Operating and Maintenance Manual - Ajax Boiler · PDF fileOperating and Maintenance Manual AJAX BOILER INC. Designed and Manufactured in Accordance with ASME Code Section IV, Heating

Operating and Maintenance Manual

AJAX BOILER INC.

Designed and Manufactured in Accordance with ASME Code Section IV, Heating Boilers

Photo shown may vary from actual model.

Model “DRF, WRF andWRF 30ppm NOx” Forced Draft Water Boiler (also known as DF & WF)

E.T.L. Listed

E.T.L. Canadian

Listed

c

ASME

ASME

AJAX BOILER INC. Page 2

Table of Contents Page

3 Operating and Installation Instruction 4 The Boiler Name Plate and Model Number 5 The Parts of the Boiler Exploded Boiler View Parts 6 Receiving your Boiler and Installation Code requirements Boiler placement Combustion air Venting Relief valve Check burner Stud nuts on boiler headers Water connections Gas connections Manual main gas shut-off valve Fuel oil connections Electrical Pump selection Expansion tank Indoor & outdoor boilers 9 Size of Piping to Gas Boilers Pipe delivery schedule Additional length of pipe to be added for each elbow or tee bend in the line 10 Installation Diagram – DRF Model 11 Installation Diagram – WRF & WRF-NOx Model 12 Installation with Refrigeration System 13 Water Treatment 14 Before Start-up Clean system Fill the boiler Fill oil tank Additional controls Venting Check factory assembled joints and head bolts 15 Start-up Instruction – Gas After start-up check list

Shutting down the boiler 17 Start-up Instruction – Oil

After start-up check list Shutting down the boiler

19 Maintenance Instruction Maintenance intervals

Removing and sealing the manway access door 25 Adjusting Gas Pilots on Power Flame C & J Burners 26 Trouble-shooting Guide Condensation Cold start-up Sooting 28 Quick Reference Guide Replacement parts Material Safety Data Sheet Contact Us Warranty Manufacturers Cut-Sheets (Disclaimer: Some parts may vary from actual model)


Operating and Installation Instructions (Model DRF, WRF, & WRF-NOx) Congratulations on your purchase of a new Ajax Boiler. In this book, we have included installation and maintenance instructions that, if followed, will provide you with many years of service from your boiler. Also included are instruction manuals for each of the controls furnished with the boiler. Please read them carefully. They should be helpful in both the installation and services of the boiler. Keep these instructions with the boiler for future reference. The Ajax water boiler is of rugged construction, yet of simple design. The boiler is of the inclined water tube type, consisting of two water headers with interconnecting, 2" O.D., straight inclined tubes. Normally, steel tubes are supplied on “closed” systems where the amount of make-up water is negligible. Copper tubes should be used on “raw” water applications, where a total or a high percentage of water make up takes place, or where water with high corrosive properties is encountered. The tubes are rolled and flared into tube sheets with a minimum 1/2" thick, P.V. quality steel plate. The boiler is equipped with removable head plates, front and rear, giving easy access to the straight tubes for inspection, cleaning or replacing. The combustion chamber and flue passages are designed to give maximum efficiency and serviceability. The best grade of castable refractory is used. Expansion joints are provided to allow for normal contraction and expansion of the refractory. The refractory is backed up with 3” of rockwool insulation. The boiler is enclosed in a casing of 18 gauge-galvanized steel. The boiler serial number is stamped on the front header plate and on the boiler nameplate, generally mounted on the right hand side of the boiler. All boilers furnished with copper tubes will have a decal applied on the front and rear head plates and will have sacrificial anodes fixed in the water box section of the head plates. Experience in the field has proven that the Ajax Boilers, if properly applied and maintained, will give many years of efficient, dependable and economical service. Ajax Boiler Inc. February 2007


The Boiler Nameplate And Model Number The Boiler Name Plate The following illustration is an accurate depiction of the nameplate found on the right hand side of the boiler. You will also find an ASME nameplate on the front head plate with some of the same information. A. Boiler description B. Model number C. Serial number D. Minimum relief valve capacity E. Maximum Btu/Hr fuel input F. Maximum Btu/Hr output** G. Boiler horsepower H. Square feet of heating surface I. Minimum Btu/Hr fuel input* J. Minimum Btu/Hr output*** K. Gross E.D.R. L. Max. allowable working press.*** M. Supply voltage N. Electrical supply Hertz O. Electrical supply Phase P. Required Amperage Q. Motor amp draw**** R. Control voltage**** S. Control amp draw**** T. Min. Gas pressure***** U. Max. Gas pressure***** V. Manifold gas pressure***** W. Fuel type (See model #) X. Gallons per hour oil**** Y. Int. Group Prim Safety**** Z. Minimum distances btw. boiler and adjacent construction.

* Minimum Btu/Hr ratings apply to high-low and modulating type boilers only. ** Boiler output ratings are based on factory tests under appropriate conditions. Field results may vary. *** Maximum allowable working pressure for boiler only. Relief valve set pressure should not exceed the lowest

MAWP of any component in your system. **** Applies to forced draft type burners only ***** Minimum and maximum gas pressure values are measured at the point of connection to the boiler gas train.

Manifold gas pressures are measured after the gas train.

The Boiler Model Number

D R F G 50 W Type of boiler: WR = 125 PSIG MAWP Hot Water DR = 150 PSIG MAWP Hot Water HR = 15 PSIG MAWP Low Pressure Steam SR = 150 PSIG MAWP High Pressure Steam Type of burner: Firing Rate: N = Atmospheric (H-Burner) 150 = 150,000 Btu/Hr. F = Forced Draft (On high pressure steam, # represents HP) E = High Efficiency Forced Draft P = Premix Low NOx R = Atmospheric (Round Burner) Fuel Type: G = Natural Gas W = Outdoor P = Propane O = #2 Oil C = Combination #2 Oil/Natural Gas D = Dual Gas (Natural Gas/Propane)

B

A

C D

E F G H

I J K L

M N O P Q R S

T U V W

X Y

Z


The Parts of the Boiler Exploded Boiler View

Parts

1a Outer sheet metal jacket 7 Rear head plate 1b Rear jacket 8 Flue collector 1c Upper jacket panel 9,9a Firebox door, glass eye 2a-c Thermafiber 10 Frame 3a/b Thermotek Block 11 Galvanized floor 4a Header 12 Castable refractory 4b Waterbox 13 Kastite 4c Tubes 14 Refractory support 4d Head plate studs 5 Header gasket 16a-b Refractory 4e Head plate nuts 15 TCO panels 17,18 Low water probe , Pressure gauge 6 Front head plate 19,20 ASME data plate, Forced draft burner

See manufacturer’s cut-sheets enclosed with the boiler for complete information on the various parts.


Receiving your boiler And Installation Receiving your boiler Check Equipment Received: Inspect the boiler for any shipping damage. Make sure you have received all loose parts, such as draft hoods or controls packaged separately, which are listed on the packing slip. Note any damages or shortages on the bill of lading prior to signing it. If a boiler is received damaged or missing parts, it is your responsibility to notify the shipping company and file a freight claim. Ajax Boiler cannot send replacement parts for freight damaged or missing equipment as warranty items. Consignee must file claims for shortages and damages with the carrier. Permission to return goods must be received from the factory prior to shipping. Goods returned without a Returned Goods Authorization number will not be accepted. Purchased parts are subject to replacement only under the manufacturer’s warranty. The warranty does not include the cost of labor, removal, or installation of the warranted part. Installation Code Requirements: It is very important that your installation comply with all federal, state and local codes (NFGC, NEC, NFPA, CSD-1) as well as meet good industry practices as shown in publications issued by ASME, AGA, UL, ASHRAE, ABMA, ANSI etc. Boiler Placement: The boiler should be placed on a solid foundation, preferably a concrete pad, adequately sized for your boiler. Ajax Boilers are not suitable for installation on combustible surfaces. Electrical conduit should not be imbedded in the concrete directly under the boiler without first consulting with the engineer of the approved boiler pad. Provide adequate clearance for normal inspection and maintenance purposes and allow proper clearances for combustion air. Also, allow tube pull length clearance in the front or rear of the boiler for servicing (see boiler dimensions page for tube lengths). The minimum clearances to combustible surfaces are listed under the UL-795 clearance guidelines and on the boiler nameplate. Make sure the boiler is level, from side to side and front to back. Use metal shims if necessary.

Combustion Air: Adequate combustion air is one of the most important requirements for an atmospheric fired boiler. A lack of proper airflow can result in poor combustion, sooting and premature failure to the boiler. Sizing combustion air intakes according to the National Fuel Gas Code or NFPA 54 is acceptable. Ventilation openings should be provided per the National Fuel Gas Code. The boiler room should have two permanent openings. One opening shall be within two feet of the ceiling and one more within two feet of the floor. Each opening should have a free area of not less than 1 square inch per 1,000 BTU/HR of the total input of every combustion product in the boiler room. The openings should not be obstructed from the outside and air conditioning or exhaust fans should not interfere with proper airflow and ventilation of the boiler room. Consideration should always be given to the blocking effect of louvers in determining total free area. Always leave adequate clearance around the base of the boiler to allow the combustion air to freely enter the combustion chamber. The combustion air entering the boiler must be free of hazardous and flammable vapor fumes. This includes such fumes as perchlorethylene, chlorine, etc.

Venting: This particular boiler will produce positive and negative draft conditions as a result of the burner firing. All possible points of air infiltration or ex-filtration must be sealed. If the unit is to be fired under positive combustion chamber conditions, extreme care must be taken to ensure that a 100% seal is maintained. Please consult with a stack specialist for use of appropriate stacking material. Before attaching the breeching or extending the stack, be sure there are no obstructions or foreign materials in the vent or on the tubes of the boiler. The boiler should be vented as directly as possible. The stack must be the same diameter as the boiler vent or the combined area of multiple boiler vents. The recommended upward slope of the horizontal breaching is 1” per linear foot. In other words, the stack should rise 1” vertically for each foot horizontally. The stack should reach at least 3 feet above the highest obstruction of the roof to insure proper venting. The stack must be equipped with an appropriate


weather cap of the correct size. At no time should the boiler support the stack weight. (Refer to the latest version of the National Fuel Gas Code for additional installation requirements).

When a draft inducer is required, a draft proving switch must be wired to the boiler to prevent the boiler from firing unless the draft is proven.

Relief Valve: The relief valve discharge must be piped to a floor drain to eliminate the potential of scalding burns. The drain line must be the same size as the relief valve outlet and have a downward slope to insure proper drainage. The drain line termination should be visible to see discharge. Check the relief valve nameplate. The boiler operating pressure cannot exceed that listed on the relief valve. Also, confirm the boiler does not exceed the maximum Btu rating on the relief valve.

Check Burner: Check the burner mounting bolts and tighten if loose.

Stud Nuts on Boiler Headers: During shipment, the head plate nuts may loosen. Tighten these if required to the torques specified later in this manual. After the boiler has been in operation for a few days, check and retighten the head plate nuts. Refer to Quick Reference Guide.

Water Connections: See typical piping diagram as shown in the installation instructions (page 10).

Gas Connections: Check supply gas pressure and select gas line pipe size for adequate capacity at boiler firing rate. Install a condensate trap in the gas line ahead of the boiler gas valve regulator. Do not use Teflon tape on the gas line pipe threads. Use a pipe compound rated for use with gas. All gas piping must be leak tested after installation as components may work loose during shipment. Do not check for gas leaks with an open flame. Use a bubble test. Do not test the boiler gas piping at a pressure higher than the boiler maximum gas pressure rating as this can damage the gas train components. Support the gas piping with hangers, not by the boiler or its accessories. Manual Main Gas Shutoff Valve: This valve is located on the upstream of the main gas pressure regulator and is normally located on the lower right side of the boiler. The gas supply is to be connected to this valve. Boilers with a minimum input rating are set for the specified rating at the factory. The minimum input rating is not adjustable in the field.

Fuel Oil Connections (Where applicable): Use copper tubing with flare fittings or iron pipe on all installations. All units must utilize the proper size and type of suction line oil strainers. Do not install manual valves in the return line between the pump and the tank unless required by a specific code. The fuel tank should be mounted above the pump level. If not, a two-pipe system is recommended. A check valve should be installed at the burner and a foot valve is recommended on the suction line within the fuel tank. These are installed to prevent the loss of oil supply, which can be damaging to the pump. It is recommended that prior to installation, MFPA-31 and all other national, state and local codes be followed. The size of the oil feed pipe depends on the length of line and whether the system is gravity or suction feed. (Please see the burner manual for oil line sizing). All lines should be tested for leaks after they have been installed. This should be done prior to running oil through them. The suction line should pass a vacuum test before placing oil in the tank. Plugging the tank end of the suction line may do this and connecting a vacuum gauge, valve and vacuum pump to the suction line stub in the boiler room. Air should be exhausted from the suction line until the vacuum gauge reads 24" of mercury (this figure is based on sea level conditions; for higher altitudes, corresponding lower values may be used). The valve should then be closed tightly and the test equipment should be allowed to stand for 24 hours, during which time, the gauge pressure should not decrease by more than ½ inch.


Electrical: The boiler is wired for 120volts 60hz 1phase and 12 amps, unless otherwise noted on the boiler nameplate. Verify the electrical supply using a voltmeter. The voltage tie-in leads are indicated on the wiring diagram. For your safety, turn off electrical power supply at the service entrance before making any electrical connections. This boiler contains sensitive control components and should be protected by a suitable commercial grade surge protection device and properly grounded. The boiler must be installed in accordance with the National Electric Code and in accordance with all state and local codes. Pump Selection: An appropriate sized pump will need to be installed, to pump water through the boiler at its appropriate flow rate. Ajax recommends using a delta T of 20° to 40°F through the boiler. The boiler circulation pump must interlock with the boiler, so the pump will operate under normal boiler operation.

Expansion Tank: A properly sized expansion tank is required on the boiler-piping loop.

Indoor Boilers: Protect all electrical components from moisture. The venting must be completely sealed to prevent spent flue gas into the boiler room. The draft diverter must be installed on top of metal screws in the boiler vent(s) per U.L. requirement. Note: Boilers are not designed to support stack weight.

Outdoor Boilers: The boiler must not be installed under any overhang that is less than 6 feet from the top of the boiler. Outdoor boilers have been tested to light off in 40 MPH and operate in 10 MPH wind conditions. Boiler must be protected from excessive wind and or down draft conditions (see venting). Three sides must be open in the area under the overhang. All roof water drainage must be diverted away from the boiler. Outdoor forced draft boilers require vent piping with an approved rain cap.


Size of Piping to Gas Boilers In determining the size of gas pipe, the following factors should be considered:

a.) Length of pipe and number of fittings. b.) Maximum gas consumption to be provided for (including possible future expansion). c.) Allowable loss in pressure from meter outlet to boiler.

The volume to be used (in cubic feet per hour) shall be determined, whenever possible, directly from BTU ratings of the boiler which will be installed and the heating value of the gas to be used. To obtain the cubic feet per hour, divide the total BTU input of the boiler by the BTU heating value per cubic foot of gas.

PIPE DELIVERY SCHEDULE

Length of Pipe in Feet

1”

1-1/4”

1-1/2”

2”

2-1/2”

3”

4”

6”

10 520 1,050 1,600 3,050 4,800 8,500 17,500 44,00020 350 730 1,100 2,100 3,300 5,900 12,000 31,00030 285 590 890 1,650 2,700 4,700 9,700 25,00040 245 500 760 1,450 2,300 4,100 8,300 22,00050 215 440 670 1,270 2,000 3,600 7,400 19,00075 175 360 545 1,020 1,650 2,900 6,000 16,000

100 150 305 460 870 1,400 2,500 5,100 14,000150 120 250 380 710 1,130 2,000 4,100 11,600

* Capacity of Pipes in Cubic Feet of Gas per Hour ** Pipe sizes in the table are based on a pressure drop of 0.3 inches water column and a specific gravity of 0.60.

ADDITIONAL LENGTH OF PIPE TO BE ADDED FOR EACH ELBOW OR TEE BEND IN THE LINE

Pipe Size Inches

Elbow

Tee

1 2.62 ft. 5.24 ft. 1-1/4 3.45 ft. 6.90 ft. 1-1/2 4.02 ft. 8.04 ft.

2 5.17 ft. 10.3 ft. 3 7.67 ft. 15.3 ft.

4 Fl. 5.37 ft. 15.1 ft. 6 Fl. 8.09 ft. 22.8 ft.


Installation Diagram (DRF Model)


Installation Diagram (WRF & WRF-NOx Model)


Installation of Boiler with Refrigeration System The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler.

1. Install valves 1, 2, 3 and 4. Valves 1, 2, 3 and 4 may be manual or automatic. 2. Close valves 1 and 2 when operating water chiller. 3. Close valves 3 and 4 when operating boiler. 4. Water supply valve remains open at all times.

