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HomeMy WebLinkAboutBP23-063PERMIT # ZJL SECTION 3 TYPE OF WORK JOB LOCATI OWNER; CONTRACTOR COST w CO #_w - 06 3 DATE: �l0 3 EXP ril/1L/L�AVL'Sj/G -- FEE /mac- C4 / ✓P TCO # FEE DATE DATE FOOTING FOUNDATION FRAMING RGH FRAMING INSULATION PLUMBING G RGH PLUMBIN/ GAS L � SPRINKLER ELECTRIC ���� LOW -VOLT 0 ALARM C� AS BUILT O FINAL I NSP all Pk, N.3 —D5y ,4/.0e)C0l/7 &4eye ss �/9 �/��l - Qa3l oCST &Xecw1e7cal �►co/'n &Oki ess�9/ To�3 --071v 4/ Y OTHER APPROVALS ARB BOT PS ZBA r �E VILLAGR, RVE BROOK WESTCHES' R COUNTY, NEW YORK No: 23-113 Certificate of Occupaucp This is to certify that Te4jff C'Or'cQrGC/� of, PqC, &,040kA1 having duly filed an application on JtiAe IQ, 20 c;2.3 requesting a Certificate of Occupancy for the premises known as, 4 Braok Rye Brook,NY, located in a/'C�Zoning District and shown on the most current Tax Map as Section: 13n Block: —/— Lot: 7 and having fully complied with the requirements of the Building Code and the Zoning Ordinance under Building Permit No.03- 0103, issued 5JA0 20--W3, such authority and permission is hereby granted to the property owner to lawfully occupy or use said premises or building or part thereof listed under the following New York State Classifications, Use: "<3 One— &oz;le 0 —, Construction: for the following purposes: r Subject to all the privileges, requirements, limitations, and conditions prescribed by law, and subject also to the following: This certificate does not in any way relieve the owners or any person or persons in possession or control of the premises, building,or any part thereof from obtaining such other permits or licenses as may be prescribed by law for the uses or purposes for which the building or premises is designed or intended. Furthermore, it does not relieve such owners or persons from complying with any lawful order issued with the object of maintaining the premises or building in a safe and lawful condition. No changes or rearrangement in the structural parts o e building or in the exit facilities shall be made, and no enlargement, whether by extending on any side or by increasing i he sh a de,nor all the building-be moved from one location to another until a permit to accomplish such change as o tained om th ilding ector. Building Inspector,Village of Rye Brook: Date: JUL 1 9 2023 19 VILLAGE OF RYE BROOK MAYOR 938 King Street, Rye Brook,N.Y. 10573 ADMINISTRATOR Jason A. Klein (914) 939-0668 Christopher J. Bradbury www.ryebrook.org TRUSTEES BUILDING& FIRE INSPECTOR Susan R. Epstein Steven E. Fews Stephanie J. Fischer David M. Heiser Salvatore W. Morlino CERTIFICATE OF COMPLIANCE July 19,2023 Peter Corcoran 14 Brook Lane Rye Brook,New York 10573 Re: 14 Brook Lane,Rye Brook,New York 10573 Parcel ID#: 135.73-1-7 This document certifies that the work done under Mechanical Permit #23-076 issued on 5/16/2023 for the installation of a new gas boiler and water heater has been satisfactorily completed. Sincerely, Steven E. Fews Building&Fire Inspector /to f� (� ri=� j�n�� I�� E VU E IJ V E ci - For office use rr i 1 BUILDN, DEPARTMENT PERMIT# JU 2 � �I VILLAGE OF RYE BROOK ISSUED: 9 8 KING STREET;Ryt BROOK,NEvv YORK 10573 DATE: - • a� VILLAGE OF RYE BROOK (914)939-0668 FEE: 1,Q*1ke& PAm[3 BUILDING DEPARTMENT �v ebirti +r APPLICATION FOR CERTIFICATE OF OCCUPANCY,CERTIFICATE OF COMPLIANCE, AND CERTIFICATION OF FINAL COSTS TO BE SUMaTTED ONLY UPON COMPLETION OF ALL WORK AND PRIOR TO THE FrMU. INSPECTION #####*#*#**#A:###################+######**##k:M########*########*•*`#**#***#*###########*#Aoki#####**#***###*##################•## Address: 4 i�� ti rv,"U,/ p p 7 Occupancy/Use: C� dParcel ID#: 1 j � 1 " 1 Zone: Owner: [ Address: i1 r P.E./R.A. or Contractor: Address: 7n vYL' Person in responsible charge: Address: �- mc" Application is hereby made and submitted to the Building Inspector of the Village of Rye Brook for the issuance of a Certificate of Occupancy/Certificate of Compliance for the structure/construction/alteration herein mentioned in accordance with law: STATE OF NEW YORK,COUNTY OF WESTCHESTER as: {� I 41nr being duly sworn,deposes and says that he/she resides at f✓1 t f�C. L ,Q/ Tint Name of Applicant) �j., (No.and Street) in ! f✓ __in the County of 1i"��� Q in the State of that (City/Town/Yitlage) he/she has supervised the work at the location indicated above,and that the actual total cost of the work,including all site improvements, labor,materials,scaffolding,fined equipment,professional fees,and including the monetary value of any materials and labor which may have been donated gratis was:$ for the construction or alteration of. Deponent further states that he/she has examined the approved plans of the structure/work herein referred to for which a Certificate of Occupancy/Compliance is sought,and that to the best of his/her knowledge and belief,the structure/work has been erected/completed in accordance with the approved plans and any amendments thereto except in so far as variations therefore have been legally authorized,and as erected/completed complies with the laws governing building construction.Deponent further understands that it shall be unlawful for an owner to use or permit the use of any building or premises orpart thereofhereafter created,erected,changed,converted or enlarged,wholly or partly,in its use or structure until a Certificate of Occupancy or Certificate of Compliance shall have been duly issued by the Building Inspector as per§250-10.A_ofgthe Code —of the Village of Rye Brook. Sworn to befoA me this ! C) Sworn to before me this day of _.. ,20 `I%a day of , 20 Signature of Property Owner Signature of Applicant Piro the of Property Owner Print Name of Applicant Not Public DiAt4NE ROJAS Notary Public PNotary Public-State of New York Nu,01 R06 127547 Qualified u7 westchester County 8/12/202: My Commission Expires May 23,2Q25 �C BRIDI C}�k. w � BUILDING DEPARTMENT ❑BUILDING INSPECTOR ❑ASSISTANT BUILDING INSPECTOR VILLAGE OF RYE BROOK ❑CODE ENFORCEMENT OFFICER 938 King Street • Rye Brook,NY 10573 (914) 939-0668 FAx (914) 939-5801 www r ebrook.or - - - - - - - - - - - - - - - - - - - - INSPECTION REPORT - - - - - - - - - - - - - - - - - - - - ADDRESS: •^°"" DATE: PERMIT# A " Y/ �� -� ISSUED, SECT: BLOCK: LOT: LOCATION: v�`' r 1 G - 5�� — OCCUPANCY: L ❑ Violation Noted THE WORK IS... PASSED ❑ FAILED REINSPECTION ❑ SITE INSPECTION REQUIRED ❑ FOOTING ❑ FOOTING DRAINAGE ❑ FOUNDATION ❑ UNDERGROUND PLUMBING NOTES ON INSPECTION: ❑ ROUGH PLUMBING ❑ ROUGH FRAMING ❑ INSULATION ❑ Natural Gas ❑ L.P. Gas ..eS FUEL TANK ❑ FIRE SPRINKLER FINAL PLUMBING ❑ CROSS CONNECTION ❑ FINAL OTHER �E BRC�v . BUILDING DEPARTMENT ❑BUILDDING INSPECTOR ❑ASSISTANT BUILDING INSPECTOR VILLAGE OF RYE BROOK ❑CODE ENFORCEMENT OFFICER 938 King Street• Rye Brook,NY 10573 (914) 939-0668 FAx (914) 939-5801 www.ry_ebrook.org - - - - - - - - - - - - - - - - - - - - INSPECTION REPORT - - - - - - - - - - - - - - - - - - - - ADDRESS �,_ DATE: arm v ISSUED:''� SECT: BLOCK: LOT: _ LOCATION: `� � \ �' 1 ,`- V OCCUPANCY: ❑ Violation Noted THE WORK IS... ❑ PASSED ❑ FAILED REINSPECTION ❑ SITE INSPECTION REQUIRED ❑ FOOTING ❑ FOOTING DRAINAGE ❑ FOUNDATION ❑ UNDERGROUND PLUMBING NOTES ON INSPECTION: ❑ ROUGH PLUMBING ❑ ROUGH FRAMING ❑ INSULATION ❑ Natural Gas ❑ L.P. Gas ❑ FUEL TANK ❑ FIRE SPRINKLER ❑ FINAL PLUMBING ❑ CROSS CONNECTION ❑ FINAL ❑ OTHER O o `� 5 N a v N ; in cr . �. 44 r A W ^ O y u 04 V CJ� V M � vv � W tti0x n ~ Ox F tl t 0 �> o72n H _ H a - CC**44",4 Ob J y w p ° � uw F © (� °° �i 0 o a � oU V = , . 01% r .. WI � cu upa a t .. Z 00 u a W r d Oq � V b Uw v uQ� lu O z w � > o � u 9 -o -o : BUILDING DEPARTMENT D E C E G V ED VILLAGE OF RYE BROOK 938 KING$TRJEET RYE ftom,NY 10573 JUN - 2 2022 (914)939-0668 WWRr,it'�,l�l'OpC:9TQ VILLAGE OF RYE BROOK BUILDING DEPARTMENT INTERIOR BUILDING PERMIT APPLICATION FOR OFFICE USE ONLY: Approval Date: MAY 16 10 P t#: PP pplication Fee: $ Approval Signature: A V Permit Fees: $ —-6 U Disapproved: Other: +twwwwwwwwwww*www*rtwwwwwwww*ww,twww*wxw*wwwww,t***wwwwwwwwww**w**w*,t****wwwwwwwwwwwwwwwww+t*wwwwwww+kw*wwwtsrtwww* Application dated: Z ZC 7 Z is hereby made to the Building Inspector of the Village of Rye Brook,NY,for the issuance of a Permit for the interior alteration of an existing building,or for a change in use,as per detailed statement described below. 1. Job Address SBL: 1,35. 73 - 1 - 7 Zone: ?-` 1 a 2. Proposed Improvement.(Describe in detail): 0 p 4) &7 �0 I,) (:, l�, �-tC) r! pIIE'S1- 4 .�%1�1 S�-Let tf � truj L' Ck L QM 1 �� G G Ai tX-11( ti 5 . 3. Does the proposed improvement involve a Home-Occupation as per§250-38 of the Code of the Village of Rye Brook? No:-,)(- Yes: If yes,indicate: TIER 1: TIER II: TIER III: 4. Will the proposed project require the installation of a new,or an extension/modification to an existing automatic fire suppression system(Fire Sprinkler,ANSL System,FM-200 System,Type I Hood,etc...) :No:�Yes: (If yes,please submit a separate Automatic Fire Suppression System Permit application&2 sets of detailed engineered plans) 5. Occupancy;(I fam.,2 fam.,comm.,etc...)Prior to Construction: ( FA . After Construction: L Fi -kn . 6. NX State Construction Classification: N.Y. State Use Classification: gcn( b 7. Property Owner:_PEt;VL. W ef_'QP.d,- Address: 1Zk S LZ_-pV_- L r"k-NLr Phone#i (4 41?-7 576 Cell# email: Lac.✓C p7�� mQ.�c��, 8. Applicant: pc-Tc-e [C)QC&2 4V&J Address:—L q e>eW ir- L44J Phone# Cell# email: 9. Architect: Address: Phone# Cell# email: 10. Engineer: Address: Phone# Cell# email: 11. General Contractor: &5C& Address; L 5 6Z CC-" _h2J -7 Phone# Cell# email: 12. Estimated cost of construction $ 2,5_ � A (NOTE:The estimated cost shall include all labor,materi9l,scaffolding,Fixed equipment,professional fees,and material and labor which may be donated gratis.) 13. Job Timetable: Start: - D Z, Finish: (1) 8/12/2021 BUILDING D"ARTMENT RIECMWEFT�� VILLAGE OF RYE 04OOK JUN _ 2 2022 938 KING$TnET RYE BROM NY 10573 (914) 9-066$ VILLAGE OF RYE BROOK BUILDING DEPARTMENT *wwwww,t,t*wwwwww,rwwww,r*www*wwwwwwww,rw*www*wwwwwwwwwww*ww*wwww+tww+t,twwww,t,t,t,t,r,aww*www wwwwwwwwww*ww*www,rww*w AFFIDAVIT OF COMPLIANCE VILLAGE CODE §216 • STORM SEWERS AND SANITARY SEWERS THIS AFFIDAVIT MUST BEAR THE NOTARIZED SIGNATURE OF THE LEGAL PROPERTY OWNER AND BE SUBMITTED ALONG WITH ANY BUILDING OR PLUMBING PERMIT APPLICATION. ANY BUILDING OR PLUMBING PERMIT APPLICATION SUBMITTED WITHOUT THIS COMPLETED AND NOTARIZED FORM WILL BE RETURNED TO THE APPLICANT . STATE OF NEW YORK, COUNTY OF WESTCHESTER ) as: P r `T_ CCU C ` , residing at, G <L `37�x>L (e AcA, (Print name) (Address where you live) being duly sworn, deposes and states that (s)he is the applicant above named, and further states that (s)he is the legal owner of the property to which this Affidavit of Compliance pertains at; 1'4t 5 2Cd C_ L l�;f~ _ , Rye Brook,NY. (Job Address) Further that all statements contained herein are true, and that to the best of his/her knowledge and belief, that there are no known illegal cross-connections concerning either the storm sewer or sanitary sewer, and further that there are no roof drains, sump pumps, or other prohibited stormwater or groundwater connections or sources of inflow or infiltration of any kind into the sanitary sewer from the subject property in accordance with all State, County and Village Codes. (Signature of Property Owner(s)) 2 (Print Name of Property Owner(s)) Sworn to before me this da of \�.,1� , 20 �_�D, (Notary Public) SHARI MELILLO Notary Public,State of New York No.OIME6160063 Quallfled In Westchester County (2) Commisslon Expires January 29,2 8/12/2021 This application must be properly completed in its entirety and must include the notarized signature(s) of the legal owner(s) of the subject property, and the applicant of record in the spaces provided. Any application not properly completed in its entirety and/or not properly signed shall be deemed null and void and will be returned to the applicant. Please note that application fees are non-refundable. STATE OF NEW YORK,COUNTY OF WESTCHESTER ) as: OE!'- _ C'�) L-ZC 01z a4 ,being duly sworn,deposes and states that he/she is the applicant above named, (print name of individual signing as the applicant) and further states that (s)he is the legal owner of the property to which this application pertains, or that (s)he is the for the legal owner and is duly authorized to make and file this application. (indicate architect,contractor,agent,attorney,etc.) That all statements contained herein are true to the best of his/her knowledge and belief,and that any work performed,or use conducted at the above captioned property will be in conformance with the details as set forth and contained in this application and in any accompanying approved plans and specifications,as well as in accordance with the New York State Uniform Fire Prevention&Building Code,the Code of the Village of Rye Brook and all other applicable laws,ordinances and regulations. By signing this application,the property owner further declares that he/she has inspected the subject property, and that to the best of his/her knowledge there are no roof drains, sump pumps or other prohibited stormwater or groundwater connections or sources of infiltration into the sanitary sewer system on or from the subject property. Sworn to before me this Swom to before me this day of ly� , 20 C;�__)_ day of , 20 Signature of Property Owner signature of Applicant Print Name of Property Owner Print Name of Applicant Notary Public Notary Public SHARI MELILLO Notary Public,State of New York No.01ME6160063 Quallfied In Westchester County Commission Expires January 29,20�� (4) 8/12/2021 i ti _ © LnLO o a tn }+� ZF to � a o � 4 � I � S ,ry ✓; ow z! Z tA ` ww w Cl) s a; W O � r pq if z pcn ■ � � ICI � � � a ::) iw04 .+ I�1 - ,� o w * � x; a m u z At ►� v a' �w V � W z zN H 1-4 R GC� EW BUILDIN DEPARTMENT VILLAGE 4 RIQOK SUN 202 938 Knvc,S°rT'1Y1 BR©oK,NY 10573 (914)`939 066$; '` VILLAGE OF RYE BROOK www yebryok.org IBUILDING DEPARTMENT PLUMBING PERMIT APPLICATION FOR OFFICE USE ONLY BP#: Q 3—Q10'S PP#: 00-0-'5 4 Approval Date: MAY 1 6 202k,,n Permit Fee: $ 40471 c r Approval Signature: Other: Disapproved: (fees are non-refundable) Application dated,_(� 2-0 L'7 is hereby made to the Building Inspector of the Village of Rye Brook NY, for the issuance of a Permit to install and/or remove Plumbing as per detailed statement described below.The applicant&property owner,by signing this document agree that said plumbing work will be in conformance with all applicable Federal,State, County and Local Codes. 1.Address: I A J5 KD 1— F- SBL: 05- 7-3- 1-`1 Zone: 12,_I() 2.Proposed Work: P-�V(/KE -4- 3.Property Owner: QL77 ��- Cd CCU(Z 1+-1U Address: I C�-00 L Phone#: `{Lf 9 q I S�,6 r Cell#: email: 4.Master Plumber: &/'NC-oc-yl j f5�:4 P(n S-5, Address: 3 iK,00 kL— [ C --. Lic.#:1 Phone#: 1/4( LM � well#: email: Company Name: e-i t-tc-x4) C5LA Q C 7,5 l.-k- Address: '3 L-� '(j!(ZOO t�!}�_� +� �1�['2 INDICATE FIXTURES&LINES TO BE INSTALLED AS PER THE FOLLOWING SCHEDULE: Location Water Urinals Drinking Sinks Showers Bath Laundry Domestic Fire Sanitary Natural/ Other* Total Closets Fountains Tubs Tubs Service Service Sewer LP Gas Basement 1 st Floor 2nd Floor 3rd Floor 4t'Floor 5t'Floor Exterior 5.*List Other Equipment/Provide Details: OCI L E= W '� le-- (�-'A, TK 1ZZ 9-EP {/-�c t✓ Mcx (Notarized Signatures Required Next 2 Pages) -1- 8/12/2021 STATE OF NEW YORK,COUNTY OF WESTCHESTER ) as: 1-1 NCO t_-k-1 D ViZ fv i-,S 5 ,being duly sworn,deposes and states that he/she is the applicant above named, (print name of individual signing as the applicant) and further states that(s)he is the legal owner of the property to which this application pertains,or that(s)he is the l u tM 71 - for the legal owner and is duly authorized to make and file this application. (indicate architect,contractor,agent,attorney,etc.) That all statements contained herein are true to the best of his/her knowledge and belief,and that any work performed,or use conducted at the above captioned property will be in conformance with the details as set forth and contained in this application and in any accompanying approved plans and specifications,as well as in accordance with the New York State Uniform Fire Prevention&Building Code,the Code of the Village of Rye Brook and all other applicable laws,ordinances and regulations. Sworn to before me this ,: Sworn to before me this day of �v ,20 2D_ day of ,20 4 Signature of Property Owner Si attire of applicant Pn &--(Z Co Q.(o 0, G ei I ej =S Print Name of Property Owner Print Name of Applicant Notary Public 'NotaryPublic SHARI MELILLO ARI MELILLO Notary Public,State of New York Notary Public,State of New York No.OIME6160063 No.OIME6160063 Qualified in Westchester County, Qualified In Westchester County Commission Expires January 29,2 Commission Expires January 29,2� This application must be properly completed in its entirety and must include the notarized signature(s) of the legal owner(s) of the subject property, and the applicant of record in the spaces provided. Applications not properly completed in its entirety and/or not properly signed shall be deemed null and void and will be returned to the applicant, 8/12/2021 BUILDIl�F DE 'ARTMENT �] IE C r� E VILt(AGE OF"-R.,, ft"0OK 938 KING Sm Eye R BXtD,oK,NY 10573 JUN - 2 2022 VILLAGE OF RYE BROOK robl :ar BUILDING DEPARTMENT AFFIDAVIT OF COMPLIANCE VILLAGE CODE §216 • STORM SEWERS AND SANITARY SEWERS THIS AFFIDAVIT MUST BEAR THE NOTARIZED SIGNATURE OF THE LEGAL PROPERTY OWNER AND BE SUBMITTED ALONG WITH ANY BUILDING OR PLUMBING PERMIT APPLICATION. ANY BUILDING OR PLUMBING PERMIT APPLICATION SUBMITTED WITHOUT THIS COMPLETED AND NOTARIZED FORM WILL BE RETURNED TO THE APPLICANT . STATE OF NEW YORK, COUNTY OF WESTCHESTER } as: ?'Crc'-V_- CCAZC0 1e A- c4k ZRC >L LNG - , residing at, (Print name) (Address where you live) [; being duly sworn, deposes and states that (s)he is the applicant above named, and further states at(s)he is the legal owner of the property to which this Affidavit of Compliance pertains at; (Job Address) Rye Brook, NY. Further that all statements contained herein are true, and that to the best of his/her knowledge and belief,that there are no known illegal cross-connections concerning either the storm sewer or sanitary sewer, and further that there are no roof drains, sump pumps, or other prohibited stormwater or groundwater connections or sources of inflow or infiltration of any kind into the sanitary sewer from the subject property in accordance with all State, County and Village Codes. (Si ature of Property Owner(s)) >/ (Print Name of Property Owner(s)) Sworn to before me this d of 20 ag, (Notary Public) SHARI MEULLO Notary Public,State of New York No.01ME6160063 Qualified In Westchester County .3 Commission Expires January sr12/2021 f S i. N Vi N � tin cl) a. ❑ 0 s ° .: O, a a t' ice. Mot ■ 00 H w W N R ° c � I-t-I°I � �W��rr11 `�..� f/�1/�y1 z "•y � A � I/N Y~ y� M rV' 1• LO r h'S ICI C�j � �y M � � W � c7 � � � � a• � �► i� } Fri T" A �.'' C7 r�7 C C y V CN uq. i MM v 4 G i V �Z CW� N �i r {6 w G C W �I .3 u W ., U 0 ,c FBI V �I f45 � z c� Z; c et z a w o z a W� p t� cV e .. d U O 0F .� ytea ' 5: a BUILDING DEPARTMENT j] IE C r V V>2,LA:G1� +laF RYEBRoox 938 KINGSTREET, wvvw_ BR,0 ',NY 10573 �U - 2 2022 ry hr.06 L6iv VILLAGE OF RYE BROOK BUILDING DEPARTMENT ED APPLICATION FOR PERMIT TO INSTALL AND/OR REMOVE HEATING VENTILATION AND/OR AIR CONDITIONING EQUIPMENT FOR OFFICE USE ONLY: PERMIT#: Approval Date: Y Permit Fee: $ C?) Approval Signature: Other: Disapproved: (fees are non-refundable) W***W***WWW******WWW******WWW**W***WW**#*WW**WWWW*WWW***WWW*WWW****W**W******WWW*WWW****WW**W*****WWW*W RE UIREMENTS FOR RELEASE OF PERMIT&CERTIFICATE of COMPLIANCE: 1. Properly completed& Signed Application. 2. Site/Staging Plan if Required by the Building Inspector. 3. Copy of Licensed Contractor's Liability Insurance. (Village of Rye Brook must be fisted as certificate holder) &Workers Compensation Insurance on a NYS Board form(Form#C105.2 or Form#U26.3/or NY State Workers Compensation Waiver) 4. Payment of Fees/Unit. RESIDENTIAL=$100.00/unit• COMMERCIAL-$350.00/unit. 5. Inspection by the Building Department for removal and/or installation. (48 hour notice required) 6. Electrical work requires a separate Electrical Permit&Electrical Inspection. 7. Plumbing/Gas work requires a separate Plumbing Permit&Plumbing Inspection. WW**deW�+r�r�c;E*WW9r**W**irie�k*lek9c*Jede�lc*dc4;***W�r�rWaB9t�t*iFWW�r�rde9;W**WW�k*de*ic,,kWieW�ek�r k**WW9e*�Fk*ir**WWde�k*W****Wek*WfesE Application dated, Zt Z 0- Zis hereby made to the Building Inspector of the Village of Rye Brook for a permit for the installation and or removal of the HVAC equipment as listed below. The applicant and property owner,by signing this document agrees that said equipment will be installed and/or removed in conformance with all applicable Local,County, State&Federal laws, codes,rules and regulations. 1. Address: -e Q go SBL: j3 5, 73 ~ 1_ Zone: (� 2. Property Owner: ZL Z e A Address: 14 E 2QC)K I-A4tF Phone#: cl I ct Lf 9Z Cell#: email: 3. Contractor: t Address: 3 Lt Phone#: `I 11 cP 6 7 0 2 Z � _Cell#: `I 14 1-(11 7 S email:_z (� ly , 3 0) ,;�,f;'-y�• ,.c i 4. Applicant: Address: Phone#: Cell#: email: 5. Scope of Work:.New Installation •Replacement( }•Removal( }•Other( }: 6. List Equipment: •A ,- t 7. Location of Equipment: e�7- 8. Method of Installation/Removal(list all equipment needed to perforrn Job): C.0 IV,p&-I? r-EVS 1 8/12/2021 STATE OF NEW YORK,COUNTY OF WESTCHESTER ) as; _e 1 nl C C L t--1 i3\kQ-' b t 5 S ,being duly sworn,deposes and states that he/she is the applicant above named, (print name of individual signing as the applicant) and further states that(s)he is the legal owner of the property to which this application pertains,or that(s)he is the p[u t5� - !Z for the legal owner and is duly authorized to make and file this application. (indicate architect,contractor,agent,attomey,etc.) That all statements contained herein are true to the best of his/her knowledge and belief,and that any work performed,or use conducted at the above captioned property will be in conformance with the details as set forth and contained in this application and in any accompanying approved plans and specifications,as well as in accordance with the New York State Uniform Fire Prevention&Building Code,the Code of the Village of Rye Brook and all other applicable laws,ordinances and regulations. Sworn to before me this Sworn to before me this day of��. L ,20 r — day of 20 aa, d _ Signature of Property Owner *Siae of pplicant Rf&� Cc)z 4 , Print Name of Property Owner Print Name of Applicant 4NoPublic SHARI MELiLLO atary PublicSHARI MELILLO Notary Public,State of New York Notary Public,State of New York No.©iME6160063 No.01.ME6160063 Qualified In Westchester County. Qualified In Westchester county Commission Expires January 29,2 commission Expires January 29,2;23 This application must be properly completed in its entirety and must include the notarized signature(s) of the legal owner(s)of the subject property, and the applicant of record in the spaces provided.Applications not properly completed in its entirety and/or not properly signed shall be deemed null and void and will be returned to the applicant. -2- 8/12/2021 n 9JEREMe LAIN® CG a Weil-McLain,com CAST IRON GAS BOILER Water I Natural or Propane Gas 1 38-233 MBH 17 sizes Series 3 1 Atmospheric/Natural Draft 84% AFUE U.S. DEPARTMENT OF ENERGY 2021 COMPLIANT ILV „!RS ! k r 5 Now with built-in low water cut off CAST TO LAST Ideal for residential and commercial installations Durable cast iron design for long service life 111111 Built by North America's leading boiler manufacturer HEAT E%CHANGER MADE IN THE USA DIMENSIONS ;� - STANDARD EQUIPMENT: BOILER ■ Integrated Boiler Control Module with 35 intermittent electronic ignition system & indicator/diagnostic lights Frashalr ■ Integrated low-water cutoff, S 6-------- - opanlnp with test button ■ Two-piece top jacket panel ■ Insulated extended steel jacket ULs 2 ■ Cast iron sections with built-in air 3 6 �;j separator ■ Radiation plates Top vIEW SIDE ELEVATION TOP VIEW ■ Vertical draft hood Is Automatic vent damper --I D i' ■ Combination gas valve for 24 volt ■ Wiring harness 2% ■ Non-linting pilot burner 1 13A ■ Stainless steel burners -"4j/` 4s/``~ ■ Electrical junction box 0 H ■ Rollout thermal fuse element xoM - ( ■ High-limit temperature control ■ Circulator(when ordered) 19 - Sizes 25-5:Taco 007e '9 1313A. - Sizes 6-8: Taco 007 ■ Spill switch 9 w 12 ■ 30 PSI ASME relief valve (boiler sections tested for 50 PSI FRONT LEFT SIDE ' RIGHT SIDE working pressure) Note:Boiler circulator is shipped ■ Combination pressure-temperature toase.Circulator may be mounted on either boiler supply or return piping.See dimension chart for pipe size of circulator flange provided. gauge ■ Drain valve Carton Dimensions- ■ 40 VA transformer Nat or LP Outside Measurements Dimensions(In.) Supply Return Gas (In,) Is Plug-in connector and wiring Mode! q p W H piping Piping Connection (In.) (In.) Size(in.) L W€ H ADDITIONAL EQUIPMENT: CGa-25 5 4 10 453/e 3/43/a %z 30 27'h 35 ackage— CGa-3 5 4 10 52% 1 1 %2 30 271/2 35 ■ shipped in separansion tank ate carton CGa-4 6%2 5 13 54% 1 1 1/2 30 27A 35 (expansion tank fill&check valve, auto air vent and fittings) CGa-5 8 6 16 577/a 1 1 1/2 36 27%2 35 ■ Outdoor Reset Kit(part#381-356-586) CGa-6 9'% 6 19 607/a 11/, 11/a 36 42 27%2 35 Low cost,simple plug-in sensor—check CGa-7 11 7 22 62/a 174 1/a 3/a 42 27%2 35 local utility program for possible rebate, CGa-8 12%2 7 25 1647/a 1%2 1 1%2 3/4 42 271A 35 ■ Zone Interface Harness Kit(part #381-356-585)Used to communicate 'Circulator flange supplied with boiler is the same size as recommended pipe size.For supply and return bolter tapping size, between and existing relay panel wired see installation manual. into the systtem and boiler,to separate DHW from space heating demands. RATINGS LIMITED TRANSFERABLE DOE Net AHRI Approx. Boller WARRANTY: Heating Water Shipping water ■ Residential:20 Years Heat Exchanger;. Input Capae3 Ratings Weight Content Model' MBH3 MBH MBH• AFUE (Ill (Gal.) Chimney Size 2 Years Parts CGa-25 38 32 27 84.0% 200 15 4"I.D,x20, ■ Commercial:10 Years Heat Exchanger; CGa-3 67 56 48 84.0% 200 1.5 4"1.D,x20' 1 Year Parts CGa-4 100 85 73 84.0% 240 2.1 5"I.D.x20' CGa-5 133 113 98 84,0% 260 2J 61110.x201 2Add"PiN"for natural gas,"PIL"'for propane. 'Based standard test procedures prescribed by the CGa-6 166 141 122 84.0% 325 3 Unit.3 6"LD,x20' United States Department of Energy. CGa-7 200 170 147 84.0% 370 3.8 7"LD.x20° 'Net AHRI ratings are based on net installed radiation of CGa-B 233 198 172 84.0% 425 4,4 7"LD.x20' sufficient quantity for the requirements of the building and nothing needs to be added for normal piping and pick-up. Ratick-up aowance of CGa boilers are C.S.A.design certified for installation on combustible flooring.Tested for 50 PSI working pressure. 1135.1 Ansaddiaretionall allowancle sho shand ould be made for unusual piping and pick-up loads. J°�f'•\\ �+,/�.v�,,5 ENGINEERED, lr I IZLrfI 1 DOE 5(}{)} DESIGNED IG \\C�1_\y�// "5 awssRNR�ED In the interest of continual improvement in product and one+°® 1n IM USA performance,Weil-McLain reserves the right to change H specifications without notice, N!M'lrlrlq RRr3 rlid('(.a CGa SERIES BOILER CG SUGGESTED SPECIFICATIONS I. General Requirements A. Furnish and install ( ) low pressure packaged cast iron sectional boiler(s) that operate under natural draft. B. Install boiler-burner unit(s) in compliance with manufacturer's installation instructions. All work must be done in a neat and workman-like manner. C. Weil-McLain qty. ( ) CGa ( ) PIDN, ( ) PIDL boiler(s) capable of burning natural gas at 5 to 13"w.c. or propane 11 to 13" W.C. inlet pressure. 1. Packaged boiler (standard). 2. Natural or propane gas fired. 3. Water. 4. Minimum 84% efficiency. 5. Natural draft. D. Boiler(s) shall have an AHRI gross output(s) at 100% firing rate— ( ) MBH per boiler. E. Boiler(s) shall be manufactured to conform to Section IV of the ASME Boiler and Pressure Vessel Code. 1. Individual sections (and section assembly) to be hydrostatically pressure tested at factory in accordance with ASME requirements. 2. Maximum allowable working pressure 50 PSIG water and cast as part of section with ASME symbol. F. Regulatory Requirements Boiler(s) and controls to comply with applicable regulations. G. Submittals 1. Submit shop drawings and product data. 2. Submittal packet to include boiler (and burner) manufacturer descriptive literature, installation instructions, operating instructions, and maintenance instructions. Weil-McLain EO LUE1 (ne LAI H 500 Blaine Street ■ Michigan City, IN 46360-2388 Weil-mclain.com Pagel of 3 C-878R3(0720) II. Product A. Acceptable boiler/burner manufacturer(s) include(s): 1.Weil-McLain only, as specified in Part 1, Paragraph C. 2. Other manufacturer(s) or other Weil-McLain boiler(s) must comply with specifying engineer's requirements, including: a) Full intent of these specifications, and provide complete submittal including literature, wiring diagrams, fuel piping diagrams, and a list of similar installations. b) Submittal to be presented to specifying engineer at least seven working days for approval before bid opening. Substitutions are not permitted after contract is awarded. c) Energy Management Control System(s) must be tested and approved for installation with specified boiler by boiler manufacturer. B. Boiler construction 1. Boiler sections a) Assembled with tie rods. b) Parallel ground sealed with high temperature silicone sealant to assure permanent gas-tight seal. c) Sealed water-tight by elastomer sealing rings, not cast iron nipples. Each port opening is machined to accept elastomer sealing rings between sections. d) Provided with sufficient tappings to install required controls. C. Boiler(s) 1 Provided with cast-in air elimination to separate air from circulating water. 2 Provided with expansion tank tapping to divert separated air to expansion tank. 3 Constructed to provide balanced water flow through entire section assembly using single supply and return connections for water. No external headers are necessary. 4 Designed with a low silhouette to provide maximum headroom. 5 Elastomer sealing rings are to be used to provide permanent water-tight seal between sections. Unlike cast iron or steel push nipples, the elasticity of the seals fills any gaps caused by misalignment or expansion or contraction. 6 Constructed with stainless steel burner tubes. 7 Shipped with insulated heavy gauge steel jacket(s) with durable powdered paint enamel finish. Jacket shall have two piece top panel for easier servicing. E. Boiler foundation(s): Installer to construct needed support and level concrete foundation(s) where boiler room floor is uneven or will not support the weight of the boiler(s). E. Boiler trim: 1. All electrical components to be of high quality and third (3rd) party recognized. Wei!-McLain LUEWMLAIN 500 Blaine Street Michigan City, IN 46360-2388 weil-mclain.com Page 2 of 3 C-878R3(0720) a) Water boiler(s) controls furnished: 1) High temperature limit setting to be 140 —240 degrees. 2) Integrated low water cut off functionality. 3) Combination pressure-temperature gauge with dial clearly marked and easy to read. 4) ASME certified pressure relief valve, set to relieve at 30 PSIG. Optional relief valves available up to and including maximum allowable pressure. Side outlet discharge type; contractor to pipe outlet to floor drain or near floor, avoiding any area where freezing could occur. 5) Integrated spark module for vent damper control, with indicator lights for easy troubleshooting. D. Boiler Manuals: 1. Boiler manual. 2. Gas control supplement. 3. User's information manual. Wei]-McLain WEIt500MC LAI� Blaine Street ■ Michigan City, IN 46360-2388 Weil-mclain.com Page 3 of 3 C-878R3(0720) WEILaMiLYA►IH (: (; a DESI��Y ® sP A� �+ s� Series 3 iC US �FR r I F\�� CERTIFIED Gas-Fired Water Boilers Boiler Manual • Installation • Maintenance • Startup • Parts E ow With Built In er Cut off Functionality , �a Aw�Rrli�1G This manual must only be used by a qualified heating installer/service technician. Before Installing, read all instructions,including this manual,and any related supplements.Perform steps in the order given.Failure to comply could result in severe personal injury,death or substantial property damage. Part Number 550-142-300/0520 SeriesCGa i - Boller How it works . . . OControl module The control module responds to signals from the room thermostat and boiler limit circuit to operate the boiler circulator,pilot burner,gas valve and vent damper.When room thermostat calls for heat,the control module starts the system circulator and activates the vent damper(causing it to drive open). When the vent damper has opened completely, the control module opens the pilot valve and activates pilot ignition spark. For natural gas,the control module allows up to 15 seconds to establish pilot flame.If flame is not sensed within 15 seconds,the control module will turn off the gas valve,flash the Flame light,and immediately start a new cycle. This will continue indefinitely until pilot flame is established or power is interrupted.Once pilot flame is proven, the control module opens the gas valve to allow main burner flame. For propane gas,the control module allows up to 15 seconds to establish pilot flame.If flame is not sensed within 15 seconds, the control module will turn off the gas valve, flash the Flame light,wait 1 minute,then start a new cycle.If flame is still not sensed after the second trial,two more attempts are made with 5 minute and 60 minute wait periods in between. If flame is not sensed after 4 tries,control will lockout and flash all lights.Control must be manually reset to place back into service.Once pilot flame is proven,the control module opens the gas valve to allow main burner flame. When the room thermostat is satisfied,the control module turns off the gas valve and deactivates the vent damper (causing it to close). The control module indicator lights show normal sequence when the lights are on steady.When a problem occurs, the control module flashes combinations of lights to indicate the most likely reason for the problem.See page 49 for details. OTkansformer The control transformer reduces line voltage to 24 volts for the gas valve and limit circuit. O Draft hood The draft hood provides a minimum draft for the boiler, assuring adequate air for combustion if installed in accordance with manual and not modified in any way. ® Spill switch The spill switch will shut down the boiler (requiring manual reset of the switch reset button)if the vent system becomes blocked. OWater temperature/ LWCO sensor The water temperature/LWCO sensor provides a signal to the control module to turn off the gas valve if the tem- perature in the boiler goes above its setting or if a low water condition is sensed.(The circulator will continue to run as long as there is a call for heat.) © Boiler circulator The boiler circulator circulates water through the external (system) piping.The circulator is shipped loose,and can be mounted on either the boiler supply or return piping. The factory-installed circulator wiring harness provides ample length for either location.NOTE—The control module provides a pump exercising routine.If the boiler is not operated for 30 days,the control module will power the circulator for 30 seconds,then turn off. OVent damper The vent damper closes during off cycles to reduce heat loss from the house up the vent. Other boiler components: a supply to system f pressure/temperature gauge k pilot burner,typical b return from system g relief valve 1 stainless steel burners c flue outlet h air vent connection m cast iron boiler sections d burner manifold ii flame rollout switch n flue collector e gas valve j burner orifice o junction box 2 Part Number 550-142-300/0520 Gas-Fired r Boller — Boller Manual Fol CGa Series 3 Gas-Fired Water Boner 4 k F� 6y ) ri l IIiwY�IT�~II�N Y33 '�3 q i��8 at f own m O O .I tl a Part Number 550-142-300/0520 3 Gas-Fired itBoller lFm Contents HowIt works .................................waus..............2-3 Hazarddefinitions ............................................... 4 Please read before proceeding............................ 5 1 Prepare boiler location ...................................6-11 2 Prepare boiler...............■..............................■ 12-15 3 Water piping ..............................................u■ 16-25 4 Gas piping ■..................uu.................................. 26 rJ Field wiring ....................................................... 27 SStart-up ........................................................28-32 7 Check-out procedure......................................... 33 8 Department of Energy Compliance ................... 