Installation, Start-Up, and Operating Instructions

Transcription

1 Installation, Start-Up, and Operating Instructions Gas-Fired Natural Draft Steam Boilers Sizes 05,000 thru 99,000 Series A BS BS ama ASME NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler. MODEL BS Continuous Pilot MODEL BS Electronic Intermittent Ignition A959 A9000 Index Page SAFETY CONSIDERATIONS... INTRODUCTION... BOILER RATINGS AND CAPACITIES...4 LOCATING THE BOILER...5 Form: IM-BSA-0 Cancels: IM-BSA-0 Printed in U.S.A. -95 Catalog No. 9-BS-A7

2 FRESH AIR FOR COMBUSTION Boiler Located in Unconfined Space...5 Boiler Located in Confined Space...6 INSTALLATION SYSTEM PIPING For Use with Cooling Units...0 CHIMNEY AND VENT PIPE CONNECTION...0- Checking Chimney...0 Chimney Sizing...0 Connecting Vent Damper and Vent Connector...0- Minimum Vent Pipe Clearance... Removing Existing Boiler from Common Venting System...- VENT DAMPER OPERATION...- Automatic Operation of Vent Damper...- Manual Operation of Vent Damper... GAS SUPPLY PIPING...-4 Checking Gas Supply... Connecting Gas Piping... Checking Gas Piping...4 ELECTRICAL WIRING Electric Power Supply...4 Installing Thermostat...4 Electronic Thermostats...4 Vent Damper...4 Wiring Diagrams CONTROLS AND ACCESSORIES Pop Safety Valve...7 Steam Pressure Gage...7 Water Level Gage...7 Steam Pressure Control...7 Low Water Cut-Off (LWCO)...7 Water Feeder (Optional)...7 Vent Damper...7 Rollout Switch (Flame Rollout Safety Shutoff)...7 Spill Switch (Blocked Vent Shutoff System) FOR YOUR SAFETY READ BEFORE OPERATING...8 GAS VALVE OPERATING INSTRUCTIONS Intermittent Ignition Boiler VR804A/VR804M Gas Valve Continuous Pilot Boiler VR800A/VR800A Gas Valve...9 OPERATING BOILER...0 How a Steam System Operates...0 Filling System with Water...0 Water Level...0 Automatic Gas Valve...0 Thermostat...0 CHECKING AND ADJUSTING...0- Pilot Burner Adjustment...0 Main Burner Air Adjustment...0 Gas Valve Safety Shutdown Test...0- Steam Pressure Control Adjustment... Checking Controls... CLEANING BOILER...- Skimming...- Blowdown... MAINTAINING BOILER...- Water Level... Pop Safety Valve... Low Water Cut-Off (LWCO)... Burners... Boiler Flue Passages...- Vent Pipe... Cleaning Boiler Flue Passages and Burners... Foaming, Priming, or Surging... Boiler Water Treatment (Other Than Cleaners)... Between Heating Seasons... SERVICE HINTS...4 REPAIR PARTS...5-8

3 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as maintaining water level. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply. Follow all safety codes. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA No /ANSI Z.-99. Wear safety glasses and work gloves. Have fire extinguisher available during start-up and adjustment procedures and service calls. Recognize safety information. This is the safety-alert symbol. When you see this symbol on unit or in instructions and manuals, be alert to potential for personal injury. Understand the signal words DANGER, WARNING, and CAUTION. These words are used with safety-alert symbol. DANGER identifies most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. INTRODUCTION These Gas-Fired Steam Boilers are low-pressure, sectional cast iron boilers design certified by the American Gas Association (A.G.A.) for use with natural and propane gases. They are constructed and hydrostatically tested for a maximum working pressure of 5 psi in accordance with the American Society of Mechanical Engineers (A.S.M.E.) Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers. Check to be sure boiler size is correct before starting installation. See rating and capacity tables shown in Fig.. Also be sure new boiler is for the type of gas being used. Check rating plate on right side of boiler. The boiler must be supplied with correct type of gas, fresh air for combustion, and a suitable electrical supply. Boiler must also be connected to a suitable chimney and an adequate piping system. Finally, a properly located thermostat is needed for control of heating system. If there are any doubts as to the various requirements, check with local authorities and obtain professional help where needed. Take time to complete all the steps for SAFE and PROPER operation of heating system. These boilers are designed for use in closed heating systems where all of the steam is returned to boiler as condensate and the amount of make-up water required is minimal. These boilers are not designed for or intended for use in open systems or process applications using 00% make-up water. Damage to boiler resulting from such use shall not be covered under the warranty. Where required by authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-. Before installing the boiler in the United States, refer to the current edition of the NFGC. For further information, the NFGC is available from National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 069; American Gas Association, 55 Wilson Boulevard, Arlington, VA 09; or from Literature Distribution. The installation must conform with requirements of the authority having jurisdiction, or in absence of local codes, to the NFGC. The following steps are all necessary for proper installation and safe operation of boiler.. LOCATING THE BOILER. FRESH AIR FOR COMBUSTION. INSTALLATION SYSTEM PIPING 4. CHIMNEY AND VENT PIPE CONNECTION 5. GAS SUPPLY PIPING 6. ELECTRICAL WIRING 7. CHECKING AND ADJUSTING WARNING: liquids. Keep boiler area clean and free from combustible materials, gasoline, and other flammable vapors and WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product. Failure to follow this warning could result in electrical shock, fire, personal injury, or death. Natural gas boilers are not to be converted to propane gas.

