Gas-Fired Hot Water Induced Draft Boilers

1 FSB SeriesGas- fired Hot Water Induced Draft BoilersINSTALLATION, OPERATION & MAINTENANCE MANUALP/N 1305002 Rev. B [11/09]RAn ISO 9001-2000 Certified CompanyPennco Boilers85 Middle , NY 140482 Tested for 50 lbs. ASME Working Certified for Natural gas or PropaneThe following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk Instructions ..3 boiler Ratings And Capacities ..3 Before You Start ..4 Locating The boiler ..5 Fresh Air For Combustion ..6 Installation System Piping ..10 Chimney & Vent Pipe Connection ..12 Horizontal Venting Instructions .. 15 Optional Horizontal Venting Instruction .. 20 Gas supply Piping ..21 Electrical Wiring .. 22 Sequence of Operation .. 22 Wiring Diagrams .. 23 Equipment & Optional Accessories .. 24 Starting Your boiler .. 26 Checking and Adjusting ..27 Initial Operational boiler Test Check-Out Procedure.

2 29 Maintaining Your boiler ..31 Service 32 TABLE OF CONTENTSSAFETy SymBOLSNOTICEIMPORTANT: Read the following instructions COM-PLETELY before installing!NOTICEKeep this manual near boiler and retain for future refer-ence.! DANGERI ndicates an imminently hazardous situation which, if not avoided, WILL result in death, serious injury or substantial property damage.! WARNINGI ndicates an imminently hazardous situation which, if not avoided, may result in death, serious injury or substantial property damage.! CAUTIONI ndicates an imminently hazardous situation which, if not avoided, may result in injury or property information which should be followed to ensure proper installation and 1 -RATINGS NATURAL AND PROPANE GASESM odelNumber of SectionsAGA/CGAI nput *MBHH eating Capacity *MBH+Net IBR Rating *MBHW idth AVent Diameter (Inches)To Chimney(Category I)Horizontal Vent(Category III) * MBH = 1,000 Btuh = British Thermal Unit Per Hour.

3 Boilers are equipped for altitudes up to 2,000 feet only. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level. Canada Only - Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10% de-rate.+ Heating Capacity based on (Department of Energy) test CERTIFIED FORNATURAL AND PROPANE GASHThis boiler cannot be used with all types of chimneys. Read these instructions carefully before Gas-Fired Hot Water Boilers are low pressure, sectional cast iron Boilers Design Certified by (Canadian Standards Associ-ation) for use with Natural and Propane Gases. They are constructed and hydrostatically tested for a maximum working pressure of 50 psi in accordance with boiler and Pressure Vessel Code Sec-tion IV Standards for cast iron heating york City mEA Number 484-84-E Vol.

4 Ratings marked Net I=B=R Ratings indicate the amount of re-maining heat input that can be used to heat the radiation or terminal units. The Net I=B=R Ratings shown are based on an allowance of in accordance with the factors shown on the I=B=R Standard as published by The Hydronics of boiler size should be based upon Net I=B=R Rating being equal to or greater than the calculated heat loss of the manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup INSTruCTIONSBOILEr rATINgS ANd CApACITIES! WARNINGI mproper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or information consult a qualified installer, service agency or the gas 1 - boiler ratings and CapacitiesThese instructions must be affixed on or adjacent to the to be sure you have the right size boiler before starting the installation.

5 See rating and capacity table on previous page. Also be sure the new boiler is for the type of gas you are using. Check the rating plate on the right side of the that the boiler is supplied with the correct type of gas, fresh air for combustion, and a suitable electrical supply. Also, the boiler must be connected to a suitable chimney or horizontal venting system and an adequate piping system. Finally, a thermostat, properly located, is needed for control of the heating system. If you have any doubts as to the various requirements, check with local authorities and obtain professional help where needed. Take the time to complete all of the steps for SAFE and PROPER operation of the heating this boiler is installed in a building under construction, special care must be taken to insure a clean combustion air supply dur-ing the construction process. Airborne particulates such as from drywall dust and from fiberglass insulation can clog the burner ports and cause incomplete combustion and sooting.

6 Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically fired Boilers , No. installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Canada, the boiler shall be installed according to and .2, Installation Code for Gas Burning Appliances and For use At High AltitudeThis boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level, the input ratings are reduced by a change in main burner orifice Only - For altitudes above 2,000 feet above sea level, input ratings should be reduced at the rate of 4% for each 1,000 feet above These Boilers must stand on a noncombustible floor.

7 If installed on a combustible floor, please refer to the Repair Parts manual for the appropriate Combustible Floor Base part number. These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron Boilers Design Certified by CSA (Canadian Standards Associa-tion) for use with Natural and Propane Gases. They are constructed and hydrostatically tested for a maximum working pressure of 50psi (pounds per square inch) in accordance with (American Society of Mechanical Engineers) boiler and Pressure Vessel Code Section IV Standards for cast iron heating level. Consult the National Fuel Gas Code (NFPA54/ANSI revision), or the manufacturer for correct orifice siz-ing information. High altitude orifices are available from the boiler Only - For altitudes in the range of 2,000-4,500 feet above sea level, Boilers may be field equipped for use at high altitude by using a certified field conversion kit.

8 The change in main burner orifice size results in the boiler s input rating being reduced by 10%.The conversion shall be carried out by a manufacturer s authorized representative, in accordance with the requirements of the manufac-turer, provincial or territorial authorities having jurisdiction and in accordance with the requirements of the and Installation Codes. The certified field conversion kit includes a conversion data plate, which must be attached to the boiler adja-cent to the rating plate, indicating that the boiler has been converted for high altitude use. The conversion data plate must be filled in with the correct conversion - Follow local regulations with respect to instal-lation of CO detectors. Follow maintenance recommenda-tions in this instruction boiler area clean and free from combustible materi-als, gasoline and other flammable vapors and liquidsBOILEr rATINgS & CApACITIESBEFOrE yOu STArT5If the boiler is part of a planned heating system, locate it where shown on your plan.

9 If boiler is to be part of an existing system, it is usually best to put it where the old one was. If you plan to change location, you will need additional materials as well as an adequate base. The following rules apply:The boiler must be level. Metal shims may be used under base 1. legs for final a raised base if floor can become wet or The vent pipe connection should be as short as Additional clearances for service may exceed clearances for fire 4. protection. Always comply with the minimum fire protection clearances shown on the boiler . An 18 inch clearance should be maintained on any side where passage is required to access for cleaning, servicing, inspection or replacement of any part that may need attention. An 18 inch clearance is recommended on the control side for servicing. Figure 2 and Table 2 shows minimum clearances to combustible construction.

10 Consult the National Fuel Gas Code for further information. Equipment shall be installed in a location in which the facilities 5. for ventilation permit satisfactory combustion of gas, proper venting, and maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced (see Fresh Air for Combustion ).Advise owner to keep air passages free of obstructions. Ven-6. tilating and combustion air must enter boiler room without floor supporting the boiler must be noncombustible. If it is 7. combustible, please refer to Repair Parts List for the appropriate Combustible Floor Base part number. We use a 2 Cladlite pad as a combustible floor base. These are available from your local supplier.