Installation OUTDOOR PRESSURIZED BOILER Models: 6150, 6200, 6300, 6490 INDOOR PRESSURIZED BOILER Models: 6130NS, 6150NS, 6200NS, 6300NS, 6490NS www.royallfurnace.
Thank you for purchasing a ROYALL pressurized Solid Fuel appliance. Boilers are a quality Solid Fuel Appliance designed to effectively heat structures. Please read and follow all safety instructions to ensure optimal performance. The installation and operation of the is quite simple. Nevertheless, we recommend that the instructions be carefully read and followed. On INDOOR models, pay particular attention to the chimney and chimney connector installations as they present a significant fire danger.
PRODUCT REGISTRATION CARD Warranty is in effect from the date of purchase upon receipt of this card. NAME STREET ADDRESS CITY STATE ZIP CODE PHONE EMAIL ADDRESS DATE OF PURCHASE MODEL NUMBER SERIAL NUMBER DEALER CITY STATE Reason for choosing Royall over other brands __Price __Features __Safety __Previously owned Royall __Recommended to you __Other PRODUCT REGISTRATION CARD Warranty is in effect from the date of purchase upon receipt of this card.
OWNER’S REGISTRATION CARD MUST BE COMPLETED AND RETURNED T0 ROYALL AT TIME OF INSTALLATION.
CONTENT GENERAL SAFETY.................................................................................................................................................. Pg 4 PRESSURIZED BOILER SPECIFICATIONS.......................................................................................... Pg 5 PRODUCT DESCRIPTION.................................................................................................................... Pg 6 INSTALLATION INSTALLATION TIPS................................
SAFETY NOTICE ALL STATE or LOCAL CODES take precedence and MUST be observed. These models have been certified compliant to UL 391-06 through independent testing. Additionally, some of these recommendations align with the National Fire Protection Assign. Code 211. Before installing or starting operation, read and familiarize yourself with all instructions. Installation is to be performed only by qualified licensed heating professional.
APPLIANCE OPERATION: Before opening the fuel door to a fired system, ensure that the draft blower is OFF, the damper rod is pulled out, wait 5-10 seconds, and ALWAYS hesitate momentarily between the first and second latches when opening doors to allow unburned gases to ignite. Failure to do so could result in severe burns. DO NOT • Block flow of combustion or ventilation air to the appliance. • Turn off the water circulation pump or prevent fluid flow during operation.
PRODUCT DESCRIPTION The Indoor/Outdoor Solid Fuel Boilers are designed to burn either seasoned, split cord wood or coal. A water circulating pump moves the heated water to a heat exchanging device. This can be a base board radiator, finned based board radiator, water to air exchanger, or existing boiler system; with the correct safety apparatus installed to local codes. The wood fire combustion process is controlled by an aqua stat that senses exiting water temperature.
INSTALLATION TIPS AVOIDING AIR LOCKS All ROYALL Solid Fuel Boilers are designed not to exceed 30 psi, and will vent to the atmosphere if necessary. Air trapped in the lines prevents circulation. Poor circulation is a common start up problem. Reduced flow can be difficult to detect because the pipes will feel hot. It is essential to provide a means for the air in the lines to escape as the system is being filled.
INSTALLATION PLACEMENT IMPORTANT NOTE • • CHECK WITH INSURANCE COMPANY PRIOR TO INSTALLATION. IT IS THE OWNER’S RESPONSIBILITY TO ENSURE THAT THE APPLIANCE IS ACCEPTABLE TO THEIR INSURANCE CARRIER. VERIFY LOCAL CODES AND ORDINANCES PRIOR TO INSTALLATION. IT IS THE OWNERS RESPONSIBILITY TO ENSURE THAT THE APPLIANCE MEETS ALL LOCAL CODES AND ORDINANCES WHICH TAKE PREEDENCE AND MUST BE OBSERVED PROVIDING THEY ARE MORE RESTRICTIVE.
CONTENTS INSTALLATION: CLEARANCES – INDOOR MODELS The Indoor boiler must be installed with these minimum clearances from NON-COMBUSTIBLE surface: Front = 30”/ Back = 30” / Sides = 12” The Indoor boiler must be installed with these minimum clearances from any COMBUSTIBLE surface: Front = 48”/ Back = 30” / Smoke pipe / Sides = 18” Recommended maintenance clearances = 18” Back 30 / one side 36 DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
CONTENTS (CONT.) INSTALLATION: INSPECTING CONTENTS BOXED COMPONENTS SHIPPED LOOSE INSIDE (component illustrations located in repair parts section) ROYALL INDOOR BOILER Fire Brick Aquastat Pressure and Temperature Gauge Draft blower and gasket Pressure Relief Valve Spring Handles for doors, shaker grate and damper plate Owners warranty / registration card Installation and Operation Manual BAFFLE PLATE (all boilers) The unit comes with a cast iron baffle installed inside the fire box.
