INSTALLATION, OPERATION & MAINTENANCE MANUAL - Carrier
OIL FIRED CAST IRONHOT WATER BOILERINSTALLATION, OPERATION &MAINTENANCE MANUALModels (Series 5BAH-210BW5RAH-210Select ModelsCAC/BDP7310 WEST MORRIS ST.INDIANAPOLIS, IN 46231P/N# IM-BW4-01[240009548, Rev. C [12/2012]
SAFETY NOTICESIntroductionSafety Notices .3Boiler is a natural draft oil fired hot water boiler comprisedof cast iron sections. Boiler is available with 3, 4, or 5 castiron sections. These sections are held together by cast ironpush nipples.Boiler Ratings And Capacities .4Fresh Air For Combustion.8System Piping . 10Chimney And Chimney Connections . 17Boiler is capable of firing #2 fuel oil from 0.65 gph upto 1.75 gph. All packaged boilers include a swing door,Honeywell limit, temperature and pressure gauge, safetyrelief valve, drain valve, flue brush, and extra boiler tap forexpansion tank or air elimination.Typical Chimney Connection . 18Electrical Connections . 19Filling The Boiler . 20Operating The Boiler . 21Checking And Adjusting Controls . 24Maintenance . 25Oil Boiler / Burner Cleaning Instructions . 26Oil Burner Cleaning . 27Service Hints . 28Electrical Wiring . 31Equipment And Optional Accessories . 32Boiler installation shall be completed by qualified agency.Become familiar with symbols identifying potentialhazards.This is the safety alert symbol. Symbol alerts youto potential personal injury hazards. Obey all safetymessages following this symbol to avoid possible injury ordeath.!DANGERIndicates a hazardous situation which, if not avoided,WILL result in death or serious injury! WARNINGIndicates a hazardous situation which, if not avoided,could result in death or serious injury.! CAUTIONIndicates a hazardous situation which, if not avoided,could result in minor or moderate injury.NOTICEUsed to address practices not related to personalinjury.2
BOILER RATINGS AND CAPACITIESFigure 1 - DimensionsBOILER RATINGS AND CAPACITIESBOILER MODEL NO.INPUT gph 3A.F.U.E. NO.SEC.BoilerWaterCapacity(US 11½* Mbh 1,000 BTU per hour [BTU British Thermal Unit]**Heating Capacity based on 13% CO2 with a 0.02” w.c. draft over fire, and a #1 smoke or less. Testing was done inaccordance with the D.O.E. (Department of Energy) test procedure. gph Gallons per hour oil at 140,000 BTU per gallon A.F.U.E. Annual Fuel Utilization Efficiency based upon D.O.E. test procedure.‡ Net AHRI Water Ratings based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler forinstallations having unusual piping and pickup requirements, such as intermittent system operation, extensive pipingsystems, etc. As Energy Star Partner, manufacturer has determined this product meets Energy Star guidelines for energy efficiency.3
SAFE INSTALLATION AND OPERATION! WARNING! WARNINGFire, explosion, burn, scald hazard. Use onlynumber 2 fuel oil. Do not use gasoline, kerosene,crankcase oil or any oil containing gasoline. Failureto follow these instructions could result in death orserious injury.Burn and scald hazard. Safety relief valve coulddischarge steam or hot water during operation.Install discharge piping per these instructions.11. Be aware when piping the safety relief valve if systempressure exceeds safe limit of 30 pounds per squareinch, the safety relief valve will automatically liftopen. Lifting of the safety relief valve can dischargelarge quantities of steam and hot water, which maydamage the surroundings. Before installing the safetyrelief valve read the manufacturer’s instructions andmaintenance section of the manual on safety reliefvalves.NOTICEThis boiler has been designed for residentialinstallations. If used for commercial applications,all jurisdictional requirements must be met. Thismay require wiring and/or piping modifications.Manufacturer is not responsible for any changes tothe original design.12. Installation and sizing of the expansion tank must1. Read the Owner’s Manual for Safe Operation. Failureconsider heating systems total water volume,temperature, boiler initial fill pressure, and systemarrangement. Improperly installed