34 9 Operation - spark-ignited pilot boilers..........34-41 14 Service and maintenance .............................42-47 11 Troubleshooting: Spark-ignited pilot boilers ............................48-56 12 Replacement parts .......................................58-63 13 Dimensions and ratings................................64-65 Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury,death or substantial property w ,= y damage. AWARtV�I�G Indicates presence of hazards that can cause severe personal injury, death or substantial property damage. ACAUTI0�1 Indicates presence of hazards that will or can cause minor personal injury or property damage. NQTICE Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage. Glycol -- potential fire hazard -- All glycol is flammable when exposed to high temperatures.If glycol is allowed to accumulate in or around the boiler or any other potential ignition source,a fire can develop.In order to prevent potential severe personal injury,death or substantial property damage from fire and/or structural damage: • Never store glycol of any kind near the boiler or any potential ignition source. Monitor and inspect the system and boiler regularly for leakage.Repair any leaks immediately to prevent possible accumula- tion of glycol. • Never use automotive antifreeze or ethylene glycol in the system.Using these glycols can lead to hazardous leakage of glycol in the boiler system. 1 Part Number 550-142-300/0520 Gas-FiredrBailer Please read before proceeding AWARN1h1C Installer—Read all instructions, including this NOTICE Write in the Consumer Protection(CP)number in manual and all other information shipped with the the space provided on the Installation certificate on boiler,before installing.Perform steps in the order page 33 if not already shown, give no prevent personal injury or death. When calling or writing about the boiler—Please User—This manual is for use only by a qualified have the boiler model number from the boiler rating heating installer/service technician. Refer to User's label and the CP number from the boiler jacket. Information Manual for your reference. Consider piping and installation when determining User — Have this boiler serviced/inspected by a boiler location. qualified service technician,at least annually. Any claims for damage or shortage in shipment Failure to comply with the above could result in severe must be filed immediately against the transportation personal injury,death or substantial property damage. company by the consignee. If any part of a boiler,burner or its controls has Saltwater Damage -- The exposure of boiler components to been sprayed with or submerged under water, saltwater can have both immediate and long-term effects.While the either partially or fully, DO NOT attempt to op- immediate effects of saltwater damage are similar to those of fresh- erate the boiler until the boiler has been either water(shorting out of electrical components,washing out ofcritical replaced or completely repaired,inspected,and lubricants,etc.),the salt and other contaminants left behind can lead you are sure that the boiler and all components to longer term issues after the water is gone due to the conductive are in good condition and fully reliable. and corrosive nature of the salt residue.Therefore,Weil-McLain Otherwise,by operating this boiler,you will cause equipment contaminated with saltwater or polluted water will no a fire or explosion hazard,and an electrical shock longer be covered under warranty and should be replaced. hazard,leading to serious injury,death,or substan- Electrical Damage--If any electrical component or wiring tial property damage.See the instructions at right. came into contact with water,or was suspected to have come into contact with water,replace the boilerwith a new Weil-McLain boiler. AWAFiNING Failure to adhere to the guidelines below can result in severe personal injury,death or substantial property damage. When servicing boiler— Boiler water— Freeze protection fluids — • To avoid electric shock,disconnect all Do not use petroleum-based cleaning . NEVER use automotive or standard electrical supplies to the boiler before or sealing compounds in boiler sys- glycol antifreeze. Use only freeze- performing maintenance. tem. Gaskets and seals in the system protection fluids made for hydronic may be damaged. This can result in systems. Follow all guidelines given • To avoid severe burns,allow boiler to substantial property damage, by the antifreeze manufacturer. cool before performing maintenance. Do not use "homemade cures" or Thoroughly clean and flush any re- This boiler contains ceramic fiber "boiler patent medicines". Serious placement boiler system that has used and fiberglass materials. Refer to damage to boiler, personnel and/or glycol before installing the new boiler the WARNING and instructions on property may result. page 66. Continual fresh makeup water will ACAUTI©hl Frozen Water Damage Boiler operation — reduce boiler life.Mineral buildup in Hazard sections reduces heat transfer, over- Residences or buildings that are unat- • Do not block flow of combustion or heats cast iron, and causes section tended in severely cold weather, boiler ventilation air to boiler. failure.Addition of oxygen and other system components failures,power out- Should overheating occur or gas sup- gases can cause internal corrosion. ages, or other electrical system failures ply fail to shut off,do not turn off or Leaks in boiler or piping must be could result in frozen plumbing and water disconnect electrical supply to pump. repaired at once to prevent makeup damage in a matter of hours. For your Instead,shut off the gas supply at a water, protection,take preventative actions such location external to the appliance. as having a security system installed that pp Do not add cold water to a hot boiler. operates during power outages senses low Combustion air— Thermal shock can cause heat ex- changer to crack. temperature,and initiates an effective ac- • DO NOT install combustion air in- tion.Consult with your boiler contractor take where their is a risk of combos- or a home security agency. tion air contamination. Part Number 550-142-30010520 5 Gas-Fired r Boller Boller Manual R� laPrepare r r p e boiler location — codes & checklist installations must follow these codes: Local,:state,provincial,and national codes,laws,regilations and ordinances. • National Fuel Gas Code,ANSI Z223.IINFPA'54 latest edition. • Where required by the authority having jurisdictionthe installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-I — latest edition. • National Electrical Code,ANSI INFPA 70--latest edition. • For Canada only:Natural Gas and Propane Installation Code,CANICSA B149.1 or B149.2 Installation Code,CSA C22.1 Canadian Electrical Code Part 1 and any local codes. NOTICE The CGa boiler gas manifold and controls meet safe operating and other performance criteria when boiler underwent tests specified in ANSI Z21.13--latest edition. Before locating the boiler, check the following: • Check for nearby connection to: • System water piping • Venting connections • Gas supply piping • Electrical power • Check area around boiler. Remove any combustible materials, gasoline and other flammable liquids, or other contaminants. AWARNING Failure to keep boiler area clear and free of combustible materials, gasoline and other flammable liquids and vapors can result in severe personal injury,death or substantial property damage. • Boiler must be installed so that gas control system components are protected from dripping or spraying water or rain during operation or service. • If new boiler will replace existing boiler, check for and correct system problems, such as: 1. System leaks causing oxygen corrosion or section cracks from hard water deposits. 2. Incorrectly-sized expansion tank. 3. Lack of antifreeze in boiler water causing system and boiler to freeze and leak. 6 Part Number 550-142-300/0520 SeriesCGa I llBoller l lbPrepare iboiler location clearances Recommended SERVICE clearances (Fig, 1 a) Figure 1 b Required MINIMUM clearances 1. Provide clearances for cleaning and servicing the boiler and for access to controls and components.See Figure la for recommen- 7: dations. 2. Provide at least screwdriver clearance to jacket front panel screws ry, for removal of front panel for inspection and minor service. If is if;f,f£ I�Im• + m unable es in system so bo ovide at least lriver clearance,install and can be moved forervicing 3y-liogl Figure 1a '; � Recommended 5+`gal � � i� tip' ep9n9 i 3 service 3 clearances 1 ` < (see WARNING below) + Q fil l��;� P� Flooring o94oz The CGa boiler is approved for installation on combustible flooring,but must never be installed on carpeting. 08405 AWARNING Do not install boiler on carpeting even AWARNIlG If any clearance is less than in Figure 1 a,pro- if foundation is used. Fire can result, vine openings for combustion and ventilation causing severe personal injury, death air located on the wall or door opposite the or substantial property damage. boiler FRONT(see Figure t b), These openings must be located as shown in Figure lb to provide Foundation roper air flow around the boiler.The free area of each opening{pafter deducting for louvers) must be at least one square inch 1. Provide a solid brick or minimum 2-inch thick concrete per 1,000 Btuh of boiler input. If the building is of unusually foundation pad if any of the following is true: tight construction(see page 11 for definition),the air openings floor can become flooded. must connect directly to outside or the building must have air openings to the outside as specified on page 11. the boiler mounting area is not level. If clearances are equal to or greater than Figure 1a,see pages 10 2. Minimum dimensions are 25"length by: and 11 for location and sizing of combustion air openings. Minimum foundation width: Failure to comply can result in severe personal injury,death or CGa-2513 12" CGa-s 21" substantial property damage and reduced boiler hfe. CGa-4 15" CGa-7 24" Required MINIMUM clearances (Fig. 1 b) CGa-5 18" CGa-8 271' AWARIdING Never install the boiler in a space with clear- Residential garage installations ances less than the minimum clearances shown Take the following special precautions when installing the in Figure 1b.Failure to comply can result in severe boiler in a residential garage. If the boiler is located in a personal injury,death or substantial property dam- residential garage,per ANSI Z223.1,—latest edition: age and reduced boiler life. Mount the boiler a minimum of 18 inches above the 1. Hot water pipes: at least 1/2 inch from combustible material. floor of the garage to assure the burner and ignition 2. Single-wall vent pipe: at least 6 inches from combustible mate- devices will be no less than 18 inches above the floor, rial. 3. Type B double-wall metal vent pipe: refer to vent manufacturer's Locate or protect the boiler so it cannot be damaged recommendation for clearances to combustible material. by a moving vehicle. Part Number 550-142-300/0520 7 SeriesCGa iBoiler BoilerFm 1 C Prepare p e boiler location — vent system AWARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions,causing severe personal injury or death. Inspect existing chimney before installing boiler.Failure to clean or replace perforated pipe or tile lining will cause severe personal injury or death. Do not alter bailer draft hood or place any obstruction or non-approved vent damper in breeching or vent system, CSA certification will become void.Flue gas spillage and carbon monoxide emissions will occur causing severe personal injury or death. When removing boiler from an Chimney or vent require- existing common vent system; ments At the time of removal of an existing boiler,the following 1. Venting must be installed according to Part 7,Vent- steps shall be followed with each appliance remaining ing of Equipment,of National Fuel Gas Code,ANSI connected to the common venting system placed in op- Z223.1-latest edition and applicable building codes. eration,while the other appliances remaining connected Canadian installations must comply with B 149.1 or to the common venting system are not in operation. 13149.2 Installation Codes. a. Seal any unused openings in the common venting 2. See Ratings table on page 65 for minimum chimney system. or vent sizes.A chimney or vent without a listed b. Visually inspect the venting system for proper cap should extend at least 3 feet above the highest size and horizontal pitch and determine there is no point where it passes through a roof of a building blockage or restriction,leakage,corrosion or other and at least 2 feet higher than any portion of a deficiencies which could cause an unsafe condition. building within a horizontal distance of 10 feet. c. Test vent system—Insofar as is practical,close all A chimney or vent must not extend less than the building doors and windows and all doors between distances stated above. the space in which the appliances remaining con- 3. A lined chimney is preferred and must be used when netted to the common venting system are located required by local, state, provincial and national and other spaces of the building. Turn on clothes codes,laws,regulations and ordinances.Vitreous tile dryers and any appliance not connected to the com- linings with joints that prevent retention of moisture mon venting system.Turn on any exhaust fans,such and linings made of noncorrosive materials are best. as range hoods and bathroom exhausts,so they will Advice for Flue connections and chimney linings can operate at maximum,speed.Do not operate a sum- g mer exhaust fan.Close fireplace dampers. be obtained from local gas utility.Type B double- wall metal vent pipe or single-wall vent pipe may d. Place in operation the appliance being inspected. be used as a liner. Follow the operating instructions.Adjust thermostat so appliance will operate continuously. 4. Cold masonry chimneys, also known as outside chimneys, typically have one or more walls ex- c. Test for spillage at draft hood relief opening after posed to outside air. When any atmospheric gas- 5 minutes of main burner operation.Use the flame fired boiler with automatic vent damper is vented of a match or candle. through this type of chimney,the potential exists for f. After it has been determined that each appliance condensation to occur. Condensation can damage remaining connected to the common venting system a masonry chimney.Neil-McLain recommends the properlyvents when tested as outlined above,return following to prevent possible damage. doors, windows, exhaust fans, fireplace dampers, a. Line chimney with corrosion-resistant metal and any other gas-burning appliance to their previ- liner such as AI.29-4C*'single-wall stainless ous conditions of use. steel or B-vent.Size liner per National Fuel Any improper operation of common venting; system Gas Code ANSI Z223.1 -latest edition. should be corrected so the installation conforms with 1). provide drain trap to remove any condensate. the National Fuel Gas Code, ANSIZ223.1/NFPA 54 -latest edition.Correct by resizing to approach the mini- 5. Where two or more gas appliances vent into a mum size as determined using the appropriate tables in common chimney or vent,equivalent area should Part 13 of that code.Canadian installations must comply be at least equal to area of vent outlet on largest with Natural Gas and Propane Installation Code,CAN/ appliance plus 50 percent of vent outlet area on C:SA B149.1 or 13149.2 Installation Code, additional appliance. 8 Part Number 550-142-300/0520 COO Series 3 Gas-Fired Water Bailer Boiler ldPrepare `pa a boiler location — air contam�nat�on Please review the following information on potential Refer to Table 1 for products and areas which may cause combustion air contamination problems. contaminated combustion air. AWARN[IdG ....TO prevent potential of severe personal injury.or death,check for products or areas.listed Mow before installing boiler.If any of these contaminants are.found,` remove contaminants permanently OR. isolate boiler and provide outside combustion air.Sce national,provincial or local Bodes for further information. Table 1 Corrosive contaminants and likely locations Products to avoid Areas likely to have contaminants Spray cans containing ehloro/fluorocarbons Dry cleaning/laundry areas and establishments Permanent wave solutions Swimming pools Chlorinated waxes/cleaners Metal fabrication plants Chlorine-based swimming pool chemicals Beauty shops Calcium chloride used for thawing Refrigeration repair shops Sodium chloride used for water softening Photo processing plants Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants Hydrochloric acid/muriatic acid Furniture refinishing areas and establishments Cements and glues New building construction Antistatic fabric softeners used in clothes dryers Remodeling areas Chlorine-type bleaches,detergents,and cleaning Garages with workshops solvents found in household laundry rooms Adhesives used to fasten building products and other Buildings under construction(where air is contaminated similar products with particulates) Airborne particulates(drywall dust,fiberglass particles, road or gravel dust, lint,etc.) Part Number 550-142-300/0520 9 Gas-Firedit Boiler iFom lePrepare b iboiler location air openings AWARV111A1G Combustion air opening,lacation'and sizing Figure 2 Air openings to interior spaces requirements depend,on the clearances around`. the boiler.Check the boiler placement compared to: G . Figure 1a;page 7 1:.._... _ -7 Each opening free area- uro rr4 If.all clearances•are at least equal to Figure 16, 1 sq.inch per 1,OOD Btuh� page 7,`apply the sizing and placement of openings' CG, given art pages'10 and 11. bo,W Add ar°p. `� � 4utltl ag is ggGl If ANY is less than'Fi ore 1a . a e 7Olt- clearance - � f p � � �appliances you must provide air openings sized and located as i I g I showninFigurei '®®Ib .7bQ 1VQ7' ' the i z and location information shown.on page:10 or 11. q Figure 3 Air directly through outside wall Air openings must be provided moo rr Combustion air and ventilation openings must comply with the National Each opening free area Fuel Gas Code ANSI Z223.1-latest edition, or applicable local building 1 sq.inch per 4,000 8ruh a codes.Canadian installations must comply with B 149.1 or B 149.2 ° P Y Instal- lation Codes. AWARNING Provide adequate combustion and ventilation air to °p ,C0S assure proper combustion and reduce the risk of severe } personal injury,death or substantial property damage i caused by flue gas spillage and carbon monoxide °_~ emissions. Figure 4 Air from outdoors — vertical ducts Air opening options Two openings — Air supply from inside the building � �/ Outside arver,Ula ted attic 1. If the building is of unusually tight construction(see definition,next Each opening free area page),the building must also be provided with air openings directly 1 sq•inch per4,000 6tuh to the outside,sized and located per Figure 3,Figure 4 or Figure 5. CGa . , W., 2. Buildings of typical construction should provide adequate combustion s Oth°r p� air from natural infiltration,so additional air openings to the building ° ,°^�S are not required. 3. See Figure 2.Provide two openings through the interior wall,within 12 inches of the ceiling and the floor,sized per Figure 2. -: Ventilated ," Two openings — Air supply directly from outside I,,2,° _a__." arawispace N 1. Air openings must be directly through an outside wall,or into a space that connects directly to the outside(such as a ventilated attic or crawl Figure 5 Air from outdoors — horizontal ducts space,for example). 2. See Figure 3—Openings directly through an outside wall—provide C tla r E i two openings within 12 inches of the ceilingand the floor,sized Each opening free area a per 1 sq.inch per 2,000 Btuh Figure 3, 3. See Figure 4—Air supplied through vertical ducts—provide two ;G,.n, (15 openings terminated within 12 inches of the ceiling and the floor,sized i per Figure 4. otter o appLan°o& 4. See Figure 5 — Air supplied through horizontal ducts— provide two openings within 12 inches of the floor and the ceiling,sized per Figure 5. 10 Part Number 550-142-300/0520 Gas-Fired i iFun Prepare boiler location — air openings le p pe �ngs Unusually tight construction NOTICE FREE AREA of openings the minimum areas Unusually tight construction means(per ANSI Z223.1) given in this manual are free area (equals`the area, buildings in which: length tunes Width Of oper ng,after deduction for louver obstruction) a. Walls and ceilings exposed to the outside atmo- Use the free area"information provided by the louver manufacturer. sphere have a continuous water vapor retarder with When this inf6rrnation'is not available,assume: a rating of 1 perm or less with openings gasketed, and... Wood louvers-- assume free area is 20%of total;so the actual area b Weather-stripping has been added an openable of each opening with wood louvers would'be 5 times the required windows and doors,and... free area. , Metal louvers—assume free area is 60%of actual area;so,for wood C. Caulking or sealants are applied to areas such as louvers,the actual area of each opening must be 1.67 times the re- joints around windows and door frames,between quired free area. sole plates and floors,between wall-ceiling joints, between wall panels,at penetrations for plumbing, electrical,and gas lines,and in other openings. Single air opening option For such construction cases,if appliances use inside air A single combustion air opening can be used in lieu of the two-opening for combustion,provide air openings into the building options on page 10,provided: from outside. Size and locate these openings per the appropriate case in Figure 3,4 or 5 on page 10. Clearances from boiler to walls • The boiler must have clearances of at least those shown in Figure la, page 7. Opening must be directly to outside Exhaust fans and air movers • The opening must connect directly to the outdoors or to a space that The appliance space must never be under a negative communicates directly to the outdoors(not to an interior space), pressure,even if the appliance(s) are installed as direct • The air can be provided through a direct opening or through a horizontal vent.Always provide air openings sized not only to the or vertical duct. dimensions required for the firing rate of all appliances, but also to handle the air movement rate of the exhaust Opening placement fans or air movers using air from the building or space. • The top of the air opening must be within 12 inches of the ceiling. Opening size • The free area of the opening must be at least equal to the sum of the Motorized air dampers area of all equipment vent connectors in the space,and... If the air openings are fitted with motorized dampers, • The free area of the opening must be at least 1 square inch per 3,000 electrically interlock the damper to: Stu/hr input rating of all equipment located in the space. Prevent the boiler from firing if the damper is not fully open. Exception for large spaces Shut the boiler down should the damper close dur- No combustion air openings are needed when the boiler (and other ap- ing boiler operation. pliances)are installed in a space with a volume at least 50 cubic feet per To accomplish this interlock,wire an isolated contact 1,000 Btuh of all installed appliances,provided: (proving the damper open) in series with the thermo- • the building must not have unusually tight construction(see defini- stat input to the boiler.The boiler will not start if this tion,this page) contact is open, and will shut down should it open • all clearances around the boiler must be no less than shown in Figure I a, during operation. page 7. To determine if the space is large enough to qualify: • Add the total input of all appliances in MSH (1,000's of Btuh). • Multiply this number times 50 to determine minimum room volume. • Example: For a total input of 100 MSH (100,000 l3tuh), minimum volume is 50 x 100 = 5,000 cubic feet.At a ceiling height of 8 feet,the space must have at least 5,000 S =625 square feet (25 feet x 25 feet, for instance). Part Number 550-142-300/0520 L 1 CGa Series ire r Boller — Bailer Manual 2aPrepare boiler — placement and setup Place boiler/crate near , , Correctly-sized manifold orifices must be used. Failure to do so will pOSltlOn result in severe personal injury, 1. Leave boiler in crate and on pallet until installa- death or substantial property dam- tion site is ready. age. 2. Move entire crate and pallet next to selected location. 3. Level and straighten burners. 3. Remove crate.Leave boiler on pallet. Burners must be properly seated in 4. Remove boiler from pallet as follows: t slots in burner rest with their open- a. Tilt left side of boiler up and place a board under ings face up. Main burner orifices left legs, must inject down center of burner. b. Tilt boiler the other way and place a board under Failure to properly seat burners right legs. will result in severe personal injury, c. Slide boiler backwards off pallet and into posi- death or substantial property dam- tion. age. NOTICE Do not drop boiler or bump jacket on floor or pallet.Damage to boiler 4. Reinstall access panel. can result. 5. Check level. ACAUTIDN Do not operate boiler without ac- a. Shim legs,if necessary. cess panel secured in place. Failure b. Do not alter legs. to comply could cause momentary flame rollout on ignition of main flame, resulting in possible fire or Inspect orifices and burners personal injury hazard. 1. Remove front jacket door.Remove base access panel (See Figure 32,item 4,page 60). Orifice replacement procedure 2. Check for correct sized manifold orifices. See (when required) Table 2 below for sizing,(The orifice size is stamped on the orifice spud barrel.) 1. Remove access panel. Table 2 Manifold orifice sizing 2. On gas manifold,mark location of main burner with attached pilot assembly. Location Natural gas 3. Remove main burner with attached pilot assembly U.S. 0-2,000 ft. over 2,000 ft. from manifold.Remove all remaining burners. 2.00 mm (Note 1) 4. Remove and discard all main burner orifices in gas manifold. Canada 0-2,000 ft. 2,000.4,500 ft. 5. Apply a small amount of pipe dope to each of the 2.00 mm 1.90 mm new orifices and install in the manifold.Make sure the orifices are aligned correctly,not cross-threaded in the manifold tappings. Location ::. Propane gas AWARNING Use only pipe dope compatible with U.S. 0-2,000 ft. over 2,000 ft. propane gas,even if boiler is to be CGa 25 #61 (Note 1) operated on natural gas. Failure to CGa 3-8 #56 (Note 1) comply could result in severe per- sonal injury, death or substantial Canada 0-2,000 ft. 2,000-4,500 ft. property damage. CGa 25 #61 .95mm CGa 3-8 #56 #57 6. Reinstall main burner with attached pilot assembly at location marked on gas manifold. Reinstall all Note 1:For elevations above 2,000 feet,contact your remaining burners. Well-McLain sales office for details. 7. Follow check-out procedure,Section 7,page 33. 12 Part Number 550-142-300/0520 Series it 2b Prepare boiler — p pressure test Hydrostatic pressure test 4. Close shutoff valves, S. Slowly reopen boiler drain valve until test pressure Pressure test boiler before attaching water or gas piping of not more than 45 psi is reached on the pressure/ or electrical supply(except as noted below), temperature gauge. Prepare boiler for test 6. Test at no more than 45 psi for no more than 10 minutes. 1. Remove the shipping nipple (from CGa supply AWARMfNG Do not leave boiler unattended. tapping) and remove the boiler relief valve. A cold water fill could expand and Temporarily plug the relief valve tapping with a a/;" cause excessive pressure, resulting NPT pipe plug. in severe personal injury, death or 2. Remove 11/4" nipple, reducing tee and drain substantial property damage. valve from accessory bag. Install in boiler return 7. Make sure constant gauge pressure has been main- connection as shown on page 3 or in Figure 34,item tained throughout test. Check for leaks. Repair if 3,page 62.Install circulator on either the return or found. supply. 3. Remove 1'/a"nipple,11/4"tee,bushing and pressure/ temperature gauge from accessory bag. Pipe to Leaks must be repaired at once. boiler supply-connection as shown in Figure 34, , ►WARNING Failure to do so can damage boiler, page 62-.(Use pipe dope sparingly.) resulting in substantial property 4, Connect a hose to boiler drain valve,the other end damage. connected to a fresh water supply.Make sure hose can also be used to drain boiler after test. 5. Connect a nipple and shutoff valve to system supply r Do not use petroleum-based clean- connection on the 11/4"tee.This valve will be used ing or sealing compounds in boiler to bleed air during the fill. (Valve and nipple are system. Severe damage to boiler not included with bailer.) will occur, resulting in substantial property damage. 6. Connect a nipple and shutoff valve to system return connection(at circulator flange if circulator installed on return). This valve will be used to bleed air during the fill. (Valve and nipple are not Drain and remove fittings included with boiler.) I. Disconnect fill water hose from water source. Fill and pressure test 2. Drain boiler at drain valve or out hose,whichever 1. Open the shutoff valves you installed on supplyand provides best access to drain. Remove hose after draining if used to drain boiler. return connections, 2. Slowly open boiler drain valve and fresh water 3. Remove nipples and valves unless they will remain supply to fill boiler with water. for use in the system piping. 3. When water flows from shutoff valves,close boiler 4. Remove plug from relief valve tapping.See Section 3 drain valve. to replace relief valve. Part Number 550-142-300/0520 13 Gas-Fired t lBoiler 2cPrepare boiler — draft hood & spill switch Draft hood installation Spill switch installation 1. Orient draft hood with spill switch mounting holes to front of boiler 1. Fasten spill switch to draft hood as shown in Figure 6 as shown in Figure 7. and Figure 7. 2. Secure draft hood to outlet at top of boiler with sheet metal screws. 2. See Wiring diagram to connect wires:. 3. Bottom of draft hood or"skirt"must have clearance dimension above jacket top panel as indicated on draft hood, a. Spark-ignited pilot boiler— R, Do not alter boiler draft hood or place any obstruction or see pages 36 and 37 , non-approved vent damper in breeching or vent system. AWARMING Improper orientation of spill switch CSA certification will become void.Flue gas spillage and may cause boiler to shut down.The carbon monoxide emissions will occur causing severe loss of heat can result in significant personal injury or death. damage due to freezing. Figure 6 Install spill switch Figure 7 Spill switch with wire harness r Draft hood Z. r -'' Spit] switch Spill switch l 11 �" Spill switch wire I harnessr. p v; Damper harness knockout - Draft hood - j w l 3 f; 2d Pre pare boiler — install vent piping 1. Connect from draft hood or vent damper outlet to chimney or vent Long horizontal vent connector, With same size vent connector. AWARNING excessive number of elbow or 2• Where possible,vertical venting to the outside from the draft hood or tees, or other obstructions that vent damper outlet will offer best performance, restrict the flow of combustion 3. Where horizontal vent connector is used,slope upward at least 'A"per gases should be avoided. Severe lineal foot toward chimneyor vent and support with hangers to prevent personal injury,death or substan- sagging, tial property damage could result. 4. Breeching must not be connected to any portion of a mechanical draft system that can operate under positive pressure. 14 Part Number 550-142-300/0520 Gas-Fired it 2e Pre pare boiler — Vent damper enstailation NOTICE These systems are used on gas-fired boilers with vent Installation dampers as shipped from factory.Boiler will not operate without vent damper installed. I. Install vent damper horizontally or vertically as Only vent dampers listed in the Replacement arts list shown in vent damper manufacturer's instructions. A WAI?NING y P P P on page 58 are certified for use with CGa boilers.Any Vent damper must be installed so that it serves onlyone boiler and so damper blade indicator is visible other vent damper installed could cause severe personal to the user.See Figure 8. injury or death. 2. Screws or rivets used to secure the vent damper to Damper blade the draft hood must not interfere with rotation of the damper blade. 3. Install damper harness between damper actuator Spark-ignited pilot systems—Refer to vent manu- and knockout in jacket top panel.Use strain relief facturer's instructions to install plug(shipped with connectors and Iocknuts to secure both ends of damper)in damper hole.For spark-ignited pilot damper harness, boilers only,install plug with no hole in vent damper Keep wiring harness clear of all hot hole. A CAUTION surfaces. Minimum clearances WARNING LINE UP KEYWAY WHEN Provide a minimum of 6"between the vent damper and CONNECTING PLUGS. any combustible material.(Provide a minimum of 36" FORCING A MISMATCH between jacket top and combustible ceiling.) CAN CAUSE A HAZARDOUS CONDITION. t , Do not modify draft hood or vent damper,or make an- ` other connection between draft hood and vent damper T or boiler except as noted below. This will void CSA certification and will not be covered by Weil-McLain . warranty.Any changes will cause severe personal injury, Keyway Key 593oa death or substantial property damage. 4. Read and apply the harness plug warning label (shown above)so that it is visible after installation. Figure 8 Vent damper assemblies 5. Plug damper harness receptacle into damper harness plug. Effikal or Field Controls l Bypassing(jumpering)vent damper damper Refer to vent manufacturer's instructions to install will cause flue products such as plug (shipped with damper)in damper hole. carbon monoxide to escape into the house. This will cause severe personal injury or death. 1 � � � ACAUTION After boiler has operated once,if ei- ther end of harness is disconnected, Damper the system safety shutdown will oc- blade cur.The boiler will not operate until indicator harness is reconnected. k � X NOTICE Effikal or Field Controls damper— Damper hold open switch must be Hold-open switch (Effikal only) _ in Automatic Operation position Install vent damper so that switch for system to operate properly. is visible and accessible to user. 59325 Part Number 550-142-300/0520 15 CGa Series l ' — Boller Manual —1 3aWater general information piping -- g o anon General piping information Circulator If installation is to comply with ASME or Canadian requirements,an ad- The circulator is shipped loose (wiring pre-attached to ditional high temperature limit is needed.Install control in supply piping boiler) to allow you to locate it either in the return or between boiler and isolation valve.Set second control to minimum 207F supply piping,as desired.See page 3 for a typical instal- above setpoint of first control. Maximum allowable setpoint is 2407F. lation.Pipe the expansion tank to the suction side of the See page 36,for wiring. circulator whenever possible.Install an air separator in Use backflow check valve in cold water supply as required by local codes. the supply piping.Connect the expansion tank to the air separator only if the separator is on the suction side of Water temperature/LWCo sensor the circulator.Always install the system fill connection A low water cutoff device is required when boiler is installed above radix- at the same point as the expansion tank connection to the system. Figures 9 and 10 show typical near-boiler tion level or by certain state or local codes or insurance companies.The piping connections. boiler has a pre-installed water temperature/LWCO sensor. Pressure/temperature gauge System water piping Install pressure/temperature gauge in tee on supply piping(as shown in See Figure 9(diaphragm-type or bladder-type expansion drawing on page 3). tank) or Figure 10 (closed-type expansion tank), and Table 3 below, for near-boiler and single-zone systems Isolation Valves designed for return water at least 1307E Isolation valves are required to enable servicing of theboiler's temperature See pages 18-19 to complete multiple-zone piping or pages 20-25 to complete piping for radiant heating sys- tems or converted gravity systems(large-volume systems originally designed for circulation by natural convection Relief valve rather than a pump).See page 25 for boilers used with Install relief valve vertically in 3/a"tapping on side of boiler.See Figure 9 refrigeration systems. or 10,page 17,and the tag attached to the relief valve for manufacturer's instructions. Table 3 Water pipe size(based on 207F rise) Boiler model To From C� system system AWARNIIt1G To avoid water damage or scalding due to relief ---- - — --.-..-..--- ---..-Y.-.--- -- - --- ---- valve operation: CGa-25 - 3/4" 3/4.. • Discharge line must be connected to relief valve outlet and run to a CGa-3,4,5 1„ 1 ll safe place of disposal.Terminate the discharge Pane to eliminate CGa-6,7 11/4" 1'/4" possibility of severe burns should the valve discharge. CGa-8 _ _ 11/2" 1 1/z" • Discharge line must be as short as possible and be the same size Note:The boiler supply and return connections,the return/ as the valve discharge connection throughout its entire length. thre�boler are the 4"Nsupply/gauge 7lyb euof the supplied flanges supplied with the boiler is 11/4".The other circulator • Discharge line must pitch downward from the valve and terminate flange is the size of the recommended system piping at least b"above the floor drain where any discharge will be clearly _shown above: -_-...._...................................