SHROUD INSTALLATION 1. Attach Shroud mount corners to Boiler using supplied hardware. Each corner is designed to fit a specific corner of the unit. 2. Attach Shroud side panels to corners. Panels will fit inside the corners. 3. Install Shroud top. Top must be installed before aquastat is installed. Attach with supplied hardware. SHROUD TOP SHROUD MOUNTING CORNER NOTE: SHROUDS ORDERED AS A SET SET INCLUDES: 4 CORNER 2 SIDES 1 TOP HARDWARE SHROUDS ARE UNIQUE FOR EACH UNIT.
FIREBRICK INSTALLATION The appliance comes with the firebrick packaged inside. Brick size: 9” x 4-1/2” x 1-1/4” (Royall pin number firebrick standard split). MODEL 6130 (6) Full Bricks & (2) Cut Brick Starting in the BACK lay 3 full brick then 1 cut brick. Repeat for 2nd side. Model 6130 MODEL 6150 & 6200 (12) Full & (2) Cut Bricks Starting in the BACK of the unit, place ½ brick on end, then add 4 full brick on end. Last lay 2 full bricks side down. Repeat for 2nd side.
INDOOR BOILER INSTALLATION: VENTING All single wall chimneys must be at least 18” from any combustible surface. Fire can DANGER result, causing severe personal injury, death, or substantial property damage. DANGER A major cause of chimney-related fires is failure to maintain required clearances (air spaces) to combustible materials. It is of the utmost importance that all chimneys be installed in accordance with the manufacturer’s instructions.
INSTALLATION: VENTING CHIMNEY HEIGHT To prevent downdrafts, chimney, or vent without a listed cap should extend at least 3 feet above the highest point where it passes through a roof and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet. A chimney or vent must not extend less than the distances stated above. **Check local codes or ordinances for additional requirements** 2 FT. 2 FT. 10 FT. 3 FT.
PLUMBING CONNECTIONS SIZE OF BOILER FITTINGS 3 7 2 1 4 8 6 5 Front View Back View September 2012 Page 15
COMPONENT ASSEMBLY INDOOR BOILER : CONNECTIONS (OUT DOOR BOILERS ASSEMBLED AT FACTORY, INDOOR UNITS SHIPPED WITH COMPOTES BOXED AND STORED IN FUEL CHAMBER FOR PROTECTION DURING SHIPPING) INSTALL COMPONENTS AS FOLLOWS AND LOCATE PER REFERENCE CHART AND DIAGRAM ON PREVIOUS PAGE. PRESSURE TEMPERATURE GAUGE (#2) • Apply pipe sealer and Teflon tape to threads. • Install in threaded coupling in upper left front of boiler. • Tighten with proper wrench. • Do not over tighten.
PRESSURE RELIEF VALVE (#3) (CONT.) • No shutoff valve shall be installed between the relief valve and boiler, or in the discharge line. Do not plug or place any obstruction in the discharge line. • Test the operation of the valve after filling and pressurizing system by lifting the lever. Ensure the valve discharges freely. If the valve fails to operate correctly, replace it with a new relief valve. WIRE HANDLES (4) Turn the wire handles on to the levers in a clockwise direction.
ELECTRICAL ELECTRICAL INSTALLATION MUST COMPLY WITH • National Electrical Code and any other national, state, provincial or local codes or regulations. • In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes. Appliance must be electrically grounded as required by National Electrical Code ANSI/NFPA 70–latest edition. Ensure ground wiring is installed per wiring diagram. Good grounding is extremely important for proper operation.
ELECTRICAL (CONT.) INSTALLATION: SETTING THE ANALOG AQUASTAT ANALOG IMMERSION AQUASTAT (Indoor units -Outdoor factory installed) 1) Loosen screw on right side of case and remove cover. SET the high limit set point knob to the desired shut off water temp (never above 195 degrees). NOTE these units have a built in 10 degree drop differential. 2) Insert the sensing probe into the immersion well. The sensing probe MUST touch the bottom of the well. Sharp bends in sensing probe wire could impair operation.