and sized expansiontank may result in frequent lifting of the safetyrelief valve or other heating system problems. Forproper installation, sizing, and maintenance of theexpansion tank follow guidelines established by tankmanufacturer.to follow rules for safe operation and instructions cancause malfunction of boiler and result in death, seriousbodily injury, and/or property damage.2. Check your local codes and utility requirements beforeinstallation. Installation must be in accordance withtheir directives, or follow NFPA 31 Installation of OilBurning Equipment, latest revision.13. Expansion tank performance and life expectancy can3. Before servicing, allow boiler to cool. Always shut offbe hindered by overfilling the boiler. Recommend initialfill pressure of 10-12 psig. For higher fill pressuresexpansion tank’s air charge will need to be increased tomatch fill pressure. Consult manufacturer’s guidelinesfor sizing and selection.any electricity and oil to boiler when working on it.4. Inspect oil line and connections for leaks.5. Be certain oil burner nozzle is the size required. Overfiring will result in early failure of the boiler sections.This will cause dangerous operation.14. Purging the heating system of air and gases when6. Never vent this boiler into enclosed space. Always ventfirst putting boiler into service is critical for propercirculation and quiet performance. Once air and gasesare purged, for boiler installations using float typevents, air vents should be closed for normal operation.If air is heard or noticed by loss of heat, purge systemand open vents for short period of time.to outside. Never vent to another room or inside abuilding.7. Be sure there is adequate air supply for completecombustion.8. Follow regular service and maintenance schedule forefficient and safe operation.9. Keep boiler area clean and free of combustible material,gasoline and other flammable vapors and liquids.10. Oil burners are not do-it-yourself items. Thisboiler must be installed and serviced by qualifiedprofessionals using combustion test instruments.4
LOCATING THE BOILERComplete Prior To Installing Boiler.1. Place boiler in location centralized with the pipingsystem and as close to chimney as possible.A. Verify you have selected the right size boiler withproper capacity. AHRI rating of boiler selectedshould be greater than or equal to calculated peakheating load (heat loss) for building or area(s)served by boiler and associated hot water heatingsystems. See boiler rating and capacity tablepreviously listed in this manual. Any heat losscalculations used should be based on approvedmethods.2. Boiler must be level. If necessary use metal shimsbeneath boiler’s feet.3. Use raised base if floor can become wet or damp.4. Maintain clearances for fire safety as well asservicing. 18” clearance must be maintained ata side where passage is required for access toanother side for cleaning, servicing, inspection, orreplacement of any parts that normally may requiresuch attention. Boilers must be installed at least 6”from combustible material on all sides and above.Allow at least 24” front clearance for servicing.B. Boiler must be supplied with proper oil supplyand oil piping, sufficient fresh combustion air, andsuitable electrical supply.C. Boiler must be connected to suitable venting systemand piping system adequate to distribute heatingload.5. Fresh air for combustion must be available at frontof the boiler. Fresh air for ventilation must beavailable to front and rear of boiler. Air passagesmust be free of obstructions at all times. Ventilatingand combustion air must enter boiler room withoutrestrictions.D. Properly locate and install thermostat for heatingsystem control.Any doubts as to requirements, check with local authoritiesand obtain professional help where needed. OPERATINGINSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, andMAINTENANCE sections in this manual are vital to theproper and safe operation of the heating system.! WARNINGFire hazard. Do not install boiler