Document zzYKaNEa2zjzEGG9yKoZrB6z7

AMERICAN GW GAS STANDARD BOILER INSTRUCTION MANUAL NON PACKAGED BOILERS t I form NO. BP- 31408-06 DESIGN CERTIFIED BY AMERICAN GAS ASSOCIATION NOTICE TO INSTALLER AND OPERATOR THIS BOOKLET MUST BE AFFIXED ON OR ADJACENT TO THE HEATING EQUIPMENT. SERIES NO. 1B-J1 02135 TO THE OWNER; The American-Standard Boiler which has been Installed for you is the heart of your hydronic heating system. Its design represents advanced engineering and manufacturing techniques to produce a product which will provide you with heating comfort at the lowest operating and maintenance cost. The sections are made of cast iron which is well known for its long life and corrosion resistant properties. When hot water is used as a heating medium, the entire system is filled with water and an expansion tank provides space for the increased volume as the water in the system expands when it is heated. Under no conditions should any boiler be fired unless it is properly filled with water. If a boiler is not in use during the winter season it must be drained or otherwise protected against freezing temperatures. A gas fired boiler uses gas as a fuel. The chemical composition of natural gas is similar to gasoline which is used as the fuel in an automobile engine. The toxic nature of auto mobile exhaust fumes is well known. These fumes are toxic because the hydrocarbon fuel is not completely burned. In a properly adjusted and normally operating gas fired appliance such as a kitchen range, boiler, water heater, etc., the hydrocarbon fuel is burned com pletely, producing harmless combustion by-products, and these products are normally vented to the outside atmosphere. Normal prudence will dictate that the venting system and combustion process of any gas fired appliance be checked periodically to assure that normal operation is taking place. Any abnormalities in combustion or venting of flue products to the outside atmosphere should be promptly corrected. By following the suggestions contained in this manual, you can assume your boiler will function properly for many years. Should any problem arise, contact your nearest AmericanStandard contractor, whose name can be found in the "yellow pages" of your telephone direc tory. AMERICAN STANDARD, INC. Information relative to the rating and fuel requirements 1s located on the rating plate mounted on the front of the boiler. Please refer to this informatlor and include-model number and series number when ordering replacement parts. 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 parts 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 ticket). 02136 TABLE OF CONTENTS ITEM PAGE NO. GENERAL INFORMATION 1 SETTING THE UNIT 1 CHIMNEY 2 AIR SUPPLY 2 GAS PIPE SIZE AND DELIVERY SCHEDULE 3 RATINGS - DATA 3 CONTROL TAPPINGS 4 PIPING RECOMMENDATIONS 4 DIMENSIONS FOR INLETS AND OUTLETS 5 BOILER INSTALLATION 10 WIRING DIAGRAMS 14 f 14* t 14b & 15 FILLING SYSTEM 16-17 LIGHTING INSTRUCTIONS -- 24 VOLT SYSTEM 18 LIGHTING INSTRUCTIONS --S.E. SYSTEM 19 LIGHTING INSTRUCTIONS -- 24 VOLT & S.E. COMBINATION CONTROL 20 MANIFOLD PRESSURE ADJUSTMENT 22 MAIN BURNER AIR ADJUSTMENT 22 PILOT ADJUSTMENT GENERAL MAINTENANCE 22 24 INSPECTION AND CLEANING OF BOILER 25 SUPPLEMENTARY INSTRUCTIONS FOR MODULAR BOILER INSTALLATIONS 26 02137 GW GAS BOILER 1 GENERAL INFORMATION The GW boiler, designed for maximum comfort and efficiency, is the latest development in cast iron boiler technology. Developed specifically for forced water circulation, the boiler is available for use with natural and propane gases. The boiler design is A.G.A. certified, and is constructed and tested in accordance with A.S.M.E. regulations for up to 50 psig working pressure (100 psig working pressure available on order). The cast iron surfaces will afford long trouble-free service while providing optimum com pactness for an atmospheric gas-fired Hydronic system. Relatively small water content, and specially designed burners and controls permit close temperature control of the boiler water. Consequently, this boiler is not equipped with a domestic hot water supply. The GW features: compact, light weight design; no separate base or combustion chamber-, 8 thru 10 sections ranging from 462 Mbh to 594 Mbh input. This manual gives the necessary information for the proper assembly, installation, opera tion, maintenance, and service of the units. For special installation problems contact American-Standard, Hydronics Department, 25 Rano Street, Buffalo, New York. INSTALLATION REQUIREMENTS This boiler should be installed in accordance with the latest American National Standards "Installation of Gas Appliances and Gas Piping" obtainable from the American Gas Association, 1515 Wilson Blvd., Arlington, Virginia 22209. Installation should also conform with require ments of local gas company and all state and city building codes. This boiler is approved for installation on non-combustible flooring only. On hot water systems, the expansion tank should not be installed in cold or exposed place. If pipe leading to or from the tank freezes, serious damage may