AQUASTAT CONTROL SETTING September 2012 Page 20
ELECTRICAL DIAGRAMS INSTALLATION: BOILER PIPING 1) BOILER DRAIN VALVES A) Drain valves are recommended to assist in filling and purging air. See chart in connection section in door and out door locations B) Pipe in Tee at bottom of return (“Cold”) pipe. C) Pipe in Tees at top of both return (“Cold”) and supply (“Hot”) pipes. 2) PUMP A) A pump is required. If using isolation flanges, ensure that they are positioned so that the shut off is accessible.
SYSTEM PLUMBING INSTALLATION: GENERIC SYSTEMS CAUTION The system Diagrams provided are only suggested schematics for generic systems and do not purport to show all required components necessary to meet all required codes. Complex systems should be designed by a professional heating system.
TYPICAL SYSTEM SCHEMATICS OPERATION 1) The solid boiler pump runs constantly, circulating water through the solid fuel boiler via the primarysecondary Tees. 2) If the thermostat calls for heat, the existing boiler will start the boiler pump. The burner will not fire as long as the start temperature is above the aquastat setting on the existing boiler. 3) If the temperature from the solid fuel boiler falls below the existing boiler aquastat setting, the existing boiler will fire as normal.
TYPICAL SYSTEM (CONT.) OPERATION 1) Water circulates continuously through the solid fuel boiler. 2) When the thermostat calls, either the zone pump turns on or the existing boiler turns on it’s pump, allowing water to flow to the baseboard. PIPING INSTALLATION 1) Ensure that the expansion tank is not isolated from the Boiler. 2) Position closely spaced Tees 4 to 8 inches apart. 3) For the zone pump use either a zoning circulator (with built-in relay) or a regular pump with a zone pump control panel.
TYPICAL SYSTEM SCHEMATICS (CONT.) 2) LOW TEMP RADIANT or MIXED TEMP SYSTEM Low temperature radiant systems require some sort of tempering device, most commonly a thermostatic mixing valve. Low temperature and high temperature applications can be easily accommodated by the solid fuel boiler. MIXING VALVE DETAILS • The mixing valve MUST be piped such that a pump pulls water through it. • The best location for the pump is 10” to 12” down stream of the “Mixed” port of the mixing valve.
INITIAL SYSTEM FILL 1) FILL, ISOLATE, AND PRESSURE TEST Although the solid fuel boiler is factory pressure tested, it should be tested in the field to ensure that no damage has occurred during shipping. Isolate the solid fuel boiler from the system prior to pressure testing. A) Shut off isolation valves “B” and “C”. B) Shut drain valve “G”. C) Open drain valves “D” and “E”. D) Keep fill valve or attach hose to drain valve “G”. (either side is acceptable).
INITIAL SYSTEM FILL(CONT.) 2) TEST WATER QUALITY Test system water pH to determine if water treatment is necessary. Heating system water pH of 8.5 to 11.0 is recommended. Swimming pool pH test kits are readily available from other sources. Consult local water treatment companies for unusually hard water areas (above 7 grains hardness) or low pH water conditions (below 7.0). Use only water treatment designed for hydronic systems.
FIRST FIRE OPERATION - FOLLOW ALL SAFETY PRECAUTIONS BEFORE STARTING A FIRE • ENSURE the isolation valves are open. • Start the pump. The pump is lubricated with water. DO NOT run dry. • Cycle the FAN switch to check for proper draft blower operation. • Inspect the loading door gasket before lighting the first fire and a few days after, looking for any indications of a poor seal. DANGER DO NOT use gasoline, kerosene, or other flammable liquids.
BOILER CONTROL (CONT.) 8) AUXILIARY “DUMP ZONE” A safety limit aquastat should be used. Set the safety limit aquastat below water temperature. In a hot water base board system the zone valves should open and the circulating pump should start. Reset to 15° above the solid fuel boiler aquastat setting. Never set safety limit aquastat above 200°F. 9) Monitor water pressure. Maintain about 15 psi (hot water pressure) by adding water as air is purged from the system.
BURNING WITH COAL BURNING COAL A barometric draft damper MUST be installed between the solid fuel boiler and the chimney. Determine and research what types of coal are commonly available in your area. You will get more heat and longer burn periods if you are educated on how to burn the type of coal available to you. Number 3 “hard” coal tends to work best. When burning any type of coal in the boiler do not fill the fire box above the firebrick.
