2
INSTALLATION AND OPERATING INSTRUCTIONS
USING THIS MANUAL 2
A. MANUAL ORGANIZATION . . . . . . . . . . . . . . . . . . . . . . . .2
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . . . . . . . . . .2
1. PREINSTALLATION 3
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
B. CODES & REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . .3
C. ACCESSIBILITY CLEARANCES . . . . . . . . . . . . . . . . . . . . .3
D. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
E. AIR COMBUSTION AND VENTILATION . . . . . . . . . . . . . .4
F. PLANNING THE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . .6
2. BOILER PLACEMENT & ASSEMBLY 7
A. PACKAGED BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3. VENTING 7
A. CHIMNEY OR VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
B. AUTOMATIC VENT DAMPER
INSTALLATION – GENERAL . . . . . . . . . . . . . . . . . . . . . . .7
C. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4. BOILER PIPING 10
A. STEAM BOILER PIPING – SINGLE
BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
B. STEAM BOILER INDIRECT WATER HEATER
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5. FUEL PIPING 12
A. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
B. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6. CONTROLS & TRIM 13
A. STEAM BOILER CONTROLS & TRIM . . . . . . . . . . . . . . .13
7. ELECTRICAL 15
A. CONNECT SUPPLY WIRING . . . . . . . . . . . . . . . . . . . . . .15
B. MOUNT REMAINING CONTROLS . . . . . . . . . . . . . . . . .15
C. INSTALL CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . .16
8. BOILER OPERATION 20
A. SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .20
B. FILL THE BOILER (STEAM BOILERS) . . . . . . . . . . . . . . .20
C. OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . .20
D. PILOT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
E. MAIN BURNER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .20
F. CONTROLS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
G. CLEAN THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
H. BOILER SHUT-DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . .22
9. MAINTENANCE 25
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
B. DAILY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .26
C. WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .26
D. MONTHLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .26
E. ANNUAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .26
F AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . .27
10. TROUBLESHOOTING 28
11. BOILER DIMENSIONS & RATINGS 32
12. REPAIR PARTS 34
TABLE OF CONTENTS
A. INSTRUCTION MANUALS
The Installation, Operation & Maintenance Manual is
divided into four basic sections:
1. Preinstallation (Section 1)
2. Installation (Sections 2 through 8)
3. Start-Up (Section 9)
4. Maintenance (Section 10)
B. SPECIAL ATTENTION BOXES
Throught this manual special attention boxes are
provided to supplement the instructions and make
special notice of potential hazards.
USING THIS MANUAL
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