4 BOILER RATINGS AND CAPACITIES RELIEF VALVE VENT DAMPER N.P.T. PRESSURE GAGE TRANSFORMER PRESSURE LIMIT CONTROL LOW WATER CUT-OFF GLASS GAGE WATER LINE A LOW WATER CUT-OFF PROBE GAS LINE S86 GAS VALVE 4 LEFT SIDE FRONT RIGHT SIDE Natural Gas-Fired Steam Boilers A90064 BOILER MODEL NUMBER Intermittent Ignition with Vent Damper Standing Pilot with Vent Damper NO. OF SECTIONS AGA Input MBH NATURAL GAS* Heating Capacity MBH Net I=B=R Rating MBH Net I=B=R Rating Sq Ft Radiation DIMENSIONS (IN.) Flue Diameter BSAAN000075AAAA BSAAN000075AAAA /4 BSAAN000AAAA BSAAN000AAAA / BSAAN00050AAAA BSAAN00050AAAA /4 BSAAN00087AAAA BSAAN00087AAAA BSAAN0005AAAA BSAAN0005AAAA /4 BSAAN0006AAAA BSAAN0006AAAA / BSAAN00099AAAA BSAAN00099AAAA /4 Width A BOILER MODEL NUMBER Intermittent Ignition with Vent Damper Standing Pilot with Vent Damper Propane Gas-Fired Steam Boilers NO. OF SECTIONS AGA Input MBH PROPANE GAS* Heating Capacity MBH Fig. Dimensional Drawing and Boiler Ratings and Capacities DIMENSIONS (IN.) The ratings marked "Net I=B=R Rating" indicate the amount of equivalent direct cast iron radiation each boiler will take care of under normal conditions and thermostatic control. The Net I=B=R Steam Ratings shown are based on an allowance of. in accordance with the factors in the I=B=R Code as published by The Hydronics Institute. Selection of boiler size should be based upon "Net I=B=R Rating" being equal to or greater than installed radiation in sq ft. Consult manufacturer before selecting a boiler for installations having unusual piping and pickup requirements. Specifications and dimensions are subject to change without notice. Net I=B=R Rating MBH Net I=B=R Rating Sq Ft Radiation Flue Diameter BSAAP000070AAAA BSAAP000070AAAA /4 BSAAP00005AAAA BSAAP00005AAAA / BSAAP00040AAAA BSAAP00040AAAA /4 BSAAP00075AAAA BSAAP00075AAAA BSAAP0000AAAA BSAAP0000AAAA /4 BSAAP00045AAAA BSAAP00045AAAA / BSAAP00080AAAA BSAAP00080AAAA /4 * For altitudes above 000 ft, ratings should be reduced at the rate of 4% for each 000 ft above sea level. Heating Capacity is based on Department of Energy (DOE) test procedure. MBH 000 Btuh Btuh British Thermal Unit Per Hour NOTE: Add 5-/ in. to height for Vent Damper. Width A 4

5 LOCATING THE BOILER. Select level location as centralized with piping system and as near chimney as possible.. Place crated boiler at selected location. Remove crate by pulling crate sides from top and bottom boards. When boiler is to be installed on a combustible floor, a combustible floor base must be used. This boiler must not be installed on carpeting.. Boiler is to be level. Metal shims may be used under base legs for final leveling. 4. ACCESSIBILITY CLEARANCES MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES. An 8-in. clearance must be maintained at a side where passage is required to access another side for cleaning or servicing, inspection, or replacement of any parts that normally may require such attention. Boilers must be installed at least 6 in. from combustible material on all sides. Allow at least 4-in. front and right side clearance for servicing. (See. Fig..) 6 MIN 4 MIN 6 FRONT GAS SUPPLY PIPE 4 MIN THIS UNIT MUST BE SET ON A CONCRETE OR OTHER NON-COMBUSTIE MATERIAL BASE OR FLOOR. Fig. Minimum Clearance Dimensions 5. Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide necessary air, outside air shall be introduced as described in Fresh Air for Combustion section. 6. Advise owner to keep air passages free of obstructions. Ventilation and combustion air must enter boiler room without restrictions. 7. The boiler shall be installed such that the automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (condensate trap, control replacement, etc.). FRESH AIR FOR COMBUSTION Provision for combustion and ventilation air must be in accordance with Section 5., Air for Combustion and Ventilation, of the NFGC, ANSI Z.-99, or applicable provisions of local building codes. WARNING: Be sure to provide enough fresh air for combustion. Enough air ensures proper combustion and ASSURES THAT NO HAZARD WILL DEVELOP DUE TO LACK OF OXYGEN. Failure to follow this warning can cause a fire, personal injury, or death. A9540 CAUTION: Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Excessive exposure to contaminated combustion air will result in safety and performance related problems. CAUTION: If a fireplace or a kitchen or bathroom exhaust fan is used, an outside air intake should be installed. These devices rob the boiler and water heater of combustion air. Enough fresh air must be provided to assure proper combustion. The fire in the boiler uses oxygen. It must have a continuous supply. The air in a house contains only enough oxygen to supply the burner for a short time. Outside air must enter the house to replace that used by the burner. The exact fresh air requirements depend on whether the boiler is located in an unconfined or confined space. PROCEDURE BOILER LOCATED IN UNCONFINED SPACE An unconfined space is defined as a space with volume not less than 50 cu ft per 000 Btuh of total input rating of all appliances installed in that space. If boiler is in an open area (unpartitioned basement) in a conventional house, air that leaks through cracks around doors and windows will usually be adequate to provide air for combustion. The doors should not fit tightly. Do not caulk cracks around windows. 5

