LOCATING THE BOILER...........................................................................................................................................................................................4
FRESH AIR FOR COMBUSTION ...........................................................................................................................................................................5-6
Boiler Located in Unconfined Space .......................................................................................................................................................................5
Boiler Located in Confined Space ...........................................................................................................................................................................6
INSTALLATION—SYSTEM PIPING......................................................................................................................................................................6-8
For Use with Cooling Units .....................................................................................................................................................................................8
CHIMNEY AND VENT PIPE CONNECTION .....................................................................................................................................................8-11
Checking Chimney....................................................................................................................................................................................................8
Chimney Sizing.........................................................................................................................................................................................................8
Connecting Vent Damper and Vent Connector..................................................................................................................................................8-10
Minimum Vent Pipe Clearance ..............................................................................................................................................................................10
Removing Existing Boiler from Common Venting System ............................................................................................................................10-11
VENT DAMPER OPERATION..................................................................................................................................................................................11
Automatic Operation of Vent Damper...................................................................................................................................................................12
Manual Operation of Vent Damper .......................................................................................................................................................................12
GAS SUPPLY PIPING ..........................................................................................................................................................................................12-13
Checking Gas Supply ........................................................................................................................................................................................12-13
Connecting Gas Piping ...........................................................................................................................................................................................13
Checking Gas Piping ..............................................................................................................................................................................................13
ELECTRICAL WIRING ........................................................................................................................................................................................13-18
Electric Power Supply ............................................................................................................................................................................................13
Installing Thermostat ..............................................................................................................................................................................................18
Electronic Thermostats ...........................................................................................................................................................................................18
Vent Damper...........................................................................................................................................................................................................18
Wiring Diagrams ...............................................................................................................................................................................................14-17
CONTROLS AND ACCESSORIES ...........................................................................................................................................................................19
Relief Valve ............................................................................................................................................................................................................19
Steam Pressure Gauge ............................................................................................................................................................................................19
Water Level Gauge .................................................................................................................................................................................................19
Steam Pressure Control ..........................................................................................................................................................................................19
Low Water Cut-Off (LWCO).................................................................................................................................................................................19
Water Feeder (Optional) .........................................................................................................................................................................................19
Vent Damper...........................................................................................................................................................................................................19
Rollout Switch (Flame Rollout Safety Shutoff) ....................................................................................................................................................19
Spill Switch (Blocked Vent Safety Shutoff)..........................................................................................................................................................19
FOR YOUR SAFETY READ BEFORE OPERATING .......................................................................................................................................19-20
GAS VALVE OPERATING INSTRUCTIONS....................................................................................................................................................20-21
Intermittent Ignition Boiler—VR8204A/VR8304M Gas Valve............................................................................................................................20
Continuous Pilot Boiler—VR8200A/VR8300A Gas Valve ............................................................................................................................20-21
OPERATING BOILER ..........................................................................................................................................................................................21-22
How a Steam System Operates ..............................................................................................................................................................................21
Filling System with Water ................................................................................................................................................................................21-22
Water Level.............................................................................................................................................................................................................22
Automatic Gas Valve..............................................................................................................................................................................................22
Thermostat...............................................................................................................................................................................................................22
CHECKING AND ADJUSTING ...........................................................................................................................................................................22-23
Pilot Burner Adjustment.........................................................................................................................................................................................22
Main Burner(s)........................................................................................................................................................................................................22
Gas Valve Safety Shutdown Test ..........................................................................................................................................................................22
Steam Pressure Control Adjustment .................................................................................................................................................................22-23
Checking Controls ..................................................................................................................................................................................................23
CLEANING BOILER.............................................................................................................................................................................................23-24
Skimming ................................................................................................................................................................................................................23
Blowdown ..........................................................................................................................................................................................................23-24
MAINTAINING BOILER......................................................................................................................................................................................24-25
Water Level.............................................................................................................................................................................................................24
Relief Valve ............................................................................................................................................................................................................24
Low Water Cut-Off (LWCO).................................................................................................................................................................................24
Burners ....................................................................................................................................................................................................................24
Boiler Flue Passages...............................................................................................................................................................................................24
Vent Pipe.................................................................................................................................................................................................................24
Cleaning Boiler Flue Passages and Burners.....................................................................................................................................................24-25
Foaming, Priming, or Surging................................................................................................................................................................................25
Boiler Water Treatment (Other Than Cleaners) ....................................................................................................................................................25
Between Heating Seasons.......................................................................................................................................................................................25
SERVICE HINTS ........................................................................................................................................................................................................26
REPAIR PARTS.....................................................................................................................................................................................................27-29
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