Slant-Fin V-180, V-33 User Manual

Victory
HOT WATER MODELS V-33 THROUGH V-180
GAS-FIRED CAST-IRON BOILERS FOR NATURAL AND L.P. PROPANE GASES
INSTALLATION AND OPERATING INSTRUCTIONS
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE
Ratings and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Requirements:
Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Boiler Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Minimum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chimney and Type “B” Venting . . . . . . . . . . . . . . . . . . .4
Horizontal Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Vertical Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Regular Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .6
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electrical Controls and Wiring . . . . . . . . . . . . . . . . .11
Boiler Room Air Supply and Ventilation . . . . . . . . . . . .11
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operating Instructions:
Filling and Venting Water Systems . . . . . . . . . . . . . . . .12
Initial Start, Safety and Lighting Instructions . . . . . . . .12
IID System with Honeywell VR8204 or VR8304 . . .12
ner Adjustment, Checking Gas Input . . . . . . . . . . .13
Bur
Care and Maintenance:
Annual Inspection and Cleaning . . . . . . . . . . . . . . .14
Safety Check for Control Systems . . . . . . . . . . . . . . . .15
Protection from Freezing . . . . . . . . . . . . . . . . . . . . .15
ater Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
W
Appendix A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Sequence of Oper
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Pump or Valve Zoning of Water Boilers . . . . . . . . . . . . . .18
General T
Piping a Heating-Cooling System . . . . . . . . . . . . . . . . . . .20
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
roub
ations . . . . . . . . . . . . . . . . . . . . . . . . . .
leshooting Guide
. . . . . . . . . . . . . . . . . . . . .
17
19
IMPORTANT
READ ALL OF THE FOLLOWING
WARNINGS AND STATEMENTS
BEFORE READING THE
ALLATION INSTRUCTIONS
INST
WARNING
LIQUEFIED PETROLEUM (L.P.)
PROPANE FIRED GAS BOILERS
Installation location ONLY as permitted in paragraph entitled "LIQUEFIED PETROLEUM (L.P.) PROPANE GAS FIRED BOILER LOCATION" on page 3 of this instruction book.
The above warning does not apply to fired boilers.
The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1-latest edition. The installation must also conform to the additional requirements in this Slant/Fin Instruction Book.
In addition where required by the authority having juris­diction, the installation m ety of Mechanical Engineers Safety Code f Controls and Safety De
No. CSD-1.
.
Boilers
This man hung on or adjacent to the boiler f
This boiler installed, connected, ser trained, experienced service technician, familiar with all precautions required f licensed or otherwise qualified, in compliance with the author
ual must be left with owner and should be
, gas piping and accessor
ity having jurisdiction.
ust conform to American Soci-
or Automatically Fired
vices f
ARNING
W
viced and repaired by a
or gas fired equipment and
NATURAL gas
or
or reference
ies must be
.
Printed in U.S.A. 301 Publication No.V-40
art No. 44-0596 Rev. M
P
2 VICTORY
Figure 1. Left End View
Figure 2. Front View
Figure 3. Right End View
NOTE: Height Dimension increases to 30-3/16" and depth dimension increases to 22-1/4" when combustible floor kit is used.
Boiler Model
V-33 2 81⁄8"14 V-60 3 11 V-90 4 14 V-120 5 17 V-150 6 20 V-180 7 23
No. of
Sections A B D
5
8"3" — 9
1
8"17
1
8" 205⁄8" 3" 5" 141⁄2" 310
1
8"23
1
8"26
1
8"29
5
8"3" —12
5
8" 3" 5" 171⁄2" 365
5
8" 3" 5" 201⁄2" 425
5
8" 3" 5" 231⁄2" 485
Dimensions (inches)
C = Vent Dia.
Pressure Horizontal
or Vertical Venting
Natural draft chimney
or type “B”venting
Approx.
Total Wt.
Full Of
Water
(lb.)
1
2" 190
1
2" 250
Size of Gas Line
Connection to Boiler
Natural Propane
Orifice Sizes for High Altitudes
Boiler Model
-33 Natural #48 49 50 50 50 51 51 52 52 52
V
Gas
Type
Orifice
Size for
Sea Level
2000 3000 4000 5000 6000 7000 8000 9000 10000
Includes 4% Reduction for Each 1000 Feet
ation — Feet
v
Ele
V-33 Propane #56 56 56 57 57 57 58 59 59 60 V-60 thru V-180 Natural #50 51 51 51 52 52 52 52 53 53 V-60 thru V-180 Propane #57 58 59 59 60 60 61 62 63 63
(inches)
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
1
2"
ifice siz
Or
es indicated f
or sea level above are factory installed in boiler unless otherwise specified by the local authority. Orifice table is based on a higher heating value between 1000 Btuh and 1009 Btuh for Natural Gas (see III, page 13, if local higher heating value exceeds these numbers). See III, page 13, for burner input adjustment.