result. If valve of any description is installed in the piping leading to or from the expansion tank BE SURE THAT IT IS OPEN WHILE THE BOILER IS IN OPERATION. LOCATION Locate the boiler near the chimney or flue and as centralized with respect to the heat distribution system as practicable. Provide the necessary service accessibility clearance. For locations where the floor is not level or if water conditions exist, the boiler should be mounted on a concrete base, preferably to a height of 3". SERVICE ACCESSIBILITY CLEARANCES Between boiler, vent collector and any combustible material - 6 inches. Front or sides for servicing, cleaning or removal of controls, burners nH circulator - 24 inches. < In utility room installations, the door shall be wide enough to allow the largest part to enter or to permit the replacement of another appliance such as a water heater. 02138 GW GAS BOILER COMBUSTION AIR 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 to interior space having adequate infiltration from the outside, one near the floor, the other near the ceiling, installed in the door or a single wall of the boiler room. Each opening must have a minimum free area of one (1) square inch per 1000 Btu per hour of input rating of all appliances in the room. (b) Additional opening to exterior space when combustion air must be obtained from outside, minimum free area of 1 square inch per 5000 Btu per hour of input rating, or in accordance with the methods outlined in the latest issue of A.N.S. Z21.30 entitled "Installation of Gas Appliances and Gas Piping". CHIMNEY 1. Flue or vent connection to chimney or breeching shall not be smaller than the outlet on the drafthood. 2. Where two or more appliances vent into a common flue, the area of the common flue should at least equal the area of the largest flue or vent connector plus 50% of the areas of the additional flue or vent connectors. 3. Flue or vent connector must be inserted into, but not beyond, the inside of the chimney flue. 4. Horizontal runs of flue pipe should be kept at a minimum and should pitch upward from the boiler at least 1/4" per foot. TESTING Before connecting boiler, plug openings, fill boiler with water and subject to not less than io lbs. nor more than 50 lbs. pressure. Inspect boiler inside and outside for leakage as a result of breakage from handling and shipping. To safeguard accuracy of gauge and controls supplied with boiler, do not install until after test of boiler. This precaution of testing the boiler will simplify handling of any necessary replacements or adjustments and assist in treating claims against transportation companies. After test drain and remove plugs where required. GW GAS BOILER PIPE DE LIVERY SCHEDULE Capacity of Pipes in Cubic Feet of Gas Per Hour. Based on a pressure drop of 0.3 in. W.C. and 0.6 specific gravity gas. Length of Pipe In Feet 10 20 30 40 50 70 100 1" 520 350 2S5 245 215 180 150 Pipe Size 1-1/4" 1050 730 590 500 440 370 305 1-1/2" 1600 1100 890 760 670 560 460 Boiler Number GW-8 GW-9 GW-10 SIZE OF GAS CONNECTION Natural Gas Propane 1 3/4 1 3/4 1 3/4 Table 1 - GAS PIPE DELIVERY SCHEDULE AND CONNECTIONS Table 2 - RATINGS FOR NATURAL AND PROPANE GASES Boiler Number GW-8 GW-9 GW-10 A.G.A. Input Btu/Hr. 462,000 528,000 594,000 A. G. A. Output Btu/Hr. 369,600 422,400 475,200 Net Installed Radiation Mbh Water 321.7 367.0 413.9 I-E=It Approved A. G. A. DESIGN CERTIFIED 02140 BOILER control APPLICATION SECTION ASSEMBLY SHOWING TAPPINGS LOCATION SEE OF ON BOILER TAPPING OONTRXS I FIG. 1 A X 2 LMT CONTROL a i MUdMFr UAflT CONTROL OR OPERATIC CONTROL c 4X TEMPERATURE AND PRESSURE GAGE b4 EXPANSION TAW E4 PRESSURE RELIEF VALVE BOILER NUMBER GW-8 SUPPLY (IN) 2 RETURN (IN) 2 GW-9 2 2 GW HO 2 2 MINIMUM PIPING RECOMMENDATIONS FORCED HOT WATER FIG. 2 n 02141 nw GAS BOILER T * ft IM m-m * *u TT A * 13 0 f* 1) I- M earraat M*TV OWT MK asuoi it* JSSft. rrr****1 -44 M * m * -1 -( m M* * _di_ DIMENSIONS for inlets and outlets FIG. 3 02142 GW GAS BOILER It' RECOMMENDED PIPING WHEN AUX. MANUAL SHUTOFF VALVE OR SEPARATE MANUAL SHUTOFF VALVE AND AUTOMATIC GAS VALVE ARE SUPPLIED. VALVE NOT SUPPLIED BY AR&SS CORP FIG. 4 RECOMMENDED PIPING FOR DRIP LEG CONNECTION TO BOILER 02143 GW GAS BOILER GW BOILER WITH ELIMINAIItE The E LIME'IAIRE is a unique built-in air separator which prevents air from being transmitted to the system and directs the air to the compression tank. External air separators such as dip tube or inlined accessories are not required. This important feature on the L. H. END SECTION7 also allows for considerable simplification of the near boiler piping (See Figure Belov/) and assures positive air separation essential to proper system performance. The ELL'.IINAIRE plus the recommended piping provides for a substantia] saving in material an:! installation cost. n FLOW PIPE I-------- EXPANSION TANK 4 PIPING FOR FLOW PIPE S EXPANSION TANK FIG. 5 02144 GW GAS BOILER CAUTION If and when this boiler is used in connection with refrigeration systems, boiler should be so installed that chilled medium is piped parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the