Slant/Fin VHS-180 User Manual

HOT WATER MODELS VHS-30 THROUGH VHS-180
GAS-FIRED CAST-IRON BOILERS FOR NATURAL AND L.P. PROPANE GASES
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 Z223.1­latest 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 must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.
WARNING
This boiler, gas piping and accessories must be installed, connected, serviced and repaired by a trained, experienced service technician, familiar with all precautions required for gas-fired equipment and licensed or otherwise qualified, in compliance with the authority having jurisdiction.
WARNING
The venting system of this boiler is under positive pressure when it is connected to the outdoors with 3" diameter pipe. Leakage from this system can be hazardous and if not avoid­ed can result in death or serious injury. In addition to the rec­ommendations within this manual and the User’s Information Manual, the venting system, from the blower to the outdoor discharge, must be carefully checked annually by a qualified service agency.
This manual must be left with owner and should be hung on or adjacent to the boiler for reference.
VICTORY II
Models with Intermittent Pilot System – Spark Ignition
INSTALLATION AND OPERATING INSTRUCTIONS
Publication No. VHS-41 Rev.B Part No. 44-0849 Printed 1013
Heating Contractor
Address
Phone Number
Boiler Model Number
Boiler Serial Number
Installation Date
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
Dimensions, Rating and Orifice Sizes . . . . . . . . . . . . . . . . . . .2
Installation Requirements:
Boiler Location and Foundation . . . . . . . . . . . . . . . . . . . . .3
Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Boiler Room Air Supply and Ventilation . . . . . . . . . . . . . . .4
Flue Gas Venting Requirements . . . . . . . . . . . . . . . . . . . . . . .4
Category II and III Venting:
Venting Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Flue Length Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Category I Venting:
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Vent Connector Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Venting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Venting System Regular Inspection . . . . . . . . . . . . . . . . . . . .14
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Boiler Water Temperature Control . . . . . . . . . . . . . . . . . . .19-23
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Piping a Heating-Cooling System . . . . . . . . . . . . . . . . . . . . .26
Operating Instructions:
Filling and Venting Water Systems . . . . . . . . . . . . . . . . . .27
Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Operating Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Sequence of Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
General Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . .32
Appendix A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
WARNING
SEE “WARNING” ON PAGE 3 FOR LIQUEFIED
PETROLEUM (L.P.) PROPANE GAS-FIRED BOILERS
IMPORTANT
READ ALL OF THE FOLLOWING WARNINGS
AND STATEMENTS BEFORE READING THE
INSTALLATION INSTRUCTIONS
VICTORY II VHS Models
2
NOTE: Height dimensions increase by 13⁄4" and depth increases to 221⁄4" when combustible floor kit is used.
Natural #49 50 50 50 51 51 51 52 52 52 Propane #57 58 59 59 60 60 61 62 63 63
VHS-30EP 30,000 2 8
1
8"14
5
8" 190
VHS-60EP 60,000 3 11
1
8"175⁄8" 250
VHS-90EP 90,000 4 14
1
8"205⁄8" 310
VHS-120EP 120,000 5 17
1
8"235⁄8" 365
VHS-150EP 150,000 6 20
1
8"265⁄8" 425
VHS-180EP 180,000 7 23
1
8"295⁄8" 485
Boiler Model
No. of
Sections
Input
Btuh
AB
Approx.
Total Wt.
Full of
Water (lb.)
Gas
Type
2000 3000 4000 5000 6000 7000 8000 9000 10000
Orifice
Size for
Sea Level
Orifice Sizes for High Altitudes
Includes 4% Reduction for Each 1000 Feet
Elevation — Feet
Orifice sizes indicated for 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 1010 Btuh for Natural Gas (See page 21, if local higher heating value exceeds these numbers). See page 21, for burner input adjustment.
LEFT END VIEW FRONT VIEW RIGHT END VIEW
Figure 1. Views - Dimensions - Data
Figure 2. Base Assembly Victory II - VHS Boiler
Gas manifold
Burners
Pilot
Burner access door
Gas valve
VICTORY II VHS Models
3
INSTALLATION REQUIREMENTS
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 Z223.1­latest edition.
