Document zog4Lkzd3ZNXpDQonbwrEpxq7

a/zc< f STANDARD BOILERS by African-c^tafldard Installation-Operation AND Maintenance Manual FOR TYPE 4G GAS FIRED BOILERS APPROVED .BY AMERICAN GAS ASSOCIATION notice TO installer AND operator THIS BOOKLET MUST BE AFFIXED ON OR ADJACENT TO THE HEATING EQUIPMENT AMERICAN-^tcMtdafd First in heating ... first in plumbing 19016 STANDARD BOILERS GENERAL DIMENSIONS FOR 6 TO 11 SECTION BOILERS TYPE 4G NO. OF NO. OF NO. OF BOILER SECTIONS BURNERS 4-G- 6 6 10 4-G- 7 7 12 4-G - 8 8 14 4-G- 9 g 10 4-G-IO 10 18 4-G- II ii 20 A 74 7/fl 76 5/a 78 ''s 79 7/8 81 '/2 83 B 693/8 70 Va 7IV8 727/a 74 75 NOTF. Mr.ucht Tmk Spud Hol lers icpluce the Ancle Type Spud Holders shown in cut D 11 12 13 14 15 16 L 27 31 35 39 43 47 19017 STANDARD BOILERS ------E GENERAL DIMENSIONS FOR 13 TO 41 SECTION BOILERS TYPE 4G 1 4BNO-OGIL. -EOIRF3 SENCO1T.3IOOFNS BUNRO2N.4EORFS 4-6-15 15 25 A 76 ve 75 `4i B 7710V*ag c 3304**8* 4-6-17 17 32 79 72*8 38*a 4-6-19 (9 4-6-21 21 35 40 SI *2 74 53 75 4426^4a* 4-6-22 22 42 781* 7l*a 34*a 4 -G-25 25 4-G-28 25 4-6-31 31 45 54 60 79 *e 8 1 ''i 1 83 | 72 *s 74 75 35*8 42*a 46** 4-6-33 33 64 79'/a 1 72'/a 38*e 4-G-37 37 72 81 */* 74 42*e 4-G-4I 41 SO 53 75 45*6 0 1123 14 1150 13 14 15 15 14 15 16 NOTE Siraight Type Spud Holden replace me Angle Tvpe Spud Holden shown m cut. E FL 3304*** 1175-V*f8e 61*4 80*4 38^4 te^a 77'4 42*4 46*4 2l*e 85*4 23*e 93*4 34*4 17*8 103*/2 38*4 I9*b ll5'/2 42*. 21*8 127 */2 46*. 23*a 139 >2 36*. 19*8 153*. 42*4 21*8 169*. 45*4 23*e 185*4 19018 2 STANDARD BOILERS TYPE 4G ERECTING CAUTION On hut u ater s\ stems, expansion tank should not be installed in coM or exposed place No valves of an\ type should be installed in piping between boiler and expansion tank Sealing s\ stem at am time during operation may cause bieakage of boiler or radiators. LOCATION If water condition is encountered in basement, or if it has been necessary to water-proof the base ment floor, boiler should be mounted on concrete or hollow tile base at least 3 inches above floor level NOTE All leferences to Right or Left parts refer to observers right or left when facing front of boiler All sections are stenciled with word "Front'' and individual numbers "1". "2",' 3 '.etc indicating the position which each section is to occupy m the boiler. ASSEMBLY OF SECTIONS 1. Select right end section (less two 1" trim tappings; stenciled No. I) and place in approximau final position with front of section facing correctly. Support with wood prop Clean nipples am nipple openings with kerosene or gasoline and apply good lubricating oil. Do not use paint or red lead L.-i)oui Ol Flow Anil Return Taiipintis BOILER | NO or sections M N CMOS 40- 4-G 9 4-0-lO 4-0 l 1 4-G >3 4-0- l i 4-o y 29 4 30 34 4 39 4 2-. 46 >4 *0 /? T9 /> -- -- -- -- -- 30 4 34 V-. 394 -- -- -- -- -- -- -- -- -- i 2 2 0 0' 0 0 0 0 1 1 4 s 6 7 6 * 0 2 4 BOILER 1 4-G-1* 4-0-2' 4-0 22 4-G-2S 4-G-29 4-G-3' 4-G-33 4-0-37 4*0*4 1 4 ,, 2 /> 02 V. 1414 29*. 39 *. 133 i9 I9S M 42 '4 494 34 /. 39 /. 49'4 39 4 4 2/4 494 1N -- -- 34 . 39 4? 49 4 39 . 42 4 - 46 4 HO [NOS 2 Of SECTIONS IN T CB . .. t f t MtoiAtrs ctNTl i i9 2 >6 2 2i 2 27 3 36 19019 STANDARD BOILERS TYPE 4G 3 2 Drive nipples squarely into end section using block of wood and hammer Gage nipples m both directions to insure that they are driven squarely and to proper depth in nipple openings, nipple setting gage is provided for this purpose Cutout in gage should rest on both sides of nipple v. hen legs of gage aie touching finished pads on section. Most nipple leaks are caused by tilted or cocked ripples See F.g 1. 3 Paint ground ribs around outside edge of sec tion only, with red lead. 4 Place center section in position on nipples in end section. Drive sections together with heavy block of wood, striking sections squarely as possible over nipple ports Assemble sections m numerical order with fronts (stenciled with position number) facing in same direction. 