Base Assemb Victory Boiler
ly
ners
Bur
Pilot
Burner Access Door
alve
V
Gas
Gas Manifold
VICTORY 3
NSTALLATION REQUIREMENTS
I
The installation must conform to the requirements of the
uthority having jurisdiction or, in the absence of such
a requirements, to the National Fuel Gas Code, ANSI Z223.1-
atest edition.
l This installation must also conform to the additional require­ments in this Slant/Fin instruction book.
NATURAL GAS FIRED BOILER LOCATION
Provide a level, solid foundation for the boiler. Location should be as near as possible to chimney or outside wall so
hat the flue pipe from boiler is short and direct. (See
t Appendix B for vent terminal location restrictions.) The location should also be such that the gas ignition sys­tem components are protected from water (dripping, spray­ing, rain, etc.) during appliance operation and service (circu­lator replacement, condensate trap, control replacement, etc.).
WARNING LIQUEFIED PETROLEUM (L.P.) PROPANE FIRED GAS BOILER LOCATION
REQUIRES SPECIAL ATTENTION Liquefied Petroleum (L.P.) propane gas is Therefore, propane boilers, piping, valves must NOT be installed in locations where propane leaking from defective equipment and piping will "pool" in a basement or other space below the leak.
A spark or flame from the boiler or other source may ignite the accumulated propane gas causing an explosion or fire. Provide a level, solid foundation for the boiler. Location should be as near the chimney as possible so that the flue pipe from boiler to chimney is short and direct.
The UNIFORM MECHANICAL CODE may be in effect in your geographic area.
The following precautions are cited by the 1994 UNIFORM MECHANICAL CODE, section 304.6:
"LPG Appliances. Liquefied petroleum gas-burning appliances shall not be installed in a pit, basement or similar location where hea Appliances so fueled shall not be installed in an abo grade under-floor space or basement unless such loca­tion is provided with an approved means for removal of
unburned gas." Consult Chapter 5 of the 1994 UNIFORM MECHANICAL CODE for design criteria of the "approved" means for removal of unburned gas.
BOILER FOUND
A. Provide a solid, level foundation, capable of supporting
the weight of the boiler filled with water, and extending at
least 2" past the jacket on all sides. See dimensions of
boilers B. For installation on non-combustible floors only*. C. If boiler is to be located over buried conduit containing
electric wires or telephone cables, consult local codes or
the National Board of Fire Underwriters for specific
requirements.
* Installation on combustible flooring allowed only with proper Com-
bustible Floor Kit. Kit part number is printed on boiler rating plate. In no case may the boiler be installed on carpeting.
ATION
, page 2.
vier-than-air-gas might collect.
heavier than air.
v
e-
INIMUM CLEARANCES FROM COMBUSTIBLE
M CONSTRUCTIONS
A. Minimum boiler clearances shall be as follows:
VICTORY BOILER
MINIMUM CLEARANCE FOR COMBUSTIBLE CONSTRUC­TION. MINIMUM ALCOVE AND CLOSET CLEARANCE.
Front 6"
ear 6"
R Left Side 6" Right Side 12" Top (above boiler) 12" Flue Connector 6"
B. Provide accessibility clearance of 24" on sides requiring
servicing and 18" on sides used for passage.
C. All minimum clearances shown above must be met. This
may result in increased values of some minimum clear­ances in order to maintain the minimum clearances of others.
D. Clearance from hot water pipes shall be 1 inch**.
** At points where hot water pipes emerge from a floor,
wall or ceiling, the clearance at the opening through the finished floor boards or wall or ceiling boards may be not less than 1/2 inch. Each such opening shall be covered with a plate of uncombustible material.
SAFETY
KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.
FLUE GAS VENTING REQUIREMENTS
The Victory series boiler is a high efficiency, mechanically induced draft boiler and, therefore, requires different venting arrangements than natural draft, lower efficiency boilers.
THE FOLLOWING INSTRUCTIONS MUST BE CAREFULLY READ AND FOLLOWED IN ORDER TO AVOID ANY HAZ­ARDOUS CONDITIONS DUE TO IMPROPER INSTALLA­TION OF THE FLUE GAS
ent piping installation MUST be in accordance with
The v these instructions and with ANSI Z223.1-latest edition NATIONAL FUEL GAS CODE, Part 7, Venting of Equipment. Other local codes may also apply and must be followed. Where there is a conflict between these requirements more stringent case shall apply
If this boiler is replacing a boiler which is connected to a common venting system with other natural draft, gas fired appliances, the removal of the existing boiler from the vent­ing system is likely to cause the system to be too large for proper venting of the appliances remaining connected to it. At the time of removal of the existing boiler, the test proce­dure specified in Appendix "A" m
Figure 5 shows the models, vent sizes, conditions and requirements for different types of venting.