--.---..-........... visible. • The discharge line shall terminate plain, not threaded, with a AWARidIAtG Chillers or air handling units: material serviceable for temperatures of 3757F or greater. Install boiler such that--- • Do not pipe the discharge to any place where freezing could Chilled medium, if used, is piped in parallel with occur. heating boiler. Use appropriate valves to prevent No shutoff valve shall be installed between the relief valve and chilled medium from entering boiler.Consult AHRI • Installation and Piping Guides. boiler,or in the discharge line.Do not plug or place any obstruc- If boiler is connected to heating coils located in tion in the discharge line, air handling units where they can be exposed to • Failure to comply with the above guidelines could result in fail- refrigerated air, use flow control valves or other ure of the relief valve to operate,resulting in possibility of severe automatic means to prevent gravity circulation personal injury,death or substantial property damage. during cooling cycle. Circulation of cold water • Test the operation of the valve after filling and pressurizing through the boiler could result in damage to the heat system by lifting the lever.Make sure the valve discharges freely. exchanger, causing possible severe personal injury, If the valve fails to operate correctly,replace it with a new relief death or substantial property damage. valve. 16 Part Number 550-142-300/0520 SeriesCGa Gas-Fired Boller Boiler man&gal 3bWate-rpiping — single-zone system LAGAUTIONJ Undersized expansion tanks cause system water to be lost from relief valve and makeup water to be added through fill valve.Eventual section failure can result. Diaphragm-type or bladder- Closed-type expansion tank type expansion tank (Figure 9) (Figure 10) 1. Ensure expansion tank size will handle boiler and 1. Ensure expansion tank size will handle boiler and system water volume and temperature.Tank must system water volume and temperature. See tank be located in boiler return piping as close to boiler manufacturer's instructions for details. as possible,before inlet side of circulator.See tank 2. Connect tank to 1/2"NPT tapping located behind manufacturer's instructions for details. supply outlet, using 1/2" NPT piping. Pitch any horizontal piping up towards tank 1 inch per 5 feet 2. Install an automatic air vent as shown. of piping. AWARNING Use Figure 9 or Figure 10 only for single-zone systems designed for return water at least 130°F. For systems with low return water temperature possible, such as converted gravity systems and radiant heating systems, refer to the special piping suggestions of pages 20-25. Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners,resulting in severe personal injury,death or substantial property damage. Figure 9 Diaphragm-or bladder-type expan- Figure 10 Closed-type expansion tank — Single- sion tank — Single-zone system using zone system using closed-type expan- diaphragm-type or bladder-type expan- sion tank.See Table 3 for piping sizes. sion tank. See Table 3 for pipingsizes. Cold CLOSED-type From water expansion tank system fill To DIAPHRAGM From expansion tank system Cold water fill �I and fittings Isolation / valve Isolation Isolation valve Isolation valve valve To system Relief Relief To system Circulator* valve valve Circulator* Automatic air vent .- Circulator Drain valve NO Drain *Alternate valve 59307 location Circulator *Alternate so1n6 location Part Number 550-142-300/0520 17 Series Boller Boller 3c Water 'e piping — multiple zones Piping multiple zones . Piping for radiant heating Follow instructions on pages 16 and 17 to install near- systems or converted gravity boiler or single-zone piping. (Also refer to Piping systems for radiant heating systems or converted gravity systems,below,if applicable.) Converted gravity (or steam) systems See Figure 11 or Figure 12,page 19, to complete in- Whenever possible,use the primary/secondary piping stalIation. shown in Figures 13 or 14 on page 21.This piping de- sign allows changing boiler flow rate without affecting Zoning with circulators (Figure 11) primary circuit flow rate. (return temp over 130°F) If Figures 13 or 14 cannot be used,use the boiler-bypass 1. Size each circulator to individual circuit require- piping shown in Figure 15 or Figure 16 on page 23.You meats. can also use the piping shown in Figure 17 on page 25 2. Do not install circulator on boiler (except for (system-bypass),if the reduced flow rate in the heating primary/secondary piping). system will not cause heat distribution problems. 3. Install isolation(balancing)valves to adjust flow to AWARNING Failure to prevent low return water distribute heat to all zones. temperature to the boiler could cause 4. Install and wire a separate relay for each zone corrosion of the boiler sections or burn- circulator. ers,resulting in severe personal injury, death or substantial property damage. Zoning with zone valves (Figure 12) Radiant heating systems (return temp over 130°F) preferably, use primary/secondary piping, as shown 1. Install isolation(balancing)valves to adjust flow to in Figures 13 or 14 on page 21.Alternatively, use the distribute heat to all zones. method of either Figure 15 or Figure 16 on page 23. 2. Provide a separate 24-voit transformer to power the Do not use the piping of Figure 17(system-bypass), zone valves.Size the transformer to handle the total because this method does not control radiant system rated load of all connected zone valves. supply temperature. If radiant system tubing has no oxygen barrier,a heat B,CAUTIO DO NOT connect directly from exchanger must be used. 3-wire zone valves to the?T termi- nals on the boiler.When using 3-wire zone valves, install an isolation relay. Connect the zone valve end switch wires to the isolation relay coil.Connect the isolation relay contact across the boiler T-T terminals. Failure to comply can result in damage to boiler components orcause unreliable operation,resulting in severe property damage. AWARNtNG Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature(such as provided by an injection pumping control).Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant. DO NOT apply the methods in this manual if the system is equipped with an outdoor reset control. Instead, provide controls and piping which can regulate the boiler return water temperature at no less than 130°F regardless of system supply temperature.Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners,resulting in possible severe personal injury,death or substantial property damage. 13 Part Number 550-142-300/0520 CGa Series 3 Gas-Fired Water Boiler - Sofler Manual 3c Water—piping — multiple zones (continued) Figure 11 Zoning with circulators — return water Figure 12 Zoning with zone valves — return water 130°F or higher. 130°F or higher. r---------------��---------i r-.-_____ ZONE 2 - - - r------ + --- ---------- ZONE 2 - - -----�� -----' I I i E ZONE 1 ZONE 1 I r I 2 Lr3 I J^ I I CAI 2 1 0 1 3 ; E 5 r LJ > _ 6 13 6 � 13 62j--,4 6 1 � 1 Alternate 3i circulator location I 9. 10 Y 9 njl 10 Cold 11 cow n 11 water = L_ l- - water— fill — fill .�i I 1 Boiler isolation (balancing) 10 Automatic air vent(with diaphragm-type expansion tank),or connect valves to tank fitting(closed-type expansion tank).DO NOT use an automatic air vent when using closed-type expansion tank. It would allow air to 2 Flow/check valve leave the system,causing waterlogging of the expansion tank. 3 System or zone circulator 11 Fill valve 12 Diaphragm-type or bladder-type expansion tank,if used(For closed- 5 Zone valve type expansion tank,pipe from top of air separator to tank fitting as in Figure 10,page 17.) 6 Drain valve 13 Air separator and automatic vent,if used(Note that the fill valve must always be connected to the expansion tank, regardless of location of 9 Relief valve expansion tank circulator or air separator. AWARNING For systems with possible low return-water temperature(such as converted gravity systems, radiant heating systems and heat pump systems),refer to the special piping suggestions of Figures 13--17,as applies.Failure to prevent sustained low return water temperature to the boiler could cause corrosion of the boiler sections,resulting in severe personal injury, death or substantial property damage, Part Number 550-142-300/0520 19 SeriesCGa it iter — Boller Manual 3dWate' r piping how temperature systems Primary/secondary (preferred) water temperature being supplied to the radiant tubing. Bypass piping method Gauge 8 is required on all systems to assure the return Primary/secondary bypass piping is preferred because water temperature is accurately set for a minimum of the flow rate and temperature drop in the heating 130°F.If this gauge is not available however,adjust the circuit(s) is determined only by the heating circuit valves such that the boiler-mounted temperature/pres- circulator(s). So adjustment of the bypass valves in sure gauge reads at least 150°F when the system return the boiler circuit will not cause a change in the heating water is cold(approximately 607 water temperature). circuit rate and temperature distribution. Figures 13 and 14,page 21, show suggested bypass Vale adjustment arrangements using primary/secondary bypass piping (Figures 13 and 14 only) (preferred)for low temperature systems such as radiant 1. Set the valves while the system is coo[,setting for the heating systems or converted gravity systems.For coldest expected water temperature (usually 60°F alternatives,see pages 22 through 25. since the system will often drop to room tempera- The bypass valves(items 7a and 7b)provide mixing of ture between cycles). hot boiler outlet water with cooler system return water 2 Start with valve 7a fully closed and 7b fully open. —set to assure a minimum return water temperature (at least 130°F)to the boiler.Set the valves as explained 3. Gradually open valve 7a while closing valve 7b until below. the temperature at gauge 8 reads 130°F when gauge 4a reads 60°F. Temperature gauges Gauge 4a is suggested,but optional on any system. 4. Note that valve 7a regulates the amount of hot wa- ter from the boiler supply which mixes with return Gauge 4b is optional on converted gravity systems,but water.Valve 7b regulates the amount of system water required on radiant heating systems—to display the flowing through the boiler secondary loop. ,�A,WARIdlNG Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners,resulting in severe personal injury,death or substantial property damage. Radiant heating system piping should include a means of regulating the moiler return water temperature and the system supply temperature(such as provided by an injec- tion pumping control). Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant. DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control.Instead,provide controls and piping which can regulate the boiler return water temperature at no less than 134°F regardless of system supply temperature.Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners,resulting in possible severe personal injury,death or substantial property damage. 20 Part Number 550-142-300/0520 Gas-FiredBoller 3dWater piping — low temperature systems (continued) Figure 13 Primary/secondary piping Figure 14 Primary/secondary piping Zoning with circulators Zoning with zone valves r-------------- +----- ---------I ZONE 2 `--- ---- - - -------------+------ E +--- � '------------- a. -------- ZONE 2 �------- Icy 1 ......,._.........�ZON_E-.....1.. ZONE 1 i � Lr 2 4a ,12, 4b O 3 T '- 1 4a 12 r 4b 3 -0 6 MAX. �L7 Lj��•- �� �--v"Tr-�---:ter-w-r--�-r —�-�'r' r�►p MAX. j-r- T a '16 1 7b 13 �j g I6 1 7b 13 1 B -� 7a - Alternate 78 , g Circulator O—Fµ circulatorAlternate IeCation �Er , i I tion AI Cold E 10 11 water— cold 11 fill r -� water�,� fill 12 i � � f 12 59310 .-L. 69311 1 Boiler isolation(balancing)valves 10 Automatic air vent(with diaphragm-type expansion tank),or connect to tank fitting(closed-type expan- sion tank), DO NOT use an automatic air vent when 3 System or zone circulator(circulator should cycle using closed-type expansion tank. It would allow with zone valve and switches,using circulator valve air to leave the system,causing waterlogging of the or zone control panel) expansion tank. 4 System temperature gauges 11 Fill valve 5 Zone valve 12 Diaphragm-type or bladder-type expansion tank, if used (For closed-type expansion tank, pipe from 6 Drain valve top of air separator to tank fitting as in Figure 10, 7 System temperature valves(see instructions to the page 17.) left for adjusting valves) 13 Air separator and automatic vent,if used(Note that 8 Blend temperature gauge the fill valve must always be connected to the expan- sion tank, regardless of location of expansion tank, 9 Relief valve circulator or air separator.) Part Number 550-142-300/0520 21 Gas-Fired r Boiler — Boiler Manual Fun] 3 Water piping — low temperature systems (continued) BOILER-bypass piping to the boiler. (When setting the valves without gauge method 4a installed—using cold or room temperature water —assume the return water temperature to be 60°F.Set This piping method(Figure 15 or 16,page 23)is called the valves so gauge 8 reads at least 120°F. a boiler-bypass because part of the circulator flow is Gauge 4b is optional on converted gravity systems,but bypassed around the boiler (through valve 7a). This required on radiant heating systems—to display the method reduces the flow rate throughout the boiler,in water temperature being supplied to the radiant tubing. order to raise the average water temperature in the boiler enough to prevent flue gas condensation.Boiler-bypass Gauge 8 is required on all systems to assure reliable piping is effective for some boilers — including the adjustment of the bypass valves.The boiler-mounted CGa—provided the flow rates are adjusted according temperature/pressure gauge can be used if a separate to the instructions following. temperature gauge is not installed. Figures 15 and 16 are alternative piping suggestions for converted gravity (large water content or steam Valve adjustment systems) or radiant heating system —for use when primary/secondary piping can't be applied.(Figure 17, 1. Start with valve 7a fully closed and 7b fully open. page 25,is another alternative,using system bypass in 2, Gradually open valve 7a while closing valve 7b place of boiler-bypass piping. Figure 17 however, is until the temperature at gauge 8 reads 60°F higher not suitable for radiant heating applications because it than gauge 4a,A minimum 607 temperature rise does not protect the radiant system from possible high through the boiler assures a low enough flow rate water temperature.) and high enough average temperature to prevent Boiler-bypass piping keeps system flow rate as high as condensation even with low system return water possible and temperature drop as low as possible,help- temperature. ing to equalize the building heat distribution. 3. Valve 7a regulates the system flow rate,while valve Temperature gauges 7b regulates the boiler flow rate. Gauge 4a is optional if the bypass valves will be ad- 4, The boiler-mounted temperature/pressure gauge justed using cold (or room temperature) return water may be used in place of a separate gauge 8. AWA#tNING Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners,resulting in severe personal injury,death or substantial property damage. Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature(such as provided by an injec- tion pumping control). Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant. DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control.Instead,provide controls and piping which can regulate the boiler return water temperature at no less than 130OF regardless of system supply temperature.Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners,resulting in possible severe personal injury,death or substantial property damage, 22 Part Number 550-142-300/0520 SeriesCGa 190 3dwater piping — low temperature systems (continued) Figure 15 Boiler-bypass piping Figure 16 Boiler-bypass piping Zoning with Circulators Zoning with zone valves (Alternative to primary/secondary piping (Alternative to primary/secondary piping Figures 13 and 14) Figures 13 and 14) r---------------r r - ------ - -----+--------- ZONE 2 --------- ---�____ -r. y _-___ ZONE 2 ---- NE - ZO ZONE 1 1 , r ;3 r E'. , 2 r`F 5- Fk1 1 <;, i Lrr 4a 4b 2 � r4 3 C 4b 5 ; [ 13 I 6 1 F 1 6 6 M Anarnato i FAG t] 13 Grculalor ►—} ]—�� lac©rinni !3 7a 8 7a 6 7b 7b .-! 1 9� 10 9., 10 Cold612 1 4a water flit Gold 011 -�- i'.. "wj water fill F12 { � I I 59312 —, 59313 1 Boiler isolation (balancing)valves 10 Automatic air vent (with diaphragm-type expansion tank),or connect to tank fitting(closed-type expansion 2 Flow/check valve tank).DO NOT use an automatic air vent when using closed type expansion tank.It would allow air to leave 3 System or zone circulator the system,causing waterlogging of the expansion tank. 4 System temperature gauges 11 Fill valve 5 Zone valve 12 Diaphragm-type or bladder-type expansion tank, if 8 Drain valve used (For closed-type expansion tank, pipe from top 7 System temperature valves (see instructions of air separator to tank fitting as in Figure 10.) to the left for adjusting valves) 13 Air separator and automatic vent,if used(Note that the 8 Blend temperature gauge fill valve must always be connected to the expansion tank,regardless of location of expansion-tank,circulator 9 Relief valve or air separator.) Part Number550-142-300/0520 23 CGa Series ireBailer Boller Manual run] 3dWater piping — l®vv temperature systems (continued) SYSTEM-bypass piping DO NOT apply system-bypass piping if the reduced method flow in the system could cause poor heat distribution. That is, system-bypass piping reduces the flow in the This piping method (Figure 17, page 25) is called a system and increases the water temperature supplied to system-bypass because part of the circulator flow by- the system.This can cause increased heat from radiators passes the system(through valve 7a).This bypassed hot at the beginning of the system and reduced heat from water from the boiler outlet mixes with cooler system radiators near the end of the system. return water temperature in order to provide minimum 130°F return water to the boiler.Valve 7b will most often be full open,but may need to be slightly closed on some Valve adjustment low pressure drop systems in order to cause enough flow through valve 7a. 1. Start with valve 7a fully closed and 7b fully open. Figure 17 is an alternative piping method that provides return water temperature control for boilers installed 2. Gradually open valve 7a while closing valve 7b until on converted gravity systems (large water content the temperature at gauge 8 reads at least 130°F at all or steam systems). times. DO NOT apply the piping of Figure 17 on radiant heating systems. It provides no method of regulat- 3. Valve 7a regulates the amount of boiler supply water ing the water temperature provided to the system and mixed with return water.Valve 7b causes a pressure could result in excessive water temperature in the radi- drop in the system needed to balance flow through ant tubing, valve 7a and the system. System-bypass piping as shown in Figure 17 can be used with either zone valve or circulator zoning.When used 4. The valve adjustment should be done with the with circulator zoning however, the boiler circulator system at the coldest expected temperature (60°F (item 3),must be piped as shown.It cannot be used as for converted gravity systems or high mass radiant one of the zoning circulators. systems). AWARNING Failure to prevent low return water temperature to the boiler could cause corrosion of the boiler sections or burners,resulting in severe personal injury,death or substantial property damage. Radiant heating system piping should include a means of regulating the boiler return water temperature and the system supply temperature(such as provided by an injection pumping control). Boiler return water temperature will be adequately controlled using the methods shown in this manual provided the system supply temperature is relatively constant. DO NOT apply the methods of this manual if the system is equipped with an outdoor reset control.Instead,provide controls and piping which can regulate the boiler return water temperature at no less than 130OF regardless of system supply temperature.Contact your Weil-McLain representative for suggested piping and control methods. Failure to prevent cold return water temperature to the boiler could cause corrosion damage to the sections or burners,resulting in possible severe personal injury,death or substantial property damage. 24 Part Number 550-142-300/0520 CGa Series 3 Gas-Fired Water i Bailer i Pol 3 d w ater piping -- low temperature systems (continued) From system 4A To system Figure 17 System-bypass I„ ., g piping — Zoning with 78 7b zone valve or circulators, return water 130OF or higher-- (Alternative to boiler- i K - bypass piping Figures 18 and 16, E page 23) f Alternate i, ;location°f 3 System or zone circulator 10 7 System temperature valves(see instructions to the left for adjusting valves) Colds 8 Blend temperature gauge water fill i I 9 Relief valve i 412 3 10 Automatic air vent (with diaphragm-type expansion tank),or connect to tank fitting(closed-type expansion tank). DO NOT use an automatic air vent when using closed-type expansion tank.It would allow air to leave the system,causing waterlogging of the expansion tank. 11 Fill valve 12 Diaphragm-type or bladder-type expansion tank,if used (For closed-type expansion tank, pipe from top of air 5931A separator to tank fitting as in Figure 10,page 17.) 3 e water piping — refrigeration systems Figure 18 piping refrigeration systems Prevent chilled wafter from 1 entering boiler System Expansion tank Y ; Install boiler so that chilled medium is piped in parallel supply with the heating boiler,Use appropriate valves to prevent w S hut-Ehut- boiler. See Figure off g chilled medium from enterin 18 for Circulator �k valve typical installation of balancing valve and check valve. 1-- If boiler is connected to heating coils located in air han- Water dling units where they can be exposed to refrigerated chiller air, use flow control valves or other automatic means to prevent gravity circulation during cooling cycle. Strainer Boiler Check valve S m -->. return Balancing 59315 valve - - Part Number 550-142-300/0520 25 CGa Series - Boiler manual 4Gasi p ping Connect gas supply piping to boiler Natural Gas: 1. Remove jacket front panel and refer to Figure 19 to pipe gas to boiler. 1. Refer to Table 4 for pipe length and diameter.Base a. Install drip leg at inlet of gas connection to boiler.Where local on rated boiler input(divide by 1,000 to obtain cubic utility requires drip leg to be extended to the floor,use appropri- feet per hour).Table 4 is only for gas with specific ate length of pipe between cap and tee. gravity 0.60, with a pressure drop through the b. Install ground joint union for servicing,when required. gas piping of 0.30" w.c. For additional gas pipe c. Install manual shutoff valve in gas supply piping outside boiler sizing information,refer toANSI Z223.1(or B149.1 jacket when required by local codes or utility requirements. or B149.2 for Canadian installations). d. In Canada—When using manual main shutoff valve,it must be 2. Inlet pressure required at gas valve inlet: identified by the installer. Maximum: 13"w.c. 2. Support piping with hangers,not by boiler or its accessories. Minimum: 5"w.c. 3. Purge all air from gas supply piping. Manifold gas pressure:3.5"w.c. 4. Before placing boiler in operation,check boiler and its gas con nec- 3. Install 100%lockup gas pressure regulator in supply tion for leaks. fine if inlet pressure exceeds 13"W.C.Adjust for a. Close manual main shutoff valve during any pressure testing at 13"w.c,maximum. less than 13"w.c. b. Disconnect boiler and gas valve from gas supply piping dur- ing any pressure testing greater than 13"w.c. Propane Gas; AWARNING no not check for gas leaks with an open flame— 1. Contact gas supplier to size pipes,tanks and 100% Use bubble test.Failure to use bubble test or check for lockup gas pressure regulator, gas leaks can cause severe personal injury, death of 2 Adjust propane supply regulator provided b 1S substantial property damage, l P P PP Y g P y g� 5. use pipe dope compatible with propane gases.Apply sparingly only supplier for 13"w.c.maximum pressure. to male threads of pipe joints so that pipe dope does not block gas flow. 3. Inlet pressure required at gas valve inlet: Failure to apply pipe dope as detailed above can result Maximum: 13"w.c. AWARNING in severe personal injury,death or substantial property Minimum: 11"w.c. damage. Manifold gas pressure: 10"w.c. Table 4 Pipe capacity for 0.60 specific gravity natural gas Figure 19 Gas supply piping Gas pipe Capacity of pipe for pipe size of; length (Capacity in cubic feet gas per hour) (feet) 1/211 ,/a" t„ 11/a„ 1,/�„ Manual main shutoff gas valve 10 132 278 520 1050 1600 (when required) 20 92 190 350 730 �1100 30 73 152 285 590 860_ Ground joint union - 40 63 130 245 500_� 760 (when required) 50 56 115 215 440 670 75 45 93 175 360 545 -,-__Tee 100 38 79 150 305 460 150 31 64 120 250 380 Nipple `` Cap �I i 59322 26 Part Number 550-142-300/0520 a i i i 5 Field wiring AWARNING For your safety,turn off electrical power supply at ser- the wiring diagram shown in Figure 25b,page 37. vice entrance panel before making any electrical con- For other devices,refer to manufacturer's specifica- nections to avoid possible electric shock hazard.Failure tions. Wiring diagram on boiler gives setting for to do so can cause severe personal injury or death. control module and gas valve.Also see instructions with thermostat. N0T1CF Wiring must be N.E.G.Class 1. DHW If rollout thermal fuse element wire as supplied with boiler must be replaced,type 200°C wire or equivalent must be Connect DHW aquastat as shown in wiring below. used.If other original wiring as supplied with boiler must Economy function isn't utilized with DHW input. be replaced,use only type 1050C wire or equivalent. Boiler must be electrically grounded as required by Junction box (furnished) National Electrical Code ANSI/NFPA 70—latest edition. 1. Connect 120 VAC power wiring(Figure 20). 2. Fused disconnect or service switch(15 amp.recom- Installation must comply With: mended) may be mounted on this box.For those installations with local codes which prohibit instal- 1. National Electrical Code ANSI/NFPA 70—latest edition lation of fused disconnect or service switch on boiler, and any other national,state,provincial or local codes or install a 2 x 4 cover plate on the boiler junction box regulations. and mount the service switch remotely as required 2. In Canada,CSA C22.1 Canadian Electrical Code Part 1, by the code. and any local codes. Wiring connections Wiring multiple zones Boiler is shipped with controls completely wired,except spill Refer to zone valve manufacturer's literature for wiring pp P Y p p and application.A separate transformer is required to switch and vent damper. Refer to wiring diagrams shown power zone valves.Zoning with circulators requires a on page 36 for spark-ignited pilot boiler. relay for each circulator. Thermostat ACAUTION DO NOT connect directly from 3-wire zone valves to the T T terminals on 1. Connect thermostat as shown on wiring diagram on the boiler. When using 3-wire zone boiler. valves,install an isolation relay.Connect 2. Install on inside wall away from influences of drafts,hot the zone valve end switch wires to the or cold water pipes,lighting fixtures,television,sunrays isolation relay coil.Connect the isolation or fireplaces. relay contact across the boiler T-T 3. If thermostat has a heat anticipator,set heat anticipator terminals.Failure to comply can result in in thermostat to match power requirements of equip- damage to boiler components or cause ment connected to it.If connected directly to boiler,set unreliable operation,resulting in severe for 0.1 amps plus gas valve current.See information on property damage. Figure 20 l 120VAc IsService l Hot M1Flrutral i GrauncE 17-1 o-"I switch Field wiring connec- DH v ar smf ssvilch tions — service switch, DHW ' .� sOrvire I i 1 1 I I (if used)and "i�`I' I� thermostat Q I I I I (or end switch)pro- i I II I I Ia vided by installer l ) J J J Thunrarvl5vnlrh 0-m;l screw i�o,,•a�.;..m 01 I31ari. I>,Vhll.• A�Gwwl 153ack E3lack Efluc It, 1 a ti 7hi,I;l,gS9•;S DHW Ic8J5. JuncLmt 1,ux, ° � liar=L;,Ihraiu,{h Ifunni h builor b.{I slde laf.64 left•t0. 1..O sl l,,ll ild Part Number 550-142-300/0520 27 CQa Series it Boller • Boller Manual 6aStart-up — preparation Check for gas leaks Determine if water treatment is needed AWARNING Before starting the boiler,and during Do not use petroleum-based clean- initial operation,smell near the floor ing or sealing compounds in boiler and around the boiler for gas odorant system. Severe damage to boiler will or any unusual odor.Do not proceed occur,resulting in substantial property with start-up if there is any indication damage. of a gas leak.Repair any leak at once. AWARNING Eliminate all system leaks. Continual fresh makeup water will reduce boiler AWARNING propane boilers only—Your propane life.Minerals can build up in sections, supplier mixes an odorant with the reducing heat transfer,overheating cast propane to make its presence detect- iron,and causing section failure. able. In some instances, the odorant can fade and the gas may no longer Verify water chemistry have an odor. Consult local water treatment companies for unusually hard water areas(above 7 grains hardness) or low pH wa- • Propane gas can accumulate at ter conditions(below 7.0).Boiler water pH of 7.0 to 8.5 is floor level. Smell near the floor recommended. for the gas odorant or any unusual odor.If you suspect a leak,do not attempt to light the pilot. Freeze protection [when used] • Periodically check the odorant level Use antifreeze made especially for hydronic systems.Inhib- of your gas. ited propylene glycol is recommended. AWARNING Do not use ethylene glycol, automo- • Inspect boiler and system at least tive or undiluted antifreeze. Severe yearly to make sure all gas piping personal injury or death can result. is leak-tight. 1. Determine antifreeze quantity according to system water content.Boiler water content is listed on page 65. Consult your propane supplier Remember to include expansion tank water content. regarding installation of a gas leak 2. Follow antifreeze manufacturer's instructions. detector.There are some products on the market intended for this 3 A 50% solution of propylene glycol/water provides purpose.Your supplier may be able maximum protection to about-30°F. to suggest an appropriate device. 4. Loral codes may require back flow preventer or actual disconnect from city water supply. 5. When using antifreeze in a system with automatic fill, install a water meter to monitor water makeup.Glycol will leak before the water begins to leak,causing glycol level to drop. Added water will dilute the antifreeze, reducing the freeze protection level. 28 Part Number 550-1 k2-300/0520 SeriesCGa iier — Boller Manual Fffn] 6aStart-up — preparation (continued) Fill the system with water Inspect system water piping 1. Close manual and automatic air vents and boiler After filling the boiler and system with water,inspect drain cock. all piping throughout the system for leaks. If found, 2. Fill to correct system pressure.Correct pressure repair immediately. Repeat this inspection after the will vary with each application.Typical cold water boiler has been started and the system has heated up. fill pressure for a residential system is 12 psi. AWARNfNG Leaks must be repaired at once. 3. Purge air from system: Failure to do so can damage the a. Connect a hose to the purge valve (see drain boiler, resulting in substantial valves, item 6, in suggested piping diagrams property damage, on pages 17 through 23,Figure 9 through Fig- ure 16).Route hose to an area where water can , Do not use petroleum-based drain and be seen. cleaning or sealing compounds b. Close the boiler or system isolation valve be- in boiler system. Severe damage tween the purge valve and fill connection to the to boiler will occur, resulting in system. substantial property damage. c. Close zone isolation valves. d. Open quick-fill valve on cold water makeup line. e. Open purge valve. f. One zone at a time, open the isolation valves. Inspect base insulation Allow water to run through the zone,pushing out the air. Run until no noticeable air flow is AWARIfNG The boiler contains ceramic fiber present.Close the zone isolation valves and pro- and fiberglass materials. Use care ceed with the next zone.Follow this procedure when handling these materials until all zones are purged. per instructions on page 66 of this g. Close the quick-fill water valve and purge valve manual. Failure to comply could and remove the hose.Open all isolation valves. Watch that system pressure rises to correct cold- result in severe personal injury, fill pressure. Failure to replace damaged in- h. After the system has operated for a while,elimi- Hate any residual air by using the manual air sulation or reposition insulation vents located throughout the system. can result in a fire hazard,causing i. If purge valves are not installed in system,open severe personal injury, death or manual air vents in system one at a time,begin- substantial property damage. ning with lowest floor. Close vent when water Check to make sure base insulation is secure against squirts out.Repeat with remaining vents, all four sides of the base. If insulation is damaged or 4. Open automatic air vent (diaphragm-type or displaced,do not operate boiler.Replace or reposition bladder-type expansion tank systems only) one insulation. turn. 5. Open other vents: a. Starting on the lowest floor,open air vents one at a time until water squirts out. b. Repeat with remaining vents. 6. Refill to correct pressure. Part Number 550-142-300/0520 29 SeriesCGa i — Sailer Manual Fun] 6bStart-up '� operate boiler AWAR�lING €}O NOT proceed with boiler operation unless boiler and system have been filled with water and all instructions and.procedures of previous manual sections have been completed ailure;to do so could result in severe personal injury,death or substantial property damage.Before starting the boiler,do the following: Read manual Section 9 and the Operating instruction procedure(see Table 5,below). • Verify the boiler and system are frill of water. Verify the'Start up preparation procedures of Section 6 have been completed. ;Table 5 Operating instruction location guide Models Spark ignited puot Gas Page CGa-25 Honeywell VR8204NR8304 NaturallPropane 38 to CGa-6 Robertshaw 720fl Natural 39 While-Rodgers 36E Natural 40 CGa.T Honeywell VR8204NR8304 Natural/Propane,­ 38 66.64" White-Rodgers 36C Natural 41 Adjust boiler control settings 6C31L;�S BOILER OPERATING TEMPERATURE T ; With power turned on, control module receives a signal from the temperature/LWCO sensor and displays boiler temperature. ;. The control knob labeled BOILER'.TEMP is used to adjust the operating temperature setpoint, turning clockwise to increase i temperature setting and counterclockwise to decrease. When the knob is turned to adjust temperature the display will brighten to indicate adjustment mode. After temperature is set to desired , value,display will dim after approximately 5 seconds to indicate measurement mode. • ADJUST BOILER OPERATING TEMPERATURE TO DESIRED SETPOINT. BOILER ECONOMY SETTING IMPORTANT To comply with Department of Energy regulations, the control module circulates available hot water before turning on the boiler In accordance with Section 325 (f) (3) of the Energy Policy and to attempt to satisfy a call for heat. While attempting to satisfy Conservation.Act,this boiler is equipped with a feature that saves the heat demand, the control module also monitors the boiler energy by reducing the boiler water temperature as the heating temperature changes via the tempera ture/LWCO sensor and load decreases.This feature is equipped with an override which determines whether or not the available hot water will satisfy the 's provided primarily to permit the use of an external energy demand, adjusting the time delay to turn on the boiler until it management system that serves the same function. determines that additional heat will be needed, The knob labeled THIS OVERRIDE MUST NO"I'BE USED UNLESS AI'LEAST ECONOMYADJUST provides an adjustment between maximize ONE OF THE FOLLOWING CONDITIONS IS TRUE: (MAX)and minimize(MIN) time delay. The maximum(MAX) An external energy management system is installed that adjustment position should be used to maximize energy savings, reduces the boiler water temperature as the heating load Turning the knob counterclockwise decreases the delay time and decreases. should only be used in the event that the heated space becomes uncomfortable, This bailer is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • ADJUST ECONOMY TO DESIRED POSITION (MAX IS This boiler is equipped with a tankless coil. THE PREFERRED SETTING). 