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 that the flue pipe from boiler is short and direct. (See Appen­dix A 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
SPECIAL ATTENTION FOR LIQUEFIED PETROLEUM
(L.P.) PROPANE GAS-FIRED BOILER INSTALLATIONS
LPG appliances (boilers) shall be installed in accordance with applicable provisions of NFPA 58 ( Liquefied Petroleum Gas Code) latest edition for installations in US and CAN/CGA B149.1 latest edition for installations in Canada.
Liquefied Petroleum (LP) propane gas is heavier than air therefore Propane gas accumulate at floor level. If you sus­pect a leak, do not attempt to operate boiler. A spark or flame from the appliance (boiler) or other sources may ignite the accumulated propane gas causing an explosion or fire. It is recommended that inspections for gas leaks be per­formed periodically by licensed professional and that leak detection devices be installed as a further safety measure.
BOILER FOUNDATION
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, page 2. 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.
MINIMUM CLEARANCES FROM COMBUSTIBLE CONSTRUCTIONS
A. Minimum clearances to the exterior surfaces of the boiler
shall be as follows: MINIMUM ALCOVE AND CLOSET CLEARANCE
For Combustible Recommended
Surface
Construction for Service Front 6" 18" Rear 6" 18" Left Side 6" 18" Right Side 12" 24" Top 12" 12" Flue Connector:
Enclosed — 6" 6" Unenclosed — 2" 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.
Figure 3.
VICTORY II VHS Models
4
BOILER ROOM AIR SUPPLY AND VENTILATION
An ample supply of air is required for combustion and venti­lation. When buildings are insulated, caulked and weather­stripped, now or later on, direct openings to outside may be required and should be provided. If the boiler is not near an outside wall, air may be ducted to it from outside wall openings.
Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Venti­lation, of the National Fuel Gas Code, ANSI Z223.1-latest edition, or applicable provisions of the local building codes. The following recommendation applies to buildings of ener­gy-saving construction, fully caulked and weatherstripped.
INSTALLATION IN ENCLOSED BOILER ROOM REQUIRES TWO UNOBSTRUCTED OPENINGS FOR PASSAGE OF AIR INTO THE BOILER ROOM:
1. Air drawn horizontally from outdoors DIRECTLY through an outside wall; one louvered opening near the floor and one louvered opening near the ceiling, each opening with a minimum FREE air passage area of 1 square inch per 4000 Btuh of total appliances’ input.
2. Air drawn horizontally through HORIZONTAL DUCTS; one opening near the floor and one opening near the ceiling, each opening with a minimum FREE air passage area of 1 square inch per 2000 Btuh
of total
appliances’ input.
3. Air drawn VERTICALLY from outdoors; one opening at the floor and one opening at the ceiling, each opening with a minimum FREE air passage area of 1 square inch per 4000 Btuh of total appliances’ input.
4. Air drawn from inside the building; one opening near the floor and one opening near the ceiling, each opening with a minimum FREE air passage area of 1 square inch per 1000 Btuh of total appliances’ input.
IF BOILERS ARE INSTALLED ADJACENT TO OTHER FUEL BURNING EQUIPMENT, THE AREA OF FREE OPENINGS MUST BE APPROPRIATELY INCREASED TO ACCOMMODATE THE ADDITIONAL LOAD.
Openings must never be reduced or closed. If doors or win­dows are used for air supply, they must be locked open. Pro­tect against closure of openings by snow and debris. Inspect frequently.
No mechanical draft exhaust or supply fans are to be used in or near the boiler area.
The flow of combustion and ventilating air to the boiler must not be obstructed.
FLUE GAS VENTING REQUIREMENTS
The Victory II 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 VENTING SYSTEM.
The vent piping installation MUST be in accordance with 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, the more stringent case shall apply.
The use of a vent damper or similar devices is NOT permit­ted on this boiler series.