The use of a vent damper is NOT permitted on this boiler series.
VENTING SYSTEM.
, the
.
ust be followed.
4 VICTORY
NATURAL DRAFT CHIMNEY AND TYPE “B”VENTING
ICTORY boilers are power (fan assisted) vented boilers. All
V
ictory boiler models can be PRESSURE side wall or verti-
V
ally vented by connecting the proper 3" diameter vent to the
c 3" diameter collar and adapter factory equipped on the Victory boilers. See “HORIZONTAL PRESSURE VENTING” and “VERTICAL PRESSURE VENTING”.
Models V-33 and V-60 can ONLY be pressure vented as
escribed above and must NOT be vented into a chimney or
d “B” vent.
Models V-90, V-120, V-150 and V-180 may be vented into a natural draft chimney or natural draft “B” vent if the factory equipped 3" diameter flue collar and adapter on the boiler is REMOVED and REPLACED by the 5" diameter flue collar
anufactured by Slant/Fin Corporation and included in the V-
m 90 through V-180 shipping crates. (See figures 6a and 6b.)
If the boiler vent is to be installed into a natural draft masonry chimney or Type “B” venting, it must be in
For a masonry vitreous tile-lined chimney which is not
xposed to the outdoors, use Table 1 in this Slant/Fin
e
anual for venting requirements. DO NOT install this
m
ystem into an unlined masonry chimney.
s If a masonry chimney is exposed to the outdoors on one
or more sides below the roof line (exposed chimney),it must be re-lined with a UL LISTED metallic liner system. See Table 2 in this Slant/Fin manual for venting require-
ents of metallic re-lined chimneys.
m If a Type “B” vent system is used, it must NOT be
exposed to the outdoors below the roof line. See Table 2 in this Slant/Fin manual for venting requirements.
connectors serving appliances vented by natural draft shall NOT be connected into any portion of mechanical draft sys-
ems operating under positive pressure. Single or multiple
t appliance venting is shown in Figures 6a and 6b.
All Victory boilers require a condensate drain and drain trap.
ent connectors must be liquid tight.
V
accordance with National Fuel Gas Code ANSI Z223.1­latest edition, Part 7, Part 11 and Appendix G.
Table 1. Masonry Vitreous Tile-Lined Chimney (not metal lined)
Chimneys not exposed to the outdoors below the roof line. (5" dia. collar must be used)
Reference Table No. *
Appliance Connector Requirements*
(ANSI Z223.1)
Victory Boilers Type “B” 1. Connector diameter must be upsized to 7". 11-3 (V-90, V-120, V-150 and V-180) 2. Chimney height limits: Min. 15 ft., Max. 30 ft. Single Appliance 3. Lateral length restriction applies (see table 11-3)
4. Internal area of chimney: Min. 50 sq. in., Max. 269 sq. in.
Victory Boiler Single-wall 1. Connector diameter must be upsized to 7". 11-4 (V-180 only) 2. Chimney height limits: Min. 15 ft., Max. 30 ft. Single Appliance 3. Max. lateral length may not exceed 2 ft.
4. Internal area of chimney: Min. 50 sq. in., Max. 269 sq. in.
Victory Boilers Type “B” 1. See table 11-8 for chimney height and connector 11-8 (V-90, V-120, V-150 and V-180) length restrictions. plus another gas appliance 2. Connector may have to be upsized to 6" diameter
to meet requirement of 11-8.
Victory Boilers Single-wall 1. See table 11-9 for chimney height and connector 11-9 (V-150 and V-180 only) length restrictions. plus another gas appliance 2. Connector may have to be upsized to 6" diameter
to meet requirement of 11-9.
Vent
le 2. Type “B” Venting and Metal-Lined Masonry Chimney
ab
T
UL LISTED MATERIALS ONLY. (5” dia. collar must be used)
Reference Table No. *
Appliance
Connector Requirements*
(ANSI Z223.1)
Victory Boilers Type “B” See table 11-1 for minimum and maximum of vent 11-1 (V-90, V-120, V-150 and V-180) height and lateral length restriction. Single appliance
Victory Boiler
Single-wall See table 11-2 for minimum and maximum of vent 11-2 (V-90, V-120, V-150 and V-180) height and lateral length restriction. Single appliance
Victory Boilers Type “B” 1. See table 11-6 for vent height and connector 11-6 (V-90, V-120, V-150 and V-180) length restrictions. plus another gas appliance
Connector and v
2. creased to 6”
ent diameter ma
to meet requirement of table 11-6.
or 7”
y have to be in-
Victory Boilers Single-wall 1. See table 11-7 for vent height and connector 11-7 (V-120, V-150 and V-180 only) length restrictions. plus another gas appliance 2. Connector and vent diameter may have to be
increased to 6” to meet requirement of table 11-7.