30 Part Number 550-142-300/0520 Gas-Fired 6bStart- up --r operate boiler (continued) Start the boiler • Follow the Operating Instructions from Section 9 to start the boiler.Remove boiler jacket door and AWARNING Eliminate .all system leaks. note the gas valve manufacturer and model number. Continual fresh makeup.water Use only the operating instruction which applies to will reduce`.boilerlife. Minerals'. this gas valve(see Table 5,page 30).(The operating can build up.'n sectigns;:reduc instruction label on the boiler provides the same ing heat transfer,overheating cast information.) iron,and causing section failure. See Section 6c if boiler fails to start. Check System and boiler AWARNING If you discover evidence of.any I. Check system piping for leaks. If found, shut gas leak,shut down the boiler at down boiler and repair immediately. once: Find the leak source with bubble test and repair immedi 2. Vent air from system using manual vents.Air in ately. Do not start boiler again the system will interfere with circulation and cause until corrected:Failure to comply heat distribution problems and noise. could result in"severe personal injury,death or substantial prop 3. Inspect vent system thoroughly for signs of erty damage. . deterioration from corrosion, physical damage or sagging.Verify that masonry chimney liners are in good condition,with no obstructions,and there are no openings into the chimney. , t , Do not use petroleum-based cleaning or sealing compounds 4. Check around the boiler for gas odor following the in boiler system. Severe damage procedure of Section 6a of this manual. to boiler will occur, resulting in 5. Verify operation per Section 6d.Perform check-out substantial property damage. procedure in Section 7 and fill in the Installation and service certificate on the same page. 6C Start-up — if boiler doesn't start . . . Check for: 1. Loose connections,blown fuse or service switch off? 4. Gas not turned on at meter or boiler? 2. Boiler temperature adjustment set below boiler 5. Incoming gas pressure less than: water temperature? 5"w.c. for natural gas? 1 I"w.c.for propane gas? 3. Thermostat set below room temperature? 6. if none of the above corrects the problem,refer to Troubleshooting,Section 11 of this manual. Part Number 550-142-300/0520 31 Gas-Fired r Baflar — Sailerl 6dStart-up — verify operation Nf17ICE See Section 9 for operation and operating information. Check burner flames Figure 21 Typical pilot burner flame Pilot burner flame (Figure 21) PROPER pilot flame Spark Inner 1. Blue flame. electrode cone 2. Inner cone engulfing pilot flame sensor (spark- ignited pilot). I I . 3. Pilot flame sensor glowing cherry red. IMPROPER pilot flame 1. Overfired—Large flame liftingor blowing past pilot Pilot flame flame sensor. sensor 2. Underfired—Small flame.Inner cone not engulfing pilot flame sensor. 3. Lack of primary air—Yellow flame tip. Main burner flame (Figure 22) 5931e PROPER main burner flame Figure 22 Typical main burner flame 1. Yellow-orange streaks may appear(caused by dust). IMPROPER main burner flame: 1. Overfired—Large flames. 2. Underfired—Smallflames. Transparent 3. Lack of primary air— Yellow tipping on flames blue flame (sooting will occur). Inner flame Check vent damper operation 59319 3 1. Raise room thermostat to call for heat --Vent damper actuator will slowly open vent damper. 5. Return thermostat to normal setting. 2. When vent damper is fully open—Pilot will light, 6. Set thermostat heat anticipator setting indicated on then allow main burners to ignite. wiring diagram. Vent damper must be fully open before main burners light. If vent Check vent system operation damper does not fully open, flue products such as carbon monoxide 1, Check vent system at least once a month during will escape into house, causing se- heating season. With boiler firing, hold candle or vere personal injury or death. match below lower edge of draft hood "skirt". If [lame does not blow out, but burns undisturbed, 3. Lower thermostat setting—Main burner flames vent system is functioning properly.If flame blows will go out,then vent damper will close. out or flickers drastically, inspect vent system for 4. Repeat Steps 2 through 4 several times to verify obstructions or other causes of improper venting operation. (such as exhaust fans in boiler room). 32 Part Number 550-142-300/052G SeriesCGa i I Fal 7Check-out procedure — checklist ❑ Boiler and heat distribution units filled with water? ❑ Set Boiler Temp adjustment knob to system temperature re- quirements.Adjust balancing valves and controls to provide ❑ Automatic air vent,if used,open one full turn? design temperature to system. ❑ Air purged from system? ❑ Set Economy mode,fully clockwise. ❑ Air purged from gas piping?Piping checked for leaks? ❑ For multiple zones, adjust flow so it is about the same in ❑ Correctly sized manifold orifices installed?Refer to Table 2, each zone. page 12 to check size and fuel type. ❑ Verify thermostat heat anticipator (if available) set t , Correctly sized manifold orifices must be used. properly?Refer to Field wiring,manual Section 5,page 27, Failure to do so will cause severe personal Thermostat(s). injury,death or substantial property damage. ❑ Followed operating instructions on boiler or in manual ❑ Cycle bailer with thermostat—Raise to highest setting and Section for proper start-up? verify boiler goes through normal start-up cycle.Lower to lowest setting and verify boiler goes off. ❑ Proper burner flame observed?Refer to Check burner flame, ❑ Cycle DH�V A ua manual Section 6d. y q stat if used. ❑ Test temperature limit—While burners are operating,turn Cl Measure natural gas input: Boiler Temp adjustment knob counterclockwise until display a. Operate boiler 10 minutes. reading is below actual boiler water temperature. Burners should go off while circulator continues to operate. Turn b. Turn off other appliances. Boiler Temp adjustment knob clockwise until display read- C. At natural gas meter, measure time (in seconds) re- ing is above boiler water temperature and ignition sequence quired to use one cubic foot of gas, should resume. ❑ Test low water cut off—While burners are operating,press d. Calculate gas input: and hold"LWCO TEST"button on control.Burners should go off while circulator continues to operate and LWCO light 3600 x 1000 = Btuh should turn ON.Release"LWCO TEST"button and ignition number of seconds from step c sequence should resume. ❑ Test field-installed controls—If the boiler has an additional C. Btuh calculated should approximate input rating on lowwater cutoff,additional high limit or other controls,test boiler rating label. for operation as outlined by manufacturer.Burners should ❑ Check manifold gas pressure by connecting manometer to be operating and should go off when controls are tested. downstream test tapping on main gas valve.Manifold pres- When controls are restored,burners should reignite. sure for natural gas should be 3.5"w.c.and for propane gas ❑ Button on spill switch pushed in? should be 10"w.c. ❑ Test ignition system safety device ❑ Observe several operating cycles for proper operation. Connect manometer to outlet side of gas valve.Start boiler, allowing for normal start-up cycle to occur and main burn- ❑ Set room thermostat to desired room temperature. ers to ignite.With main burners on,manually shut off gas supply at manual main shutoff gas valve.Burners should go ❑ Fill in Installation and service certificate below? off.Open manual main shutoff gas valve.Manometer should ❑ Review all instructions shipped with this boiler with owner confirm there is no gas flow.Pilot will relight,flame sensing or maintenance person.Return instructions to envelope and element will sense pilot flame and main burners reignite. give to owner or place in pocket inside front panel in boiler. Installation and service certificate Boiler model Series Consumer Protection number Date installed Measured Btuh input ❑ Installation instructions have been followed. Check out sequence has been performed. Above information is certified to be correct. ❑ Information received and left with owner/maintenance person Installer (company) (address) (phone) Installer's signature: Part Number 550-142-30010520 33 Gas-Fired l — Bailer Manual 8 Department of Energy - compliance This boiler is equipped with a control system that automatically adjusts a time delay period to turn on the boiler during a call for heat.This is accomplished by circulating available hot water in the system while measuring water boiler water tempera- ture changes. The control calculates a suitable delay based on temperature measurements and turns the boiler on only after it determines that the demand for heat cannot be satisfied with the available hot water, Due to the wide variety of controls used in boiler installations,this control is also equipped with an adjustment for the cal- culated time delay period(ECONOMY ADJUST),In the MIN position,the time delay is zero and the IMPORTANT notice below must be observed: IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act,this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases.This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: • An external energy management system is installed that reduces the boiler water temperature as the heating load decreases. This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. 9a Operation — spark-ignited pilot boilers NOTICE Follow all procedures given in this manual b. Natural Gas- If pilot does not light within 15 seconds, and operating instructions when operating the pilot valve is closed and spark generator is turned off.Control boiler. Failure to do so could result in severe module waits 5 minutes,then attempts to ignite pilot again. personal injury, death or substantial property This cycle will continue indefinitely if pilot ignition control damage. does not sense pilot flame. 1. Standby:With no call for heat,the vent damper and circulator c. Propane Gas- If pilot does not light within 15 seconds, are de-energized.No gas flows to pilot or main gas valve. pilot valve is dosed and spark generator is turned off.Control 2. Call for heat(thermostat circuit closes): module waits 1 minute then attempts to ignite pilot again. After first failed ignition retry attempt,control module will a. While attempting to satisfy the heat demand,the control attempt to ignite pilot 2 more times with a 5 minute wait module monitors the boiler temperature changes via the period after the second try and a 60 minute wait period after temperature sensor and determines whether or not the the third try.If the ignition control does not sense pilot flame available hot water will satisfy the demand,only running during these trials, it will lock out the boiler and require a the circulator. If additional heat is needed,the sequence manual reset procedure to allow further attempts. continues.When DHW(if used) calls for heat,sequence above is bypassed. Manual Reset Procedure for Propane Gas Lockout— b. Vent damper and circulator energized if pilot status ac- ,1� • Unburned propane gas may have accumulated ceptable.Vent damper drives open.When vent damper end in combustion chamber.Provide adequate switch makes circuit,ignition control begins pilot ignition ventilation to completely remove any attempt. accumulated LP gas from boiler and adjacent area before attempting to reset and light boiler. C. Ignition control checks for false flame signal: If ignition Failure to do so will cause severe personal control senses pilot signal when no pilot gas should be injury,death or substantial property damage. present,control will lockout,requiring reset procedure as Propane Gas Lockout manual reset—ONLY given in Figure 24. after boiler area has been cleared of any 3. Pilot ignition: Control module sparks the pilot and opens pilot accumulated LIB gas: valve to main gas valve. Push and hold TEST button,see page 50,Item 11. a. If pilot does light and control module senses flame While holding TEST button, rotate Economy Adjust knob current,spark generator is turned off and main valve opens. fully clockwise then fully counter clockwise. • Release TEST button. • Control module is reset. 34 Part Number 550-142-300/0520 Gas-Fired Bailer Bailer i 9aOperation — spark-ignited pilot boilers 4. Main burner operation: 5. Thermostat satisfied (thermostat circuit opens) —Pilot and a. Control module monitors pilot flame current.If signal main gas valves are closed—Vent damper is de-energized,and cycles is lost,main valve closes,spark generator activates and to closed position.Circulator is shut off. sequence returns to step 4. 6. Boiler is now in the standby mode. b. If power is interrupted,control system shuts off pilot 7. Thermostat anticipator setting:Set thermostat heat anticipator as and main gas valves and restarts at step 1 when power is instructed in Figure 25b,page 37. restored. c. In the event the limit control shuts down the boiler—The control module closes the main gas valve,but keeps the circulator operating and the vent damper open. Figure 24 Ignition control module sequence of operation — status light indications j Call for POWER TSTAT LIMIT I DAMPER FLAME LWCO Timing Heat? CIRC € STEPS __ _ -___ _ ---------. (following step 7,cycle gees back to step 1.) I€ I M 11. Standby — • Waiting for call for heat NO EQ n ( _ ............. Circulator on YESC) n - • Limit controls closed YES I ( — 4. Damper circuit • Damper proven open YESle I ft Q 0 5. Flame proven * I • Gas valve open i YES • Ignitor remains on ; ' i 15 sec • Boiler producing heat I € 6. Limit cycle • Limit circuit open YES - — • Gas valve closed - 7. Flame outage Flame out YES Q ' Boiler recycles I I I Q 6. Thermostat satisfied NO A Q • Circulator off '- 9. Circulator exercise routine • Circulator turns on for 3o seconds if NO 30 sec boiler not operated for days ._..m.�_-.._._._..... ._ .�.__.__-_._� -- P y _ ._. - ------ 10. LL CO circuit YES NO I • LWCQ circuit open .... ON = OFF See Section 9,Items 3b and 3c for controls response to failure to prove pilot flame. Control will lockout under the following conditions: Control will reset after these lockouts: • Line voltage polarity is reversed • 1 hour waiting period • Stray voltage is sensed on thermostat line Opening and closing of thermostat circuit for 2 to 20 seconds • Damper end switch not proven within 5 minutes from thermostat ! Removal of 1211 VAC power for 2 to 211 seconds call for heat •Flame is sensed when it shouldn't be there Part[Number 550-142-300/0520 35 SeriesCGa e — Bailer Manual N 9 ` , Operation 'pe anon — spark-ognated pilot system (continued) Figure 25a Schematic wiring diagram — Spark-ignited pilot system ACAUT�QN DO NOT connect directly from 3-wire zone valves to the T-T terminals on the boiler.When using 3-wire zone valves, install an isolation relay. Connect the zone valve end switch wires to the isolation relay coil.Connect the isolation relay contact across the boiler T T terminals. Failure to comply can result in damage to boiler components or cause unreliable operation, resulting in possible severe property damage. NOTICE ' The control module is polarity-sensitive to the incoming 120 VAC power. If polarity is reversed, control will flash the POWER light when powered and will not cycle boiler. All contacts shown without power applied. • Connector and status light locations/orientations may vary. FIELD 120 VAC— ♦Hot *Neutral aGnd WIRING ` I CIRCULATOR SERVICE I Items not ® SWITCH I provided Ground� screw VENT DAMPER Wire nuts ` a r Black White Green Junction box, Y boiler left side R BK B W l W TRANSFORMER Y - G PK/BL o )M", POWER E ; o CIRC W CIRC POWER is LIMIT � � DAMPER PILOT MAIN G FLAME p LWCO CIRC O BRIY K TRANSFORMERER B —"� W SPILL SWITCH/ �� BK R BUIRNER LOT Additional , G Y Ilmlts,if used K C R (note 7) BK - ——R — Bt_ To DHW Aquastat OUTDOOR LWCO SENSOR TSTAT SL (if used) ir, U TEST 14 i....' ROLLOUT ii THERMOSTAT TFELi L _ W BL W R O R G 8K BK OUTDOOR �_., `��� �.C•� To Black t,'WIRrNG',:Black TEMPERATURE [ U1 R „A„ ,, Ground SENSOR c I Screw (if used) TEMPERATURE/ LWCO SENSOR w -- GAS VALV Terminal block Jacket opening, 59374b+LWCO (Honeywell VR8204 shown) boiler left side 36 Part Number 550-142-300/0520 CGa Series 3 Gas-Fired Water Bailer — Boller Manual 9a0peration — spark-ignited pilot system (continued) Figure 25b Ladder wiring diagram — Spark-ignited pilot system WARNING Electrical shock hazard-can Hot cause severe injury or death. Neutral Grltl Disconnect power before installing 120 VAC or servicing, SERVICE SWITCH [ELECTRODE Legend for ladder wiring diagram CONTROLMODULI:120 VAC field wiringIGH 120 VAC Low voltage field wiring LTAGE SECTION CIRCULATOR 120 VAC factory wiring 11Low voltage factory wiring PILOT High voltage spark ignition wiringGNITION Ground connectors 120 VAC Table G:Gas valve terminals and anticipator settings Gas valve "A^ ^g^ ^C Anticipator amps Honeywell VR8204 MVIPV MV PV 0.6 24 VAC Honeywell VR8304 MVIPV MV PV 0.8 White-Rodgers 36E 2 1 3 0.64 24 VAC • ��$m Power CONSTANT White-Rodgers38C 2-4' 1 3 0.7 THERMOSTAT*- *Terminals 2-4 are factory-jumpered on the White-Rodgers 36C gas valve. [ I Z 1 Tstat Circ 1. All wiring must be installed in accord with: 24 VAC VENT A. U.S.A.---N.E.G.And any other national,state, CALL DAMPER or local code requirements. DHW(if used) FOR HEAT B. Canada—C.S.A. C22.1 C.E.C.Part 1 and any other national, provincial,or local code TEMPERATURE requirements. LWCO SENSOR 2. Pilot lead wires are not field replaceable. Replace pilot assembly if necessary. ROLLOUT SPILL 3. If any of the original wire as supplied with the TFE SWITCH �( appliance must be replaced, use minimum 105 "' f R] Limit °C wire or equivalent. Exception-�--wires to a Zi itional M PILOT GAS rollout TFE must be 200°C or equivalent, limits (note 7) VALVE 4. Thermostat anticipator setting(single zone)— Outdoor Temperature 1 „CEO see Table G for anticipator setting,depending Sensor(if used) Ii1A„ on which gas valve is installed in boiler. 111311 5. For multiple zoning, use either zone valves or oR Damper circulators. Refer to the component manufac- DAMPER END SWITCH MAIN GAS turer's instructions and this manual for applica- (INTERNAL TO DAMPER) VALVE tion and wiring suggestions. See A VEble G 6. Refer to control component instructions PILOT FLAME R Flame packed with the boiler for application informa- SENSOR _ tion. HIGH 7. Wire any additional limit controls(low water VOLTAGE LWCO cut-off,additional high limit,etc.)in series with boiler rollout TFE and spill switch as shown. Control Module Low Voltage Section 59374a+LWCO Part Number 550-142-300/0520 37 WaterCGa Series 3 Gas-Fired Bailer Boiler 9bOperatingc instructions CGa-25 t0 �eVla""� • Spark pilot *.:Natural'gas• Propane gas V� �eVI Gas valve: HoneywellVR8204NR8304 �FOROUR SAFETY READ BEFORE OPERATING AWARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use only your hand to turn the gas control knob.Never use tools.If which automatically lights the pilot. Do not try to the knob will not turn by hand, don't try to repair it, call a qualified light the pilot by hand. service technician. Force or attempted repair may result in a fire or B. BEFORE OPERATING, smell all around the explosion. appliance area forgas.Be sure to smell nextto the D. Do not use this appliance if any part has been under water. floor because some gas is heavier than air and will Immediately call a qualified service technician to inspect the settle on the floor.See below, appliance and to replace any part of the control system and any gas control,which has been underwater. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. a Immediately call your gas supplier from a neighbor's phone. • Do not touch any electric switch; do not use Fallow the gas supplier's instructions, any phone in your building. • If you cannot reach your gas supplier,call the fire department. IMENEEM OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 7. Waitfive(5)minutes to clear out any gas.Then smell for gas, 2. Set the thermostat to lowest setting, including near the floor.If you smell gas,STOP!Fallow"B" 3. Turn off all electrical power to the appliance. in the safety information above.If you don't smell gas,go to 4. Remove front panel. the next step. 5. This appliance is equipped with an ignition device which 8. Turn gas control knob counterclockwise �-� to"ON." automatically lights the pilot.Do not try to light the pilot by hand. 9. Turn on all electric powerto the appliance. 6. Turn gas control knob clockwise r-�, to"OFF" 10. Set thermostatto desired setting. woll 11. If the appliance will not operate,follow the instructions"To "°°` Turn Off Gas To The A Rance" and call our service Position ® 0 - Gas Appliance" Y indicator1: 0 Oo ° control technician orgas supplier. (shown in knob -oN"position) O ON a 12. Replace front panel. OFF 59331 TO TURN OFF GAS TO THE APPLIANCE 1. Set the thermostat to lowest setting. 3. Remove front panel. 2. Turnoff all electric power to the appliance if service is to be 4. Turn gas control knob clockwise n, to"OFF."Do not force. performed. 5. Replace front panel. [nrunu[[[[u unn[[u[Ill 550-223-041(0415) 38 Part Number 550-142-300/0520 SeriesCGa - ®- Boller 9bOperating in�s+t�ructions CGa-25 to CGa-6 Spark pilot • Natural gas • Gas vale: Robertshaw 1200 FOR YOUR SAFETY READ BEFORE OPERATING AWARNING I If you do not follow these instructions exactly, a fire or explosion may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use only your hand to depress or move the selector arm.Never use which automatically lights the pilot. Do not try to tools.If the selectorarm will not depress ormove by hand,don't tryto lightthepilotby hand. repair it,call a qualified service technician.Force or attempted repair B. BEFORE OPERATING, smell all around the may result in afire or explosion. appliance area for gas.Be sure to smell next to the D. Do not use this appliance if any part has been under water, floor because some gas is heavier than air and will Immediately calla qualified service technician to inspect the appliance settle on the floor.See below. and to replace any part of the control system and any gas control, which has been underwater. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. 0 Immediately call your gas supplier from a neighbor's phone. Follow • Do not touch any electric switch; do not use any thegassupplier's instructions. phone in your building. • Ifyou cannotreach yourgas supplier,call thefire department. 4° OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 7. Wait five(5)minutes to clear out any gas.Then smell for 2. Set the thermostat to lowestsetting, gas, including near the floor. If you smell gas, STOP! 3. Turn off all electrical powertothe appliance. Follow"B"in the safety information above.If you don't 4. Remove front panel, smell gas,go to the next step. Z. This appliance is equipped with an ignition device which 8.' Move selector arm right to"ON." automatically lights the pilot.Do not try to light the pilot by hand. g. Turn on all electric power tothe appliance. 6. Depress and move selector arm left v�- to"OFF."Note:Selector 10, Set thermostat to desired setting. arm cannot be moved to"OFF"unless selector arm is depressed slightly.Donotforce. 11. If the appliance will not operate,follow the instructions "To Turn Off Gas To The Appliance" and call your Selector service technician or gas supplier. Position o% o arm 12. Replace front panel. indicator e, (shown in 'OFF'posllfon) O 5c117 TO TURN OFF GAS TO THE APPLIANCE MEN= 1. Set the thermostat to lowest setting. 3. Remove front panel. 2. Turnoff all electric power to the appliance if service is to be 4. Depress and move selector arm to"OFF."Do not force. performed. 5. Replace front panel. 550-223-044(0511) Part Number 550-142-300/0520 39 CGa Series 3 Gas-Rred Water BaHer — Mailer Manual 9bOperating instructions CGa-25 to Ca-6 ' spark pilot " • Natural gas Gas valve: White-Rodgers 36E FOR YOUR SAFETY READ BEFORE OPERATING KWARNINC- If you do not follow these instructions exactly, a fire or explosion fl may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use only your handtoturn the gas control knob.Never usetoois.If the which automatically lights the pilot. Do not try to knob will not turn by hand,don't try to repair it,call a qualified service lightthe pilot byhand. technician.Force or attempted repairmay resultin afire or explosion. B. BEFORE OPERATING, smell all around the D. Do not use this appliance if any part has been under water. appliance area for gas.Be sure to smell next to the Immediately calla qualified service technician to inspect the appliance floor because some gas is heavier than air and will and to replace any part of the control system and any gas control, settle on the floor.See below. which has been underwater. WHAT TO DO IF YOU SMELL GAS • Do nottryto lightany appliance. • Immediately call your gas supplier from a neighbor's phone. Follow • Do not touch any electric switch; do not use any the gas supplier's instructions. phone in your building. • If you cannot reach your gas supplier,call the fire department. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 7. Wait five(5)minutes to clear out any gas.Then smell for gas, 2. Set the thermostat to lowest setting. including near the floor.If you smell gas,STOP!Follow"B"in 3. Turnoff all electrical power to the appliance. the safety information above.If you don't smell gas,go to the 4. Remove front panel. next step. 5. This appliance is equipped with an ignition device which 3' Turn gas control knob counterclockwise n to"ON." automatically lights the pilot.Do not try to light the pilot by 9. Turn on all electric powerto the appliance. hand. 6. Turn gas control knob clockwise to"OFF." 10. Set thermostat to desired setting. 11. If the appliance will not operate,follow the instructions"To o — Turn Off Gas To The Appliance" and call your service Position 0 Gas technician or gas supplier. indicator I _ control (sh knob 12. Replace front panel. "ON"positiani 1i0 s' TO TURN OFF GAS TO THE APPLIANCE ' 1. Set the thermostat to lowest setting. 3. Remove front panel. 2. Turn off all electric power to the appliance if service is to be 4. Turn gas control knob clockwise r), to"OFF."Do notforce. performed. 5. Replace front panel. 550-223.042 0906 40 Part Number 550-142-300/0520 SeriesCiGa - i 9bW Operating Instructions CGa-7 to CGa-8 ' spark pilot • Natural gas V! • Gas valve: :White-Rodgers uc FOR YOUR SAFETY READ BEFORE OPERATING AWARDING If you do not follow these instructions exactly, a fire or explosion may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use onlyyour hand to depress orturn the gas control knob.Never use which automatically lights the pilot. Do not try to tools.If the knob will not depress or turn by hand,don't try to repair it, lightthe pilot by hand. call a qualified service technician. Force or attempted repair may B. BEFORE OPERATING, smell all around the resu It in afire or explosion. appliance area for gas.Be sure to smell next to the D. Do not use this appliance if any part has been under water. floor because some gas is heavier than air and will Immediately calla qualified service technician to inspect the appliance settle on the floor.See below. and to replace any part of the control system and any gas control, which has been underwater. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Immediately call your gas supplier from a neighbor's phone. Fallow Do not touch any electric switch; do not use any the gas supplier's instructions. phone in your building. I If you cannot reach your gas supplier,call the fire department. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 7. Wait five(5)minutes to clear out any gas,Then smell for gas, 2. Set the thermostat to lowest setting. including near the floor.If you smell gas,STOP!Follow"B"in 3. Turn off all electrical power to the appliance. the safety information above.If you don't smell gas,go to the 4. Remove front panel. nextstep. 5. This appliance is equipped with an ignition device which 8. Turn gas control knob counterclockwise n to"ON." automatically lights the pilot.Do not try to light the pilot by 9. Turn on all electric powertothe appliance. hand. 6. Depress gas control knob slightly and turn clockwise r--to 10. Set thermostat to desired setting. "OFF."Note:Knob cannot be turned to"OFF"unless knob 11. If the appliance will not operate,follow the instructions"To is depressed slightly.Donotforce. Turn Off Gas To The Appliance" and call your service technician or gas supplier. Position Gas 12, Replace front panel, indicator; a control (shown � `•4' %• knob "ON"position) L��. P" TO TURN OFF GAS TO THE APPLIANCE 1. Set the thermostat to lowest setting. 3. Remove front panel. 2. Turn off all electric power to the appliance if service is to be 4. Depress gas control knob slightly and turn clockwise r'�, to performed. "OFF."Do not force. 5. Replace front panel. 550-223-043(0906) Part Number 550-142-300/0520 41 SeriesrBallar Manual 10a service and maintenance — schedule VERIFY PROPER OPERATION AFTER SERVICING Table 6 Service and maintenance schedules(service technician and user) --............._.-._--.-.------------ ..................-..... ;-.-.-..-.-.-.-...--.-.-.--.-.-.-.-_.....-.-....-.-_.-..----.-_..-.-...--------- ...._...._-.-.- I Service technician Owner maintenance {see following pages for instructions) I (see CGa User's Information Manual for instructions) .--.-__-......................_............._-----------—.-.. .............. -- .........._...,__.........-...-- --... _._.._.....-..----.-..-.--. • Check boiler area Inspect: • Check air openings • Reported problems • Check boiler pressure/ • Boiler area temperature gauge • Air openings ............._.-..,...-. -- -......_...............................- • Flue gas vent system • Check boiler interior piping • Pilot and main burner flames • Check venting system • Water piping • Check air vents • Boiler heating surfaces Check boiler relief valve • Burners and base + Check condensate drain system • Condensate drain system • Check automatic air vents(if used) Service: • Oiled-bearing circulators • Temperature/LWCO sensor .. • Test low water cutoff Start-up: _........._................... -- _..-.-..--.-..----..... • Perform start-up per manual Check/test: • Operate relief valve • Gas piping • Cold fill and operating pressures • Air vents and air elimination • Limit controls and cutoffs • Expansion tank . . . Shut down procedure • Boiler relief valve Review: • Review with owner AWARNfE' G Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler.Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury,death or substantial property damage. 42 Part Number 550-142-300/0520 SeriesCGa 10bService & maintenance — annual startup of the contaminants listed in Table 1 on page 9 of this manual.If any of these are present in the boiler AWARNING The boiler should be inspected and started annu- intake air vicinity, they must be removed. If they ally,at the beginning of the heating season;only cannot be removed, install combustion air piping by'a qualified service technician. In addition, to the boiler in accordancewith national,provincial the maintenance and care of the boiler designated . or local codes. in'Tabie 6,page 42,and explained on the follow- ing pages must be performed to assure maximum' Air openings boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in I. Verify that combustion and ventilation air open- equipment failure: ings to the boiler room and/or building are open and unobstructed.Check operation and wiring of Eliminate all system or boiler leaks.Continual automatic combustion air dampers,if used. A WAIVING fresh makeup water will reduce boiler life.Minerals can build up in sections, reducing heat transfer, 2. Verify that boiler vent discharge and air intake are overheating cast iron,and causing section failure. clean and free of obstructions. Leaking water may also cause severe property damage. Flue gas Trent system 1 , Do not use petroleum-based cleaning orsealing 1. Visually inspect entire flue gas venting system compounds in boiler system. Severe damage to for blockage, deterioration or leakage. Repair any boiler will occur,resulting in substantial property joints that show signs of leakage in accordance with damage, vent manufacturer's instructions. AWARNING electrical shock hazard — Turn off power to 2. Verify that masonry chimneys are lined,lining is in the boiler before any service operation on the good condition,and there are not openings into the boiler except as noted otherwise in this instruction chimney. manual.Failure to turn off electrical power could result in electrical shock,causing severe personal AWARNING Failure to inspect for the above injury or death. conditions and have them repaired can result in severe personal injury or death. Pilot and main burner flames ❑ Inspect .. , . 1. Visually inspect pilot burner and main burner Reported problems flames as directed under Section 6d,page 32 of this Inspect any problems reported by owner and correct manual. before proceeding. Boiler area Water piping I. Verify that boiler area is free of any combustible 1. Check the boiler interior piping and all system pip- materials, gasoline and other flammable vapors ing for signs of leaks. and liquids. 2. Verify that boiler area(and air intake)is free of any 2. Repair any leaks before proceeding. Part Number 550-142-300/0520 93 Gas-Fired — Bollgr 10bService & maintenance - annual start-up (cont.) ❑ Inspect . . . 3. If burners must be cleaned, raise rear of each Boiler heating surfaces burner to release from support slot,slide forward 1. Disconnect the vent pipe at the boiler draft hood and remove.Then brush and vacuum the burners thoroughly,making sure all ports are free of debris. and remove draft hood after turning off power to Carefully replace all burners, making sure burner the boiler, with pilot bracket is replaced in its original position 2. Use a bright light to inspect the boiler flue collector and all burners are upright(ports up). and heating surfaces. 4. Inspect the base insulation. 3. If the vent pipe or boiler interior surfaces show a. Pay attention to the WARNINGS on page 66 evidence of soot, follow Cleaning boiler heating regarding working with insulation materials. surfaces in this manual section. Remove the flue b. Verify that the insulation is intact and secure collector and clean the boiler if necessary after closer against all four sides of the base. inspection of boiler heating surfaces. 4. If there is evidence of rusty scale deposits on boiler ❑ SerV ce ., surfaces,check the water piping and control system piled-bearing circulators to make sure the boiler return water temperature is properly maintained(per this manual). 1. The circulator shipped with the CGa boiler is water- properly No oiling is required. 5. Reconnect vent and draft hood. Replace all boiler 2 Check other circulators in the system. Oil any components before returning to service. circulators requiring oil, following circulator 6. Check inside and around boiler for evidence of any manufacturer's instructions. Over-oiling will leaks from the boiler.If found,locate source of leaks damage the circulator. and repair.Burners and base Temperature/LWCO sensor 1. The temperature/I.WCO sensor may accumulate deposits on the probe surface. Annual inspection AWARNING The boiler contains ceramic and cleaning of the probe will improve boiler fiber and fiberglass materials. performance. Use care when handling these Disconnect power,unplug harness from sensor. materials per instructions on a. Drain boiler water to a level below the sensor. page 66 of this manual.Failure b. Remove sensor from boiler. to comply could result in severe c. Wipe any built up contaminates from probe personal injury. and insulator surfaces. d. Reinstall sensor into boiler using appropriate AWARNING If insulation is damaged or thread sealant.Do not overtighten. displaced, do not operate the e. Refill boiler. boiler. Replace or reposition insulation as necessary.Failure ❑ Start-up ,. to replace damaged insulation can result in a fire hazard, 1. Perform all start-up procedures given in Section 8 causing severe personal injury, of this manual. death or substantial property 2. Verify cold fill pressure is correct and that fill damage. system is working properly. 3. Verify antifreeze level(if used)is at the right con- centration and that inhibitor level is correct. 4. Check gas piping,per manual Sections 4 and 6, 1. After turning off power to the boiler, remove the verifying no indications of leakage and all piping jacket door and base access panel(Figure 32,item 4, and connections are in good condition. page 60). 5. [lead the Operating instructions(manual 2. Inspect burners and all other components in the Section 9 ) applying to the boiler. boiler base. 6. Start the boiler fallowing appropriate Operating instructions (manual Section 9). 