Residential • Gas fired • Hot Water Boilers User’s ...

1 Residential Gas fired Hot Water BoilersUser s information ManualBobcat Direct-Vent Sealed Combustion Condensing BoilerModel B-120A and B-200 AFORYOURSAFETY: Before operating this boiler , READ this manual . DO NOT attempt to install, service or repair this boiler yourself. There are no user serviceable parts. Contact a qualified service agency if your boiler needs repair or maintenance. Ask your gas supplier for a list of qualified service agencies. A qualified service agency should inspect the venting system of this boiler on an annual store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other DO IF YOU SMELL GAS DONOTtry to light any appliance. DO NOT touch any electrical switch DO NOTuse any phone in your building. Immediately call your gas supplier from a neighbor s phone. Follow the gas supplier s instructions. If you cannot reach your gas supplier, call the fire and service must be performed by a qualified installer, service agency or the gas : If the information in this manual is notfollowed exactly, a fire or explosion may resultcausing property damage, personal injury or lossof gas boiler must be installed and serviced by a qualified service agency or lack of proper service can result in a dangerous manual must be left with owner, hung on oradjacent to the should retain manualfor future in 808 Part No.

2 86-5757000 Publication No. BA-UIM Bobcat Model B-120A and B-200A2 WELCOME TO OUR VALUED CUSTOMERYou are now the owner of a Slant/Fin Bobcat series gas-firedboiler, another quality heating product designed and manu-factured by an industry leader, to provide your family withmany years of reliable comfort and trouble-free care and maintenance of your new boiler is important toprevent a hazardous condition which might result form lackofproper servicing. Therefore, you should perform regular owner inspections as described in this manual (and reportany concerns to a qualified service technician) as well ashave your boiler serviced by a qualified service technician atleast once a year, preferably before the beginning of eachheating , read and then follow the procedures on the lightinginstructions label attached to the boiler . For reference, wehave reproduced those instructions in this NOT use this boiler if any part has beenunderwater.

3 Immediately call a qualified servicetechnician to inspect the boiler and to replaceany part of the control system and any gascontrol which has been overheating occur or the gas supplyfail to shut off, DO NOT turn off or disconnectthe electric supply to the circulator ,shut off the gas supply at a locationEXTERNAL to the DOES NOT PERMIT THE USE OFVENT DAMPERS ON BOBCAT B-120 or B-200 SERIES DAMPERS ORDEVICES WITH SIMILAR PURPOSE ARE NOT the boiler area clean and free of all materials that can close or reduce openings that supply air for the boiler fire and for 1. Location and identification of parts. (model 120A shown)Bobcat Model B-120A and B-200A3 INSPECTIONYour boiler and heating system will last an indefinitely longtime at full efficiency, if it is inspected regularly and is keptin good repair and adjustment. You, the user , should makeregular inspections, and report any problems to your service agency. At regular intervals, you should have thatagency inspect the system and make repair adjustments asnecessary.

4 What you and the service agency should do islisted below. Contact your gas supplier for a list of qualifiedservice and repair INSPECTIONThe user should make the following inspections at leastonce each month during the heating season and once justbefore cold weather starts. Bobcat B-120 and B-200 boil-ers may be installed and vented either as direct-vent boil-er, which all air for combustion is obtained directly fromoutside through the air intake piping or as non-direct-vent boiler , which all air for combustion is taken frominside the boiler room. Typical direct-vent installations areshown on Figures 2 and 3. Non-direct-vent installation isshown on Figures 4, 5 and VENTING AND AIR INTAKE SYSTEM REGULARINSPECTIONI nspect the system regularly for condensation, corrosion,sagging and/or physical damage. A qualified professionalshould service the boiler annually and include such aninspection at that time. The homeowner should look over thesystem monthly for damage, Water stains, any signs of rust,other corrosions or separation of the vent and air intake piping (if direct-vent).

5 Should an inspection turn up signs of condensation, corrosion, sagging or damage, the boiler should be shutdown immediately and the condition should be corrected bya qualified the boiler is vented horizontally through the wall, the outside termination, louvers and screen should be checkedfor any debris blocking the opening and cleaned INTAKEPIPE3 PIPEOUTSIDEWALLVENTTERMINATIONOUTSIDETER MINATIONPANELF igure 2. Direct vent, sidewall venting INTAKE3 PIPE3 INTAKEPIPEF igure vent,venting and air intake through a Model B-120A and B-200A43 IN. INTAKE(DO NOT BLOCK)VENTTERMINATIONOUTSIDE WALLF igure 4. Non-direct vent, sidewall Model B-120A and B-200A5 Figure vent,venting through the INTAKE(DO NOT BLOCK)Figure 6. Non-direct vent, utilizing an existing chimney as a PLATE3 INCH INCH INTAKE(DO NOTBLOCK)UNUSEDCHIMNEYVENTTERMINATIONB obcat Model B-120A and B-200A62. CONDENSATE REMOVAL SYSTEMThe Bobcat B-120 and B-200 Boilers are equipped witha built-in condensation drain and trap.

