Assessments - 2, GPA: 4.5
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P. AqUASTAT CONTROLLER INSTALLATION (BOILERS WITH TANKLESS HEATER ONLY). 1. On boilers with tankless heater, install the L4006A aquastat controller well (found in Part Carton) into .” NPT tapping in tankless heater plate. 2. Remove the L4006A aquastat controller with factory attached harness from Control Carton. 3. Slip the bulb of the aquastat controller into the well and secure the controller in place with the set screw. WARNING Aquastat bulb must be fully inserted into the well. 4. Feed the L4006A aquastat controller harness end thru external electrical enclosure top flange middle right bushed hole. See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 5. See Figures 18, 19 and 20 (whichever applicable) for tankless heater aquastat connection details. 6. Using needle nose pliers form hook on harness each stripped end and wrap hooks around screws under terminals "R" and "G" of the R8285C Transformer- Relay; then, tighten screws securely. q. SAFETY VALVE AND DRAIN VALVE INSTALLATION. 1. Remove safety valve and related piping (3/4” NPT x 3” lg. black nipple, 3/4” NPT x 8” lg. black nipple, .” NPT 90° black elbow and .” NPT black coupling) from Part Carton. 2. Thread 3/4" NPT x 3” lg. black nipple into rear section safety valve tapping, install .” NPT 90° black elbow facing upward, then, thread 3/4" NPT x 8” lg. black nipple into the elbow, and, install .” NPT black coupling onto nipple end. 3. Thread safety valve into the .” NPT black coupling. Pipe the safety valve discharge as shown in Figure 11 “ Recommended Boiler Piping For Gravity Return Steam Boiler” shown in Section III of this manual. Installation of the safety valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV. WARNING Safety valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps. 4. Remove 1-1/2" NPT x 5” lg. black nipple, 1-1/2” x 1-1/2” x .” NPT black tee and drain valve from Part Carton. NOTICE Lower rear section Tapping "H" is used standard condensate return on steam boilers. for 5. Thread 1-1/2" NPT x 5” lg. black nipple into lower rear section tapping, then, install 1-1/2” x 1-1/2” x .” NPT black tee onto nipple end. Black tee side outlet may be oriented to either left, or, right side. 6. Install the drain valve into black tee .” NPT side outlet. R. OIL BURNER INSTALLATION. 1. Install oil burner, refer to Figure 10. a. Open burner carton and remove contents. b. Check oil nozzle in burner for size, angle and type, inspect electrode settings, check head setting, check air band and air shutter settings, refer to Table 8 at rear of this manual. c. Place oil burner gasket on burner and align holes. CAUTION Do not install burner without gasket. d. Remove three (3) 5/16-18 x 3/4 lg. cap screw from burner swing door used for mounting burner. e. Thread (1) 5/16-18 x 3/4 lg. cap screw, approximately three (3) full turns, into tapping located at 12:00 o'clock on burner swing door. 0 f. Insert oil burner into the opening of burner swing door. Align and engage keyhole slot in burner flange over head of protruding cap screw installed in previous Step. Rotate burner to the right to lock flange behind head of cap screw. g. Align holes and install two (2) remaining cap screws. Level burner and fully tighten all three (3) screws. h. Plug burner power cord into power outlet receptacle located in lower right corner of front panel. Figure 10: Oil Burner Installation 1 SECTION III: STEAM BOILER PIPING & TRIM WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Do not increase steam boiler input above the ratings. A. EVALUATE THE ExISTING STEAM SYSTEM. The single most important factor in determining the expected life cycle of a steam boiler, is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler. These contaminants greatly accelerate corrosion of the cast iron boiler sections. 1. Assure that all system radiators, piping and vents are absolutely leak tight. a. When a steam boiler is installed in an existing system, ALL air vents should be replaced at the same time. This assures that the new boiler will not be compromised by existing system leaks. b. If the system contains hidden supply or return piping (hidden behind walls, buried in concrete, etc.) pressure test this piping to assure there are no leaks. 2. Repair any leaks in the system. 3. Install accurate water meter on the fresh water supply to the boiler. B. CONNECT SYSTEM SUPPLY AND RETURN PIPING TO BOILER. See Figure 11 for piping details. Also consult I=B=R Installation and Piping Guides. CAUTION Maintain minimum . inch clearance from hot water piping to combustible materials. NOTICE Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh wat...
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