* Also see Z223.1 Part 7 and see Part 11 for use of mentioned tables.
VICTORY 5
HORIZONTAL PRESSURE VENTING
All VICTORY models are certified for horizontal pressure venting with the following restrictions:
1. Vent Material
. The vent system for horizontal venting must be UL list-
A
ed single wall Saf-T 3" diameter #AL 29-4Csstainless steel manufactured by Heat-Fab, Inc. The manufactur­ers’ part numbers for various items of the vent system are listed in SLANT/FIN Parts List, Publication # V-
10PL. B. DO NOT use plastic or galvanized flue pipe. C. For horizontal, through the wall venting, the 3" flue
ollar and adapter MUST be used. The vent pipe size
c
must be 3" diameter from the boiler to the outside ter-
mination. Certain restrictions on the location of the
vent terminal are specified in APPENDIX "B" and must
be followed.
Installation
.
2
A. Figures 7 and 8 show the allowed venting arrange-
ments. The maximum equivalent vent length is 40 feet
plus vent terminal for all models except V-180 which
has a 20 feet maximum equivalent vent length. Every
90° turn in the vent piping is equivalent to 5 feet of
straight run, (eg. a V-120 system with 3 elbows and the
outside terminal would allow 40 - 15 = 25 feet of
straight run). The minimum allowable equivalent vent
length is 2 feet and 1 elbow plus vent terminal for all models, see table below. NOTE: For best operation, elbows should be at least five diameters apart other­wise maximum vent length should be reduced.
B. When joining the various components of the above list-
cturers’instructions
d vent systems, the man
e should be closely followed to insure proper sealing. Use GE-RTV 106 or Dow Corning 732 Sealant for sealing of pipe and fittings. See figure 4 for proper
pplication of vent pipe sealant.
a
. All Victory boilers require a condensate drain and drain
C
trap. The horizontal pipe must be sloped TOWARD the con-
densate drain at least 1/4" per 1' of run. The horizontal portion must also be supported with pipe straps at intervals no greater than indicated by vent pipe manu­facturer’s instruction.
Where the vent pipe goes through the outside wall, a thimble must be used (see Figures 7 and 8).
Heat-Fab pipes and fittings Use slip joint connector (Heat-Fab part no. 7324GC) to adjust pipe lengths dimensions.
ufa
cannot be cut to length.
Diameter Venting System Restrictions
3”
Maximum
Equivalent
Length
including
Model
V-33
to 40 ft. 5 ft. 2 ft. 1
V-150 V-180 20 ft. 5 ft. 2 ft. 1
* Vent terminal is in addition to the allowed vent pipe length and elbows.
Elbows*
alent
Equiv
Length
of Elbows
Minimum
Length*
Minim
No. of
Elbows*
Figure 4. Vent Sealing Instructions
(Consult vent manufacturer’s instructions.)
um
s: AL 29-4C is a registered trademark of Allegheny Ludlum Corp.
6 VICTORY
Figure 5.
Model/Vent Size
NATURAL DRAFT CHIMNEY AND TYPE “B”VENTING
V-90, V-120, V-150 and V-180 boilers may be vented into a chimney (see “Chimney and type “B” venting” paragraph on page 4) or into a type “B” vent, ONLY when converted to the 5" dia. Slant/Fin flue collar supplied unassembled with these boilers and ONLY as described here, other places in this booklet and in figures 6a and 6b.
PRESSURE HORIZONTAL AND VERTICAL VENTING
V-33, V-60, V-90, V-120, V-150 and V-180 may be vented horizontally and vertically ONLY when boilers are equipped with the Slant/Fin factory installed 3" dia. flue collar and adapter is used ONLY as described here, other places in this booklet and figures 7, 8 and 9.
The condensate drain should be installed as close to the
boiler as possible.The drain fitting size is 3/8" or
1/2"depending on the type of drain assembly. Clear plastic
tubing (3/8" I.D. or 1/2” I.D.) sized to fit the fitting must be
connected to the drain fitting. The clear tubing should be
formed into approximately a 4-5 inch diameter loop to form
a trap.The loop should be tied with cord or a cable tie
where the loop crosses over itself. See figures 6,7,8 and 9.
