Install Instructions

ii
USING THIS MANUAL 1
A. MANUAL ORGANIZATION . . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
B. CODES & REGULATIONS . . . . . . . . . . . . . . . .2
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2
D. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .2
E. AIR COMBUSTION AND VENTILATION . . . .3
F. INSTALLATION SURVEY . . . . . . . . . . . . . . . .6
G. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .6
2. BOILER PLACEMENT & ASSEMBLY 7
A. PACKAGED BOILER . . . . . . . . . . . . . . . . . . . .7
B. KNOCKDOWN BOILERS – SPLIT BLOCK . . .7
C. KNOCKDOWN BOILERS – ASSEMBLED
BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
D. KNOCKDOWN BOILERS – CONTROL &
MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . .8
E. KNOCKDOWN BOILERS – FLUE COLLECTOR
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .8
F. KNOCKDOWN BOILERS – HYDROSTATIC
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
G. KNOCKDOWN BOILERS – ASSEMBLE
JACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3. VENTING 11
A. CHIMNEY OR VENT . . . . . . . . . . . . . . . . . . .11
B. AUTOMATIC VENT DAMPER
INSTALLATION – GENERAL . . . . . . . . . . . .11
C. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . .12
4. BOILER PIPING 14
A. WATER BOILER PIPING – SINGLE
BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
B. WATER BOILER PIPING – MULTIPLE
BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
C. STEAM BOILER PIPING – SINGLE
BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
D. STEAM BOILER INDIRECT WATER HEATER
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
E. STEAM BOILER PIPING – MULTIPLE
BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5. FUEL PIPING 17
A. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .17
B. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .17
6. CONTROLS & TRIM 19
A. STEAM BOILER CONTROLS & TRIM . . . . .19
B. WATER BOILER CONTROLS & TRIM . . . . .20
7. ELECTRICAL 22
A. CONNECT SUPPLY WIRING . . . . . . . . . . . .22
B. MOUNT REMAINING CONTROLS . . . . . . . .22
C. INSTALL CONTROL WIRING . . . . . . . . . . . .23
8. BOILER OPERATION 29
A. SYSTEM INSPECTION . . . . . . . . . . . . . . . .29
B1. FILL THE BOILER (WATER BOILERS) . . . . .29
B2. FILL THE BOILER (STEAM BOILERS) . . . . .29
C. OPERATING INSTRUCTIONS . . . . . . . . . . .29
D. PILOT CHECK . . . . . . . . . . . . . . . . . . . . . . . .29
E. MAIN BURNER CHECK . . . . . . . . . . . . . . . .30
F. CONTROLS CHECK . . . . . . . . . . . . . . . . . . .30
G. PURGING AIR . . . . . . . . . . . . . . . . . . . . . . . .30
H. CHECK SYSTEM PRESSURE . . . . . . . . . . . .30
I. CLEAN THE BOILER . . . . . . . . . . . . . . . . . . .30
J. BOILER SHUT-DOWN . . . . . . . . . . . . . . . . .31
9. MAINTENANCE 35
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .36
B. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .36
C. WEEKLY MAINTENANCE . . . . . . . . . . . . . .36
D. MONTHLY MAINTENANCE . . . . . . . . . . . . .36
E. ANNUAL MAINTENANCE . . . . . . . . . . . . . .36
F. AS REQUIRED MAINTENANCE . . . . . . . . . .37
10. TROUBLESHOOTING 38
11. BOILER DIMENSIONS & RATINGS 42
12. REPAIR PARTS 44
TABLE OF CONTENTS
TABLE OF CONTENTS