Approved Venting Applications
Victory II model VHS-90 through 180 are Category III and VHS-30 and 60 are Category II boilers, these boilers must be vented by proper 3" diameter venting system (see Cate­gory II and III venting - page 5). Models VHS-90 through 180 are also Category I boilers when using a minimum of 5" diameter connector and vented into a natural draft chimney or Type “B” vent using a 3"x5" diameter vent adapter (see Category I venting - page 9).
VICTORY II VHS Models
5
CATEGORY II AND III VENTING
1. Vent Material
A) The vent system for horizontal or vertical venting (Category II and III) must be UL listed single wall 3" diameter AL29-4C
stainless steel material. The follow­ing manufacturers’ systems are approved for use within a specified minimum and maximum equivalent vent length for each model. Proper adapter must be used as a connector between Victory II boilers flue collar and venting system as shown below:
Heat-Fab Part Numbers for various items of vent system are listed in Slant/Fin Part List, Publication No. VHS-10PL.
B) When joining the various components of the above
listed vent systems, the manufacturers’ instructions should be closely followed to insure proper sealing.
C) Use sealant specified by vent system manufacturer
for sealing of pipe and fittings. See Figure 4 for proper application of vent pipe sealing for Safe-T vent
system by Heat-Fab. Inc. D) All vent connections must be liquid and pressure tight E) Flue vent system CANNOT be cut to length. Consult
manufacturer’s instructions. For Heat-Fab system, use
slip joint connector (Part No. 7324-GC) to adjust pipe
lengths dimensions. F) DO NOT use plastic or galvanized flue pipe.
2. Flue Length Restriction
Maximum and minimum equivalent flue length for different systems are given in the tables on page 6. Equivalent flue length is sum of straight flue lengths and equivalent length of elbows. The vent termination is in addition to the allowed equivalent lengths.
Example:
Boiler Model VHS-180 is to be installed at sea level with 2 elbows using Heat-Fab vent system. Maximum straight run would be: 40 - 2 x 3 = 34ft. If same boiler is to be installed in Colorado Springs (5,980 ft. altitude), the maxi­mum straight run would be: 20 - 2 x 3 = 14 ft.
3. Installation A. Horizontal Venting:
Figures 5 and 6 show typical horizontal venting. For combustible wall passage of vent piping a U.L. listed thimble must be used. See Figures 5 and 6 for wall thimble Part Numbers and more information.
CAUTION: Flue gasses exiting from the vent terminal will condense. Building materials in the area of the vent terminal should be protected from discoloration and degradation.
VENT TERMINATION LOCATION AND CLEARANCES
1. The venting system shall terminate at least 3 feet above any
forced air inlet located within 10 feet.
2. The venting system shall terminate at least 12 inches below, or
12 inches horizontally from, any door, window or gravity air inlet into any building. The bottom of the vent terminal shall be at least 12 inches above grade or the normal snow leve whichever is greater.
3. Through the wall vents shall not terminate over public
walkways or over areas where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment. Minimum clerance of 4 feet horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.
4. Vent termination must not be located in any confined space (i.e.
window wells, alcoves, narrow alleys) or under anyoverhang or deck. Vent termination should not allow flue gas discharge towards neighbor’s windows or where personal injury or property damages can occur.
B. Vertical Venting:
Figure 7 shows typical vertical venting. A fire stop is required for each ceiling and floor penetration. An existing chimney (see Figure 8) may be used as a chase for vertical venting. Other appliances CANNOT be vented into the same chimney or vent pipe within the chimney.
For both, horizontal and vertical venting, the following points MUST be followed: A. All Victory II boilers are equipped with a built-in condensation
drain and trap. The trap loop must be filled with water. DO NOT operate the boiler without filling the trap with water to prevent flue gas discharge into space. The drain should extend to a floor drain or to a container which may require emptying periodically.
B. The horizontal vent pipe must be sloped upward from the
boiler at a pitch of at least 1/4" per 1 foot of run, so that the condensate from the vent system runs to the drain trap.