heating boiler. When hot water heating boilers are connected to heating coils located in air handling units, where they may be exposed to refrigerated air circulation, such boiler piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. The expansion tank should not be set in a cold or an 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. FIG. 6 02145 GW GAS BOILER 9 FIG. 7 GW BOILER ASSEMBLY 02146 GW GAS BOILER BOILER INSTALLATION Non-packaged boilers are shipped with the boiler sections and canopy factory assembled. The remaining boiler parts are to be assembled on the job-site. Installation should be accomplished as follows: BOILER ASSEMBLY 1. Remove section assembly from shipping skid and place boiler in approximate final location (refer to Page 1, Location). 2. Inspect and test boiler (refer to Page 2, Testing). 3. Place insulation in front and rear cover plates. Install two (2) #10 x 3/4" sheet metal screws in rear plate to retain insulation (see Figure 8). 4. Assemble front and rear plates using four (4) 5/16" x 1-1/4" hex. machine screws and 5/16" star washers provided. Putty between top of front plate and sections to form gas seal. (See Figure 9). FIG. 8 FIG. 9 02147 GW GAS BOILER 11 5. Place the steel "T" bar burner support In position so that it engages the lugs on the end sections. NOTCHED SIDE MUST FACE TO FRONT OF BOILER. 6. Attach manifold piping and control assembly to front of boiler with four (4) 5/16" x 1/2" hex. head screws and 5/16" flat washers provided. 7. Attach pilot burner bracket and tubing assembly to the main burner with #10-24 x 5/16" truss head machine screws. 8. See that air shutters are attached to tube ends of burners, then assemble the burners to the boiler. Start at either end and insert the burners over the manifold and into position with tube end of each burner mounted onto its respective spud on the manifold and with each burner resting on the burner support. Lug on the bottom of each burner must enter its respective notch in the burner support to insure that the burners are properly located. Refer to Fig. 23 for the location of the main burner to which the pilot burner assembly is to be attached. 9. Vent tube which is attached to pilot burner (when required) is to be connected to the tapping on the automatic gas valve. The end with the tip should be 3/8" below top of the main burner. INSTALLATION OF JACKET 1. Install the burner access doors with the holes in the doors engaging the projections on the front plate. 2. Install the four jacket angle clips to the front and rear plates with #8 x 3/8" sheet metal screws (see Fig. 10) FIG. 10 02148 GW GAS BOILER 3. Hang the L. H. side panel and the R. H. side panel onto the jacket angle clips. 4. Attach the jacket liner to the side panels with #8 x 3/8" sheet metal screws. LEAVE ALL JACKET SCREWS SLIGHTLY LOOSE UNTIL ENTIRE JACKET E ASSEMBLED. Drape the loose end of the jacket liner insulation over the canopy (see Figure 11). 5. Attach the back panel to the side panels with #8 x 3/8" sheet metal screws. 6. Attach the tie bar to the side panels at the lower front portion of the boiler with #8 x 3/8" sheet metal screws (see Figure 12). 7. Place the black upper front panel so that it engages the slots in the side panels and attach the top panel with #8 x 3/8" sheet metal screws. 8. Attach the number and series plate and the lighting instructions plate to the jacket liner with #6 x 1/4" sheet metal screws. fig. n Bar FIG. 12 02149 INSTALLATION OF CONTROLS AND PIPING 1. Install the temperature-pressure gauge and the relief valve (with 3/4" nipple and elbow) in the L. H. side of the boiler (See Figure 3). 2. Install the gas piping including drip leg connection to boiler (refer to Page 3). All pipe joints must be made using compound resistant to propane gas. 3. Attach the safety pilot switch (when used) to jacket liner with #8 x 1/2" sheet metal screws. 4. Connect the pilot gas line from the combination control or safety pilot switch to the pilot burner. When safety pilot switch is supplied, install pilot gas supply line from switch to pilot shutoff valve on manual shutoff valve. 5. Electrical service should be brought to the boiler and connections made to accord with the wiring diagram furnished on the inside of the jacket liner. Install and connect transformer and operating control according to applicable wiring diagram. 6. Install drain cock in 1/2" tapping at rear of boiler using 1/2" nipple and coupling provided therefore. 7. Place drafthood firmly on the flue outlet collar of the canopy which projects above the jacket and connect to chimney. 8. Install water supply and return lines (refer to Pages 4, 5, 7, and 8). A full sized discharge pipe from the relief valve to drain is recommended. 9. Fill System (refer to Pages 16 and 17). 10. Test water system for tightness. Check all gas piping joints for leakage by using a soapsuds solution before operating unit. 11. Light boiler (refer to Pages 18, 19, and 20). 