Granby B*G-3, B*G-4, B*G-5, B*G-6, B*G-7 Installation, Operation And Service Manual

Installation, Operation and

Service Manual

Cast Iron Boiler SERIES

B*G, 3 sections illustration

INSTALLATIONS MUST MEET ALL LOCAL AND FEDERAL

CODES THAT MAY DIFFER FROM THIS MANUAL

THE FOLLOWING PAGES INCLUDES WARNINGS, INSTALLATION AND MAINTENANCE

INSTRUCTIONS SPECIFIC TO GAS-FIRED UNITS. PLEASE REVIEW THIS MANUAL
CAREFULLY IF YOUR BOILER IS NATURAL GAS-FIRED OR PROPANE GAS-FIRED

Please read the manual in its entirety before beginning installation.

This manual must be kept with the boiler for future reference.

GRANBY FURNACES INC.

PO Box 637
12118 Hwy 209
Parrsboro Nova Scotia Canada
B0M 1S0

www.granbyindustries.com 04-07-2015 G2014-E5G Rev. D

Gas

-

Fire

B*G-3 sections
B*G-4 sections
B*G-5 sections
B*G-6 sections
B*G-7 sections
B*G-8 sections

* = Brand name, G=Gas

1

N

OTE:

THE BURNER INSTRUCTION MANUAL AND THE BURNER USER’S
INFORMATION MANUAL ARE CONSIDERED PART OF THIS MANUAL
AND THEIR INSTRUCTIONS MUST BE FOLLOWED EXCEPT WHEN
SPECIFICALLY MENTIONNED IN THIS MANUAL.

WARNING: If the information in this manual is not followed

exactly, a fire or explosion may result, causing property damage,

personal injury or death.

- Do not store or use gasoline or other flammable vapors or

liquid in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

o Do not try to light the appliance,

o Do not touch any electrical switch; do not use any

phone in your building,

o Immediately call your gas supplier from an outside

p

hone. Follow the gas supplier’s instructions,

o If you cannot reach your gas supplier,

call the fire department.

- Installation and service must be performed

by

a qualified installer, service agency or the

gas supplier.

2

TABLE OF CONTENTS

B

*C - Gas

1.0 IMPORTANT SAFETY ADVICE 3

2.0 PRODUCT INFORMATION 4

3.0 UNIT INSTALLATION 5

3.1 PLACEMENT & LEVELING OF THE UNIT 5

3.2 JACKET ASSEMBLY & CONTROL INSTALLATION 5

4.0 PIPING 9

5.0 ELECTRIC WIRING 12

6.0 CHIMNEY INFORMATION 14

7.0 FUEL SYSTEM 17

7.1GAS-FIRED BOILERS 17

8.0 ACCESSORY INSTALLATION 21

9.0 BURNER INSTALLATION & SETTING 22

9.1 GAS-FIRED BOILERS 23

9.2 GAS-FIRED BOILERS LIGHTING INSTRUCTIONS 25

10.0 TECHNICAL INFORMATION 26

10.1 GAS-FIRED BOILERS 26

10.2 BOILER INFO 28

11.0 BOILER START UP & OPERATION 28

11.1 START UP PROCEDURE 28

11.2 L7248 HONEYWELL CONTROL 29

11.3 TROUBLE SHOOTING THE CONTROL 30

12.0 MAINTENANCE / SERVICE 31

12.1 CLEANING THE BOILER 32

12.2 BURNER CLEANING NOTES 33

12.3 PERFORM COMBUSTION TEST 33

13.0 EXPLODED PARTS VIEW 34

3

1.0 IMPORTANT SAFETY ADVICE

Please read and understand this manual before installing, operating or
s

ervicing the furnace. To ensure you have a clear understanding of the

operating procedures of the appliance please take the time to read section

IMPORTANT SAFETY ADVICE of this manual.

THE INSTALLATION OF YOUR GAS-FIRED BOILER MUST CONFORM TO THE
REQUIREMENT OF THE AUTHORITY HAVING JURISDICTION OR IN THE ABSENCE OF
SUCH REQUIREMENTS, TO THE NATIONAL FUEL GAS CODE ANDSI Z223.1/NFPA 54
AND/OR NATIONAL GAS AND PROPANE INSTALLATION CODE CAN/CSA B149.1.
WHERE REQUIRED BY THE AUTHORITY HAVING JURISDICTION, THE INSTALLATION
MUST CONFORM TO THE STANDARD FOR CONTROLS AND SAFETY DEVICES FOR
AUTOMATICALLY FIRED BOILERS ANSI/ASME CSD1.

SHOULD OVERHEATING OCCUR OF THE GAS SUPPLY FAILS TO SHUT DOWN, DO
N

OT TURN OFF OR DISCONNECT THE POWER SUPPLY TO THE CIRCULATOR,

INSTEAD SHUT OFF THE GAS SUPPLY AT A LOCATION EXTERNAL TO THE
APPLIANCE.

DO NOT USE THIS BOILER IF ANY PART HAS BEEN UNDER WATER. IMMEDIATELY
CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE BOILER AND TO
REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL, WHICH
HAS BEEN UNDER WATER.

