INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS ADVANTAGE .

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INSTALLATION, OPERATINGAND SERVICE INSTRUCTIONSADVANTAGE SERIESCAST IRON OIL-FIRED BOILER9700609For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide BoilerModel Number and Serial Number as shown on Rating Label.Boiler Model NumberBoiler Serial NumberInstallation DateAOHeating ContractorAddress104105-05 - 8/14Phone Number

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY1. Read and understand all instructions, including all those contained in component manufacturers manuals which areprovided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep thismanual and literature in legible condition and posted near appliance for reference by owner and service technician.2. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout andinstallation of hydronic heating systems should attempt installation of any boiler.3. All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes andthe regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authoritieshaving jurisdiction should be consulted before installations are made.In all cases, reference should be made to the following Standards:USA BOILERSA. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, forrecommended installation practices.B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid FuelBurning Appliances”, For Venting requirements.C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices forAutomatically Fired Boilers”, for assembly and operations of controls and safety devices.D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/orLocal Regulations.IMPORTANTThis boiler is equipped with a feature that saves energy by reducing the boiler watertemperature as the heating load decreases. This feature is equipped with an overridewhich is provided primarily to prevent the use of an external energy managementsystem that serves the same function. THIS OVERRIDE MUST NOT BE USEDUNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: An external energy management system is installed that reduces the boiler watertemperature as the heating load decreases. This boiler is not used for any space heating. This boiler is part of a modular or multiple boiler system having a total input of300,000 BTU/HR or greater. This boiler is equipped with a tankless coil.DANGERDO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any otherappliance.2

WARNINGThis boiler is suitable for installation on combustible flooring. Do not install boiler on carpeting.Installation is not complete unless a pressure relief valve is installed into the tapping located on top leftcorner of rear section - See Piping and Trim Sections of this manual for details.This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oilcontaining gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All flammable debris, rags, paper,wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free offire hazards.This boiler needs fresh air for safe operation and must be installed so there are provisions for adequatecombustion and ventilation air.This boiler must be connected to an approved chimney in good condition. Serious property damagecould result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney fluemust be inspected and cleaned before the start of the heating season for any obstructions. A clean andunobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life tovent safely and will contribute toward maintaining the boiler's efficiency.Inspect flueways at least once a year - preferably at the start of the heating season. The inside ofthe combustion chamber, the vent system and boiler flueways should be cleaned if soot or scale hasaccumulated.When cleaning this boiler, do not damage combustion chamber liner and/or rear target wall. If damaged,combustion chamber insulation must be replaced immediately.This boiler requires regular maintenance and service to operate safely. Follow the instructions containedin this manual. Installation, maintenance, and service must be performed only by an experienced, skilledand knowledgeable installer or service agency.It is the responsibility of the installing contractor to see that all controls are correctly installed andare operating properly when the installation is completed. Do not tamper with or alter the boiler orcontrols.Do not operate unit if any control, switch, component, or device has been subject to water.Oil Burner and Controls must be checked at least once a year or as may be necessitated.All boilers equipped with burner swing door have a potential hazard which if ignored can cause severeproperty damage, personal injury or loss of life. Before opening swing door, turn off service switch toboiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swingdoor fastener completely when service is completed.Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavymetals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances whichcan cause death or serious injury and which are known to the state of California to cause cancer, birthdefects and other reproductive harm. Always use proper safety clothing, respirators and equipment whenservicing or working nearby the appliance.High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tanklessheater for domestic water supply, a flow regulator and automatic mixing valve must be installed properlyin tankless heater piping. See Piping and Trim Sections of the manual for details.3