6 Table Fresh Air Duct Capacities for Ducts Supplying Fresh Air to Boiler in Tightly Constructed Houses (Btuh)* FRESH AIR DUCT SIZE (IN.) /4-IN. MESH SCREEN WOOD LOUVERS METAL LOUVERS X 44,000 6,000 08,000 8X8 56,000 64,000 9,000 8X 84,000 96,000 88,000 8X6 5,000 8,000 84,000 * Based on opening covered by /4-in. mesh screen, wood louvers, or metal louvers. FRESH AIR DUCT BOILER A954 Fig. Fresh Air Duct for Tightly Sealed House PROCEDURE BOILER LOCATED IN CONFINED SPACE A. All Air From Inside Building The confined space shall be provided with permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of sq in. per 000 Btuh of total input rating for all gas utilization equipment in the confined space, but not less than 00 sq in. One opening shall be within in. of the top and within in. of the bottom of the enclosure. B. All Air From Outdoors The confined space shall be provided with permanent openings, commencing within in. of the top and commencing within in. of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.. When directly communicating with the outdoors, each opening shall have a minimum free area of sq in. per 4000 Btuh of total input rating of all equipment in the enclosure.. When communicating with the outdoors through vertical ducts, each opening shall have a minimum free area of sq in. per 4000 Btuh of total input rating of all equipment in the enclosure.. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of sq in. per 000 Btuh of total input rating of all equipment in the enclosure. 4. When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than in. INSTALLATION SYSTEM PIPING The near boiler piping (the piping around the boiler) must be considered as part of the boiler for proper water level control and to produce dry steam. Correct near boiler piping is crucial to proper operation of boiler and heating system. Follow these recommendations carefully.. Place boiler in selected location as near chimney as possible.. Install pop safety valve using factory-supplied /4-in. coupling into /4-in. pipe nipple on top of boiler. Make a discharge pipe using /4-in. pipe (field supplied) to carry water or steam to a nearby drain. Do not connect discharge pipe directly to drain but leave an air gap. The downstream end of discharge pipe must be unthreaded. No shutoff of any description shall be placed between pop safety valve and boiler, or on discharge pipes between such safety valves and the atmosphere. Installation of pop safety valve shall conform to requirements of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for any water damage.. This boiler is equipped with two -/-in. supply connections and two -/-in. return connections, each on both the left and right sides of boiler. Unused connections must be plugged with factory-supplied -/-in. plugs. 4. Recommended near boiler piping for gravity return systems is shown in Fig. 4. This configuration uses supply and return tapping. This setup can be used on any size boiler in this series. The supply and return connections may be piped both into the same side (either left or right) or into each side of boiler. 5. For installers choosing to use both supply tappings, refer to Fig. 5 for the CORRECT way to pipe system. Fig. 6 shows the WRONG way to pipe a header with risers. a. Headers must be fitted with header offsets or swing joints, or be equipped with expansion joints, so that thermal expansion and contraction of header will not damage boiler. Headers shall not be welded. b. System takeoffs from header must be between equalizer and riser to header nearest equalizer. System takeoffs must never be between risers. 6. System takeoffs from header must never be bullheaded. If steam main goes in directions, there must be takeoffs from header, for each main. 6

7 PIPE FULL SIZE SAME AS BOILER TAPPING ( / ) 5 MIN. STEAM MAINS POP SAFETY VALVE FLUE COLLAR 4 MIN. REDUCING ELL POINTING DOWN / MIN. PIPE SIZE 6 TO 0 MAIN VENT DRY RETURN MAIN 5 MIN. WATER LINE 4 / MIN. TEE WITH PLUG FOR SKIMMING CLOSE NIPPLE 6 8 MIN. - DIMENSION A WET RETURN WATER FEED / FULL PORT BALL VALVE FOR BOTTOM OW DOWN AND DRAINING BOILER & SYSTEM (NOT FURNISHED) GATE VALVE (NOT FURNISED) DRAIN VALVE (FURNISHED) FOR FLUSHING SYSTEM Fig. 4 Recommended Near Boiler Piping Using Supply Tapping A Near boiler piping shall be threaded iron or steel pipe only. Copper shall not be used other than for wet returns. 8. All boilers in gravity return systems MUST be equipped with a Hartford Loop as shown in Fig. 5 and When piping vertical risers from boiler to header, the bottom of header must be a minimum of 4 in. above water level line on right side of boiler. 0. Steam riser(s) and header shall be -/-in. pipe size.. Equalizer line shall be a minimum -/-in. pipe size.. The near boiler piping shall include a -/-in. tee with a plug located on supply line for skimming (surface blowdown). (See Fig. 4 or 5.). The near boiler piping shall include a -/-in. ball valve in return piping for bottom blowdown and draining. (See Fig. 4 or 5.) 4. For gravity return systems, the bottom of lowest steam carrying pipe, be it dry return or end of steam main, must be at least 8 in. above normal water level line on right side of boiler. This is known as "Dimension A." 5. For pumped return systems, follow condensate pump or boiler feed pump manufacturer s instructions for proper installation and hookup. 6. In connecting cold water supply to water inlet valve, make sure that a clean water supply is available. When water supply is from a well or pump, a sand strainer should be installed at pump. 7

8 PIPE FULL SIZE SAME AS BOILER TAPPING ( /") 5 MIN. STEAM MAINS POP SAFETY VALVE CONNECT RISER TO BOILER WITH / ELBOW AND NIPPLE (NOT SHOWN) FLUE COLLAR 4 MIN. REDUCING ELL POINTING DOWN / MIN. PIPE SIZE 6 TO 0 MAIN VENT DRY RETURN MAIN 5 MIN. WATER LINE 4 / TEE WITH PLUG FOR SKIMMING CLOSE NIPPLE 6 8 MIN. - DIMENSION A WET RETURN WATER FEED / FULL PORT BALL VALVE FOR BOTTOM OW DOWN AND DRAINING BOILER & SYSTEM (NOT FURNISHED) GATE VALVE (NOT FURNISED) DRAIN VALVE (FURNISHED) FOR FLUSHING SYSTEM Fig. 5 Recommended Near Boiler Piping Using Supply Tappings A

9 THIS PIPING CONFIGURATION IS INCORRECT TO SHOW COMMON MISTAKES WRONG WAY DO NOT BULLHEAD, USE TAKE OFFS WRONG WAY TAKE OFFS MUST BE BETWEEN RISER & EQUALIZER WRONG WAY SWING JOINTS ARE MISSING WRONG WAY MISSING TEE FOR SKIMMING WATER LINE Fig. 6 Common Near Boiler Piping Mistakes A