CAUTION

DO

NOT START THE BURNER UNTIL ALL FITTINGS, COVERS AND DOORS ARE IN

PLACE. DO NOT TAMPER WITH THE BOILER OR CONTROLS, CALL A QUALIFIED
BURNER TECHNICIAN. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE
VAPOURS AND LIQUIDS IN THE VICINITY OF THIS UNIT OR ANY OTHER APPLIANCE.

IMPORTANT

This manual contains instructional and operational information for the B*G GAS-FIRED boiler .
Read the instructions thoroughly before installing boiler or starting the burner. Consult local
authorities about your local FIRE SAFETY REGULATIONS. All installations must be in
accordance with local state or provincial codes. Improper installation will result in voiding of
warranty.

4

2.0 PRODUCT INFORMATION

PHYSICAL DIMENSIONS

Length : ( 3 sections 18 7/8 ‘’ ) ( 4 sections 22 1/2’’ ) ( 5 sections 26 ¼’’ )

( 6 sections 31 1/8’’ ) ( 7 sections 35 ½’’) ( 8 sections 39 ¼’’)

CLEARANCE

Proper clearances must be maintained not only from combustible materials but also to provide
adequate access for servicing. All installations must comply with local codes and CSA B149.1
(gas) in Canada and NFPA 54 (gas) in the United States. Consult local fire codes for required
clearances. Connections to chimney must be made with the proper gauge thickness and
diameter of fluepipe as required by CSAB149.1,NFPA 54, whichever is applicable.

CLEARANCE (minimum) FOR SERVICING – Gas

Front 24” (609 mm)
Rear 24” (609 mm)
Left Side 24” (609 mm)
Right Side 2” (50.8 mm)
Top 10” (254 mm)

CLEARANCE (minimum) TO COMBUSTIBLES – Gas

Top 10” (254 mm)
Front 24” (609 mm)
Rear 24” (609 mm)
Left Side 24” (609 mm)
Right Side 2” (50.8 mm)
Chimney Connector 9” (229 mm)

SPECIFIC TO GASFIRED BOILERS

*** A gasfired boiler must NOT be installed on carpeting.

D

RAFT PRESSURE

Breech draft pressure -0.02’’ w.c. – Gas-Fired Boiler

5

FLUE PIPE CONNECTION

GasFired boilers (C

HIMNEY ONLY applications)

CLEANOUTS

Rear removable smoke hood cover & Combustion Front Door Opening

FUEL

GasFired  Natural Gas or Liquefied Petroleum Gas  LPG

ELECTRICAL

CANADA : 120 Volts, 60Hz,15 amps fuse or breaker
U

SA : 13.3 amps, circuit protection 20 amps.

AIR SUPPLY

CAUTION: Adequate air supply for both combustion and ventilation must be available.
See page 17 for details.

3.0 Unit installation

3.1 PLACEMENT & LEVELING OF THE UNIT

The boiler should be located on firm foundation in an easily accessible area that meets the
previously discussed clearances and air requirements. In situations where the floor may be
uneven the unit may be levelled by using the leg levellers provided on the boiler or through the
insertion of shims under the legs.

3.2 JACKET ASSEMBLY AND CONTROL INSTALLATION

The boiler jacket has been designed for ease of assembly and removal. The following step-by­s

tep process will ease installation. A screwdriver, 17 mm socket and ratchet or a 17 mm

wrench or adjustable wrench are needed.

Adjustable

Leg Leveler

Rail

6

STEP 1 VERIFY CONTENTS OF JACKET ASSEMBLY PACKAGE.

Your jacket assembly will contain two (2) manifolds with gaskets, a
fastening package which includes all necessary bolts, screws, nuts
and washers for assembly along with burner studs, nuts and
washers, block insulation, rear of block insulation, aluminum faced
tape, levelling frame rails, two (2) side panels, a rear panel top
panel and re-insulated top and bottom front panels

S

TEP 2 FRAME RAIL CONNECTION

Attach 10 mm bolts to the underside of the frame rails. These will be used to level the boiler.
Screw the 4 mm jacket affixing screw to the frame rail from the top down. Both the bolt and
affixing screw will be located on the same end of the frame rail. The frame rail will then be
bolted to the legs of the boiler with the frame rail and containing the affixing screw facing in the
direction of the front end of the boiler.

S

TEP 3 MANIFOLD INSTALLATION

Using the gaskets and bolts supplied connect the manifolds directly to the boiler block. The
top supply manifold will have a 3/4” npt tapping for a relief valve and 1/4” npt tapping for a
gauge. The bottom return manifold has 3/4” npt tapping for a drain vlave. Both manifolds have
1-1/4” male npt threads for sytem connection.

7

STEP 4 INSULATION INSTALLATION

Drape the large piece of block insulation directly over the block taking care to provide adequate
c

learance from frame rails. Using the aluminum faced tape attach the preshaped rear
inslulation to the block insulation. The process is simply taping the two pieces together. The
front panels come pre-insulated.