Table of ContentsI. General Information . 4VI.II. Installation Instructions . 7VII. Repair Parts .22III. Indirect Water Heater Piping . 14VIII. AppendixBurner Specifications .26IV. Operating & Service Instructions . 15Boiler Cleaning .20V. Maintenance & Service Instructions. . 18I. General InformationA. INSPECT SHIPMENT carefully for any signs ofdamage.1. ALL EQUIPMENT is carefully manufactured,inspected and packed. Our responsibility ceasesupon delivery of crated boiler to the carrier in goodcondition.2. ANY CLAIMS for damage or shortage in shipmentmust be filed immediately against the carrier bythe consignee. No claims for variances from,or shortage in orders, will be allowed by themanufacturer unless presented within sixty (60) daysafter receipt of goods.B. LOCATE BOILER in front of final position beforeremoving crate. See Figure 1.1. LOCATE so that smoke pipe connectionto chimney will be short and direct. BOILERIS SUITABLE FOR INSTALLATION ONCOMBUSTIBLE FLOOR. Boiler cannot beinstalled on carpeting.42. FOR BASEMENT INSTALLATION, provide asolid base, such as a concrete pad, if floor is notlevel, or if water may be encountered on flooraround boiler.3. PROVIDE SERVICE CLEARANCE of at least24” on top of boiler for cleaning flueways. Provideat least 24” clearance from front jacket panel forservicing.4. For minimum clearances to combustible materials.See Figure 2.C. PROVIDE AIR SUPPLY AND VENTILATION toaccommodate proper combustion. If natural ventilationis inadequate, provide a screened opening or duct fromthe boiler room to the outside. The opening or ductmust be sized so the boiler input will not exceed 4,000BTUH/Sq. In. of free area. If other air consumingappliances are near the boiler, the air inlet should belarger. Consult respective manufacturers.

5Figure 1: AO(T)-3 Thru AO(T)-5 Water Boiler

TABLE 1: DIMENSIONAL DATA (SEE FIGuRE "A""B""C"Approx. Water Content(Gallons)Heat TransferSurface Area(Sq. 7/8"2427.46800Maximum Working Pressure - Water: 50 PSIBoilers are shipped with a 30 PSI relief valve.TABLE 2: RATING DATABurnerCapacityGPHMBHDOE .501.752.00BoilerModel No.AO(T)-3AO(T)-4AO(T)-5NET AHRIWater Ratings(MBH)Minimum Chimney RequirementsAFUERoundIn. Dia.RectangleIn. x 8x81585.128024121088x81584.7Figure 2: Minimum Installation Clearances To Combustible Materials 41866NOTE 1: Listed clearances comply with American NationalStandard NFPA 31, Standard for the Installation of OilBurning Equipment.6NOTE 2: Advantage Series boilers can be installed inrooms with clearances from combustible material as listedabove. Listed clearances cannot be reduced for alcove orcloset installations.NOTE 3: For reduced clearances to combustible material,protection must be provided as described in the ANSI/NFPA31 standard.

