INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR Series 2

Advisory Committee under the Board of Examiners of Electrical Contractors pursuant to N J S A 45:5A-23 et seq b) Except as set forth in (c) below, this chapter shall apply to the following: 1) All applicants seeking licensure to engage in burglar alarm or fire alarm businesses as defined in N J A C 13:31A-1 2;

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INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR Series 2

103698-02 - 10/12 Price - $5 00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR Series 2® Gas - Fired Boiler For service or repairs to boiler, call your heating contractor

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FOODSERVICE DISPOSER Installation Manual

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103698-02 - 10/12Price - $5.00

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FORSeries 2®Gas - Fired Boiler ,reliobnonoitamrofnign rebmuNlaireSrelioBetaDnoitallatsnI2 rotcartnoCgnitaeHrebmuNenohP sserddA

9700609

2 NOTE: The equipment shall be installed in accordance with those installation r egulations in force in the area where the

installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before

installations are made.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or lo

cal regulations. All wiring on boilers installed in Canada shall be made in accordance wi th the Canadian Electrical Code and/or local regulations. The City of New York requires a Licensed Master Plumber supervise the installation of thi s product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Ser ies 2 boiler. See the Massachusetts Board of Plumbers

and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or

ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter. to important information concerning the life of the product.

DANGER

Indicates presence of a hazard which will cause

severe personal injury, death or substantial property damage if ignored.

CAUTION

Indicates presence of a hazard which will or can

cause minor personal injury or property damage if ignored.

WARNING

Indicates presence of a hazard which can cause

severe personal injury, death or substantial property damage if ignored.

NOTICE

Indicates special instructions on installation,

operation, or maintenance which are important but not related to personal injury hazards.

DANGER

If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use

any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas

WARNING

in this manual. Improper installation, adjustment, alteration, service or maintenance ca n cause property damage, personal injury or loss of life. Read and understand the entire manual before at tempting installation, start-up

operation, or service. Installation and service must be performed only by an experienced, skilled and

knowledgeable installer or service agency

This boiler must be properly vented.

combustion and ventilation air.

The interior of the venting system must be inspected and cleaned before the start of the heating season

and should be inspected periodically throughout the heating season for any obstructions. A clean and

unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life

Installation is not complete unless a pressure relief valve is installed into the tapping located on top of

boiler. - See the Boiler Water Piping Section of this manual for details. This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start

without service. If damage due to frozen pipes is a possibility, the heating system should not be left

unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. to disconnect any components of this boiler without positively assuring the water is cool and has no

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the

temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are co ol. Boiler materials of construction, products of combustion and the fuel contain alumina, si lica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause

death or serious injury and which are known to the state of California to cause cancer, birth defects and

or working nearby the boiler. Failure to follow all instructions in the proper order can cause persona l injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing. All cover plates, enclosures and guards must be in place at all times.

NOTICE

This boiler has a limited warranty, a copy of which is included with this boiler. It is the responsibility of

the installing contractor to see that all controls are correctly installed and are operating properly when the

installation is complete. 4

I.4 II.6 III.8 IV.9 V.14 VI.18

VII.22

VIII.26

IX.30 X.33 XI.38 54
55
The Series 2 boilers are low pressure cast iron gas water heating systems. These boilers are Category

I draft hood equipped appliances, which must be

I. P

RODUCT

ESCRIPTION

, S

PECIFICATIONS

AND DImENSIONAL DATA

vented by natural draft using a lined masonry or listed metal chimney system. An adequate supply of air for combustion, ventilation and dilution of 5 I. P

RODUCT

ESCRIPTION

, S

PECIFICATIONS

AND DImENSIONAL DATA

CONTINUED

Figure 1: Line Drawing

Connection

Content

Vent Size

Approx.

ABCDEFG

202X20126445-5/88-1/24-3/41/23.2262

20320126445-5/88-1/24-3/41/23.2262

207332512-1/2750-1/810-3/86-5/83/46.2458

20939-1/231-1/215-3/4852117-1/43/47.7550

21042-3/434-3/417-3/8852117-1/43/48.5608

II. P

RE -I

NSTALLATION

AND BOILER mOUNTING

WARNING

If you do not follow these instructions exactly,

damage or personal injury.

A. INSPECT ShIPMENT carefully for any signs of

damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of Boiler to the carrier in good condition. Any immediately against the carrier by the consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within sixty (60) days after receipt of equipment. B

. BOILER INSTALLATION must conform to the requirements of the authority having jurisdiction, or in the absence of such requirements, to:

U.S.A. -

National Fuel Gas Code, ANSI Z223.1.

When required by the authority having juris-

diction, the installation must conform to

ANSI/ASME No. CSD-1.

C ANADA - Installation Codes for Natural and LP Gas

Burning Appliances and Equipment, CAN/

CSA-B149.1.

C. These Gas Boilers are DESIGN CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORING. DO NOT INSTALL ThESE BOILERS ON

CARPETING

NOTICE

Do not drop boiler. Do not bump boiler jacket

D. LOCATE BOILER in front of or behind installation as close to chimney as possible. For basement installations, provide a solid base such as concrete, if

The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, control replacement, etc.).