10 PROCEDURE FOR USE WITH COOLING UNITS. This boiler, when used in connection with chilled water systems, must be installed so that chilled water is piped in parallel with the heating boiler. Appropriate valves must be used to prevent chilled water from entering the heating boiler. (See Fig. 7.). When this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, the piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during cooling cycles. TO SYSTEM B A C D WATER CHILLER VALVES C & D CLOSE FOR HEATING; OPEN FOR COOLING VALVES A & B OPEN FOR HEATING; CLOSE FOR COOLING Fig. 7 Chilled Water Piping CHIMNEY AND VENT PIPE CONNECTION For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the NFGC ANSI Z.-99 and applicable provisions of local building codes. PROCEDURE CHECKING CHIMNEY This is a very important part of heating system. It must be clean, the right size, properly constructed, and in GOOD CONDITION. No boiler can function properly with a bad chimney. Inspect chimney and verify that construction and size of chimney meet all applicable provisions of the NFGC and local building codes. Fig. 8 gives an idea how a boiler might be vented to a chimney. Note that the height (HT) is measured from vent pipe to the top. PROCEDURE CHIMNEY SIZING Chimney sizing and all other aspects of the vent installation must be in accordance with Part 7 of the NFGC ANSI Z.-99 and applicable provisions of local building codes. PROCEDURE CONNECTING VENT DAMPER AND VENT CONNECTOR Refer to Fig. flue diagram for size and location of vent (flue opening). Use 8 gage (minimum) galvanized pipe to connect to chimney. IMPORTANT: The damper blade on factory-supplied vent damper has a /-sq in. hole (approximately /4-in. diameter). On boilers equipped with standing pilot, the hole MUST be left open. On boilers equipped with intermittent ignition, the hole should be plugged using plug supplied with vent damper.. Position factory-supplied vent damper on top of flue outlet collar. Fasten damper securely to flue outlet collar with sheet metal screws. Make sure damper blade has clearance to operate inside of diverter. As An Option: The damper may be installed in any horizontal or vertical position, closer to the flue outlet collar preferred. Follow diagrams shown in Fig. 9, 0, and.. Install vent damper to service only the single boiler for which it is intended. The damper position indicator shall be in a visible location following installation. Locate damper so that it is accessible for servicing.. The damper must be in open position when appliance main burners are operating. 4. The boiler is equipped with a factory-wired harness that plugs into vent damper. The thermostat must be connected to black wires marked "4 volt thermostat" on boiler. 0 A954

11 FT. MIN. HT FT. MIN. ROOF RIDGE /4 HT MAXIMUM MUST SLOPE UP AT LEAST /4 INCH PER FOOT OF HORIZONTAL RUN Fig. 8 Typical Masonry Chimney Requirements 5. Vent pipe must be same size as flue outlet collar. 6. Slope pipe up from boiler to chimney not less than /4 in. per ft. 7. Run pipe as directly as possible with as few elbows as possible. 8. Do not connect to fireplace flue. 9. End of vent pipe must be flush with inside face of chimney flue. Use a sealed-in thimble for chimney connection. 0. Horizontal run should not be longer than /4 the chimney height (HT). (See Fig. 8.) The sections of vent pipe should be fastened with sheet metal screws to make the piping rigid. Horizontal portions of vent system must be supported to prevent sagging. Use stovepipe wires every 5 ft to support pipe from above. If vent pipe must go through a crawlspace, double-wall vent pipe should be used. Where vent pipe passes through a combustible wall or partition, use a ventilated metal thimble. The thimble should be 4 in. larger in diameter than vent pipe. PROCEDURE 4 MINIMUM VENT PIPE CLEARANCE Wood and other combustible materials must not be closer than 6 in. from any surface of single-wall metal vent pipe. Listed Type-B vent pipe or other listed venting systems shall be installed in accordance with their listing. PROCEDURE 5 REMOVING EXISTING BOILER FROM COMMON VENTING SYSTEM When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following items shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.. Seal any unused openings in the common venting system.. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. A9544

12 HORIZONTAL INSTALLATION FLOW NO YES YES TO FURNACE OR BOILER VENT DAMPER TO CHIMNEY NO INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY. DO NOT MOUNT ABOVE OR BELOW VENT. VERTICAL INSTALLATION CAUTION: Do not install the vent damper within 6 in. (5 mm) of combustible material. NO TO CHIMNEY FLOW TO FURNACE OR BOILER VENT DAMPER ACTUATOR MAY BE INSTALLED IN ANY POSITION A9545 Fig. 9 Horizontal and Vertical Vent Damper Installation CHIMNEY FLUE GAS FLOW CLOSED OPEN DAMPER CLOSED ROTATION FLUE GAS FLOW A9547 Fig. 0 Effikal Vent Damper Position Indicator CLOSED OPEN DAMPER OPEN ROTATION BOILER WATER HEATER Fig. Typical Installation for Vent Damper (Note Caution and Footnotes). Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe. 6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use. 7. Any improper operation of the common venting system should be corrected so the installation conforms with the NFGC ANSI Z.-99. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the NFGC ANSI Z.-99. For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipment, of the NFGC ANSI Z/-99 and applicable provisions of local building codes. Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure. VENT DAMPER OPERATION PROCEDURE AUTOMATIC OPERATION OF VENT DAMPER For safe, efficient operation, the vent damper and all flue product carrying areas of appliance must be checked annually with particular attention given to deterioration from corrosion or other sources. If corrosion or other deterioration is observed, contact your heating contractor for repairs. Check vent damper operation as follows:. When boiler is off, check that vent damper position indicator points to CLOSED position. (See Fig. 0.). Install the vent damper to service only the single appliance for which it is intended. If improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result.. Do not install the vent damper on vent pipe curve.. Do not run wires near high temperature surfaces. Use stand-off brackets if necessary. A9546