Note: When hot water heating boilers are connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, the boiler piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.


Water Treatment We, the manufacturer of your boiler, wish to call to your attention to the necessity for a sound approach to the broad problem of boiler feed water treatment. Boilers used for space heating purposes only, operate with a closed system of piping in which all of the boiler water is brought back to the boiler. Under these conditions, very little raw makeup water is added to the system. Unless there are system leaks, only a small amount of makeup is required and there is little need for attention to the problem of feed water treatment. Heating boilers are subject to idle periods during the warmer months of a year. Protection of such idle boilers to prevent corrosion should be considered. Such protection can be provided in several ways and can be recommended by a qualified feed water treatment service or chemical supply company in your area. Makeup water continuously introduces contaminants; scale forming solids, corrosive minerals and oxygen, which is the primary cause of corrosion, in both water and steam boilers. The application of your boiler system, the condition of your boiler system and its operation should be carefully considered. For example, during initial operating periods of a new or a remodeled boiler system, all or a large amount of the water may be wasted. There are other reasons for water losses such as piping leaks, a faulty relief valve, blow down, summer drainage, etc. Whenever appreciable amounts of raw makeup water are continuously added to your system, we recommend that the problem be brought to the attention of a qualified water consultant. Boiler water treatment means more than just scale prevention. It actually includes:

1. The kind and control of the chemical treatment. 2. A suitable method of regulating the preheating and pretreatment of raw water. 3. Regulating and the method of blow down of the boiler water in amounts proportionate to the raw

water makeup.

The treatment program maintains the boiler water concentration within safe and acceptable limits for longer boiler life and reduced maintenance. The feed water treatment is dependent upon the make-up water conditions. We, the manufacturer, offer the following general guidelines for water treatment. Refer to Quick Reference Guide. The analysis for and the supervision of this treatment and control can only be handled by a qualified operator, of your own or an outside chemical service that specializes in the field. Particular care is exercised in handling the water problems in large utility central station plants. Modern industrial boilers deserve comparable attention. All modern boilers, including the smaller industrial types, are designed with lower water storage content than was used many years ago. They operate at ratings above those employed on the boilers of yesterday. This is one of the reasons we draw your attention to the importance of the proper handling of the water problem. Water treatment is a specialized subject that we, as boiler manufacturers, are not qualified to carry on a water treatment service. We, therefore, recommend that a qualified feed water treatment service company be used to supervise all phases of the water problem that may be encountered in your installation. This service should be picked most carefully as the prevention of trouble costs far less than the cost of repairs to equipment that has been neglected. Final proof of any feed water treatment program is in the continued observation of its effectiveness on the waterside surfaces of the boiler. Regular internal inspection of the boiler, therefore, should become part of the maintenance program.


Before Start-up

1. Clean system: The boiler and the entire system should be cleaned and flushed prior to filling the boiler.

2. Fill the boiler: a.) After cleaning, fill the system with a treated water mixture according to a water treatment

specialist’s recommendation and to the correct system pressure. Further information can be found at www.H2Ochem.com.

b.) To prevent the boiler from becoming air bound, open the relief valve located on the top rear of the boiler and leave it open until a steady flow of water is observed. On boilers equipped with a float type low water cut-off, the top cross in the low water cut-off piping should be opened to bleed off any air that may be trapped in the piping. Once this is done, close the relief valve, and low water cut-off assembly if applicable and complete filling the system to the correct pressure.

c.) After filling the system, inspect all piping throughout the system for leaks. If found, make necessary repairs.

3. Fill oil tank: Fill the oil tank with the proper grade of oil (If applicable, Models DRFO & DRFC). If

the fuel tank is below the burner level, be sure to prime the pump. If the oil pump is above the tank level, the pump should be lubricated to prevent damage by running dry. In some cases, the fuel pump may become air bound. To remove the air, remove the plug on the discharge side of the pump and run the burner until oil flows freely from the discharge. Afterwards, replace the plug and restart the burner.

4. Additional controls: Boilers are pre-wired at the factory. If additional controls are to be installed, care should be taken not to disturb the continuity of the existing circuit. Refer to the boiler wiring diagram and control manufacturer’s instructions supplied with the boiler.

5. Venting: The venting will include a barometric damper (draft hoods are not approved). A wind deflecting vent cap that prevents down drafts, must be securely fastened to the vent outlet. Outdoor units will be provided with a rain cap as standard.

6. Check factory assembled joints and head bolts: Although the boiler pressure vessel and the gas train are pressure tested prior to shipping, often times during shipment, items may work loose. These items may include head plate nuts, relief valves and gas train assemblies. These items should be checked prior to operating the boiler and tightened. Refer to Quick Reference Guide.

Important! The boiler gas piping and all connections should be tested for leaks before starting up the boiler. Do not use a flame test. It is important that you check the boiler gas train as some components may shift during transport. The boiler has been furnished completely assembled at the factory and furnished to deliver the rated capacity, as designated on the boiler nameplate. The manifold pressure must be set between the specified gas pressures recommended in the burner manual. The supply pressure to the boiler regulator must be set between the minimum and maximum pressures stated on the boiler nameplate.


Start-up Instructions – Gas Important! When starting up your boiler for the first time, run it at low fire for 30 minutes prior to running it at high fire. The refractory panels may contain moisture from the curing process. Running the boiler at low fire will dry out the panels. If the boiler is immediately operated at high fire, there may be a chance that the refractory will crack. A "cold" boiler should be treated the same way. Please see the burner operation manual for complete instructions.

1. Read manual: Before attempting to start-up the boiler, read this manual in its entirety and be familiar with the details contained within.

2. Verification: Locate the boiler nameplate and verify the voltage, type of gas, gas pressure and

regulator setting. Ensure free combustion air openings to the boiler room meet the requirements on the boiler nameplate, local codes, gas industry standards and the O&M manual. The venting will include a draft hood or barometric damper (Indoor units only). A wind deflecting vent cap that prevents down drafts, must be securely fastened to the vent outlet. Outdoor units will be provided with a rain cap as standard.

3. Inspect: Turn off all electric power and open the main gas valve. Smell for gas, especially around

the floor. If you smell gas, shut the main gas valve to the boiler immediately and check for piping leaks! If you do not smell gas, go on to the next step.

4. Operating controller: Set the operating temperature controller to its lowest setting and the hi-limit

15°F above the operating temperature control. (Figure 1.4)

Figure 1.4

5. Main power: Set the main power switch and the burner panel control switch to the ON position.

The burner blower motor will start and after a suitable pre-purge period (this will vary based upon the control safeguard used – usually 30 to 90 seconds). If equipped, the manual firing rate potentiometer should be set at its lowest setting.

6. Flame: Once flame has been established, run the boiler at low fire for ½ hour. This will evaporate

the moisture in the refractory panels. 7. Low fire run time: After running the boiler at low fire for ½ hour, open the manual gas valves fully.

Make sure the boiler operating temperature control is set at the desired output temperature. 8. Full fire: The boiler will continue to operate at full fire until it satisfies its set operating temperature.

Once satisfied, the boiler will shut down or go to low fire if equipped.


9. Testing: While the boiler is running, test all interlocks and safeties. Once the boiler has reached at least 150°F, test the high limit by turning the temperature dial to its lowest setting. The boiler should shut down and lock out. To put the boiler back in operation, turn the high limit temperature setting to 15°F higher than the operating temperature setting and press the reset button on the high limit. The boiler will now resume.

10. Testing low water cut-off: To check the low water cut-off, push the test button located on the

boiler control panel, labeled LWCO. Hold it for 5 seconds. This will produce a simulated low water shutdown. Upon release on the button, the boiler will remain locked out. The boiler will remain locked out until the low water cut-off reset button, located on the control panel, is depressed.

11. Draft: Stack Draft Requirements (FD), -0.02” to -0.04” Water Column.

12. Boiler Circulation: Proper water flow is required for water boilers; low water flow may cause

overheating of the water in the boiler tubes. Prolonged operation of the boiler under this condition may cause damage to the unit. The most common WARNING sign is a knocking sound, from which the water inside the boiler tubes is flashing to steam.

After Start-up Check List

Has air been purged from the system? Has the gas line piping been checked for gas leaks? Have the operating and high limit temperature controls been set? Is the boiler inlet water temperature above 140°F? Is the blow fan rotating in the appropriate direction? Flue gas spillage and soot: Check for spillage at the draft hood. Check for soot around the sheet

metal joints. Use the smoke from a match to detect flue gas spillage. If spillage is present, determine the cause of the problem and correct it.

Leaks: Look for water on the floor. Check for water leaks from any part of the boiler, valves or piping. Supports: Check for proper supports on the water piping and gas lines. Caution: Keep flammable materials away from the boiler. In the event of the boiler overheating –

shut the boiler down by (1) turning off the manual gas valve located in the gas controls manifold adjacent to the boiler and (2) turn off the electricity to the boiler.

Shutting Down the Boiler 1. Operating controller: Set the operating temperature controller to its lowest setting. 2. Burner: Follow the instruction in the burner manual for proper shutdown. 3. Power: Turn off the boiler by switching the toggle switch on the control panel into the OFF position. 4. Gas valves and oil line: Close the main gas valve and/or oil lines.


Start-up Instructions – Oil Important! When starting up your boiler for the first time, run it at low fire for 30 minutes prior to running it at high fire. The refractory panels may contain moisture from the curing process. Running the boiler at low fire will dry out the panels. If the boiler is immediately operated at high fire, there may be a chance that the refractory will crack. A "cold" boiler should be treated the same way. Please see the burner operation manual for complete instructions.

1. Read manual: Before attempting to start-up the boiler, read this manual in its entirety and be familiar with the details contained within.

2. Verification: Locate the boiler nameplate and verify the voltage, type of gas, gas pressure and

regulator setting. Ensure free combustion air openings to the boiler room meet the requirements on the boiler nameplate, local codes, gas industry standards and the O&M manual. The venting will include a draft hood or barometric damper (Indoor units only). A wind deflecting vent cap that prevents down drafts, must be securely fastened to the vent outlet. Outdoor units will be provided with a rain cap as standard.

3. Valves: Open all valves in the oil lines.

4. Operating controller: Set the operating temperature

controller to its lowest setting and the hi-limit 15°F above the operating temperature control. (Figure 1.4)

Figure 1.4

5. Main power: Set the main power switch and the burner panel control switch to the ON position. The burner blower motor will start and after a suitable pre-purge period (this will vary based upon the control safeguard used – usually 30 to 90 seconds). If equipped, the manual firing rate potentiometer should be set at its lowest setting.

6. Flame: Once flame has been established, run the boiler at low fire for ½ hour. This will evaporate

the moisture in the refractory panels.

7. Low fire run time: After running the boiler at low fire for ½ hour, open the manual gas valves fully. Make sure the boiler operating control is set at the desired output temperature.

8. Full fire: The boiler will continue to operate at full fire until it satisfies its set operating temperature.

Once satisfied, the boiler will shut down or go to low fire if equipped.

9. Testing: While the boiler is running, test all interlocks and safeties. Once the boiler has reached at least 150°F, test the high limit by turning the temperature dial to its lowest setting. The boiler should shut down and lock out. To put the boiler back in operation, turn the high limit temperature


setting to 15°F higher than the operating temperature setting and press the reset button on the high limit. The boiler will now resume.

10. Testing low water cut-off: To check the low water cut-off, push the test button located on the

boiler control panel, labeled LWCO. Hold it for 5 seconds. This will produce a simulated low water shutdown. Upon release on the button, the boiler will remain locked out. The boiler will remain locked out until the low water cut-off reset button, located on the control panel, is depressed.

11. Draft: Stack Draft Requirements (FD), -0.02” to -0.04” Water Column.

After Start-up Check List

Has air been purged from the system? Has the gas line piping been checked for gas leaks? Have the operating and high limit temperature controls been set? Is the boiler inlet water temperature above 140°F? Flue gas spillage and soot: Check for spillage at the draft hood. Check for soot around the sheet

metal joints. Use the smoke from a match to detect flue gas spillage. If spillage is present, determine the cause of the problem and correct it.

Leaks: Look for water on the floor. Check for water leaks from any part of the boiler, valves or piping. Supports: Check for proper supports on the water piping and gas lines. Caution: Keep flammable materials away from the boiler. In the event of the boiler overheating –

shut the boiler down by (1) turning off the manual gas valve located in the gas controls manifold adjacent to the boiler and (2) turn off the electricity to the boiler.

Shutting Down the Boiler 1. Operating controller: Set the operating temperature controller to its lowest setting. 2. Burner: Follow the instruction in the burner manual for proper shutdown. 3. Power: Turn off the boiler by switching the toggle switch on the control panel into the OFF position. 4. Gas valves and oil line: Close the main gas valve and/or oil lines.


Maintenance Instructions

1. Keep tubes clean: In order to maintain high boiler efficiency and boiler life, the boiler tubes should be cleaned periodically, both inside and outside. The frequency of cleaning the inside of the boiler tubes depends on the characteristics of the water and the type of installation. When a large amount of makeup water is used, it is good practice to inspect and clean, if necessary, the inside of the tubes after 30 days. The accumulation of lime and other solids within this time will establish the criterion for how often the boiler tubes should be cleaned. On closed systems, where only a small amount of makeup water is used, the insides the boiler tubes should be examined and if necessary, cleaned at the end of the heating season. When makeup water is negligible, such as boilers connected to unit heaters or radiators, the boiler should be flushed at the end of each heating season. All water boilers should have a tee installed at the boiler inlet for draining the boiler. Clean tubes will not only ensure higher boiler efficiency but will also prevent possible damage to the boiler. The boiler should never be fired unless it is full of water.

2. Gaskets: Tighten gaskets during start up and periodically thereafter. Leaky gaskets will cause the

use of excessive makeup water and could cause corrosion of the stud bolts. It is good practice to use a new gasket; however, if the gasket is not damaged, it may be reused. Use a soft gasket compound on both sides of the gasket. Specify boiler model number and the height and width of the boiler head plate when ordering new gaskets.

3. Studs: Keep studs protected from corrosion with paint or oil. Keep stud bolts tight to prevent leaky

gaskets. Stud bolts will not corrode if they are kept dry and protected. Use caution in removing and reinstalling head plates. The boiler must be shut down and drained. Before removing the nuts, apply penetrating oil and allow it to set for a few minutes. Tap the head plate lightly around each stud bolt before trying to break the nut loose. Forcing the nut off could cause breakage. Use a torch to heat the nut and it will come off easier. If a torch is not available, take a cold chisel, place it across the flat of the nut, and strike several sharp blows with a heavy hammer. This should loosen the nut. If necessary, it is better to split the nut open and replace it than to break the stud off.

Should, for any reason, a stud bolt on a boiler head be broken, it can be replaced as follows:

without removing the heat plate, use a slow speed drill to drill out the remaining portion of the stud. Re-drill the header and tap using a standard thread tap. Spare studs may be obtained from the factory.

4. Controls: Under normal conditions, controls furnished with the Ajax Boiler require very little

service. It is important, however, that the controls be protected from moisture and dirt. All controls should be checked frequently to make sure that they are working properly. Turn both the operating controls and the safety controls up and down to verify that they will operate satisfactorily. The high limit control furnished with the boiler should only be used as a safety control.

5. Power burner: Reference the maintenance and service instruction in the burner manual.

6. Relief valve: Boilers are equipped with a lever type relief valve of “ASME” rated capacity. To

maintain the valve in good working condition, it should be manually opened once a month on “closed” systems and once a week on “open” systems. The relief valve outlet should be piped directly to an open drain and the drain checked frequently for discharge. If the relief valve is leaking or does not operate freely, it should be replaced.


7. Low water cut-off: A low water cutoff is furnished to protect the boiler against damage by

preventing it from operating without water. This is particularly important when the boiler is installed above the water level, i.e., on a roof. Low water level cutoffs should be checked periodically by lowering the water level in the boiler and verifying that the safety circuit opens. Float type low water cutoffs should be flushed at least once a week on “open” systems and once a month on “closed” systems (if applicable). If neglected, accumulation of sediment within the low water cutoff casing may render the control inoperative and thereby become a safety hazard. Probe low water cutoffs may accumulate deposits on the grounding element. These should be carefully cleaned.

8. Operating control: The operating temperature control sets the desired boiler water temperature

output. To adjust the water temperature, insert a small straight screwdriver into the slotted screw hole at the front of the controller. This controller has an adjustable differential wheel under its casing.

9. High limit manual reset: The boiler is equipped with a manual reset high limit temperature safety

designed to shut down the boiler in the event the boiler water temperature exceeds the high limit set point. The high limit should be set 15°F above the operating temperature controller.

10. Gas pressure switches (Optional, where applicable): The low gas pressure switch is designed

to shut down the boiler if the gas supply drops below its set point. The high gas pressure switch is designed to shut the boiler down if the gas pressure exceeds its set point. Both switches will lock out and must be manually reset if tripped.