on combustibleflooring or carpeting. Failure to follow theseinstructions could result in death or serious injury.6. Floor supporting boiler must be noncombustible andsufficiently stable. If it is combustible, place boileron 2” concrete patio blocks or 2” Cladlite Pad .Blocks or pad must be under entire boiler to protectthe floor.7. Installation shall be in accordance with theFigure 2 - Clearancesrequirements of the local authorities havingjurisdiction. Compliance with these regulations isrequired. In the absence of local codes, follow NFPA31 Installation of Oil Burning Equipment, latestrevision.6”Min.6”Min.BoilerFront6” Min./18”With CoilBOILER CLEARANCES24” Min.Accessibility,Flue toCleaning, and nceTop6”18”24”Left Side24”Right All distances measured from the cabinet of the boiler.5
6OIL LINESOIL FILTERSHUT OFFVALVEOIL TANK2" FILLPIPEMIN. 2" I.D.VENT PIPETO OUTSIDEFOUNDATIONSLINES TO OTHERAPPLIANCESENTRANCESWITCHSERVICE LINEOIL BURNERELECTRIC LINERELIEF VALVECIRCULATINGPUMP INRETURN LINEOR AFTER THEEXPANSIONTANKFROM RADIATIONTO RADIATIONVENTPIPEDRAFTREGULATORDIAPHRAGMEXPANSION TANKAUTOMATICFILL VALVEAND SHUTOFFGENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATIONOVERCURRENTPROTECTEDSAFETY SWITCHCHIMNEYLOCATING THE BOILERFigure 3 - Boiler With Piping System
FRESH AIR FOR COMBUSTIONEXAMPLE 2: Boiler Located in Confined Space! WARNINGAsphyxiation, fire hazard. Do not obstruct airopenings to combustion area. Follow instructionsbelow, to maintain adequate combustion air.All Air from Inside the Building: Confinedspace shall be provided with two permanent openingscommunicating directly with additional room(s) of sufficientvolume so the combined volume of all spaces meets thecriteria for unconfined space. Total input of all combustionequipment installed in combined space shall be consideredin making this determination. Each opening shall haveminimum free area of one square inch per 1,000 Btu perhour of total input rating of all combustion equipment in theconfined space, but not less than 100 square inches. Oneopening shall be within 12 inches of top and one within 12inches of bottom of the enclosure.Example: Your boiler is rated at 100,000 Btu per hour.Water heater is rated at 30,000 Btu per hour. Total is130,000 Btu per hour. You need two grilles, each with 130square inches of FREE opening. Metal grilles have about60% FREE opening. To find louvered area needed, multiplyfree opening required by 1.7 (130 x 1.7 221.0 sq. in.louvered area). In this example, two grilles each having 8”x 30” (240 sq. in.) louvered area would be used.A.NOTICEInstall outside air intake if you use fireplace orkitchen or bathroom exhaust fan. These devices robboiler and water heater of combustion air.Provide enough fresh air to assure proper combustion.Fire in the boiler uses oxygen. It must have continuoussupply. Air in the house contains only enough oxygen tosupply burner for short time. Outside air must enter thehouse to replace air used by the burner. Study the followingexamples 1 and 2 to determine your fresh air requirements.EXAMPLE 1: Boiler Located in Unconfined SpaceIf your boiler is in an open area (un-partitioned basement)in conventional house, air that leaks through cracks arounddoors and windows will usually be adequate to provide airfor combustion. Doors should not fit tightly. Do not caulkcracks around windows.An unconfined space is defined as space whose volume isnot less than 50 cubic feet per 1,000 Btu per hour of totalinput rating of all appliances installed in that space.Figure 4 - Air Openings For Boiler Located InConfined Space (Utility Room)7