13 . Turn thermostat or controller up to call for heat and check that vent damper indicator points to OPEN position. (See Fig. 0.). Turn thermostat or controller down again and check that vent damper position indicator returns to CLOSED position. 4. If system has central air conditioning, set thermostat to COOL and turn it down to call for cooling. Cooling system should operate. 5. Return thermostat to desired position. The vent damper must be inspected at least once a year by a trained, experienced service technician. The name of the person who originally installed vent damper is shown on installation label. PROCEDURE MANUAL OPERATION OF VENT DAMPER The Effikal vent damper may be placed in OPEN position to permit burner operation by using the HOLD DAMPER OPEN switch located on damper controller. The thermostat will control burner firing as before while damper remains open. DO NOT turn damper open manually or motor damage will result. Set switch to AUTOMATIC OPERATION to close vent damper during burner off cycle. For further information and for a vent damper troubleshooting guide, refer to the Effikal manual packaged with vent damper. GAS SUPPLY PIPING PROCEDURE CHECKING GAS SUPPLY The gas pipe to boiler must be the correct size for length of run and Btuh input of all gas utilization equipment connected to it. See Table for proper size. Be sure gas line complies with local codes and gas company requirements. The boiler and its individual shutoff valve must be disconnected from gas supply piping system during any pressure testing of gas supply piping system at test pressures in excess of 0.5 psig (.5 kpa). The boiler must be isolated from gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 0.5 psig (.5 kpa). PROCEDURE CONNECTING GAS PIPING Refer to Fig. for general layout at boiler. It shows the basic fittings needed. The gas line enters boiler from right side. The following rules apply:. Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction or in the absence of such requirements, by the NFGC ANSI Z Use pipe joint compound suitable for LP gas on male threads only.. Use ground joint unions. 4. Install a sediment trap upstream of gas controls. 5. Use pipe wrenches when making connection to gas valve to keep it from turning. 6. Install a manual shutoff valve in vertical pipe about 5 ft above floor. 7. Tighten all joints securely. 8. Propane gas connections should only be made be a licensed propane installer. 9. Two-stage regulation should be used by propane installer. 0. Propane gas piping should be checked by propane installer. Table Gas Pipe Sizes NATURAL GAS Length of Pipe Pipe Capacity Btuh Input Includes Fittings (Ft) / in. /4 in. in. -/4 in. 0 9,000 90,000 50,000 65, ,000 0,000 45, , ,000 05,000 95,000 65,000 LP GAS Pipe Capacity Btuh Input Length Includes Fittings of Pipe Copper Tubing* Iron Pipe (Ft) 5/8 in. /4 in. / in. /4 in. 0,000 6,000 89,000 9, ,000 45,000 9,000 67, ,000,000 0,000 7,000 * Outside diameter. NOTE: The length of pipe or tubing shown should be measured from gas meter or propane second-stage regulator. GROUND JOINT UNION AUTOMATIC GAS VALVE MANIFOLD MANUAL SHUT-OFF VALVE SEDIMENT TRAP FLOOR LINE Fig. Gas Piping at Boiler A9548

14 PROCEDURE CHECKING GAS PIPING Upon completion of piping, check immediately for gas leaks. Open manual shutoff valve. Test for leaks by applying soap suds (or a liquid detergent) to each joint. Bubbles forming indicate a leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE. WARNING: Never use a match or open flame to test for leaks. Use a soap-and-water solution. A failure to follow this warning could result in fire, explosion, personal injury, or death. ELECTRICAL WIRING See Fig. and 4 for wiring diagrams for the various models. PROCEDURE ELECTRIC POWER SUPPLY WARNING: Turn off electric power at fuse box before making any line voltage connections. Follow local electric codes. Failure to follow this warning could result in electrical shock, personal injury, or death. All electrical work must conform to local codes as well as the National Electrical Code (NEC) ANSI/NFPA Run a separate 0-v circuit from a separate overcurrent protective device in electrical service entrance panel. This should be a 5-amp circuit. Locate a shutoff switch at boiler. It must be turned off during any maintenance. Connect 0-v electrical supply to primary leads on 4-v transformer. Solder and tape or securely fasten these connections with wire nuts. The boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction, or in the absence of such requirements, with the NEC ANSI/NFPA Run a 4 gage or heavier copper wire from boiler to a grounded connection in service panel or a properly driven and electrically grounded ground rod. PROCEDURE INSTALLING THERMOSTAT The thermostat location has an important effect on the operation of boiler system. BE SURE TO FOLLOW INSTRUCTIONS INCLUDED WITH THERMOSTAT. Locate thermostat about 5 ft above floor on an inside wall. It may be mounted directly on wall or on a vertically mounted outlet box. It should be sensing average room temperature so avoid the following: DEAD SPOTS: Behind doors Corners and alcoves HOT SPOTS: Concealed pipes Fireplace TV sets Radios Lamps Direct sunlight Kitchens COLD SPOTS: Concealed pipes or ducts Stairwells drafts Doors drafts Unheated rooms on other side of wall Set heat anticipator at 0.8 amps for boilers equipped with standing pilot and at.0 amps for boilers equipped with intermittent ignition. The 4-v thermostat leads shall be connected to the black wires tagged "4 volt thermostat" on boiler. One wire is located on secondary of 4-v transformer. The second wire is located on pressure limit control. PROCEDURE ELECTRONIC THERMOSTATS Certain types of electronic thermostats may lose their memory or shut down each time they call for heat due to internal circuit in vent damper. If this is the case, an isolation relay is required for thermostat circuit. A 4-v single-pole single-throw (SPST) normally open (N.O.) relay is required such as Honeywell R8A or equivalent. Wire as shown in Fig. 5. PROCEDURE 4 VENT DAMPER The boiler is equipped with a factory-wired harness with a 4-pin Molex plug which plugs into 4-pin Molex receptacle inside vent damper operator. The vent damper must be connected for boiler to operate. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. 4

