C-SERIES BOILER - NATCO

1 1C- series BOILERINSTALLATION AND OPERATION MANUALMODEL #:BURNER MODEL #:SERIAL #:BURNER SERIAL #:NATIONAL BOARD #:DISTRIBUTOR:National Combustion Co., 180thStreetJamaica, NY 11433Ph: 718-291-8400Fx: : BOILERINSTALLATION AND OPERATION MANUALT able of ContentsGeneral Information3 BoilerRoom / Chimney4 Dampers / Makeup Air5 Parts and Installation6-8 Front BOILER Diagram9 Rear BOILER Diagram10 Wiring & Burner Installation11-12 Filling, Flushing and Maintenance13-14 Notes on op. pressures & softeners15 Control of Oxygen Corrosion of Tubes16-19 Limited Warranty203 WHATISANATCO?TheNATCO isamodifiedScotchMarineboilerthatisspeci ficallydesignedtobeusedas throughasubmergedtanklesscoilanditsoutle ttemperatureiscontrolledbyan optionalthermostatic , ,whenheated, ,and :Beforeinstallation,checkwithbuildingdep artmentandanyothercityorgovernmentagenci eshavingjurisdiction;suchasFireDept.

2 ,SmokeAbatementCommission,BuildingInspec tor,etc., ' ' , , ,pressure controls,thesafetyreliefvalve, , , tightroomisnecessarysoifforanyreasonthep roductsofcombustiongointotheboilerroom, :Thechimneymustbeconstructedinaccordance withalllocalcodesandifSmoke Abatementrulesareapplicable, ,thefumesmustbepreventedfromenteringtheb oilerroom,forwhenPercisburned,verycorros iveandtoxicgasesareformed whichinadditiontobeingdangeroustohumanli fe,quicklyattacktheburner, , :BarometricDampersarehelpfulforfuelecono mywhenthereis positivepressureintheboilersandunlessthe chimneyislargeandtall, , , , , :Itismostimportantthattheboilerroombecon structedtoprovideadequatemakeup , ,iflouversorscreensareused, , , following tables indicated the sizes of fresh air openings required forvarious NATCO Air Guidelines, NATCO BoilersNATCOS quare InchesDiameter, SingleSquare InchesModel#Gas Input, MBTUOil Input, GPHT otal Fresh Air OpeningFresh Air THE BOILER FOR MISSING OR DAMAGED ITEMS:The following items come equipped on theboiler.

3 -Steel jacketing covering a 2 fiberglass burner mounting plate covering a burner refractory peep-site front inspection plate insulated by copper heat exchanger with a steel or bronze following items come in a separate parts box:-A brass piping assembly including:oA brass pigtailoA brass teeo2 brass nippleso1 brass elbowo1 brass street-elbow-A iron piping assembly including:oAn iron nippleoAn iron teeo2 iron PA404A Operating Pressure Control-Honeywell L4079B Manual Reset Pressure Control w/ brass McDonald and Miller PS801-120 Operating Low Water Cutoff-Pressure Gauge-ITT McDonald and Miller PS851M-120 Manual Reset Low Water Cutoff-Gauge Glass & Gauge Cock Assembly-Dial Thermometer-2 Air VentsThe following items are optional items.

4 -Tempering Valve-Automatic Water Feeder-Magnesium Anode Rod(s)ASSEMBLE AND INSTALL and install the air vent Teflon tape ateach connection, attach nipple on center of tee and street-ells onsides of install air vents so that they are facing air vents on assembly first, and then install entireassembly on the R1 (on diagram)connection on the top ofthe BOILER closest to therearof the BOILER (burner mountingside). the steam outlet. If the steam outlet is not being utilized,cap it with a plug of appropriate pop safety relief valveon R2 on the diagram. We suggestthat you pipe the outlet to the floor or a not reducethe outlet piping from the initial size of the relief valveoutlet.

5 For example, if the relief valve has a2 outlet,your drain-off piping should be 2 Honeywell L4079B to desired redundant secondary highlimit. Usually, this should be set between 12 and 15 PSI. UsingTeflon tape, attach control to a brass pigtail and attach tolocationR3 onthe diagram of therearof the the PA404A operating pressure control setting anddifferential. The setting for the pressure is on the outside of thecontrol. It is important that the setting is lower than the settingfor the L4079B manual reset most applications, setthe cut out to 9 PSI, and the differential to 2 PSI. Thedifferential is set underneath the Teflon tape at each connection, assemble the brassassembly first before installing.