FRESH AIR FOR COMBUSTIONB.All Air from Outdoors: Confined space shallbe provided with two permanent openings, onecommencing within 12 inches of top and commencingwithin 12 inches of bottom of enclosure. Openingsshall communicate directly, or by ducts, with outdoorsor spaces (crawl or attic) that freely communicate withoutdoors.1. When directly communicating with outdoors, eachopening shall have minimum free area of onesquare inch per 4,000 Btu per hour of total inputrating of all equipment in the enclosure.2. When communicating with outdoors throughvertical ducts, each opening shall have minimumfree area of one square inch per 4,000 Btu perhour of total input rating of all equipment in theenclosure.3. When communicating with outdoors throughhorizontal ducts, each opening shall haveminimum free area of one square inch per 2,000Btu per hour of total input rating of all equipmentin the enclosure.4. When ducts are used, they shall be of same crosssectional area as free area of openings to whichthey connect. Minimum dimension of rectangularair ducts shall be not less than three inches.Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler InTightly Constructed HousesFRESH AIR DUCT CAPACITIESTHROUGH LOUVERS¼” uh)*3 ½” x 12”144,00036,000108,0008” x 8”256,00064,000192,0008” x 12”384,00096,000288,0008” x 16”512,000128,000384,000Fresh AirDuct Size*Btuh British Thermal Units per hour based onopening covered by ¼” mesh screen , wood louvers,or metal louvers.8
SYSTEM PIPING1. Installation of boiler for new heating system,Figure 6a - Safety Relief Valve InstallationInstall all of radiation units (panels, radiators,baseboard, or tubing) and supply and return mainsfirst. After all heating system piping and componentshave been installed, make final connection of systempiping to boiler. It is recommended to mount circulatingpump on supply side piping, such that it pumps awayfrom expansion tank. Refer to figures on next pages.2. Equip hot water boiler installed above radiationlevel with low water cut off device. Periodic inspectionis necessary, as is flushing of float type devices, perlow water cut off manufacturer’s specific instructions.3. Packaged boiler is set up with 1¼” NPT supplyand return piping from front of boiler. Boiler supplyand return piping can be moved to rear of boiler. Boilershould not be piped return line to front, supply lineto rear, or vice versa, will cause boiler water to shortcircuit heat exchanger. Piping connections may requireadditional fittings and parts.Follow Instructionsto install dischargepiping from safetyrelief valve to drain.4. Install drain valve provided with boiler in return tee. .5. Install Safety Relief Valve in rear section using ¾”nipple and street elbow provided with boiler. See figure6a.A. Install safety relief valve with spindle in verticalposition.B. Do not install shutoff valve between boiler andsafety relief valve.C. Install discharge piping from safety relief valve. Use ¾” or larger pipe. See figure 6b. Use pipe suitable for temperatures of 375 F(191 C) or greater. Individual boiler discharge piping shall beindependent of other discharge piping. Size and arrange discharge piping to avoidreducing safety relief valve relieving capacitybelow minimum relief valve capacity stated onrating plate. Run pipe as short and straight as possible tolocation protecting user from scalding and properlydrain piping. Install union, if used, close to safety relief valveoutlet. Install elbow(s), if used, close to safety relief valveoutlet and downstream of union (if used). Terminate pipe with plain end (not threaded).Figure 6b - Discharge Piping From Safety ReliefValveSAFETY RELIEF VALVEDISCHARGELINECheck localcodes formaximumdistancefrom flooror allowablesafe point ofdischarge.6. Verify clean cold water supply is available whenconnecting to pressure reducing valve. When watersupply is from well or pump, a sand strainer should beinstalled at the pump.9
