Use and Care Manual

8
II. INSTALLATION INSTRUCTIONS
A. REMOVE CRATE
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other
inside protective spacers and bracing. Remove
miscellaneous water trim carton.
3. Using hand truck or pipe rollers under skid, move
boiler into position along side installation site.
B. REMOVAL OF BOILER FROM SKID
1. Boiler is secured to base with 4 carriage bolts, 2 on
left side and 2 on right side. See Figure 3. Remove
all bolts.
section. Thread 1½" x ¾" x 1½" NPT tee onto
5" nipple. Thread ¾" drain valve into ¾" NPT
connection on tee. Tighten all joints with wrench
until water tight and 1½" NPT return connection on
tee is facing away from boiler horizontally to allow
for proper burner swing door clearance, see Figures
1 and 4.
NOTE: Vertical piping will prevent door from opening
fully for service and cleaning of boiler.
2. Thread relief valve onto factory installed ¾" NPT
x 7¼" nipple located in left rear corner on top of
boiler as shown in Figure 1a or 1b. Valve spindle
must be in vertical position. Tighten with wrench.
Pipe discharge as shown in Figure 4. Installation
of the relief valve must be consistent with ANSI/
ASME Boiler and Pressure Vessel Code, Section IV.
F. CONNECT SUPPLY AND RETURN PIPING TO
HEATING SYSTEM.
1. CLEARANCES — Hot water pipes shall have
clearances of at least ½” from all combustible
construction.
2. See Figure 4 FOR PIPING. Also, consult
Residential Hydronic Heating Installation and
Design I=B=R Guide.
3. Use a boiler water bypass if the boiler is to be
operated in a system which has a large volume
or excessive radiation where low boiler water
temperature may be encountered (i.e. converted
gravity circulation system, etc.).
Install a pipe tee between the circulator and boiler
return along with a second tee in the supply piping
as shown in Figure 4. The bypass should be the
same size as the supply and return lines. Locate
valves in the bypass and supply outlet as illustrated
in Figure 4 for regulation of water ow to maintain
higher boiler water temperature.
Set the by-pass and boiler supply valves to a half
throttle position to start. Operate boiler until the
system water temperature is a normal operating
range.
Adjust the valves to provide 180° to 200°F supply
water temperature. Opening the boiler supply
valves will raise the system temperature, while
opening the bypass valve will lower the system
supply temperature.
4. 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
with ow control valves to prevent gravity
circulation of boiler water during the operation of
the cooling system.
2. Tilt boiler to right and to rear. Using right rear leg
as pivot, rotate boiler 90° in a clockwise direction,
and lower left side of boiler to oor. Tilt boiler
and remove crate skid. Care should be exercised to
prevent damage to jacket or burner.
C. MOVE BOILER TO PERMANENT POSITION by
sliding or walking.
D. INSPECT COMBUSTION TARGET WALL AND
COMBUSTION CHAMBER LINER
1. OPEN FLAME OBSERVATION DOOR AND/
OR BURNER SWING DOOR on front of boiler.
Use ashlight to inspect target wall secured to
rear section with silastic sealant. Inspect ceramic
ber blanket secured to oor of boiler with water
glass adhesive. If either is damaged they must be
replaced.
E. INSTALL TRIM AND CONTROLS, AS REQUIRED
(see Figure 1a or 1b)
1. Install return piping supplied with boiler. Apply
Teon or Sealant to all joints prior to assembly.
Thread 1½" NPT x 5" Lg. return nipple into 1½"
NPT tapping located in lower left corner of front
Figure 3: Removal of Boiler From Skid