INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SPACEMASTERTM D I R EC T VEN T N AT U R A L GAS - FI RED BOI LER F o r s e r vi c e o r r e p a i r s to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r. W he n s e e k i ng i nfo r m a ti o n o n b o i le r, p r o vi d e B o i le r M o d e l Num b e r a nd S e r i a l Num b e r a s s ho wn o n Ra ti ng L a b e l.
IMPORTANT INFORMATION PLEASE READ THIS PAGE CAREFULLY This boiler has a limited warranty, a copy of which is printed on the back page of this manual. Post instructions near boiler for reference by owner and serviceman. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler. Maintain instructions in legible condition.
SPACEMASTER WALL MOUNTED GAS BOILER – DIMENSIONAL DATA Figure 1 MAXIMUM DESIGN WORKING PRESSURE – 45 PSI; WATER ONLY Table of Contents I. II. III. IV. V. VI. General Installation Requirements ................... 4 Installation Instructions ..................................... 7 Operating Instructions ....................................... 13 Service ................................................................. 23 Repair Parts ........................................................
I. General Installation Requirements 1 INSPECT SHIPMENT carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of Boiler to the carrier in good condition. Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment.
a. Combustion air is provided 100% from the outdoors. Air is pulled in on all four sides of vent terminal cover, through the air intake duct and to the combustion area enclosure. The vent terminal must be mounted on a flat surface which is flush or protrudes outward from the exterior wall. Avoid recesses, niches or areas which might have reduced fresh air circulation. b.
TABLE I *NOTE – For all practical purposes, each 90° elbow can be considered as the following equivalent in length of straight pipe: ½” – 1.6 ft. 1” – 2.6 ft. ¾” – 2.1 ft. M a xi m um C a p a c i ty o f P i p i ng i n C ub i c F e e t o f Ga s P e r Ho ur ( B a s e d o n a P re s s ure D ro p o f 0 .3 " Wa te r a nd 0 .
II. Installation Instructions DETERMINE BEST MOUNTING LOCATION for boiler which meets site requirements outlined in Section I, pages 4 through 6. 1 INSTALLING BOILER MOUNTING WALL BRACKET (See Figure 5). a. Locate wall bracket packed in miscellaneous parts carton. b. Hold wall bracket in desired location. On studded walls, mounting bracket must be secured directly to main vertical support studs. Interior wall coverings such as paneling, plaster and drywall are not suitable to support the unit’s weight.
h. Secure boiler to boiler mounting wall bracket with five (5) ¼”-20 x ¾” long machine screws and washers provided. NOTE: Tools required — 7/16” socket, extension bar(s) and drive ratchet i. Secure interior telescoping intake air duct to back plate of boiler. Pull duct forward until duct and weld studs are engaged through 4½” x 5½” rectangular opening and holes in back plate. Make sure gasket is in place and flat against back plate.
b. Drill four (4) pilot holes, properly sized for the non-corrosive fasteners (stainless steel, brass or aluminum) to be used to secure the wall flange to wall. c. Attach four (4) ½” long threaded aluminum spacers to the outer flanges of the exterior telescoping intake air duct wall flange with four (4) #10-32 x ¼” long stainless steel machine screws provided. (See Figure 5). d.
e. A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation. If a low water cut-off is required, it must be mounted in the system piping above the boiler. The minimum safe water level of a hot water boiler is just above the highest water containing cavity of the boiler; that is, a hot water boiler must be full of water to operate safely. f.
Figure 7 RECOMMENDED PIPING FOR COMBINATION HEATING & COOLING (REFRIGERATION) SYSTEMS Figure 9 EXPLODED JACKET ASSEMBLY 11
support the removable door. (See Figure 9). Place jacket top panel over top side panels with ventilation louvers to the left. Secure top panel with four (4) #8 x ½” long sheet metal screws provided. e. Lift jacket bottom panel up to bottom of side panels with front channel forward and ventilation louvers to the left. Secure bottom panel with four (4) #8 x ½” long sheet metal screws provided. f. Install jacket removable door. Hold door parallel with top of door slightly above flat top panel.
III. Operating Instructions Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13. 1 INSPECT INSTALLATION BEFORE STARTING. 2 INITIAL START c. Be sure that gas to pilot and main burners has been off for at least five minutes. d. Open valve on main gas line at meter. e. PURGE AIR FROM GAS PIPING.
NOTE: YOUR BOILER IS EQUIPPED WITH A HONEYWELL VR8204 OR VR8304 GAS VALVE.
Figure 11 SCHEMATIC WIRING DIAGRAM
Figure 12 LADDER WIRING DIAGRAM 16
SEQUENCE OF OPERATION 1. When the thermostat calls for heat, relay coil (1M) is energized closing two sets of NO contacts. One set (1M2) energizes the 24 volt limit circuit and the other set (1M1) completes the 120 volt circulator circuit. 2. With the thermal cutout switch (on the burner access panel), the high limit switch, and the suction pressure switch in their normally closed positions, the fan relay coil (2M) is energized closing two sets of NO contacts.
TROUBLE SHOOTING Use the Trouble Shooting Guide (pages 19 to 21) to assist in locating where a malfunction in the control system is occurring. 4 PROCEDURE FOR MEASURING FAN DIFFERENTIAL PRESSURE (See Figure 13). a. With boiler off, remove black silicone tubing from low side of pressure switch. b. With tee and ¼” aluminum stubs, connect manometer as shown with additional tubing. c. Start boiler and read differential pressure on manometer. Should be -0.6” wc or greater (example -0.7” wc). d.
6 7 8 9 10 MAIN BURNER FLAMES should have a clearly CHECK PILOT FLAME. Flame should be a blue medium hard flame enveloping approximately 3/8” of the end of the sensing probe, see Figure 14. defined inner cone, see Figure 15, with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and stop burners. 11 CHECK LWCO OPERATION (if so equipped).
IV. Service 1 GENERAL — Inspection should be conducted annually. Service as frequently as specified in paragraphs below. While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be “off.” brush flueways thoroughly from top of boilers as illustrated in Figure 16. Replace canopy and seal. 4 BURNERS AND FIREBOX SHOULD BE CLEANED ANNUALLY a. Remove jacket front panel. CAUTION b.
where conditions warrant) to flush out the sediment chamber so the device will be free to function properly. Low water fuel cutoffs and water feeders should be dismantled annually by qualified personnel, to the extent necessary to insure freedom from obstructions and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc. and clean as required.
Im p o r t a n t P r o d u c t S a fe t y In fo r m a t io n R e fr a c t o r y C e r a m ic F ib e r P r o d u c t Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. After this product is fired, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health.
V. Repair Parts All Spacemaster™ Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408. A ny p a r ts no t li s te d c a n b e o r d e r e d b y d e s c r i p ti o n o r p a r t num b e r o n the i te m . Part No. 81660145U 1.
VI. Low Water Cut Off (LWCO) WAR N IN G D O N OT AT T E M P T to c u t fa c to r y w ir e s to in s ta ll a n a fte r m a r k e t L o w Wa te r C u t Off (LW C O). On ly u s e c o n n e c tio n s s p e c ific a lly id e n tifie d fo r L o w Wa te r C u t Off. In a ll c a s e s , fo llo w th e L o w Wa te r C u t Off (LW C O) m a n u fa c tu r e r ' s in s tr u c tio n s .
Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS Subject to the terms and conditions set forth below, U.S. Boiler Co., Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1,1991: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS U.S. Boiler Co., Inc.