II. Installation InstructionsA. REMOVE CRATE1. Remove all fasteners at crate skid.2. Lift outside container and remove all otherinside protective spacers and bracing. Removemiscellaneous water trim carton.3. Using hand truck or pipe rollers under skid, moveboiler into position along side installation site.B. REMOVAL OF BOILER FROM SKID1. Boiler is secured to base with 4 carriage bolts, 2 onleft side and 2 on right side. See Figure 3. Removeall bolts.5" nipple. Thread ¾" drain valve into ¾" NPTconnection on tee. Tighten all joints with wrenchuntil water tight and 1½" NPT return connection ontee is facing away from boiler horizontally to allowfor proper burner swing door clearance, see Figures1 and 4.NOTE: Vertical piping will prevent door from openingfully for service and cleaning of boiler.2. Thread relief valve onto factory installed ¾" NPTx 7¼" nipple located in left rear corner on top ofboiler as shown in Figure 1. Valve spindle mustbe in vertical position. Tighten with wrench. Pipedischarge as shown in Figure 4. Installation of therelief valve must be consistent with ANSI/ASMEBoiler and Pressure Vessel Code, Section IV.F. CONNECT SUPPLY AND RETURN PIPING TOHEATING SYSTEM.Figure 3: Removal of Boiler From Skid2. Tilt boiler to right and to rear. Using right rear legas pivot, rotate boiler 90 in a clockwise direction,and lower left side of boiler to floor. Tilt boilerand remove crate skid. Care should be exercised toprevent damage to jacket or burner.C. MOVE BOILER TO PERMANENT POSITION bysliding or walking.D. INSPECT COMBUSTION TARGET WALL ANDCOMBUSTION CHAMBER LINER1. OPEN FLAME OBSERVATION DOOR AND/OR BURNER SWING DOOR on front of boiler.Use flashlight to inspect target wall secured torear section with silastic sealant. Inspect ceramicfiber blanket secured to floor of boiler with waterglass adhesive. If either is damaged they must bereplaced.E. INSTALL WATER BOILER TRIM AND CONTROLS,(see Figure 1)1. Install return piping supplied with boiler. ApplyTeflon or Sealant to all joints prior to assembly.Thread 1½" NPT x 5" Lg. return nipple into 1½"NPT tapping located in lower left corner of frontsection. Thread 1½" x ¾" x 1½" NPT tee onto1. CLEARANCES — Hot water pipes shall haveclearances of at least ½” from all combustibleconstruction.2. WATER BOILERa. For Forced Circulation HOT WATER HEATING.See Figure 4. Also, consult Residential HydronicHeating Installation and Design I B R Guide.b. Use a boiler water bypass if the boiler is to beoperated in a system which has a large volumeor excessive radiation where low boiler watertemperature may be encountered (i.e. convertedgravity circulation system, etc.).Install a pipe tee between the circulator andboiler return along with a second tee in thesupply piping as shown in Figure 4. The bypassshould be the same size as the supply and returnlines. Locate valves in the bypass and supplyoutlet as illustrated in Figure 4 for regulationof water flow to maintain higher boiler watertemperature.Set the by-pass and boiler supply valves to a halfthrottle position to start. Operate boiler until thesystem water temperature is a normal operatingrange.Adjust the valves to provide 180 to 200 Fsupply water temperature. Opening the boilersupply valves will raise the system temperature,while opening the bypass valve will lower thesystem supply temperature.c. If this boiler is connected to heating coils locatedin air handling units where they may be exposedto refrigerated air the boiler piping must beequipped with flow control valves to preventgravity circulation of boiler water during theoperation of the cooling system.7

Figure 4: Recommended Boiler Piping for Series Loop Hot Water Systemd. If this boiler is used in connection withrefrigeration systems, the boiler must beinstalled so that the chilled medium is piped inparallel with the heating boiler using appropriatevalves to prevent the chilled medium fromentering the boiler, see Figure 5. Also, consultResidential Hydronic Heating Installation andDesign I B R Guide.e. A hot water boiler installed above radiation levelmust be provided with a low water cutoff deviceas part of the installation. See Section VIII, LowWater Cut-Off for additional details.3. OXYGEN CONTAMINATION:a. There are many possible causes of oxygencontamination such as:i. Addition of excessive make-up water as aresult of system leaks.8ii. Absorption through open tanks and fittings.iii. Oxygen permeable materials in thedistribution system.b. In order to insure long product life, oxygensources should be eliminated. This can beaccomplished by taking the following measures:i. Repairing system leaks to eliminate the needfor addition of make-up water.ii. Eliminating open tanks from the system.iii. Eliminating and/or repairing fittings whichallow oxygen absorption.iv. Use of non-permeable materials in thedistribution system.v. Isolating the boiler from the system water byinstalling a heat exchanger.See Section V, Paragraph B for additional details.