SYSTEM PIPINGLow Design Water Temperature Systems (Below140 F) And Large Water Content SystemsFigure 7 - Bypass Piping Arrangement Diagram LOW DESIGN WATER TEMPERATURESYSTEMS Significant condensation may form in this boiler and/or venting system if boiler is operated with returntemperatures of less than 120 F. Condensation is corrosive and can eventually causedamage to boiler and venting system. Minimum designreturn water temperature to prevent this condensationin boiler and venting is 120 F. Boiler used in heating system where design watertemperatures below 140 F are desired (e.g. radiant floorheating), a 3-way or 4-way mixing valve or suitablealternative (e.g. Bypass Piping Arrangement shownin diagram on following page) is required to preventlow temperature (below return 120 F) return waterfrom entering boiler. When using mixing valve, followmanufacturer’s installation instructions. Boiler connected to system having large water content(such as former gravity system), use of Bypass PipingArrangement shown in diagram on following page issuggested. LARGE WATER CONTENT SYSTEMS PIPING ARRANGED FOR “POWERPURGING” AIR OUT OF THE SYSTEMPIPING, REFER TO THIS MANUAL’SSECTION ON “FILLING THE SYSTEMWITH WATER” OPTION #1Adjust two throttling valves to maintainat least 120 F in boiler return.Throttling valves are used for bypasspiping, if required.10
SYSTEM PIPINGFigure 8 - System Piping Arrangement Zoning With Zone Valves CIRCULATOR ON SUPPLY PIPING PUMPSAWAY FROM EXPANSION TANKNOTE: CIRCULATOR CAN ALSO BE INSTALLEDON RETURN PIPING. PIPING ARRANGED FOR “POWER PURGING”AIR OUT OF SYSTEM PIPING, REFER TOTHIS MANUAL’S SECTION ON “FILLING THESYSTEM WITH WATER” OPTION #111
SYSTEM PIPINGFigure 9 - System Piping Arrangement Zoning With Circulators CIRCULATOR ON SUPPLY PIPING PUMPSAWAY FROM EXPANSION TANK PIPING ARRANGED FOR “POWER PURGING”AIR OUT OF SYSTEM PIPING, REFER TOTHIS MANUAL’S SECTION ON “FILLINGTHE SYSTEM WITH WATER” OPTION #112
SYSTEM PIPINGFigure 10 - System Piping Arrangement Alternate Near Boiler Piping DIAPHRAGM EXPANSION TANK MOUNTEDOFF THE BOILER CIRCULATOR ON SUPPLY PIPING PUMPSAWAY FROM EXPANSION TANK13PER THIS MANUAL, USE OPTION #2 IN“FILLING THE SYSTEM WITH WATER” THIS PIPING ARRANGEMENT CAN BE USEDWITH ZONE VALVES OR ZONECIRCULATORS
SYSTEM PIPINGTankless Coil Piping ArrangementBoilers may be factory packaged with tankless heatercoil see figure below. Coil provides instantaneous heatingof water for domestic use if proper burner and water supplyline controls are used. Tankless coils are meant to providedomestic hot water for intermittent draws, not continuousflow.NOTICEDo not use tankless coil if your water is excessivelyhard with lime or other deposits which willaccumulate inside the coil.When using tankless coil, boiler is configured so HoneywellL7248 operates with Honeywell L4006 low limit mountedon well installed in tankless heater. Mount factory wired lowlimit on well.Tempering valve (mixing valve) is required as shown below.Flow restrictor may be required on tankless coil inlet pipingso that flow rates are matched to boiler heat input (seetable).!BoilerModelBurnerInputRate .201683.45BW5(B,R)AH-2451.752454.00‡ Gallons of water per minute heated from 40 F to 140 F with200 F boiler water temperature, intermittent drawDANGERWater temperatures exceeding 125 F will causesevere burns instantly or death by scalding.Figure 11 -Tankless Coil Piping Arrangement14
SYSTEM PIPING ARRANGEMENTAntifreeze added to boilers must be nontoxic, andmust be of type specifically intended for use in closedhydronic heating systems. Under no circumstancesshould automotive antifreeze be used. Antifreeze usedin any boiler may reduce capacity by 10% or more andincrease fuel consumption. Tankless coil performancewill fall as concentration of antifreeze is increased. Referto boiler and piping water volumes tables.PIPING WATER VOLUMESPIPE SIZE½”¾”1”1 ¼”1 ½”2”COPPER PIPEFACTOR82.540.023.315.310.86.2STEEL PIPEFACTOR63.536.022.212.89.55.8Divide total length of piping in feet by appropriate factorin table to determine volume in gallons.BOILER WATER VOLUMESNumber ofTotal VolumeBoiler Section(Gallons)39.6411.6513.715
