User Guide

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE .............1
B. SPECIAL ATTENTION BOXES ............1
1. PREINSTALLATION 2
A. ACCESSIBILITY CLEARANCES ...........2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION ......................2
C. AIR FOR COMBUSTION &
VENTILATION .........................3
D. INSTALLATION SURVEY ................6
E. PLANNING THE LAYOUT ...............6
F. WATER TREATMENT ...................6
2. BOILER SET-UP 7
3. WATER PIPING & CONTROLS 8
A. BOILER SUPPLY & RETURN .............8
B. SAFETY RELIEF VALVE .................9
C. PIPING FOR ZONED SYSTEMS ..........10
D. EXPANSION TANK ...................11
E. INDIRECT-FIRED WATER HEATER .......11
F. FREEZE PROTECTION .................11
4. VENTING 12
A. INTEGRAL DRAFT HOOD ..............12
B. VENT DAMPER INSTALLATION –
GENERAL ...........................12
C. VENT PIPING & CHIMNEY ..............13
D. BOILER REMOVAL FROM COMMON
VENTING SYSTEM ....................14
5. GAS PIPING 15
6. ELECTRICAL 17
A. WIRING .............................17
B. ZONED SYSTEM WIRING ..............17
C. CONTROLS ..........................17
D. SEQUENCE OF OPERATION ............20
7. START-UP PROCEDURES 21
A. COMPLETING THE INSTALLATION ......21
B. CONTROL DESCRIPTIONS .............24
C. ADJUSTMENT OF GAS PRESSURE
REGULATOR ........................24
D. CHECKING BURNER INPUT .............24
E. CHECK-OUT PROCEDURE ..............25
8. TROUBLESHOOTING 26
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
BLOCKED VENT SHUT-OFF SWITCH OR
FLAME ROLL-OUT SAFETY SHUT-OFF
SWITCH ............................26
B. TROUBLESHOOTING GUIDES ..........26
9. MAINTENANCE 29
A. GENERAL ...........................30
B. DAILY (WITH BOILER IN USE) ..........30
C. WEEKLY (WITH BOILER IN USE) ........30
D. MONTHLY (WITH BOILER IN USE) .......30
E. ANNUALLY (BEFORE START OF HEATING
SEASON) ...........................30
10. BOILER DIMENSIONS & RATINGS 32
11. REPAIR PARTS 33
A. BASE/COMBUSTIBLE FLOOR PAN .......33
B. MANIFOLD, GAS VALVE & PILOT ........34
C. BLOCK/DRAFT HOOD & JACKET ........36
D. CONTROLS/CIRCULATOR/VENT &
DAMPER ............................38
TABLE OF CONTENTS
TABLE OF CONTENTS