11. Anodes: Magnesium anodes are standard on all copper tube boilers. They will extend the life of

the boiler, and must be replaced periodically. The replacement frequency can vary from six months to several years. Higher temperatures and/or higher total dissolved solid contents in the boiler water will speed electrolysis and decrease the life of the anodes. Normally, two anodes in each header are adequate for header protection. Under adverse conditions, it may be necessary to install as many as three or four anodes in each header. New anodes may be purchased from your Ajax Boiler representative.

12. Venting system (indoor boilers): Examine the venting system externally at least once a year for:

a.) Tightness of all joints and connections including the draft hood to the boiler and the vent connection from the draft hood to the stack.

b.) Corrosion of metal in the vent ducting.

14. Flue gas passageways: Inspect and clean, if necessary, at least once every five years. a.) Shut off gas and turn off electric power to boiler. b.) Disconnect vent pipe and remove draft hood(s) or vent cap on outdoor boilers. c.) Examine flue gas passageways and the inside of the venting system for soot and corrosion. d.) If cleaning is needed, open front door, remove main burners, and cover burner orifices and

pilot burner with a waterproof covering. e.) Protect controls, electrical, etc. with waterproof covering. f.) Clean tube bundle through vent opening(s) at top of boiler using a water or steam hose.

Clean out and reassemble boiler after cleaning.

Note: If any parts need tightening or replacement, consult a qualified serviceman. It is highly recommended that an operator’s log be kept as a record of boiler readings as a way of tracking operational changes that may affect warranty and/or boiler reliability.


Maintenance Intervals Daily Maintenance

1. Check water level: An unstable water level can indicate several problems such as excessive solids or water treatment, contamination from oil, overload or control malfunction. Ensure there is water in the gauge glass (if applicable) every time you enter the boiler room.

2. Check combustion visually: Look at the flame to see if anything has changed. Changes may be an indication that a problem is developing.

3. Treat water according to the established program: Add chemicals and take tests as outlined by your chemical feed water consultant.

4. Record boiler operating pressure and temperature: An excessive steam or water temperature drop will alert you to excessive loading on the boiler.

5. Record feed water pressure and temperature: A change in pressure or temperature may indicate a problem is developing with your feed pump(s), deaerator or packaged feed system.

6. Record stack temperatures: Changes in stack temperatures could indicate the boiler is sooting, scaling or there is a problem with baffles or refractory.

7. Record oil-atomizing pressure (if applicable): Changes in pressure could have an effect on combustion in the boiler.

8. Record gas pressure: Changes in pressure could have an effect on combustion in the boiler and indicate a problem in the gas delivery system.

9. Check with general boiler/burner operation personnel: Has anything changed from the day before? If so, why?

10. Record boiler water supply and return temperatures: On hot water boilers, record these temperatures to assist in detecting system changes. Return temperatures below 140ºF will cause the boiler to condense.

11. Record makeup water usage: Excessive makeup water could be an indication of system problems (leaks) in both steam and hot water systems.

12. Check auxiliary equipment: There is a vast difference between "is it running" and "is it running properly." Take nothing for granted, as auxiliary equipment can shut down your operation.

Weekly Maintenance 1. Check for tight closing fuel valves: Check to ensure fuel does not flow through the fuel

valve(s) when the burner is shut off. 2. Check fuel and air linkage: Check to ensure that all set-screws on linkages are tight and

securely holding the linkage in place (Forced Draft boilers). 3. Check indicating lights and alarms: Check for burned out or loose light bulbs. In addition,

check to ensure the alarm bell sounds on the appropriate shut down condition. 4. Check operation of water level controls: Stop the boiler feed pump and allow the control to

stop the boiler under normal low fire conditions. 5. Check for leaks, noise, vibration, unusual conditions, etc.: Checking for these items, is a

cost-effective way to detect system operational changes. Small problems can be corrected before they become large problems.

6. Check operation of all motors: By developing a routine, any change in operation or bearing temperature will usually be caught in time to avoid a failure.

7. Check the flame scanner assembly (if applicable): Using the appropriate meter, check the flame signal strength at the program relay flame amplifier. Ensure the scanner assembly is clean and dry.


8. Check gauge glass: Ensure there are no scratches or etching in the glass or leakage around the package.

Monthly Maintenance 1. Inspect burner operation: Do a visual inspection of the pilot flame and main burner flame

throughout the firing range. 2. Analyze combustion: Take the flue gas analysis over the entire firing range, comparing the

combustion analysis and stack temperature reading with the pervious month. 3. Check cams (Power burners): Inspect the cam springs for scoring, tightness of set-screws,

free movement, alignment of cam followers and other related parts. 4. Check for flue gas leaks: Ensure something hasn't changed in the breaching, stack or overall

system that allows flue gas to be drawn into the boiler room. 5. Check boiler blow down: Review boiler blow down to determine that a waste of treated water

is not occurring. Check water treatment and testing procedures with your feed water consultant.

6. Check all combustion air supply inlets: Ensure sufficient combustion air is being supplied to the boiler room and burner.

7. Check all filter elements (oil, gas and air): Clean or replace as needed. On “self-cleaning” filters, make certain that impurities are flushed or discharged from filter body.

8. Check the fuel system: Make sure certain strainers, vacuum gauges, pressure gauges and pumps are properly cared for.

9. Check lubrication: Verify lubrication requirements of all bearing supported equipment. Do not over-lubricate electric motors.

Semi-Annual Maintenance 1. Clean low water cut-off(s): Remove the head assembly or probes, inspect and clean out any

sediment or contamination in the column or piping. Determine why sediment or contamination condition exists.

2. Pre-heaters: Check oil pre-heaters by removing the heating element and inspect for sludge or scale.

3. Repair refractory: Repair all cracks and fill in gaps. 4. Clean oil pump strainer and filter: Ensure they are not plugged, thus reducing the flow of the

required oil to the burner. 5. Reset combustion: The entire combustion process should be carefully checked, O2 readings

taken and necessary burner adjustments made. Make certain readings are recorded and used as a basis of comparison for future tests. Combustion adjustments should only be made by those thoroughly familiar with all aspects of burner adjustments and combustion.

Annual Maintenance 1. Clean fireside surfaces: Clean fireside surfaces by brush or use a powerful vacuum cleaner

to remove soot. After the cleaning process, and if the boiler is to be left open, it is advisable to spray all fireside surfaces with some type of corrosion preventative.

2. Clean breaching: Inspect breaching, stack, and remove any soot build-up. 3. Clean waterside surfaces: Remove all head plates and inspect tubes. Inspect water

columns, tee and float assemblies from water columns. Thoroughly wash all waterside surfaces.

4. Check gauge glass for possible replacement: If internal erosion at water level is noted, replace with new glass and gaskets.

5. Remove and recondition safety valves: Have them reconditioned by an authorized safety valve facility. The safety valve is an important device yet possibly receives less attention than any other device.


6. Boiler feed pumps: Strainers should be reconditioned. Feed-pump elements wear and must be replaced. Sometimes a review of the condensate return system and chemical feed arrangement will reveal causes of short pump life.

7. Chemical feed systems: Chemical feed systems should be completely emptied, flushed and reconditioned. Metering valves or pumps should be reconditioned at this time.

8. Tighten all electrical terminals: All terminals should be checked for tightness, particularly on starters and moveable relays.

9. Check linkages: Check to ensure the linkage ball connectors have not worn out. Worn connectors can cause inconstancy in the linkage movement and result in unrepeatable excess air levels in the combustion process.

Removing and Sealing The Manway Access Door Every Ajax Boiler, size 50HP and up, includes a bricked access door to the combustion chamber on the left side of the boiler. This manway entrance provides access to the combustion chamber, the burner nozzle and the first row of boiler tubes for ease of maintenance. Boilers under 50HP will have front-hinged door access. Opening The Manway

1. Remove the sheet metal plate covering the manway access. The plate is sheet metal screwed to the side of the boiler.

2. Remove the fiberglass insulation, the Fibrex board (if applicable) and the fitted refractory panel. These items have been laid in the access hole. Once these items have been removed, this will give access to the refractory brick set and mortared in place.

3. Use a chisel and hammer or a saber saw to carefully break the brick from the pre-cast refractory panels. Do not hit the bricks with a hammer, as this may damage the surrounding refractory panels.


Closing The Manway 1. Remove all loose debris around the manway opening. 2. Using a high temperature refractory brick, fill in the opening. Some of the bricks will require cutting

in order to fit. Set the bricks in loosely first to guarantee a perfect fit. The bricklayers must be staggered.

3. Once the bricks have been arrange so they fit, remove them and reinstall each brick with a high temperature mortar. Install each brick until the manway hole is covered.

4. After the bricks have been placed, trowel a ½" layer of mortar to the backside of the bricks to seal. 5. Reinstall the refractory panel, Fibrex board (if applicable), the fiberglass insulation and the sheet

metal panel.


Adjusting Gas Pilots On Power Flame C & J Burners Scanner Pilot

1. Ensure gas pressure does not exceed pilot regulator specifications 2. Set pilot gas pressure at 1 ½" to 4" WC. Best flame signal at test tee on pilot. 3. Ensure there is an adequate earth ground. 4. Check for proper electrode gap and depth in pilot head. See Burner Manual. 5. Check for strong blue spark from ignition transformer. 6. Ensure air holes in pilot body are unobstructed. 7. Clean pilot electrode of soot. 8. Check for pilot pressure at main flame light off. If pilot pressure drops at the point when the main

gas valve opens, check for proper gas supply. Gas line may be undersized our under-pressured. 9. Adjust pilot to improve signal. 10. Check boiler draft. High draft may affect pilot reliability.

Flame Rod Pilot

1. Ensure flame rod is clean. 2. Make sure all grounding points on pilot are clean. 3. Check for proper electrode gap and depth in pilot head. See Power Flame Manual. 4. Check for strong blue spark from ignition transformer. 5. Flame sensing wire resistance should be near 0 ohms. 6. Ensure static inlet gas pressure does not exceed pilot regulator. 7. Set pilot gas pressure at 1 ½" to 4" WC. Best flame signal at test tee on pilot. 8. Check for pilot pressure at main flame light off. If pilot pressure drops at the point when the main

gas valve opens, check for proper gas supply. Gas line may be undersized our under-pressured. 9. Ensure air holes in pilot body are unobstructed. 10. Check the draft through the boiler in the off-cycle, pre-purge and pilot flame establishing pressure.

High draft will affect pilot reliability and can cause pilot failures. Reduce draft via barometric damper or other draft control device.


Trouble Shooting Guide The following is a list of items that can cause boiler performance problems if not installed correctly.

Available combustion air: Normal Conditions: 1 sq. in. open area per 1000 Btu/hr. Note: This must be open area between louvers. Stack draft: Normal Conditions: Forced Draft: Balanced draft, -0.02” to -0.04” WC. Combustion Chamber Pressure: The combustion chamber pressure should not exceed 0.25” WC on “DRF” boilers and should not exceed +0.50” WC on “DRF” boilers with lox NOx burners installed by factory. Fuel pressure: See Burner Manual. Inlet water treatment, flow, and/or temperature: Minimum inlet water temperature without boiler recirculator line = 140°F

The following are common problems with possible causes and solutions. 1. Nuisance flame failures: See Burner Manual. 2. Boiler not putting out enough heat: The main reason a boiler will not put out enough heat is

usually due to there not being enough gas reaching the burners. Check the following: a.) Have you been able to accurately measure the gas flow (oil) rate at the meter? b.) What is the gas pressure at the burner manifold? c.) What is the inlet gas pressure, while the burner is firing? This number will be lower than

when the burner is not firing? d.) Review combustion report, if the boiler is under fired, there should be too much Oxygen in the

stack gases? e.) Is the boiler at altitude? If yes, has it been derated?

4. Boiler is sooting up: a.) Condensate: Check the boiler's flue gas using a combustion analyzer and compare those to

the ideal combustion list. Refer to Ideal Combustion Rate. A high percentage of CO in the combustibles is an indication of a sooting problem. Running the boiler in a condensing mode with inlet water temperatures below 140°F. When this happens, it will “rain” down on the burners and appear to be leaking. The boiler will subsequently soot up.

b.) Insufficient gas/air ratios: See Burner Manual. c.) Check Start-up or Combustion report: d.) Combustion: Open a door to the boiler room. Any improvement? If so, there is not enough

combustion air in the boiler room. e.) Pressurization: Is the room pressurized? Is there other equipment in the room? Is there an

extractor fan in the room?

5. My boiler is leaking: Sometimes boilers appear to be leaking when they are actually operating in a condensing mode. To prevent condensing, inlet water temperature should be 140°F or higher.


Condensation During startup conditions, when the boiler water temperature is below 140°F, condensation will occur. Condensation will stop when the return boiler water temperature exceeds 140°F. Water tube boilers, including the Ajax Boiler, should not be operated at water inlet temperatures below 140°F. Prolonged operation of the boiler under condensation conditions will cause damage to the boiler. If the boiler application requires inlet water temperatures below 140°F, a boiler recirculation system must be installed so that the cold inlet water is mixed with hot boiler water in a ratio to ensure that condensation does not occur. Cold Start-ups Too many cold startups will be evidenced by rust stains on the refractory inside the boiler and around the boiler doors. If condensation occurs regularly, eventually the boiler tubes and firebox area may rust apart and collapse. Frequent shutdowns of the heating system can endanger the boiler life expectancy. With a water boiler, maintain at least the minimum inlet water temperature recommended (140°F). If an outdoor reset control is used, the controls must be arranged so that the boiler never falls below the recommended water temperature. Soot No matter what kind of fuel is used (gas, oil, LPG), soot and scale deposits will accumulate on the outside of the boiler tubes. If the tubes aren’t cleaned regularly, boiler efficiency will be sacrificed and fuel will be wasted. Soot has excellent insulating properties, which can result in a tremendous heat loss and increased fuel consumption.

CAUTION: 1. Check daily to be sure that boiler area is free and clear of combustible materials, gasoline, solvents,

and other flammable vapors, liquids or materials. 2. Check daily to be sure that the flow of combustion and ventilating air to the boiler is not obstructed. 3. If the boiler overheats, shut it down immediately by (1) turning off the manual gas valve located on

the boiler and (2) turning off the electric power to the boiler.

For other trouble shooting issues, please reference the specific control sheets included in this manual.


Quick Reference Guide Head Plate Torque Requirement 5/8" studs 90ft.lbs 3/4" studs 150ft.lbs 7/8" studs 240ft.lbs Stack Draft Requirements (FD)* -0.02” to -0.04” Water Column Manifold gas pressure (Nat. Gas) 3.5” to 4” Water Column Manifold gas pressure (LPG) 11” Water Column Minimum Inlet Water Temperature 140ºF Water Treatment Hardness Less than 0.3 ppm PH Value 7.2 to 9.5 Suspended solids Less than 10 ppm Dissolved solids Less than 3000 ppm Oxygen before scavenger addition Less than 0.2 ppm Oxygen after scavenger addition Less than 0.007 ppm Total alkalinity Less than 350 ppm * Draft range is provided as a guide. Adjustment of Forced Draft burners for smooth operation, burner performance and proper combustion is one of the primary start up and maintenance requirements for a successful installation Replacement Parts Ajax Boilers have been manufactured since 1924. In the course of these years, many improvements have been incorporated in the design of our boilers. Information on the Ajax Boiler is subject to change without notice as design improvements continue. Ajax Boiler maintains a complete equipment list for each boiler filed by boiler serial number. In order for us to give prompt service and to ensure that correct parts are supplied, please be sure and supply the boiler model and serial number.

1. Head Plate Gaskets: Specify the height and width of the boiler head plate with the model and serial number when ordering.

2. Anodes: Give boiler model and serial number when ordering. 3. Burners: When ordering burner parts advise boiler model, serial number of both boiler and burner. 4. Boiler Tubes: All Ajax Boilers are equipped with 2” O.D. steel or copper tubes. These tubes are

rolled and flared into a tube sheet with a minimum thickness of 1/2”. Furnish overall boiler length, taken at the top of the jacket, with the model and serial numbers when ordering boiler tubes.

5. Studs: If a stud on a boiler header should break, see stud replacement in the service instructions. Material Safety Data Sheets Some of Ajax Boiler products contain materials that have been recognized as posing health risks. Material Safety Data Sheets for these materials are available from your local Manufacturer’s rep. When requesting this information, be sure to have the model number and serial number available.

If you do not know who your local Manufacturer’s Rep is, you can find out by logging into the www.ajaxboiler.com website, and clicking on the Representative tab found in the table of contents.

Ajax Boiler Inc.

2701 S. Harbor Blvd. Santa Ana, CA 92704 Parts: 714.437.9050 www.ajaxboiler.com

email: [email protected]

AJAX BOILER INC. - ACE BOILER INC.

