BOBCAT Hung On Or Adjacent To The Boiler For Reference.

Bobcat Models B-120A and B-200A6MOUNTING THE BOILER ON A WALLBe sure that the wall is vertically plumb and capable of carryingthe weight of the boiler and the system piping, when full ofwater. See page 2 for the boiler weight.4.Lift the boiler up against the wall, with the top edge of thejacket slightly above the wall bracket tabs. There are 2holes in the upper corners of the jacket rear panel, thatcan visually be aligned with the 2 larger diameter holes inthe wall bracket, to ensure that the wall bracket tabs lineup and engage with the boiler jacket near top lip notchesproperly.5.There are 2 fastener holes in the lower area of the boilerrear panel, just below the flue collector, for insuring theboiler does not move off the wall bracket. Mark these 2holes, with the boiler in place, then lift the boiler off the wallbracket.6.Determine which fastener type will best engage with thewall construction at the location of the 2 market holes. Drillout the appropriate diameter and depth holes for thefasteners, where marked.7.Lift the boiler up onto the wall bracket again, as describedin Step 4. Secure the boiler to the wall, with the 2 fastenersin the lower rear panel area.Be sure that there are studs available in the proper locations,for securing the boiler wall bracket and back panel.(See Figures 4a and 4b).For wood stud walls, use lag screws or wood screws with acoarse thread and a minimum of 3” in length.For metal stud walls, use toggle-style bolts that are specificallydesigned for such and maximum capacity exceeds the weightof the boiler and the system piping when full of water.DO NOT use anchors driven into sheetrock to hold the boilerup on the wall. If mounting the boiler on a cement wall, useanchors that are specifically designed for such, and maximumcapacity exceeds the weight of the boiler and the systempiping, when full of water.A. INSTALL THE WALL BRACKET. SEE FIGURE 4a.1.2.8.Remove the wall bracket from the boiler jacket rear panel,by unfastening the single screw that holds it in place, forshipping purposes only.If able to, the 1/2” diameter lifting pipe should be removedfrom the boiler rear panel.9.Select the location on the wall where the boiler will bemounted. The upward facing tabs of the wall bracket willalign with the top surface of the boiler jacket, and 3 feet ofopen wall space will be needed to accommodate the boilerjacket rear panel below this.The 4 boiler legs may be removed at this time, if desired. 2screws hold each leg in place, from inside the jacketpanel.10. The boiler side panels can be replaced at this time, but thefront panel should be left off, for the startup procedurelater in the installation.3.For sheetrock and stud construction, locate the studs anddetermine which set of holes in the wall bracket best alignwith the center of the studs. For cement walls, determinea location for the wall bracket to mount where the anchorswill be secure, devoid of seams or cracks.4.Place the bracket in the selected location, with the 2 tabspositioned up and facing outward, level it out, and markthe holes to be used. A minimum of 4 of these holes mustbe utilized, regardless of wall material.5.6.Drill the appropriate diameter and depth holes for thefasteners used in the wall, where marked.Fasten the wall bracket to the wall, being sure that thetabs face upward and outward, and the fasteners haveengaged the wall properly.VENTING APPLICATIONThe Bobcat B-120A and B-200A are sealed combustion typeboilers, they may be installed and vented either as a direct ventboiler which all air for combustion is obtained directly from outside or as a non-direct vent boiler which air for combustion istaken from inside the boiler room.The Bobcat B-120A and B-200A boilers must be vented by 3"diameter PVC, CPVC schedule 40 pipe, or the proper 3” diameter stainless steel venting system (see “vent material” on page7) through the roof or sidewall.BOILER ROOM AIR SUPPLY AND VENTILATIONAn ample supply of air is required for combustion and ventilation. When buildings are insulated, caulked and weatherstripped, now or later on, direct openings to outside may berequired and should be provided. If the boiler is not near anoutside wall, air may be ducted to it from outside wall openings.B. INSTALL THE BOILER ON THE WALL. SEE FIGURE 4b.1.Remove the boiler jacket front cover, by turning the 2 blackscrews 1/4 turn to the open position, then lifting off.2.Remove both the boiler jacket side panels, by