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Gas-Fired Boiler Table of Contents
1.0 INTRODUCTION ........................................1
2.0 SAFETY......................................................1
2.1 General ....................................................... 1
2.2 Training....................................................... 1
2.3 Safety Features .......................................... 1
2.4 Safety Labels ..............................................2
2.5 Safety Precautions......................................2
2.5.1 Electrical Hazards................................. 2
2.5.2 Burn, Fire, and Explosion Hazards....... 2
2.5.3 Crush Hazards...................................... 3
2.5.4 Chemical Hazards ................................ 3
2.5.5 Pressure Hazards................................. 4
2.5.6 Slip, Fall Hazards ................................. 4
3.0 INSTALLATION ..........................................5
3.1 Receiving and Storage ...............................5
3.1.1 Initial Inspection.................................... 5
3.1.2 Storage Prior to Installation ..................5
3.2 Compliance with Codes.............................. 5
3.3 Setup........................................................... 5
3.3.1 Foundation............................................ 5
3.3.2 Placement............................................. 5
3.3.3 Clearances ........................................... 6
3.4 Electrical Connections ................................ 6
3.5 Combustion Air ........................................... 7
3.6 Flue Venting................................................7
3.6.1 Vent Elbows.......................................... 8
3.6.2 Barometric Damper .............................. 8
3.6.3 Automatic Vent Damper ....................... 8
3.6.4 Flue Connection ................................... 8
3.6.5 Vent Termination .................................. 8
3.6.6 Removing an Existing Boiler ................ 9
3.7 Gas Piping .................................................. 9
3.7.1 Gas Supply Piping by Installer ........... 11
3.7.2 Gas Bleeds and Vents by Installer ..... 11
3.8 Boiler Water Piping................................... 11
3.8.1 Piping Design......................................11
3.8.2 Boiler Inlet and Outlet Connections ....12
3.8.3 Boiler Water Piping by Installer...........12
3.8.4 Flushing and Filling.............................13
3.8.5 Water Quality ......................................13
3.9 Burner and Ignition System.......................13
3.9.1 Inspection............................................13
3.10 Pre-Start Check List ................................13
3.11 Safety Checks .........................................14
3.11.1 Test of Ignition Safety System ..........14
3.11.2 Test of Low Water Cut-off.................14
3.11.3 Test of Limit Controls........................14
3.11.4 Test of Low Gas Pressure Switch.....15
3.11.5 Test of High Gas Pressure Switch....15
3.12 Initial Adjustments ...................................15
3.12.1A – Configuring the Local Controller...15
3.12.1B Optional Remote Control................20
3.12.2 Air Flow Adjustments ........................20
3.12.3 Gas Pressure Adjustment.................21
4.0 OPERATION ............................................22
4.1 General......................................................22
4.1.1 Control Panel Front.............................22
4.2 Lighting and Shut-Down Procedures ........22
4.2.1 Lighting Procedures............................22
4.2.2 Normal Shut Down Procedures ..........23
4.2.3 Emergency Shut Off............................23
4.3 Typical Boiler Operating Conditions..........23
5.0 MAINTENANCE ......................................24
5.1 Maintenance and Inspection Schedule .....24
5.1.1 Daily ....................................................24
5.1.2 Weekly ................................................24
5.1.3 Monthly (During Operation).................24
5.1.4 Semi-Annually.....................................24
5.1.5 Annually ..............................................25
5.2 Cleaning the Burner ..................................25