12. Make final burner adjustment and check out controls (refer to Pages 22 and 23). I 02150 g-- MrJ if c5"* GW GAS BOILER * * ) in s S 51 3 I %tWF KMilM mUiVPLT CONTPOL* I AUIILMPT CmCPLATOPCOHfPOL) 14 02151 GW GAS BOILER 1- 24 V T H ffttfO tT A T HCAT I 5-1 lit* il lj5 13 a 02152 1*4 b 24 V TMCMI09TAT NCAT cmCULATOM COCTHCX. --- II-----~X/- !4* ** U XJ tMtTT tmrt* 0- - FI . IZJ mum 14 VOCT COMTKOC* (umMtrr cmocatoa comtoo FIG. 13 b 02153 GW GAS BOILER TERMINALS THERMOSTAT THERMOSTAT ZONE VALVE WIRING DIAGRAM THERMOSTAT THERMOSTAT note: wires must clear the manual opening levei^ OF EACH ZONE VALVE AND ALL LEVERS MUST FACTORY PRESET IN THE "MAN OPEN" POSITION^ PRIOR TO PACKING. FIG. 14 02154 GW GAS BOILER FILLING SYSTEM (GENERAL INFORMATION) CAUTION: Never start boilers unless they are properly filled. Fol lowing filling, the piping elsewhere in the system should be checked for leaks. After boilers are in operation make-up water should be added slowly. When filling a system, the pressure must not exceed 50 lbs. (100 lbs. with 100 lb. relief valve). If it does, it must be relieved immedi ately and the relief valve failure investigated and corrected, other wise pressure may build up and cause damage to heating system. The owner should occasionally check the readings on the press-temp gauges. The higher range scale indicates the water temperature within the boiler header; and, should the water exceed 250F, opera tion must be discontinued until the system is checked and the fault corrected. The lower range scale indicates the pressure within the system and should not exceed 50 lbs. (100 lbs. with 100 lb. relief valve). In a closed system the boilers and piping are entirely filled with water except for a cushion of air in the upper portion of the ex pansion tank. When the water is heated, it expands, compressing the air. If, for any reason, this air were completely displaced from the tank, there would no longer be a cushion. In that event an in crease in water temperatures would cause a corresponding increase in volume and pressure would force the relief valve open to discharge the excess volume. To correct such a condition, the expansion tank must be drained enough to permit the tank to fill with air. 02155 GW GAS BOILER 17 The following procedure should be used to fill a series loop Heatrim system (See Fig. 15; Close all zone valves except the one for the zone to be filled with water and purged . of air. 2 Open the drain valve on the boiler. 3. Open the fill valve. 4. Close the purge valve. 5. Open the relief valve. .6 Open the valve to the second zone to be purged; then close the first. Repeat this step until all zones have been purged of air and filled with water; but always have one zone open. (Zones are purged and filled when water can be felt in the pipe at the end of the zone.) .7. Close the drain valve. 8 When water appears, release the lever on the relief valve, allowing it to close. 9. Continue filling the system until the pressure gauge reads 12 psi without heat or . 25 psi at 200F; close the fill valve. 10 Open the purge valve. Following the completion of the installation, a thorough check should be made of the entire hydronic system to locate possible leaks. NOTE: For a single loop Heatrim system no additional vents, cocks, valves or other accessories are required. 02156 GW GAS BOILER PIPING ARRANGEMENT AND LIGHTING INSTRUCTIONS 24 VOLT SYSTEM 8, 9, and 10 SECTION - NATURAL GAS 10 SECTION - PROPANE GAS INSTRUCTIONS FOR SHUTTING OFF AND LIGHTING MANUAL IGNITION-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 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 PHOT VALVE "B" PRESS PLUNGER "C" ON AUTOMATIC PILOT SWITCH AND LIGHT PILOT "d". HOLD PLUNGER "C" FOR ONE MINUTE. 5. OPEN MANUAL SHUTOFF VALVE "A". TURN ON SWITCH IN ELECTRIC LINE TO APPLIANCE. SET THERMOSTAT TO DESIRED TEMPERATURE. IN THE EVENT OF IGNITION FAILURE REPEAT FROM STEP 1. (DO NOT ATTEMPT TO LIGHT PILOT OR START BURNERS UNTIL COMBUSTION CHAMBER HAS BEEN THOROUGHLY PURGED OF POSSIBLE GAS ACCUMULATION.) I OTIS7 FIG. 16 D ASSEMBLY OF GAS VALVE AND MANIFOLD - 24 VOLT SYSTEM FIG. 17 02157 GW GAS BOILER PIPING ARRANGEMENT AND LIGHTING INSTRUCTIONS S. E. SYSTEM 8, 9, and 10 SECTION - NATURAL GAS 10 SECTION - PROPANE GAS iwrTULKmowi row twrrmc 0rr a0 licktiwc imwuM. (cwmow-pg*. avTorr irLj.rMr^iwe cowTXQLl TO SHUT Of r I. pOilootmvAIwO "B"Jhutorr it "A" TO LIGHT 1. Sot rooa tKamofllst to (avast tamparatwa. I. 9* *<f manual MNCOff Tllvo "A" jn* piMl vatwo "B" nava Mananutaff for at tout fivo ninutas Pttwo piocaMn(. 3. Opan potol votvo "V 4. Pumi piunfor "C" on automatic pilot twiten ana Hint pilot. HoM piuncsr "C" f ana 5. Ooon manual sAutaff vaivt "A*'. I. Sot loom tnarawatat to aaauaa (sawMautt. % 07133 FIG. 18 19 a GAS MANIFOLD ASSEMBLY OF GAS VALVE AND MANIFOLD SE. SYSTEM FIG. 19 < 02158 .0 GW GAS BOILER PIPING ARRANGEMENT AND LIGHTING INSTRUCTIONS 24 VOLT AND S. E. 8 and 9 SECTION PROPANE GAS (LESS PRESSURE REGULATOR) FIG. 20 ASSEMBLY Of COAWUTXN CONTROL AM) MAMFOLO 24 VOLT SYSTEM COMBINATION CONTROL COMBBUTON AUTOMATIC PILOT. PRESSURE REGULATOR. AUTOMATIC GAS VALVE. ANO MANUAL SHUTOfY VALVE Fig. 21 mtmwinn tiptm C0MMAT10N AUTOMATIC PU3T. PRESSURE REBULATOR. AUTOMATIC SAS VALVE.AM) MAMJAL 9MTTOPT WUE. Fig. 22 02159 G'vV GAS BOILER 8 SECTION BOILER 9 SECTION BOLER il |2jj5] PILOT BURNER WITH THERMOCOUPLE PLOT BURNER WITH TTCRMOCOUPUE 10 SECTION BOILER wBQggSflflQ Jg^ll PILOT BumER WITH TTCRMOCOUPLE FIG. 23 PILOT LOCATION FOR ALL GASES 21 < Fig. 24 BURNER AND PILOT ASSEMBLY FOR MANUAL IGNITION 02160 GW GAS BOILER PILOT BURNER Location and assembly is shown in Figs. 23 and 24. 