TABLE 3: TANKLESS HEATER DATABoiler ModelRating (Gal/Min)Pressure 4AO(T)-54.008.04.258.84.759.6Figure 5: Recommended Piping for CombinationHeating & Cooling (Refrigeration) SystemsCAUTIONOxygen contamination of the boiler waterwill cause corrosion of iron and steel boilercomponents, and can lead to boiler failure.Advantage's Standard Warranty does not coverproblems caused by oxygen contamination ofboiler water or scale (lime) build-up caused byfrequent addition of water.G. CONNECT TANKLESS HEATER PIPING ASSHOWN IN Figure 6. See Table 3 for Tankless HeaterRatings.during “off” periods when it is possible for heatto be conducted back through the supply line. Theflow regulator also limits the flow of supply waterregardless of inlet pressure variations in the range of20 to 125 psi.2. TEMPERING OF HOT WATER — Installationof an automatic mixing valve will lengthen thedelivery of the available hot water by mixing somecold water with the hot. This prevents excessiveand possibly scalding hot water at the fixtures. Inaddition, savings of hot water will be achieved sincethe user will not waste as much hot water whileseeking water temperature to his liking. Highertemperature hot water required by dishwashers andautomatic washers is possible by piping the hotwater from the heater prior to entering the mixingvalve. The mixing valve should be “trapped” byinstalling it below the cold water inlet to heater toprevent lime formation in the valve.WARNINGInstall automatic mixing valve at tankless heateroutlet to avoid risk of burns or scalding due toexcessively hot water at fixtures. Adjust andmaintain the mixing valve in accordance with themanufacturer's instructions.Figure 6: Schematic Tankless Heater PipingTHE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER:1. FLOW REGULATION — If flow through the heateris greater than its rating, the supply of adequate hotwater may not be able to keep up with the demand.For this reason a flow regulator matching the heaterrating should be installed in the cold water line tothe heater. The flow regulator should preferably belocated below the inlet to the heater and a minimumof 3’ away from the inlet so that the regulator is notsubjected to excess temperatures that may occur3. FLUSHING OF HEATER — All water containssome sediment which settles on the inside of thecoil. Consequently, the heater should be periodicallybackwashed. This is accomplished by installinghose bibs as illustrated and allowing water at citypressure to run into hose bib A, through the heater,and out hose bib B until the discharge is clear. Thetees in which the hose bibs are located should bethe same size as heater connections to minimizepressure drop.4. HARD WATER — A water analysis is necessary todetermine the hardness of your potable water. Thisis applicable to some city water and particularly towell water. An appropriate water softener shouldbe installed based on the analysis and dealer’s9

recommendation. This is not only beneficial to thetankless heater but to piping and fixtures plus themany other benefits derived from soft water.H. INSTALL SMOKEPIPE — The Advantage Seriesboiler should be vented into a fireclay tile-linedmasonry chimney or chimney constructed from type Lvent or a factory built chimney that complies with thetype HT requirements of UL103. The chimney andvent pipe shall have a sufficient draft at all times, toassure safe proper operation of the boiler. See Figure 7for recommended installation.1. Install a draft regulator following the instructionsfurnished with the regulator. See Figure 8 for draftregulator locations.2. Consider the chimney overall. Chimneys that havea high heat loss may become less suitable as theheat loss of the home goes down and the efficiencyof the boiler installed goes up. Most homes havea chimney appropriate for the fuel and the era inwhich the home was built. That may have been acoal fired or an inefficient oil fired boiler built intoa home without insulation or storm windows. Withincreasing fuel prices that home probably has beeninsulated and fitted with storm windows so thatthe heat loss of the home has been reduced. Thisrequires less fuel to be burned and sends less heat upthe chimney.Figure 7: Recommended Smokepipe Arrangementand Chimney RequirementsA new boiler probably has a higher efficiency thanthe boiler being replaced. That probably means thatthe stack temperature from the new boiler will belower than that from the old boiler and with lessroom air being drawn up the chimney to dilute thestack gases. The combination of a large uninsulatedchimney, reduced firing rate, reduced firing time,lower stack temperature and less dilution air can,Figure 8: Proper and Improper Locations of Draft Regulator10

in some cases, contribute to the condensing ofsmall amounts of water vapor in the chimney. Suchcondensation, when it occurs, can cause chimneydeterioration. In extreme cases, condensed watermay be visible on the outside of the breeching orchimney. In those extreme cases, the chimney mayhave to be lined to insulate the chimney and thusprevent the condensation. The addition of dilutionair into the chimney may assist in drying thechimney interior surfaces.A massive chimney on a cold, or exposed outsidewall may have produced adequate draft when itwas fired with a higher input and

manual and literature in legible condition and posted near appliance for reference by owner and service technician. 2. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler. 3.

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