15 EFFIKAL RVGP VENT DAMPER MOLEX PLUG INTERMITTENT IGNITION OVERCURRENT PROTECTED DISCONNECT HOT NEUT 0V POWER SUPPLY W 4 BR OPTIONAL WF-U-4 WATER FEEDER NOTE: TERMINAL NO. APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON. WIRE NUT COLOR CODE -ACK BR-BROWN O -ORANGE Y -YELLOW R -RED BT W G O -ACK WITH TRACER -WHITE -GREEN Y Y THERMOSTAT t BT BT 4 5 P O PRESSURE LIMIT LOW WATER CUT OFF S8600(F,M) INTERMITTENT PILOT CONTROL MV MV/PV PV GND. RGW (4V) (GND.) (4V) BT SPARK ROLLOUT SWITCH GND W PV G PV/MV R MV LWCO PROBE TO PILOT SPILL SWITCH GAS VALVE HOT OVERCURRENT PROTECTED DISCONNECT RVGP 4 MOT LWCO K(DPDT) 0/60/ POWER SUPPLY NC C (LS) (LS) C NC 4 (K) 6 RVGP LWCO 5 RVGP 0V PRIMARY 4V SECONDARY TO GAS VALVE NO NO LWCO PRESSURE LIMIT S8600(F,M) (4V) (GND.) (4V) 5 6 ROLLOUT SW SPILL SW SEE NOTE (LS) (K) C 5 NC NO RVGP THERMOSTAT t NOTE : VD SHOWN CLOSED : LS,, ARE END SWITCHES IS MANUAL "HOLD OPEN" SWITCH (SPDT) SHOWN IN "AUTOMATIC" POSITION : ISOLATION RELAY MAY BE REQUIRED FOR SOME TYPES OF ELECTRONIC THERMOSTATS NEUT. A9550 EFFIKAL RVGP VENT DAMPER 4 VOLT MOLEX PLUG TRANSFORMER 4 OVERCURRENT PROTECTED BR O Y DISCONNECT HOT THERMOSTAT t NEUT W Y 0V POWER SUPPLY OPTIONAL WF-U-4 WATER FEEDER WIRE NUT COLOR CODE -ACK BR-BROWN O -ORANGE Y -YELLOW R -RED BT W G NOTE: TERMINAL NO. APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON. -ACK WITH TRACER -WHITE -GREEN BT BT 4 5 P O PRESSURE LIMIT TR BT LOW WATER CUT OFF TH ROLLOUT SWITCH LWCO PROBE GAS VALVE STANDING PILOT SPILL SWITCH HOT OVERCURRENT PROTECTED DISCONNECT RVGP 4 MOT LWCO K(DPDT) 0/60/ POWER SUPPLY NC C (LS) RVGP LWCO 5 NO RVGP 0V PRIMARY 4V SECONDARY LWCO TR GAS VALVE SEE NOTE (LS) (LS) (K) C C 5 NC NO NC NO 4 (K) 6 PRESSURE LIMIT ROLLOUT SW SPILL SW TH RVGP THERMOSTAT t NOTE : VD SHOWN CLOSED : LS,, ARE END SWITCHES IS MANUAL "HOLD OPEN" SWITCH (SPDT) SHOWN IN "AUTOMATIC" POSITION : ISOLATION RELAY MAY BE REQUIRED FOR SOME TYPES OF ELECTRONIC THERMOSTATS NEUT. A955 NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 05 C thermoplastic wire or its equivalent. Fig. Wiring Diagrams for Boilers with PS-80 Probe-Type Low Water Cut-Off 5

16 EFFIKAL RVGP VENT DAMPER 4 VOLT MOLEX PLUG TRANSFORMER 4 OVERCURRENT PROTECTED BR O Y DISCONNECT HOT THERMOSTAT t NEUT W 0V POWER SUPPLY OPTIONAL WF-U-4 WATER FEEDER EFFIKAL RVGP VENT DAMPER 4 VOLT MOLEX PLUG TRANSFORMER 4 OVERCURRENT PROTECTED BR O Y DISCONNECT HOT THERMOSTAT t NEUT W 0V BT POWER SUPPLY Y OPTIONAL WF-U-4 WATER FEEDER NOTE: TERMINAL NO. APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON. WIRE NUT COLOR CODE -ACK BR-BROWN O -ORANGE Y -YELLOW R -RED BT NOTE: TERMINAL NO. APPEARS ONLY ON WATER FEEDER MODELS WITH MANUAL FEED PUSH BUTTON. WIRE NUT COLOR CODE -ACK BR-BROWN O -ORANGE Y -YELLOW R -RED BT W G LOW WATER CUT OFF 4 -ACK WITH TRACER -WHITE -GREEN 4 Y LOW WATER CUT OFF O O PRESSURE LIMIT TR PRESSURE LIMIT S8600(F,M) INTERMITTENT PILOT CONTROL MV MV/PV PV GND. RGW BT (4V) (GND.) (4V) BT SPARK ROLLOUT SWITCH GND W PV G PV/MV R MV TH ROLLOUT SWITCH INTERMITTENT IGNITION SPILL SWITCH GAS VALVE TO PILOT GAS VALVE STANDING PILOT SPILL SWITCH HOT OVERCURRENT PROTECTED DISCONNECT 4 MOT LWCO K(DPDT) 0/60/ POWER SUPPLY NC C (LS) NO 0V PRIMARY 4V SECONDARY LWCO TR GAS VALVE SEE NOTE (LS) (LS) (K) C C 5 NC NO NC NO 4 (K) 6 PRESSURE LIMIT ROLLOUT SW SPILL SW TH THERMOSTAT t NOTE : VD SHOWN CLOSED : LS,, ARE END SWITCHES IS MANUAL "HOLD OPEN" SWITCH (SPDT) SHOWN IN "AUTO" POSITION : ISOLATION RELAY MAY BE REQUIRED FOR SOME TYPES OF ELECTRONIC THERMOSTATS BT-ACK WITH TRACER W -WHITE G -GREEN A955 NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 05 C thermoplastic wire or its equivalent. Fig. 4 Wiring Diagrams for Boilers with Float-Type Low Water Cut-Off 6 HOT OVERCURRENT PROTECTED DISCONNECT 4 MOT K(DPDT) 0/60/ POWER SUPPLY NC C (LS) (LS) C NC 4 (K) 6 0V PRIMARY 4V SECONDARY TO GAS VALVE NO NO S8600(F,M) ROLLOUT SPILL LWCO SW SW SEE NOTE (LS) (K) C 5 NC NO PRESSURE LIMIT (4V) (GND.) (4V) 5 6 THERMOSTAT t NOTE : VD SHOWN CLOSED : LS,, ARE END SWITCHES IS MANUAL "HOLD OPEN" SWITCH (SPDT) SHOWN IN "AUTO" POSITION : ISOLATION RELAY MAY BE REQUIRED FOR SOME TYPES OF ELECTRONIC THERMOSTATS NEUT. A955 NEUT.