FACTORY LIMITED WARRANTY POLICYThe Ajax Boiler Factory limited warranty provides assurance that all products are free from manufacuteres defects at the time of shipment and meet specifi cations and performance described in the product literature.

It is important to understand the difference between a factory warranty and an installed warranty. There are many factors that can occur to the products after they are shipped that the company has no control over and can not fully verify. These includes:

1. Hidden damage during the shipping. 2. Handling damage. 3. Damage during storage. 4. Installation conditions. 5. Other unknown variables in the system design: maintenance, pulsation and vibrations.

The installed warranty is the responsibility of the architech, specifying engineer, contractor and/or owner who jointly have control over the application, installation, location, operating and maintenance conditions.

The Ajax Boiler Inc. warranty excludes extended liabilities. Extended liability typically occurs when products are installed without proper drainage, fl ooding containment or when safety devices are not tested and repaired or replaced when needed.

Product problems are often caused by the condition of the water, the lack of water treatment and/or the improper treatment of the water, insuffi cient combustion air, improper draft conditions, bolts not re-tightened, pipes not fl ushed and cleaned of oil, metal chips, rags, vibration and pulsation etc. These are installation, operating and/or maintenance conditions that are beyond the seller’s responsibility and are not covered by the factory warranty, but may be covered by the installer’s warranty.

The factory warranty covering company products is based upon extensive product development and testing. Combustion products under go certifi cation testing and approvals to Underwriters Laboratory (UL) standards. Auditing of the production of combustion products is conducted by a nationally recognized testing laboratory.

Pressure vessel products are designed and manufactured to American Society of Mechanical Engineering (ASME) and National Board (NB) Design standards. Design reviews, factory product manufacturing quality inspections and testing are carried out by a third party National Board authorized inspection agency.

Ajax Boiler Inc. products have proven themselves in service for over 85 years which indicates that the company products perform exceedingly well when normal installation, operating and maintenance conditions exist.

The following is a review from the terms and conditions of sale. Also included in paragraph two, below, is the Ajax Boiler Inc. non-conformance policy.

1. Ajax Boiler Inc. warrants its products against defective material and/or workmanship only. The warranty does not apply to operational failures, electrical failures, gasket leaks, and/or other malfunctions caused by improper application, installation and/or maintenance.

2. It is the buyer’s responsibility to inspect and accept the product, when received, as conforming to their purchase order, specifi cations and approved drawings. All claims for non-conformance, errors, shortages, etc. must be made within 10 days after receipt of the shipment. 3. Ajax Boiler Inc. do not provide a warranty or guarantee, express or implied, in any manner, form, usage of trade, merchant -ability or fi tness which extend beyond the product description and quotation. 4. Ajax Boiler Inc. liability is limited to the factory repair or replacement of warranty failures, or non-conformance, upon the return of the product to the factory.

5. Ajax Boiler Inc. is not liable for any direct or consequential damages.

6. The Ajax Boiler Inc. warranty is based upon section 23161(2) of the uniform commercial code and is printed in the terms and conditions of sale which is referenced in every quotation, on the back of sales order acknowledgements and invoices. It is legally correct and is an industry standard policy.

February-2007


WARRANTYLIMITED

THERMAL SHOCK In addition to our standard one (1) year warranty against defective parts and workmanship, Ajax Boiler Inc. provides the following guarantee with all commercial hot water, forced circulation, space heating boilers:

Ajax Boiler Inc. guarantees this new boiler pressure vessel for twenty (20) years after date of installation from damage due tothermal shock. Thermal shock occurs when cold makeup water, up to 150ºF less than the boiler water outlet temperature, is added directly into the boiler while the boiler is operating within the normal temperature range from 140ºF to 250ºF with a temperature rise from 20ºF to 40ºF. This guarantee shall cover damage to the boiler tubes, tube headers, and tube sheets when such damage is attributed to unequal expansion, poor circulation and/or other causes quite often described as “thermal shock”. This guarantee does not cover damage or failures that can be attributed to corrosion, condensation, scale, boiler treatment chemicals, dirt accumulation, low water conditions, or any other abnormal operating conditions.

The liability of Ajax Boiler Inc. is limited solely to the replacement of the complete pressure vessel, with tubes, if found by our inspection to be damaged by thermal shock. In no event shall Ajax Boiler Inc. be held liable for replacement labor charges or for freight or handling charges.

2701 South Harbor Blvd.Santa Ana, California 92704United StatesTel. (714) 437-9050Fax (714) 437-9060http://[email protected]

June-2010


LIMITED

WARRANTYAjax Boiler Inc. provides a limited warranty on its products against defective material and/or workmanship only. This limited warranty is not applicable to operational failures, electrical failures, gasket leaks, wear or malfunctions caused by improper application, installation, and/or maintenance.

Product Period - The following Limited Warranty period are from date of shipment: Boiler Pressure Vessels: One year. Carbon Steel Tank and Heat Exchanger Pressure Vessels: One year. Stainless Steel Tanks: Three years. Boiler Copper Fin Coils: Three years. Single-wall or Double-wall Tank/Exchanger Coils: One year. Single-wall or Double-wall Mini-Packs™: One year. Atlas Series Condensing Boiler: One year. Linings: (Pro-rated Warranty) In Section VIII Tanks: Glass 30" dia. and above (Five years). Glass 24" dia. and under (One year). Cement (Five years). Pre-Krete (Ten years). In Section IV Tanks: Glass (One year). Controls: Components manufactured by other than Ajax Boiler Inc. such as controls, instruments, forced draft burner, etc., provided with the boilers and packaged products are not covered by the Ajax Boiler Inc. Warranty. However, Ajax Boiler Inc. extends to the customer the same warranty provided by the manufacturer to Ajax Boiler Inc. The customer shall receive the full benefi ts of adjustments made to Ajax Boiler Inc. by the manufacturer.

Any claim for adjustment under this limited warranty must be made within the warranty period. Ajax Boiler Inc.’s liability shall be limited to factory repair or, at Ajax Boiler Inc.’s option, replacement of all parts which, upon test and examination by Ajax Boiler Inc., prove to be defective material and/or workmanship and within the above limited warranty. If required by Ajax Boiler Inc., parts which are claimed to be defective must be promptly delivered to the Ajax Boiler Inc. facility, transportation charges prepaid. This warranty does not cover the cost of labor, removal, or installation of the warranted item during the limited period.

This warranty is limited to the above and applies only for the period set forth. Ajax Boiler Inc. will not be liable for any loss damage, direct, incidental or consequential damages of any kind, whether based upon warranty, contract, negligence or strict liability and arising in connection with the sale, use or repair of the products. Ajax Boiler Inc.’s maximum liability shall exceed the contract price for the product’s merchantability or fitness for any particular purpose and in no event shall be held responsible for any consequential damages.

For complete Limited Warranty conditions see Section G and H under terms and condition of sale.

Ajax Boiler Inc., also doing business as Ace Boiler Inc., is referred to herein as Ajax Boiler Inc.


February-2007


WARNINGPRODUCT

SAFETY NOTICEAJAX BOILER AND WATER HEATER PRODUCTS OPERATE AT HIGH TEMPERATURE AND PRESSURES

AND NOT FOR INSTALLATION ON COMBUSTIBLE FLOORING.

• Before using this product, read and understand instructions. Save these instructions for future use.• Before servicing, to prevent serious burns or injury, the boiler and water heater products must be cooled to less than 80°F (27°C) and the pressure must be 0 psi (0 bar).• Turn off the electrical power before making electrical connections to prevent electrical shock.• These products must be placed in a controlled location where untrained or unqualifi ed personnel cannot access the operating or safety controls, must not be able to come in contact with high temperature or high pressure parts and must not perform maintenance or demolition work. • All work performed must be by qualifi ed properly equipped personnel trained in the proper application, installation, and maintenance or demolition of plumbing, steam, and electrical equipment and/or systems in accordance with all applicable codes and ordinances.• Ajax Boilers and Water Heaters are complete package units with safety and operating controls and are constructed with non ASBESTOS materials. Any replacement gaskets, refractory, insulation, etc used must not contain Asbestos. • No additional insulation is required on the Boilers and Water Heaters. • Additions or replacement of insulation on any connecting pipes or accessories to the Boilers and/or Water Heaters must be of “NON-ASBESTOS” and contain only non-hazardous materials.• Crystalline Silica, a material known to cause cancer, may be encapsulated in some refractory or insulation materials and must be handled only by authorized trained personnel. Crystalline Silica as used is encapsulated and is not harm full in this form. Care must be taken during removal or replacement of refractory or insulation to remove it in bulk form and avoid generation or inhalation of dust. Removal must be properly performed by trained, qualifi ed and equipped personnel. This is also true of Asbestos not contained in Ajax products but may be otherwise contained in replacement materials or parts, in connecting piping or other nearby products. • All safety and operating controls must be set within the specifi ed operating limits and tested periodically to assure proper operation. All limit and operating controls must be installed in series on the boiler.• Connect drain pipes to a safe drain to prevent serious personal injury from relief valve discharge and or from boiler blow down discharge.• After installation, check for proper operation of all limit and operating controls before leaving the site.• Perform scheduled and annual inspections including checking Controls for proper calibration and performance.

Failure to follow these warnings, to allow access by unauthorized persons and the use of non-properly trained and equipped personnel in the operation, service, modifi cation, removal or demolition of these products or replacement of parts with non-authorized factory non-asbestos materials could cause damage, personal injury or death.


Effective: November-2008

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n•

Non

met

allic

dis

c-to

-met

al s

eatin

g

PR

ES

SU

RE

- T

EM

PE

RA

TU

RE

Ser

ies

174A

Pre

ssur

e ra

nge:

30

psi

to

150

psi

(2

to 1

0 b

ars)

with

corr

esp

ond

ing

high

BTU

/hr

ratin

gs f

rom

650

,000

to 1

4,37

0,00

0 B

TU/h

r.M

axim

um T

emp

erat

ure:

250

°F (1

21°C

).N

o. 3

74A

Pre

ssur

e ra

nge:

rat

ed u

p t

o 5

50,0

00 B

TU

/hr

at a

30

psi

(2 b

ars)

set

ting

only

.

Ser

ies

740

Pre

ssur

e ra

nge:

30

PS

I to

75 p

si (2

to

5 b

ars)

with

cor

-re

spo

ndin

g h

igh

ratin

gs

fro

m 9

25,0

00 t

o 1

0,70

0,00

0B

TU/h

r.M

axim

um T

emp

erat

ure:

250

°F (1

21°C

).

STA

ND

AR

DS

Test

ed a

nd r

ated

by

A.S

.M.E

. Nat

iona

l Boa

rd o

f B

oile

ran

d P

ress

ure

Ves

sel I

nsp

ecto

rs.

Mee

ts M

ilita

ry S

pec

. M

IL-V

-186

34B

, Ty

pe

I, C

lass

3A

,S

tyle

A (B

ronz

e B

ody)

, Sty

le B

(Iro

n B

ody)

.

CA

PAC

ITY

ES

-174

A-7

40 0

026

© W

atts

Reg

ulat

or

Co

., 19

98P

rinte

d in

U.S

.A.

USA:

815

Che

stnu

t St.,

No.

And

over

, MA

0184

5-60

98; w

ww.

wat

tsre

g.co

mCa

nada

: 543

5 No

rth S

ervi

ce R

d., B

urlin

gton

, ONT

. L7L

5H7

; ww

w.w

atts

cda.

com

HVNB

AS

ME

Size

(Dn)

Hei

ght

Leng

thW

eigh

tN

o.in

.m

mM

odel

in.

mm

in .

mm

lbs.

kg.

374A

3 ⁄4 x

3 ⁄420

x 2

0–

35 ⁄892

21 ⁄264

1.13

.517

4A3 ⁄4

x 3 ⁄4

20 x

20

M3

51 ⁄813

021 ⁄2

641.

50.7

174A

1 x

125

x 2

5M

153 ⁄4

146

376

3.13

1.4

174A

11 ⁄4 x

11 ⁄4

32 x

32

M1

83 ⁄821

343 ⁄4

121

6.25

2.8

174A

11 ⁄2 x

11 ⁄2

40 x

40

M9

229

47 ⁄812

47.

253.

317

4A2

x 2

50 x

50

M11

5 ⁄829

561 ⁄4

159

13.7

56.

2

Ser

ies

740

740

3 ⁄4 x

120

x 2

5M

155 ⁄8

143

376

1.88

.974

01

x 11 ⁄4

25 x

32

M71 ⁄4

184

31 ⁄289

3.13

1.4

740

11 ⁄4 x

11 ⁄2

32 x

40

M83 ⁄4

222

45 ⁄811

76.

132.

874

011 ⁄2

x 2

40 x

50

M91 ⁄4

235

51 ⁄413

37.

503.

474

02

x 21 ⁄2

50 x

65

M11

5 ⁄829

563 ⁄4

171

16.5

07.

5

Ser

ies

174A

BT

U/h

r S

team

Pre

ssu

re D

isch

arg

e C

apac

itie

sA

s te

sted

and

rate

d by

the

Nat

iona

l Boa

rd o

f Boi

ler a

nd P

ress

ure

Vess

el In

spec

tors

Set

3 ⁄4" x

3 ⁄4"

1" x

1"

11 ⁄4" x

11 ⁄4

"11 ⁄2

" x 1

1 ⁄2"

2" x

2"

Pres

sure

20 x

20m

m25

x 2

5mm

32 x

32m

m40

x 4

0mm

50 x

50m

mps

iba

rsM

odel

M3

Mod

el M

1M

odel

M1

Mod

el M

Mod

el M

302.

0765

0,00

01,

005,

000

1,68

2,00

02,

020,

000

3,81

5,00

033

2.27

695,

000

1,07

5,00

01,

788,

000

2,15

0,00

04,

080,

000

352.

4172

5,00

01,

125,

000

1,87

7,00

02,

250,

000

4,25

0,00

036

2.48

740,

000

1,14

5,00

01,

916,

000

2,31

0,00

04,

344,

000

402.

7680

0,00

01,

240,

000

2,07

1,00

02,

490,

000

4,69

0,00

045

3.10

875,

000

1,35

5,00

02,

265,

000

2,72

0,00

05,

130,

000

503.

4595

0,00

01,

470,

000

2,45

9,00

02,

950,

000

5,57

5,00

055

3.79

1,02

5,00

01,

590,

000

2,65

3,00

03,

190,

000

6,01

0,00

060

4.13

1,10

0,00

01,

702,

000

2,84

7,00

03,

425,

000

6,45

0,00

065

4.58

1,17

0,00

01,

820,

000

3,04

1,00

03,

660,

000

6,89

0,00

070

4.82

1,24

5,00

01,

935,

000

3,23

5,00

03,

890,

000

7,33

0,00

075

5.17

1,32

0,00

02,

055,

000

3,42

9,00

04,

125,

000

7,77

0,00

080

5.51

1,40

0,00

02,

166,

000

3,60

5,00

04,

360,

000

8,21

5,00

085

5.86

1,47

0,00

02,

285,

000

3,81

7,00

04,

590,

000

8,65

0,00

090

6.60

1,54

5,00

02,

400,

000

4,01

1,00

04,

825,

000

9,09

0,00

095

6.55

1,62

0,00

02,

520,

000

4,20

5,00

05,

060,

000

9,53

0,00

010

06.

891,

695,

000

2,63

5,00

04,

399,

000

5,29

0,00

09,

970,

000

105

7.23

1,77

0,00

02,

750,

000

4,59

3,00

05,

525,

000

10,4

10,0

0011

07.

581,

845,

000

2,86

5,00

04,

787,

000

5,76

0,00

010

,850

,000

115

7.92

1,92

0,00

02,

980,

000

4,98

1,00

05,

990,

000

11,2

90,0

0012

08.

271,

995,

000

3,10

0,00

05,

175,

000

6,22

5,00

011

,730

,000

125

8.61

2,07

0,00

03,

215,

000

5,37

0,00

06,

460,

000

12,1

70,0

0013

08.

962,

145,

000

3,33

0,00

05,

564,

000

6,69

0,00

012

,610

,000

135

9.30

2,22

0,00

03,

445,

000

5,75

8,00

06,

925,

000

13,0

50,0

0014

09.

652,

295,

000

3,56

5,00

05,

952,

000

7,16

0,00

013

,490

,000

145

9.99

2,37

0,00

03,

680,

000

6,14

6,00

07,

390,

000

13,9

30,0

0015

010

.34

2,44

5,00

03,

795,

000

6,34

0,00

07,

630,

000

14,3

70,0

00

Ser

ies

174A

Set

3 ⁄4" x

1"

1" x

11 ⁄4

"11 ⁄4

" x 1

1 ⁄2"

11 ⁄2" x

2"

2" x

21 ⁄2

"Pr

essu

re20

x 2

5mm

25 x

32m

m32

x 4

0mm

40 x

50m

m50

x 6

5mm

psi

bars

Mod

el M

3M

odel

M1

Mod

el M

1M

odel

MM

odel

M30

2.07

925,

000

1,30

0,00

02,

105,

000

2,90

0,00

05,

250,

000

332.

