background image

A

JAX

 B

OILER

 I

NC.

 - A

CE

 B

OILER

 I

NC.

W

ARNING

PRODUCT

SAFETY NOTICE

AJAX BOILER AND WATER HEATER PRODUCTS OPERATE AT HIGH TEMPERATURE AND PRESSURES

• Before 

using this product, read and understand instructions.  Save these instructions for future use.

• Before 

servicing, to prevent serious burns or injury, the boiler and water heater products must be cooled to less than  

 

80°F (27°C) and the pressure must be 0 psi (0 bar).

• 

Turn off the electrical power before making electrical connections to prevent electrical shock.

• 

These products must be placed in a controlled location where untrained or unqualifi ed personnel cannot access the  

 

 operating or safety controls, must not be able to come in contact with high temperature or high pressure parts and must  

 

not perform maintenance or demolition work. 

• 

All work performed must be by qualifi ed properly equipped personnel trained in the proper application, installation, and 

 maintenance or demolition of plumbing, steam, and electrical equipment and/or systems in accordance with all 

 applicable codes and ordinances.

• Ajax Boilers and Water Heaters are complete package units with safety and operating controls and are constructed with 

 

non ASBESTOS materials.   Any replacement gaskets, refractory, insulation, etc used must not contain Asbestos. 

• No 

additional insulation is required on the Boilers and Water Heaters. 

• Additions or replacement of insulation on any connecting pipes or accessories to the Boilers and/or Water Heaters must 

 be 

of 

“NON-ASBESTOS” and contain only non-hazardous materials.

• Crystalline Silica, a material known to cause cancer, may be encapsulated in some refractory or insulation materials 

 

and must be handled only by authorized trained personnel.   Crystalline Silica as used is encapsulated and is not harm 

 full 

in this form.  Care must be taken during removal or replacement of refractory or insulation to remove it in bulk 

 

form and avoid generation or inhalation of dust.   Removal must be properly performed by trained, qualifi ed and 

 equipped personnel.   This is also true of Asbestos not contained in Ajax products but may be otherwise contained in 

 replacement 

materials or parts, in connecting piping or other nearby products.  

• 

All safety and operating controls must be set within the specifi ed operating limits and tested periodically to assure proper 

 operation.  All limit and operating controls must be installed in series on the boiler.

• Connect 

drain pipes to a safe drain to prevent serious personal injury from relief valve discharge and or from boiler blow 

 down 

discharge.

• After 

installation, check for proper operation of all limit and operating controls before leaving the site.

• 

Perform scheduled and annual inspections including checking Controls for proper calibration and performance.  

Failure to follow these warnings, to allow access by unauthorized persons and the use of non-properly trained and 

equipped personnel in the operation, service, modifi cation, removal or demolition of these products or replacement 

of parts with non-authorized factory non-asbestos materials could cause damage, personal injury or death.

2701 South Harbor Blvd.
Santa Ana, California 92704
United States
Tel. (714) 437-9050
Fax (714) 437-9060
http://www.ajaxboiler.com
[email protected]

          A

CE 

Heating Solutions, LLC 

                 2701 S. H

ARBOR 

B

LVD

. • S

ANTA 

A

NA

, CA 92704 

                 P

HONE

: (714) 540-2230 • FAX: (714) 540-2239 

                                 www.aceheatingllc.com 

                 Ace Heating Solutions, LLC

November 2014 ace

                            ACE  BOILER AND WATER HEATER PRODUCTS OPERATE AT HIGH TEMPERATURE AND PRESSURES 
 

• Before using this product, read and understand instructions. Save these instructions for future use. 
• Before servicing, to prevent serious burns or injury, the boiler and water heater products must be cooled to less than 
80°F (27°C) and the pressure must be 0 psi (0 bar). 
• Turn off the electrical power before making electrical connections to prevent electrical shock. 
• These products must be placed in a controlled location where untrained or unqualified personnel cannot access the 
operating or safety controls, must not be able to come in contact with high temperature or high pressure parts and must 
not perform maintenance or demolition work. 
• All work performed must be by qualified properly equipped personnel trained in the proper application, installation, and 
maintenance or demolition of plumbing, steam, and electrical equipment and/or systems in accordance with all 
applicable codes and ordinances. 
• ACE Boilers and Water Heaters are complete package units with safety and operating controls and are constructed with 
non ASBESTOS materials. Any replacement gaskets, refractory, insulation, etc used must not contain Asbestos. 
• No additional insulation is required on the Boilers and Water Heaters. 
• Additions or replacement of insulation on any connecting pipes or accessories to the Boilers and/or Water Heaters must 
be of “NON-ASBESTOS” and contain only non-hazardous materials. 
• Crystalline Silica, a material known to cause cancer, may be encapsulated in some refractory or insulation materials 
and must be handled only by authorized trained personnel. Crystalline Silica as used is encapsulated and is not harm 
full in this form. Care must be taken during removal or replacement of refractory or insulation to remove it in bulk 
form and avoid generation or inhalation of dust. Removal must be properly performed by trained, qualified and 
equipped personnel. This is also true of Asbestos not contained in ACE products but may be otherwise contained in 
replacement materials or parts, in connecting piping or other nearby products. 
• All safety and operating controls must be set within the specified operating limits and tested periodically to assure proper 
operation. All limit and operating controls must be installed in series on the boiler. 
• Connect drain pipes to a safe drain to prevent serious personal injury from relief valve discharge and or from boiler blow 
down discharge. 
• After installation, check for proper operation of all limit and operating controls before leaving the site. 
• Perform scheduled and annual inspections including checking Controls for proper calibration and performance. 
 
