Carrier 61SW User Manual

HEATING & COOUNG

Gas-Fired Induced-Combustion Water Boilers

Installation, Start-Up, and Operating Instructions

Sizes 042—225, Series 101

NOTE: AFFIX THESE INSTRUCTIONS ADJACENT TO THE

BOILER.

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person
nel should install, repair, or service heating equipment.

When working on heating equipment, observe precautions in the
literature, tags, and labels attached to or shipped with the unit and
other safety precautions that may apply.

Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code NFPA No. 54-

1988/ANSI Z223.1-1988. Wear safety glasses and work gloves.
Have fire extinguisher available during start-up and adjustment
procedures and service calls.

Recognize safety information. This is the safety-alert symbol ^ .
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury,

Understand the signal word DANGER, WARNING, or CAU
TION. These words are used with the safety-alert symbol. DAN
GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards that could
result in personal injury or death. CAUTION is used to identify
unsafe practices which would result in minor personal injury or
product and property damage.

These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing residen
tial construction practices.

minimum for a safe installation.

Model 61SW is a low-pressure, sectional, cast-iron water boiler.
The design of model 61SW is certified by A.G.A. for use with
natural and propane gases (model 61SWC with natural gas and
61SWE with propane gas). It is tested for a maximum working
pressure of 50 psi on water in accordance with American Society

-of—Mechanical—Engineers-(A.S.M.E..)—Code_IM_Standards_for_
cast-iron boilers. It is to be installed indoors only. All boilers are
factory assembled.

“All installations are subjectTo Codes established by localTitiiities or

other authorities having jurisdiction. This jurisdiction normally
covers electrical wiring, gas piping, flue specification, and insula
tion of adjacent combustible material where required clearances

cannot be maintained. The installation must conform with the
National Fuel Gas Code, NFPA No. 54-1988/ANSI Z223.1-1988.

Where required by the authority having jurisdiction, the installa
tion must conform to the American Society of Mechanical Engi
neers’ Safety Code for Controls and Safety Devices for Automat
ically Fired Boilers, No. CSD-1.

We require these instructions as a

INTRODUCTION

61 sw

lama

Fig. 1—Model 61SW-075100

Consult the local building codes or ordinances that may apply.

INSTALLATION

£k CAUTION

Do not install the boiler in a corrosive or contaminated

"atmosphere. Make~sure~ all”combustion“and“circulating-air
requirements are adhered to, in addition to all local codes and
ordinances.

Do not use this boiler during construction when adhesives,

"sealersrand/or new carpets are being installed-If-lhe-boiler-is-

required during construction, use clean outside air for com

bustion and ventilation. Compounds of chlorine and fluorine
when burned with combustion àirïbim“aci3swKiclrwill cause
corrosion of the sections and metal vent systems. Some of
these compounds are found in paneling and dry wall adhe

sives, paints, thinners, masonry cleaning materials, and many
other solvents commonly used in the construction process.

Step 1—Location

1. The boiler must be installed on a level foundation. Metal
shims may be used to level if required. Locate the boiler near
a gas vent or a chimney.

A.S.M.E.

A85085

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1 4 PC 101

Tflh Iftalfta

Catalog No. 536-113 Printed in U.S.A.

Form 61S-2SI

pgi

10-92 Replaces: 61S-1SI

Fig. 2—Dimensional Drawing

A85084

2. Combustible floors-Do not install the boiler on carpeting.
When the boiler is installed on a combustible floor, you must
use a factory-supplied combustible floor installation kit con
taining a rectangular piece of insulation material. Position the
insulation on the combustible floor and place the boiler on top
of the insulation.

3. Alcove installation only — Maintain at least 6 in. from com
bustible material on the left-hand (LH) side, 6 in. from the
back and 6 in. from the top.

4. Leave enough room for service access on the right-hand (RH)
side and front. A minimum of 24 in. is required.

A WARNING

The boiler, when installed, must be electrically grounded in
accordance with the National Electrical Code, ANSI/NFPA
No. 70-1988.

Step 2—Air For Combustion and Ventilation

Table 2—Dimensions (In.)

MODEL

AND SIZE
61SW-042100
61SW-075100
61SW-112100

-etsw^rsoioo”
61SW-187100
61SW-225100

*With factory-supplied adaptor installed.

11

14-1/4.
17-1/2

■'20-3/4“
24

27-1/4

The relief-air supply must be in the same atmospheric pressure
zone as the combustion-air inlet supply to the boiler.

^^1 gas-fired equipment must'be'supplied^witlrthe airthat enters’

into the combustion process and is then vented to the outdoors.
Sufficient air must enter the boiler room to replace that air drawn
up the vent stack. Replacement air must be provided by means of

ducts from the outside to the boiler location or conditioned space.
Under all conditions, enough air must be provided to insure there
will not be a negative pressure condition within the boiler room or
space.

In the past, the infiltration of outside air assumed in heat loss
calculations (1 air change per hour) was assumed to be sufficient.
However, current construction methods using more insulation and

WA

VENT

CONNECTION

4*
4*
4*

■ 4*~

vapor barriers, tighter fitting and gasketed doors and windows or
weather-stripping, and mechanical exhaust fans now require the
positive introduction of outside air.

The requirements for combustion and ventilation air depend upon
whether the boiler is located in a confined or unconfined space.
An unconfined space is defined as a space whose volume is not
less than 50 cu ft per 1000 Btuh of the total gas input rating of all
appliances installed in that space.

Advise the owner of the necessity for keeping air passages to the
boiler area free of obstructions. This clearance is necessary so
combustion air can enter freely into the combustion chamber. It is
also necessary to provide adequate ventilating air.