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 adjusting screw is located on combination control or pilot throttling cock. NORMAL INPUT FOR PILOT BURNERS Input per Burner Btu/Hr. NAT.Propane 1400 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. Boiler input should be adjusted at rated input as indicated on nameplate in accordance with procedure outlined below. Gas Consumption (Cubic Feet per Hr.) INPUT RATING (Btu per Hr.) Heating Value of Gas (Btu per Cu. Ft.) 1/8" pipe plug is placed in the manifold to provide for checking 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 gas. To adjust the pressure, remove the cap cm 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 manifold pressure vary more than plus or minus 0.3 inches water column from the above specified pressure. Any necessary major changes in the flow should be made by changing the size of the burner orifice. Refer to combination control instruction sheet for making regulator adjustments. MAIN BURNER AIR ADJUSTMENT Drill port burners are normally used with natural gas. To adjust the air setting, allow 5 minutes for the burners to heat up; open the air shutter until flame lifts off the burner (too much air), then close until the flame returns to the burner. There should be no yellow in the flame. (Orange appearance is caused by lint and dust particles in air and does not affect normal performance). Ribbon burners - Propane gas Propane burner flames must be adjusted properly to prevent excessive burner temperatures. Adjust the air shutter to a blue-green inner flame without yellow in flame. (Refer to Fig. 25) 02161 GW GAS BOILER TXLLOW TIPS (CAUSES CARBON FORMATIONS IN BOILER FLUES) LAZT, (SEEN INNER FLAME NOT ENOUGH PRIMARY AIR WRONG FIG. 25 23 Ribbon burners Natural gas Adjust air shutter to give sharp blue flame with no yellow. For natural gas, good performance is usually obtained with air shutter set to maximum open position. TEMPERATURE LIMIT CONTROL The temperature limit control is located in the upper left corner of the control vestibule. The limit control can be checked and adjusted by removing the front door. If replacement is necessary, more ready access is obtained by: 1. Removing jacket top panel screws on each side. 2. Lifting top panel in front only until side panels can be moved outward approximately 1/4 inch allowing upper front panel to be removed. 3. Limit control is now completely exposed for service. 4. Replace panels and screws in reverse order. 5. Set limit control to 220F or lower, if desired. 02162 GW GAS BOILER vtAfNTENANCE GENERAL IT IS IMPORTANT THAT THIS BOILER BE INSPECTED ONCE A YEAR BY A COMPETENT SERVICEMAN TO INSURE CONTINUED RELIABLE, SAFE OPERATION. This inspection should include checking of all boiler safety controls, pilot,section flueways and burners. See next page for instructions on burner and section inspection and cleaning. fN 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 in this manual. MAINTENANCE OF BOILER WHILE IN OPERATION Check water level regularly and add water slowly when needed. If water must be added frequently, check system for leaks. This boiler is fired automatically. IN WINTER WHILE NOT IN OPERATION Drain entire system to prevent damage from freezing. Drain through drain cocks located at lowest point in system. Be sure boiler is completely drained. IN SUMMER WHILE NOT IN OPERATION Keep the system filled as during the heating season. This is the recommended time to have a periodic check up of all safety controls and a close inspection of the burners, flue passageways, 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. GENERAL MAINTENANCE OF HEATING SYSTEM Keep radiators and convectors clean. 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. Fill hot water systems only as directed in this manual. 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. 02163 GW GAS BOILER INSPECTION AND CLEANING OF BOILER BURNERS AND FLUEWAYS For maximum efficiency and safe operation, burners and boiler flue passages should be inspected and cleaned, if necessary, once a year. Inspection Procedure: 1. Turn manual shutoff valve and pilot shutoff valve to off positions. 2. Remove lower front panel from boiler by lifting upward and pulling out. 3. Remove pilot line, vent line, and thermocouple. 4. Remove the burner access door (See Figure 24) 5. Remove burners by lifting at the rear, sliding them toward the back of the boiler until free of the spuds, and lifting them out over the manifold. 