5. For 6 to 11 Section Boilers--Insert one tie rod through each bolt hole above lower nipple ports and one tie rod through upper nipple port. Place as sembling block or. upper rod and assembling wash ers on lower rods as shown and place nuts and wash ers on all rods. See Fig. 2. Flc. 1--Gaging Nipple For 13 to 41 Section Boilers--Use assembling clamps with loose jaws against end section in place of nuts and washers. Place clamps on rods with flat side against section. Insert jaws in blocks with serrated end against rod and draw up on rod from opposite end. Tap jaw lightly to tighten grip on rod. Do not permit jaws to clamp on threads Place nuts and washers on other end. See F.g 3. All Sizes--Draw up evenly on nuts until sections make con tact at ground joints. Bumping sections with heavy block of wood alternately at nipple ports during drawing up operation will facilitate assembly. Apply oil or grease freely to tie rod threads while assembling sections to prevent stripping of threads on rods. Fic 2--Assembling Sections 19020 4 STANDARD BOILERS TYPE 4G Arrange for suitable blocking under center section. Paint ground rib of earn section with red load and continue assem bling center sections ONE AT A TIME Shift blocking each time so that support is under the last section assembled See Figs. 1 and 2 9 5?.. 6 For 13 to 41 Section Boilers--Continue to assemble sec tions until ready for intermediate (thick) section Bolt two burner support brackets to each side of intermediate base and lengthen tie rods with couplings. Repeat this operation as each intermediate section is assembled See Fig 4 7 All Sizes--Remove upper tie rod and assembling blocks Remove nuts and washers from lower rods. Place left end section in position and insert tie rods through bolt holes in sections Draw sections together as in previous operations until all ground joints are tight Back oil all tie rod nuts until they are finger tight only $ 1. J<* 7. Clamor Fic 0 Assembling Clamps 3^ -BT" 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 out side for leakage to insure against breakage from han dling and shipping. To safeguard accuracy of gage sup 1. Right End Section 2. Intermediate Se :>on S. Center Sections plied with boiler do not install gage until after test of --Assembling Larger Boiler boiler This precaution of testing the boiler will simplify handling of any necessary replacements or adjustments and assist in treating with claims against transportation companies. After test, drain and remove plugs where required. ASSEMBLY OF PLATEWORK 1. Screw short threaded end of brass studs into tapped bosses in recesses between sections and attach cleanout cover plates to front of boiler See that asbestos gasket is on each plate and makes gas seal when drawn up tight. See Fig. 5 Attach filler plates in like manner to back of boiler. Putty openings between plates and sections Putty outside of sections at joints with boiler putty. 19021 STANDARD BOILERS 2 Place burner supports in pockets provided on end sections, and in bolted-on supports of intermediate sec tions on 13 to 41 section boilers See Fig 5. 3 Fill grooves on back of burner access door frames with putty and attach frames to sections with hex head screws using washers under heads. Attach manifold brackets to front and back burner access door frames with hex head screws. See Fig. 6. TYPE 4G 5 } Fic. 5--Section Assemblage ASSEMBLY OF BURNERS AND CONTROL PIPING 1. Assemble sub-assemblies of manifold, manifold piping, automatic gas valve and gas pressure regulator or automatic pilot valve and attach to boiler. See that orifice spuds hi ends of spud holders are screwed in tight and that orifices are drilled to size specified on tag at tached to manifold. (See Figs. 7, 8, 9, 10 and 11.) )i NOTE Straight Type Spud Holden replace the Angle Type Spud Holden shown ui cut 12 I. Burner Accra Door Frame t. Hex Head Screen i Fic. S--Assembling Burner Access Door Frame 19022 6 STANDARD BOILERS TYPE 4G 2. See that air shutter is assembled on each mixer tube, then place mixer tubes firmly on spud holders and burner support. Assemble main burners on tapered ends of mixer tubes so they are straight and level. (See Figs. 7, 8, 12, 13, 14 and IS for proper burner locations). 3. Place front and back secondary air baffles on lugs on end and intermediate sections. The baffle Ranges should be away from burners and turned downward. See Figs. 7 and 8. I, Gas Supply line t. Manual Shut-Off Valv* Assembly 1. Gas Pressure Regulator 4. Automatic Gas Valves t. breuer Coupling ft, Manifold Pipe 1, Spud Holders L Union For l) Section 1, Gas Supply Lines 2. Manual Shut-Off Valve Assemblies 2, Gas Pressure Regulators ft. Automatic Gas Valves L Manifold Pipe I. Spud Holden Manifold Piping for HIiL, Nil, Mixed and LP-Air Fte. 9-A--Mfd. and LP-Air (S through U sec- Fx. 9-B--Mfd. and LP-Air (IS through IT sections) Hons) Nat and Mixed (ft through U seclions) Nat. and Mixed (13 21 sections) NOTE Straight Type Spud Holders replace the Angle Type Spud Holders which are shewn in illustrations on thia page 19023 STANDARD BOILERS TYPE 4G 7 Nat and Mixed (22 througn 41 sections! 