CHIMNEY AND CHIMNEY CONNECTIONSFor oil fired boilers for connections to vents or chimneys,vent installations shall be in accordance with applicableprovisions of INSTALLATION OF OIL BURNING EQUIPMENT,NFPA31 latest revision, and applicable provisions of localbuilding codes.! WARNINGFire Hazard. Maintain minimum vent pipe clearanceof 18” from surface of vent to wood and othercombustible materials. Failure to comply may resultin death or serious injury.NOTICEFresh air (ventilation) is important to properventing. Ventilation and venting are two parts of thesame system. Inadequate ventilation will result ininadequate venting. Always be sure to have enoughventilation to support proper venting.Chimney Connector And Draft Regulator Venting the boiler requires 6” diameter chimneyconnector pipe and use of manufacturer provided draftregulator. Regulator, when properly installed, automaticallycontrols the draft. Install in horizontal section of pipe, may also beinstalled in angled or vertical section of pipe. Verify “top” of regulator is at the top and short pipesection which holds the vane is horizontal. Even though locating draft regulator close to chimneyreduces noise, install draft regulator as close aspracticable to the boiler. Install chimney connector, start at boiler with verticalpipe, elbow, then install draft regulator horizontally. When regulator is in place, start at chimney and workback to the regulator. Join the two sections with draw-band. Horizontal pipe must slope up toward the chimney atleast 1/4 inch per linear foot of venting. Chimney connector must not leak and must be firmlysupported. Join each section with at least two sheet metal screws.Support every second section with a stovepipe wire.Check your chimney to make certain that it is right size,properly constructed and in good condition.See Table “Recommended Minimum Chimney Sizes”.For additional chimney design and sizing information,consult the National Standard for Chimneys, Fireplaces,Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211.NFPA RECOMMENDED MINIMUM CHIMNEY SIZESFIRING RATE(gph)CHIMNEYHEIGHT (ft)NOMINALCHIMNEYROUNDLINER INSIDESQUARELINER INSIDE0.60 - 1.30158” x 8”6”6 ¾” x 6 ¾”1.31 - 1.80158” x 8”7”6 ¾” x 6 ¾”1.81 - 2.00208” x 8”8”6 ¾” x 6 ¾”For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.16
TYPICAL CHIMNEY CONNECTIONFigure 12 -Typical Chimney ConnectionMinimum height: Must be at least 3ft. (.9m) higher thanhighest part of passage through roof. Must be at least 2ft. (.7m) higher than anyneighboring object within 10ft. (3m). Must have unobstructed top opening.Must be at least 4 in.(101mm) thick- and be tight17
ELECTRICAL CONNECTIONS! WARNINGElectrical shock hazard. Turn OFF electrical power supplyat service panel before making electrical connections.Failure to do so could result in death or serious injury.ThermostatInstall 24 Volt thermostat (not provided) in proper location.Location of thermostat has effect on boiler system operation.Follow instructions included with thermostat.GroundingPermanently ground boiler according to local codes andlatest revision of the National Electrical Code. Run 14gauge or heavier copper wire from boiler to groundedconnection in service panel or properly driven andelectrically grounded ground rod.Electric Power SupplyInstallation must comply with the latest revision of theNational Electrical Code, any other national, state, or localcodes or regulations.Connect 115 volt electrical supply to L1 and L2 terminalson limit and two thermostat wires to T and T terminals onsame limit. See wiring diagram page 28.Run separate circuit from separate over current protectiondevice in your electrical service entrance panel. Minimum15 ampere circuit. Locate shutoff switch at boiler. Turn offduring any maintenance. Solder and tape or securely fastenconnections with wire nuts.Oil Burner WiringFor boilers packaged with oil burners, burners are wiredat the factory. For boilers shipped without a burner, wiringconnections are shown in the electrical wiring diagrams ofthis manual.18