6. Check burner gas ports or ribbons for lint and dirt. 7. Section cleanliness can be checked with a mirror and light inserted in the opening where the burners have been removed. BURNER CLEANING If burner inspection reveals rust scale or lint present, clean as follows: 1. Drilled Port Burner - Pass a #30 or #31 drill through the ports and shake any dislodged material out through the mixing tube. 2. Ribbon Burners - Remove ribbon hold down clamps and then remove ribbons. Separate ribbons by fanning out and clean with wire brush. Reassemble to burner. SECTION CLEANING If section inspection reveals soot or scale, clean as follows: 1. IMPORTANT - BE SURE TO REMOVE BURNERS BEFORE PROCEEDING. 2. Remove flue pipe, jacket top, and canopy-drafthood assembly. 3. Clean sections with a wire flue brush. 4. Reassemble, carefully locating all parts. 5. Install burners and light pilot. 6. Check burner air adjustment as directed in this manual. -JV4' 3 ..y T. J- ft -j 02164 GW GAS BOILER SUPPLEMENTARY INSTRUCTIONS FOR MODULAR BOILER INSTALLATIONS t 02165 GW GAS BOILER GENERAL INFORMATION The American Standard GW boilers developed specifically for forced water circulation, provide cast iron, gas-fired, boilers which may be used in multiple-unit installations, in lieu of one large boiler. Multiple combinations start with a 924, 000 Btu/hr. input, and increase in 66, 000 Btu/hr. increments up to a virtually unlimited capacity. The major benefit of 66, 000 increments, is that there is no need to overbuy capacity of a boiler. Model GW units are pre-asssmbled 8, 9, and 10 section modules. Jackets and burners are packaged separately. Combinations of each model can be arranged in batteries, which in turn, can be arranged as multiple batteries. The GW features: compact, light weight design; no separate base or combustion chamber; 8 thru 10 sections ranging from 462 Mbh to 594 Mbh input (see Table 2). The boilers may be manifolded together to give input combinations as listed in Table 3. Other installation data are also given in Tables 3 and 4. The installation requirements given in the front part of this manual apply with the additions outlined in the following sections. BOILER SPACING A minimum of six inches of clearance should be allowed between boilers for installation of temp-pressure gauge and relief valve. WATER HEADER INSTALLATION Gw Modular Boilers permit a selection of piping arrangements for multiple boiler systems which meets particular needs and preferences. Primary-secondary hookup may be accom plished by following the arrangement shown in figures 26 and 27. Secondary circulators should be installed in accordance with these figures after the jackets are installed. An alternate arrangement is to use a return header which is suited to parallel flow hookup (see figure 28). The GW boiler will function well under either of these arrangements but the piping must be customized in the field. INSTALLATION OF GAS SUPPLY HEADER The gas supply header should be sized in accordance with the information given in Table 4. All pipe joints must be made using compound resistant to propane gas. 02166 % GW GAS BOILER ^tallation of e le ctrica l service Electrical service should be brought to the boilers and connections made to accord with the appropriate wiring diagram. 1. For primary-secondary hookup refer to the wiring diagram shown in Figure 29. Primary-secondary hookup requires the use of one R8227B transformer-circulator relay per boiler. This control is used in lieu of the transformer furnished with the boiler. 2. For parallel flow hookup refer to the wiring diagram shown in Figure 13. If the 8-stage boiler sequencing control is used, it should be wired in accordance with Figure 30. If electronic controls are used refer to the instructions contained in the electronic controls installation manual. 02167 > ~ 12 --21 2 st o* M00dN0N00N0N0N0N0NNN0NNN0N0N0N0N0N0N0N0N0e0M0N0N0N0N0NeN>N0No ?> a> * ^ tf . S5 3sa^ UQ u9iniAU9Wco<eteaoaoaoooaoaoaooo ^ ^ i"4 pH ^4 ^ ^ p* ^ pP pH pH ^ pH pH ph vj jvg *_ 4^ >.5 a oo &m l| 2CD* NNNN N(NfNilClJNnwrtpjajrtrtnocj^i1^^ ^^^^ 2 oooa z HooHio^HNoH^H0MH)N^hfhOnH(hOHci*iHei<HNioH(u0}HoH(i0AN(AeHf^tH<aQH(9OHooHooHNo)Hta<)^^o] I- 5 fS nocs^noac O O CO (0 f N efelJo*tNA>^'afA^OiAAMOoCieAOHOMH^^MHco^^^c{O^OcN{^ie}W^c^fl^iOfoiiHooo0^eooaeaN-oti*^flAC^DooO)uOartoOWiAH^^M4^Nh^ONf. rnmt 3s.<g aE 2oa2o2>w<^rBioHi)oHn>p4#)^HiuOrt5H'"inHiiiHntr.ri(Ht.a>^jIHHHOeH)OJH^eM)^Nne<n)N(^.iN^aNom(N.e^N(o-Ntt-N-o(NooNo m a "7 *' 1 << ooo-<<nZZooo -<e^nooooo>-<eW''OOOo>-ieJCT I-l li 1 0 i* a 1? IB << -^N^oZZo-^pjeopJ "lOO-HNM^'eoM'HOejcO'^'irt'^fC'jN tiCM -- O O CO Cfli-HOOOO^COOJ^OOOOOC^N'HOOOOO J js |$2 `S8 zb N^0l5Oi005 ifj0HO(0tNp0^3-......0...0.N.i..0.....I.r.N...t.o..w.t.......5.^.I0.i...A.(..N...0.. ia.ofl( 0Oif(Ilc(H(*0I ^|NIar^o*7# o^Nw7Ov#c?pheH,d--f1 cHa? ^ccv?noircw?ctecw?iNc-?h*oeuo?op ieuf0^* cw?er?=?c--aCC7:OOo ^ 5 aouoaoooorn aorp orp orP orp arp arp orp orP urp orp orP orp orp orP roP roP f: * *? , _ 02168 IVased on ^ ^ y s te m = 20F JO g 25 If 3us x OOOOOOOOOOOOOOOOOOOOOOOOOOOO . 