BURNING WITH COAL (CONT.) • The solid fuel boiler will maintain water temperature based on the aquastat settings. • Room temperature is controlled by a thermostat in the room. • The loading door and ash removal door must tightly shut and the seals maintained in good condition during operation, otherwise overheating will occur. WHEN LOADING • Place FAN switch in OFF position. • Open loading door – pausing momentarily between the first latch and the safety latch to allow any combustion gases to burn off.
EMERGENCY ACTIONS OVER HEATING 1) Manually turn off the draft fan at the fan switch (place switch in OFF position). 2) The pump must have power to remove heat from the appliance. 3) Turn the thermostats fully up in the structure being heated by boiler to remove heat from the appliance as fast as possible. 4) Allow the appliance to cool down. 5) Once the unit has cooled down: • Determine and correct the cause of the overheating • Refill the system if necessary CHIMNEY FIRE 1) CALL 911 – INDOOR UNITS ONLY.
MAINTENANCE Keeping the solid fuel boiler in good repair will result in more efficient operation and longer appliance life. You are responsible for safely maintaining the unit. Follow the Service and Maintenance procedures given throughout this manual and in component literature shipped with the appliance. DANGER Failure to perform the service and maintenance could result in damage to the boiler or system.
MAINTENANCE (CONT.) BEGINNING OF SEASON • Chimney: Remove cap from chimney. Inspect chimney. Ensure chimney is not blocked (check for animal or bird nests). • Loading Door: Oil door hinges and latch. Inspect gaskets. Verify that door seals tightly (apply thin coat of lipstick to loading flange, shut door, reopen and inspect marking on the gasket). • Plumbing: Open all isolation valves. • Pump: The circulator shipped with the appliance is water-lubricated. No oiling is required.
MAINTENANCE (CONT.) **PRESSURE (SAFETY) RELIEF VALVE ** Failure to re-inspect the pressure relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death or substantial property damage. AT LEAST ONCE A YEAR: Pressure relief valves must be operated to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative.
TROUBLE SHOOTING 1) PROBLEM: LOSING PRESSURE IN SYSTEM. A) Air bleeding out of system will cause pressure loss. When the appliance is first filled, it may take 3- 4 days to purge all the air. Add water as needed until pressure stabilizes. B) An undersized expansion tank will cause large pressure changes as the system water temperature changes. C) If pressure consistently drops, it indicates a leak in system. Check joints, fittings, relief valves, etc. 2) PROBLEM: UNIT OVER HEATS.
TROUBLE SHOOTING (CONT.) 4) PROBLEM: WATER TEMPERATURE DOES NOT REACH FAN CONTROL AQUASTAT SETTING. (DRAFT FAN RUNS CONTINUOUSLY.) A) B) C) D) E) F) G) Wood may be too wet or green. Try mixing woods. Check for obstructions in draft fan. A defective solenoid may cause flapper on fan not to open when fan comes on. A partially clogged chimney or exhaust plenum may be restricting air flow in the appliance. A buildup of ashes in the ash trough can restrict the exhaust of combustion air.
TROUBLE SHOOTING (CONT.) 7) PROBLEM: SMOKE “PUFFS” FROM THE UNIT A) Wood may be too wet or green. Try mixing woods. B) Check for obstructions in draft path (Blower, Chimney Connector, Chimney). C) A partially clogged chimney or exhaust plenum may be restricting air flow in the appliance. D) A buildup of ashes in the ash trough can restrict the exhaust of combustion air. E) A buildup of ashes on top of the grates can restrict combustion air. F) Ensure that the Chimney has adequate draft (.06” w.c.
REPLACEMENT PARTS LISTING (CONT.
REPLACEMENT PARTS LISTING (CONT.) Damper Plate J 3/16x2 1/2 Cotter Pin I Damper Rod H Spring Handle Ref.
REPLACEMENT PARTS LISTING (CONT.) P R E S S U R E R E L I E F VA LV E PRESSURE/TEMP GAUGE K L A Q U A S T AT W / W E L L M FUEL DOOR N Q POSITIVE SHUT OFF 1/4-20x1 1/4 HHCS 1/4-20 NUT P DRAFT BLOWER W/H GASKET O ASH DOOR G - L AT C H R G - L AT C H A S H PA N S Ref.
20 YEAR LIMITED LIFETIME WARRANTY Warranty On Solid Fuel Appliances ROYALL Solid Fuel Appliances are warranted by ROYALL to the original user against defects in workmanship under normal use, from the date of purchase. This warranty is subject to the condition that the ROYALL Product(s) must have been installed in accordance with manufacturer’s instructions. The Purchaser’s warranty registration card must be on file at ROYALL to qualify for warranty.