2798

9,00

01,

390,

000

2,25

0,00

03,

100,

000

5,61

3,00

035

2.41

1,03

2,00

01,

450,

000

2,34

5,00

03,

235,

000

5,85

5,00

036

2.48

1,05

3,00

01,

480,

000

2,39

5,00

03,

300,

000

5,97

5,00

040

2.76

1,13

9,00

01,

600,

000

2,59

0,00

03,

569,

000

6,46

1,00

045

3.10

1,24

5,00

01,

750,

000

2,83

0,00

03,

903,

000

7,06

7,00

050

3.45

1,35

2,00

01,

899,

000

3,07

5,00

04,

237,

000

7,67

2,00

055

3.79

1,45

9,00

02,

049,

000

3,31

5,00

04,

572,

000

8,27

7,00

060

4.13

1,56

6,00

02,

200,

000

3,56

0,00

04,

907,

000

8,88

3,00

065

4.58

1,67

2,00

02,

349,

000

3,80

0,00

05,

241,

000

9,48

8,00

070

4.82

1,77

9,00

02,

499,

000

4,04

5,00

05,

575,

000

10,0

93,0

0075

5.17

1,88

6,00

02,

649,

000

4,28

5,00

05,

909,

000

10,7

00,0

00

Ser

ies

740

Ser

ies

174A

-740

ASM

E W

ater

Pre

ssur

eRe

lief V

alve

sfo

r P

ress

ure

Pro

tect

ion

of

Ho

t W

ater

Hea

ting

Bo

ilers

Siz

es: 3 ⁄4

" th

roug

h 2"

(20

- 50

mm

)S

erie

s 17

4AB

ronz

e b

od

y sa

fety

rel

ief

valv

es f

or

pre

ssur

e p

rote

ctio

n o

nly

of

all t

ypes

of

hot

wat

er h

eatin

g b

oile

r eq

uip

men

t.

Pre

ssur

era

nge

30 t

o 1

50 p

si (2

- 1

0 b

ars)

with

co

rres

po

ndin

g h

igh

rat-

ing

s fr

om

650

,000

to

14,

370,

000

BT

U/h

r. F

emal

e in

let

and

outle

t co

nnec

tions

. S

izes

3 ⁄4"

to 2

" (2

0 to

50m

m).

Ser

ies

374A

Iro

n b

od

y w

ith f

org

ed b

ronz

e in

let,

550

,000

BT

U/h

r ra

ting

.S

ize

3 ⁄4"

(20m

m) o

nly.

Ser

ies

740

Iron

bod

y w

ith e

xpan

ded

out

lets

for

hot

wat

er s

pac

e he

atin

gb

oile

rs.

Pre

ssur

e ra

nge

30 t

o 75

psi

(2

to 5

bar

s) w

ith c

orre

-sp

ondi

ng h

igh

ratin

gs fr

om 9

25,0

00 to

10,

700,

000

BTU

/hr.

FEA

TU

RE

S•

Sea

t lo

cate

d a

bov

e d

rain

; wat

er c

an’t

be

trap

ped

and

sed

imen

t ca

n’t

foul

sea

t.•

Non

-mec

hani

cal s

eat-

to-d

isc

alig

nmen

t w

ill n

otst

ick

or f

reez

e.•

Wat

er s

eal o

f hi

gh t

emp

erat

ure

resi

stin

g m

ater

ial i

sola

tes

sprin

g w

orki

ng p

arts

fro

m w

ater

dur

ing

relie

f.

SP

EC

IFIC

AT

ION

SB

oile

r R

elie

f V

alve

sA

n A

SM

E S

ectio

n IV

cer

tifie

d p

ress

ure

relie

f va

lve

shal

l be

inst

alle

d o

n ea

ch b

oile

r as

no

ted

. T

he v

alve

sha

ll ha

ve a

BTU

rat

ing

in e

xces

s of

the

BTU

rat

ing

of t

he b

oile

rs h

eat-

ing

out

put

. E

ach

hot

wat

er s

pac

e he

atin

g b

oile

r sh

all

be

equi

pp

ed w

ith a

pre

ssur

e re

lief

valv

e se

t to

rel

ieve

bel

ow

the

max

imum

boi

ler

wor

king

pre

ssur

e. T

he v

alve

sha

ll fe

a-tu

re a

rai

sed

sea

t an

d n

on-

mec

hani

cal

dis

c al

ignm

ent.

Wo

rkin

g p

arts

and

sp

ring

sha

ll b

e is

ola

ted

fro

m a

ny d

is-

char

ge b

y a

high

tem

per

atur

e re

sist

ant

mat

eria

l. V

alve

sha

llb

e a

Wat

ts 1

74A

or

740

Ser

ies.

ES

-174

A-7

40

OP

ER

AT

ION

As

ther

mal

exp

ansi

on

cond

itio

ns d

evel

op

, p

ress

ure

bui

lds

upto

the

set

ting

of t

he r

elie

f va

lve.

Thi

s w

ill c

ause

dis

char

ging

of

smal

l qua

ntity

of w

ater

.S

houl

d o

per

atin

g c

ont

rols

fai

l, p

erm

ittin

g r

unaw

ay f

irin

g,

the

bo

iler

wat

er m

ay r

each

ste

am t

emp

erat

ures

. T

he v

alve

will

then

op

en t

o d

isch

arg

e st

eam

at

the

rate

or

fast

er t

han

the

bo

iler

can

gen

erat

e it,

thu

s re

sto

ring

sys

tem

pre

ssur

e to

asa

fer

leve

l.Im

po

rtan

t: T

he d

isch

arg

e lin

e m

ust

be

the

sam

e si

ze a

s th

eva

lve

out

let,

and

mus

t p

itch

do

wnw

ard

fro

m t

he v

alve

to

asa

fe p

lace

for

dis

pos

al.

Val

ve le

ver

mus

t b

e tr

ipp

ed a

t le

ast

onc

e a

year

to

insu

re t

hat

wat

erw

ays

are

clea

r.

Thi

s d

evic

e is

des

igne

d f

or

emer

gen

cysa

fety

rel

ief

and

sha

ll no

t b

e us

ed a

s an

op

erat

ing

cont

rol.

Seri

es 1

74A

Seri

es 7

40

For

Hot

Wat

er B

oile

r A

pp

licat

ion

s

Job

Nam

eC

ontr

acto

r

Job

Loc

atio

nA

pp

rova

l

Eng

inee

rC

ontr

acto

r’s

P.O

. No.

Ap

pro

val

Rep

rese

ntat

ive

Wat

ts p

rod

uct

spec

ifica

tio

ns i

n U

.S.

cust

om

ary

unit

s an

d m

etri

car

e ap

pro

xim

ate

and

are

pro

vid

ed f

or

refe

renc

e o

nly.

Wat

ts r

e-se

rves

the

rig

ht t

o c

hang

e o

r m

od

ify p

rod

uct

des

ign,

co

nstr

uctio

n,sp

ecifi

catio

ns,

or

mat

eria

ls w

itho

ut p

rio

r no

tice

and

with

out

incu

r-ri

ng a

ny o

blig

atio

n to

mak

e su

ch c

hang

es a

nd m

od

ifica

tio

ns o

nW

atts

pro

duc

ts p

revi

ous

ly o

r su

bse

que

ntly

so

ld.

FIG

. 5-I

NS

ER

TIO

N IN

TO D

UC

T

�In

sert

bul

b an

d ho

lder

into

con

trol

led

area

thr

ough

ho

le p

repa

red

in S

tep

1 (F

ig.

5).

FIG

. 6-F

AS

TE

NIN

G H

OL

DE

R T

O D

UC

T W

AL

L.

�F

aste

n bu

lb h

olde

r to

duc

t w

all w

ith s

crew

s fu

rni

shed

, as

sho

wn

in F

ig.

6.

To In

stal

l AF

ast

Res

po

nse

Mo

del

Use

duc

t ho

lder

ass

embl

y fo

r th

e se

nsin

g co

il.

Dril

l a 1

-5/

8 in

ch h

ole

in t

he d

uct

wal

l to

rece

ive

the

who

le c

oil,

and

then

use

the

mou

ntin

g pr

oced

ure

for

the

stan

dard

mod

el.

WA

RN

ING

: D

o no

t st

retc

h th

e co

il m

ore

than

eigh

t in

ches

on

the

hold

er.

To In

stal

l Sen

sin

g B

ulb

In T

ank

Or

Bo

iler

The

bul

b m

ay b

e in

sert

ed d

irect

ly in

to a

tank

or

boile

rta

ppin

g by

mea

ns o

f a

pres

sure

fitt

ing,

or

the

bulb

may

be in

sert

ed in

to a

n im

mer

sion

wel

l tha

t is

scr

ewed

into

the

tank

or

boile

r.

FIG

. 7-P

RE

SS

UR

E F

ITT

ING

AS

SE

MB

LY.

To s

uppo

rt t

he b

ulb

in t

he d

uct,

use

bulb

hol

der

acce

s-so

ry (

see

Fig

. 2)

. FIG

. 2-B

UL

BH

OL

DE

R

�D

rill a

3/4

inch

hol

e in

the

duc

t w

all t

o ad

mit

the

sens

ing

bulb

and

hol

der.

�U

sing

the

hol

der

as a

tem

plat

e, m

ark

and

drill

ho

les

for

bulb

hol

der

mou

ntin

g sc

rew

s.

FIG

. 3-S

HO

RT

EN

ING

TH

E B

UL

B H

OL

DE

R.

�B

reak

off

bulb

hol

der

to d

esire

d le

ngth

, as

sho

wn

inF

ig.

3.

NO

TE

: H

olde

r sh

ould

be

long

eno

ugh

to

hold

sen

sing

bul

b in

fre

ely

circ

ulat

ing

air,

away

fr

om d

uct

wal

l. N

eatly

coi

l any

exc

ess

capi

llary

tu

bing

at

cont

rolle

r ca

se o

r at

bul

b ho

lder

.

FIG

. 4-I

NS

ER

TIN

G C

AP

ILL

AR

YT

UB

ING

IN

HO

LD

ER

�P

lace

cap

illar

y tu

bing

in b

ulb

hold

er c

hann

el,

and

pinc

h to

p ed

ges

of h

olde

r to

geth

er a

t ea

ch s

egm

ent,

assh

own

in F

ig.

4.CA

PIL

LAR

Y

TH

RE

AD

SE

NS

ING

CO

MP

OS

ITIO

NP

AC

KIN

G

PA

CK

ING

NU

T

SLO

TT

ED

WA

SH

ER

S

BO

ILE

R P

LUG

CO

NT

RO

LLE

DA

RE

AS

CR

EW

HO

LES

IN

DU

CT

WA

LL

BE

SU

RE

TH

IS T

UB

E I

S

T991

APr

opor

tiona

l Tem

pera

ture

Cont

rolle

rs

INS

TA

LL

AT

ION

IN

ST

RU

CT

ION

FE

AT

UR

ES

GE

NE

RA

L

T99

1AP

ropo

rtio

nal T

empe

ratu

re C

ontr

olle

rs p

rovi

dem

odul

atin

g co

ntro

l of

wat

er o

r ai

r te

mpe

ratu

res

in d

ucts

,ta

nks,

and

sim

ilar

appl

icat

ions

. S

tand

ard

mod

els

have

a se

nsin

g bu

lb a

nd c

apill

ary;

fas

t re

spon

se m

odel

sha

ve a

coi

led

sens

ing

elem

ent

that

ope

rate

s at

leas

tfo

ur t

imes

fas

ter

than

sta

ndar

d co

ntro

llers

, de

pend

ing

upon

ope

ratin

g co

nditi

ons.

• A

ll m

odel

s co

mpe

nsat

e fo

r ef

fect

s of

am

bien

tte

mpe

ratu

re o

n th

e ca

se a

nd t

ubin

g.

•

Con

trol

s te

mpe

ratu

re o

f ai

r or

liqu

id.

•

Sen

sing

ele

men

t ca

pilla

ry t

ubin

g al

low

s re

mot

e m

ount

ing

of s

ensi

ng e

lem

ent.

•

Set

poi

nt m

ay b

e re

ad a

nd a

djus

ted

thro

ugh

cove

r.

•

Thr

ottli

ng d

ial i

nsid

e ca

se a

djus

t pr

opor

tioni

ng

rang

e.

® U

.S. R

egis

tere

d T

rade

mar

kC

opyr

ight

© 1

996

Hon

eyw

ell I

nc.

•

All

Rig

hts

Res

erve

d

CA

UT

ION

Dis

conn

ect

pow

er s

uppl

y.

Inst

alla

tion

shou

ld b

e m

ade

only

by

a qu

alifi

ed s

ervi

ce-

man

. F

ollo

w in

stru

ctio

n of

sys

tem

man

ufac

ture

r, if

avai

labl

e.

LO

CA

TIO

N

The

T99

1Am

ay b

e m

ount

ed in

any

con

veni

ent

posi

tion

on a

fla

t su

rfac

e w

here

the

am

bien

t te

mpe

ratu

re d

oes

not

exce

ed 1

25ºF

. W

hen

mou

ntin

g on

a h

ot o

r co

ldsu

rfac

e, m

ount

the

cas

e on

a w

ood

boar

d or

oth

er in

su-

latin

g m

ater

ial.

The

cap

illia

ry t

ube

prov

ides

for

rem

ote

mou

ntin

g.

MO

UN

TIN

GO

n re

plac

emen

t ap

plic

atio

ns,

mou

nt t

he T

991A

in p

lace

of o

ld c

ontr

ol if

req

uire

men

ts u

nder

LO

CA

TIO

N a

bove

,ar

e m

et.

Mou

nt c

ase

acco

rdin

g to

inst

ruct

ions

bel

ow.

Use

old

sen

sing

bul

b ho

le,

bulb

hol

der,

imm

ersi

on w

ell,

or c

ompr

essi

on f

ittin

g if

thes

e ar

e su

itabl

e; o

ther

wis

e,fo

llow

the

inst

ruct

ions

bel

ow f

or n

ew a

pplic

atio

ns.

Mo

un

tin

g t

he

Co

ntr

olle

r C

ase

�R

emov

e co

ver.

Usi

ng t

he c

ase

as a

tem

plat

e,

mar

k th

ree

scre

w h

ole

loca

tions

on

mou

ntin

g su

rfa

ce,

then

pun

ch o

r dr

ill h

oles

.�

Fas

ten

T99

1Ase

cure

ly t

o m

ount

ing

surf

ace

with

th

e fu

rnis

hed

mou

ntin

g sc

rew

s.

To In

stal

l Sen

sin

g B

uld

in A

ir D

uct

Lo

cate

the

sen

sing

bul

b w

here

duc

t ai

r of

ave

rage

tem

-pe

ratu

re c

an c

ircul

ate

free

ly a

roun

d it.

Avo

id m

ount

ing

the

bulb

clo

se t

o ho

t pi

pes,

coo

ling

coils

, an

d ot

her

plac

es w

here

air

tem

pera

ture

s ar

e no

t re

pres

enta

tive.

AD

JUS

TM

EN

TS

AN

D C

HE

CK

OU

T

Tem

per

atu

re S

etti

ng

: Tu

rn k

nob

on f

ront

of

case

unt

ilpo

inte

r in

dica

tes

desi

red

set

poin

t te

mpe

ratu

re.

Thi

s is

the

cent

er p

oint

of

the

prop

ortio

nal r

ange

.

FIG

. 10-

PR

OP

OR

TIO

NIN

G R

AN

GE

AD

JUS

TM

EN

T

Ran

ge

Ad

just

men

t: T

he T

991A

may

be

adju

sted

to

vary

the

tem

pera

ture

ran

ge w

ithin

whi

ch p

ropo

rtio

nal

actio

n is

des

ired.

W

ith c

over

off,

tur

n ad

just

men

t w

heel

until

poi

nter

indi

cate

s de

sire

d ra

nge.

Exa

mpl

e:

If th

e te

mpe

ratu

re o

f th

e co

ntro

lled

med

ium

is t

o be

mai

ntai

ned

at 1

30ºF

, an

d pr

opor

tiona

l act

ion

from

125

ºF t

o 13

5ºF

( a

ran

ge o

f 10

deg

rees

) is

des

ired

- tu

rn t

he t

empe

ratu

re s

et p

oint

indi

cato

r to

130

ºF a

ndth

e pr

opor

tiona

l ran

ge a

djus

tmet

n w

heel

to

10.

CH

EC

KO

UT

Afte

r m

ount

ing

and

wiri

ng h

ave

been

com

plet

ed,

let

the

cont

rolle

d eq

uipm

ent

oper

ate

until

sys

tem

tem

pera

ture

stab

ilize

s (f

rom

1 t

o 3

hour

s).