STEP 5 SIDE AND BACK PANEL ATTACHMENT

Affix panel mounting nuts to the rear of the tie rods. Mount the side panels by placing the
p

anel over the frame rail so that the hole in the bottom lip of the panel fits directly over the
jacket affixing screw on the rail. You can then lock the panel in place by sliding it slightly
forward. The slot on the rear of the panel will now be in position to slide over the tie rod at the
rear of the boiler. Tighten the nuts on the tie rod end to firmly secure the panel. Repeat on the
other side. Screw the back panel to the side panels.

¸

8

STEP 6 CONTROL SENSOR ATTACHMENT

Prior to jacket top and front panel installation the control sensor must be inserted into the brass
well located on the top of the boiler and secured by a clip. Feed the sensor through the hole
on the front of the right side panel from the outside. Penetrate the block insulation to insert the
sensor. The sensor must be fully inserted to the bottom of the well.

STEP 7 TOP AND FRONT PANEL ATTACHMENT

Affix the top panel by placing the holes located on the underside of the panel over the jacket
a

ffixing pins. Press down on the top panel and it will snap in place. Affix the lower front panel
by placing the openings on the lips of the panel over the jacket affixing screws and pushing
downward on the panel. The panel will lock in place. Repeat the process for the top front
panel.

Upon completion of the jacket assembly the Honeywell control can be mounted on the
side of the boiler. (Left or right)

Boiler control

Manual

Air Vent

9

T

he boiler is now ready for piping and connection to the fuel system, heating and

domestic hot water, thermostat and 110 Volt - 60Hz power source.

CAUTION: Safety or relief valve discharge should be piped downward to within

6” of the floor or to a drain. The valve must be mounted in a vertical position.

4.0 PIPING

Prior to connecting the B*C/G boiler to an existing piping system, certain procedures must be
f

ollowed. The system should be flushed to insure that scale and sludge will not be introduced

to the boiler. This is a must when replacing a gravity open system.
The boiler is a low mass boiler requiring low water content and steps must be taken to insure

that the boiler is not flooded from an existing high volume standing cast iron system. If the
conversion is from a high volume system a bypass loop must be installed.

Manual shut off valves must be installed on both the supply line and on the boiler bypass
loop. ASME Boiler Code requires that feed or make up water be introduced to the piping
system and not directly to the boiler. Pressure reducing valves should be installed and
adjusted to 12psi cold water. The pressure relief valve must be piped from the boiler and
downward to within 6” of the floor or to a height to meet existing code. An expansion tank,
circulating pump and automatic air eliminators must be part of the system. The relief valve,
backflow preventer and drain valve should be piped according to code to a drain with piping
that is the same size as the relief valve. The installation of the relief valve must be consistent
with ANSI/ASME Boiler and pressure vessel code Section IV or Boiler, Pressure vessel and
Pressure piping code CSA B51 as applicable.

All piping, including heating, domestic hot water and fuel lines must be done in accordance
with all local codes. It is suggested that you refer to the Water Installation Survey and
Hydronics Institute Residential Hydronic Heating Installation/Design Guide. All piping must be
properly sized, free from defect and be made of copper, steel, brass, aluminum or PEX.

Circulating Pump

A calculation for proper pump selection must be performed for all installations. The pump(s)
s

hould not be operated at maximum working pressures above 30 psi or maximum working
temperatures above 185°F and within limits advised by the manufacturer. The pump must not
be operated unless the system has been bled of all air and completely filled with water.

Recommended locations for the circulating pump, expansion tank, relief

valve and other trim are shown in Figure 1, Figure 2, Figure 3 and Figure 4.

10

F

igure 1

A typical installation with no domestic hot water and no by-pass loop

installed.

Figure 2

A

typical installation with no domestic hot water and with a by-pass loop

installed.

11

F

igure 3

A typical installation with domestic hot water supplied by an indirect heater

and with no by-pass loop installed.

Figure 4

A typical installation with domestic hot water supplied by an indirect heater

a

nd with a by-pass loop installed.

12

P

IPING INSTRUCTIONS SPECIFIC TO GASFIRED BOILERS

• A hot water boiler installed above radiation level or as required by the authority

having jurisdiction, must be provided with a low water cut off device either as part

of the boiler or at the time of boiler installation.

• The boiler shall be installed in such a way that the gas ignition system components

are protected from water (dripping, spraying, etc.) during appliance operation and

service (circulator replacement, condensate trap, control replacement, etc.).

• The boiler, when used in conjunction with a refrigeration system, must be installed

so the chilled medium is piped in parallel with the boiler with appropriate valves to

prevent the chilled medium from entering the boiler.

• The boiler piping system of a hot water boiler connected to the heating coils

located in air handling units where they may be exposed to refrigerated air

circulation must be equipped with flow control valves or other automatic means to

prevent gravity circulation of the boiler water during the cooling cycle.

5.0 ELECTRICAL WIRING

All external wiring must be performed in compliance with existing electrical codes within the
l

ocal jurisdiction. In Canada the CSA, STANDARD C22-1 and the Canadian Electrical Code.
Only qualified individuals should carry out electrical connections in accordance with this
manual and;

• The boiler and burner should only be operated on 120 Vac – 60Hz.