This loop should then be filled with water to form a liquid
filled trap. DO NOT OPERATE THE BOILER WITHOUT
INSTALLING THIS TRAP AND FILLING WITH WATER.
Periodic inspection should be made of this assembly for
deterioration of the tubing and to insure that the trap is not
plugged. If it is plugged or appears to have excessive
sediment in it, it should be removed from the drain assem-
bly, straightened out to clear the obstruction, reformed,
filled with water and reinstalled as before. The drain
should extend to a floor drain or to a plastic container
which will require emptying periodically. D. WHEN VENTING HORIZONTALLY, COMMON VENTING
WITH OTHER APPLIANCES IS NOT ALLOWED.
VERTICAL PRESSURE VENTING
Vertical pressure venting (not natural draft chimney and type “B” venting) is allowed with the 3" flue collar and adapter and #AL
s
29-4C
stainless steel vent system previously shown in “Hori-
zontal Pressure Venting” paragraph No.1. This arrangement is
wn in Figure 9.
sho Note, that when using a 3" diameter vent for vertical pressure
venting, a chimney may be used as a chase for a vertical vent (support is required in conjunction with firestop as per vent manufacturers’ instruction).The 3" vent system MUST extend the total length of the chimney but not longer than the equivalent length limitations indicated on page 5 under
“HORIZONTAL PRESSURE VENTING” paragraph 2A. Other appliances can NOT be vented into the same chimney.
As noted previously, all Victory boilers MUST be installed with a condensate drain trap.Vent system must be sealed liquid and pressure tight.
The instructions indicated in “HORIZONT
on pages 5 and 6 must also be followed for the above
ING”
AL PRESSURE
VENT
described Vertical Pressure Venting except, use figure 9 includ­ing the clearances shown in figure 9 in place of figures 7 and 8.
REGULAR INSPECTION
A. Inspect the system regularly for condensation, corrosion and/or physical damage. A qualified professional should service
Requirements
Standard vent connector materials (i.e. galvanized or stain­less steel vent pipe). Condensate drain and liquid tight seal is required. See figures 6a, 6b and “Chimney and type “B” venting” on page 4.
ONLY 3" dia. single wall Saf-T #AL 29-4C
s
stainless steel manufactured by Heat-Fab, Inc. may be used. Condensate drain and liquid and pressure tight sealing is required. See figures 7, 8, and 9.
the boiler annually and include such an inspection at that time. The homeowner should look over the system monthly for dam­age, water stains, any signs of rust, other corrosion or separation of the flue (vent) tubing and fittings.
B. Should an inspection turn up signs of condensation, corrosion or damage, the boiler should be shut down immediately and the condition should be corrected by a qualified professional.
GAS PIPING
A. Local installation codes apply. The pipe joint compound used
on threads must be resistant to the action of liquefied petrole­um gases.
B. The gas supply line to the boiler should be run directly from
the meter for natural gas or from the fuel tank for L.P. propane gas. See page 2 for location of union and manual main shut­off valve that may be specified locally. Selecting pipe size for natural gas:
1. Measure or estimate the length of piping from the meter to the installation site.
2. Consult gas supplier for heating value of gas (BTU/cu. ft.).
3. Divide boiler rated input by heating value to find gas flow in piping (cu. ft. per hour).
4. Use table below to select proper pipe size.
Example: Boiler model V-150 is to be installed. Distance from gas meter to the boiler is 30 ft. Heating value of natural gas is
.
1020 BTU/cu.
Gas flow =
At 30 ft.
length of pipe, match required capacity from tab
Select proper pipe siz
ft.
150,000 BTU/hour
1020 BTU/cu.
e
= 147 cu. ft. per hour
ft.
(choose higher capacity, in this case is 152 cu. ft. per hour). Required pipe size is 3/4".
Improper gas pipe sizing will result in pilot flame outages, insuffi­cient heat and other installation difficulties. For more information and also if other appliances are to be attached to the piping sys­tem, see Appendix C of National Fuel Gas Code ANSI Z223.1­latest edition. C. The boiler and its gas connection must be leak tested
Use liquid soap
ore placing the boiler in oper
bef
-
This boiler and its individual shutoff valve must be discon-
solution f
or all gas leak testing.
ation.
DO NOT use open flame.
nected from the gas supply piping system during any pressure testing of that system at test pressures in
xcess of 1/2 PSIG.
e This boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve dur-
y pressure testing of the gas supply piping system
ing an
le below
s: AL 29-4C is a registered trademark of Allegheny Ludlum Corp.
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