Obs

erve

the

mot

or a

ctio

nto

see

if it

sta

biliz

es.

If

the

mot

or s

haft

cons

tant

lym

oves

bac

k an

d fo

rth,

wid

en t

he T

991A

prop

ortio

nal

rang

e (a

bout

fiv

e de

gree

s at

a t

ime)

unt

il th

e sy

stem

isst

able

.

To in

stal

l pre

ssu

re f

itti

ng

:�

Dra

in s

yste

m,

and

scre

w b

oile

r pl

ug in

to p

rope

rly

size

d an

d th

read

ed b

oile

r or

pip

e ta

ppin

g (1

/2-1

4 N

PT

).�

Pla

ce p

acki

ng n

ut o

n T

991A

capi

llary

tub

e.�

Slid

e se

nsin

g bu

lb c

ompl

etel

y th

roug

h bo

iler

plug

.�

Pla

ce c

ompo

sitio

n di

sc a

nd t

he f

our

slot

ted

bras

s w

ashe

rs o

n tu

bing

in t

he o

rder

sho

wn

in F

ig.

7.�

Slid

e th

e as

sem

bly

into

the

boi

ler

plug

, an

d tig

hten

the

pack

ing

nut.

�R

efill

the

sys

tem

and

che

ck f

or le

aks.

N

eatly

coi

l ex

cess

cap

illar

y tu

bing

at T

991A

case

.

FIG

. 8-I

MM

ER

SIO

N W

EL

LA

SS

EM

BLY

To in

stal

l im

mer

sio

n w

ell:

�D

rain

sys

tem

. S

crew

the

wel

l int

o pr

oper

ly s

ized

and

thre

aded

boi

ler

tapp

ing

or p

ipe

fittin

g.�

Ref

ill t

he s

yste

m a

nd c

heck

for

leak

s.�

Inse

rt s

ensi

ng b

ulb

into

wel

l unt

il it

botto

ms.

�F

it bu

lb r

etai

ning

cla

mp

over

imm

ersi

on w

ell f

lang

ean

d ca

pilla

ry t

ubin

g, a

nd t

ight

en s

crew

, as

sho

wn

in F

ig.

8.C

oil e

xces

s ca

pilla

ry t

ubin

g at

T99

1Aca

se.

WIR

ING

All

wiri

ng m

ust

com

ply

with

loca

l cod

es.

Two

knoc

kout

s ar

e pr

ovid

ed a

t to

p an

d bo

ttom

of

case

for

1/2

inch

con

duit.

F

ollo

w a

ny w

iring

inst

ruct

ions

fur

-ni

shed

with

hea

ting

or c

oolin

g sy

stem

. I

n re

plac

emen

tap

plic

atio

ns,

mak

e ce

rtai

n th

e T

991A

is w

ired

in t

hesy

stem

to

oper

ate

the

sam

e w

ay a

s ol

d co

ntro

l. F

ig.

9sh

ows

typi

cal w

iring

.

FIG

. 9-T

YP

ICA

LH

OO

KU

P

24 V

OLT

, 3-

WIR

EM

OT

OR

, V

ALV

E R

ELA

YT

991A

BU

LB R

ETA

ININ

G C

LIP

CA

PIL

LAR

YW

ELL

SP

UD

IMM

ER

SIO

N W

ELL

SE

TP

OIN

TA

DJU

ST

ME

NT

KN

OB

PR

OP

OR

TIO

NIN

G R

AN

GE

AD

JUS

TM

EN

TW

HE

EL

95-5

971—

22

L400

8A,B

,E,L

; L6

008A

,G,H

REM

OTE

BU

LB A

QU

AST

AT®

CO

NTR

OLL

ERS

The

Aqu

asta

t® c

ontr

olle

r ca

n be

rem

otel

y m

ount

ed—

eith

er v

ertic

ally

on

a w

all o

r pa

nel,

or d

irect

ly o

n th

e bo

iler,

tank

, or

vess

el.

If th

e sy

stem

is fi

lled,

dra

in th

e sy

stem

to a

poi

nt b

elow

the

boile

r ta

ppin

g, o

r to

whe

reve

r th

e se

nsin

g bu

lb is

to b

ein

stal

led.

Mou

ntin

g th

e Ca

se�

Rem

ove

the

cove

r an

d fa

sten

the

case

to th

e w

all o

rpa

nel u

sing

the

thre

e m

ount

ing

hole

s in

the

back

of

the

case

.�

Whe

n m

ount

ing

the

rem

ote

bulb

, if d

esira

ble,

rou

teth

e tu

bing

to r

un th

roug

h an

y of

the

othe

r th

ree

corn

er n

otch

es in

the

case

. Be

care

ful n

ot to

kin

k or

bend

tubi

ng s

harp

ly. B

e su

re b

ends

hav

e at

leas

t 1 in

.(2

5.4

mm

) rad

ius.

Inst

allin

g Re

mot

e Bu

lb w

ith Im

mer

sion

Wel

lF

it w

ell,

if us

ed, t

o se

nsin

g bu

lb s

nugl

y fo

r go

od th

erm

alre

spon

se. I

nser

t bul

b un

til it

res

ts a

gain

st th

e bo

ttom

of t

hew

ell;

then

hol

d it

ther

e w

hile

tigh

teni

ng th

e tu

bing

cla

mp.

�S

crew

the

wel

l int

o th

e bo

iler,

tank

or

pipe

tapp

ing.

�In

sert

the

bulb

into

the

wel

l, pu

shin

g th

e tu

bing

unt

ilth

e bu

lb b

otto

ms

in th

e w

ell.

�A

ttach

the

reta

iner

cla

mp

to th

e en

d of

the

wel

l spu

d.Lo

osen

the

draw

nut

and

spr

ead

the

jaw

s of

the

clam

p w

ith th

e sc

rew

driv

er if

nec

essa

ry.

�W

ith th

e re

tain

er c

lam

p at

tach

ed to

the

wel

l spu

d (b

esu

re ja

ws

of c

lam

p ho

ok o

ver r

idge

at e

nd o

f the

spud

, as

show

n in

Fig

. 2, p

oint

s A

). A

djus

t tub

ing

to fi

tth

roug

h re

tain

er c

lam

p gr

oove

, as

show

n at

poi

nt B

.�

Tig

hten

the

draw

nut

so

the

reta

iner

cla

mp

is fi

rmly

atta

ched

to th

e w

ell s

pud

and

the

tubi

ng is

hel

d by

the

clam

p.

Mou

ntin

g w

ith B

ulb

Com

pres

sion

Fitt

ing

�S

crew

the

fittin

g in

to th

e bo

iler

or p

ipe

tapp

ing.

�S

lide

seal

ing

was

her

onto

the

bulb

.�

Inse

rt th

e bu

lb in

to th

e fit

ting

until

bul

b bo

ttom

s.�

Slid

e sp

lit s

leev

e in

to fi

tting

.�

Pla

ce c

lam

ps A

and

B o

n as

sem

bly

so th

at s

leev

e is

draw

n in

to fi

tting

whe

n sc

rew

s ar

e tig

hten

ed.

NO

TE

:M

ake

sure

that

the

nub

on c

lam

p A

enga

ges

spac

e be

twee

n sl

eeve

and

cla

mp.

�T

ight

en c

lam

p sc

rew

s ev

enly

.

M87

77

WE

LLB

ULB

SP

UD

MO

UN

TIN

GC

LAM

P

A

DR

AW

N

UT

TU

BIN

G

B

INS

ER

T—

MO

UN

TIN

G C

LA

MP

SC

RE

WD

RIV

ER

SP

RE

AD

JA

WS

TO

FIT

OV

ER

RID

GE

ON

W

ELL

SP

UD

JAW

S

Fig

. 2.

Im

mer

sion

wel

l fit

ting.

IMP

OR

TA

NT

Do

not s

ecur

e dr

aw n

ut s

o tig

htly

that

reta

iner

clam

p co

uld

cut o

r col

laps

e tu

bing

.

M88

15

CLA

MP

B

CLA

MP

AC

LAM

P S

CR

EW

S (

2)

BU

LB

CO

MP

RE

SS

ION

F

ITT

ING

SE

ALI

NG

W

AS

HE

RBU

LB

INS

ER

TIO

N L

EN

GT

HA

PP

RO

X. 3

-3/1

6 IN

. (81

MM

)S

PLI

T S

LEE

VE Fig

. 3.

Bul

b co

mpr

essi

on f

ittin

g.

Mou

ntin

g w

ith C

apill

ary

Com

pres

sion

Fitti

ng�

Scr

ew fi

tting

into

the

boile

r or

pip

e ta

ppin

g.�

Pla

ce p

acki

ng n

ut o

n tu

bing

.�

Slid

e bu

lb c

ompl

etel

y th

roug

h fit

ting.

�P

lace

com

posi

tion

disc

and

4 s

lotte

d br

ass

was

hers

on tu

bing

in th

e or

der

show

n in

Fig

. 4. T

urn

bras

sw

ashe

rs s

o th

at s

lots

are

180

deg

rees

to e

ach

othe

r.�

Slid

e se

al a

ssem

bly

into

fitti

ng a

nd ti

ghte

n pa

ckin

g nu

t.

CO

MP

OS

ITIO

N D

ISK

(SLO

TT

ED

)

BO

ILE

R P

LUG

CA

PIL

LAR

Y T

UB

ING

EX

AM

PLE

OF

SLO

TT

ED

WA

SH

ER

S

AS

SE

MB

LED

IN

PA

IRS

:P

AC

KIN

G N

UT

M88

16

IMM

ER

SIO

NB

ULB

Fig

. 4.

Cap

illar

y co

mpr

essi

on f

ittin

g.

WIR

ING

All

wiri

ng m

ust a

gree

with

app

licab

le c

odes

and

ord

inan

ces

and

regu

latio

ns in

suc

h m

atte

rs a

s w

ire s

ize,

type

of

insu

latio

n, a

nd e

nclo

sure

. The

con

trol

lers

are

pro

vide

dw

ith c

ondu

it kn

ocko

uts

in th

e to

p an

d bo

ttom

of c

ase.

Ref

er to

Fig

. 5 o

r 6

for

a ty

pica

l con

nect

ion

diag

ram

.

X-X

X U

L

INST

ALLA

TIO

N IN

STRU

CTIO

NS

®U

.S. R

egis

tere

d T

rade

mar

kC

opyr

ight

© 1

995

Hon

eyw

ell I

nc.

• A

ll R

ight

s R

eser

vedL4

008A

,B,E

,L; L

6008

A,G,

HAq

uast

at® C

ontro

llers

APPL

ICAT

ION

The

se re

mot

e bu

lb (s

ee F

ig. 7

), im

mer

sion

type

(see

Fig

. 1)

cont

rolle

rs o

pera

te in

res

pons

e to

tem

pera

ture

cha

nges

inhy

dron

ic h

eatin

g sy

stem

s an

d ot

her

heat

ed li

quid

s.

Ele

ctric

al R

atin

gs:

Sw

itch

ratin

gs a

re s

how

n on

the

insi

de c

over

of e

ach

devi

ce. T

he e

lect

rical

requ

irem

ents

on

cont

rolle

d eq

uipm

ent

mus

t not

exc

eed

this

ratin

g.L4

008A

—br

eaks

the

burn

er c

ircui

t on

a ris

e in

wat

erte

mpe

ratu

re. I

t is

norm

ally

use

d as

a li

mit

cont

rolle

r.W

hen

used

as

an o

pera

ting

cont

rolle

r or

low

lim

it, a

sepa

rate

hig

h lim

it co

ntro

l mus

t be

used

.L4

008B

—m

akes

a c

ontr

ol c

ircui

t on

a ris

e in

wat

erte

mpe

ratu

re. I

t is

norm

ally

use

d as

a c

ircul

ator

cont

rolle

r to

pre

vent

circ

ulat

or o

pera

tion

until

boi

ler

wat

er te

mpe

ratu

re is

at o

r ab

ove

the

cont

rol s

ettin

g.L4

008E

—br

eaks

the

burn

er c

ircui

t and

lock

s ou

t on

aris

e in

wat

er te

mpe

ratu

re. I

t is

used

as

a hi

gh li

mit

cont

rolle

r w

here

man

ual r

eset

is d

esira

ble.

L400

8L—

is u

sed

as a

2-s

tage

Aqu

asta

t® c

ontr

olle

r.L6

008A

—m

akes

the

burn

er c

ircui

t on

a dr

op in

wat

erte

mpe

ratu

re. I

t is

norm

ally

use

d as

a c

ircul

ator

and

low

lim

it co

olin

g co

ntro

ller.

L600

8G—

is u

sed

as a

2-s

tage

Aqu

asta

t® c

ontr

olle

r to

cycl

e 2-

stag

e ga

s va

lve.

L600

8H—

is u

sed

as a

low

fire

Aqu

asta

t® c

ontr

olle

r.

If im

mer

sion

wel

l or

capi

llary

com

pres

sion

fitti

ng m

ust b

eor

dere

d, r

efer

to fo

rm 6

8-00

40, W

ells

and

Fitt

ings

for

Tem

pera

ture

Con

trol

lers

, for

par

t num

bers

and

ord

erin

gin

form

atio

n.

INST

ALLA

TIO

N

Whe

n In

stal

ling

this

Pro

duct

…1.

Rea

d th

ese

inst

ruct

ions

car

eful

ly. F

ailu

re to

follo

wth

em c

ould

dam

age

the

prod

uct o

r ca

use

a ha

zard

-ou

s co

nditi

on.

2.C

heck

the

ratin

gs g

iven

in th

e in

stru

ctio

ns a

nd o

nth

e pr

oduc

t to

mak

e su

re th

e pr

oduc

t is

suita

ble

for

your

app

licat

ion.

3.In

stal

ler

mus

t be

a tr

aine

d, e

xper

ienc

ed s

ervi

cete

chni

cian

.4.

Afte

r in

stal

latio

n is

com

plet

e, c

heck

out

pro

duct

oper

atio

n as

pro

vide

d in

thes

e in

stru

ctio

ns.

CA

UT

ION

Dis

conn

ect p

ower

sup

ply

befo

re in

stal

latio

n to

prev

ent e

lect

rical

sho

ck o

r eq

uipm

ent d

amag

e.

Dep

endi

ng o

n m

odel

and

inst

alla

tion

requ

irem

ents

, ins

tall

the

tem

pera

ture

sen

sing

bul

b ei

ther

in a

n im

mer

sion

wel

l(s

ee F

ig. 2

) th

at e

xten

ds in

to th

e bo

iler

or ta

nk, o

r di

rect

lyim

mer

se th

e te

mpe

ratu

re s

ensi

ng b

ulb

in th

e liq

uid.

For

inst

alla

tions

not

usi

ng a

wel

l, se

cure

the

bulb

with

a b

ulb

com

pres

sion

fitti

ng (s

ee F

ig. 3

), or

a c

apill

ary

com

pres

sion

fittin

g (s

ee F

ig. 4

). O

rder

the

wel

l or

the

fittin

g se

para

tely

.

The

boi

ler

man

ufac

ture

r ge

nera

lly p

rovi

des

a ta

ppin

g fo

rin

sert

ing

the

Aqu

asta

t® c

ontr

olle

r se

nsin

g el

emen

t. Lo

cate

this

tapp

ing

in a

rep

rese

ntat

ive

poin

t whe

re ty

pica

l wat

erte

mpe

ratu

re c

an b

e m

easu

red.

Nev

er lo

cate

the

bulb

or

prot

ectin

g im

mer

sion

wel

l clo

se to

a h

ot o

r co

ld w

ater

inle

tor

ste

am c

oil.

Inst

all t

he b

ulb

in th

e su

pply

line

of a

nin

dire

ct w

ater

hea

ter,

in th

e in

dire

ct w

ater

hea

ter

itsel

f, or

in th

e fe

ed r

iser

abo

ut 6

in. (

152

mm

) ab

ove

the

boile

r. If

the

riser

is v

alve

d, in

stal

l the

bul

b be

twee

n th

e bo

iler

and

the

valv

e.

95-5

971-

2

Fig

. 1.

Int

erna

l vi

ew.

M88

06

SE

TP

OIN

TIN

DIC

AT

ING

DIA

L

DIF

FE

RE

NT

IAL

AD

JUS

TM

EN

TW

HE

EL

AD

AP

TE

R C

LAM

PS

CR

EW

S

INS

ER

TIO

NE

LEM

EN

T

WIT

H V

ER

TIC

AL

MO

UN

TIN

G O

F IM

ME

RS

ION

WE

LL,

ELE

ME

NT

IS A

TT

AC

HE

D T

O B

OT

TO

M O

F T

HE

CA

SE

.

SE

LEC

T M

OD

ELS

HA

VE

SC

RE

W T

ER

MIN

AL,

NO

T T

AB

T

ER

MIN

AL.