1. Gas Supply Lines ). Automatic Gas Valves 2. BASO 300 Senes Automatic 4. Manifold Pipe 1. Gas Supply Lme 1. BASO 300 Senes Automatic Pilot Valves ! Automatic Gas Valves 4. Manifold Pipe &. Spud Holders Manifold Piping for Liquefied Petroleum Gases (Install Manual Shutoff Valve m Gas Supply Line Upstream Prom Item 1}' Ptc 11-A--6 Through 19 Section Boilers Pic. 11-B 21 Through 41 Section Boilers NOTE Straight Type Spud Holders replace the Angle Type Spud Holders which are shown in illustrations on this page 19024 8 STANDARD BOILERS TYPE 4G in d P ilo t In tta llB h o n F o r M(<1 G i cziczi 0=100 -OOCOl rK TfgSr 6 HssH acz j Lgi cua -m `' 9 HP 11 55 , -@- yii? rgS-t 7r 77 - IS TS1P -gap "gg-* 9 ^114 "g7gg? -s- ? an: Lg-J ih . f7i7 -g- 7Y '7^37 ,-lsg^-* "ggca CUCZ3 -gg- A HCeZM=sU s ?!^ sk is -tfgilif- aa -gDC3 aa aa Heap r-i aa -ggaa 77 -SSaa -gg- 19025 STANDARD BOILERS Iff! 4G 9 F*. 13-- B u n w P ilo i In s ta lla tio n F o r Nat and M ix e d Caaaa -g3- _____ - aaJ&r -aa- He:car? a*!-a: LCa3I He:cai a caca - as - -ea- 7i a -aa- Qfcaearf --ea_a- Hea^ Sis Hilr -aa- ' 7@ir C3C3 -eaH - 7ear PO - 19026 10 STANDARD BOILERS 19027 TTO 4G V ia. 14-- B u m o r ond P ilo t In fU llo lio n F o r L P C m STANDARD BOILERS TYPE 4G 11 Fie 15-- B u rn e r and P ilo t In s ta lla tio n F o r L P - A ir Gas at., 0' CD '^ir ag 0a I i <: a &TTg A ig tS Si o* ^ 5 ; S ' 5hi!i| woi*9QTQ ?: I -sgr -can o<r (& o.t>, r c ,<9 Ti- /dA Oi^ -fgi- ft __ O' iSf tgr (I; `"J'O HI Olp* 19028 12 STANDARD BOILERS TYPE 4G Pilot Tubing Connections when one Manual Shutoff Valve is used at end of Boiler Pilot Tubing Connections when (wo Manual Shutoff Valves are used at end of Boiler. Pilot Tubing Connections for 13 t^ruon assembly lor manufactured and LP-Air Gases FtC- 16--Supply Piping Arrangements NOTE. All Piping Shown Below Manual Shutoff Valve Not supplied by AR & SS Corp 4 Install manual shutoff valve assembly as shown in Fig. 16. ASSEMBLY OF JACKET 1. Fill putty grooves at top of sections with boiler putty and place canopy or canopies in position so that turned down edges are firmly imbedded in the putty to make gas seal. Smooth off excess putty. NOTE Straight Type Spud Holder* replace the Angle Type Spud Holders which arc shown in illustration on this page. Fic. 17--Jacket Assembly; 13 through 21 section water boiler shown 19029 STANDARD BOILERS TYPE 4G 13 2 Place rear half of left end jacket pane! in position, then place front half m position Fallen two halves together having washer head screws pass through front half of panel into caged nuts at tached to rear half of panel, attach panels to boiler section with washer head screws On Water Buiiers put temperature bulb tubing under jacket panel corner 3 In similar manner attach two halves of right end jacket panel to boiler section fL i I Fic 16--Jacket Assembly, 3 comhnsiion ehnmltcr boiler shown 1 combustion chamber boiler jacket includes 2 center panel insulation* ^9030 ]4 STANDARD BOILERS 4 Place front jacket panel in position. Flanges of front jacket panel to lap over end jacket panels and bottom to lap over cast iron burner access door frame. Attach jacket panel to burner access door frame with washer nead screws TYPE 4G 5 For 13 to 41 Sections--Attach individual panels together with washer head screws for making up com plete front or rear panels Refer to Figs. 18 and 19. Place key strips between front and rear burner access door frames and attach with washer head screws. 6. Attach rear jacket panel in similar manner. 1. Washer Head Sere* 7 Place four short vertical keys in position at ends Fic. 20--Attache* Corner K>* of front and rear burner access door frames, inserting top of keys under flanges of front and rear jacket panels Attach keys to cast iron burner access door frame with washer head jacket screws See Fig 20 8. Place canopy frame m position. See that frame is down tight over top edges of jacket panels 9. Place draft hood on flue outlet of canopy. STEAM BOILERS 1 Assemble low water cutoff and water column piping as shown in Fig. 21 and attach to boiler as shown in Fig. 22. Assemble the working mechanism to the low water cutoff with gasket and screws (furnished m separate package). Make steam gage connection with nipple and tee to V* inch tap ping on upper part of low water cutoff. Connect steam control element on automatic gas valve with steam gage tee using copper tubing and connectors. Fill tubing with water and screw steam gage into tee. Check operation of Low Water Cutoff as shown on Page 23. 