44 Part Number 550-142-300/0520 00a Series 3 Gas-Fired Water Boller — Boiler M&nuaj Fun] 10bService & maintenance ntenance - annual start-up (cont.) ❑ Check/test Expansion tank 1. Expansion tanks provide space for eater to move in Gas piping an out as the heating system water expands due to temperature increase or contracts as the water cools. 1. Sniff near floor and around boiler area for any in- Tanks maybe open,closed or diaphragm or bladder dication of a gas leak. type.See Section 3 of this manual for suggested best 2. Test gas piping using bubble test,per Section 4 location of expansion tanks and air eliminators. of this manual,if there is any indication of a leak. Open-type — located above highest radiator or baseboard unit,usually in the attic or closet.Has a Cold fill and operating pressures gauge glass and overflow pipe to a drain. 1. While the system is cold,note the pressure reading Closed-type—welded gas tight and located above on the boiler pressure/temperature gauge.Verify that boiler.Tank is partially filled with water,leaving an cold fill pressure is correct. air cushion for expansion. 2. Watch the pressure as the boiler and system heat Make sure this type of tank is fitted with a tank up to ensure pressure rise is normal.Too high a rise fitting, such as the B & G Tank-Trot or Taco would indicate a waterlogged or undersized expan- Taco-Trot This fitting reduces gravity circula- sion tank. tion of air-saturated tank water back to the Air vents and air elimination system and prevents the air from bubbling up through the water as it returns from the system. 1. Inspect automatic air vents (if used).Also inspect Do not use automatic air vents in systems air separators to ensure they are operational. with closed-type tanks. The air will escape 2. The cap must be unscrewed one turn to allow air to from the system instead of returning to the tank. escape. Eventually,the tank will waterlog and no longer 3. See Figure 26.If the air vent is leaking,remove cap control pressurization. The boiler relief valve A and briefly push valve B and then release to clean will weep frequently. the valve seat. Diaphragm- or bladder-type —welded gas tight 4. Replace cap A by twisting all the way onto valve B with a rubber membrane to separate the tank pres- and then unscrewing one turn. surizing air and the water. May be located at any point in the system,but most often found near the Figure 26 Automatic air vent,typical boiler. • Systems with this type of expansion tank require A at least one automatic air vent,preferably lo- cated on top of an air eliminator,as shown in a examples in manual Section 3. 2. If relief valve has tended to weep frequently, the expansion tank may be waterlogged or undersized. Closed-type tank — tank is most likely water- logged.Install a tank fitting if not already installed. Then check fill level per fitting manufacturer's instructions. If fill level is correct,check tank size against manufacturer's instructions. Replace with a larger tank if necessary. Diaphragm- or bladder-type — first, check tank Limit Controls and cutoffs size to be sure it is large enough for the system. if size is too small, add additional tank(s) as neces- 1. Inspect and test the boiler limit control.Verify op- sary to provide sufficient expansion. If tank size is eration by turning control set point below boiler large enough,remove tank from system and check temperature.Boiler should cycle off.Return dial to charge pressure (usually 12 psig for residential ap- original setting. plications).If tank won't hold pressure,membrane 2. Inspect and test additional limit controls or low has been damaged.Replace tank. water cutoffs installed on system. Part Number 550-142-300/0520 45 ManualCGa Series 3 Gas-Fired Water Boiler — Boiler Fun] 10bService & maintenance _ annual start-up (t;ont) 2. After following the above warning directions, if the relief valve AWARNING Safety relief valves should be rein- weeps or will not seat properly, replace the relief valve. Ensure spected AT !-EAST ONCE EVERY that the reason for relief valve weeping is the valve and not over- THREE YEARS;by a licensed plumb pressurization of the system due to expansion tank waterlogging ing contractor or authorized inspection or undersizing, agency,to ensure that the product has not been affecfed by.corrosive water conditions and to ensure that the valve Figure 27 Relief valve,typical acid discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may , corrode.the.valve or its components over time,rendering the valve inopera- tive:Such conditions are not detectable , unless the Valve and its components are physically removed and inspected.This inspection must only be conducted by a plumbing contractor or authorized Al. inspection agency--not by the owner. y ° Failure to reinspect the boiler relief _.. valve as directed could result in unsafe pressure buildup,which can result in „N severe personal injury, death or sub- stantial property damage. AWARNING Following installation,the valve lever FA Review with owner must be operated AT LEAST ONCE I. Review the User's Information Manual with the owner. A YEAR to ensure that waterways are 2. Emphasize the need to perform the maintenance schedule speci- clear.Certain naturally occurring min- fied in the User's Information Manual (and in this manual as eral deposits may adhere to the valve, well} rendering it inoperative.When manu- ally operating the lever,water will dis- 3. Remind the owner of the need to call in a licensed contractor charge and precautions must be taken should the boiler or system exhibit any unusual behavior. to avoid contact with hot water and to 4. Remind the owner to follow the proper shutdown procedure avoid water damage. Before operating and to schedule an annual start-up at the beginning of the next Iever,check to see that a discharge line is connected to this valve directing the heating season. flow of hot water from the valve to a proper place of disposal otherwise ❑ Cleaning boiler heating severe personal injury may result. If no water flows,valve is Inoperative. Surfaces Shut down boiler until a new relief valve has been installed. AWARNING The boiler contains ceramic fiber and fiberglass materials. Use care when handling these: materials per instructions on page 66 of this manual.Failure ❑ C12eC■��,teS,t (continued) to comply could result in severe personal injury. ■V 1. Shut down boiler: • Follow"ToTurn Off Gas to Appliance"instructions on boiler Boiler relief valve and Operating instructions. I. Inspect the relief valve and lift the lever to verify flow as Do not drain boiler unless it will be exposed to freezing tem- in the following warnings,excerpted from a relief valve peratures. If using antifreeze in system,do not drain. manufacturer's warning label. Before operating any 2. Follow shutdown procedure. relief valve,ensure that it is piped with its discharge in 3. Remove venting system connection to boiler. a safe area to avoid severe scald potential.Read manual 4. Remove top jacket panel.Turn back insulation. Section 3 before proceeding further. 5. Remove flue collector.Clean sealant from assembly and sections. 46 Part Number 550-142-300/0520 Gas-Fired — Boller 10bService & maintenance - annual start-up (cont.) ❑ Cleaning boiler heating surfaces (continued) 6. Remove radiation plates hanging between sections. 11. Reinstall radiation plates. 7. Remove burners from base. Brush and vacuum burners to 12. Replace collector box/transition assembly.Seal with sealant. remove all dust and lint.Verify that all burner ports are free Obtain gas-tight seal to prevent flue gas spillage and carbon of debris. monoxide emissions, resulting in severe personal injury or 8. Place newspapers in base of boiler to collect soot. death. 9. Clean between sections with wire flue brush. 13. Replace insulation and jacket top panel. 10. Remove newspaper and soot. Vacuum or brush base and 14. Start up boiler following Section 6 of this manual and the surrounding area. boiler Operating instructions(Section 9b).Excessive sooting indicates improper gas combustion.If found,check for proper combustion and make any necessary adjustments. 11a Troubleshooting — components Temperature/LWCO sensor AWARDING Label all wires prior to disconnection when servicing controls.Wiring errors can cause 1. The boiler temperature/LWCO sensor is a resistance-type improper and dangerous operation. device. AWARNING Never jumper (bypass) rollout thermal 2. The Table 7,below shows the correct value for the sensor at fuse element or any other device except for various temperatures. momentary testing as outlined in.Trouble- 3. Use the resistance values at 32°F, 607 707 and 212°F to shooting Charts.Severe personal injury, measure the sensor resistance at known temperatures (ice death or substantial property damage can point,room temperature and sea level boiling point).For ice result, point and boiling point,insert the sensor in water at that tem- AWARDING Burner access panel must be in position perature,Use an ohmmeter to read resistance value between during boiler operation to prevent mo- thermister#and thermistor common.See Figure 30,page 50, mentary flame rollout on ignition of main for sensor plug details. flame.Severe personal injury or substantial property damage will result. Table 7 Temperature/LWCO sensor resistance values)— NDTICF See pages 48 through 56 for additional troubleshooting information. Sensor resistance values Temp Sensor ohms Temp Sensor ohms Before troubleshooting: (°) Min Max (°F) Min Max 1. Have the following items; 32 34265 37871 120 4517 4992 a. Voltmeter that can check 120 VAC and 24 VAC. 40 27834 30764 130 3698 4088 b. Microammeter with a minimum scale range of I -- — --- — 0-25. 50 21630 23907 140 3043 3364 c. Continuity checker. _ 60 16944 18727 150 2517 2782 d. U-tube manometer. _ 2. Check for 120 VAC (minimum 102 VAC to maximum 70� 13372 14780 160 2091 2311 132 VAC)to boiler. --- 3. Make sure thermostat is calling for heat and contacts 80 10629 11747 170 1744 1928 (including appropriate zone controls)are closed.Check 90 8504 - 9399 180 1461 1615 for 24 VAC between thermostat wire nuts and ground. 100 6847 7568 190 1229—-1359 110 5545 6129 2D0 1038 1147 Part Number 550-142-300/0520 47 Gas-Fired I llaTroub' leshooting -- procedure (continued) Check the following: pliers on flat shaft between damper and actuator. Boiler will fire.Verify that damper service switch is 1. Wire connectors to control module are securely in Hold Damper Open position. (Figure 28) plugged in at module and originating control. 3. Do not leave vent damper permanently in this 2. Gas pressures: position. Replace actuator immediately. If vent a. With boiler off—13"w.c,maximum natural damper is left in open position,boiler will not oper- or propane gas pressure upstream of gas valve. ate at published efficiencies. b. With boiler on: If troubleshooting chart recommends replacing actua- • 5"w.c.minimum natural gas pressure or for and actuator is not immediately available,damper 11"w.c.propane gas pressure upstream of blade can be fixed in an open position to allow boiler gas valve. operation.Follow these instructions only in case of no 3.5"w.c.minimum natural gas pressure or heat or damper actuator malfunction.See Figure 28. 10"w.c.propane gas pressure downstream tapping on gas valve—Can be adjusted by 1. Turnoff power to boiler. regulator on gas valve. AWARNING Failure to turn off power to boiler can In event of vent damper result in severe personal injury,death failure: or substantial property damage. 2. Refer to vent damper manufacturer's instructions EffMal or Field Controls damper for procedure to fix vent damper in open position. If troubleshooting chart recommends replacing actua- tor and actuator is not immediately available,damper 3. Turn on power to boiler. blade can be fixed in an open position to allow boiler operation.Manually turning blade can cause actuator 4. Using wrench or pliers on flat shaft section,manu- damage. Follow these instructions only in case of no ally rotate damper blade until green light turns on. heat or damper actuator malfunction. Boiler will fire.(Figure 28) 1. Move damper service switch to Hold Damper Open 5. Do not leave vent damper permanently in this posi- position.Apply call for heat to boiler.Damper blade tion.Replace actuator immediately.If vent damper should then rotate to open position and boiler will re. is left in open position, boiler will not operate at 2. If step 1 does not open damper, manually rotate published efficiencies. damper blade to open position using wrench or Figure 28 Manually Effikal or Field opening the Controls damper vent damper - open s � Closed t' Y 3 { damper blade indica€or s Wrench or pliers sssoa AWARNING 'Verily proper operation after servicing. •See vent damper manufacturer's instructions packed with vent damper for additional information.Failure to comply could result in severe personal injury,death or substantial property damage. �18 Part Number 550-142-300/0520 CGa I lBoiler llbTroubleshooting ® spark-plot boilers NOTICE The information on this page and Control indicator lights — pages 50through 5t apply only to spark-ignited nited pilot CGa boilers. HARD LOCKOUT Summary (Flashing LSD's) These boilers are equipped with MAY remove 120 VAC power for more than 2 seconds to clear lockout OR an ignition control module that ignition control will automatically restart sequence of operation after 1 hour has indicator lights to show control waiting period after fault condition is cleared. status. Charts 1 through 7, pages 51-57,help you identify problems INDICATOR LIGHT CONDITION based on indicator light condi- POWER 120 VAC connection to boiler tions. Flashes once per second reversed or there is insufficient earth ground. Figure 29 CGa/EG Ignition control module Flash code 2* Internal fault, microprocessor or memory. Flash code 3* Internal fault, LWCO circuit. II' Flash code 4* Unused. �I li Flash code 5* Internal fault,water thermistors disagree. Flash code 6* Internal fault, gas valve circuit. Flashes once per second �.-� � t kev.PRxs Flash code pattern: POWER LED flashes 2, 3,etc.times rapidly followed by 2 seconds off, then repeats. iar " ALL LED'S FLASHING Failure to establish pilot flame after 4 attempts. SOLID LWCO LED Low water condition occurred. SOFT LOCKOUT Summary (Flashing LSD's) i�l!l� =1Gf� MAY remove 120VAC power for more than 2 seconds,cycle thermostat for between 2 and 20 seconds, OR ignition control will automatically restart sequence of operation after 1 hour waiting period. INDICATOR LIGHT CONDITION POWER+TSTATlCIRC High voltage detected on TSTAT circuit. POWER+DAMPER Damper stuck closed or unable to close end switch within 45 seconds from TSTAT call. Control module POWER+FLAME Flame sensed without call for heat or out of sequence during ignition trial. AWARNING Solder or water splatter be- CAUTION Summary (Flashing LSD's) tween plugs and circuit board can cause improper operation of INDICATOR LIGHT CONDITION control module.Place a shield over DAMPER Damper end switch opened after it had the boiler internal controls and been proven closed, components during installation. LIMIT Fauitdetected in temperature sensing Failure to comply could result in hardware, severe personal injury, death or FLAME Flame loss or flame not sensed during substantial property damage. trial for ignition. IUlake sure ground wiring is in- LWCO LWCO circuit approaching lockout state. NOTICE Sensor requires maintenance.LWCO stalled per wiring diagram, Good LED will Flash 3 times when maintenance grounding is extremely important is required. for proper operation. Troubleshooting the control module See Figure 30,page 50, for location of harness plug receptades and plugs on the control module. Part Number 550-142-300/0520 49 Gas-Fired N1AN NN pNN�� m llb Troubleshooting — spark-pilot boilers (continued) Figure 30 Control module connections Black Pink/Blue 120 VAC H 24 VAC Whrte Brown/Yellow z U U ❑ O 120 VAC 9 IN >< c p � W Cn 1€1911 voltage to pilot spark electrode �c O Transformer = O 120 VAC IN m � � t� 8 O „ 2 E r 2 0 � Brown U p 3 N to Sprll Switch and to 7 E Additionallimits,if used Yellow m m c m o o p a [L�� v 24 VAC control TSTAT Qf circuits f. � �Z L> t0 > TSTAT From end switch m 3a N � CD rn 24 VAC iCaVAC Red Grace Connector plug ice+ POWER in vent damper 24 VAC to vent damper 0 TSTAT CIRC VAC call for heat t_ 0 LIMIT Gmen 24 VAC Common Q varraw m DAMPER c� 0 FLAME C) LWCO Yello 720 VAC H :Otw 7 120 VAC to transformer O 120 VAC N r ------� S Sense wire to flame sensor 120 VAC to circulator POWER w PQWER� 0 L O IM171T c3 120 VAC IN 8 ®DAMPER PILOT MAIN i ®Lwco eme o r Flame sense wire to pilot SF R`"""--�Transformer AR I x High voltage to spark electrode O OaleOOR LW CO SENSgIl TSTAT I ES .'' I ,�j Thermostat Thermistor t TEST Red 24VAC vent damper connections24VAC to control circuits white Therm Outdoor Sensor Common Thermistor 2 (if used) 9 Temperaturell-WCO Sensor Sutton for LWCO test and Ignition reset,(LP boilers only), ® Temperature/LWCO ogo0s+l wC0 sensor 50 Part Number 550-142-300/0520 CGa Ili ire i • Boiler Manual FN 11bTrou b' leshootin spark- pilot spark plot boilers (continued) POWERCHART I — Usually indicates reversed 120 VAC polarity if POWER light flashes by itself — AWARIdEPdG Electrical shock hazard—Wherever you see ♦ TURN OFF POWER ♦, follow the instructions. Failure to follow instructions could result in severe personal injury,death or substantial property damage. Is POWER light off? Make sure service switch or circuit breaker is on or No Yes fuses are good. • Remove 120 VAC IN plug (Figure 30, Item 3, page 50)on control module. • Using voltmeter, check across black and white wire Is POWER light.. . pins of 120 VAC IN plug. Flashing Flashing with On steady Does voltmeter indicate 120 VAC? alone another light (NOT flashing) No Yes. TSTAT/CIRC Chart Problem is with incoming light flashing 2 electricity. Have licensed DAMPER Chart electrician repair circuit. light flashing 3 FLAME Chart Chart Reconnect 120 VAC IN plug. light flashing 4 6 Remove transformer plug (Figure 30, Item 2, LWCO Chart page 50)on control module. Using voltmeter, check across left side top and light solid 7 bottom pins of transformer receptacle. For insufficient heat or no heat problem, go to Does voltmeter indicate 120 VAC ? Chart 6, page 56, if POWER light is on steady, with no other light flashing. No Yes • Usually indicates polarity on incoming 120 VAC power Replace control module.Retest. line is wrong or has insufficient earth ground. • Check grounds to make sure unit has sufficient grounding. ♦ TURN OFF POWER ♦ at service switch or breaker, • Reinstall transformer plug. then reverse the HOT and NEUTRAL wires entering • Remove TSTAT transformer plug (Figure 30, Item 5, the boiler in the J-box. page 50)on control module. Restore POWER at service switch or breaker. • Using voltmeter, check across left and right pins of Is POWER light flashing now? receptacle. No YeS Does voltmeter indicate 120 VAC ? No Yes Have system checked by a licensed electrician. Boiler should now If problem persists,contact Replace transformer. Replace control module. your Weil-McLain Technical operate normally. support. Retest. Retest, Part Number 550-142-300/0520 51 SeriesCGa filerBoller llbTroubleshooting - spark-pilot boilers (continued) CHART 2 Spark-ignited Pilot —TSTAT CIR&& POWER lights flashiho — Usually indicates�S VAC on thermostat circuit (stray voltage) — AWARNING Electrical shock hazard—Wherever you see • TURN OFF POWER ♦,follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. • Disconnect the two external wires connected to the boiler If a voltage does occur under any condition, check and thermostat leads(two black low voltage leads in J-box). correct the external wiring. (This is a common problem when using 3-wire zone valves). • Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve and relay in the external Once the external thermostat circuit wiring is checked and circuit one at a time and check the voltmeter reading corrected if necessary, reconnect the external thermostat across the wires. circuit wires to the boiler thermostat wires and allow the boiler to cycle. • There should NEVER be a voltage reading. Did you find a voltage across the two external thermostat circuit wires ? Yes No Leave external boiler thermostat connection wires If no voltage is found under any condition on the external disconnect from boiler. thermostat circuit,connect the two boiler thermostat connection leads together(or jumper the boiler aquastat Troubleshoot the external thermostat circuit until you find T-T terminals). the source of the stray voltage.(Pay close attention to the wiring connections to 3-wire zone valves). Turn off power to the boiler for 1 minute. • Correct the problem and repeat the voltmeter test above, Turn on power and allow boiler to cycle. verifying there is no longer a voltage reading under any condition in the external thermostat circuit. Do the TSTAT and POWER lights still Rash ? No Yes Boiler should now operate per normal sequence of Replace control module. operation shown in Figure 24, page 35. Retest. 52 Part Number 550-142-300/0520 Gas-FiredMailer llbTroubleshooting — spark plot boilers (continued) CHART 3—.Spairk-ignited pilot_�116AIVIPEIII light flashing — If POWER light is flashing: Usually indicates vent damper failed to prove open within 45 seconds - - If POWER light is steady; Usually indicates vent damper closed during run cycle — AWARNlNG Electrical shock hazard—Wherever you see ♦ TURN OFF POWER ♦,follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. • Reset boiler control by turning off power at service switch or turning down thermostat for 2 to 40 seconds. Thermostat should call for heat and appropriate zone valves open.The TSTAT CIRC and LIMIT lights should come on. Does vent damper operate ? No Yes • Wait 45 seconds, Does vent damper operate ? No Yes • Remove Damper plug (Figure 30, Item B,page 50) Wait 5 minutes. from plug receptacle of control module. Is Damper light flashing? • Place voltmeter leads across the top two pins(1 and 4) of the Damper receptacle, No Yes Does voltmeter indicate 24 VAC ? No Yes • Try reseating plug in • Boiler should be in module receptacle and normal operating restart, sequence. Does vent damper actuator If vent damper still does • Observe operation until indicator show damper is not work,replace vent thermostat is satisfied. open ? damper assembly or actuator. • Retest. No Yes Are the TSTAT CIRC and LIMIT lights on steady? Yes No Remove damper wiring plug at damper and firmly Replace vent damper reconnect. • Replace control Make sure thermostat is assembly or actuator. Recheck boiler operation. module. calling for heat. If lights Retest. If problem persists, • Retest, still don't come on, see replace vent damper Chart 6, page 56. assembly or actuator. Part Number 550-142-300/0520 53 00a Series 3 Gas-Fired Water Boiler — Boiler Manual RA llbTroubleshooting """""' spank-plot boilers (continued) CHART 4 Spark-ignited pilot:—�FLAME�&��pOWER lights flashing Usually indicates flame sensed when it shouldn't be there — AWARNIPIG Electrical shock hazard—Wherever you see ♦ TURN OFF POWER ♦,follow the instructions. Failure to follow instructions could result in severe personal injury,death or substantial property damage. Are manual main shutoff valve and gas valve open ? No Yes Leave main manual gas valve closed. Turn off power to boiler at service switch or breaker. • Turn off power to boiler at service switch or breaker. Wait at least 45 seconds. • Wait at least 45 seconds. Turn on power to boiler. • Turn on power to boiler. Restart boiler,following Operating instructions in this Restart boiler,following Operating instructions in this manual(Section 9b)or on boiler label. manual(Section 9b)or on boiler label. Look through the pilot inspection port to see if the pilot is Do FLAME and POWER lights still flash ? burning. Is pilot buming? No Yes No Yes • Replace control module. • Retest. Allow boiler to continue cycling. Replace gas valve. Retest. Are FLAME and POWER lights flashing? Are FLAME and POWER lights flashing? No Yes No Yes • ♦ TURN OFF POWER A . Boiler may now be • Replace control Boiler should now Replace control to boiler at service switch or breaker. operating module. operate normally. module. normally. • Retest. Original flashing Retest. • Open main manual gas • Perform start-up FLAME light valve. procedures in caused by gas • Turn on power to boiler at boiler manual to valve not service switch or verify proper operating properly. breaker. operation. • See normal • Restart boiler per sequence of operating instructions, operation, • Perform start-up Figure 24, procedures in boiler page 35. manual to verify proper operation. 54 Part Number 550-142-300/0520 SeriesCGa r BoilerFua 11bTroubleshooting � - e •spark pilot boilers (continued) CHART:5 Spark-ignited pilot FLAIYIIIIEAi�htflashling and POWER light on steady ALS6 Troubleshooting AWARDING Electrical shock hazard—Wherever you see A TURN OFF POWER A,follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Are main manual shutoff valve and gas valve open? Is pilot flame visible through inspection port= No Yes . No Yes • ♦TURN OFF POWER A to boiler at service switch or breaker. • Check the voltage across • Make sure ground wire • Open main manual shutoff valve and boiler gas valve(per main gas valve terminals terminal is securely fastened Operating instructions in this manual).Wait at least 45 of the gas valve. to control module mounting seconds. • Turn on power at service switch or breaker.Allow boiler to cycle. Is 24 VAC present there? screw. Does FLAME light flash now? Yes No No Yes • If the wiring from the • Check the voltage across • Boiler should be in + Verifyinlet as pressure at as control module to gas valve main gas valve terminals g p g is intact,replace the control of the gas valve. normal operating valve: module, Is 24 VAC present there? sequence. Natural gas -5.0"w.c. min/14.0" • Observe operation w.c.max • Retest. No Yes until thermostat is Propane -11.0"w.c. min/14.0" satisfied and vent w.c. max damper has closed. Is gas present at gas valve inlet and • Verify inlet gas pressure at gas valve: within above range? Natural gas -5.0"w.c. min/14.0"w.c, max Yes No Propane-11.0"w.c.min/14.0"w.c. max Is gas present at gas valve inlet and within above range? •A TURN OFF POWER♦ Contact gas supplier to correct No Yes to boiler at service switch or pressure or gas supply. breaker. • Remove base access panel • ♦TURN OFF POWER A t;sense iler at service switch or breaker. (see Figure 32,Item 4, • Check flame signal-Detach lead from ignition control page 60 for location. A TURN OFF POWER A (Figure 30, Item 8, page 50). to boiler at service switch or breaker. • Connect negative lead of MICROAMMETER to control sense • Verify pilot gas line is not kinked,obstructed or dam- . Remove base access panel terminal (Figure 30,Item 8, page 50).Connect positive aged and is correctly attached (see Figure 32,item 4, lead of MICROAMMETER to sense wire. to pilot and gas valve. page 60 for location. • DISCONNECT red wire connected to main gas valve terminal • Verify pilot ignition electrode, of the gas valve. electrode ceramic and spark • Turn on power to boiler and allow to cycle.As soon as pilot lead wire from control are in • Verify pilot burner is securely at- is burning,the MICROAMMETER should read at least 1.0 good condition.Spark gap tached to pilot bracket,bracket should be approximately 1/8". is securely attached to cross-tie, microamp. • Correct any above problems, and there is no corrosion on the Is flame signal at least 1.0 microamp ? replacing pilot if burner or wir- ground path for flame sense, ing is damaged. Verify that pilot flame rod,flame No Yes • Reinstall base access panel to rod ceramic and lead wire from operate boiler for retest after control module to flame rod are any changes or corrections. in good condition. • If none of the previous steps • If none of the above corrects Correct any above problems, (including replacing pilot) c the wiring from the problems,then replace the replacing pilot if burner or wir- corrects problem,then replace control module togas control module,reinstall base Ling is damaged, the control module,reinstall valve is intact,replace the access panel,and retest. base access panel and retest, control module and retest. Part Number 550-142-300/0520 55 SeriesCGa i RN llbTroubleshooting spark plot boilers (continued) • AWARNIfVG Electrical shock hazard—Wherever you see • TURN OFF POWER •,follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. • Has it been at least 5 minutes since setting thermostat to Is boiler System circulator operating? call for heat? If not,wait 5 minutes. Is system heating? • Is thermostat set to call for heat? Remove thermostat No Yes wires at boiler and check continuity across the two wires. If circuit isn't closed, check external thermostat(zone valve, relay,etc.)wiring. Correct problems and retry. . Remove CIRCULATOR harness plug from • Reconnect external thermostat wiring at boiler. CIRCULATOR plug receptacle(Figure 30, Is thermostat circuit closed(continuity across wires)? Item 7, page 50).Check with voltmeter across pins of control module receptacle. No Yes Does voltmeter show 120 VAC across pins? Are all red lights off? • Boiler is in standby. No Yes No Yes • Set thermostat to call for heat and recheck operation. . Replace control • Repair/replace • Verify Sequence of module, circulator. Retest. • Wait 30 seconds. operation, Figure 24, . Retest. • Repair/replace Are all red lights off? Page 35. wiring. Retest. No Yes • Wait 5 minutes. • Replace control Is FLAME light on? module. • Retest. Yes No • If you have sufficient heat-boiler should be in normal operating sequence. (See normal sequence of operation, Is LIMIT light on? Figure 24, page 35. • If you have less than sufficient heat- No Yes Is vent or combustion air piping free of blockage? No Yes Check temperature EReelpilace control module.sensor for correct est. resistance. Are resistance values • Correct conditions and Contact your Weil--McLain correct? recheck operation, Technical support, • See Figure 24, page 35 No Yes Check spill switch and for normal sequence of rollout switch continuity- operation. LReplace temperature Are switches closed? nsor. No Yes test. • Reset spill switch,or replace rollout switch. Check any other limit controls wired ` into the limit If rollout thermal fuse element or spill switch has circuit. If all are opened,determine cause and correct condition. OK,then replace Failure to do so will cause severe personal injury, control module, death or substantial property damage. • Retest. 56 Part Number 550-142-300/0520 Seriesire filer ilea Manual EN 11bTroubleshooting -- spark-pilot 00 �nc� spark p�lot boilers (continued) CHART T"m.Trotibi6iii4.�o�ti�g:LWCO::an�.p6WER light Solid • AWARNING Electrical shock hazard—Wherever you see A TURN OFF POWER A,follow the instructions. Failure to follow instructions could result in severe personal injury, death or substantial property damage. Is boiler pressurized? Yes .: No T__ - • Pressurize boiler to system design pressure. Are lights still solid? Check system for leaks. No Yes Is system leaking or not maintaining pressure? No �— Yes • System was low on water. • Check system fill piping for leaks or damage. • System is losing water. • LWCO sensor is bad or fouled. Repair leak and retest. • Clean LWCO sensor • Retest. Are lights still solid? No Yes • Sensor was fouled. Sensor is bad. Replace sensor. • Check wafer quality and Retest. maintenance schedule. Part Number 550-142-300/0520 57 SeriesCGa i it - - Boiler Manual 12aReplacement parts Section assembly ..............................................59 Base.................................................................. 60 Jacket ...............................................................61 Trim................................................................... 62 Controls ............................................................63 AWARNING Replacement parts must be purchased through a local Weil-McLain distributor. When ordering,specify boiler model and size and include description and part number of replacement part.Results from using modified or other manufac- tured parts will not be covered by warranty and may damage boiler or impair operation. NOTICE Weil-McLain part numbers are found in Weil-McLain Boilers and Controls Repair Parts Lists. AWARNING The boiler contains ceramic fiber and fiberglass materials. Use care when handling these materials per instructions on Page 66 of this manual. Failure to comply could result in severe personal injury. 58 Part Number 550-142-300/0520 CGal Series 3 Gas-Fired Water Boller — Boller Manual Fun] 12bReplacement parts section assembly Figure 31 Section assembly,flue collector,draft hood and vent damper 411 09007 L •-I 1 � I I p I `y€ I I tF 3 U J) Item Description item number Part number number Description Part number 1_ End section,left hand,51124 311-1_03-851 2 End section,right hand 51128 311 103 821 9 Temperature/LNCO sensor 511-724-305 3 Intermediate section,5112_7 311-103-845 10 Draft hood CGa 25---____ _ 450-021-240 not shown Replacement CGa-25 and CGa-3 321-114-360 CGa-3 450-021-241 section CGa-4 321-114-361 CGa-4 450-021-242 assembly CGa-5 321-114-362 CGa-5 450-021-243 CGa-6 321-114-363 CGa-6 450-021-244 CGa-7 321-114-364 CGa-7 450-021-245 CGa-8 321-114-365 _ __ CGa-8 450-021-246 not shown Section replacement kit,includes seals and 381-354-527 11 Spill switch(210°F) CGa-25-8 510-300-013 sealant for 1 joint 4 Tie rod,7116" CGa-25&CGa-3 560-234-500 12 Vent Damper CGa-25&3 4" 381-800.474 without nut CGa4 560-234-501 CG84 5" 381.800.475 (3 per boiler): CGa-5 560-234-502 CGa-5&6 6" 381.800-476 CGa-6 560-234-503 CGa-7&8 7" 381-800-477 CGa-7 560-234-504 13 _ Vent Damper Actuator W_._ — 510-512-337� CGa-8 560-234-505 5 Nut,ill6"(2 per tie rod) 561-928-235 14 Vent Damper Harness 591-3911-795 8 Washer,7116"(1 per tie rod)_ 562-248-684 mm�----- — 7 Radiation plate CGa 25 &3460.003.018 (1 per joint) CGa 4-8 460-003-017 8 Collector hood CGa-25 381-354-625 CGa-3 381-354.626 CGa4 381-354-627 CGa-5 381-354-628 CGa-6 381-354-926 CGa-7 381-354-630 CGa-8 381-354-631 Part Number 550-142-300/0520 59 CGa Series ire Bailer Boiler Manual run] l2cReplacement parts base Figure 32 Base assembly, manifold,orifices and burners ................ .__._. .-....................._...-............................_.....................•-•---._.__..__..__ —-----___._._ Item Description Part number number Base assembly kit -� CGa-25 381-354-362 (includes base panels CGa-3 381-354-356 items 1,2, 3,4,5, 6 and 7, CGa-4 381-354-357 plus insulation,air box gaskets, CGa-5 381-354-358 and hardware)) CGa-6 381-354-359 CGa-7 381-354-360 F CGa-8 381-354-361 1 Base side panel(in Base assembly) 2 Base front cross-tie assembly(in Base assembly) 3 Base back cross-tie assembly(in Base assembly) s $ s 4 Access panel(in Base assembly) S Base pan angle, left side(in Base assembly) o E 6 Base pan angle, right side(in Base assembly) 7 Base pan(in Base assembly) �. -------------._..__.... - .............-......................._._......................_.._.. 8 Burner rest CGa-25 450-003-742 CGa-3 450-003-736 r, CGa-4 450-003-737 (' t) CGa-5 450-003-738 CGa-6 450-003-739 CGa-7 450-003-740 .i CGa-8 450-003-741 __.............__.._...-......._.........................,..,..,..,....,.......-...-......................................_........ -- ( , 9 Base insulation kit CGa-25 381-354-518 (included Insulation for all base CGa-3 381-$54-518 parts above plus gasket material CGa-4 381-354-518 needed between block assembly CGa-5 381-354-518 and base) CGa-6 $81-354-519 CGa-7 381-354-519 i ........-- --................. ..................-..---_._..._.,......_..... ..... 381-354-519 CGa-B ._._.-��.-_,._ Boiler leg kit._.-._-_.__..-_-.-..._-.-__...-•----.__.-._ ______- 590 424-253 11 Manifold CGa-25� -591-126-615 CGa-3 591-126-616 ti,• CGa-4 591-126-617 -, CGa-5 591-126-618 CGa-6 591-126-619 ✓ r CGa-7 591-126-556 -CGa-8 591-126-557 ,.� 12 Main burner orifice-Natural gas,sea level 560-528-997 Main burner orifice-Natural gas,sea level 560-528-998 13 Burner,stainless steel 512-200-077 14 Burner with pilot 512-200-078 - �✓ 15 Screw, 10-32 x 0.38 STP type IJ hex,washer available at f head slot local supply house 16 Rollout thermal fuse element 512-050-230 7 63a?St a 60 Part Number 550-142-300/0520 SeriesCGa iBoller 12dReplacement parts — jacket Figure 33 Jacket assembly E Zv ¢p�� x } [ 3 t 1 � Y } _.__............_..,......__._._._.__. __._._ ._..._..__......_._._._...L.__.,_.m_..4...__ .__..-_._.,......___._._5 ---------- Junction box,2 x 4 Jacket panel,left side,with insulation Jacket anet, Jacketp anel, Jacket panel, right si de,€de, top front top rear with insulation Natural Gas Propane Gas Spark Pilot Spark Pilot ? Boiler __._ _ Y___.. _ _.._ __._..----- Boller Model Part numbers Moue! CGa-25 381-359-201 381-359-208 381-359-229 381-359-230 381-359-236 CGa-25 CGa-3 381-359-202 381-359-209 381-359-229 381-359-230 381-359-236 CGa-3 CGa-4 (Available at local 381-359-203 381-359-210 381-359.229 381-359-231 381-359-237 CGa-4 CGa-5 381-359-204 381-359-211 381-359-229 381-359-232 381-359-238 CGa-5 CGa-6 supply house) 381-359-205 381-359-212 381-359-229 381-359-233 381-359-239 CGa-6 CGa-7 381-359-206 381-359-213 381-359-229 381-359-234 381-359-240 CGa-7 CGa-8 381-359-207 381-359-214 381-359-229 381-359-235 381-359-241 CGa-8 6 7 _ 8 9 1 10 .._.