removingthe 2 sheetmetal screws in the top and bottom front edge,then lift off.3.To aid in lifting the boiler, a 3 foot long, 1/2” inside diametersteel pipe can be slid through the holes in the sides of theboiler rear panel. Let the pipe extend out each side of thejacket evenly, for hand-holds, and pick up the boiler withoutletting it tilt, for safety.Provisions for combustion and ventilation air must be made inaccordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1-latest edition, or applicable provisions of the local building codes. Thefollowing recommendation applies to buildings of energy-savingconstruction, fully caulked and weatherstripped.INSTALLATION IN ENCLOSED BOILER ROOM REQUIRESTWO UNOBSTRUCTED OPENINGS FOR PASSAGE OF AIRINTO THE BOILER ROOM:

Bobcat Models B-120A and B-200A7A. NON-DIRECT VENT INSTALLATION1. Air drawn horizontally from outdoors DIRECTLY throughan outside wall; one louvered opening near the floor andone louvered opening near the ceiling, each opening with aminimum FREE air passage area of 1 square inch per 4000Btuh of total appliances’ input.ADDITIONAL REQUIREMENTS FOR THE COMMONWEALTHOF MASSACHUSETTS2. Air drawn horizontally through HORIZONTAL DUCTS;one opening near the floor and one opening near the ceiling,each opening with a minimum FREE air passage area of 1square inch per 2000 Btuh of total appliances’ input.(1). Exisiting chimneys shall be permitted to have their use continuedwhen a gas conversion burner is installed, and shall be equipped with amanual reset device that will automatically shut off gas to the burner in theevent of a sustained back-draft.3. Air drawn VERTICALLY from outdoors; one opening at thefloor and one opening at the ceiling, each opening with aminimum FREE air passage area of 1 square inch per 4000Btuh of total appliances’ input.(2)(a). For all side wall horizontally vented gas fueld equipment installed inevery dwelling, building or structure used in whole or part for residentialpurposes, including those owned or operated by the Commonwealth andwhere the side wall exhaust vent termination is less than seven (7) feetabove finsihed grade in the area of the venting, including but not limited todecks and porches, the following requirements shall be satisfied:4. Air drawn from inside the building; one opening near thefloor and one opening near the ceiling, each opening with aminimum FREE air passage area of 1 square inch per 1000Btuh of total appliances’ input.IF BOILERS ARE INSTALLED ADJACENT TO OTHER FUELBURNING EQUIPMENT, THE AREA OF FREE OPENINGSMUST BE APPROPRIATELY INCREASED TO ACCOMMODATETHE ADDITIONAL LOAD.B. DIRECT VENT INSTALLATIONAdequate air supply should be provided to prevent overheating ofthe boiler controls and boiler room. Openings for passage of airinto the boiler room for direct-vent installation must be at least 1 2of the openings required for the non-direct vent asmentioned above.If additional non-direct vent appliances are installed in the samespace and adequate air openings are provided for them, thereare no additional air openings required for the BobcatB-120A and B-200A boilers.For both direct and non-direct installation, the following must beconsidered:- Openings must never be reduced or closed. If doors orwindows are used for air supply, they must be lockedopen.- Protect against closure of openings by snow and debris.Inspect frequently.- No mechanical draft exhaust or supply fans are to beused in or near the boiler area.- Boiler area must never be under negative pressure. Theflow of combustion and ventilating air to the boiler mustnot be obstructed.FLUE GAS VENTING REQUIREMENTSThe Bobcat B-120A and B-200A series boilers are high efficiency,mechanically forced draft boilers and, therefore, require differentventing arrangements than natural draft, lower efficiency boilers.THE FOLLOWING INSTRUCTIONS MUST BE CAREFULLYREAD AND FOLLOWED IN ORDER TO AVOID ANY HAZARDOUS CONDITIONS DUE TO IMPROPER INSTALLATIONOF THE AIR INTAKE AND FLUE GAS VENTING SYSTEM.The vent piping installation MUST be in accordance with theseinstructions and with ANSI Z223.1-latest edition NATIONALFUEL GAS CODE, Part 7, Venting of Equipment. Other localcodes may also apply and must be followed. Where there is aconflict between these requirements, the more stringent caseshall apply. The use of a vent damper is NOT permitted on thisboiler series.When the Bobcat is installed and used in the Commonwealth of Massachusetts, the following additional requirements pursuant to Massachusettscode 248 