0a) xU> Jfi OQ N^NNNMNNNNNNNNNN^N^NrtCOJOnnfOOeOonnrtrt TABLE 3 - GW MODULAR BOILER RATINGS AND DATA (cont'd.) on t 8 yS te m = 2 0 F . U)<D(O(O(0(D(D(O(O(OO(0<DtO(O(O(O(O(0tO(0(OC0(OV(O(Oc0O pH pH f 03 c- CO CO <* pH 03 e 03 t- CO CO ** 0- 03 CO 03 H 03 r CO 0- CO CO 03 CO pH 03 03 CO r- co e- o- o pH pH 03 03 CO CO * ** CO CO CO CO CO CO CO CO CO CO CO CO * * * ** "O o* o* 03 03 03 ** 03 03 03 s a pH pH ** 03 e- 03 03 CO * CO 03 e H CO pH 03 0- 003 03 CO CO pH pH 03 03 CO CO 0* f pH pH 03 03 CO CO * CO * ** *r * -0* * <** Tf -0* * 9a s 3 03 ** 03 <* pH ** pH e 03 03 O 03 03 pH 0- Hf c- Hf c CO t> CO CO CO pH 03 03 CO t- pH 03 03 CO e* o* Mt 3 = 8 1*>5 "i a ^u <o* 5 as E> 3? zo o^iotst-maiNn laiOf'Osaon'finat-oooiOH^inffit' wio^nfi^OBt-eiflvnNHOcot-cifl'fnMHooot'iow ooooooooooooooooooooooooooooo M _, J? 2! J8 Is* T 03 *r *,ON'1eONCO'*' i11flia11 iisisi isi ifilisi iAi ifi lioi iai ifiiifiiia ia (O 0 1 N 00 t- n ** i i 1* o 03 i o t* .. 03 05 03 03 03 03 ^ __ . 0" T i r T' i i i * ooo OOUOOOUO -o V as rt <2 02169 >, g2 S fc oooooooooooooooooooooooooooooo 3L u S*s il XoL QX * OOOOOOOOOc^CMMC^e^M nnnnnnnnnnnnnnn M eg CM eg NNNC4NNNNNNNNM TA B LE 3 - GW M ODULAR B O ILE R RATINGS AND DATA - (c o n t'd .l tased on t system =20F. CO I s5 M>("g* t^tflOiAiAiAtAiAiAlAiAlAlAtAlAiAlAiAiAiAiAiAlAlAtAiDiniA bfi 5 a JS as -a -v S z 3 -C o23- ^Se in eg o' c- ao o eg o' c o in o in c fH CO CO e eg o' CO o O co o eg ^4 eg CO fi-n4 eg o eg eg om eg eg in eg eg o o* co eg aCOo co eg o* n o' eg o ao o eg eg in eg orin eg m CO eg o' co CO eg wCO4 eeg co in eeg o o 00 eg CO O' CO eg in ao eg CO eg eg eg CO eg o CO ao o CO ^4 eg co in co co c* eg co CO eg CO O' CO CO cO' o o CO CO o* CO o ao CO o eg o ao CO o' eg o ao co -0* eg o ao CO o* eg o ao CO o' eg o ao CO eg Ce*O* co CO eg o* ao o' o' CO in rao in o Tf CO eg O) CO in O' ao O) f H in ao O' CO in 0) o o eg CO o w<n4 ao co eg eg Ct>O eg CO eg CO eCO eg CO O' o00' O' eCO m o 0) in co O' CO CO 0) CO ao oe' *4 o O' m oe* eg eg eg eg eg eg eg eg eg eg eg eg co CO. CO co co CO CO CO CO CO co CO CO CO co CO CO CO 3 a S j= -D S o co eg CO O' eg CO O' eg CO O' eg ao O' eg O' CM O' e- CO CO co CO eg eg eg eg eg ~4 05 * ~4 eg CO CO o' O' C* ao o eg eg CO O' O' eg CO CO CO CO co co CO CO CO CO CO CO CO CO CO O' O' O' O' o* O' O' O' O' O' O' O' O' o' M H >- J, o co 73 4 - >? 5e 5O (m 0 is 1 =* zo 1> *o3 ^egcoo'*-<egcoo'c-i-*egeoo'c'-*eg oooooooooooooooooooooooooooooo OONOO^OfflNQDfOtfMflOl'O^Na^O'fiNaS^OWN^ c-?ocococoegegegegeg^(30 e5C,^,-CS4f3C^,J<^,l/3C<oc^co^egegcoo'0'C'-ao i i i i i ti i i i i i iifiiiiTTTi ilTr* 'J 'J " Z ' Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z Z C - 02170 sA \ -g2 M o= ooooooooooooooooooo !- nOnOnOnOnOnOnOnOnOpOjn^OoOn wCO r5Dt w50 w w w p _o CO CO OtotocotoooaoQOcOQoaoaoaoaocpaoooaOQO < H < Q a z < CO ZO H 5 o ** o o in c- in a- CO 00 CO e- 03 03 o m en c cCO 0or0- CO 03 CO uo3 o0o0 CO m ooin m CO3 in o in ACO3 in 0r0M m ACinO3 CCAOOm HAin oCO* m CO mm iCimnnO oo CO in K 3 M A3 o 00 CO o- A3 oo CO <* A3 o oo <o *< A3 o 00 CO o o 3a JjdS 32 -H *0<3* m C0mO3 O) CO AoA3- iitnn* 0o000 o 0CO0 Ci-HO 03 CO C0O3 03* o Aro3- A3 r-4 AA- o ACO3 ACCO3D CCcOOo 0C0D CO H es O ~ in in in n in m in m m in CO CO CO CO CO CO CO CO CO 3 => Q O 2 3 - ^(OOntOANtOQNOA^OtO(ONNAOlAON^AOi(A0dMtSQiOO^NOe<OOlNA S s AAO^Hp]nn^U)U)t0t*fAAO o PI o 3 a < V 5^ s -i o aociO^AiiocofaDCso-^o^cococ-aooi s aas _ 3 > Of0i0^nNHOC0N(0U) ao o Jh 3 ooooooooooooooooooo l-l a "3 3 "oS j1j s5 <! to CD I O n 03 c I a 03 co I N o c- I CD AS HA* I f 03 HC'* I o < ^c* I (O A3 c* I AA3 (CAD ccio* ta- N mai- AO ifrni A C CI* N f O (O N t-N A- t0o0 N03 3 otfl AI* fcI* tI I AI* CIO r . *. - ' -- c o o c o o o' r*. ft* rm rm r > fa o * 3 a a> s 02171 TABLE 4 - GAS PIPE DELIVERY SCHEDULE AND CONNECTIONS 2 3 CD QD G o, jgE CCDD o u O- u o 3 .a *tS, af"i -* nO $ Ss? 2 a2 *o fi*4 Q^2 -oSO3 gg ^ O MU u s 32 u a, 3 a 3 |S 8 g' * S a *2 oo 8. CJ Q O in J2 S 2 ^ pH 00 ^H CO o 4 pH CO Oi e ^H CD* c-aoo2 -* N CO ph* ^n-^N^hifnlnHt- ninOO2P2 pH* T V H^nNcO-rt)tA-HOoOotOflOSOS H N ^ t* N ^ w* o! ^<aNoratts-^irtc: <^0f-^210 *4 N ifl ^ <N CO o*,ic*oo^coooo2222 HN Ct< rtnoooooo co^e^as22 H U5 a & w4 C* S o pH CO t- w2222 JS HO N pH *-f CD * a 3 J t*0oOO HNiflOOJOHifliflWO pH pH pH Q0 * 00 pH pH ^oooo22 H N 3 50 ** pH C4 rt0000 >csd^^CO-^^2**2* HN ^ ^tmaoo222 pH N D1 nnoooo22o NsfHpif5lnf.HoHW$20 H C4 CD ceDocCo~*cCcoDoC-C002'5222?tf223 02172 GW GAS BOILER njgm --m ijrt to mmr mb i 0 m 'mm Figure 26 02173 GW GAS BOILER cnouw rtm ft Figure 27 02174 GW GAS BOILER ) A A- * itl Hi MM'I Figure 28 02175 115 V 60 CT C,\V GASBOILEn AUXILIARY LIMIT CONTROL (WHEN USED* LIMIT CONTROL 37 OPERATING CONTROL H 115 V 60 CY '--a CIRCULATOR W 0 32025 GW BOILER wiring oiagram INTERMITTENT CIRCULATOR OPERATION 2A VOLT CONTROLS Figure 29 02176 } 115 V 60 CY GW GAS BOILER 3 7a AUXILIARY LIMIT CONTROL (WHEN USED) UMIT CONTROL pilot safety SWITCH OPERATING CONTROL I H -------------------------------------------------- 115 V 60 CY------------------------------------------------ -G Kl --a CIRCULATOR W 32025 SW BOILER WIRING DIAGRAM INTERMITTENT CIRCULATOR OPERATION 24 VOLT CONTROLS FIGURE 29a 02177 38 GW GAS BOILER 02178 8-STAGE BOILER S E Q U jjjp E R WIRING DIAGRAM CAUTION TO INSTALLERS AND OWNERS The heat transfer surface of this boiler has been carefully designed to give optimum performance and reliability. However, the