__Jacket V_anel'.._._.__..__._.Jacket crass ties_._._..........._.___._.................._......_.__......................_..._______._..__..__.,._.__.+......_.........................__._.._.._..__.__....___.__._._..-....-----•-----_.._..._._ p Jacket panel, Jacket panel Boiler , Not shown h rear, touch-up oor bottom front Interlor, insulation p paint .__..----._._.___..__. ,______...._._..---__.._.____ with€nsulation - wit _.._....._...._................__.._.._._. Part numbers^m___.__._..__.__.____ Boiler _Model __ Model CGa-25 381-359-248 381-359-260 381-359-266 381-359-272 CGa-25 CGa-3 381-359-248 381-359-260 381-359-266 381-359-272 CGa-3 CGa-4 381-359-249 381-359-261 381-359-267 381-359-273 381-359-278 Cloud CGa-4 j CGa-5 381-359-250 381-359-262 381-359-268 381-359-274 384-000-141 Slate CGa-5 CGa-6 381-359-251 381-359-263 381-359-269 381-359-275 CGa-6 CGa-7 381-35-9252 381-359-264 381-359-270 381-359-276 CGa-7 1 CGa-8 381.359-253 1 381-359-265 381-359-271 381-359-277 CGa-8 E......,..._.______.__.__...__...._.-_........._..._�._-._.._-_...,.....,..._._..__.w_..............__._..._....._ __......._.._.. _-_.,...,..�_..._.._.._... __.,.. _.._-.....-.... ...___.._.,_.._..._�_....... .........._..____-.,.._ .-..�.__,. Part Number 550-142-300/0520 61 Water Boller Manual - 12eReplacement parts trim Figure 34 Trim assembly T 5 o a 16) n.w. 5fl�53 Item Description _ number Part number 1 Pressure relief valve,ASME,30 PSIG,'/-0'male inlet 511-546-920 Pressure relief valve,ASME,30 PSIG,I/,"female inlet 511-546-924 (Fittings shown are factory-installed on boiler.) 2 Combination pressure-temperature gauge,3Ye,"diameter,short shank 380-000-000 (Fittings shown are shipped loose with boiler.) ..-.-3 Drain valve,z/�" � ...�----------�._...--_._...__---_-... ._._.�.----.-.-.._..__..._-.-.-..-----•----._.-.-.--.-._...__-___--- ---511-214-423 -- (Fittings shown are included with boiler,) 4 Circulator CGa 25-5 511 405-153 (Fittings shown are shipped loose with boiler.) CGa 6-8 511-405-113 5 Circulator gasket,universal(2 per boiler) 590-317-535 Circulator hardware kit,Includes: 1 flange,2 nuts,2 screws, 1 gasket — not shown 3/4"NPT—CGa-25 381-354-530 1"NPT—CGa-3 through CGa-5 ------ ------ 381-354-525 1'/4"NPT--CGa-6 and CGa-7----------.----_— 381-354-526 1'/VNPT—CGa-8 ---------_----------.--.-_---- _ 381-354-531 6 Circulator wiring harness kit,spark-ignited with Molex(loose) 381-356-528 Ci2 Part Number 550-142-300/0620 Series Boller l 12fReplacement -�parts controls Figure 35 Gas control components Spark-ignited pilot controls t. 211 �eak�w as .: [f11�l�gIHItIIIIIIH •��• 0 59354 LWCO Item Description Boiler model Part number number _.._._.,_....--.-......._.__._•...,...__-........................ -----._.-_._._-....,... - .-.-._._.,..,..,...._.._,....•.... -.-.....__.._-....•..... .-.— _-.._...-.-.-.. Natural gas components ...................._•_-.-..--,..................- -_.,..,........__._.._ _ _.................--- _ 1 Gas Valve, '/"x'/V CGa-25 through CGa-6 511-044-381 Gas valve,3/"x 3/a' CGa-7&CGa-8 511-044-382 _- ..................... -._._.__._.-._- ------------- .--.............................. ............. ...-.-............__..._.--.-._._.._.__-___ -.-.__._...._..... Pilot kit wlo rifice&aluminum pilot gas tubing 511-330-2i8 Liquefied Petroleum(Propane)gas components 1 Gas Valve,3/"x'/." CGa-25 through CGa-7 - - 511-044-356 Gas Valve,3/"x 3/s" CGa-8 511-044-366 2 Pilot kit w/orifice&aluminum pilot gas tubing — -- — — 511-330-273 Natural gas and Liquefied Petroleum(Propane)gas components 3 Control Module-Natural gas - 381-330-039 -Liquefied Petroleum(Propane)gas 381-330-038 ----------_-_._.-._..._,., __._...-------._.-._._.,.,_.._...._. ----- not shown Wiring Harness,Junction box to Control Module 591-391-975 __-------------__. not shown Wiring Harness,Controls to Control Module 591-391-977 not shown Wiring Harness,Thermostat 591-392-006 ......................... — notshown Wiring Harness,Water Temperature/LWCO Sensor 591-391-995 4 Control Transformer 381-356-578 Part Number 550-142-300/0520 63 Gas-Firedi 13aDimensions Figure 36 Dimensional drawing — ALL DIMENSIONS IN INCHES O Supply piping (note 1) O I Q Return piping (note 1) 6/a ® Relief valve,3/a" NPT - Do not cut or alter draft hood in any way.Boiler combustion will be affected, causing severe ® 1/"NPT to expansion tank/air vent TOP VIEW 4 personal injury, death or substantial property Q Vent connection to vent damper damage. © Draft hood Note 1: Boiler supply and return tappings are both 1%"NPT.See - Table 3,page 16 for recommended system supply and re- turn piping sizes. ® Drain valve Nole2: Boiler circulator is shipped loose. Circulator may be Q Gas supply entrance (right or left side) mounted on either boiler supply or return piping. Circulator f ange provided with boiler is same size as rec- ® Pressure/temperature gauge ommended pipe size in Table 3,page 16. ALL DIMENSIONS IN INCHES � r: - 5 —131/4 —-Y `-NOTE 2 23/a t— r NOTE 2 — o s ---Y� 43/4 Imo— —YI 43/4 ,3 9 H .I, 0 28% -- — 19 _.. 19 13'1/1a w r Y 12 —Y I W -- Y 5532G LEFT SIDE FRONT RIGHT SIDE Boiler Supply Return Gas connection r'Arr rrJDrr _Wrr JrHrr model tapping tapping & manifold size Vent Vent Jacket Damper number (inches NPT) (inches NPT) Note 3 location diameter width height (inches NPT) (inches) (inches) (inches) (inches) CGa-25 11/4 11/4 1/2 5 4 10 45-318 CGa-3 11/4 11/4 1/2 5 4 10 52-318 CGa-4 11/4 11/4 1/2 6'/2 5 13 54-2/8 CGa-5 11/4 11/4 1/2 8 6 16 57-718 CGa-6 1 1/4 1 'A 1/2 9-1/2 6 19 60-718 CGa-7 11/4 11/4 3/4 11 7 22 62-1/8 CGa-8 1 1/4 1 '/4 3/4 12-1/2 7 25 64-718 Note 3: Gas piping from meter to boiler to be sized per local utility requirements. 64 Part Number 550-142-300/0520 00a Series 3 Gas-Fired Water Bailer - Bailer Manual 13bRatings Q�SfGy A ® SH �� SM �+ SH � E C U$ �FR71F���� CERTIFIED e H AHR! Certified Ratings Chimney Boiler Seasonal Boiler and model 0 -2,000 feet 2,Q00 -4,500 feet Heating Efficiency Net water breeching number Altitude Altitude Capacity PIDN-PIDL Ratings content size (Note 1) input Output Input Output Btuh ) AFUE% {NBtuh ote 3) (gallons) Inches (Btuh) (Btuh) (Btuh)" (Btuh) (Note 2 CGa-25 38,000 32,000 34,000 29,000 32,000 84.0 27,000 1.5 4"I.D. x 20' CGa-3 67,000 56,000 601000 50,000 56,000 84.0 48,000 1.5 4"1.D.x 20' CGa-4 100,000 84,000 90,000 76,000 85,000 84.0 73,000 2.1 5"I.D.x 20' CGa-5 133,000 112,000 120,000 101,000 113,000 84.0 98,000 2.7 6"I.D.x 20' CGa-6 166,000 139,000 149,000 125,000 141,000 84.0 122,000 3.3 6"I.D. x 20' CGa-7 200,000 168,000 180,000 151,000 170,000 84.0 147,000 3.8 7"I.D. x 20' CGa-8 233,000 196,000 210,000 176,000 198,000 84.0 172,000 4.4 7"I.D. x 20' 1. Add "PIN" for natural gas boiler-"PIL" for Liquefied Petroleum (propane) gas boiler. Notes 2. Based on standard test procedures prescribed by the United States Department of Energy. 3. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15. An additional allowance should be made for unusual piping and pickup loads. 'fable S Ignition system model suffixes Pilot ignition system Natural gas Propane gas Spark-ignite pilot PIDN PIDL NUTICE Install CGa boilers for residential radiant panel systems,converted gravity heating systems or other low water temperature applications per instructions in this manual to avoid damage due to condensation. CGa boilers are CSA design certified for installation on combustible flooring. CGa boilers are ASME rated for 50 psig working pressure. Part Number 550-142-300/0520 65 00a Series 3 Gas-Fired Water ScHer — Ballar Manual —1 Fm Handling ceramic fiber and fiberglass materials REMOVAL OF COMBUSTION CHAMBER REMOVAL OF FIBERGLASS WOOL LINING OR BASE PANELS or AWARN�NG The combustion chamber lining or base INSTALLATION.OF FIBERGLASS WOOL, . . insulation panels in this product con COMBUSTION CHAMBER LINING OR fain:ceramic:fiber materials.' Ceramic fibers can be converted to cristobalite in BASE PANELS. very high temperature applications.The International Agency for Research on AWARDING This product contains fiberglass jacket !. Cancer(IARC)has concluded,"Cr stal- insulation and ceramic fiber rnawri- y als in combustion chamber lining or line silica inhaled in the form of quartz base panels in gas fired products. Air- or cristobalite from occupational sources borne fibers from these materials have is carcinogenic to humans(Group 1).": been listed by:the State of California Precautionary measures as a possible cause of cancer through inhalation. .. _ ❑ ;Avoid breathing fiberglass dust and contact with skin or eyes. Precautionary measures Use NIOSH certified.dust respirator (N95). El Avoid breathing fiberglass dust and contact with skin This type of respirator is based on the or eyes. OSHA requirements for fiberglass wool at the Use NIOSH certified dust respirator (N95). time this document was written. Other types of This type of respirator is based on the respirators may be needed depending on the OSHA requirements for fiberglass wool at the job site conditions.Current NIOSH recommen- time this document was written. Other types of dations can be found on the NIOSH web site respirators may be needed depending on the at http://www.cdc.gov/nioshihomepage.html. job site conditions.Current NIOSH dations can be found on the NIOSH web site recommen NIOSH approved respirators,manufacturers,and at http://www.cdc.gov/niosh/homepage.html. phone numbers are also Iisted on this web site. NIOSH approved respirators,manufacturers, • Wear long-sleeved,loose fitting clothing,gloves, and phone numbers are also listed on this web and eye protection. site. ❑ Apply enough water to the combustion chamber lining Wear long-sleeved,loose fitting clothing,gloves, or base insulation to prevent airborne dust. and eye protection. ❑ Remove combustion chamber lining or base insulation ❑ Operations such as sawing, blowing, tear out, and from the boiler and place it in a plastic bag for disposal. spraying may generate airborne fiber concentration requiring additional protection. ❑ Wash potentially contaminated clothes separately from ❑ Wash potentially contaminated clothes separately other clothing. Rinse clothes washer thoroughly. from other clothing. Rinse clothes washer thoroughly. NIOSH stated First Aid NIOSH stated First Aid. C] Eye: Irrigate immediately. ❑ Eye: Irrigate immediately. ❑ Breathing: Fresh air. ❑ Breathing: Fresh air. 66 Part Number 550-142-300/0520 Series itBollev Boller Manual Fun] Notes __._I E €W - ._..-. _..__.�._._._....-...,..,..-.._ . ._..._. -....... ! { 3 f i � ! � I � -f r 1,-"�-----�•_- I i -•��F_._._�_-�f--tFj--�-�-• i � I I 1 lif I l I I f f [f[ f I I f I I lij { j , I I , I I I E {{ .............�_........._.--' .. _--.._. ..-.-......... -- - - -... .. --.._ ._. i t f I I € I I I I I I I I f L i } I I ; f-.,•.,.,..,�..-.-.-.,,. I I I I , ' -_ 33 , i 1 ! j I I , E I II f f f j . --- i. _.i -- I-- ..,__._.f.... ....__ _._.E - ...— l......---1 _.. s 1........._. __ I I �W__-! I I•__._.... E I I f 3 � i I E i ....... -_�._._. .._3 €{ I I I -.....-. -. .,1..= .._� .......... ....._. ............�:- ...._.I, I I --.... i -- --------- -. —k-- _. ._. _...l....... I__- I E � I I 1 , _ _..._.- I i I _ _ �--__- _. E � ._i.W , I _ i I Part Number 550-142-300/0520 67 OGa Series it Weil-McLain ® WEIL■m[LAIN� 5, I Blaine Street Michigan City, N 46360-2388 !ur x//sysvrv.svc>il-rrrrinirr.c•nur 68 Part Number 550-142-30010620 PERFORMANCE PLATINUM"m eem !� The new degree of comfort" The PERFORMANCE PLATINUM' High Efficiency atmospheric gas water heaters offer more hot water at a lower cost Efficiency Self-Cleaning 0.58-.65 UEF ■Fights sediment and ;; d mineral buiid-up " Performance ■Reduces fuel costs C�FHR: 69-97 gallons Z M Recovery: Up to 51 GPH at a Longer Life 90'F rise,depending on model N Premium grade anode rod provides r Diagnostic Vale long-lasting tank protection Self powered diagnostic High Altitude Compliant gas control valve for 23 Certified to 10,200 ft. above sea level t improved monitoring and service Plus... 0 Dual certified for both potable water Low Emissions and space heating ■Eco-friendly burner, low NOx design Durable brass drain valve ®Meets 40 ng/J NOx requirements ■Temperature and pressure relief valve .i,4 tip. Maintenance Free included -- Burner System ®Low lead compliant M Exclusive air/fuel shut-off device ®Standard replacement parts =VA ®Standard Cat. I,double-wall, B-vent, ®Maintenance free-no filter to clean M Disables the heater in the presence of 374"combo vent flammable vapor accumulation Warranty ® nd par limited warranty for tank PERFORMANCE PLATINUM and parts,3 year full in-home labor warranty* Atmospheric Comdusdon Shut-off System " Flame Arrestor Plats 'See written warranty for complete details 40, 50 and 55-Gallon Capacities Units meet or exceed ANSI requirements and have Up to 50,000 Btu/h been tested according to D.O.E.procedures.Units fl meet or exceed the energy efficiency requirements state to energy ASHFAE standard an e cr Code and all Malntsnanee Free state energy eciency performance criteria. � �p IEW Pdm-r Sae specifications chart on back. 12120 FORM NO.THE-PPHE RW.7 Tha new degree of camfc-t." PERFORMANCE • Atmospheric 1%to Water Water UnHom tT81140 inal Rated Gee Input Remery Fist Hour Ntte Tank Gas Went Conn. Fitt.to Side Conn. Ship Energy an Galan Model In Thous, In G.P.H. Rating Vent Height Glam. Cann. Slap Center T&PYalw Sin Might Factof jjj adv CapaeEtr NunBrar Bhfth 90°F Rise (Gallons) A B C D E F 6 H OR (UM 5 55 XGSST12EC50UD 50 51 97 59-1/4 5G 23-3/4 14-1/4 4 8 48-314 3/4 175 0.62 0 49 XG50T12HE4000 40 40A 77 62-3/4 59.1/4 21-1/2 14 3or4 8 52.1/2 3/4 165 G.64 0 38 XG40T12HE4000 4D 40.4 84 63-3/4 60.1/4 19-1/2 14 3or4 a 53-1/2 3/4 135 0.65 o 48 XGSOS12HE40UO 40 40.4 86 54-1/4 51 23.314 14 3or4 8 44 314 165 0.64 0 39 XG40S12HUBUD 38 38.4 69 53-3/4 50-1/4 21-1/2 14 3 8 44 314 125 0.58 0 48 XP50T12HE36U0 36 36.4 77 62-314 59-1/4 21-1/2 14 3or 4 8 52-1/2 314 165 0,64 0 38 XPOT12HE3600 36 36.4 84 63-314 60.1/4 19-1/2 14 3 or4 8 53-1/2 3/4 135 0.65 Short 40 39 XP40.572HE36U0 36 36.4 69 53-314 50-114 $1-112 14 3 8 44 3i4 125 0.59 Uniform Frergy Factor and rated gallon capacity based on department of Energy[OE)requirements. 0 FLUE ANODE ROD HOT O O H WATER r COLD CONNECTION WATER ; CONNECTION p-H FEI ' 3I4"N.P.T. RELIEF VALVE OPENING 0 C A B '/2" G D in Weeping with its policy of continuous progress and product improvement Rheem reserves the right to make changes without notice. Rheem Water Heating - 1115 Northmeadow Parkway,Suite 100 Roswell,Georgia 30076 • www.rheem,com 12120 FORM N0.THm-PPHE Rev.7 CAW 3 ING: This water heater is not suitablUse & Care Manual With Installation Instructions for the Installer fk z Residential Gas - FVIR Cert1fied Water Heaters E, Y YESC Z n Z4 f t y z,�s � ��r,� � >1 55r '� ; i t vi� , S E t � � �. �Residenf a129, 30 V,' s�50�SS and G0�Gallon th Electmiauc Control` .v„..w.uf this 7i.,�u„�,.� The purpose o manual is twofo d. one,to provide the installer with the basic directions jl}` E and recommendations for the proper installation and adjustment of the water heater;and two, 5 for the owner—operator,to explain the features,operation,safety precautions,maintenance and y 3' troubleshooting of the water heater.This manual also includes a parts list. 3 It is imperative that all persons who are expected to install,operate or adjust this water heater " read the instructions carefully so they may understand how to perform these operations.If you ' ` x do not understand these instructions or any terms within it,seek professional advice. Any questions regarding the operation,maintenance,service or warranty of this water heater r should be directed to the seller from whom it was purchased,If additional information is required,refer to the section on"If you need service." Do not destroy this manual.Please read carefully and keep in a safe place for future reference. �5 ARecognize this symbol as an indication of Important Safety Information! ........... California Proposition 65 Warning:This product contains chemicals known to the State of California to cause cancer,birth defects or other reproductive harm, A WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage,personal injury or death. A FOR YOUR SAFETY! — Do not store or use gasoline or other If you cannot reach your gas supplier,call flammable vapors or liquids or other the fire department. combustible materials in the vicinity of this or 0 Do not return to your home until authorized any other appliance. To do so may result in an by the gas supplier or fire department. explosion or fire. --Improper installation, adjustment, alteration, --- WHAT TO DO IF YOU SMELL GAS service or maintenance can cause property Do not try to light any appliance. damage,personal injury, or death.Refer to Do not touch any electrical switch; do not this manual.Installation and service must be use any phone in your building. Performed by a qualified installer, service agency or the gas supplier. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. GN AP16801-2(08/14) Safety Information Safety Precautions....... 3-6 FP Gas Models ........... 5 FOR YOUR RECORDS Write the model and serial numbers here: s Installation Instructions 1 Location................. 7 _... Water Supply Connections.. 9 You can find them on a label on the appliance. Gas Supply.............. 11 Staple sales slip or cancelled check here. Proof of the original purchase date is needed to obtain service under Pipe Insulation............13 the warranty. Heat Traps ...............13 Installation checklist.......15 Potable/Space Heating ... 16 z READ THIS MANUAL Operating Instructions '� Inside you will find many helpful hints on how to use and maintain your water heater properly.A little preventive care Fighting Instructions...... 17 on your part can save you time and money over the life of your Water Temperature .... 18, 19 water heater. You'll find many answers to common problems in the Troubleshooting Guide.If you review the chart of Care and Cleaning Troubleshooting Tips first,you may not need to call for service. Draining................ 20 Maintenance............. 20 { Butner Inspection ........ 21 READ THE SAFETY INFORMATION Extended Shut-Down ......21 Pss Your safety and the safety of others are very important. There are many important safety messages in this manual and on your appliance. Always read and obey all safety messages. Troubleshooting Tips Before You Call ®This is the safety alert symbol.Recognize this symbol as an indication of Important Safety Information! For Servrce''''''''''' 22,23 This symbol alerts you to potential hazards that can kill or hurt you and others. Codes All safety messages will follow the safety alert symbol and either the word"DANGER","WARNING","CAUTION"or Status Light Codes ........24 "NOTICE". These words mean: ADANGER An imminently hazardous situation that will result in death or serious Customer Service injury. Parts List................ 25 A WARNING A potentially hazardous situation that could result in death or serious injury If You Need Service .......28 and/or damage to property. A CAUTION A potentially hazardous situation that may result in minor or moderate injury. NOTICE: Attention is called to observe a specified procedure or maintain a specific condition. 2 IMPORTANT SAFETY INFORMATION. READ ALL INSTRUCTIONS BEFORE USING. Be sure to read and understand the entire Use and Care Manual before attempting to install or operate this water heater.It may save you time and money.Pay particular attention to the Safety Instructions. Failure to follow these warnings could result in serious bodily injury or death.Should you have problems understanding the instructions in this manual,or have any questions,STOP, and get help from a qualified service technician, or the local gas utility. AD-A-NGER! INSTALL THE DRAFT HOOD AND PROPERLY VENT THE z y WATER HEATER.. Failure to install the draft hood and properly vent the water heater to the outdoors as outlined in the Venting Section of the Installation Instructions in this manual can result in unsafe operation of the water heater.To avoid the risk of fire, explosion,or asphyxiation from carbon monoxide, never operate this water heater unless it is properly vented and has an adequate air supply for proper operation.Be sure to inspect the vent system for proper installation at initial start-up; and at least annually thereafter.Refer to the Care and CIeaning section of this manual.for more information regarding vent system inspection. i vY}z AWARm NG! Gasoline,as well as other flammable materials and liquids(adhesives, solvents,paint thinners etc.), and the vapors they produce are extremely dangerous.DO NOT handle, use or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater or any other appliance.Be sure to read and follow warning label pictured below and other labels on the water heater, as well as the warnings printed in this manual.Failure to do so can result in property damage,bodily injury or death. Fjammable Vapors FIRE AND EXPLOSION HAZARD Can result in serious injury or death. ®Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.Storage of or use of gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance can result in serious injury or death. 3 IMPORTANT SAFETY INFORMATION. READ ALL INSTRUCTIONS BEFORE USING. ®DANGER! is€ sir t WATER TEMPERATURE SETTING Safety and energy conservation are factors to be considered when selecting the water temperature setting of a water heater's gas control.Water temperatures above 125°F can cause severe burns or death from scalding.Be sure to read and follow the warnings outlined on the label pictured below. This label is also located on the water heater. Time/Temperature Relationship in Scalds • Water Temperature Time To Produce a Serious Sum 120OF More than 5 minutes 125OF 11/2 to 2 minutes 130OF About 30 seconds 135°F About 10 seconds 140OF Less than 5 seconds ■ 145OF Less than 3 seconds 150*F About 11h seconds 155OF About 1 second Table courtesy of Sbriuers sum Institute HOT The chart shown above may be used as a guide in determining the proper water temperature for your home. ®,DANGER:Households with small children,disabled,or \,N 3 4 elderly persons may require a 120°F or lower Combination Gas Control(Thermostat)setting to prevent contact with "SHOT"water. Maximum water temperatures occur just after the Water temperature over 1250 F burner has shut off.To find water temperature being can cause severe burns delivered,turn on a hot water faucet and place instantly or death from scalds. a thermometer in the water stream and read the thermometer(see page 18 and 19 for more details). Children,disabled and elderly are The temperature of the water in the heater can be at highest risk of being scalded. regulated by setting the temperature knob on the See instruction manual before front of the Combination Gas Control(Thermostat). setting temperature at water To comply with safety regulations the Combination heater. Gas Control(Thermostat)was set at its lowest Feel water before bathing or setting before the water heater was shipped from the showering. factory. Temperature limiting valves are The illustration below details the approximate water available,see manual. temperature for each mark on the Combination Gas Control(Thermostat). NOTICE: Mixing valves are recommended for reducing 50OF 15sO point of use water temperature by mixing hot and cold water 140OF in branch water lines.It is recommended that a mixing valve complying with the Standard for Temperature Actuated 1 °F Mixing Valves for Hot Water Distribution Systems,ASSE 1250 F n OLD 1017 be installed. See pages 18 & 19 for more details and 190 F contact a licensed plumber or the local plumbing authority for further information. ADANGLR:Hotter water increases the potential for Hot Water SCALDS. 4 ADANGER! LIQUEFIED PETROLEUM (LP - PROPANE OR BUTANE) � AND NATURAL GAS MODELS LP and Natural gas have an odorant added to aid in detecting a gas leak.Some people may not physically be able to smell or recognize this odorant.If you are unsure or unfamiliar with the smell of LP or Natural gas,ask the gas supplier.Other conditions, such as "odorant fade",which causes the odorant to diminish in intensity, can also hide or camouflage a gas leak. Water heaters utilizing LP gas are ANGER:If a gas teak is present or different from Natural gas models. suspected: A Natural gas water heater will not DO NOT attem t to find the cause function safely on LP gas and vice versa. p yourself: C, No attempt should ever be made to convert the water heater from Natural 0 DO NOT try to light any appliance. gas to LP gas.To avoid possible ;DO NOT touch any electrical switch. equipment damage,personal injury or fire,do not connect the water heater to a '' DO NOT use any phone in your building. fuel type not in accordance with the unit £= Leave the house immediately and make data plate.LP for LP units. Natural gas sure your family and pets leave also. for Natural gas units.These units are not Q�Leave the doors open for ventilation certified for any other fuel type. and contact the gas supplier, a qualified LP appliances should not be installed service agency or the fire department. below grade(for example,in a basement) if such installation is prohibited by aStay away from the house(or building) federal, state and/or local laws, rules, until the service call has been made,the regulations or customs. leak is corrected and a qualified agency has determined the area to be safe. LP gas must be used with great caution. It is heavier than air and will collect first in lower areas making it hard to detect at nose level. @ Before attempting to light the water heater, make sure to look and smell for gas leaks.Use a soapy solution to check all gas fittings and connections.Bubbling at a connection indicates a leak that must be corrected.When smelling to detect a gas Ieak,be sure to sniff near the floor also. Gas detectors are recommended in LP &Natural gas applications and their installation should be in accordance with the detector manufacturer's recommendations and/or local laws, rules,regulations or customs. It is recommended that more than one method, such as soapy solution,gas detectors,etc.,be used to detect leaks in gas applications. 5 IMPORTANT SAFETY INFORMATION. READ ALL INSTRUCTIONS BEFORE USING. AWARNP4G! For your safety, the information in this manual must be followed to minimize the risk of fire or explosion, electric shock, or to prevent property damage,personal injury,or loss of life. FOR INSTALLATIONS IN THE STATE OF CALIFORNIA W California Law requires that residential water heaters must be braced, anchored or 3 strapped to resist falling or horizontal displacement due to earthquake motions.For residential water heaters up to 52-gallon capacity,a brochure with generic earthquake bracing instructions can be obtained from: Office of the State Architect, 1102 Q Street, Suite 5100, Sacramento, CA 95814 or you may call 916445-8100 or ask a water heater dealer. However, applicable local codes shall govern installation.For residential water heaters of a capacity greater than 52 gallons,consult the local building jurisdiction for acceptable bracing procedures. SAFETY P y RECAUTIONS � Y ft ds Have the installer show you the location of the gas shutoff valve and how to shut it off if necessary, 'Than off the manual shut-off valve if the water heater has been,subjected to overheating, fire,flood,physical damage or if the gas supply fails to shut off, tti--'Read this manual entirely before installing DO NOT attempt to repair or replace or operating the water heater. any part of your water heater unless it is Use this appliance only for its intended specifically recommended in this manual. purpose as described in this Use and Care All other servicing should be referred to a Manual. qualified technician. �9 Be sure your appliance is properly installed in accordance with local codes and the provided installation instructions. % ' 1' READ AND FOLLOW THIS SAFETY INFORMATION CAREFULLY. i to SAVE THESE INSTRUCTIONS 6 Installing the water heater. This water heater must be installed in accordance with these instructions,local codes,utility company requirements,and/or in the absence of local codes,use the latest edition of the American National Standard/National Fuel Gas Code.A copy can be purchased from either the American.Gas Association, 400 N. Capitol Street NW,Washington,DC 20001 as ANSI standard Z223.1 or National Fire Protection Association, 1 Batterymarch Park, Quincy,MA 02269 as booklet NFPA 54. Location Combustion Air Inlet The water heater should not be located damage,for example,by moving vehicles, Openings in an area where leakage from the tank area flooding,etc or connections will result in damage =zs;The water heater should be installed Max to the area adjacent to the heater or to as close as practical to the gas vent or 2" lower flours of the structure. chimney. - When such areas cannot be avoided it is r�Long hot water lines should be insulated to recommended that a suitable drain pan, conserve water and energy. adequately drained,must be installed under the water heater. s The water heater and water lines should The pan must not restrict air flow to the be protected from exposure to freezing Diameter of combustion air inlet openings(perforationtemperatures. water heater openings)located around the lower ?DO NOT install the water heater in plus 2"min. perimeter of the water heater. bathrooms,bedrooms,any occupied The auxiliary drain pan Drain pan kits are available from the store rooms normally kept closed,or in installation MUST conform where the water heater was purchased,or unprotected outdoor areas. to local codes. any water heater distributor. wy Minimum clearance from combustible Make certain the floor underneath the water construction: heater is strong enough to sufficiently Location Front* I Sides Rear Top** support the weight of the water heater once Alcove 3" 0" 0" 12" it is filled with water. A gas-fired water heater or any other Closet 3" 1 0" 1 0" 12" appliance should not be installed in a space where liquids which give off * "Front"clearance dimension is measure flammable vapors are to be used or stored. from the Combination Gas Control Such liquids include gasoline,LP gas (Thermostat)to the closet door. (Butane or Propane),paint or adhesives and ** "Top"clearance dimension is measure their thinners,solvents or removers. from the jacket top of the water heater to When installed in a closet,DO NOT the ceiling. block or obstruct any of the combustion If the clearances stated on the Instruction/ air inlet openings located around the Warning Label,located on the front of perimeter of the water heater. A the heater differ,install the water heater minimum of 1"is required between these according to the clearances stated on the combustion air inlet openings and any label. obstruction. 0 If the water heater is installed in an Because of natural air movement in a room alcove or closet,the entire floor must be or other enclosed space,flammable vapors covered by a wood or metal panel. can be carried some distance from where A minimum of 24"clearance from the Iiquids which give off flammable vapors front and top should be available for are to be used or stored.The open flame of adequate inspection and servicing. the water heater's pilot or main burner can 15 The water heater may be installed on ignite these vapors and create a shut down combustible floors,but not directly on condition of the water heater which carpeting.If the water heater must be A WARNING: Combustible will not allow the water heater to ignite installed on carpeting,place a metal or construction refers to until examined by a Qualified Service wood panel beneath the water heater, adjacent walls and ceilings Technician. extending beyond its full width and and should not be confused FVIR certified gas water heaters can be depth at least 5"in all directions. with combustible or installed on a residential garage floor flammable products and without the use NOTICE: For proper operation and t accordance with t materials.Combustible an ainch stand in maintenance,a minimum clearance of and/or flammable products he National Fuel Gas 1.5 inches must be provided from the and materials should never Code,NFPA 54,ANSI Z2e and Local unless combination temperature and pressure be stored in the vicinity of otherwise directed by State an relief valve to any wall or object. this or any gas appliance. code requirements.The water heater must be located so it is not subject to physical 7 Installing the water heater. Inspect Shipment Inspect the water heater for possible type of gas supplied corresponds to the damage.Check the markings on the rating water heater requirements. plate of the water heater to be certain the Combustion and Ventilation Air Proper operation of the water heater (but not less than 100 square inches),if requires air for combustion and each opening communicates with other ventilation.Provisions for combustion unconfined areas inside the building. and ventilation air must comply with referenced codes and standards. Buildings of unusually tight construction skull have the combustion and ventilation When installed in a closet,DO NOT air supplied from outdoors,or a freely block or obstruct any of the combustion ventilated attic or crawl space. air inlet openings located around the perimeter of the water heater. A If air is supplied from outdoors,directly or minimum of 1"is required between through vertical ducts,there must be two these combustion air inlet openings and openings located as specified above and any obstruction. each must have a minimum net free area of not less than one square inch per 4,000 NOTICE:If the water heater is Btuh of the total input rating of all the installed in an unconfined space within a appliances in the enclosure. building of conventional frame,masonry or metal construction,infiltration If horizontal ducts are used to air is normally adequate for proper communicate with the outdoors,each combustion and ventilation.If the opening must have a minimum net free water heater is installed in a confined area of not less than one square inch per space,provisions for combustion and 2,000 Btuh of the total input rating of all ventilation air must be made. the appliances in the enclosure.If ducts are used,the minimum dimensions of A confined space is one having a volume rectangular air ducts shall not be less than of less than 50 cubic feet per 1,000 Btuh 3", of the aggregate input of all appliances NOTICE:If the duct openings which enin within that space. p g supply combustion and ventilation air The air must be supplied through two are to be covered with a protective permanent openings of equal area.One screen or grill,the net free area is to be located within 12"above the floor (openings in the material)of the and the other is to be located within 12" covering material must be used in from the ceiling. determining the size of the openings. The minimum net free area of each opening Protective screening for the openings must not be less than one square inch g MUST NOT be smaller than 114"mesh per 1,000 Btuh of the total input rating to prevent clogging by lint or other of all the appliances in the enclosure debris. NOTICE:The water heater Corrosive Atmospheres should not be installed near an air supply containing The air in beauty shops,dry cleaning Propellants from common spray cans halogenated hydrocarbons. establishments,photo processing or gas leaks from A/C and refrigeration labs, and storage areas for liquid and equipment are highly corrosive after powdered bleaches or swimming pool passing through a flame, chemicals often contain such halogenated The water heater warranty is voided when hydrocarbons. failure of the heater is due to operation in An air supply containing halogenated a corrosive atmosphere. hydrocarbons may be safe to breathe, but when it passes through a gas flame corrosive elements are released that will shorten the life of any gas burning appliance. 