CMR MUST be met:1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the timeof installation of the side wall horizontal vented fueled equipment, theinstalling plumber or gasfitter shall observe that a hard wired carbonmonoxide detector with an alarm and battery back-up is installed on thefloor level where the gas equipment is to be installed. In addition, theinstalling plumber or gasfitter shall observe that a battery operated or hardwired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wallhorizontal vented gas fueled equipment. It shall be the responsibility of theproperty owner to secure the services of qualified licensed professionalsfor the installation of hard wired carbon monoxide detectors.a. In the event that the side wall horizontally vented gas fueld equipmentis installed in a crawl space or an attic, the hard wired carbon monoxidedetector with alarm and battery back up may be installed on the next adjacent floor level.b. In th event that the requirements of this subdivision can not be met atthe time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however,that during said thirty (30) day period, a battery operated carbon monoxidedetector with an alarm shall be installed.2. APPROVED CARBON MONOXIDE DETECTORS. Each carbonmonoxide detector as required in accordance with the above provisionsshall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.3. SIGNAGE. A metal or plastic identification plate shall be permanentlymounted to the exterior of the building at a minimum height of eight (8)feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shallread, in print size no less that one-half (1/2) inch in size, “GAS VENTDIRECTLY BELOW, KEEP CLEAR OF ALL OBSTRUCTIONS”.4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless,upon inspection, the inspector observes carbon monoxide detectors andsignage installed in accordance with the provisions of 248 CMR5.08(2)(a)1 through 4.(b) EXEMPTIONS. The following equipment is exempt from 248 CMR5.08(2)(a)1 through 4:1. The equipment listed in Chapter 10 entitled “Equipment NotRequired TO Be Vented” in the most current edition of NFPA 54 asadopted by the Board; and2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or part for residential purposes.

Bobcat Models B-120A and B-200A8PVC/CPVC PIPE GENERAL ASSEMBLY METHODVENT AND AIR INTAKE MATERIALSThe vent and air intake system for direct or non-direct ventinstallation must be 3” diameter PVC/CPVC schedule. 40 pipe,or UL listed single wall 3” diameter AL29-4C* stainless steelmaterial. The following manufacturers’ systems are approved foruse within a specified minimum and maximum equivalent ventlength in this manual.ManufacturerType/SystemSealantHeat-Fab. Inc.Saf-T VentEZ SealNot RequiredProTech System,Inc.FasNSealNot RequiredFlex-LInternational, Inc.StaR-34GE-IS806N/APVC pipe,Schedule 40PVC primerand cementN/ACPVC pipe,Schedule 40CPVC primerand cement*AL29-4C is a registered Trademark of Allegheny Ludlum CorpWhen joining the various components of the listed stainlesssteel vent systems, the manufacturers’ instructions should beclosely followed to insure proper sealing. Use sealant specifiedby vent system manufacturer for sealing of pipe and fittings, ifrequired. When joining the PVC/CPVC pipe and fittings, followthe instructions provided in this manual. All connections mustbe liquid and pressure tight. DO NOT use galvanized flue pipeor any plastic-type materials other than CPVC Schedule 40.The integral adapters on the boiler are designed to accommodate either PVC/CPVC Schedule 40 pipe or the listed stainlesssteel vent systems. These adapters have built-in sealing rings,so no additional sealant is required. Make sure the pipes areround and burr-free, and push down into the appropriate stepof the adapter, until snug. (See Figure 5). Apply liquid soap tothe outer end of the pipes for easy insertion.The following are the recommended methods for cutting,cleaning and connecting PVC and CPVC pipes:1. When laying out the piping system, work from the boilervent and air intake adapter to the point of outsidetermination.2. Cut the pipes to the required lengths, and pre-assemblethe entire system, before sealing. Disassembly aftersealing, to make any corrections, will not be possible.3. Once the pre-assembled PVC/CPVC piping system isverified to be of the proper length pipe and fittingorientation, begin disassembling and preparing the pipesand fittings for the sealing process. This can be donesection by section, or the complete vent and