1 2

2

1

95-5

971—

24

L400

8A,B

,E,L

; L6

008A

,G,H

REM

OTE

BU

LB A

QU

AST

AT®

CO

NTR

OLL

ERS

Hom

e an

d B

uild

ing

Con

trol

Hon

eyw

ell L

imite

d-H

oney

wel

l Lim

itée

740

Elle

smer

e R

oad

Scar

boro

ugh,

Ont

ario

M1P

2V

9

Hel

ping

You

Con

trol

You

r W

orld

95-5

971—

2 J

.H.

Rev

. 9-9

5 P

rinte

d in

U.S

.A

QU

AL

ITY

IS

KE

Y

Hom

e an

d B

uild

ing

Con

trol

Hon

eyw

ell I

nc.

1985

Dou

glas

Dri

ve N

orth

Gol

den

Val

ley,

MN

554

22

Adju

stin

g L6

008G

Inte

rsta

ge D

iffer

entia

lT

he L

6008

G C

ontr

olle

r ha

s an

adj

usta

ble

inte

rsta

gedi

ffere

ntia

l. T

he s

etpo

int a

djus

tmen

t kno

b de

term

ines

the

tem

pera

ture

at w

hich

the

right

sw

itch

oper

ates

. The

left

switc

h ca

n be

adj

uste

d to

ope

rate

from

3°

to 1

0°F

(1.

7° to

5.6°

C)

abov

e th

e po

int o

f ope

ratio

n of

the

right

sw

itch.

The

Inte

rsta

ge d

iffer

entia

l is

adju

sted

by

turn

ing

the

star

whe

elw

ith a

nar

row

scr

ewdr

iver

inse

rted

into

the

rect

angu

lar

hole

in th

e ch

assi

s. S

ee F

ig. 8

CHEC

KOUT

WA

RN

ING

CA

N C

AU

SE

PR

OP

ER

TY

DA

MA

GE

, SE

VE

RE

INJU

RY

OR

DE

AT

H.

Thi

s pr

oduc

t is

inte

nded

for

use

only

in s

yste

ms

with

a p

ress

ure

relie

f val

ve.

Che

ck to

be

sure

the

Aqu

asta

t® c

ontr

olle

r is

pro

perly

inst

alle

d an

d ad

just

ed. P

ut th

e sy

stem

into

ope

ratio

n an

dob

serv

e th

e ac

tion

of th

e co

ntro

l thr

ough

sev

eral

cyc

les

tom

ake

sure

that

it p

rovi

des

prop

er c

ontr

ol o

f the

sys

tem

as

desc

ribed

in th

e O

pera

tion

sect

ion.

Mak

e an

y ad

ditio

nal

adju

stm

ents

nec

essa

ry to

ass

ure

com

fort

req

uire

men

ts.

M89

72

RIG

HT

SW

ITC

H

LEF

T S

WIT

CH

ST

AR

WH

EE

L (I

NT

ER

ST

AG

ED

IFF

ER

EN

TIA

L A

DJU

ST

ME

NT

)

1

1

SE

LEC

T M

OD

ELS

HA

VE

FO

UR

TE

RM

INA

LS.

Fig

. 8.

Int

erst

age

diffe

rent

ial

adju

stm

ent

on a

n L4

008L

or L

6008

G.

95-5

971—

23

L400

8A,B

,E,L

; L6

008A

,G,H

REM

OTE

BU

LB A

QU

AST

AT®

CO

NTR

OLL

ERS

L1

(HO

T)

L2 1

1 2

2

PO

WE

R S

UP

PLY

. PR

OV

IDE

DIS

CO

NN

EC

T M

EA

NS

AN

D

OV

ER

LOA

D P

RO

TE

CT

ION

AS

RE

QU

IRE

D.

SE

LEC

T M

OD

ELS

HA

VE

1/4

IN. T

AB

TE

RM

INA

L F

OR

WT

ER

MIN

AL.

L400

8A O

R E

HIG

H L

IMIT

C

ON

TR

OLL

ER

L600

8AC

IRC

ULA

TO

RLO

W L

IMIT

C

ON

TR

OLL

ERR

WB

CIR

CU

LAT

OR

IGN

ITIO

NT

RA

NS

FO

RM

ER

RA

89A

RE

LAY

RA

817A

PR

OT

EC

TO

RE

LAY

®C

ON

TR

OLB

UR

NE

R M

OT

OR

24V

TH

ER

MO

ST

AT

21

34

TT

1 2

3 4

M87

85

Fig

. 5.

Typ

ical

oil-

fired

hyd

roni

c he

atin

g sy

stem

with

dom

estic

hot

wat

er.

SETT

ING

Con

trol

Poi

nt:

Inse

rt a

scr

ewdr

iver

in th

e sl

otte

d he

ad v

isib

le th

roug

h th

eco

ver,

and

turn

the

indi

catin

g di

al to

the

cont

rol p

oint

.T

empe

ratu

re s

ettin

gs s

houl

d be

acc

ordi

ng to

boi

ler

man

ufac

ture

r’s r

ecom

men

datio

ns.

Diff

eren

tial

(on

adju

stab

le d

iffer

entia

l m

odel

s):

Rem

ove

cove

r an

d m

ove

the

diffe

rent

ial a

djus

tmen

t whe

el(F

ig. 1

or

7) to

a p

oint

on

the

scal

e co

rres

pond

ing

to th

ede

sire

d di

ffere

ntia

l. R

epla

ce c

over

.

Man

ual

Res

et (

L400

8E):

Afte

r bo

iler

wat

er te

mpe

ratu

re h

as d

ropp

ed to

a p

oint

belo

w th

e hi

gh li

mit

setti

ng, l

ess

diffe

rent

ial,

the

rese

tbu

tton

at th

e fr

ont o

f the

cas

e m

ust b

e pu

shed

bef

ore

the

burn

er c

an o

pera

te.

ADJU

STM

ENTS

Adju

stin

g Di

ffere

ntia

lS

et th

e di

ffere

ntia

l to

corr

espo

nd w

ith th

e bo

iler m

anuf

actu

rer

reco

mm

enda

tions

. To

adju

st m

odel

s w

ith a

djus

tabl

edi

ffere

ntia

l, ro

tate

the

whe

el o

n th

e ba

ck o

f the

sna

psw

itch,

see

Fig

. 7, u

ntil

the

desi

red

read

ing

is a

ligne

d w

ithth

e V

not

ch in

the

fram

e. T

he w

heel

pro

vide

s as

adj

ustm

ent

from

5°

to 3

0°F

(3°

to 1

7°C

). R

epla

ce th

e co

ver

on th

eA

quas

tat®

con

trol

ler.

L1

(HO

T)

L2

1

1P

OW

ER

SU

PP

LY. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D

PR

OT

EC

TIO

N A

S R

EQ

UIR

ED

.

JUM

PE

R

M89

68

HE

AT

ING

LO

AD

NO

. 2

HE

AT

ING

LO

AD

NO

. 1

RR

BB

WW

21

L600

8G

Fig

. 6.

Typ

ical

oil

burn

er i

nsta

llatio

n us

ing

L400

8Lor

L60

08G

.

L1

(HO

T)

L2

1

1P

OW

ER

SU

PP

LY. P

RO

VID

E D

ISC

ON

NE

CT

ME

AN

S A

ND

OV

ER

LOA

D

PR

OT

EC

TIO

N A

S R

EQ

UIR

ED

.

L400

8L

HL

TE

MP

RA

890F

65

T

4T

3

F1 2

2G NC

NO

CO

M

PIL

OT

VA

LVE

IGN

ITIO

N

MA

INV

ALV

E(S

)

M46

72

M89

69

DIF

FE

RE

NT

IAL

WH

EE

L

NO

TC

H IN

FR

AM

E

SN

AP

SW

ITC

H

SE

LEC

T M

OD

ELS

HA

VE

A S

CR

EW

TE

RM

INA

L IN

ST

EA

D

OF

TA

B T

ER

MIN

AL.

1

1

Fig

. 7.

Adj

ustin

g th

e di

ffere

ntia

l.

Adj

ust t

he c

ontr

ol p

oint

to c

orre

spon

d w

ith th

e bo

iler

man

ufac

ture

r re

com

men

datio

ns. T

o ad

just

, ins

ert a

scre

wdr

iver

in th

e sl

otte

d sc

rew

type

hea

d lo

cate

d be

neat

hth

e w

indo

w in

the

cove

r. T

urn

the

scal

e to

the

desi

red

cont

rol p

oint

.

Sp

ecif

icat

ion

sC

on

tro

l D

esig

n:

Op

en

cir

cuit

bo

ard

de

sig

nC

on

tact

Des

ign

: S

PD

T (

1 f

orm

C):

on

e n

orm

ally

op

en

(N

.O.)

an

d o

ne

no

rma

lly c

lose

d (

N.C

.),

no

n-p

ow

ere

d c

on

tact

s.C

on

tact

Rat

ing

s:

10

A @

12

0 o

r 2

40

VA

C r

esi

stiv

e (

12

0°F

), 1

A @

12

0,

24

0 V

AC

re

sist

ive

(1

50

°F),

1/3

H.P

. @

12

0,

24

0 V

AC

(12

0°F

)C

on

tact

Lif

e:

Me

cha

nic

al:

5 m

illio

n o

pe

ratio

ns.

Ele

ctri

cal:

10

0,0

00

op

era

tion

s m

inim

um

at

rate

d l

oa

d.

Su

pp

ly V

olt

age:

12

0,

24

0 o

r 2

4 V

AC

mo

de

ls:

+1

0%

- 1

5%

, 5

0/6

0 H

z.

20

8/2

40

Mo

de

l: 1

87

Vm

in t

o 2

55

Vm

ax.

V

AC

50

/60

Hz

Su

pp

ly C

urr

ent:

Re

lay

en

erg

ize

d 4

.4 V

A.

Sec

on

dar

y C

ircu

it:

12

VA

C R

MS

vo

ltag

e o

n p

rob

es,

1.5

mill

i-a

mp

cu

rre

nt.

Sen

siti

vity

: M

od

els

op

era

te f

rom

4.7

K t

o 2

6K

ma

xim

um

spe

cific

re

sist

an

ceTe

mp

erat

ure

: -4

0 t

o 1

50

° F.

am

bie

nt.

Term

inal

s: P

rob

e c

on

ne

ctio

ns

3/1

6”

spa

de

: L

ine

an

d p

ow

er

con

ne

ctio

ns

1/4

” sp

ace

Tim

e D

elay

s: S

tan

da

rd -

LL

CO

pro

be

, 3

se

con

ds

on

low

eri

ng

leve

lL

isti

ng

: U

L li

mit

con

tro

l re

cog

niti

on

(3

53

).

24

0 a

nd

20

8/2

40

volt

un

its a

re n

ot

U.L

. lim

it co

ntr

ol r

eco

gn

ize

d.

Inst

alla

tio

n1

. D

rill

thre

e .

18

7 d

ia.

ho

les

in c

ust

om

er

sup

plie

d b

ack

pla

teu

sin

g s

tick

on

te

mp

late

su

pp

lied

with

co

ntr

ol.

Sta

nd

ard

sta

nd

off

s a

re d

esi

gn

ed

fo

r b

ack

pla

te t

hic

kne

ss o

f .0

62

(1

/16

”).

Sta

nd

off

s a

re a

vaila

ble

fo

r b

ack

pla

tes

of

.12

5 (

1/8

”) n

om

ina

lth

ickn

ess

. If

re

tro

fit p

late

sta

nd

off

s a

re u

sed

, d

rill

thre

e .

25

0d

ia.

ho

les

in p

rop

er

loca

tion

.2

. I

nst

all

thre

e s

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ifi ca

tions

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mp

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stiv

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353

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arm

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licat

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rmat

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s no

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rder

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ract

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char

t bel

ow to

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stru

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e.

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t doe

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ry U

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imit

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rol r

ecog

nitio

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to O

rder

Use

the

Bold

cha

ract

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from

the

char

t bel

ow to

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stru

ct a

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duct

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licat

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TO

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or

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NU

AL

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SE

T (

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ele

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de

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e s

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a p

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X X

X –

X –

XX

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Tim

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age:

1

- 1

20

VA

C,

2-

24

0 V

AC

,3

- 2

4 V

AC

, *8

= 2

08

/24

0 V

AC

Sen

siti

vity

: A

- 4

.7K

, B

- 1

0K

, C

- 2

6K

* 1

87

Vm

in t

o 2

55

Vm

ax

VA

C

A.C

. Sup

ply

If m

etal

lic, t

ank

may

be

used

inst

ead

of r

efer

ence

pro

be

Low

Lev

el C

ut-0

ff P

robe

Ref

eren

ce P

robe

L1L2

G

Res

et

LLC

O

NO

NC C

Res

et B

utto

nO

ptio

nal Ge

ms

Se

nso

rs I

nc.

On

e C

ow

les

Ro

ad

Pla

invi

lle,

CT

0

60

62

-11

98

Tel:

8

60

-79

3-4

57

9F

ax:

8

60

-79

3-4

58

0

Op

tio

nal

Ch

arac

ter

Ch

art

N.C

.P

ush

bu

tto

n

C E F N P R

X X X

Po

we

rO

uta

ge

X X X X

Re

tro

fitP

late X X X

Op

erat

ion

Op

erat

ion

Op

erat

ion

Op

erat

ion

Op

erat

ion

Op

tio

nal

Op

tio

nal

Op

tio

nal

Op

tio

nal

Op

tio

nal

DIR

EC

T M

OD

E B

OT

H F

UN

CT

ION

SD

IRE

CT

MO

DE

BO

TH

FU

NC

TIO

NS

DIR

EC

T M

OD

E B

OT

H F

UN

CT

ION

SD

IRE

CT

MO

DE

BO

TH

FU

NC

TIO

NS

DIR

EC

T M

OD

E B

OT

H F

UN

CT

ION

SL

LC

O F

un

ctio

nL

LC

O F

un

ctio

nL

LC

O F

un

ctio

nL

LC

O F

un

ctio

nL

LC

O F

un

ctio

n:::: :

Whe

n th

e liq

uid

rises

to th

e el

ectr

ode

on te

rmin

al L

LCO

, the

rel

ayas

soci

ated

with

ter

min

al L

LCO

ene

rgiz

es,

chan

ging

sta

te o

f th

e lo

ad c

onta

cts.

(L

ED

will

be

lit).

T

he r

elay

rem

ains

ene

rgiz

ed u

ntil

the

liqui

d le

vel r

eced

es b

elow

ele

ctro

deon

term

inal

LLC

O.

The

ass

ocia

ted

rela

y th

en d

e-en

ergi

zes,

(LE

D w

ill n

ot b

e lit

)re

turn

ing

load

con

tact

s to

orig

inal

sta

te.

Unl

ess

othe

rwis

e sp

ecifi

ed,

ther

e is

a t

hree

-se

cond

tim

e de

lay

on d

ecre

asin

g le

vel.

Liq

uid

mus

t be

belo

w p

robe

on

term

inal

LLC

Ofo

r fu

ll th

ree

seco

nds

befo

re c

ontr

ol d

e-en

ergi

zes.

H-L

Fu

nct

ion

H-L

Fu

nct

ion

H-L

Fu

nct

ion

H-L

Fu

nct

ion

H-L

Fu

nct

ion

:::: : W

hen

the

liqui

d ris

es t

o th

e el

ectr

ode

on t

erm

inal

H,

the

asso

ciat

edre

lay

ener

gize

s, c

hang

ing

the

stat

e of

the

load

con

tact

s.

(LE

D w

ill b

e lit

).

The

rel

ayre

mai

ns e

nerg

ized

unt

il th

e liq

uid

leve

l rec

edes

bel

ow e

lect

rode

on

term

inal

L.

The

asso

ciat

ed r

elay

then

de-

ener

gize

s, (

LED

will

not

be

lit)

retu

rnin

g lo

ad c

onta

cts

toor

igin

al s

tate

. U

nles

s ot

herw

ise

spec

ified

, the

re is

a o

ne h

alf s

econ

d tim

e de

lay

onin

crea

sing

leve

l. L

iqui

d m

ust b

e in

con

tact

with

pro

be o

n te

rmin

al H

for

a fu

ll ha

lfse

cond

bef

ore

cont

rol e

nerg

izes

. T

his

func

tion

can

be w

ired

for

sing

le le

vel s

ervi

ce b

yus

ing

only

the

H te

rmin

al.

TTTT Tim

e D

elay

im

e D

elay

im

e D

elay

im

e D

elay

im

e D

elay

(D

ecre

asin

g Le

vel)

LLC

O le

vel

func

tion

3 se

c st

anda

rd,

6 se

c av

aila

ble.