8 Thermal Expansion Determine if a check valve exists in piping.This rapid pressure increase can the inlet water line.Check with your quickly reach the safety setting of the local water utility company. It may relief valve,causing it to operate during have been installed in the cold water each heating cycle.Thermal expansion, line as a separate back flow preventer, and the resulting rapid,and repeated or it may be part of a pressure reducing expansion and contraction of components valve,water meter or water softener.A in the water heater and piping system can check valve located in the cold water cause premature failure of the relief valve, inlet Iine can cause what is referred to as and possibly the heater itself.Replacing a"closed water system".A cold water the relief valve will not correct the inlet line with no check valve or back problem! flow prevention device is referred to as an The suggested"open"water system. gg sted method of controlling thermal expansion is to install an As water is heated,it expands in volume expansion tank in the cold water line and creates an increase to the pressure between the water heater and the check within the water system.This action is valve(see illustration below).The referred to as"thermal expansion'.In expansion tank is designed with an an"open"water system,expanding water air cushion built in that compresses as which exceeds the capacity of the water the system pressure increases,thereby heater flows back into the city main where relieving the overpressure condition and the pressure is easily dissipated. eliminating the repeated operation of the A"closed water system",however, relief valve.Other methods of controlling prevents the expanding water from thermal expansion are also available, flowing back into the main supply line, Contact your installing contractor,water and the result of"thermal expansion" supplier or plumbing inspector for Fan create a rapid and dangerous pressure additional information regarding this increase in the water heater and system subject. Water Supply Connections IMPORTANT:DO NOT Refer to the illustration below for suggested for servicing if necessary.The HOT and COLD apply heat to the HOT or typical installation.The installation of unions water connections are clearly marked and are COLD water connections. or flexible copper connectors is recommended 3/4"NPT on all models.Install a shut-off valve If sweat connections are on the hot and cold water connections so that in the cold water line near the water heater. used,sweat tubing to the water heater may be easily disconnected adapter before fitting adapter to the cold water Typical Installation connections on heater. Vent connector to Pitch up 1/4" Any heat applied to the chimney Union , ��.•' per foot cold water supply fittings Heat trap +Y ••• will permanently damage 6"minimum Draft hood the dip tube. Hot water outlet to Anode fixtures Union Water Heater Jacket Shut-off Temperature and valve pressure relief valve NOTICE:The National Manual gas shut-off Heat trap Fuel Gas Code B'minimum (NFGC) To gas supply mandates a manual To cold water gas shut-off valve: See supply (NFGC)for complete mound joint union Shut-off valve instructions. Local codes Thermal expansion or plumbing authority sediment trap tank(if required) requirements may vary Cap Relief valve discharge Drain line to suitable open from the instructions or I _- valve drain, diagrams provided and Thermostatic gas valve take precedent over these k`y;; Combustion Air instructions. Jacket door inlet Openings Auxiliary drain pan J� 6"Air gap Drain Pan Pipe to suitable dram. 9 Installing the water heater. A new combination temperature and pressure relief valve,complying with the Standard for Relief Valves and Automatic Gas Shut-Off Devices for Hot Water Supply Systems,ANSI Z21.22,is supplied and must remain in the opening provided and marked for the purpose on the water heater.No valve of any type should be installed between the relief valve and the tank.Local codes shall govern the installation of relief valves. Relief Valve The pressure rating of the relief valve The discharge Iine must be no smaller must not exceed 150 PSI,the maximum than the outlet of the valve and must working pressure of the water heater as pitch downward from the valve to allow marked on the rating plate. complete drainage(by gravity)of the The Btuh rating of the relief valve must relief valve and discharge line. equal or exceed the Btuh input of the The end of the discharge line should not water heater as marked on its rating plate. be threaded or concealed and should be Position the outlet of the relief valve protected from freezing.No valve of above a suitable open drain to eliminate any type,restriction,or reducer coupling potential water damage.Piping used should be installed in the discharge line. should be of a type approved for hot water distribution. To Fill the Water Heater WARNING:The tank Make certain that the drain valve is must be full of water before closed,then open the shut-off valve in the heater is turned on.The cold water supply line, water heater warranty does not cover damage or failure Open each hot water faucet slowly to resulting from operation allow the air to vent from the water with an empty or partially heater and piping. empty tank. A steady flow of water from the hot water faucet(s)indicates a full water heater. Condensation Condensation can form on the tank This condition is not unusual,and will when it is first filled with water. disappear after the water becomes heated. Condensation might also occur with a If,however,the condensation continues, heavy water draw and very cold inlet examine the piping and fittings for water temperatures. possible leaks. Drops of water falling on the burner can produce a sizzling or pinging sound. 10 ®WARNING:DO NOT attempt to convert this water heater for use with a different type of gas other than the type shown on the rating plate.Such conversion could result in hazardous operating conditions. Gas Supply The branch gas supply line to the water Where a sediment trap is not incorporated heater should be clean.,properly sized as part of the appliance,a sediment trap steel pipe or other approved gas piping shall be installed downstream of the material. equipment shutoff valve as close to the A ground joint union or ANSI design inlet of the appliance as practical at the certified semi-rigid or flexible gas time of the appliance installation.The appliance connector should be installed sediment trap shall be either a tee fitting in the gas line close to the water heater. with a capped nipple in the bottom outlet The National Fuel Gas Code(NFGC) or other device recognized as an effective mandates a manual gas shut-off valve: See sediment trap. (NFGC)for complete instructions. DO NOT use excessive force(40 ft/ If flexible connectors are used,the lbs.Max Torque)in tightening the pipe maximum length shall not exceed 35". joint at the Combination Gas Control (Thermostat)inlet,particularly if teflon Compound used on the threaded joints of pipe compound is used,as the valve body the gas piping must be of the type resistant may be damaged. to the action of LP gas.Use compound The inlet gas pressure to the water heater sparingly on male threads only, must not exceed 14"w.c. for Natural gas, or 14"w.c.for LP gas.For purposes of input adjustment,the minimum inlet gas pressure(with main burner on)is shown on the water heater rating plate.If high or low gas pressures are present,contact your gas supplier for correction. Leak Testing WARNING:Never use The water heater and its gas connections The factory connections to the an open flame to test for must be leak tested at normal operating Combination Gas Control Thermostat gas leaks,as property (Thermostat) damage,personal injury,or pressures before it is placed in operation, should also be leak tested after the water death could result. r Turn on the manual gas shut-off beater is placed in operation. valve near the water heater. Use a soapy water solution to test for leaks at all connections and fittings. Bubbles indicate a gas leak that must be corrected. Pressure Testing the Gas Supply System The appliance and its individual shutoff The appliance must be isolated from the valve must be disconnected from the gas gas supply piping system by closing its supply piping system during any pressure individual manual shutoff valve during testing of that system at test pressures in any pressure testing of the gas supply excess of 1/2 psi(3.5 kPa). piping system at test pressures equal to or less than 1/2 psi(3.5 kPa). High Altitude This water heater is suitable and certified AWARNING: Installations above the for use at high altitude.Refer to the rated altitude as specified on the altitude label on the water heater for altitude label are not authorized and maximum allowable installation altitude. may result in improper and inefficient operation of the appliance,producing carbon monoxide gas in excess of acceptable limits,which could result in serious injury or death. 11 Installing the water heater. Insulation Blankets AWARNING:If local codes Insulation blankets,available to the ACAUTION:If local codes require the require external application general public,for external use on gas application of an external insulation of insulation blanket kits water heaters are not necessary.The blanket to this water heater,pay careful the manufacturer's purpose of an insulation blanket is to attention to the following so as not to instructions included with reduce the standby heat loss encountered restrict the proper function and the lit must be carefully with storage tank heaters.This water operation of the water heater: followed. heater meets or exceeds the National DO NOT cover the operating or Appliance Energy Conservation Act warning labels attached to the water standards with respect to insulation and heater or attempt to relocate them on standby loss requirements making an the exterior of insulation blanket. insulation blanket unnecessary. DO NOT apply insulation to the top of The manufacturer's warranty does not cover any damage or defect caused by the water heater.This will interfere with installation,attachment or use of any type the safe operation of the draft hood. of energy saving or other unapproved 0 DO NOT cover the burner access door, devices(other than those authorized jacket door,Combination Gas Control by the manufacturer)into,onto or in (Thermostat)/gas valve or pressure and conjunction with the water heater.The temperature relief valve. use of unauthorized energy saving devices DO NOT apply 1 insulation to the bottom may shorten the life of the water heater and may endanger life and property. of the water heater or the area where the combustion air inlet openings are The manufacturer disclaims any located.This area must be unobstructed responsibility for such loss or injury so as not to restrict combustion air flow resulting from the use of such to the burner. unauthorized devices. 0 Inspect the insulation blanket frequently making certain it has not sagged and is restricting the air flow to the combustion air inlet openings(perforation holes) located around the lower perimeter of the water heater jacket.This could result in an unsafe operating condition. The water heater roust be installed with the factory supplied draft hood in place. ADANGER:Failure to Venting install the draft hood and properly vent the water Vent connectors must be attached to the Horizontal vent connectors must be heater to the outdoors as draft hood outlet to connect the water pitched upward to the chimney at least outlined in the Venting heater to the gas vent or chimney.The 1/4"per foot of length. Single wall vent section of this manual will vent connectors must be the same size connectors must be at least 6"from result in unsafe operation of (diameter)as the draft hood or larger, adjacent unprotected combustible surface. the water heater causing never smaller. Vent joints must be securely fastened bodily injury,explosion, by sheet metal screws or other approved fire or death.To avoid the For proper venting in certain installations method. risk of fire,explosion,or a larger vent connector size may be asphyxiation from carbon needed.Consult the Vent Tables in Test for spillage at the draft hood relief monoxide,NEVER operate Appendix G of the latest version of the opening after 5 minutes of main burner the water heater unless it is National Fuel Gas Code(ANSI standard operation.Use a flame of a match or properly vented and has Z223.1 or NFPA 54). candle or smoke.The flame or smoke adequate air supply for should be pulled into the draft hood's proper operation as relief opening(s). outlined in the Venting section of this manual. 12 Hot and Cold Pipe Insulation Installation Typical vertical piping arrangement Typical horizontal piping arrangement For increased energy efficiency,some to the illustrations above,that best meets water heaters have been supplied with your requirements. two 24"sections of pipe insulation. Please install the insulation,according T&P Insulation Installation For increased energy efficiency,this 2 3/8"section of T&P insulation.Please water beater has been supplied with a install the insulation as shown below. IGO xr� Typical Side Connect T&PArrangement. Typical Top Connect T&PA,rangement. SIip the insulation cover over the T&P Ensure the T&P Valve opening is not Valve through the center hole and align obstructed by the insulation. the hole in the side with the opening of the T&P Valve. Heat Trap For increased energy efficiency,some These heat traps may require a minimum water heaters have been supplied with of one(1),9001 3/4"NPT elbow and factory installed 3/4"NPT heat traps in may require an additional 900,3/4"NPT the hot outlet line and cold water inlet line. elbow or a 3/4"coupling depending on your installation needs. See Illustration of nipples and heat traps on page 26. 13 Installing the water heater. During Installation of this water heater. DO DON'T ❑ DO check inlet gas pressure to ensure ❑ DON'T block or restrict Combustion that it is within the range specified on the Air Wet Openings located around the lower rating plate. portion of the water heater jacket ❑ DO provide adequate air for combustion ❑ DON'T remove the BurnerAccess and ventilation as discussed in the Use and Door unless absolutely necessary.This Care Manual and the National Fuel Gas should only be done by a qualified service Cade. technician.A new burner access door gasket ❑DO maintain proper clearances to must be installed on any burner access door combustibles as specified on the rating that has been removed. plate. ❑DO ensure that the venting system ❑DON'T install this water heater where complies with the guidelines found in the standing water may occur.The base of the Use and Care Manual and National Fuel water heater is meant to be mounted on a Gas Code. dry surface. ❑ DO contact a qualified service ❑DON'T operate the water heater if the technician if the pilot or main burner will sight glass or pilot assembly door grommet not stay lit.The burner chamber is designed is damaged or broken. to be sealed utilizing a gasket and tamper resistant screws. Pilot Assembly Door Grommet ® Sight Glass 14 Installation Checklist A. Water Heater Location ❑ Close to area of vent. ❑ Provisions made to protect area from water ❑ Indoors and protected from freezing damage. temperatures. ❑ Sufficient room to service heater. ❑ Proper clearance from combustible surfaces ❑ Combustible materials,such as clothing, observed and water heater not installed on cleaning materials,rags,etc.clear of the carpeted floor, base of the heater. ❑ Sufficient fresh air supply for proper operation of water heater. ❑ Clearances from combustion air inlet ElAir supply free of corrosive elements and openings observed(see page 7). flammable vapors. B. Water Supply ❑ Water heater completely filled with water. ❑ Air purged from water heater and piping. ❑Water connections tight and free of leaks. C. Gas Supply ❑ Gas line equipped with shut-off valve,union ❑ Soap and water solution used to check all and sediment trap, connections and fittings for possible gas ❑ Approved pipe joint compound used. leak. ❑ Gas Company inspected installation(if required). D. Relief Valve ❑ Temperature and Pressure Relief Valve properly installed and discharge line run to open drain, ❑ Discharge line protected from freezing. E. Venting ❑ Flue baffle properly hung in top of heater's ❑ Vent connector(s)securely fastened together flue• with screws. ❑ Draft hood properly installed. ❑ Single wall vent connector(s)at least 6" ❑ Vent connector(s)pitched upward to chimney from combustible material, ('/a'per foot of length minimum). 15 Supplemental instructions for gas water heaters installed in potable/space heating applications. Local codes or plumbing authority requirements may vary from the instructions or diagrams provided in this manual and take precedent over these instructions. 1 Hot water Combination Potable and Space Heating Application supply to house Tee fitting must be installed as shown.This NOTICE: Suitable for combination water ensures that any air in the water lines will be (potable)heating and space heating and not 4— purged through the domestic water faucets and suitable for space heating applications only. Hot water showers. DANGER:If this water heater is installed supply to From HOT in an application intended to supply domestic heating outlet on DANGER:When this system requires hot water needs and hot water f r s unit '� water for space heating at elevated pace water heater temperatures [above 125°F(52°C)],a mixing heating purposes,DO NOT connect the Tee fitting for vertical hot valve complying with the Standard for heater to an existing heating unit or water supply lines. Temperature Actuated Mixing Valves for Hot componeuts of a heating system that have Hot water From HOT Water Distribution Systems,ASSE 1017 must previously been used with a non drinking supply be installed in the hot water supply line to su 1 to water heater outlet on water sY stem.Toxic chemicals such as those house the house in order to reduce the scald hazard used for boiler treatment may be present and potential. will contaminate the drinking water supply causing possible health risks.Never introduce ADANGER:Any piping or components used toxic chemicals,such as those used for boiler in the installation of this water heater in a treatment,into this system. Hot water supply combination potable and space heating to heating unit application must be suitable for use with NOTICE: 50,_011 maximum distance Tee fitting for horizontal hot drinking water. from water heater to fan coil(developed water supply lines. length)is required for Massachusetts State. Typical Piping Diagram for Combination Potable/Space Heating Installation Nominal 3/4"aim mixing or tempering valve Minimum of 2'-0"developed length of Pressure Gauge (refer to warning above).Follow mixing or 314"type"L"copper from the water heater 3W Chock valve with 118"Hole tempering valve manufacturer's instructions for cooncedon• 314"Sbut-0@'Valve(•lyp.) 314"Tempered installation of the valve. domesticltot water g oaded check valve in y Air vent supply to house. 3/4"cold water supply Sprm l �f � Piping leap helwcen water bating unit hot waterattpply line heater and fan coil shall and cold water return line not be flow guard gold CPVC supplied with water heater) or equal NOTICE:This check valve is 314"Shut-Off inw ''rated in some beating Valve�•ry,,, rmits.Refer to the installation t �Heat Trap l'JY•) instructions supplied with 6'Min ap. o heating tutu to tcrminc if it u required. 314"Shut- 2 Gallon Thermal Off valve Expeaalon Tank(if Isolation valve in hat water ( •) required-not supplied supply line to he�aalitrnngg unit(not with water heater) Hot water supplied widt weterheatce) to apace heater �I Ha[water coil See diagrams above far proper AID bronze pump. pipe application for vertical or Chlock valve internal horizontal supply tints. A Plump• Au bleed valve. 7empcmturo and t 1 l Pressure Relief ater Samplo Tap. valve,tic to location approved by local code 314 to Heatin"HW S g Coil&J•i9VR . Gas line to water heater To HVAC Drain valve unit (not supplied with water beater) OaN OFF Temperature and Gas Fired Isolation valve in CIQ'G.PO.TL pressure relief valve Water Heater cold water return line discharge line from beating unit(not Air Handler supplied with water hearer) WatorHeatu dram P� Gas Direct Vent discharge installed in ac4orda¢ce must comply with Local and with the Local and State State Code Code •a • ••s 0 Combustion Air Inlet vacuum Rellefvalve Electronically controlled p timer. Water Heater to be in •�t••w� pure accordance with the 0*00* Openings (Not supplied) Activator every 6 hours of r 60 seconds. Local and State Energy see*Code Wire to bronze pump. All water piping shall be insalatod in accordance with Local and State �k Energy Code. 6"Air Cap udvaLm avoar.Wm7 16 Lighting the water heater. Before operating this water heater,be sure to read and follow the instructions on the label pictured below and all other labels on the water heater, as well as the warnings printed in this manual.Failure to do so can result in unsafe operation of the water heater resulting in property damage,personal injury, or death.Should you have any problems reading or following the instructions in this manual, STOP, and get help from a qualified person. FOR YOUR SAFETY READ BEFORE OPERATING ©WARNING:If you do not follow these instructions and the Use&Care Manual instructions exactly,a fire or explosion may result causing property damage,personal injury or loss of life. A. This appliance has a pilot which is lit by a piezo-electric spark gas ignition system. • If you cannot reach your gas supplier, Do NOTopen the inner door of this call the fire department. appliance and try to fight the pilot by C. Use only your hand to turn the gas control hand! knob. Never use tools. If the knob will not B. BEFORE LIGHTING smell all around the turn by hand,don't try to repair it,call a appliance area for gas. Be sure to smell qualified service technician. Force or next to the floor because some gas is attempted repair may result in afire or heavier than air and will settle on the floor. explosion. WHATTO DO IF YOU SMELL GAS: D. Do not use this appliance if any part has • Do not try to light any appliance. been under water. Immediately call a • Do not touch any electric switch; do not qualified installer or service agency to use any phone in your building. replace a flooded water heater. Do not • Immediately call your gas supplier from attempt to repair the unit! It must be a neighbor's phone. Follow the gas replaced! supplier's instructions. LIGHTING INSTRUCTIONS 1.STOP!Read safety information above on this label. O 2.Rotate the combination gas control/thermostat knob counter-clockwise 0 to the"OFF" position. 3.Wait five(5)minutes to clear out any gas.If you smell gas,STOP!Follow"B"in the safety information above on this label.If you don't smell gas,go to the next step. 4.Remove the outer door from the water heater.Do not attempt to remove the inner door assembly.Locate the piezo-electric spark generator button which is just below the combina- tion gas control/thermostat knob. . 5.Rotate the combination gas control/thermostat knob clockwise Z)to the"PILOT"position. 6.Depress and hold the combination gas control/thermostat knob all the way in while immedi- ately depressing the piezo-electric spark generator button several times until the"STATUS" indicator light begins to blink.Once the"STATUS"indicator light begins to blink,verify the pilot is lit by viewing the pilot flame through the sight glass window located on the inner door. • If the"STATUS"indicator light does not start blinking after 90 seconds and the pilot is not lit,repeat steps 2 through 6. • If the pilot will not stay lit after several lighting sequence attempts,turn the combination gas control/thermostat knob counter-clockwise 0 to the"OFF"position and call your service technician or gas supplier. 7.Replace the outer door. 8.Release the combination gas control/thermostat knob.The knob should pop back out. it If the combination gas control/thermostat knob does not pop back out when released,stop and immediately call your service technician or gas supplier. 9.Set the combination gas control/thermostat knob to the desired setting. TO TURN GAS OFF TO THE APPLIANCE 0 Rotate the combination gas control/thermostat knob counter-clockwise C5 to the"OFF" position,Note:The"STATUS"indicator light will briefly stay lit,then go off after a short period of time. 17 Operating the water heater. A CAUTION:Hydrogen gas can be produced in a hot water system served by this water heater that has not been used for a long period of time(generally two weeks or more).HYDROGEN GAS IS EXTREMELY FLAMM"M!To dissipate such gas and to reduce risk of injury,it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before using any electrical appliance connected to the hot water system.If hydrogen is present,there will be an unusual sound such as air escaping through the pipe as the water begins to flow.DO NOT smoke or use an open flame near the faucet at the time it is open. Safety Precautions A Do turn off manual gas shut-off valve if water heater \6cE DO NOT store or use gasoline or other flammable has been subjected to overheating,fire,flood,physical vapors and liquids,such as adhesives or paint thinner, damage or if the gas supply fails to shut off. in vicinity of this or any other appliance.If such a DO NOT turn on water heater unless it is completely flammables must be used,open doors and windows for filled with water. ventilation,and all gas burning appliances in the vicinity should be shut off including their pilot DO NOT turn on water heater if cold water supply burners,to avoid vapors lighting. shut-off valve is closed. NOTICE:Flammable vapors can be drawn by air Q DO NOT allow combustible materials such as currents from surrounding areas to the water heater. newspaper,rags or clops to accumulate near water F' an difficulty If there is heater. If Y in understanding or following the Operating Instructions or the Care and Cleaning section,it is recommended that a qualified person or serviceman perform the work. Water Temperature Setting ADANGER:Hotter water The temperature of the water in the Water temperatures above 125°F can increases the Potential for Hot water heater can be regulated by setting cause severe burns or death from scalding, Water SCALDS.Households the temperature knob on the front of the Be sure to read and follow the warnings with small children, Combination Gas Control(Thermostat). outlined in this manual and on the label disabled,or elderly persons located on the water heater near the may require a 120OF or Safety and energy conservation are factors lower Combination Gas to be considered when selecting the water Combination Gas Control Thermostat. Control(Thermostat) temperature setting of the water heater's Mixing valves are recommended for setting to prevent contact Combination Gas Control(Thermostat). reducing point of use water temperature with HOT water. The lower the temperature setting,the by mixing hot and cold water in branch greater the savings in energy and operating water lines.It is recommended that a casts. mixing valve complying with the Standard To comply with safe re for Temperature Actuated Mixing Valves p y safety l(Thermostat) the for Hot Water Distribution Systems,AS SE Combination Gas Control(Thermostat} 1017 be installed. See page 4 for more was set at its lowest setting before details and contact a licensed plumber or the water heater was shipped from the the local plumbing authority for further factory.The recommended starting point temperature is 1207. information. The chart below may be used as a guide in determining the proper water temperature for your home. Time/Temperature Relationship in Scalds Water Temperature. Time To Produce a Serious Burn 120°F More than 5 minutes 125OF I1/2 to 2 minutes 130°F About 30 seconds 1357 About 10 seconds 140°F Less than 5 seconds 1457 Less than 3 seconds 150OF About 1'/2 seconds 155OF About 1 second Table courtesy of Shrinere Bum Iastitute 18 Operating the water heater. Water Temperature Setting... Maximum water temperatures occur just Therefore,always remember to test the after the burner has shut off.To determine water temperature with your hand before the water temperature,tam on a hot water use and remember that hotter water faucet and place a thermometer in the increases the risk of scald injury. water stream. The reference mark"Low"represents an Also,always supervise young children or approximate water temperature of 91°F. others who are incapacitated. The reference mark"Hot"represents an The Combination Gas Control approximate water temperature of 125°R (Thermostat)is constructed with a built The reference mark"A"represents an in safety shut-off device designed to shut approximate water temperature of 130°F off the gas supply to the burner if the pilot flame The reference mark"B"represents an is extinguished for any reason. approximate water temperature of 140OF The Combination Gas Control (Thermostat)is also equipped with a The reference mark"C"represents an single use gas shut off device that will approximate water temperature of 150°F shut off the gas supply to the burner if the The reference mark"Very Hot"represents water heater exceeds normal operating an approximate water temperature of temperatures.Refer to the(Before You 155OF Call For Service)section of this manual, A condition known as"stacking"or or contact your dealer. "layering"can occur when a series of A WARNING:Should overheating occur or short and frequent hot water draws are the gas supply fail to shut off,turn off the taken. manual gas control valve to the appliance. If the water heater has been subjected to fire, The hottest temperature water will be at flood or physical damage,turn off the manual the top of the tank,closest to the outlet gas(shut-off)valve,and do not operate the pipe delivering hot water to the home. water heater again until is has been checked by a qualified service technician. Stacking can cause this top layer of water NOTICE:DO NOT use this appliance if to be hotter than the water toward the any part has been under water.Immediately bottom of the tank near the Combination call a qualified installer or service agency Gas Control(Thermostat). to replace a flooded water heater.DO NOT attempt to repair the wait!It must be replaced. Temperatures are approximate 1550F APPROX. 150°F APROX. 1400F APPROX. arena 1300F APPROX. 125OF APPROX. AC 1200F APPROX. F o 90OF APPROX. 19 Care and cleaning of the water heater. Draining the Water Heater ACAUTION:Shut off gas to the water In order to drain the water heater,turn off heater at the manual shut-off valve the cold water supply.Open a hot water before draining water. faucet or lift the handle on the relief valve ADANGER:Before manually operating to admit air to the tank. the temperature and pressure relief Attach a garden hose to the drain valve on valve,make certain no one will be the water heater and direct the stream of exposed to the hot water released by water to a drain. Open the valve. the valve.The water drained from the tank may be hat enough to present a scald hazard and should be directed to a suitable drain to prevent injury or damage. Routine Preventative Maintenance ADANGER:Before Properly maintained,your water heater (Thermostat)sensors,causing the sensors manually operating will provide years of dependable trouble- to operate erratically.Because accumulated the relief valve,make free service. solids can prevent the Combination certain no one will Gas Control(Thermostat)sensors from be exposed to the It is recommended that a periodic accurately reading the water temperature, danger of the hot water inspection of the Combination Gas Control the water at the fixture can be hotter than released by the valve. (Thermostat),burner,relief valve,and the Combination Gas Control ermostat) The water may be hot venting system should be made by service dial setting.It is suggested that as few enough to create a scald personnel qualified in gas appliance repair. quarts of water be drained from the water hazard.The water It is suggested that a routine preventative heater's tank every month to clean the tank should be released maintenance program be established and of these deposits. into a suitable drain followed b the user. to prevent injury or y Rapid closing of faucets or solenoid valves property damage. At least once a year,lift and release the in automatic water using appliances can lever handle on the temperature pressure cause a banging noise heard in a water ADANGER:Hotter relief valve,located near the top of the pipe. Strategically located risers in the water increases the water heater,to make certain the valve water pipe system or water hammer potential for Hot Water operates freely.Allow several gallons to arresting devices can be used to minimize flush through the discharge line to an open the problem. Scalds. drain The anode rod should be removed from the NOTICE:If the temperature and water heater's tank annually for inspection pressure relief valve on the hot water and replaced when more than 6"of core ADANGER:Failure to heater discharges periodically,this wire is exposed at either end of the rod. may be due to thermal expansion in a perform the recommended Make sure the cold water supply is tarred closed water system.Contact the water Routine Preventative supplier or your plumbing contractor on off before removing anode rod. Maintenance can harm the how to correct this.DO NOT plug the This water heater incorporates a proper operation of this relief valve outlet. combustion shut off device that shuts water heater,which can A water heater's tank can act as a settling the operation of the water heater down cause carbon monoxide if undesirable combustion conditions dangers,excessive hot basin for solids suspended in the water.It occur. Such as the presence of flammable water temperatures and is therefore not uncommon for hard water vapors or blockage of the combustion air deposits to accumulate in the bottom of the inlet openings. Q other potentially tank.If allowed to accumulate,these solids penis s.Please contact a Qualified hazardous conditions. can cover the Combination Gas Control Service Technician if this occurs. Housekeeping ADANGER:Combustible Visually inspect pilot burner and relight if When installed in a closet,DO NOT materials,such as clothing, necessary. block or obstruct any of the combustion cleaning materials,or To ensure sufficient ventilation and air inlet openings located around flammable liquids,etc., the perimeter of the water heater.A must not be placed against combustion air supply,proper clearances minimum of 1"is required between these or next to the water heater. must be maintained. combustion air inlet openings and any obstruction. 20 Care and cleaning of the water heater. Venting System Inspection Inspect the gas venting system and the the flue,or replace the flue,flue baffle, chimney. and venting system before resuming Make certain the vent connector from operation of the water heater. the draft hood to the chimney is properly Test for spillage at the draft hood relief positioned and securely attached. opening after 5 minutes of burner If after inspection of the vent system you operation.Use a flame of a match or found soot or deterioration;call the local candle or smoke. gas utility to correct the problem and clean Burner Inspection Visually inspect the pilot burner and main ACAUTION:For your safety,cleaning burners annually. of the burner must be performed only by qualified service personnel.The Through the sight glass,inspect thepilot burner chamber is a sealed area.If burner flame with the main burner off and the burner access door is removed, inspect the main burner while firing. the burner access door gasket must be Proper burner and If any unusual burner operation is noted, replaced. pilot burner pattern. the water heater should be shut off For cleaning,remove the burner from the until qualified service assistance can be water heater.A vacuum cleaner can be obtained. used on the burner and floor shield inside the water heater.The burner can also be cleaned by scrubbing with mild detergent. Vacation and Extended Shut-Down NOTICE:Refer to the If the water heater is to remain idle for an After a long shut-down period,the Hydrogen Gas Caution in the extended period of time,the power and water heater's operation and controls Operating Instructions, water to the appliance should be turned off should be checked by qualified service to conserve energy and prevent a build-up personnel.Make certain the water heater of dangerous hydrogen gas. is completely filled again before placing it The water heater and should be in operation. piping drained if they might be subjected to freezing temperatures. Anode Rod NOTICE:DO NOT remove This water heater is equipped with an Water sometimes contains a high sulfate the anode rod from the water anode rod designed to prolong the life and/or mineral content and together with heater's tank,except for of the glass Iined tank.The anode rod is cathodic protection process can produce inspection and/or replacement, slowly consumed,thereby eliminating or a hydrogen sulfide,or rotten egg odor in as operation with the anode rod removed will greatly minimizing corrosion of the glass lined the heated water. Chlorination of the water shorten the life of the glass tank. supply should minimize the problem. lined tank and will exclude warranty coverage. 21 Before You Call For Service... Troubleshooting Tips STi zy s Save time and money?Review the charts on the following pages first and you may not need to call for service. This water heater incorporates a combustion shut off device that shuts the operation of the water heater ` down if undesirable combustion conditions occur. Such as the presence of flammable vapors or blockage of the combustion air inlet openings. Please contact a Qualified Service Technician if this occurs. Probleh>mi; ryy s,� Possible Causes What To Do Condensation This usually happens when 0 This is normal.After the water in the tank warms a new water heater is up,the condensation will disappear.If,however,the filled for the first time. condition persists,examine the piping and fittings for possible leaks. Moisture from the products 0 This is normal and will disappear in time,Excessive of combustion condensing condensation can cause pilot burner outage. on the tank surface. An undersized water 4D Use a water heater size that meets the requirements heater will cause of your needs. condensation. Yellow flame Scale on top of the burner. 