C. The horizontal vent pipes must be supported with pipe straps
at intervals no greater than indicated by vent pipe manufac­turer’s instructions. The vertical portion vent pipe also must be supported per manufacturer’s instructions.
D. Minimum clearances of vent pipes from combustible con-
structions must be maintained (see Page 3).
E. Common venting with other appliances or another Victory II
boiler is NOT allowed.
F. The vent piping must terminate with a screened elbow or tee.
See Figures 5 and 6 for horizontal and 7 and 8 for vertical termination information. A cap termination may be used for vertical venting.
G. See Appendix A for vent system location and condensation
drain requirements.
H. For roof passage of vent piping a U.L. listed roof flash-
ing must be used.
: AL 29-4C is a registered trademark of Allegheny Ludlum Corp.
Figure 4. Vent Sealing Instructions
(Consult vent manufacturer’s instructions.)
Manufacturer Type/System Adapter Part No. Sealant
Heat-Fab. Inc. Saf-T Vent Not Required
RTV 106 or DOW
Coming 732
Heat-Fab. Inc.
Saf-T Vent
EZ Seal
Not Required Not Required
Pro-Tech
System, Inc.
FasNSeal FSA-HFA3 Not Required
Flex-L
International, Inc
StaR-34 SRAFSA3 GE-1S806
Z-Flex, Inc. Z-Vent O2SVSSLA2 GE, RTV 106
VICTORY II VHS Models
6
Heat-Fab Saf-T Vent System
Boiler Model No.
Minimum Length, Ft.
0 to 5500 Ft. Altitudes
5500 to 7000 Ft. Altitudes
7000 to 10,000 Ft. Altitudes
Equivalent Length of each 90° Elbow, Ft.
Max. Equivalent Length (Ft.)
VHS-30, 40 40 40 3 2 60, 90 and 120
VHS-150 40 40 20 3 2
VHS-180 40 20 20 3 2
ProTech FasNSeal System
Boiler Model No.
Minimum Length, Ft.
0 to 5500 Ft. Altitudes
5500 to 7000 Ft. Altitudes
7000 to 10,000 Ft. Altitudes
Equivalent Length of each 90° Elbow, Ft.
Max. Equivalent Length (Ft.)
VHS-30, 30 30 30 6 2 60, 90 and 120
VHS-150 30 30 15 6 2
VHS-180 30 15 15 6 2
Flex-L StaR-34 and Z-Flex Z-Vent System
Boiler Model No.
Minimum Length, Ft.
0 to 5500 Ft. Altitudes
5500 to 7000 Ft. Altitudes
7000 to 10,000 Ft. Altitudes
Equivalent Length of each 90° Elbow, Ft.
Max. Equivalent Length (Ft.)
VHS-30, 35 35 35 6 2 60, 90 and 120
VHS-150 35 35 18 6 2
VHS-180 35 18 18 6 2
Note: Vent termination is in addition to the allowed equivalent length.
VICTORY II VHS Models
7
Figure 6. * Definition of Snow Line: Knowledge of local conditions will reveal the maximum height that repeated
snowfalls accumulated to. The height should be used as the SNOW LINE
Figure 5. * Definition of Snow Line: Knowledge of local conditions will reveal the maximum height that repeated
snowfalls accumulated to. The height should be used as the SNOW LINE.
“VICTORY II HORIZONTAL VENTING”
All joints must be liquid and pressure tight. Use U/L listed single wall 3" dia.
AL29-4C* S.S. venting materials (See page 5)
VICTORY II VHS Models
8
Figure 7.
VICTORY II VHS Models
9
Figure 8.
VICTORY II VHS Models
10
CATEGORY I VENTING (Natural Draft Chimney and Type “B” Venting)
1. Installation
Model VHS-90, VHS-120, VHS-150 and VHS-180 may be vented into a natural draft masonry chimney or natural draft type“B” vent if a 3" diameter stainless steel elbow connected to the boiler’s flue collar and the vent connec­tor converted to 5" diameter using a 3" x 5" vent adapter. Single or multiple appliance venting are shown in Figures 9 and 10.