DANGER

Do not install boiler where gasoline or other

hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.

CAUTION

Avoid operating this boiler in an environment

dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation.

E. REMOvE CRATE -

Remove all crate fasteners. Lift off outside

container. 2.

Remove all screws and brackets securing boiler to

skid. 3.

Save two of the wooden slats from the container

sleeve for use in Steps 4, 5 and 6. 4. Tilt the boiler to one side and slide a wooden slat under the two raised feet. 5. Tilt the boiler to the other side and slide another wooden slat under the two raised feet. 6.

Slide the boiler forward or backward off the skid

using the two wooden slats as runners.

F. Move boiler to permanent position.

G. PROvIDE CLEARANCE and AIR for

COMBUSTION and

ENTILATION.

WARNING

provided to assure proper combustion. 1.

CLEARANCES

ALL INSTALLATIONS - Practical service clearances must be considered (see Figure 2). A minimum of 24" (6.0cm) from the left side and front jacket panels is recommended for servicing but may be reduced to minimum shown in Figure 2. Subject to boiler and system piping, right side clearance may be reduced to 1" (2.5cm) if left side clearance is increased to 9" (22.9cm).

b. ALCOvE INSTALLATIONS - An alcove is considered a closet as shown in Figure 2 less front. height clearance may be reduced to 27" (68.6cm).

paragraph (2) below) - height clearance may be reduced to 27" (68.6cm). 2.

PROvIDE COMBUSTION AND vENTILATION

AIR in accordance with applicable provisions of local building codes, or: U.S.A. - National Fuel

Gas Code

, NFPA 54/ANSI Z223.1, Canada -

Natural and Propane Gas Installation Code, CAN/

CSA-B149.1.

7 building of other than unusually tight construction ventilation air as shown in Figure 2. b. Installations other than closet in paragraph (a) : i.

Determine volume of space (boiler room).

Rooms communicating directly with space

(through openings not furnished with doors) are considered part of space.

Volume [ft³](m

3 ) = Length [ft](m) x Width [ft] (m) x H eight [ft](m) ii. Determine Total Input of all appliances in space. Round result to nearest 1,000 Btu per hour (Btuh). iii. Determine type of space. Divide Volume by

Total Input.

If result is greater than or equal to 50 ft³ (1.4m3) per 1,000 Btuh, space is considered an . If result is less than 50 ft³ (1.4m3) per 1,000 Btuh, space is considered a . iv. Determine building type. A building of unusually tight construction has the following characteristics:

Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed, andFigure 2: minimum Clearances

Weather-stripping has been added on openable windows and doors, and

Caulking or sealants applied in joints around

window and door frames, between sole joints, between wall panels, at plumbing and electrical penetrations, and at other openings. v. For boiler located in a building of other than unusually tight construction, adequate combustion and ventilation air is normally cracks around windows and doors. vi.

For boiler located in building of unusually

tight construction, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches (30.5cm) of top of space. Locate remaining opening within 12 inches (30.5cm) of bottom of space. Minimum dimension of air opening is following: Direct communication with outdoors. Minimum free area of 1 square inch (6.5cm 2 ) per 4,000 Btu per hour input of all equipment in space.

Vertical ducts. Minimum free area of 1

square inch (6.5cm 2 ) per 4,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. square inch (6.5cm 2 ) per 2,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. vii. Ventilation Duct Louvers and Grilles. Equip outside openings with louvers to prevent entrance of rain and snow, and screens to prevent entrance of insects and rodents. position or interlocked with equipment to open automatically before burner operation.

Screens must not be smaller than ¼ inch

mesh.

Consider the blocking effect of louvers, grilles and screens when calculating the area. If free area of louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area.

II. P

RE -I

NSTALLATION

AND BOILER mOUNTING (continued)

BOILER

202
202X
203
204
205
206
207
208
209
210
8

III. G

AS P IPING A. CONNECT GAS SERvICE from Meter to gas control assembly in accordance with Local Piping Codes and requirements of Gas Company. They may require Connection, especially if run from meter is long or

Connection to gas control assembly.

This piping is to be supplied by the installer and must include a trap, a ground joint union and a manual shutoff valve upstream of the gas control assembly outside of the jacket when codes require, see Figure 3. A pipe thread compound resistant to the action of threaded joints in the gas piping. Pressure testing of the Gas Supply Piping Boiler and its connections is required before placing the boiler in operation.

The boiler and shutoff valve must be disconnected from the gas supply piping system during any pressure testing at pressures greater than ½ psig (3.5kPa). The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than ½ psig (3.5kPa).

RECOMMENDED SIZING OF GAS SUPPLY

PIPING

TO BOILER FOR NATURAL GAS - shall

be such as to provide the required supply of gas without undue loss of pressure between meter and the boiler. the Tables 1, 2 and 3. The following shall be taken into account: 1.

Allowable loss of pressure to assure a burner

manifold pressure of 3½" (8.9cm) water for natural gas. 2.