• Field connections should be properly sized and protected with a minimum 15-amp fuse or

circuit breaker.

• A separate fused disconnect must be installed as required by code so that power can be
shut off for servicing.

• The boiler must be bounded to the water piping or the main service ground.

• If an external electrical source is utilized, the boiler, when installed, must be

electrically bounded to ground in accordance with the requirement of the

authority having jurisdiction, or in the absence of such requirement, with the

13

National electrical code ANSI/NFPA 70 and/or the Canadian electrical code Part 1,

C

SA 22.1, electrical code as applicable.

• Label all wires prior to disconnection when servicing controls. Wiring errors can

cause improper and dangerous operation.

The connections must be made in a manner to insure that there is no crossing of the neutral
with the phase, a proper ground shall be provided and all three wires shall be connected to
the operating control.

T

ypical line voltage wiring for oil or gas burner with Honeywell L7248 boiler

control and one heating zone.

Note:

•

For Canadian application, see page 21 for proper wiring with a Block Vent Shut-Off

- BVSO safety device.

• With the Carlin EZ Gas burner, the Red/White lead on the burner relay must

be connected with L1 on the boiler control, the black lead to B1 and the

white lead to B2 on the boiler control.

• With the Riello Gas burner, B1 must be connected to L on the burner

c

ontrol and B2 with N on the burner control.

14

6

.0 CHIMNEY INFORMATION

Natural Draft Applications

CAUTION: Gas fired units must always be connected to flues with proper draft.
Specific guidelines should be followed to prevent the occurrence of the following conditions:

• Reverse flow of flue gas during or after burner shutdown.

• Positive outlet draft conditions.

• Condensation of flue gasses

Chimney Connection

To insure safe and efficient boiler operation flue gasses must be released through a clean,
p

roperly sized chimney with adequate draft that meets all local codes and regulations and be in
accordance with CSA B149.1 or NFPA 54 whichever applicable. Always inspect and clean the
chimney to insure that it is free from obstructions. Never connect the boiler to a chimney or
liner serving an open fireplace.

A 6” diameter flue pipe must be used for connection of the boiler flue outlet to the
chimney for the entire length of the connection. An exception can be made for the three,

four and five section boilers where the flue pipe may be reduced to 5” for the length of the
connection. The chimney connector should be at least 24 gauge metal, be properly supported
and be free of as many 90 degree turns as possible. The distance between the boiler and the
chimney depends on whether or not elbows are used. The distance should be at least 24” if no
elbows are used and 12” if elbows are used. The maximum length of the flue pipe. It must be
no longer than 10’ if no elbows are used and 6’ if elbows are used.

Draft Regulator

GasFired units: A double acting draft regulator must be installed on

the flue pipe.

15

C

ondensation

The B*G Series boiler is a high efficiency boiler and as a result improper venting can lead to
condensing temperatures in the chimney connector and the venting system. If condensing
temperatures of below 250°F NET are reached in the chimney connector then additional steps
shall be taken to insure proper draft. Make sure that all joints are properly sealed with a high
temperature silicone or mastic. If after sealing the joints the condition still exists then inspect
the chimney for suitability. If the masonry, brick, block chimney or tile chimney liner is in poor
condition, a new chimney liner rated for oil may have to be installed. In the event the condition
still exists after installation of a new liner consult Granby Furnaces Inc.

SPECIFIC TO GASFIRED BOILERS

When an existing boiler is removed from a common venting system, the common

venting system is likely to be too large for proper venting of the appliances connected

to it. At the time of removal of the existing boiler, the following steps shall be

followed with EACH appliance remaining connected to the common venting system,

while the other appliances remaining connected to the common venting system are

not in operation:

1. Seal any unused openings in the venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and

determine there is no blockage or restriction, leakage, corrosion and other

deficiencies which could cause an unsafe operation.

3. Insofar as is practical, close all building doors and windows and all doors

between the space in which the appliances remaining connected to the common

venting system are located and other spaces of the building. Turn on clothes

dryer and any appliance not connected to the common venting system. Turn on

any exhaust fans, such as range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer exhaust fan. Close

fireplace dampers.

16

4. P

lace in operation the appliance being inspected. Follow the lighting

instructions. Adjust thermostat operation so appliance will operate

continuously.

5. Test for spillage at the draft regulator outlet / draft hood opening after 5

minutes of main burner operation. Use the flame of a match or candle, or

smoke from a cigarette, cigar, or pipe.

6. After it has been determined that each appliance remaining connected to the

common venting system properly vents when tested as outlined above, return

doors, windows exhaust fans, fireplace dampers and any other gasburning

appliance to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so

the installation conforms with the National fuel gas code ANSI Z223.1/NFPA 54

and/or the Natural gas and propane installation code CAN/CSA B149.1. When

resizing any portion of the common venting system, the common venting

system should be resized to approach the minimum size as determined by the

appropriate tables in chapter 13 of the National fuel gas code ANSI

Z223.1/NFPA 54 and/or the Natural gas and propane installation code

CAN/CSA B149.1.

