Installation and Operation Manual

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TABLE OF CONTENTS
SECTION I - GENERAL INFORMATION
Dimensional Information ................................................................................................................. 10
Ratings/Data ....................................................................................................................................... 12
Locating the Unit . ............................................................................................................................. 13
Air Supply/Venting ............................................................................................................................. 14
SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
Knockdown Boiler w/ Factory Assembled Section ........................................................................ 17
Assembly of Sections, Manual Draw-up ........................................................................................ 18
Assembly of Sections, Hydraulic Draw-up .................................................................................... 23
Hydrostatic Test ................................................................................................................................ 24
SECTION III - BOILER ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
Install Common Parts to Block (Hinge Hardware, Flue Collector, Clean-out Covers, Etc.) ...... 25
Install Supply and Return Manifolds .............................................................................................. 27
Install Return Water Mixing Tube ..................................................................................................... 27
Install Jacket Support Frame to Block ............................................................................................ 30
Install Heat Exchanger Insulation .................................................................................................... 37
Install Internal Wiring Harness Components ................................................................................. 38
Install Jacket Top Corner Panels .................................................................................................... 43
Install Jacket Front and Rear Panels .............................................................................................. 44
Install Jacket Top and Side Panels . ................................................................................................ 45
Install Burner Swing Door (BSD) .................................................................................................... 47
Install 2
nd
and 3
rd
Pass Flueway Bafes........................................................................................... 49
Procedure to Close and Secure Burner Swing Door ..................................................................... 50
Install Burner Adapter Plate and Mount Burner (Burner Specic) ............................................... 50
Connecting Internal Wiring Harness to Burner Controls .............................................................. 51
Install Standard Water Trim and Control ......................................................................................... 52
Install Optional Controls:
• Probe LWCO ............................................................................................................................. 54
• High Limit Control w/ Manual Reset ...................................................................................... 54
• Low Fire Hold Control ............................................................................................................. 54
• Low / High / Low Control or Modulating Control .................................................................. 55
Install Flue Outlet Damper Assembly .............................................................................................. 56
Install Optional Burner Swing Door Cover Split Jacket Panels .................................................... 57
SECTION IV - INSTALLATION INSTRUCTIONS
Packaged Boiler - Shipping Information ......................................................................................... 58
Boiler Piping - Heating Applications................................................................................................ 58
Boiler Piping - Domestic Hot Water ................................................................................................. 64
Relief Valve Piping ............................................................................................................................. 64
Electric Wiring ................................................................................................................................... 64
SECTION V - OPERATING INSTRUCTIONS
Filling System .................................................................................................................................... 65
Adjusting Controls ............................................................................................................................ 65
Adjusting Burner ............................................................................................................................... 65
Test Controls ...................................................................................................................................... 66
Initial Cleaning, Water Boilers .......................................................................................................... 66
Frequent Water Addition ...................................................................................................................67
Oxygen Corrosion ............................................................................................................................. 67