 

Failure to follow these warnings, to allow access by unauthorized persons and the use of non-properly trained and 
equipped personnel in the operation, service, modification, removal or demolition of these products or replacement 
of parts with non-authorized factory non-asbestos materials could cause damage, personal injury or death.

Summary of Contents for B Series

Page 1: ...al Designed and Manufactured in Accordance with ASME Code Section IV Heating Boilers E T L Listed ASME Code Construction and Stamped Photo shown may vary from actual model Model B_G Series Gas Fired C...

Page 2: ...site http www ajaxboiler com Email info ajaxboiler com Ace Boiler Inc formerly Ace Buehler Inc is a division of Ajax Boiler Inc ACE BOILER INC E T L Listed Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q...

Page 3: ...e the heater so that leakage from tank or connections will be directed to a floor drain and will not damage adjacent area or lower level floors 2 The minimum clearance between a heater and a storage t...

Page 4: ...is measured downstream of the gas pressure regu lator Do not exceed the maximum gas pressure specified on the rating plate 4 A trap drip leg must be installed upstream of the gas pressure regulator 5...

Page 5: ...P OP Check Valve Pressure Relief Valve Pressure Temp Gauge Primary Operational Aquastat Unit Circulation Pump System Recirculation Pump Check Valve Pilot Safety Relay Ground Hi Limit Aquastat Control...

Page 6: ...STANDARD FOR CSD 1 G 22225 N A HEADER COMB GAS VALVE SHUT OFF VALVE PILOT LINE PILOT LINE TYP COMB GAS VALVE TYP HEADER SHUT OFF VALVE B2 THRU B8 INDOOR OUTDOOR CSD 1 GAS TRAIN FOR MODELS B11 THRU B1...

Page 7: ......

Page 8: ...CONTROLS AND GAS TRAIN GAS FIRED COPPER FIN CONE COIL WATER HEATERS HEAVY DUTY INDUSTRIAL WATER HEATERS MINI PACK SEMI INSTANTANEOUS WATER HEATERS PACKAGED STORAGE WATER HEATERS CLEAN STEAM BOILERS AS...

Page 9: ...and accept the product when received as conforming to their purchase order specifications and approved drawings All claims for non conformance errors shortages etc must be made within 10 days after re...

Page 10: ...4 United States Tel 714 437 9050 Fax 714 437 9060 http www ajaxboiler com mail ajaxboiler com June 2010 Ace Heating Solutions LLC ACE Heating Solutions LLC 2701 S HARBOR BLVD SANTA ANA CA 92704 PHONE...

Page 11: ...060 http www ajaxboiler com mail ajaxboiler com February 2007 ACE Heating Solutions LLC 2701 S HARBOR BLVD SANTA ANA CA 92704 PHONE 714 540 2230 FAX 714 540 2239 www aceheatingllc com Ace Heating Solu...

Page 12: ...anta Ana California 92704 United States Tel 714 437 9050 Fax 714 437 9060 http www ajaxboiler com mail ajaxboiler com ACE Heating Solutions LLC 2701 S HARBOR BLVD SANTA ANA CA 92704 PHONE 714 540 2230...

Page 13: ......

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Page 15: ......

Page 16: ...es at very high temperatures insulation shielding and air circulation may be necessary to protect the controls Proper insulation or shielding should be provided by the appliance manufac turer make sur...

Page 17: ...o ground NOTE Earth ground is not required To connect the D80B follow the wiring diagrams sup plied with the vent damper or see Fig 8 for typical connec tions Connect Ignition Module 1 Connect remaini...

Page 18: ...T DAMPER PLUG OPT 5 2ND OPERATOR 1ST OPERATOR PILOT COM MAIN VALVE DUAL VALVE COMBINATION GAS CONTROL Fig 2 S8610F H S8670D in a heating system with an atmospheric burner 5 TABLE 4 TERMINAL CROSS REFE...

Page 19: ...9 0523 MV MV PV PV GND BURNER 24V GND 24V TH W VENT DAMPER PLUG SPARK 5 S8610A B POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED ALTERNATE LIMIT CONTROLLER LOCATION MAXIMUM C...