air intakesystem can be disassembled. It is recommended to markthe various parts, before complete disassembly, toeliminate the possibility of errors during re-assembly.4. De-burr the inside and outside of every PVC/CPVC pipe, toensure that they engage fully into the fittings, and flow isnot compromised. A small chamfer on the outside of eachpipe can particularly aid in the final assembly process.5. Wipe or knock out any debris from inside the PVC orCPVC pipe, which may have accumulated there from thecutting process or storage. Debris can cause operationalproblems with the boiler combustion components.6. Thoroughly clean the outside ends of each pipe, and theinside of each fitting. The surfaces must be dry for thesealing agents to work properly. Handle the prepared pipelengths away from the cleaned ends, and handle thecleaned fittings, from the outside, to avoid contamination.7. Re-assembly of the PVC or CPVC pipe should be done insections, to avoid the primer and cement drying before theparts are engaged.8. For each joint, first apply a coat of primer to the outsidesealing surface of the pipe and the inside sealing surface ofeach fitting. Use only the primer type that is specified foreither the PVC or CPVC pipe that is being utilized.9. Before the primer dries, apply a coat of cement over it. Asecond coat of cement can be applied, if necessary, butmust be done quickly and in a manner that avoidsunnecessary build-up that would cause obstruction insidethe system. Use only the cement type that is specified foreither the PVC or CPVC pipe that is being utilized.10. Before the cement dries, insert the pipe into the fitting. Aslight twisting motion while pushing the pipe into the fittingwill aid in distributing the cement evenly and ensuring theparts fully engage.11. Quickly wipe the excess cement from the outside areas ofthe joint. Discard any rags used to avoid later getting thecement on hands, clothes and equipment.VENT AND AIR INTAKE RESTRICTIONS1. Maximum allowed equivalent vent and air intake length forall of the approved vent and air intake materials is 100 feetfor B-120A and 50 feet for B-200A.2. Equivalent of vent or air intake length is sum of thestraight pipe lengths and equivalent length of elbows asshown in the table on this page.Figure 5. Vent and Air Intake Pipe installation into BoilerAdapter.

Bobcat Models B-120A and B-200A96. The B-120A and B-200A boilers are equipped with a built-incondensation drain and trap. The trap must be filled withwater. DO NOT operate the boiler without filling the trap withwater to prevent flue gas discharge into space. The drainmust dispose of possibly large quantities of condensate,which may require a neutralizing system. Refer to the“Condensate Drainage” section of this manual. No additionalcondensation drain and trap is required on the vent pipingsystem itself.7. The horizontal vent pipe must be sloped upward from theboiler at a pitch of at least 1/4” per 1 foot of run, so thatthe condensate from the vent system runs to the boilervent adapter pipe, then out the built-in condensation drainand trap.8. The horizontal vent and air intake pipes must be supportedwith pipe straps, at intervals no greater than 5 feet, whenPVC/CPVC pipe is utilized. This support spacing appliesalso to stainless steel vent pipe, unless the manufacturer’sinstructions permit otherwise. The vertical vent and airintake pipes also must be supported, wherever the buildingconstruction provides allowance for it, such as ceiling orroof passage openings where a firestop and support orbraces can be affixed.Figure 6.3. The vent termination is in addition to the allowedequivalent lengths.4. Minimum vent length is 2 feet of straight pipe, plus one90 elbow that is required.5. Vent length restriction is for both direct and non-directvent installations.EXAMPLE: Boiler model B-120A is to be installed. Thecombustion air is provided by air intake piping directly to theboiler (direct-vent installation). The vent piping will be CPVCand installation location will require the use of 4 elbows forthe vent to run the termination. The air intake piping will bePVC, and also will require the use of 4 elbows.9. Minimum clearances of vent pipes from combustibleconstru

BOBCAT hung on or adjacent to the boiler for reference. INSTALLATION AND OPERATING INSTRUCTIONS Printed in U.S.A. 211 Part No. 86-5756000 Publication No. BA-40 Rev. I Heating Contractor Address Phone Number Boiler Model Number Boiler Serial Number Installation Date DIRECT-VENT SEAL