presence of contaminants 6uch as scale or lime, sediment and boiler sealing compounds in the section waterways may cause premature failure of the sections. If leaks occur in the system and are undetected or neglected, fresh water replaces the water lost through the leaks. Nearly all water contains dissolved minerals ('lime"). As water is heated in the boiler, the minerals are deposited, mostly at the bottom of the sections directly above the fire. No appreciable amount of lime is deposited in a system with no leaks; but when water is hard and makeup water must be added frequently and in large amounts, boiler waterways may be coated with a thick layer of lime within days or a few weeks of operation. Lime is an insulator, which causes over heating of boiler metaJ if deposition of lime is not halted, the boiler will fail. To stop lime deposition, stop system leaks. Leaks may occur occasionally in any system. These leaks are usually of such a nature that they can be prevented or corrected by good workmanship. Every effort should be mad to correct them without the use of boiler sealing compounds. If compounds are used, they should be used as sparingly as possible, and never in excess of manufacturers recommendations. Following use, the boiler must be flushed out thoroughly, or serious damage is likely to result. Sediment which may accumulate in the boiler should be flushed out in accordance with recommended maintenance practices. Excessive use of water should be avoided because of the danger of lime and corrosion buildup. Glycol anti-freeze is sometimes added to system water to protect against freezup. Although American Standard can not recommend this practice, we realize that glycol anti-f *seze will occasionally be used. Heat transfer through glycol is poorer than through water: use no more than 50 percent glycol in the system. With any proportion of glycol, radiator output will be lower than with pure water at the same temperature. It is always better, when possible, to drain the system rather than add anti-freeze? neither the heating system nor plumbing system water will freeze so long as the heating system continues to operate; and the plumbing system is not protected against freezeup when the heating system is off, whether or not the heating system contains anti-freeze. Cast iron is highly resistant to corrosion. However, some propellants used in aerosol cans break down into poison gas and corrosive gas, at high temperatures. If aerosol mixtures are used near boilers, the aerosol will enter the boiler flame and will be heated. Continued use of aerosol cans near heating system boilers can result in severe boiler heating surface corrosion and possible danger to health. The installer of this boiler is responsible for shoving to the ovoer operator the location of all emergency shutoff devices, and Instructing him in the use of each. 02179 American-Standard products normally reach owners or consumerusers through an industry channel of distributors and plumbing and heat ing contractors. Experience has shown that claims of defects in our pro ducts generally relate to abuse or to other damage which occur after our sale and are not our responsibility. Since determining proper responsibility requires local inspection, our warranty (set forth below) extends only to our direct buyers; distributors are best equipped to obtain the facts un derlying claims, to place responsibility where it belongs and to recom mend /handle repair or replacement. American-Standard warrants only to its distributors and other direct Buyers that it will furnish by freight a replacement for, or at its option repair, any product of its manufacture or part or portion thereof, proved to its satisfaction to be defective in material or workmanship under nor mal use and service within one year after installation. THERE IS NO OTHER WARRANTY, EXPRESS OR IMPLIED. IN CLUDING NO IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY FOR FITNESS FOR A PARTICULAR PURPOSE AND AMERICAN-STANDARD WILL NOT BE RESPONSIBLE FOR ANY DAMAGES WHATSOEVER NOR FOR LABOR OR TRANSPORTA TION EXPENSES RELATING TO SUCH REPLACEMENT OR SUCH REPAIR. NOR WILL IT BE HELD RESPONSIBLE FOR WARRANTY ADJUSTMENTS COSTING MORE THAN THE PRICE OF THE PRO DUCT TO ITS DISTRIBUTORS AND OTHER DIRECT BUYERS. Goods of other manufacturers sold by American-Standard are not warranted unless accompanied by an express written warranty, but the Seller will endeavor to secure for its direct Buyers the benefits of war ranties extended by such other manufacturers for such goods. American-Standard is proud of its record for product quality and for fairness in handling warranty matters; and, if an ultimate user of our products should feel our warranty system described above does not work fairly in his case, he shoftld write the Office of the President, Director of Consumer Affairs. U. S. Plumbing/Heating, American-Standard, 40 West 40th Street, New York, N. Y. 10018. DEALER'S NAMEr_______ ADORESS:___________ TELEPHONE NO.:______ DATE Of INSTALLATION: PLUM8ING A HEATING P. 0. BOX 2003 HEW BRUNSWICK, N.J. 0003 02180