For boilers connected to gas vent or chimneys, vent installation must be in

accordance with the “Venting of equipment” section of the National fuel gas code

ANSI Z223.1/NFPA 54 or the “Venting systems and air supply for appliances” section

of the Natural gas and propane installation code CAN/CSA B149.1, or applicable

provisions of the local building codes.

Vent connectors serving appliances vented by natural draft shall not be connected

into any portion of mechanical draft system operating under positive pressure.

17

Use of cellular core PVC (ASTM F*891), cellular core CPVC or Radel

(

Polyphenolsulfone) in venting systems shall be prohibited.

Connecting nonmetallic vent pipe and fittings with thermal insulation shall be

prohibited.

Horizontal portions of the venting system shall be supported to prevent sagging by

installing support every 36 inches. The horizontal runs must be sloping upwards not

less than ¼ inch per foot from the boiler to the chimney connector.

7.0 FUEL SYSTEM

(COMBUSTION & VENTILATION OPENINGS)

Install openings and ductwork to the boiler room providing fresh out-side combustion
a

nd circulating air, as installation code require by Canada CSA B139 or NFPA 31
whichever applicable. If installed in a closed room, provide two free air ventilation
openings of at least 8’’ x 12’’ (96 sq in.) free flow areas near celling and floor. Oil
burners must have sufficient air to allow vent system to operate properly.

Draft

regulator

18

7.1 GasFired boilers

T

he gas piping must be installed between the gas meter and the combination gas

valve on the boiler.

WARNING:

• Connect from the gas supply to the burner combination gas valve inlet using

new, clean black iron pipe and malleable iron fittings only. Do not use copper,

brass, cast iron or galvanized pipe or fittings.

• Provide support for gas piping. Do not rest weight of piping on burner gas

valve.

• Apply pipe dope sparingly at all joints. Use only pipe dope listed for use with

propane gas. Do not use pipe sealing tape. In doubt consult CSA B149.1 or

NFPA 54 or the authorities having jurisdiction.

• Do not hold gas valve with a pipe wrench. Use crescent wrench or other smooth

jawed device. Do not overtighten.

• Failure to comply with above could result in severe personal injury, death or

substantial property damage.

1. If possible, install a new gas line directly from the gas meter. If you are using an

existing gas line, verify it is clean and in good condition and verify it is large

enough to handle the load of all connected appliances. See the table below for

guidance on pipe sizes.

2. When branching from a common gas line, do not tap from the bottom or

horizontal sections, only from the side or top.

3. Install a main manual shutoff valve, sediment trap and ground joint union near the

burner combination gas valve connection as shown below.

19

4

. GAS SUPPLY PRESSURE

• Maximum supply pressure: 14 inches W.C.

• Minimum supply pressure: 5” inches W.C.

WARNING:

• Do not expose the combination gas valve to gas pressures in excess of 14” W.C.

The valve has a safety mechanism that interrupt the flow of gas over 14” W.C. In

any event higher pressure could damage the valve seat, resulting in potentially

hazardous conditions. When pressure testing at higher pressures, disconnect

burner from gas line before testing.

20

• If

the gas supply pressure can exceed 14 inches of water column at any time,

you must install a lockup type gas pressure regulator in the gas supply piping,

ahead of the main manual gas valve on the burner.

• The boiler and its gas connections must be leak tested before placing the boiler

in operation.

• Enough combustion air should be provided to the gasfired boiler in

accordance with the section “Air for combustion and ventilation” of the National

Fuel Gas Code ANSI Z223.1/NFPA 54 or clause 8,2, 8,3 or 8.4 of Natural gas

and Propane installation code CAN/CSA B149.1, or applicable provisions of the

local building codes.

TEST AND PURGE GAS LINE

1. Read warning above.

2. Pressure test and purge the line. The gas supplier or utility, following all

applicable codes, should do pressure testing.

21

8

.0 ACCESSORY INSTALLATION

BLOCKED VENT SWITCH (BVSO) FOR CANADIAN APPLICATION ONLY

Gas-fired appliances installed in Canada require a blocked vent switch system when installed
on a chimney. A safety switch is included with the boiler to perform this function. It is the
installer’s responsibility to install the switch in accordance with the instructions provided. Not
applicable for Direct Vent systems. Field Controls Model: WMO-1 (Manual Reset)

Switch Operation

Blocked vent switches are flue gas safety devices for detecting spillage of flue gases due to a
b

locked flue or inadequate draft. After detecting a problem, the switch de-energizes the
system’s burner control. On gas-fired Boilers, the BVSO acts as a spill switch on the outlet of
the double acting draft-regulator.

NEVER reset the switch unless the cause of the blockage has been corrected.

Installation on Gas-Fired Boilers (Figure 1)

1) Drill a 5/8” hole in to the flue vent pipe near the appliance breech connection.

2) This hole must be before the draft regulator, vertically or horizontally.

3) Remove one of the securing nuts from the threaded tube of the safety switch.

4) Tighten the other securing nut onto the pipe as far as possible.

5) Insert the threaded tube end into the pierced hole of the flue vent pipe.