0 Contact a qualified service technician to remove scale. or soot Flue or Combustion air inlet V,� Remove obstruction or debris from flue or openings are restricted. combustion air inlet openings on water heater jacket. Not enough combustion or 0 Proper operation of the water heater requires air for ventilation air supplied to combustion and ventilation. See the Combustion and the water heater location. Ventilation Air information in the"Installing The Water Heater"section of this manual. Unable to light Air in gas line. e Contact a qualified service technician to purge the air the pilot burner from the gas line. Pilot burner orifice clogged. 01, The pilot burner should be cleaned or replaced by a qualified service technician. Pilot burner tube pinched or w The pilot burner should be cleaned,repaired or clogged. replaced by a qualified service technician. Combination Gas Control Q,� See the"Lighting The Water Heater"section of this (Thermostat)Knob not depressed manual. while attempting to light pilot. Pilot burner does not stay Disconnected thermopile. 0 Ensure the thermopile wire connectors at the gas lit when the gas Combination Gas Control(Thermostat)are connected control knob is released properly. Thermopile defective. Q The thermopile should be replaced by a qualified service technician. Safety magnet defective. ;r The Combination Gas Control(Thermostat)should be replaced by a qualified service technician. Combination Gas Controls 0 The Combination Gas Control(Thermostat)should be (Thermostat's)single use gas replaced by a qualified service technician. shut-off device has opened. Combustion Shutoff Device Q The combustion shutoff device should be inspected Tripped. by a qualified service technician. CAUTION:For your safety DO NOT attempt repair of gas piping,Combination Gas Control(Thermostat),burners,vent connectors or other safety devices.Refer repairs to qualified service personnel. 22 Before You Call For Service... Troubleshooting Tips gF Save time and money!Review the charts on the following pages first and you may not need to call for service. 1;5 j;•4� �} J ��`77777 0 This water heater incorporates a combustion shut off device that shuts the operation of the water heater " down if undesirable combustion conditions occur, Such as the presence of flammable vapors or blockage of the combustion air inlet openings. Please contact a Qualified Service Technician if this occurs. ;Problem$F j yt Possible Causes What To Do III,�:�.,3���a,z° Rumbling noise Scale and sediment G Clean tank. in tank. Relief valve Pressure build up 0- This is an unacceptable condition and must be producing popping caused by thermal corrected.Contact the water supplier or plumbing noise or draining expansion to a contractor on how to correct this.Do not plug the closed system. relief valve outlet. Not enough or Water usage may have G) Wait for the water heater to recover after an no hot water exceeded the capacity abnormal demand. of the water heater. Low gas pressure. Check gas supply pressure and manifold pressure. The pilot burner may be out. G Check the pilot burner.If necessary,relight using the instructions in the"Lighting The Water Heater" section of this manual. The Combination Gas Control 01 See the"Water Temperature Setting"of The Water (thermostat)may be set too low. Heater section of this manual. Leaking or open hot 0, Make sure all faucets are closed. water faucets. Combustion Shutoff System w Contact a qualified service technician. tripped. Water is too hot The Combination Gas Control ?> See the"Water Temperature Setting"of The Water (Thermostat)is set too high. Heater section of this manual. Combination Gas Control - Contact a qualified service technician to replace the (Thermostat)Defective. Combination Gas Control(Thermostat). Pilot Bumuer Lights,but Combustion Shutoff System �'KD Contact a qualified service technician. Main Burner will not tripped. stay lit. CAUTION:For your safety DO NOT attempt repair of gas piping,Combination Gas Control(Thermostat),burners,vent connectors or other safety devices.Refer repairs to qualified service personnel. 23 Combination Gas Control, Status Light Troubleshooting STATUS LIGHT • r Li ht Flashes I if STATUS rrallghtthe pilotgTo lightPilo%see Ughting No. Color Instructions on water heater..It Status 0 - Control Off/Pilot Out Light Winks red more than one flash every 1 BLUE Normal Operation three seconds,see use&care Manual. Examples: 2 RED -Thermopile Voltage Low * Normal Operation 4 RED Hi h Tem erature Shutdown 5 RED Temperature Sensor Failure System Problem % 7 RED Gas Control or Valve Failure II'llllll I�II�flllfflrr� l'll 8 RED I Flame Sense Error I I 1 I1 I1 I%hff Pilot is lit,Status Light will briefly stay lit and turn from blue to red when knob Is turned to OFF. if�7ra� A7 iLT F6 a 'ii s `3 l'£ 3'` £ h111111511 -r: ONDTONttaggs,,, PO SO�UTYO E .< �',f .., { �,����, v� Ey a.yti.,f 5�rl,§t1419 gs ;,g.i€y =rsr ,, a � I=fy # j .� ,,y� 1 3: , r33r s"` 3sr �,s f s L iDD S� �5?. `f�`N 5� {{' � R ' 'Alf n aa.;z lily r 1, fZLvt '. � L § y Y�t1� Combination Gas Control turned Follow the operating instructions in the Use&Care off Manual to turn on the Combination Gas Control Pilot not lit Follow the lighting instructions as detailed on this water OFF heater and it's Use&Care manual to Iight the pilot Insufficient power supply(mil- Check thermopile connector to the Combination Gas livoltage) Control to ensure it is properly connected Check thermopile wires for damage and replace if needed Inspect pilot assembly Pilot recently extinguished and Follow the lighting instructions as detailed on the water Constantly lit Thermopile is cooling down heater and it's Use&Care manual to light the pilot Temperature knob recently turned to OFF position One(1)blink every three Normal Operation Set temperature knob on Combination Gas Control to (3)seconds Temperature knob in pilot position desire setting and pilot is lit Low thermopile voltage however Check thermopile connector to the Combination Gas Two(2)blinks every three pilot is lit Control to enssure it is properly connected (3)seconds Check thermopile wires for damage and replace it needed Inspect pilot assembly Four(4)blinks every High water temperature limit Contact a qualified service technician. three(3)seconds tripped See"IF YOU NEED SERVICE"on page 28 Five(5)blinks every three Water temperature sensor failure Contact a qualified service technician. (3)seconds See"IF YOU NEED SERVICE"on page 28 Seven(7)blinks every Combination Gas Control failure Contact a qualified service technician. three(3)seconds See"IF YOU NEED SERVICE"on page 28 Eight(8)blinks every False pilot flame signal Contact a qualified service technician. three(3)seconds See"IF YOU NEED SERVICE"on page 28 24 Replacement Parts. For 29, 30,40, 50, 55 and 60 gallon models using Natural or LP gas. Instructions For Placing a Parts Order All parts orders should include: 3 part description(as noted below)andThe model and serial number of the number of parts desired. water heater from the rating plate. ACAUTION:For your safety,DO 22 Specify type of gas(Natural or LP) NOT attempt repair of gas piping, as marked on the rating plate. gas control(thermostat),burners, vent connectors or other safety devices. Refer repairs to qualified service personnel. Bumer Assembly Kit' Flue baffle and hanger + Draft flood� gam— **Beat Trap **Heat Trap .� E **Nipple **Nipple Dip tube Anode ro —Dip tube gasket The kit provides extra speed clips and tamper resistant screws. *May differ as shown. � -- * Not supplied with all models. Temperature and pressure relief valve Drain valve Gas Control(Thermostat) •• Piezo Ignitor Button �. F'-*------*Thermuni1e j *Burner /*Bumer supply tube *BumerAceess Door Gasket *Sight Glass *Bumer orifice *Burner Access Door Grommet *Burner Access Door Jacket Door *Combustion Shut-off Device(enlarged view). *Combustion Shut- off Device Located inside the combustion chamber. Shield(enlarged view). Located inside the combustion chamber. 25 Notes: 26 Notes: 27 IF YOU NEED SERVICE 1. Should you have any questions about your new water heater,or if it requires adjustment,repair,or routine maintenance,it is suggested that you fast contact your installer,plumbing contractor or previously agreed upon service agency.In the event the firm has moved,or is unavailable,refer to the telephone directory, commercial listings or local utility for qualified service assistance. 2. Should your problem not be solved to your complete satisfaction,you should then contact the Manufacturer's National Service Department at the following address: 1241 Carwood Court Montgomery,Alabama 36117 Phone:1-S66-279-4566. When contacting the manufacturer,the following information will be requested: a. Model and serial number of the water heater as shown on the rating plate attached to the jacket of the heater. b. Address where the water heater is located and physical location. e. Name and address of installer and any service agency who performed service on the water heater. d. Date of original installation and dates any service work was performed. e. Details of the problems as you can best describe them. f. List of people,with dates,who have been contacted regarding your problem. 28 ! 9 2� $ > 01 Via\ GSrD + J ` ■ !4|� `� !�k � w • ^� |{ % e 2< \\ \ �K /0 t \ _ _0CL ° , l ���. . : Z \ � . � � JUL 1 § 2 � � s J � y Howuoers !90t More, done 150 t Tf iE ,1rdf r�.t f `0R r' F")TFR, N.Y 1 n`37> A.2 MANAG'ff r t,:ifr } ��'.�.� f.1C)t1711 �>l`. ''1 11lI r.%1:s tl�•;J� r'P"! rf � ./ . AI F C'ASfIff-.P E;II�#t A- F,.IREN HRCJ}q .ION ,;MV Al RM 04 78 10966 1 1 I l,J i f'� `i I��•.L.I `-A 1j�YIXwE PI- :,t1�y ,ta Ai.ARM 10I'Af_ 1�9. SALLS FAX 1.2.55 TOTAL CASH 3 . CHANrjF- I. 111111111 81 r Flillil 1112 10 t 74 t17/17/2023 5565 WTURtl Rft Y un f .I�ITTTONS A f''tiL.� ;Y tli ( } rf)!_.�f`yf'1LtiL�3 ' r ari 10/1,9 /2023 2 Mike Izzo From: Sawyer, Bailey A (DEC) <Bailey.Sawyer@dec.ny.gov> Sent: Friday,August 19, 2022 12:10 PM To: Mike Izzo Cc: Wenskoski, Brad (DEC) Subject: FW: 14 Brook Lane, Rye Brook, NY 10573 Mr. Izzo, We appreciated you taking the time to meet with us today as it was helpful to hear your perspective. I have included my response to Mr. Corcoran below for reference. Thank you again, Bailey Bailey Sawyer (she/her) Environmental Program Specialist, Floodplain Management Bureau of Flood Protection and Dam Safety Division of Water New York State Department of Environmental Conservation 625 Broadway, Albany, NY 12233 P: 518-402-9148 1 bailey.sawyer@dee.ny.gov vo eK I Department of i i vironm e ntal sraTE n table Conservation 1W From:Sawyer, Bailey A(DEC} Sent: Friday,August 19, 2022 11:52 AM To:'Peter Corcoran'<corcoranp719@gmail,com> Cc:Wenskoski, Brad (DEC)<brad.wenskoski@dec.ny.gov> Subject: RE: 14 Brook Lane, Rye Brook, NY 10573 Good morning Mr. Corcoran, We recently spoke with Mike Izzo regarding the ongoing work on your property, and discussed potential options for elevating your boiler while referencing NYS and village code requirements. We concluded that the best option is to hire a surveyor or engineer to obtain an elevation certificate, as we initially recommended and as previously suggested by the village.This will allow for you to have a value for your property's lowest adjacent grade, and therefore a starting point from which to elevate your utilities/boiler. Providing this information to the village can allow for conversations in moving forward with the project. I hope we have been able to provide some assistance. Thank you, Bailey Sawyer (she/her) Environmental Program Specialist, Floodplain Management Bureau of Flood Protection and Dam Safety z Division of Water New York State Department of Environmental Conservation 625 Broadway, Albany, NY 12233 P: 518-402-9148 1 baile .saw er dee.n . ov Yo K Department of _ STATE Environmental 111111111.0 Conservation Iquw 2 Mike Izzo From: Mike Izzo Sent: Tuesday, August 23,2022 9:01 AM To: Peter Corcoran Cc: Christopher Bradbury, Sawyer, Bailey A (DEC); Steven Fews; Michal Nowak; Tara Orlando; Laura Petersen Subject: RE: Request for Extension . 14 Brook Lane Dear Mr. Corcoran, Thank you for the email. Unfortunately, you have no open permit to extend. What you have is a permit application only for general repairs to the building and the installation of new HVAC equipment submitted on,tune 2, 2022, which is still awaiting flood plain elevation information needed to further process your application and issue your permit. As was told to you and your contractors in June by me, and to you by Bailey Sawyer, Environmental Program Specialist, Floodplain Management Division of the NYSDEC on August 19, 2022, you must retain the services of a NY State Licensed Professional Engineer to establish the flood plain elevation at your property and install a permanent marker indicating such elevation on the exterior of your house. Once the flood plain elevation for your property has been professionally established the Building Department will be able to determine a code compliant protocol for the installation of any new mechanical equipment and will issue your permit accordingly. Please note that the Village is amenable to providing whatever relief it can to assist those affected by Hurricane Ida, however that does not include granting open-ended extensions to file for needed permits for the installation of new mechanical equipment within the flood plain. Please provide an acceptable extension timetable to the Building Department for consideration. Thank you. lfll� ? c IZZO Building & Fire Inspector Village of Rye Brook, NY (914) 939-0668 From: Peter Corcoran<corcoranp719@gmail.com> Sent: Monday,August 22, 2022 3:49 PM To: Mike Izzo<Mlzzo@ryebrook.org> Cc:Christopher Bradbury<CBradbury@ryebrook.org>; Peter Corcoran <corcoranp719@gmail.com> Subject: Request for Extension Hi, please accept this email as my formal request for a permit extension due to lack of funds. Thank you for your consideration, best. Peter Corcoran i U.S..DEPARTMENT OF HOMELAND SECURITY OMB Na. 1860-Qt30$ Federal Emergency Manageoienf Agency Expiration Date:November 30,2022 National Flood Insurance Program ®� ELEVATION CERTIFICATE Important:Follow the instructions on pages 1-0. Copy all pages of this Elevation Certificate and all attachments for(1)community official,(2)insurance agent/contpany,and(3)building owner. SECTION A—PROPERTY INFORMATION FOR INSURANCE COMPANY USE Al. Building Owner's Name Policy Number: A2. Building Street Address(Including Apt.,Unit,Suite,and/or Bldg.No.)or P.O.Route and Company NAIC Number: Box No. 4 u"aa City State ZIP Code e170- N 1,05173 A3. Propertf Description(Lot and Block Numbers,Tax Parcel Number,Legal Description,eto.) 7' �---� : l.3s': `7.3 - /- A4. Building Use(e.g.,Residential,Non-Residential,Addition,Accessary,etc.) A5. LatitudeiLongitude: LaL'01,0/4Z 64 Long.!73.,61 ¢44,0 Horizontal Datum: ❑NAD 1927 ❑NAD 1988 AS. Attach at least 2 photographs of the building If the Certificate is being used to obtain flood insurance. A7. Building Diagram Number .1-A AS. For a building with a crawlspace or anclosure(s): a) Square footage of cxawlspace or enclosure(s) �1 sq ft b) Number of permanent flood openings in the crawispace or enclosure(s)within 1.0 foot above adjacent grade ---—" c) Total net area of flood openings in A8.b ----- eq in d) Engineered flood openings? ❑Y9s ❑ No A9.For a building with an attached garage: a) Square footage of attached garage .30 ( .D sq ff b) Number of permanent flood openings in the attached garage within 1.0 foot above adjacent grads ----- (� c) Total net area of flood openings in A9.b © sq In d) Engineered flood openings? ❑Yes n_No SECTION B—FLOOD INSURANCE DATE MAP(FIRM)INFORMATION B7.NFIP Community Name ll,Community Number B2.County Name` as. State 340930 `V�1 c?5`YC�e99 p r B4.Map/Panel 11135.Suffix BB. FIRM Index 67.FIRM Panel B8.Flood 139.Base Flood Elevation(s) Number Date Effective/ Zone(s) (Zone AO,use Base Rood Depth) Revised Data 361(9 C��9 F �+-A ,A00 sue{: 2S, � F 7 4' B10. Indicate the source of the Base Flood Elevation(BFE)data or base flood depth entered in Item B9: ❑RS Profile El FIRM ❑Community Determined ❑O WISout+ce: B11. indicate elevation datum used for BFE in Item B9: ❑ NGVD 1929 [K NAVD 1988 ❑ Other/Source: 812. Is the building located in a Coastal Barrier Resources System(CBRS)area or Otherwise Protected Area(OPA)? ❑Yes �,No Designation Date: CBRS ❑ OPA FEMA Form 085-0.33(1019) Replaces all previous editions. Form Page 1 of 6 OMB No. 660-0006 ELEVATION CERTIFICATE ExpirationlDate:November30,2022 IMPORTANT:In these spaces,copy the corresponding information from Section A. FOR INSURANCE COMPANY USE Building Street Address(includin Apt.,Unit,Suite,and/or Bldg.No.)or P.O.Route and Box No. Policy Number: 17 City state ZIP Code Company NAIL Number SECTION C-BUILDING ELEVATION INFORMATION(SURVEY REQUIRED) C1. Building elevations are based on: ❑ Construction Drawings` ❑Building Under Conshucdon` Finished Construction `A new Elevation Certificate will be required when construction of the building is complete. C2. Elevations-Zones Al-A30,AE,AH,A(with FIFE),VE,V1 V30,V(with BFE),AR,ARIA,AR/AE, AO. Complete Items C2.a-h below according 1e the building di ram specified in Item A7.In Puerto Ri Benchmark Utilized: _�• "/�3} 1 /i��'S+Vf V rtical Datum: �' V Indicate elevation datum used for the elevations in items a)through h)below. DEC ❑ NGVD 1929 M NAVD 1988 0 Other/Source: Z0zZ 11 Datum used for building elevations must be the some as that used for the BFE. VI C O a) Top of bottom floor(including basement,crawlspace,or enclosure floor) 2 .3'4- b) Top of the next higher floor rb'3 , 22- 0 feet ❑ meters c) Bottom of the lowest horizontal structural member(V Zones only) ❑ feet ❑meters d) Attached garage(tap of slab) q� K feet El motors e) Lowest elevation of machinery or equipment servicing the building(Describe type of equipment and location in Comments) - - 10 0 feet meten3 f) Lowest adjacent(finished)grade next to building(LAG) 7:, , 57 4 feet ❑ meters g) Highest adjacent(finished)grade nod to building(HAG) 7¢.Q 5-_ E9 feet ❑ meters h) Lowest dppart recta at lowest elevation of deck or stairs,including structural adjacent 73 , 57 ) feet ❑ meters SECTION D-SURVEYOR,ENGINEER,OR ARCHITECT CERTIFICATION This certlfcation is to be signed and sealed by a land surveyor,engineer,or architect authorized by law to certlfy elevation information. I caerlify that the information on this Certificate represents my best efforts to interpret the data available.I understand that any false statement maybe punishable by fine or imprisonment under 18 U.S. Code,Section 1001. Were latitude and longitude in Section A provided by a licensed land surveyor? ❑Yes IR NO ❑Check here if attachments. Certifises Name License Number MICHAEL MASTROGIACOMO,P.E.,L.S. NYS PE 083853 OF Nay � Title PRESIDENT Company Name MASTROGIACOMO ENGINEERING PC Address + 10 MIDLAND AVE,SUITE 204A a d83t353 City State ZIP Code pRp�E5S10�p.� PORT CHESTER New York 10573 Signature , Date Telephone Ext. 914.920.6372 Copy all pages of this Elevation Certificate and all attachments for(1)community official,(2)insurance agenticompany,and(3)building owner. Comments(including type of equipment and location,per C2(e),if applicable) FEMA Form OBM-33(12f 19) Replaces all prevlous editions. Form Rage 2 of 6 BUILDING PHOTOGRAPHS OMB No. 1660-MM ELEVATION CERTIFICATE See lnstr�ctlons for Item A6. Expiration Date.November 30,2022 IMPORTANT.In these spaces,copy the corresponding information from Section A. FOR INSURANCE COMPANY USE Bdildi t Address(including Apt.,Unik,Suite,and/or Bldg.No.)or P.O.Rome and Box No. Policy Number: City v State, ZIP Code Company NAIC Number fbof� k _ f 495`73 If using the Elevation Certificate to obtain NFIP flood Insurance, affix at least 2 building photographs below according to the instnJbtions for Item A6.Identify all photographs with data taken;"Front Vdew"and"Rear Meld;and,if required,"Right Side View and "Left Side Vow."When applicable, photographs must snow the foundation with representative examples of the flood openings or vents,as indicated In Section AS.If submdtlirg more photvaft than wIII tit on this page,use the Condnustkm Page. MAil tY. t. _ 9 Y d d Phob One,Capflon row, "�� � <st $ 4 1 Photo Two Caption - Cfp214 , 1=EMA Form 0ti6-6-33(12119) Replaces all pmvious edfi9ons. 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Y 3 r S# 3 1 l t B�t sj 3rZ£st v y - t}} 2 �\� S 33 ti 12 k}l� s yam 3 7 f-, : ITS SAW Slott too ADS tow two 1;X on 4 f ,5 \ S i3t 1 t f zy LI J a a $ Z f j. Building Permit Check List&Zoning Analysis Address•. c�, LA,,- SBL• i-�7, L _ � y Zone: — l r Use: -,7 ( Const.Type: Other Submittal Date: tP Z ZZ~ Revisions Submittal Dates: Applicant: 2 z 1-j �^ Nature of Work; A I J), (, s Reviews:ZBA: J U N - 8 2 0 2 2 PB: BOT: Other. NEED OK ( ( } FEES:Filing. 7 BP:_ �,/p; Flood Plane Legalization: ( ) (Jf APP: Dated: Notarized: ✓ SBL: ,.�Truss T.D. Cross Connection: ✓ FLO.A.: { ) ( ) Scenic Roads: Steep Slopes: Wetlands: Stowe Water Review: Street Opening. ( ) ( ) ENVIRO: Long. Short Fees: N/A: { ) ( ) SITE PLAN:Topo: Site Protection S/W Mgmt.: Tree Plan. Other: ( ) ( ) SURVEY.Dated: Current: Archival: Sealed Unacceptable: PLANS:Date Stamped: Sealed: Copies.• —Electronic: Other: License:. Workers Comp: Liability: ✓ Comp.Waiver. --Z- Other: { O CODE 753#: Dated N/A: ( ( ) HIGH-VOLTAGE ELECTRICAL:Plans: Permit: N/A: Other: ( ) { ) LOW-VOLTAGE ELECTRICAL:Plans: Pernzit: N/A Other. { ( } FIRE ALARM/SMOKE DETECTORS:Plans: Permit H.W.I.C.:—Battery:—Other: ( ( ) PLUMBING:Plans: Permit: Nat.Gas: LP Gas: N/A/: Other. ( ) { ) FIRE SUPPRESSION:Plans: Pen-nit Other. ( ( ) H V.A C.: Plans: Permit N/A Other. { ) ( ) FUEL TANK:Plans: Permit: Fuel Type: Other. ( ) ( } 2020 NY State ECCC: N/A: Other. ( ) { ) Final Survey Final Topo: RA/PE Sign-off Letter. As-Built Plans: Other ( ) ( ) BP DENIAL LETTER C/O DENIAL LETTER: Other. ( ) ( ) Other: ( )ARB mtg.date: approval: notes: ( )ZBA mtg.date: approval:- notes: (� )PB mtg. date: approval: notes., REQUIRE EXLS"IING PROPOSED NOTES Arrm%jq 9°1 L� .Area; fl$# " - Circle: •.n Fron�taae: Front Front: Sides: Rear, Main Cov Accs.Cor. Ft.H Sb: Sd.H Sb: GFA• Tot.Imp Ft.Tmn P, arlcu'S Hei ht Stories: notes: d jJp -6'-) w � a AFFIDAVIT IN SUPPORT OF FEE WAIVER RELATED TO HURRICANE IDA STATE OF 06 COUNTY OF WeALP �'c;�-C name),being duly sworn, deposes and says 1. I am the applicant fora Building Perms Certificat cu aaa Demolition Permit Electrica ermit/ bin Penni Fence& Wall Permit echanical Permit`` Pod Permit(circle all that apply) 2. I am the legal owner of property located at Rye Brook,New York(insert street address) OR I am the (Architect/Contractor/Engineer/Attomey) (circle one)for the legal owner of property located at ,Rye Brook,New York and I am duly authorized by property owner to make and file the accompanying application. 3. The following is a description of(I)the work to be performed under the permit for which I am applying; and(2)how the work arose as a direct result of Hurricane Ida: ana - -ter aM 4. The work described herein arose as a direct result of Hurricane Ida and does not include Work which was not caused by Hurricane Ida. Sworn to before me this Day of L 20 a Notary Public KATHERINE A.VIGGIANO Notary Public State of New York D E C r No.01 VI6213131 Qualified in Westchester County Commission Expires November 02, 0-0 AUG 2022 VILLAGE'OF- RYE BROOK BUILDING DEPARTMENT Renewal Deluxe Homeowners Policy QM11state. Declarations Your policy effective date is March 25,2023 Page 1 of 3 Total Premium for the Premium Period(Your bill will be mailed separately) Information as of February 1,2023 Premium for property insured $1,877.00 Summary Premium for Water Back-Up 35.00 Named Insured(s) Total $1,912xOO Peter Corcoran Mailing address Your bill will be mailed separately.Before making a payment,please refer to your 14 Brook Lane latest bill,which includes payment options and installment fee information.If you do Rye Brook NY 10573-1310 not pay in full,you will be charged an installment fee(s). Po icy number 078 606 020 Discounts (included in your total premium) Your policy provided by Multiline 25% Protective Device 5% Allstate Insurance Company Policy period Begins on March 25,2023 at 12:01 A.M. Location of property insured standard time,with no fixed date of 14 Brook Lane,Rye Brook,NY 10573-1310 expiration Premium period Rating Information Beginning March 25,2023 through March 25,2024 at 12:01 A.M.standard The dwelling is of frame construction and is occupied by 1 family time Your Allstate agency is Mobile Borsella Age Mortgagee 21 Elm PI Norte Rye NY 10580-2918 (914)921-0660 Additional Interested Party RAYMONDMOBILE@ALLSTATE.COM Some or all of the information on your None Policy Declarations is used in the rating of your policy or it could affect your eligibility for certain coverages.Please notify us immediately if you believe that any information on your Policy Declarations is incorrect.We will make corrections once you have notified us, and any resulting rate adjustments,will be made only for the current policy period or for future policy periods. Please also notify us immediately if you believe any coverages are not listed or are inaccurately listed. a a d r z wll� Renewal Deluxe Homeowners Policy Declarations Page 2 of 3 Policy number: 1078 606 020 Policy effective date: March 25,2023 Coverage detail for the property insured Coverage Limits of Liability Applicable Deductible(s) Dwelling Protection-with Building $416,131 •$1,000 Other Peril Structure Reimbursement Extended ■Hurricane Deductible Applies** Limits Other Structures Protection $41,614 •$1,000 Other Peril •Hurricane Deductible Applies** Personal Property Protection- $291,292 ■$1,000 Other Peril Reimbursement Provision ■Hurricane Deductible Applies** Additional Living Expense Up to 12 months Family Liability Protection $300,000 each occurrence Guest Medical Protection $1,000 each person Building Codes Not purchased* Water Back-Up $5,000 ■$250 Water Back-Up Workers'Compensation and Statutory/See Form Employers'Liability Coverage for Residence Employees ® Other Coverages Not Purchased. • Business Property Protection* ■ Extended Coverage on Musical • Increased Coverage on Money* • Business Pursuits* Instruments* • Increased Coverage on Securities* ■Cellular Communication System* • Extended Coverage on Sports ■ Increased Silverware Theft Limit* • Electronic Data Processing Equipment* •Lock Replacement* Equipment* ■Fire Department Charges* •Loss Assessments* •Extended Coverage on Cameras* •Home Day Care* •Optional Protection for Mold* •Extended Coverage on Jewelry, •Identity Theft Expenses' •Satellite Dish Antennas* Watches and Furs* •Incidental Office,Private School Or Studio* *This coverage can provide you with valuable protection.To help you stay current with your insurance needs,contact your agent to discuss available coverage options and other products and services that can help protect you. **$20,806(5%of your Dwelling Protection limit)is your Hurricane Deductible amount,which applies to the total of all losses a under the coverages indicated above. o r z Scheduled Personal Property Coverage Your policy does not include Scheduled Personal Property Coverage.This coverage can provide you with valuable protection.To help you stay current with your insurance needs,contact your agent to discuss available coverage options and other products and o services that can help protect you. Q 0 M 0 0 ,o D O O nQ N N co 0 i� O 0 0 o nz 0 0� 000 O M a Renewal Deluxe Homeowners Policy Declarations WAllstate. Policy number: 078 606020 Page 3 of 3 Policy effective date: March 25,2023 Your policy documents Your Homeowners policy consists of the Policy Declarations and the following documents.Please keep them together. • Deluxe Homeowners Policy-AP316 • New York Amendment Of Policy Provisions-AP1948 • New York Water Back-Up Endorsement-AP545 • New York Amendatory Endorsement-AP4729 ■ Amendatory Endorsement-AP4577 • New York Amendatory Endorsement Deluxe Homeowners Policy,Deluxe Plus Homeowners Policy,Standard Homeowners Policy,Deluxe Select Value Policy,Standard Select Value Homeowners Policy-AP497-2 • New York Hurricane Deductible Endorsement-AP585-2 ■ Declarations Supplement Page(New York)-AU233-1 • Depreciation Amendatory Endorsement-AP4989 • Off Premises Theft Endorsement-AU9010-1 ■ New York Workers'Compensation And Employers' Liability • Building Structure Reimbursement Extended Limits Coverage For Residence Employees Coverage Form- Endorsement-AP693 AP1105-2 • New York Amendatory Endorsement-AP1727 • Amendment Of Policy Provisions-AP521 Important payment and coverage information Here is some additional,helpful information related to your coverage and paying your bill:. ► Coverage A-Dwelling Protection Limit includes an approximate increase of$26,000 due to the Property Insurance Adjustment provision. Coverage B-Other Structures Protection and Coverage C-Personal Property Protection adjusted accordingly. ► Please note:This is not a request for payment. Your bill will be mailed separately. Allstate Insurance Company's Secretary and President have signed this policy with legal authority at Northbrook,Illinois. ,5�� A141— 5z�-� Thomas J.Wilson Susan L. Lees President Secretary 0 0 n a z Policy Endorsement Page 7 of 1 Policy number: OL78 606 020 Policy effective date: March 25,2023 The following endorsement changes your policy. Please read this document carefully and keep it with your policy. Amendatory Endorsement -AP4989 Throughout the policy,when determining the actual cash value of the loss,the costs necessary to repair,rebuild or replace the destroyed,damaged or stolen property may be depreciated. Such costs subject to depreciation may include, but are not limited to,goods,materials,equipment,labor,overhead and profit, taxes,fees or similar charges. All other policy terms and conditions apply. Allstate Insurance Company 0 O 0 0 0 0 0 0 0 0 0 Q 00 m 0 m N_ Q N O m L O O m Z 0�m �O� O O m Q)Allstate. Information as of February 1,2023 Policyholder(s) Page 1 of 2 Mobile eorseffa Age Peter Corcoran 21 Elm Pi Rye NY10580-2918 Policy number 078 606 020 r rl It r I r Irl r r rill I r r iu I r rl r i Your Allstate agency is I I III 111 I I I I IIII ill I IIII I III III II Mobile Borsella Age PETER CORCORAN (914)921-0660 14 BROOK LN RAYMONDMOBILE@ALLSTATE.COM RYE BROOK NY 10573-1310 Thank you for being a loyal Allstate customer—we're happy to have you with us! Here's your Deluxe Homeowners insurance renewal offer for the next 12 months.We've also included a guide to what's in this package and answers to some common questions. Renewing your policy is easy Keep an eye out for your bill,which should arrive in a couple of weeks.Just send your payment by the due date on your bill.If you're enrolled in the Allstate@ Easy Pay Plan,you won't receive a bill—we'll send you a statement with your payment withdrawal schedule,You also won't receive a bill if a mortgage company or lienholder pays your insurance premium for you. How to contact us Give your Allstate Agent a call at(914)921-0660 if you have any questions.It's our job to make sure you're in good hands. RP378-4 c Policy number: 1078606020 Page 2 of 2 Policy effective date: March 25,2023 Your Insurance Coverage Checklist We're happy to have you as an Allstate customer!This checklist outlines what's in this package and provides answers to some basic questions,as well as any"next steps"you may need to take, ❑ What's in this package? ❑ What about my bill? See the guide below for the documents that are included. Unless you've already paid your premium in full,we'll send Next steps.review your Policy Declarations to confirm you your bill separately.Next steps.please pay the minimum have the Coverages,coverage limits,premiums and amount by the due date listed on it. savings that you requested and expected. Read any You can also pay your bill online at Allstate.com/support Endorsements or Important Notices to learn about new or through the Allstate mobile app.If you're enrolled in the policy changes,topics of special interest,as well as Allstate@ Easy Pay Plan,we'll send you a statement required communications. Keep all of these documents detailing your payment withdrawal schedule.Para with your other important insurance papers. espanol,llamar al 1-800-979-4285. ❑ Am I getting all the discounts I should? ❑ What if I have questions? Confirm with your Allstate Agent that you're benefiting Visit Allstate.com/support to browse our list of frequently from all the discounts you're eligible to receive. asked questions and find information regarding billing or policy documents.You can also create an online account to access and manage your policies,Para espanol,llamar al 1-800-979-4285. A guide to your renewal package u = — made srmPle Policy Policy Important Insurance Made Declarations* (Endorsements Notices simple The Policy If changes are We use these Insurance seem Declarations made to your notices to call complicated? o lists policy policy,these attention to Our online Q details,such as documents will particularly guides explain o your property include your new important coverage terms g details and contract coverages,policy and features: coverages. language. changes and www.all$tate.comJ o madesimole o discounts, Esnanol.allstate.com /facildeentender m a m N 0 *To make it easier to see where you may have gaps in your protection,we've highlighted any coverages you do not have in the o Coverage Detail section in the enclosed policy Declarations. o o o�� �C7o o N K O P- 6 N d Policy number; 078 606 020 Policy effective date; March 25,2023 Page 1 of 1 Q)Allstate. Allstate's got you covered. At Allstate,we know how important it is to you to have the right protection at the right price.That's why we've included some savings tips and services you have access to below: Review your coverages Make sure your protection fits your current needs. Allstate) mobile app Download Allstate Mobile,where you can get tools and help,like ID cards',Allstate Identity Protection and 24./7 Roadside Assistance. Find more ways to save Discover more about your money-saving options',like Full Pay,Drivewise®or Easy Pay,by visiting Allstate Mobile or allstate.com/myaccount. 'Digital ID cards not accepted as proof of insurance in every state. Subject to terms,conditions,and availability. X74021 Affidavit of Exemption to Show Specific Proof of Workers' Compensation insurance Coverage for a 1, 2, 3 or 4 Family, Owner-occupied Residence **This form cannot be used to waive the workers'compensation rights or obligations of any party,** Under penalty of perjury, I certify that I aril the owner of the 1, 2, 3 or 4 family, owner-occupied residence (including condominiums) listed on the building permit that I am applying for, and I am not required to show specific proof of workers' compensation insurance coverage for such residence because (please check the appropriate box): ❑ I am performing all the work for which the building permit was issued. ❑ I am not hiring,paying or compensating in any way,the individual(s)that is(are)performing all the work for which the building permit was issued or helping me perform such work. I have a homeowners insurance policy that is currently in effect and covers the property listed on the P attached building permit AND am hiring or paying individuals a total of less than 40 hours per week (aggregate hours for all paid individuals on the jobsite) for which the building permit was issued. I also agree to either: acquire appropriate workers' compensation coverage and provide appropriate proof of that coverage on forms approved by the Chair of the NYS Workers' Compensation Board to the government entity issuing the building permit if I need to hire or pay individuals a total of 40 hours or more per week(aggregate hours for all paid individuals on the jobsite)for work indicated on the building permit,or if appropriate,file a CE- 200 exemption form; OR ♦ have the general contractor, performing the work on the 1, 2, 3 or 4 family, owner-occupied residence (including condominiums)listed on the building permit that I am applying for,provide appropriate proof of workers'compensation coverage or proof of exemption from that coverage on forms approved by the Chair of the NYS Workers' Compensation Board to the government entity issuing the building permit if the project takes a total of 40 hours or more per week(aggregate hours for all paid individuals on the jobsite)for work indicated on the building permit. (Signature of Homeowner) (Date Signed) Home Telephone Numbers (Homeowner's Name Printed) i Sworn to before me this day of r Property Address that requires the building permit: (Caunty Clerk or Not Public) 0 KATHERINE A. VIGGIANO Notary Public State of New York No. 01 V16213131 Qualified in Nesterester County Once notarized,this BP-1 form serves as an exemption for both workers'compensation and disability benefits insurance coverage. BP-1 (12/08) NY-WCB