FILLING THE BOILERHow A Hot Water System OperatesEntire heating system (boiler, piping, and radiation units)is filled with water. As water in the boiler is heated, itis circulated from top of boiler through supply main toradiation units. Cooler water in radiation units flows backthrough return piping through return main into the boiler.This arrangement provides positive and rapid response tothe thermostat.OPTION #2 Close air vents on all radiation units. Open valves to radiation units. Verify boiler drainvalve, expansion tank drain cock, and air bleed screwon expansion tank drain fitting are closed. Open fill valve on piping to expansion tank. Open water inlet to boiler and leave it open. Open air vent on lowest radiation unit. When all air has escaped and water starts to flow fromvent, close it. Go to next radiation unit, and repeat this process untilfinishing with highest radiation unit. If heating system has automatic vents, this manualventing is unnecessary but it will speed up proper fillingof the system.Filling The System With WaterOPTION #1 This method utilizes boiler piping as shown infigure on page 6.A. Close main shutoff valve, isolation valves, and zonevalves (if applicable). If bypass piping is installed,also close two throttling valves. Leave boiler serviceshutoff valve (if installed) and balancing valves toeach heating zone fully open.B. Open following valves in order: drain valve for powerpurging, isolating valves before and after boilercirculator (if applicable), both throttling valves (ifapplicable), and then open fill line shutoff valve. Waterwill fill bypass piping and push air through piping andout power purging drain valve. When power purgingdrain valve runs air free, close bypass piping throttlingvalve (leaving throttling valve to supply piping fullyopen).If system is a closed expansion tank system, automatic fillvalve is needed. Leave automatic fill valve open to refillsystem automatically as needed.Note initial fill pressure on boiler’s temperature / pressuregauge, which should be 10-15 psig. Any lowering ofpressure from its initial fill pressure indicates loss ofwater due to leakage. Automatic fill valve should thencompensate for this water pressure loss. If it does not,manually open this valve to refill system until needle isagain pointing to same pressure reading. Instructions arepackaged with valve.C. Next, open isolation valve (or zone valve) to firstzone. Water will fill piping and push any air out powerpurging drain valve. When power purging drain valveruns air free, close isolation valve or zone valve).Repeat this procedure for remaining heating zones.D. Once all zones are filled with water and purged of air,close power purging drain valve and fill line shut offvalve, open main shutoff valve, and adjust throttlingvalves and balancing valves as required.19
OPERATING THE BOILER Room used for supplying combustion air should beisolated from any area served by exhaust fans. Refer back to the section on Fresh Air For Combustionfor additional sizing guidelines.Start: Fill entire system with water. Vent all air fromsystem following section for Filling The Boiler.Fuel Units And Oil Lines: Install oil line(s) to oil burner. Recommend using heavy wall copper tubing andflared fittings, not compression fittings. All connections and joints must be absolutely airtight.Use an appropriate non-hardening thread sealingcompound on the threaded connections, not Teflontape. See fuel unit data sheet furnished with the burner forsizing, lift, and length of tubing recommendations.Draft Regulators: Barometric draft regulator is requiredfor controlling draft through boiler. Mount barometric draftregulator in chimney connector. Refer back to section on“Chimney And Chimney Connections”. Once draft regulatoris installed, use draft gauge to adjust to proper opening:A. Combustion chamber over fire draft will beapproximately -0.01” WC to -0.02” WC.B. Stack draft will be approximately -0.02” WC. to-0.04” WC.C. Larger installation, greater draft will be required instack to obtain desired over fire draft.Oil burner is equipped with single stage fuel unitwith bypass plug removed for single pipe installation.Satisfactory where fuel supply is on same level as orabove burner permitting gravity flow of oil. Per NFPA 31requirements, never exceed 3 psig pressure to inlet side offuel unit.W
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