6) Install the securing nut on the safety switch tube, which protrudes into the flue vent pipe.
Tighten the nut securely.

Figure 1- Illustration Granby Industries Figure 2- BVSO wiring diagram

Installation on Gas-Fired Heating Units (Figure 1)

22

W

iring BVSO (Figure2)

The BVSO is connected in series with the call for heat device (24Vac), typically a room
thermostat or a zone valve end switch

Caution: Disconnect the electrical power when wiring the unit.

Wire the blocked vent switch in accordance with The National Electrical Code and applicable
local codes. Wire the blocked vent shut off switch (BVSO) in series with the thermostat and
the aquastat control (Figure 2).

S

ystem Test Procedure (BVSO)

1) With the power re-established, block the chimney or vent pipe downstream of the switch.

2) Adjust the thermostat to call for heat.

3) Once the heating system has started the blocked vent switch should shut down the burner
within 10 minutes or sooner.

4) Once the system has cooled, the blocked vent switch can manually be reset.

5) This procedure should be tested a second time.

6) After testing the blocked vent switch the chimney should be cleared of obstruction and the
heating system should be tested over a long run cycle.

If the block vent switch shuts down the system, check to ensure there is enough draft in the
chimney and venting pipes.

IN THE EVENT OF YOUR SYSTEM SHUTTING DOWN BECAUSE OF A BVSO DEVICE
OPERATION, THE LIKELY CAUSE IS FLUE VENT OR CHIMNEY BLOCKAGE. DO NOT
ATTEMPT TO RESTART THE SYSTEM. CONTACT A QUALIFIED SERVICE TECHNICIAN
WHO WILL ADDRESS THE ROOT CAUSE OF THE BVSO SHUTTING DOWN YOUR
BOILER

9.0 BURNER INSTALLATION AND SETTING

ASSEMBLY & INSTALLATION OF BURNER

ASSEMBLY Check that the burner model is correct for boiler rating required.

Assemble as per burner manufacturer’s instructions.

See burner manufacturer’s instructions for correct setting

INSERTION

23

9.1 GasFired Boilers

CONSULT THE BURNER INSTRUCTION MANUAL THAT IS INCLUDED IN THE BURNER

BOX. In case of differences between the instructions on the burner instruction manual

and this manual, the boiler instruction manual (this manual) must be followed. The

instructions in the gas burner instruction manuals are detailed mounting, wiring,

adjusting, testing and maintenance instructions that are specific to the burner used

(Riello or Carlin). The specific adjustments specific the boiler are detailed in section

10 below. As a general guideline:

1) Use the burner instruction manual for general instructions.

2) Use this manual for specific instructions (such as for example, the initial air

gate adjustment for a specific size of boiler with a specific burner).

• RIELLO GAS BURNERS
o In the Section “Setting the burner”, disregard the table and use the initial

adjustments detailed for the appropriate boiler with Riello burner in the

section 10 of this manual below.

o In the section “Air gate adjustment”, disregard the table and use the

information in section 10 below.

o In the section “Combustion head settings”, disregard the table and use

the information in section 10 below.

o In the section “Manifold pressures”, disregard the table and use the

information in section 10 below.

o Disregard the “Pressure working chart” and the “Combustion chamber

size” sections as those sections apply only for conversion burners.

• CARLIN GAS BURNERS

o Disregard Table 1 on page 7; use the information in s

ection 10 instead.

COMBUSTION CHECKS

All combustion checks must be performed with an instrument capable of reading at

least CO2, CO and temperature.

24

• R

IELLO GAS BURNERS

o Natural Gas Maximum CO2 is 10%
o Propane Gas Maximum CO2 is 12%
o Maximum Air free PPM reading of CO is 200.
o If any of these readings exceed the values above, adjust the air gate to

increase the air intake to the burner.

• CARLIN GAS BURNERS

o Natural Gas Maximum CO2 is 10.4%
o Propane Gas Maximum CO2 is 11.8%
o Maximum Air free PPM reading of CO is 50.
o If any of these readings exceed the values above, adjust the air gate to

increase the air intake to the burner.

AFTER PLACING THE BOILER IN OPERATION, THE IGNITION SYSTEM MUST BE

TESTED.

THE METHOD OF TESTING IS AS FOLLOWS:

• Place the boiler in operation, by raising the thermostat, and observe a

normal ignition of the burner.

• Lower the thermostat. This should shut off the burner.

• Close the manual shutoff gas valve that is upstream of the gas control.

• Place the boiler in operation again, by raising the thermostat.

• After a trial for ignition period, the burner control should go in lockout

mode. A light on the red button on the burner ignition control will indicate

this.

• To restart the boiler, open again the manual gas shutoff valve that you

closed a few steps back, press the red button on the ignition control, the

burner then should retry its ignition. If this sequence is not respected,

consult the burner manual.