2. For 6 to 11 section boilers, connect safety valve to upper tapping on right end section using nip ple and elbow provided. 19031 STANDARD BOILERS TYPE 4G 15 Fic 23--Right End Connections lor Steam Boilers having 4 Automatic Caa Valves For 13 to 41 section boilers, insert bushings and connect safety valves into 3 inch tappings on in* termediate sections. Plug unused tappings with plug (or on right end, install pressure limit control assembly when 4 automatic gas valves are supplied ). Limit controls of right end gas valves should be connected to pressure limit control assembly with 'ic inch copper tubing. See Fig. 23. WATER BOILERS 1. Insert temperature bulbs in upper tappings under jacket knockouts on left end section, see Fig. 17. For more sensitive operation, discard well before installing split nut and gland. Tube leading to bulb should be installed under jacket at corners. 2. Connect combination thermometer and altitude gage to upper one inch tapping on left end sec tion with nipple and reducing coupling. 3 Plug upper tapping in right end near top unless relief valve is installed. 4. For boilers having 4 automatic gas valves, the bulbs from the valves on the right end should be installed similarly m the upper tappings under jacket knockouts on right end section. 5. If reverse acting low limit control is to be used.install it in lower 34 inch tapping on rear of left end section. 19032 16 STANDARD BOILERS ALL BOILERS 1. Install dram cock in lower 3i inch tapping on right end section 2. Plug all tappings not used. 3 Be sure flame check is in gas pressure regulator as shown in Fig 24. TYPE 4G CONNECTING CONTROLS (MFD., NAT. AND MIXED GASES) A__For 6 through 17 sections for Mfd. gas and for 6 through 21 sections for Nat. and Mixed Gases 1. Connect pilot line from manual shutoff valve assembly (See Fig 16) to front pilot burner tubings. Install on top of spud holders. Connect a similar line to the rear pilot burners. 2. Connect thermocouple leads, attached to pilot burners, to BASO 850 automatic pilot switches and attach these switches to bracket with two 10*24 x *2 inch screws and nuts which are then attached to the lower left comer of the front and rear jacket panels with two No. 10 sheet metal screws each See Figs 12 and 13 for location of BASO switches. There should be a thermocouple attached to the left pilot burner in each combustion chamber in front and in back. Assemblies Pilot Swtcnes 2. Pilot Lines f. Thermocouoirt 1. Gas Pressure Relators T. Pilot Burner Brackets 4, Vent Tubes Fic. 2$_c0nnecimg Controls 3. Connect vent tube from gas pressure regulator to union leading to vent tube tip on pilot burner bracket. When one gas pressure regulator is supplied, vent tube tip should be attached to left front pilot burner bracket. If two gas pressure regulators are supplied at the same end, one vent tube should be connected to the left front pilot burner bracket and the other vent tube to the left rear pilot burner bracket. See Fig. 7, 12, 13 and 25. 4. Wire according to wiring diagram supplied. 5. Install burner access doors. NOTE. Straight Type Spud Holders replace the Angle Type Spud Holders which are shown in illustration on Hus page 19033 STANDARD BOILERS TYPE 4G 17 B__ For 19 through 41 sections for Mfd gas and for 22 through 41 sections for Nat and Mixed Gases 1 Connect pilot line from manual shutoff valve assembly (Fig 16) to left front pilot burner tubings Install on top of spud holders Connect a similar line to left rear pilot burners Con nect similar pilot lines to right front and right rear pilot burners 2. Connect thermocouple leads (attached to pilot burners) toBASO 850 automatic pilot switches and attach these switches to bracket with two 10-24 x inch screws and nuts which are then attached to the front jacket panel with two sheet metal screws each. The location of the BASO swttches and the pilot burners having thermo couples is indicated on Figs. 12 and 13. 1. Mmual Shut-Off Valve A$iemt>iie 2. Pilot linn 3. Connect vent tube from gas pressure regula tor to union leading to nearest vent tube tip on pilot burner bracket. The locations of pilot burner brackets having vent tube tips are shown on Figs. 7, 12, 13 and 26. 4. Wire according to wiring diagram supplied. 