2. Vent Connector Material
Vent connectors may be single wall or Type “B” made of galvanized or stainless steel materials.
3. Venting Requirements
If the boiler vent is to be installed into a natural draft masonry chimney or Type “B” venting, it must be in accor­dance with National Fuel Gas Code ANSI Z223.1-latest edition, Part 12, Part 13 and Appendix G.
For a masonry vitreous tile-lined chimney which is not exposed to the outdoors, use Table 1 in this Slant/Fin manual for venting requirements. DO NOT install this sys­tem into an unlined masonry chimney.
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 require­ments of metallic re-lined chimneys.
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. Vent connec­tors serving appliances vented by natural draft shall NOT be connected into any portion of mechanical draft sys­tems operating under positive pressure.
In some cases, the vent connector diameter must be up­sized further to 6" or 7". Refer to Table 1 and 2 for instal­lations requiring this increased size.
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 “B” must be followed.
VICTORY II VHS Models
11
Table 1. Masonry Vitreous Tile-Lined Chimney (not metal lined)
Chimneys not exposed to the outdoors below the roof line. (5" dia. vent adapter must be used)
Natural Draft Chimney and Type “B” Venting Tables
Additional National Fuel Gas Code
Boiler Gas Appliance Reference Table No.*
Model(s) † in Venting System Connector Requirements* (ANSI Z223.1)
VHS-90 No Type “B” 1. Connector diameter must be upsized to 7". VHS-120 2. Chimney height limits: Min. 15 ft., Max. 30 ft. VHS-150 3. Lateral length restriction applies
(Table 13.1 (c))
13.1 (c) (2006 edition)
VHS-180 4. Internal area of chimney: Min. 50 sq. in.,
Max. 269 sq. in.
VHS-180 No Single-wall 1. Connector diameter must be upsized to 7".
2. Chimney height limits: Min. 15 ft., Max. 30 ft.
3. Max. lateral length may not exceed 2 ft. 13.1 (d) (2006 edition)
4. Internal area of chimney: Min. 50 sq. in., Max. 269 sq. in.
VHS-90 Yes Type “B” 1. See Table 13.2 (c) for chimney height VHS-120 and connector length restrictions. 13.2 (c) (2006 edition) VHS-150 2. Connector may have to be upsized to 6" diameter VHS-180 to meet requirement of 10-8.
VHS-150 Yes Single-wall 1. See Table 13.2 (d) for chimney height VHS-180 and connector length restrictions. 13.2 (d) (2006 edition)
2. Connector may have to be upsized to 6" diameter to meet requirement of 13.2 (d).
Additional National Fuel Gas Code
Boiler Gas Appliance Reference Table No.*
Model(s) † in Venting System Connector Requirements* (ANSI Z223.1)
VHS-90 No Type “B” See Table 13.1 (a) for minimum and maximum VHS-120 of vent height and lateral length restriction. VHS-150 13.1 (a) (2006 edition) VHS-180
VHS-90 No Single-wall See Table 13.1 (b) for minimum and maximum VHS-120 of vent height and lateral length restriction. VHS-150 13.1 (b) (2006 edition) VHS-180
VHS-90 Yes Type “B” 1. See Table 13.2 (a) for vent height and VHS-120 connector length restrictions. VHS-150 2. Connector and vent diameter may have to be 13.2 (a) (2006 edition) VHS-180 increased to 6" or 7" to meet requirement of
Table 13.2 (a).
VHS-120 Yes Single-wall 1. See Table 13.2 (b) for vent height and VHS-150 connector length restrictions. VHS-180 2. Connector and vent diameter may have to be 13.2 (b) (2006 edition)
increased to 6" to meet requirement of Table 13.2 (b).
Table 2. Type “B” Venting and Metal-Lined Masonry Chimney
UL LISTED MATERIALS ONLY. (5" dia. vent adapter must be used)
† Only Victory II boiler models shown for each application permitted to be installed in that manner specified.
• Also see ANSI Z223.1 –– 2006 Chapter 12 and 13.
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