Page 20: ...TOR PILOT COM MAIN VALVE DUAL VALVE COMBINATION GAS CONTROL PILOT BURNER GROUND PILOT GAS SUPPLY 9 69 0523 Fig 8 S8610F H S8670D in a heating system with an atmospheric burner and a D80B Vent Damper L...

Page 21: ...23 Fig 10 S8610F H S8670D in a hydronic heating system with a D80D Vent Damper 2 MV MV PV PV GND BURNER 24V GND 24V TH W OPT VENT DAMPER PLUG OPT SPARK 4 S8610F H S8670D POWER SUPPLY PROVIDE DISCONNEC...

Page 22: ...ne as described in Steps 1 and 5 below on initial installation and any time work is done involving the gas pip ing STEP 3 Reset the Module Turn the thermostat to its lowest setting Wait one minute As...

Page 23: ...burner igniter sensor and provide shield if necessary If flame rod or bracket are bent out of position restore to correct position STEP 3 Check spark ignition circuit You will need a short jumper wire...

Page 24: ...ing the pilot adjustment screw on the gas control clockwise to decrease or counterclockwise to increase pilot flame Following adjustment always replace pilot adjustment cover screw and tighten firmly...

Page 25: ...V PV MV PV MAIN VALVE PILOT VALVE TO 24V GND TO 24V 3 3 Fig 17 Representative schematic for S8610F H See Fig 1 for hookup S8670 is similar except the timing circuit includes a purge timer See Fig 6 fo...

Page 26: ...water pumps are in operating condition b Test low water cutoffs automatic feed water controls pressure and temperature limit control lers and relief valves in accordance with the manufacturer s recomm...

Page 27: ...ntrol after compression nut has been tightened because this can result in gas leakage at connection 2 Square off and remove burrs from end of tubing 3 Push tubing into compression nut clearance hole u...

Page 28: ...ot flame 6 Always replace pilot adjustment cover screw and tighten firmly after completing adjustment to assure pro per operation Service WARNING FIRE OR EXPLOSION HAZARD CAN CAUSE PROPERTY DAMAGE SEV...

Page 29: ...e would result in personal injury and or loss of prop erty it is the responsibility of the installer to add devices safety limit controls that protect against or systems alarm supervisory systems that...

Page 30: ...llation and adjustment CAUTION Check the installation for no flow switch operation Make appropriate adjustments to the sensitivity adjustment screw to be sure the switch restores fully at the desired...

Page 31: ...ls The thermostat or the fuse will be damaged DO NOT allow any flame to impinge on the regulator vent tubing if sup plied It may clog and cause gas valve malfunction DO NOT use the gas cock to adjust...

Page 32: ...or 6 for a typical connection diagram X XX UL INSTALLATION INSTRUCTIONS U S Registered Trademark Copyright 1995 Honeywell Inc All Rights Reserved L4008A B E L L6008A G H Aquastat Controllers APPLICATI...

Page 33: ...R IGNITION TRANSFORMER RA89A RELAY RA817A PROTECTORELAY CONTROL BURNER MOTOR 24V THERMOSTAT 2 1 3 4 T T 1 2 3 4 M8785 Fig 5 Typical oil fired hydronic heating system with domestic hot water SETTING Co...

Page 34: ...9 mm OD for both inlet and outlet Approval CE 0063AU1215 U S Registered Trademark Copyright 2000 Honeywell Inc All Rights Reserved INSTALLATION INSTRUCTIONS 69 1225 4 VR8104 VR8204 and VR8304 Intermit...

Page 35: ...mine if the pressure regulator setting factory set will meet the appliance manifold requirements after conversion NOTE Convertible pressure regulator models suffix letter R do not have field adjustabl...

Page 36: ...BINATION GAS CONTROLS 5 69 1225 4 Fig 1 Top view of convertible pressure regulator cap Install Adapters To Control If adapters are being installed on the control mount them as follows Flanges 1 Choose...

Page 37: ...hanism to reduce the pilot flow if necessary If pilot adjustment is necessary proceed as follows 1 Remove pilot adjustment cover screw See Fig 6 2 The pilot adjustment is shipped at the full pilot gas...

Page 38: ...eter reading Convert flow rate to Btuh as described in form 70 2602 Gas Controls Handbook and compare to Btuh input rating on appliance nameplate 3 IF CHECKING GAS INPUT WITH MANOMETER Make sure the g...

Page 39: ...Non Regulating On Off U Models Non regulating VR8204U Valves are designed for application in various parts of Europe where a separate distinct pressure regulator is required The VR8204U is similar to...

Page 40: ...f heater falls off this is usually a sign of lime in the coil The ACE coil will bang or knock if lim ing condition is severely restricting circulation Customers have reported operating ACE heaters and...

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