5. Install burner access doors. MOTE Straight Typ* Spud Holden replace the Angle Type Spud Holden which are shown in illustration on (his page. CONNECTING CONTROLS (LIQUEFIED PETROLEUM GASES) A--For 6 through 19 sections: 1. Connect pilot line from the pilot cock on front BASO 500 Series automatic pilot valve m . mam gas line to BASO 818 series automatic pilot valve (See Figs. 14 and 27). Connect line from 1 b inch tee at outlet of BASO 818 series valve to front pilot burners. If more than 2 front pilot burners are installed, there should be an additional BASO 818 series valve attached in series with the first, (use 16 inch close nipple) one for each additional pilot burner. The outlet tee is taken from the outlet of the last BASO valve m the senes. Connect a bypass line from the tee in the mam gas line to the push button valve which is attached to the outlet of the last BASO 818 At tach BASO 818 valve to bracket with two 10-24 screws and attach brackets to jacket with two sheet metal screws each. See Fig. 14 for the location. Connect a similar pilot line to the rear pilot burners. 19034 18 STANDARD BOILERS TYPE 4G i 2 Connect a thermocouple with female connec tion from the left front pilot burner to the BASO 500 senes valve in the mam gas line Connect a thermo couple with male connection (has smaller diameter tube) from each remaining front pilot burner to a BASO 818 series automatic pilot valve. Connect rear thermocouples similarly. When finished, there should be a thermocouple from each pilot burner to one of the automatic pilot valves m the pilot line leading to that particular pilot burner- See Figs. 7 and 14. 1. BASO 500 Seri Auiomjt'C Pilot Val 2. BASO BIB Senes Automatic Pilot Valves J. Pilot Line 4. Bypass Line ft. Thermocouples ft. Brackets T. Tee In Main Gas Line Fic. 27--Connecting BASO Automatic Pilot Valves 3. Wire according to wiring diagrams supplied. 4. Install burner access doors. NOTE Straight Type Spud Holders replace the Angie Type Spud Holders which are shown m illustration on this page. B--For 21 through 41 sections: 1.Connect pilot line from the pilot cock on the left front BASO 500 series automatic pilot valve in main gas line to inlet of BASO 818 series automatic pilot valves which should be con nected in series with ^6 inch close nipples (See Fig. 14). Attach to the lower right corner of the left front jacket panel with two No. 10 sheet metal screws. Connect pilot line from H inch tee at outlet of BASO 818 valves to left half of front pilot burners. Connect a bypass line from the tee in the main gas line to the push button valve attached to the W' tee at the outlet of the BASO 818 valves (See Fig. 27). Connect a similar pilot line to the left rear pilot burners. Connect sim ilar pilot lines to the right (front and rear) pilot burners from the right end BASO 500 series automatic pilot valves. The brackets containing the BASO 818 valves should be attached to the jacket as indicated in Fig. 27 with two No. 10 sheet metal screws each- 19035 STANDARD BOILERS TYPE 4G 19 2. Connect a thermocouple with female connec tion from the left front pilot burner to the BASO 500 series automatic pilot valve w the main gas line. Connect a thermocouple with male connection (has smaller diameter tube) from each remaining pilot burner of the left front pilot burners (See Fig. 28), to one of the BASO 818 series automatic pilot valves. Connect left rear and right (front and rear) thermocouples similarly. When finished, there should be a thermocouple from each pilot burner to one of the automatic pilot valves in the pilot line leading to that particular pilot burner. See Figs. 7 and 14. 3. Wire according to wiring diagram supplied. 4. Install burner access doors. 5. The use of two stage regulation is recommended in all eases for Liquefied Petroleum gas in stallations. Two stage pressure regulators listed by Underwriters' Laboratories are available for this purpose. NOTE. Straight Type Spud Holdm replace the Angle Type Spud TIolrlen which ere Awe in illustration on this page. CONNECTING CONTROLS (FOR LIQUEFIED PETROLEUM-AIR GASES) A--For 6 through 17 sections: 1. Connect a pilot line from the left front manual shutoff valve assembly (for the 6 through the 13 sec tion boilers, the pilot line will come from the left manual shutoff valve assembly) to the inlet of an MH V-167 electric pilot valve, which should be at tached to a bracket as shown in Fig. 29. This bracket should then be attached to the lower left corner of the front jacket panel with three No. 10 sheet metal screws. Two BASO 850 automatic pilot switches should be attached lo this bracket and for I. Bracket fS) 1* BASO 8S0 Automatic Pilot Switchet 1. M-H V-H7 Electric Pilot Valve 4 Three Sheet Metal Screws the 10 and 11 section boilers a second bracket con taining a third BASO 850 switch should be attached with two of the same screws. Pk. 29--BASO Automatic Pilot Switches M-H Electric Pilot Vale* 19036 20 STANDARD BOILERS TTFE 4G Connect the pilot line from the outlet of the MR V-167 electric pilot valve to the front pilot burners (See Fig. 15). Attach a similar bracket to the rear corner of the jacket and connect a similar pilot line to the rear pilot burners. 