6 Attach the centeroutlet of thetee to the end of the brass pigtail. Then attach the nipples tothe brass tee a street ell to one nipple and anelbow to the other the pressure control into thestreet-ell, and the pressure gauge to the elbow. Attach theassembly toR4 on theRearboiler diagram (below). the gauge glass assembly with gauge cocks onto the twoconnections indicated by F3 on the front BOILER the PS801-120 operating Low-water cutoff at location F2onthe front BOILER diagram. It is important that the operating(automatic reset) control is installed at the the PS851M-120 manual reset Low-water cutoff atlocation F1 on the front BOILER THEBURNER:The burner must be mounted to the included mounting flange so theincluded burner flange is bolted flush to the mounting flange.

7 Burners mustbe installed,and fired by qualified burner professionals. Burnerprofessionals can pipe fuel according tothe instructions in the includedburner installation manual. Professionals shall fire burner and checkrequired readings as required by the included THE BOILER /BURNER:All wiring must be installed by a qualified include an interlock circuit that allows the BOILER controls to havean effect on the firing of the burner. Check the burner installation manual orwiring diagram for the location of this circuit. If you need help locating this,contact are two ways of wiring the BOILER : the included burner interlock circuit, wire from theburner interlocksupplyto (i) the PS801-120, (ii) the PA404A operating control, and(iii) back to the return on the burner an isolation relay so that there is 115V on the control side,and appropriate supply voltage on the other side (depends on theburner), wire the L4079B manual reset pressure control and PS851M-120 Low Water Cutoff in series so that if there is a break in the circuit,no power will be supplied to the burner.

8 Think of this circuit as anautomatic emergency switch to shut off power to the :On the included burner interlock circuit, wire from the burner interlocksupply to the following inseries: (i) the PS851M-120, (ii) the PS801-120,(iii) the L4079B, (iv) the PA404A, and (v) to the burner interlock first method is preferred, because if the burner interlock fails or is leftjumped through negligence, a dangerous condition YOUHAVE ANY QUESTIONS PLEASE CONTACT NATCO FOR :Theburnerincludedisdesignedasaforceddra ftburnercapableofsupplyingallairforcombu stionagainstpositivefurnacepressurenotov er1/2"watercolumn. totalareanotlessthan1squareinchforeach2, :Thestandardgascontrolsaresizedtopassthe maximumburnerratewith6" Controlsareavailableforhigherand ,checkoutandserviceofthegasburnershouldb edoneonlybyaqualified, ,gaspressurereadingequipment,stackthermo meter,and a ,so that noforeignmaterialsareallowedtoenterthega sline.

9 Thereshouldbeafullsize"drip"pipe(ordirtp ocket) ,pipingshouldbeaccordancewith AmericanStandardRequirementsofInstallati onofGasEquipmentinLargeBoilers( )13 PRECAUTIONSTOTAKEWHENHIGHPRESSUREGASINTH ESTREETISREDUCEDTOLOWPRESSUREGASINTHEBUI LDING:Whenhighpressuregasinthestreetisre ducedtolowpressuregasinthebuilding, reducingfrom5or10 PSItoinches,verylittletroubleisencounter ed, , :besurethechemical , ,whateverimpuritiesthatwereinthewatersoo ncombinewiththemetal, ,itmaybenecessarytoflushtheNATCO moreoftenanditmayevenbenecessarytoprovid earegularboilercleaning , considerableamountofmake-upwatertotheNAT CO tocompensateforsteamlosses, , "OperatingInstructionfortheControlofOxyg enCorrosionofBoilerTubesoftheNATCO.

10 "14 CHECKALLCONNECTIONSANDFILLNATCOWITHWATER :Becertainthatallunusedoutletsareplugged ( NATCO doesnotsupplyanyplugswiththeboiler) (regulartapwater).Never fill the NATCO with softenedwater, which is extremely thewaterlevelisabout1" , , ,theboilerisairbound, , , ,checkthelow , (atleastonceayear) :WhentheNATCO isoperatingasawaterheater,onlysettheHone ywellPA404 Atocutoutat9 PSIand set the differential to 2 codepermitsit,operatebetween11 and , 4 PSI ,ifthecodepermits,13 PSIcut-outanda 6 , :Water softeners should never be used for filling the steel body of the boilerwith prime water. However, water softeners are very useful for water thatenters the heat exchanger the heated , ,thetemperatureandvolumeoftheheatedwater isimmediatelyreducedandeventually,acompl etestoppage can take , ,forunlessautomaticcontrolsaretestedandc heckedperiodically, you require an automatic water feeder, please contact NATCOso we cansize an appropriate model for your :TheNewYorkStateCode(andsomeotherstates) now include a L4079B Manual Reset Pressure Control asstandard.