Supply of gas to be provided in cubic feet.

Table 1:

m aximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of

½ psig or Less

½¾11¼½¾11¼

101322785201,0501753606801,400

2092190350730120250465950

307315228559097200375770

406313024550082170320660

505611521544073151285580

605010519540066138260530

70469618037061125240490

80439017035057118220460

90408416032053110205430

100387915030550103195400

½¾11¼

0.711.21.6

1.62.12.63.5

3.14.15.26.9

Natural Gas

Correction

0.501.101.301.07

0.551.041.401.04

0.601.001.501.00

0.650.961.600.97

0.700.931.700.94

0.750.90------

0.800.87------

Figure 3: Recommended Gas Piping

A. BOILER WATER PIPING

CAUTION

Failure to properly pipe boiler may result in

improper operation and damage to boiler or building. 1. C

LEARANCES

- hot water pipes do not require clearance from combustible construction. 2. Install drain valve and safety relief valve as shown in Figures 1 and 4. Note - Safety relief valve must be in vertical position.

WARNING

Safety relief valve discharge piping must be

burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves. 4. Install Temperature and Pressure gauge externally in boiler supply piping. All required components are included at factory supplied Miscellaneous Parts

Bag (P/N 103669-01). See Figure 4 'Near Boiler

Piping'.

circulator harness provided. 6.

For recommended water piping, see Figures 5 and 6. Also, consult Residential hydronic heating Installation and Design I=B=R Guide.

7. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler, see Figure 7. Also consult Residential h ydronic h eating Installation and Design I=B=R Guide. If this Boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be equipped circulation of boiler water during the operation of the cooling system. 8. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.). Install a pipe tee at the boiler return along with a second tee in the supply piping as shown in Figures supply and return lines with valves located in the

IV. B

OILER

WATER PIPING

Figure 4: Near Boiler Piping

bypass and supply outlet as illustrated in Figures 5 higher boiler water temperatures. Set the boiler supply valve to fully open position, and the boiler bypass valve to half throttle. Operate the boiler and adjust the bypass valve to achieve

180°F to 200°F supply water temperature by closing

the bypass valve to decrease supply temperature or opening the bypass valve to increase water temperature. If the bypass valve is fully opened and the boiler water temperature is still below 180°F, slowly begin closing the boiler supply valve to achieve 180°F to 200°F supply water temperature.

Caution:

Never fully close the boiler supply valve.

10. If it is required to perform a long term pressure test isolated to avoid a pressure loss due to the escape of air trapped in the boiler. To perform a long term pressure test including the the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air.

11. OxYGEN CORROSION:

Oxygen contamination of the boiler water will cause corrosion of the iron and steel boiler components,quotesdbs_dbs12.pdfusesText_18

[PDF] INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR Series 2

103698-02 - 10/12Price - $5.00

INSTALLATION, OPERATING AND

9700609

9700609

DANGER

Indicates presence of a hazard which will cause

CAUTION

Indicates presence of a hazard which will or can

WARNING

Indicates presence of a hazard which can cause

NOTICE

Indicates special instructions on installation,

DANGER

WARNING

This boiler must be properly vented.

NOTICE

TABLE OF CONTENTS

VII.22

VIII.26

I draft hood equipped appliances, which must be

RODUCT

ESCRIPTION

PECIFICATIONS

AND DImENSIONAL DATA

RODUCT

ESCRIPTION

PECIFICATIONS

AND DImENSIONAL DATA

CONTINUED

Figure 1: Line Drawing

Connection

Content

Vent Size

Approx.

ABCDEFG

202X20126445-5/88-1/24-3/41/23.2262

20320126445-5/88-1/24-3/41/23.2262

207332512-1/2750-1/810-3/86-5/83/46.2458

20939-1/231-1/215-3/4852117-1/43/47.7550

21042-3/434-3/417-3/8852117-1/43/48.5608

II. P

NSTALLATION

AND BOILER mOUNTING

WARNING

If you do not follow these instructions exactly,

A. INSPECT ShIPMENT carefully for any signs of

U.S.A. -

National Fuel Gas Code, ANSI Z223.1.

When required by the authority having juris-

ANSI/ASME No. CSD-1.

Burning Appliances and Equipment, CAN/

CSA-B149.1.

CARPETING

NOTICE

Do not drop boiler. Do not bump boiler jacket

DANGER

Do not install boiler where gasoline or other

CAUTION

Avoid operating this boiler in an environment

E. REMOvE CRATE -

Remove all crate fasteners. Lift off outside

Remove all screws and brackets securing boiler to

Save two of the wooden slats from the container

Slide the boiler forward or backward off the skid

F. Move boiler to permanent position.

G. PROvIDE CLEARANCE and AIR for

COMBUSTION and

ENTILATION.

WARNING

CLEARANCES

PROvIDE COMBUSTION AND vENTILATION

Gas Code

Natural and Propane Gas Installation Code, CAN/

CSA-B149.1.

Determine volume of space (boiler room).

Rooms communicating directly with space

Volume [ft³](m

Total Input.

Caulking or sealants applied in joints around