1. JUSO SSO Automat* Pilot S*ucrm 1 Ttwrunocoupm a Pilot Lon a M-H V-l*7 Eltct/ic Pilot Volw a VeM Tube a Cm PntMM Ro>Utor 1. UmU Shut-Off Vaho AgowOly 2. On the 13, 15 and 17 section boilers, attach another bracket containing two BASO 850 auto- matte pilot switches to the lower left corner of the right front jacket panel. Attach a similar bracket to the rear of the boiler. Connect a thermocouple from each front pilot burner to a nearby BASO 850 automatic pilot switch. When finished, there should be a thermo couple from each front pilot burner to a front BASO Pk. 90--Conncvung Pilot Ijncs. For larger boii*r ihcr* an aaiUf coMMcuooa on iht nght cod NOTE: Straight Type Spud Holden replace the Angle 1>pe Spud rnbten wtucfc are shown a illuatre- 850 switch which will be wired to the front automatic gas valve supplying gas to the main front burners that are lighted by that particular pilot Connect rear thermocouples similarly (See Fig. 30). 3. Connect vent tube from gas pressure regulator to union leading to vent tube tip on pilot burner bracket. When one gas pressure regulator is supplied, vent tube tip should be attached to left front pilot burner bracket If two gas pressure regulators are supplied, one should be con nected to the left front pilot burner bracket and one to the left rear pilot burner bracket See Figs. 7 and 15. 4. Wire according to wiring diagram supplied. 5. Install burner access doors. B--For 19 through 41 sections: 1 Connect a pilot line from the left front manual shutoff valve assembly (for the 19 through 25 section boilers, the pilot line will come from the left manual shutoff valve assembly) to the inlet of an MH V-167 electric pilot valve which is attached to a bracket as shown in Fig. 29. This bracket should then be attached to the lower left corner of the left front jacket panel with three No. 10 sheet metal screws. Two BASO 850 automatic pilot switches should be attached to this bracket and for the 19, 21, 28, 31, 37 and 41 section boilers a second bracket containing a third BASO 850 switch should be attached with two of the same screws. 19037 STANDARD BOILERS TYPE 4G 21 Connect the pilot line from the outlet of the MH V-167 electric pilot valve to the left front pilot burners (See Fig. 15). Attach a similar bracket to the left rear comer of the jacket and connect a similar pilot line to the left rear pilot burners 2 On the 22 to 41 section boilers, attach (to the lower right comer of the left front racket panel) another bracket for the 22 and 25 section boilers containing one BASO 850 switch; for the 28. 31, and 33, two BASO 850 switches; for the 37 and 41, three BASO 850 switches Connect a thermocouple from each pilot burner of the left front pilot burners to a nearb\ BASO 850 switch. Connect similar switches and pilot lines to the left rear and right front and rear quarters of the boiler. When finished, there should be a thermocouple from each pilot burner to a BASO 850 switch which will be wired to the automatic gas valve supplying gas to the mam burners which are lighted by that particular pilot burner. (See Fig. 30) 3. Connect vent tube from gas pressure regulator to union leading to nearest vent tube tip on pilot burner bracket. The location of pilot burner brackets having vent tube lips are shown on Figs. 7 and 15. 4. Wire according to wiring diagram supplied. 5. Install burner access doors. 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 Vi 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 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. 19038 22 STANDARD BOILERS TYPE 4G NOTE Straight Type Spud Holders replace the Angie Type Spud Holders which are shown in illustrations on this page 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. NORMAL PILOT INPUT FOR BASO PILOT BURNERS | Input Per Pilot Burner Btu. Hr. Mfd. 1000 . Nat. 1400 Gas Mixed 1200 L.P. 1000 LP-Air 1000 MAIN BURNERS INPUT ADJUSTMENT After boiler is warmed up, shut of! all other gas appliances connected to gas meter and tune 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-clockwise. 