EQUIPMENT LOCATED IN CONFINED SPACES

1. All Air From Inside Building
The confined space shall be provided with 2 permanent

openings communicating directly with an additional room(s)
of sufficient volume so that the combined volume of-all spaces
meets the criteria for an confined space. The total input of all
gas utilization equipment in the confined space shall be
considered in making this determination. Each opening shall
have a minimum free area of 1 square in. per 1000 Btuh of the
total input rating of all gas utilization equipment in the
confined space, but not less than 100 square in. One opening

shall be within 12 in. of the top and 1 within 12 in. of the
bottom of the enclosure. (See Fig. 3.)

—2wUl-Air-FTom-Outdoors

--------------------------^---------------------------

The confined space shall be provided with 2 permanent
openings, 1 within 12 in. of the top and 1 within 12 in. of the
bottom of the enclosure. The openings shall communicate
directly, or by ducts, with the outdoors or spaces (crawl of
attic) that freely communicate with the outdoors.

a. When directly communicating with the outdoors, each

-^^opening^shall-have-a-minimumTreerareamf-l-square-in-per=
4000 Btuh of total input rating of all equipment in the
enclosure. (See Fig. 4.) Use F and G.

b. When communicating with the outdoors with vertical

ducts, each opening shall have a minimum free area of 1
square in. per 4000 Btuh of total input rating of all
equipment within the enclosure. (See Fig. 4.) Use D and E.

c. When communicating with the outdoors with vertical

ducts, each opening shall have a minimum free area of 1
square in. per 2000 Btuh of total input rating of all
equipment in the enclosure. (See Fig. 4.) Use A and B or A

and C.

Table 1—Ratings and Capacities

MODEL

AND
SIZE

TYPE

Max Input Btuh

61SW-042100 Water 42,500 36,000
61SW-075100

Water

75,000 63,000
61SW-112100 Water 112,500
61SW-150100

Water

150,000 125,000

61SW-187100 ■ Water 187,500

61SW-225100 Water

‘The above gas inputs are certified for altitudes to 2000 ft.
are computed at 150 Btuh/sq ft.
The seiection factors providing for piping loss and starting

are based on an allowance of 1.15.
tin accordance with U.S. Government test procedures.

225,000 186,000

RATINGS*

For elevations above 2000 ft, reduce input 4 percent for each 1000 ft above sea level. Ratings in square ft

load are those recommended by the Institute of Boiler and Radiator Manufacturers. Net water boiler ratings

ill 12

I

___

= 1 SQ. INCH

•=• PER 1000
= BTUH

Heating Capacilyf

Btuh

94,000

155,000

12 MAX

i

RATINGS

Sq Ft

240

Btuh Sq Ft

31,000
420 55,000
620 82,000
827 109,000

1033 135,000
1240 162,000

Г'

12 MAX

1 so. INCH PER

2000 BTUH

NET

BOILER WATER APPROX

CAPACITY IN

GALLONS WEIGHT

207 1.75
367
547
727

3.00 263

4.25 320

5.50 369

900 6.75 426

TO VENTED

ATTIC

:i

1080

TO ROOF

¡1 so. INCH PER

4000BTUH

8.00 476

DUCTS

1 SO. INCH PER

SHIPPING

211

4000BTUH

VENT

TO ROOF

^=-1 SO. INCH

PER 1000

I^BTUH

____L____L____

L_.

12 MAX

A90060

Fig, 3—Air From Inside Building

d. When ducts are used, they shall be of the same cross-

-----------

“EQUIPMENT LOCATED IN ÜT^CONFÎNËD SPACÈS

seetional-area-as-the-free-area-of-the-openings-to-which-they“
connect. The minimum diniension of rectangular air ducts
shall not be less than 3 in.

An unconfined space is defined as a space whose volume is not
less than 50 cu ft per 1000 Btuh of the total gas input rating of all

appliances installed in that space. Rooms communicating directly
with the space in which the appliances are installed, through
openings not furnished with doors, are considered part of the
unconfined space.

In unconfined spaces in buildings, infiltration may be adequate to
provide air for combustion, ventilation, and dilution of flue gases.
However, in buildings of tight construction (weather stripping,
heavily insulated, caulked, vapor barrier, etc.), additional air may
need to be provided using the methods described in section,
“Equipment Located in Confined Spaces.”

VENT

TO ROOF

DUCTS TO
OUTSIDE

1 SQ. INCH PER
2000 BTUH

.

12 MAX

_________

—;гт~7'

[.

12 MAX

L-

I so. INCH PER
4000BTÜH:—

TO VENTED

CRAWL .rn

RPACF DUCT TO

OUTSIDE

-------------------

Fig*-4—Air-From-Outdoor

LOUVERS, GRILLES, AND SCREENS

-In-calculating-the^ee-arear'Consideration“shall~be“given“tO“the“
blocking effect of louvers, grilles, or screens protecting openings.
Screens used must not be smaller than 1/4-in. mesh. If the free area
through a design of louver or grille is knotvn, it should be used in
calculating the size opening required to provide that free area
specified. If the design and free area is not known, it may be
assumed that wood louvers will have a 20- to 25-percent free area
and metal louvers and grilles will have a 60- to 75- percent free
area. Louvers and grilles that provide combustion and dilution air

must be constructed so they cannot be closed.

Step 3—Water Line Connection

For water-type boilers with the circulator pump mounted on the
RH side, the water outlet (supply to system) must be on the RH

liso. INCH PER
) 2000 BTUH

------------------

A90059