6 The trap must befilled with Water . DO NOT operate the boiler without fill-ing the trap with Water to prevent flue gas discharge intospace. Periodic inspection should be made of thisassembly for deterioration of the tubing and to insurethat the trap is not it is plugged or appears tohave excessive sediment in it, it should be removedfrom the drain assembly, straightened out to clear theobstruction, reformed, filled with Water and reinstalledas before. (See Figure 7).Leave the top of the condensate drain tee open, to actas a vacuum breaker. Do not allow any part of the condensate removal system to be exposed to freezingtemperatures, or any other conditions that could a neutralizing system is installed, the filter medium willrequire periodic changing, to ensure it s to the neutralizing unit s manufacturers instruc-tions, if available, or change the medium on an PIPING INSPECTIONLook at all Water should be no leaks orsigns of leaks at any pipe joints or around the SYSTEM Water PRESSURE INSPECTIONThe boiler Water pressure is indicated on the pressuregage (See Figure 1 for location).

7 The boiler Water outlettemperature is normally indicated on the temperaturedisplay (See Figure 1 for location and Figure 9 for digitsillustration). For most installations, it should indicateabout 12 to 15 psi pressure when temperature is about70 to 100F and from 15 psi to 25 psi when temperatureis up to 195 F. FOR YOUR SYSTEM, there is one correct pressure for each temperature. ASK YOURINSTALLER OR SERVICEPERSON TO EXPLAIN ANDSHOWYOU. Learn what normal pressure to look for. Ifpressure increases from normal, the relief valve willopen to relieve the your service organiza-tion if pressures are higher or lower than normal, and ifthe relief valve spills Water . Repair or adjustment UNUSUAL NOISES tand near the boiler and look and the burnerstart and shut off, there should be no unusual SUPPLYA mple boiler room fresh air is required for combustion(non-direct vent installation) and ventilation (direct-ventinstallation).Check air vents for continues positive supply of air asrequired.

8 Air needs are greatest in cold weather if boilerinstallation is non-direct vent method. Air vents must beopen and free of :The flow of combustion and ventilating air to theboiler should not be :If you find any problem during your inspection, callfor service 7. Condensate disposal systemCONDENSATE TRAP,FILLED WITHWATERDRAIN VACUUMBREAKER, LEAVEOPENNEUTRALIZINGUNIT(IF REQUIRED)PLASTICTUBINGCONDENSATEPUMP(IF REQUIRED)DRAININSIDEBUILDINGB obcat Model B-120A and B-200A7 The combustion air supply must not be susceptible tocontaminants, which may cause corrosion or other damage to the heat exchanger and components of theboiler, causing failure of these parts or unsafe is a list of products which must be avoided frombeing stored or entering the boiler room or air supplyarea:PRODUCTS TO AVOID Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for Water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid/muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, detergents and cleaning solventsfound in household laundry rooms.

9 Adhesives used to fasten building products and other similar SERVICE AND GENERAL MAINTENANCEA trained and qualified service technician should perform inspection and general maintenance listed inInstallation and Operating Instructions (Publication ) before each heating season and at regular INSTRUCTIONSF ollow the lighting instructions in this manual . Theseinstructions are also attached to the INFORMATIONFor Your Safety Read Before OperatingA. This appliance does not have a pilot. It is equipped withanignition device which automatically lights the nottry to light the burner by BEFORE OPERATING smell all around the appliancearea for gas. Be sure to smell next to the floor becausesome gas is heavier than air and will settle on the DO IF YOU SMELL GAS: Do nottry to light any appliance. Do nottouch any electric switch:do notuse anyphone in your building. Immediately call your gas supplier from a neighbor sphone. Follow the gas supplier s instructions.

10 If you cannot reach your gas supplier, call the Use only your hand to turn the gas supply shut off valve. Never use tools. If the supply shut off will not turnby hand, don t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or NOTuse this appliance if any part has been under Water . Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under INSTRUCTIONS1. STOP! Read the safety information Set the thermostat to lowest Turn off all electric power to the This appliance is equipped with an ignition devicewhich automatically lights the nottry to lightthe burner by Open the gas supply shut off valve, by turning the handle to be parallel to the gas piping. (See Figure 8).6. Wait five (5) minutes (longer for propane) to clear out any gas, then smell for gas, including near the floor.