19039 STANDARD BOILERS TYPE 4G 23 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 noticeable inner blue cone. After adjustment, tighten screw to lock shutter in position. CHECKUP OF LOW WATER CUTOFF 1. Light pilots as indicated in Operating Instructions. Turn thermostat to highest temperature. Automatic Gas Valves should open in approximately tico minute*. 2. Open drain cock and drain water until water level is about an inch below center line of Low Water Cutoff. Automatic Gas Valves should close in approximately one minute. 3. Refill until water level is above center line of Low Water Cutoff. Automatic Gas Valves should open in approximately tioo minutes. OPERATING SHUTTING OFF. (MANUAL IGNITION; MFD., NAT. AND MIXED GASES) 1. Close manual shutoff valve(s) end pilot cock(s). 2. Turn off switch in electric line to appliance. RELIGHTING: (MANUAL IGNITION; MFD., NAT. AND MIXED GASES) 1. Set thermostat (or operating control) at lowest temperature. 2. Close manual shutoff valve(s) and pilot cock(s). 3. Turn off switch in electric line to appliance. 4. Wait 5 minutes. 5. Open burner access doors. 1. Manual Shut-OS Valve L Pilot Cock t. Pilot Burners 4. 8AS0 B50 Automatic Pilot Switches I, Reset Button (On 850 Switch) l Automatic Oat Valves ?. Manual Control Lever I. Hand Resetting Button 6 Open pilot cock(s) and light all pilot burners (front and back). 7. Close burner access doors. ' 8. Wait 2 minutes. Fie 32--Operaiing Control* Mid, Nat. mJ Mixed Gax 9. Press reset buttons on all BASO automatic pilot switches. 10. Open manual shutoff valve(s). 11. Turn on switch in electric line to appliance. NOTE Straight Type Spud Holders replace the Angle Type Spud Holders which are shown in illustration on thu peg* 12. Set thermostat (or operating control) at desired temperature. 19040 24 STANDARD BOILERS SHUTTING OFF (MANUAL IGNITION; LIQUEFIED PETROLEUM GASES) 1 Close pilot cock(s) and hand shutoff wheels on top of automatic gas valves 2. Turn off switch in electric line to appliance. TYPE 4G RELIGHTING (MANUAL IGNITION; LIQUEFIED PETROLEUM GASES) 1. Set thermostat (or operating control) at lowest temperature. 2. Close pilot cock(s) and hand shutoff wheels on top of automatic gas vaives. 3. Turn off switch in electric line to appliance. 1. Pilot Cocks 2. Automatic Vilm ! Hind Shut-Off Whcrij 4. Minuil Control Lever i. Hind ffcwiung Button Push Button Vitves . fiASC 500 Serin Automatic Pilot ViUes g. 8AS0 aifl Ser.es Automatic Pilot Valves 4. Wait 5 minutes. 5. Open burner access doors. 6 Open pilot cock(s). 7. Light match and insert in lighting rod. 8. Press left front push button valve, hold and light all pilot burners on this pilot line. FlC. 33--Operating Controls Liquefied Petroleum Gases NOTE: Straight Type Spud Holden replace the Angle Type Spud Holden which are shown in illustration on this page. 9. Hold 2 minutes. 10 Press reset buttons on all left front BASO automatic pilot valves, then release push button valve. 11. Repeat steps 8, 9 and 10 for left rear of boiler. Repeat for right (front and rear) pilot burners on boilers having 4 automatic gas valves. 12. Close burner access doors. 13. Open hand shutoff wheels on top of automatic gas valves. 14. Turn on switch in electric line to appliance. 15 Set thermostat (or operating control) at desired temperature. 19041 STANDARD BOILERS TYPE 4G 25 SHUTTING OFF fMANUAL IGNITION; LIQUEFIED PETROLEUM-AIR GASES) 1 Close manual shutoff valve(s) and pilot cock(s). 2 Turn off switch in electric line to appliance. RELIGHTING (MANUAL IGNITION; LIQUEFIED PETROLEUM--AIR GASES) I Set thermostat (or operating control) at lowest temperature 2. Close manual shutoff valve(s) and pilot cock(s). 3. Turn off switch in electric line to appliance. t P lot Co<k S. E'rctri; p.iot Valve 4. SASO 6SO Automatic P*<ot Swiienei I. Automatic Gas vjlvtt l Manual Control Kvtr I. Hano ftetetlmq Button 4 Wait 5 minutes. 5 Open burner access doors. 6 Open pilot cock(s). 7. Turn knob on left front electric pilot valve to "Manual" and light all pilot burners in this pilot line. Fic. 34--Operating Controls Liquefied Petroleum-Air Cues NOTE: Straight Type Spud Holden repleee the Angle Type Spud Holden which are shown in illustra tion on this page. 8. Repeat for left rear of boiler. Repeat for right (front and rear) pilot burners on boilers hav ing 4 automatic gas valves. 9. Close burner access doors. 10. Wait 2 minutes. 