17 4 PIN MOLEX PLUG 4 VOLT TRANSFORMER 4 BR O Y ISOLATION RELAY 4V SPST N.O. HONEYWELL R8A OR EQUIVALENT O PRESSURE LIMIT ELECTRONIC THERMOSTAT t TO LWCO & IGNITION SYSTEM A9549 Fig. 5 Steam Boiler with Isolation Relay for Electronic Thermostats CONTROLS AND ACCESSORIES PROCEDURE POP SAFETY VALVE In case of pressure control failure, pop safety valve automatically opens at 5 lbs pressure. This relieves strain on boiler and system. Run a pipe from safety valve outlet (pipe must be same size as outlet, and open end must not be threaded) to an open drain, tub, sink, or other suitable drainage point not subject to freezing. Failure to do so may cause water damage or injury should relief valve release. Do not cap off drain line from this valve! PROCEDURE STEAM PRESSURE GAGE Every system should have a pressure gage installed in boiler. This gage enables monitoring of pressure in system. If safety devices fail to shut off boiler at proper settings, notify service technician immediately. PROCEDURE WATER LEVEL GAGE The water level in boiler can be seen through glass tube in water level gage at side of boiler. Correct cold boiler water level is stamped on side jacket panel. The water level should be checked regularly for proper level. PROCEDURE 4 STEAM PRESSURE CONTROL The steam pressure limit control (pressuretrol) shuts off gas to main burners when steam pressure in boiler reaches cut-off setpoint (the sum of cut-in and differential set points). Burners refire when stream pressure drops to cut-in setpoint. System pressure requirements are based on size and condition of pipes and load. PROCEDURE 5 LOW WATER CUT-OFF (LWCO) A. Model 67 This is a float-operated switch which shuts down gas burners if water falls below visible bottom of gage glass. B. Model PS-80 This is an electronic probe-type LWCO. The probe is located inside boiler. The LWCO shuts down gas burners if water level falls below probe for a period of 0 sec. Refer to manufacturer s instructions (enclosed) for more information. PROCEDURE 6 WATER FEEDER (OPTIONAL) The model WF-U-4 water feeder may be used with either of the available low water cut-offs. The water feeder s job is to maintain a safe minimum water level. It is used to keep boiler running by compensating for minor evaporative steam leaks and to prevent freeze-ups if the homeowners are away and a return line springs a leak. McDonnell and Miller model 0 water feeders may be used; however, the water feed rates are too high and need to be regulated or throttled, and wiring must be revised. Consult boiler manufacturer before using these or any other non-standard types of controls. The automatic water feeder is a safety device not a convenience item. It is not designed to maintain a "normal" water line. The water feeder does not take the place of a responsible person monitoring and maintaining normal water line. Steam boilers require personal attention. PROCEDURE 7 VENT DAMPER This is an automatic, motorized stack damper developed to increase efficiency of heating systems by reducing standby losses from boiler and conditioned air space. The damper closes chimney vent when burner is off and fully opens it when combustion is required. PROCEDURE 8 ROLLOUT SWITCH (FLAME ROLLOUT SAFETY SHUTOFF) The rollout switch is a temperature-sensitive fuse link device. It is located on boiler base just outside fire box. In the event of heat exchanger flueway blockage causing flame to roll out of fire box, the fuse blows shutting down flow of gas to main burners. The fuse does not change in appearance when blown. If rollout switch blows, it must be replaced with an exact replacement. Check heat exchanger flueways for blockage when restoring system to operating condition. Do not operate system without a rollout switch. PROCEDURE 9 SPILL SWITCH (OCKED VENT SHUTOFF SYSTEM) The spill switch is a manual-reset disc thermostat with a fixed setpoint (80 F) and normally-closed contacts. It is located at relief opening of draft diverter. In the event of chimney or venting system blockage causing products of combustion to spill out of relief opening, the spill switch disc heats up and spill switch contacts open shutting down flow of gas to main burners by removing power to gas valve. 7

18 In the event that spill switch contacts open, the reset button on back of switch pops up. The spill switch must be reset manually, after the switch has cooled off, by pushing the reset button down. Check venting system and chimney for blockage when restoring system to operating condition. DO NOT operate system without a spill switch. FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. Some boilers are equipped with an intermittent ignition device which automatically lights the pilot. Do NOT try to light pilot by hand. Some boilers are equipped with a continuous pilot and must be lit manually. See lighting instructions in Continuous Pilot Boiler section. A match holder is included in parts bag. B. BEFORE OPERATING, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor s phone. Follow the gas supplier s instructions. If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push in or turn gas control knob. Never use tools. If knob will not push in or turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of control system and any gas control which has been under water. GAS VALVE OPERATING INSTRUCTIONS PROCEDURE INTERMITTENT IGNITION BOILER VR804A/VR804M GAS VALVE A. To Turn On Gas To Appliance. STOP! Read safety information in For Your Safety Read Before Operating section.. Set thermostat to lowest setting.. Turn off all electrical power to appliance. 4. This appliance is equipped with an ignition device which automatically lights the pilot. Do NOT try to light pilot by hand. 5. Remove lower front panel. 6. Turn gas control knob clockwise to OFF position. (See Fig. 6.) 7. Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in safety information in For Your Safety Read Before Operating section. 8. Turn gas control knob counterclockwise to ON position. (See Fig. 6.) 9. Replace lower front panel. 0. Turn on all electrical power to appliance.. Set thermostat to desired setting.. If appliance will not operate, follow instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier. INLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) WIRING TERMINALS () OUTLET PRESSURE TAP GROUND TERMINALS () GAS INLET ON GAS OUTLET GAS CONTROL KNOB SHOWN IN "ON" POSITION OFF PILOT ADJUSTMENT (UNDER CAP SCREW) PILOT OUTLET Fig. 6 VR804A/VR804M Intermittent Ignition Gas Valve A9550 8