25

9.2 GASFIRED BOILER LIGHTING INSTRUCTIONS

26

10.0 TECHNICAL INFORMATION

• *

* Honeywell control L7248 (high limit only, cool start application)

10.1 GasFired Boilers

Riello Gas Burner

27

C

arlin Gas Burner

1

0

.2 Boiler Info

28

GRANBY B*G CAST IRON SERIES

Appliance

Model

No. de

section

Length

(inches)

Shipping

weight

(lbs)

Water

Content

(gal.)

Supply Outlet

(inches)

Return Outlet

(inches)

B*G – E6-0085-**

3 18-7/8" 370 5.5 1-1/4" 1-1/4"

B*G – E7-0121-**

4 22-1/2" 437 6.9 1-1/4" 1-1/4"

B*G –E7-0152-**

5 26-3/4" 503 8.2 1-1/4" 1-1/4"

B*G – E7-0174-**

6 31-1/8" 569 9.5 1-1/4" 1-1/4"

B*G – E8-0194-**

7 35-1/2" 639 10.8 1-1/4" 1-1/4"

B*G – E8-0224-**

8 39-3/4" 705 12.2 1-1/4" 1-1/4"

WARNING: Do not operate if any controls have been submerged. Contact a
qualified technician for inspection prior to use.

11.0 BOILER START UP AND OPERATION

11.1 START UP PROCEDURE

• P

rior to start up make sure the service switch is in the OFF position.

• Check all fittings and wiring.

• Insure that the boiler and the entire heating system are completely filled with water

and that all air has been purged from the system resulting that proper system

pressure is achieved. The minimum PSIG is 12.

• Open all manual shutoffs throughout the system.

• Set operating controls to the recommended settings.

• Follow the burner manufacturer’s instructions for proper light off and setting.

Using accurate combustion test equipment set the burner for proper “steady

state” operation. The use of accurate instruments is necessary to achieve

maximum efficiency.

• Adjust the thermostat to manufacturer’s instruction

29

• P

lace this manual, the control manual and the burner manual along with related

consumer information in an easily accessible location. Installers should make the

consumer aware of the content and location of this information.

11.2 Honeywell control L7248 - Adjusting Settings

- To discourage unauthorized changing of Aquastat settings, a procedure
to enter the ADJUSTMENT mode is required.

- To enter the ADJUSTMENT mode, press the UP, DOWN and I buttons
simultaneously for three seconds.

- Press the I button until the feature requiring adjustment is displayed then
press the UP and/or DOWN buttons to move the set point to the desired
value.

Note: After 60 seconds without any button inputs, the control will automatically
return to the RUN mode and lock the setting.

Error Codes

W

hen attempting to diagnose system performance, reference to the LED display can help to
identify specific areas not working properly. The LED display will scroll ERR, followed by a
digit (1-8). Refer to the information inside the cover of the control L7248.

Err 1 Sensor fault Check sensor
Err 2 ECOM fault

Check Optional EnviraCOM

wiring
Err 3 Hardware fault Replace control
Err 4 B1 fault Check B1 wiring/voltage
Err 5 Low line Checl L1 - L2 > 110 V a/c

Err 6 Fuse

Check ECOM wires, replace

fuse
Err 7 EEPROM Reset limit values

Err 8 Multiple Err 4

Press/Hold



I for 60 sec

min*

30

1

1.3 Trouble shooting the control

System

Condition

Diagnostic

Condition

Check Action

Boiler is cold,
house is cold.

Display is OFF 120 V a/c System power. Turn system power on

Display is ON 24 V a/c T-T No 24 V; replace control

24V present; disconnect
thermostat, short T-T

Boiler starts, check wiring and thermostat.

120 V a/c at B1-B2

.

If no, replace control.

. If yes, check burner and wiring.

Boiler is hot,
house is cold.

Display is ON. 120 V a/c at C1-C2

.

120 V a/c at C1-C2, check wiring to

pump.

Wiring OK , is pump running ?

.

If not, replace the pump.

. If pump is running, ch

eck for trapped air

or closed zone valves.

TESTING SAFETY AND CONTROL DEVICES

In the event the boiler is equipped with a low water cut off, the cut off should be
tested in accordance with the manufacturer’s recommendations. When no
instructions are available follow the guidelines in ASME CSD-1 or perform the
following procedures:

• Set room thermostat at least 10°F above room temperature.

• With Burner operating, drain boiler slowly until the burner shuts off. This shut

off should occur when the water level falls below the low water cut off probe.

• Check to be sure the burner shut off is not due to an open limit or flame
safety issue.

• Reset the room thermostat to the desired temperature and refill the boiler

31

12.0 MAINTENANCE / SERVICE

Your heating appliance is designed to be maintained and serviced only by your heating
p

rofessional. The following sections provide information on maintenance and service

related activities. In the event a problem occurs consult your heating professional

C

ONDENSATION
If you have condensation in your chimney, make sure that the chimney size is according
to the tables in CSA B139. Insulating the flue pipe between the furnace and the chimney
base can increase the temperature at the entrance of the chimney. If this is not
sufficient, consider cutting or removing some flue baffles in the furnace. BE AWARE
THAT REMOVING BAFFLES REDUCES THE UNIT EFFICIENCY AND A MODIFIED UNIT IS
NO LONGER ENERGY STAR APPROVED.