11. Press reset buttons on all BASO automatic pilot switches. 12 Open manual shutoff valve(s). 13. Turn on switch in electric line to appliance. 14. Set thermostat (or operating control) at desired temperature. 19042 26 STANDARD BOILERS TYPE 4G PILOT GOES OUT If the pilot flame is extinguished, the automatic pilot will shut off the automatic gas valve. If boiler is not operating correctly, call Heating Contractor or Gas Company service man. If boiler is . operating correctly, relight as directed on pages 23, 24 and 25, whichever is applicable ELECTRIC POWER FAILURE Boilers equipped with ``Detroit" 569 VS (or VW) valves may be operated manually during electric power failure. Proceed as follows: 1. If pilot burners are out, relight as directed for "Re-Lighting (Manual Ignition)" for the appro priate gas. Follow instructions completely so boiler will resume automatic operation when power returns. 2. When pilot burners are lighted, press down on manual control lever on automatic gas valve; main burners should light; press in hand resetting button to hold lever down, burners will remain lighted. The 569 automatic gas valve has a mechanical limit control which protects the boiler from exces sive temperature or pressure. 3. Valve is lOO^o recycling and will resume 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. MAINTENANCE OF BOILER WHILE IN OPERATION 1. Check water level regularly and add water slowly when needed. 2. This boiler is fired automatically. 19043 STANDARD BOILERS TYPE 4G 27 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 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. II necessary, remove front jacket and cleanout cover plates and clean heating element. GENERAL MAINTENANCE OF HEATING SYSTEM I 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 accumu lated 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 21.) See CAUTION Note. 5 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 nec essary to add water during this operation to expel air from higher radia tors. 19044 -- 3k-r 28 STANDARD BOILERS TYPE 4G 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 necessary 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. Never place valves in piping leading to or from expansion tank BLOWING OFF STEAM BOILERS In the process of installation, oil, grease or grit works into new systems causing steam boilers to foam. Therefore, it is frequently necessary to blow off boiler under pressure, and to sometimes re peat the operation until boiler water and water column glass are clean. To blow off, remove the safety valve and fittings from the boiler and connect a 2" pipe with valve to the tapping and run pipe to a suitable drain. Close flow ami return valves if available or all ra diator valves. Fill boiler with water to top of gauge glass. Light burners as directed in Operating Instructions and when steam pressure is over 10 lbs. but below 15 lbs. open blow off valve and regu late valve to maintain pressure in boiler. Add water as required to maintain full gau^e level in boiler. Continue for about 2 hours. Then drain water to proper level, remove blow off piping and replace safety valve. If water supply has not sufficient pressure proceed as above but open blow off valve fully and let pressure drop to zero. Then close valve, replenish water and repeat several times. At end of blow off build up 10 lb. pressure, shutoff burners as directed in operating instructions and blow water out through drain opening. Refill to proper level, AFTER BOILER HAS COOLED. Do not use soda, alkali, vinegar or any acid for cleansing the boiler. In severe cases, the use of "Vinco" is rec ommended. Use 3 lbs. of Vinco for 350 Sq.Ft. radiation or less and 1 lb. for each additional 150 Sq. Ft. CAUTION After the blow off operation, a checkup should be made of the Low Water Cutoff as directed on Page 17. Note: All parts of this boiler have been carefully inspected and packed. In case of shortage, make sure that all parts have been removed from shipping container and examine packing material thor oughly. 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 si2e and series number when ordering repair parts. BOILER SIZE .................................................................................. SERIES NO. (SEE SERIES PLATE ON BOILER)............... DATE ................................................................................................... 19045 AMERICAN RADIATOR a STANDARD SANITARY CORPORATION PITTSBURGH 22. PA. * 4114 MtV. (4>M 19046