeat process adding water at intervals to maintain proper level. As a final operation bring the pressure in the boiler to about 10 lbs., close blow-off and manual shut-off valves, then open drain valve. After boiler has cooled, partly fill and flush out several 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. Note: All parts packed. Se In case of shortag shipping container cannot be found, r series number, dat Parts List and Pad SUCCESTED PIPINC ARRANCEMENT FOR BLOWINC-OFF STEAM BOILERS Caution After the blow off operation, a checkup should be made of the Low Water Cutoff as directed on Page 17. i GIVE BOII Boiler Size ... Series No. {See Date................ l 19305 _ne. When pressure intervals to maintain i the boiler to about n open drain valve. .1 times before filling if sods, or any alkali, -ating boilers because of subsequent injury IFF STEAM BOILERS be made of the Low G-4 GAS BOILER 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 removed 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 number and packer's number. (See Parts List and Packer's Check Tickets). GIVE BOILER SIZE AND SERIES NUMBER WHEN ORDERING REPAIR PARTS Boiler Size.......................................................................................... Series No. (See Series Plate on Boiler)....................................... Date.................................................................................................... \ 19306