HOMEOWNER SERVICE CAUTION

In the event of a problem with the heating system the homeowner should perform
the following limited activities.

• Check to make sure that there is fuel in the tank and that oil valves are open.

• Set the thermostat above existing room temperature.

• Check for blown fuses or circuit breakers and make sure power switches are

in an on position.

• NEVER TAMPER WITH CONTROLS, WIRING OR PIPING !

Model

# Of Baffles

2

nd

Pass 3rd Pass

3 Sections

4 X X 4 Sections

4 X X 5 Sections

2

X 6 Sections

2

X 7 Sections

2

X 8 Sections

2

X

32

12.1 CLEANING THE BOILER

Section cleaning should only be performed by a service technician and must only be performed
w

hen the boiler is out of service. The following steps should be followed:

• Remove the 2 front panels by sliding it upwards to release and then pull to remove.

• Open the front swing door by removing the four bolts; this will expose the chamber area as

well as the second and third passes. (A)

• Remove the stainless steel baffles. With a cleaning brush clean the boiler section, second

and third passes. (B)

• Remove insulation and the smoke hood cleaning access door from the rear section.

R

emove any soot that may have collected in the smoke hood. (C)

Baffles

cleaning

C access

door

A B C

•

Replace insulation on the rear section and smoke hood.

• Replace swing door and tighten bolts.

• Refit the front casing.

SPECIFIC TO INSPECTION AND SERVICE OF GASFIRED BOILERS

• The vent system must be inspected annually.

• If a low water cutoff is installed in the system, it must be inspected annually.

• The burner flame in operation must be checked regularly. It should be mostly

blue with some yellow tipping permitted.

• Check to make sure that the flow of combustion air to the burner is not

obstructed.

• Verify proper operation of the boiler after servicing

33

12.2 BURNER CLEANING NOTES

Your burner manufacturer has supplied instructions for servicing and

m

aintenance should be performed as instructed.

Riello 40 G120 Gas Burner

____________________________________

Carlin EZGas PRO Burner Burner

12.3 PERFORM COMBUSTION TEST

Perform an annual combustion check on the gas burner.

34

13.0 EXPLODED PARTS VIEW

Exploded Parts View

35

Part List

1 G*C FRONT SECTION 60 GC PNA - POCKET FOR SENSING BULBS

2 G*C INTERMEDIATE SECTION 67 TAPPING WITH AIR RELIEF VALVE
3 G*C REAR SECTION 68 REAR CASING
4 NIPPLE 83 SPECIAL PIN FOR CASING ASSEMBLY
5 STAYBOLTS 86 FIBRE-GLASS ROPE DIA. 10
6 BODY INSULATION 87 HINGE PIN

9 FRONT DOOR (MONOBLOCK) 88a HINGE - LEFT HAND SIDE
11 FRONT INSULATION 88b HINGE - RIGHT HAND SIDE
15 RUBBER GASKET 89 OUTLET FOR PRESSURE MEASUREMENT
19 REAR INSULATION A SETSCREW M10 x 30
20 SIGHTGLASS FRAME B WASHER A10.5
21 SIGHTGLASS C NUT M10

22a SIGHTGLASS FRAME INSULATION D STUD M10 x 40
22b SIGHTGLASS INSULATION E NUT M8

24 FRONT DOOR REFRACTORY F WASHER A8.4

25 / 27 / 29 2ND PASS RETARDERS G SETSCREW M5 x 15

26 / 28 3RD PASS RETARDERS H NUT M6

30 DELIVERY STUB PIPE J WASHER A6.4
31 RETURN STUB PIPE K STUD M6 x 22
44 BLANK FLANGE L SELF TAPPING SCREW S6.3 x 30
47 SMOKEHOOD DIA.150 MM M SERRATED WASHER A4.3

50

SMOKEHOOD CLEANING COVER
INSULATION

N NUT M4

51 SMOKEHOOD CLEANING COVER P SELF TAPPING SCREW S4.8 x 9.5
53 CHASSIS - LEFT/RIGHT HAND SIDE R WASHER A6.4
54 SIDE CASINGS - LEFT/RIGHT HAND SIDE S SETSCREW M3 x 6
55 FRONT CASING LOWER PART U WASHER A9
56 FRONT CASING UPPER PART V STUD M8 x 50
57 ÜST SAC Y SETSCREW M8 x 16
58 BOILER DATA PLATE Z SETSCREW M8 x 30

PARTS NOT ILLUSTRATED

AA HONEYWELL L7248 - AQUASTAT CC PRESSURE VALVE (30 lbs)
BB PRESSURE – TEMPERATURE GAGE DD DRAIN VALVE

36

G

ranby Furnaces Inc. manufactures a full line of oil and gas-fired
boilers in its 70,000 square feet facility. Granby products are sold
across Canada and the United States through a distribution
network.

Our team of engineers, designers and technicians continually
research and develop products to go beyond the demanding
specifications of today’s certifications.

Thank you

T

hank you Thank you

Thank you for choosing Granby

for choosing Granbyfor choosing Granby

for choosing Granby....