19 B. To Turn Off Gas To Appliance. Set thermostat to lowest setting.. Turn off all electric power to appliance if service is to be performed.. Turn gas control knob clockwise to OFF position. (See Fig. 6.) Do not force. PROCEDURE CONTINUOUS PILOT BOILER VR800A/VR800A GAS VALVE A. To Turn On Gas To Appliance. STOP! Read safety information in For Your Safety Read Before Operating section.. Set thermostat to lowest setting.. Turn off all electrical power to appliance. 4. Remove lower front panel. 5. Turn gas control knob clockwise to OFF position. (See Fig. 7.) 6. Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in safety information in For Your Safety Read Before Operating section. 7. Find pilot. Follow metal tube from gas control. The pilot is between burner tubes. (See Fig. 8.) 8. Turn knob on gas control counterclockwise to PILOT position. (See Fig. 7.) 9. Push down and hold the red reset button while you light pilot burner with a match. After about minute, release reset button. Pilot should remain lit. If it goes out, turn gas control knob clockwise to OFF position. To relight, repeat items 5-9. If button does not pop up when released, stop and immediately call your service technician or gas supplier. If pilot will not stay lit after several tries, turn gas control knob to OFF position and call your service technician or gas supplier. 0. After pilot remains lit when red reset button is released, turn gas control knob counterclockwise to ON position. (See Fig. 7.). Replace lower front panel.. Turn on all electrical power to appliance.. Set thermostat to desired setting. B. To Turn Off Gas To Appliance. Set thermostat to lowest setting.. Turn off all electrical power to appliance if service is to be performed.. Turn gas control knob clockwise to OFF position. (See Fig. 7.) Do not force. INLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW) WIRING TERMINALS () CONVENIENCE TERMINALS () (OPTIONAL) OUTLET PRESSURE TAP GAS INLET ON GAS OUTLET MATCH HOLDER THERMOCOUPLE CONNECTION RED RESET BUTTON OFF PILOT ADJUSTMENT (UNDER CAP SCREW) PILOT OUTLET GAS CONTROL KNOB SHOWN IN "ON" POSITION A955 Fig. 7 VR800A/VR800A Continuous Pilot Gas Valve 9 Fig. 8 Lighting Pilot A9556

20 OPERATING BOILER PROCEDURE HOW A STEAM SYSTEM OPERATES The water in boiler is heated until it reaches boiling point. As water boils, it turns into steam. The steam rises from top of water through supply main to radiation units. As it passes through radiators, it releases its heat and condenses into water. The water returns to boiler through return main. Most residential systems operate at less than lb steam pressure. PROCEDURE FILLING SYSTEM WITH WATER On steam heating systems, boiler is partially filled with water. It is very important to proper operation of entire system that boiler be filled to proper level. The correct water level is about halfway up glass water level gage as marked on boiler jacket. To fill:. Close boiler drain valve.. Open valves at top and bottom of glass water level gage. Also open drain valve at bottom of gage.. Open fill valve and allow water to run into boiler. CAUTION: Never run water into a hot, empty boiler. 4. Allow boiler to fill until water runs out gage drain valve, then close gage drain valve. 5. Continue to fill boiler until water reaches indicated water line. This is about halfway up glass tube. PROCEDURE WATER LEVEL The normal water level is shown on right side of boiler and is 4 in. above the floor. The normal water level is determined when boiler is off and cold (when all of the water in system is inside boiler and return piping below water line) and everything above water line is air, no steam. When boiler is making steam, the water level drops - in. below normal water line. PROCEDURE 4 AUTOMATIC GAS VALVE The automatic gas valve opens or closes according to heat requirements of thermostat and temperature limit control. It closes if pilot goes out. Each individual control must be operating correctly before any gas can pass to burners. Any control can hold gas supply from burners regardless of demand of any other control. PROCEDURE 5 THERMOSTAT Keep thermostat set at desired room temperature. If windows are to be opened or heat is not needed, set thermostat to a lower setting. NOTE: In the event of failure of any component, system will not operate or will go into safety lockout. The system is completely self-checking. On every call for heat, each component must be functioning properly to permit operation. On safety lockout, system has to be reset by setting thermostat to lowest setting for minute, then back to normal setting. Safe lighting and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in ANSI Z.-latest revision. CHECKING AND ADJUSTING PROCEDURE PILOT BURNER ADJUSTMENT Pilot flame should surround /8- to /-in. of pilot sensor. (See Fig. 9.) If flame needs adjusting, proceed as follows:. Remove screw cover over pilot adjusting screw.. Insert small screwdriver and adjust flame as needed. Turn screw counterclockwise to increase flame and clockwise to decrease flame.. Replace screw cover over pilot adjusting screw. PROCEDURE MAIN BURNER AIR ADJUSTMENT The primary air shutters on cast iron main burners should be adjusted so flame forms a sharp blue cone with no yellow. (See Fig. 0.) Stainless steel main burners (propane gas boilers only) do not require primary air adjustment. PROCEDURE GAS VALVE SAFETY SHUTDOWN TEST A. Boilers Equipped with Continuous Pilot With main burners firing, disconnect thermocouple from gas valve. (See Fig. 7.) Gas valve should immediately shut off main burners and pilot. 8 to OUTER CONE DARKER UE FLAME ON SENSOR INNER CONE UE Fig. 9 Pilot Flame and Sensor A9560 Fig. 0 Main Burner Flame A9559 0