TTTT Tim

e D

elay

ime

Del

ayim

e D

elay

ime

Del

ayim

e D

elay

(D

ecre

asin

g Le

vel)

H -

L f

unct

ion

1-20

sec

.TTTT T

ime

Del

ayim

e D

elay

ime

Del

ayim

e D

elay

ime

Del

ay (

Incr

easi

ng L

evel

) H

- L

fun

ctio

n1-

20 s

ecO

pti

on

al C

har

acte

rO

pti

on

al C

har

acte

rO

pti

on

al C

har

acte

rO

pti

on

al C

har

acte

rO

pti

on

al C

har

acte

r:

See

cha

rtE

ncl

osu

reE

ncl

osu

reE

ncl

osu

reE

ncl

osu

reE

ncl

osu

re:

0 0 0 0 0-

none

, 1111 1-

NE

MA

1,

4 4 4 4 4-

NE

MA

4,

7777 7- N

EM

A 7

, 12121

212 12

- N

EM

A 1

2S

tan

do

ff S

tyle

:S

tan

do

ff S

tyle

:S

tan

do

ff S

tyle

:S

tan

do

ff S

tyle

:S

tan

do

ff S

tyle

: AAAA A

- 1/

16"

pane

l, BBBB B

- 1/

8"pa

nel,

C C C C C-

scre

w m

ount

, DDDD D

- re

trof

itS

up

ply

VS

up

ply

VS

up

ply

VS

up

ply

VS

up

ply

Vo

ltag

e:o

ltag

e:o

ltag

e:o

ltag

e:o

ltag

e:

1- 1

20 V

AC

, 2-

240

VA

C,

3- 2

4 V

AC

, 8-

208

/240

VA

CM

od

e/S

ensi

tivi

ty:

Mo

de/

Sen

siti

vity

:M

od

e/S

ensi

tivi

ty:

Mo

de/

Sen

siti

vity

:M

od

e/S

ensi

tivi

ty:

H/L

, LL

CO

Dir

ect

A A A A A-

4.7K

, BBBB B

- 10

K,

CCCC C-

26K

----

H

/L,

Inve

rse

KKKK K-

4.7K

, L L L L L

- 10

K,

MMMM M-

26K

DF

XX

XX

X X

X X

X X

XD

FX

XX

XX

XX

XX

XX

DF

XX

XX

X X

X X

X X

XD

FX

XX

XX

XX

XX

XX

DF

XX

XX

X X

X X

X X

X

Op

tio

nal

Man

ual

Res

etO

pti

on

al M

anu

al R

eset

Op

tio

nal

Man

ual

Res

etO

pti

on

al M

anu

al R

eset

Op

tio

nal

Man

ual

Res

et (

Nor

mal

ly c

lose

d pu

shbu

tton

acro

ssre

set

term

inal

s.

Pus

hbut

ton

orde

red

sepa

rate

ly):

M

anua

l res

eton

ly a

pplie

s to

the

fun

ctio

n as

soci

ated

with

ter

min

al L

LCO

.W

hen

the

liqui

d ris

es t

o th

e el

ectr

ode

on t

erm

inal

LLC

O,

the

cont

rol w

ill r

emai

n de

-ene

rgiz

ed (

load

con

tact

s in

orig

inal

sta

te)

until

the

push

butto

n is

dep

ress

ed.

The

con

trol

will

then

ener

gize

, (LE

D w

ill b

e lit

) ch

angi

ng th

e st

ate

of th

e co

ntac

ts.

The

con

trol

rem

ains

ene

rgiz

ed u

ntil

the

liqui

d le

vel r

eced

esbe

low

ele

ctro

de o

n te

rmin

al L

LCO

. T

he c

ontr

ol th

en d

e-en

ergi

zes,

(LE

D w

ill g

o of

f) r

etur

ning

load

con

tact

s to

thei

ror

igin

al s

tate

. U

nles

s ot

herw

ise

spec

ified

, the

re is

a th

ree

seco

nd ti

me

dela

y on

dec

reas

ing

leve

l. L

iqui

d m

ust b

e be

low

prob

e on

term

inal

LLC

O fo

r fu

ll th

ree

seco

nds

befo

re c

ontr

ol d

e-en

ergi

zes.

Man

ual

Res

et w

ith

op

tio

nal

Po

wer

Ou

tag

e F

eatu

re:

Man

ual

Res

et w

ith

op

tio

nal

Po

wer

Ou

tag

e F

eatu

re:

Man

ual

Res

et w

ith

op

tio

nal

Po

wer

Ou

tag

e F

eatu

re:

Man

ual

Res

et w

ith

op

tio

nal

Po

wer

Ou

tag

e F

eatu

re:

Man

ual

Res

et w

ith

op

tio

nal

Po

wer

Ou

tag

e F

eatu

re:

Res

et(N

orm

ally

clo

sed

push

butto

n ac

ross

res

et t

erm

inal

s.P

ushb

utto

n or

dere

d se

para

tely

) C

ontr

ol w

ill ig

nore

pow

er lo

ss to

cont

rol.

With

liqu

id in

con

tact

with

ele

ctro

de o

n te

rmin

al L

LCO

,a

pow

er o

utag

e of

less

than

250

m s

ec. W

ill c

ause

the

cont

rol t

ode

-ene

rgiz

e, b

ut w

ill a

utom

atic

ally

ene

rgiz

e up

on r

etur

n of

pow

er.

How

ever

, los

s of

liqu

id w

ill c

ause

con

trol

to d

e-en

ergi

zean

d re

mai

n so

unt

il liq

uid

agai

n ris

es to

ele

ctro

de a

ndpu

shbu

tton

is d

epre

ssed

.TTTT T

ime

Del

ays

asso

ciat

ed w

ith

ter

min

als

H a

nd

Lim

e D

elay

s as

soci

ated

wit

h t

erm

inal

s H

an

d L

ime

Del

ays

asso

ciat

ed w

ith

ter

min

als

H a

nd

Lim

e D

elay

s as

soci

ated

wit

h t

erm

inal

s H

an

d L

ime

Del

ays

asso

ciat

ed w

ith

ter

min

als

H a

nd

L :

:

:

:

:

W

ith t

ime

dela

y on

incr

easi

ng le

vel,

the

liqui

d m

ust b

e in

con

tact

with

the

high

ele

ctro

de fo

r th

e fu

ll du

ratio

n of

the

time

dela

y be

fore

cont

rol w

ill o

pera

te.

With

del

ay o

n de

crea

sing

leve

l, th

e liq

uid

mus

t be

belo

w th

e lo

w e

lect

rode

for

the

full

dura

tion

of th

e tim

ede

lay

befo

re c

ontr

ol w

ill o

pera

te.

In s

ingl

e le

vel s

ervi

ce,

term

inal

s 3

and

4 m

ust

be ju

mpe

red

toge

ther

to

achi

eve

time

dela

ys o

n bo

th in

crea

sing

and

dec

reas

ing

leve

ls o

r ju

stde

crea

sing

leve

l.TTTT T

ime

Del

ays

asso

ciat

ed w

ith

ter

min

al L

LC

Oim

e D

elay

s as

soci

ated

wit

h t

erm

inal

LL

CO

ime

Del

ays

asso

ciat

ed w

ith

ter

min

al L

LC

Oim

e D

elay

s as

soci

ated

wit

h t

erm

inal

LL

CO

ime

Del

ays

asso

ciat

ed w

ith

ter

min

al L

LC

O:::: :

3 S

econ

d tim

ede

lay

on d

ecre

asin

g le

vel i

s st

anda

rd.

A 6

sec

ond

time

dela

yca

n be

spe

cifie

d an

d w

ould

act

in th

e sa

me

man

ner

as li

sted

abov

e.

INV

ER

SE

MO

DE

INV

ER

SE

MO

DE

INV

ER

SE

MO

DE

INV

ER

SE

MO

DE

INV

ER

SE

MO

DE

LL

CO

Fu

nct

ion

LL

CO

Fu

nct

ion

LL

CO

Fu

nct

ion

LL

CO

Fu

nct

ion

LL

CO

Fu

nct

ion

:::: : L

LCO

alw

ays

func

tions

in d

irect

mod

e on

ly s

ee a

bove

for

oper

atio

n.H

-LH

-LH

-LH

-LH

-L F

un

ctio

n F

un

ctio

n F

un

ctio

n F

un

ctio

n F

un

ctio

n:::: :

Ass

ocia

ted

rela

y en

ergi

zes

with

pow

er, (

LED

will

be

lit)

chan

ging

the

stat

e of

the

load

con

tact

s.

Whe

n th

e liq

uid

rises

to

the

elec

trod

eon

term

inal

H, t

he r

elay

de-

ener

gize

s, r

etur

ning

load

con

tact

s to

shel

f sta

te.

(LE

D w

ill n

ot b

e lit

).

The

ass

ocia

ted

rela

y re

mai

nsde

-ene

rgiz

ed u

ntil

the

liqui

d le

vel r

eced

es b

elow

ele

ctro

de o

nte

rmin

al L

. T

he r

elay

then

ene

rgiz

es.

x x x x x x x x

D G J K L R S T W

Res

etR

eset

Res

etR

eset

Res

etF

un

ctio

nF

un

ctio

nF

un

ctio

nF

un

ctio

nF

un

ctio

n

x x x x

N.C

.N

.C.

N.C

.N

.C.

N.C

.P

ush

bu

tto

nP

ush

bu

tto

nP

ush

bu

tto

nP

ush

bu

tto

nP

ush

bu

tto

n

x x x x

Po

wer

Po

wer

Po

wer

Po

wer

Po

wer

Ou

tag

eO

uta

ge

Ou

tag

eO

uta

ge

Ou

tag

e

x x x x x

Ret

rofi

tR

etro

fit

Ret

rofi

tR

etro

fit

Ret

rofi

tP

late

Pla

teP

late

Pla

teP

late

Op

tio

nal

Ch

arac

ter

Ch

art

Op

tio

nal

Ch

arac

ter

Ch

art

Op

tio

nal

Ch

arac

ter

Ch

art

Op

tio

nal

Ch

arac

ter

Ch

art

Op

tio

nal

Ch

arac

ter

Ch

art

WWWW Wir

ing

Dia

gra

mir

ing

Dia

gra

mir

ing

Dia

gra

mir

ing

Dia

gra

mir

ing

Dia

gra

m

Gem

s S

enso

rs I

nc.

On

e C

ow

les

Ro

ad

Pla

invi

lle,

CT

0

60

62

-11

98

Tel:

86

0-79

3-45

79F

ax:

8

60

-79

3-4

58

0

Sp

ecif

icat

ion

sS

pec

ific

atio

ns

Sp

ecif

icat

ion

sS

pec

ific

atio

ns

Sp

ecif

icat

ion

sC

on

tro

l Des

ign

:C

on

tro

l Des

ign

:C

on

tro

l Des

ign

:C

on

tro

l Des

ign

:C

on

tro

l Des

ign

: O

pen

circ

uit

boar

d de

sign

Co

nta

ct D

esig

n:

Co

nta

ct D

esig

n:

Co

nta

ct D

esig

n:

Co

nta

ct D

esig

n:

Co

nta

ct D

esig

n:

SP

DT

(1

form

C):

one

nor

mal

lyop

en (

N.O

.) a

nd o

ne n

orm

ally

clo

sed

(N.C

.),

non

pow

ered

con

tact

s fo

r lim

it co

ntro

l and

SP

DT

(1 f

orm

C):

one

nor

mal

ly o

pen

(N.O

.) a

nd o

neno

rmal

ly c

lose

d (N

.C.)

, non

pow

ered

con

tact

s fo

rle

vel c

ontr

olC

on

tact

Rat

ing

s:C

on

tact

Rat

ing

s:C

on

tact

Rat

ing

s:C

on

tact

Rat

ing

s:C

on

tact

Rat

ing

s: 1

0A @

120

, 208

/240

, 240

VA

Cre

sist

ive

(120

°F),

1A

@ 1

20,

208/

240,

240

resi

s-tiv

e (1

50°F

), 1

/3 H

p @

120

, 208

/240

, 240

VA

CC

on

tact

Lif

e:C

on

tact

Lif

e:C

on

tact

Lif

e:C

on

tact

Lif

e:C

on

tact

Lif

e: M

echa

nica

l - 5

mill

ion

oper

atio

nsE

lect

rica

l - 1

00,0

00 o

pera

tions

min

imum

at

rate

dlo

adS

up

ply

VS

up

ply

VS

up

ply

VS

up

ply

VS

up

ply

Vo

ltag

e:o

ltag

e:o

ltag

e:o

ltag

e:o

ltag

e:

120,

240

, or

24

VA

C m

odel

s,+

10%

, -15

%, 5

0/60

Hz.

208

/240

Mod

el:

187V

Min

to 2

55V

Max

, VA

C 5

0/60

Hz

Po

wer

Co

nsu

mp

tio

n:

Po

wer

Co

nsu

mp

tio

n:

Po

wer

Co

nsu

mp

tio

n:

Po

wer

Co

nsu

mp

tio

n:

Po

wer

Co

nsu

mp

tio

n:

120

, 20

8/24

0, 2

40,

or 2

4V

AC

bot

h re

lays

ene

rgiz

ed -

4.4

VA

.S

eco

nd

ary

Cir

cuit

:S

eco

nd

ary

Cir

cuit

:S

eco

nd

ary

Cir

cuit

:S

eco

nd

ary

Cir

cuit

:S

eco

nd

ary

Cir

cuit

: 1

2 V

AC

RM

S v

olta

ge

on

prob

es, 1

.5 m

illi-

amp

curr

ent.

Sen

siti

vity

:S

ensi

tivi

ty:

Sen

siti

vity

:S

ensi

tivi

ty:

Sen

siti

vity

: M

odel

s op

erat

e fr

om 0

-26K

ohm

sm

axim

um s

peci

fic r

esis

tanc

e (f

acto

ry s

et)

TTTT T em

per

atu

re:

emp

erat

ure

:em

per

atu

re:

emp

erat

ure

:em

per

atu

re:

-40

° to

150

° F

am

bien

tTTTT T e

rmin

als:

erm

inal

s:er

min

als:

erm

inal

s:er

min

als:

P

robe

con

nect

ions

3/1

6" m

ale

quic

kco

nnec

ts,

Line

and

Pow

er c

onne

ctio

ns 1

/4"

mal

equ

ick

conn

ects

TTTT Tim

e D

elay

s:im

e D

elay

s:im

e D

elay

s:im

e D

elay

s:im

e D

elay

s: S

tand

ard,

0.5

sec

onds

ris

ing

leve

l,LL

CO

pro

be, 3

sec

onds

low

erin

g le

vel.

Lis

tin

gs:

Lis

tin

gs:

Lis

tin

gs:

Lis

tin

gs:

Lis

tin

gs:

E

ntir

e co

ntro

l ca

rrie

s U

.L.

mot

or c

on-

trol

ler

reco

gniti

on (

UL

508)

and

U.L

. Lim

it co

ntro

lre

cogn

ition

(U

L 35

3).

208/

240

and

240

VA

C m

od-

els

carr

y on

ly m

otor

con

trol

ler r

ecog

nitio

n (U

L 50

8)

Inst

alla

tio

nIn

stal

lati

on

Inst

alla

tio

nIn

stal

lati

on

Inst

alla

tio

n1.

Dril

l fiv

e .1

87 h

oles

in c

usto

mer

sup

plie

d ba

ckpl

ate

usin

g st

ick

on te

mpl

ate

supp

lied

with

con

-tr

ol.

Sta

ndar

d st

ando

ffs a

re d

esig

ned

for

back

plat

e th

ickn

ess

of 0

.062

(1/

16")

. S

tand

offs

are

avai

labl

e fo

r bac

k pl

ates

of 0

.125

(1/8

") n

omin

alth

ickn

ess.

If

retr

ofit

plat

e st

ando

ffs a

re u

sed,

drill

5 (f

ive)

0.2

50 d

ia. H

oles

in p

rope

r loc

atio

ns.

2.In

stal

l fiv

e st

ando

ffs in

to b

ack

plat

e. I

nsta

ll tw

osu

ppor

t st

ando

ffs in

to c

ircui

t bo

ard.

S

nap

cir-

cuit

boar

d on

to s

tand

offs

. S

ee s

ketc

h fo

r pro

per

inst

alla

tion.

Ins

tall

cont

rol i

n an

app

ropr

iate

en-

clos

ure.

3.

Wire

con

trol

per

wiri

ng d

iagr

am, f

ollo

win

g

N

.E.C

. and

loca

l cod

es.

Use

app

ropr

iate

ly

si

zed

spad

e te

rmin

als.

Thi

s bu

lletin

sho

uld

be u

sed

by e

xper

ienc

ed p

erso

nnel

as

a gu

ide

to th

e in

stal

latio

n of

Dua

l Fun

ctio

n C

ontr

ols.

Sel

ectio

n or

inst

alla

tion

of e

quip

men

t sho

uld

alw

ays

be a

ccom

pani

ed b

y co

mpe

tent

tech

nica

l ass

ista

nce.

We

enco

urag

e yo

u to

con

tact

Gem

s S

enso

rs o

r its

rep

rese

ntat

ive

if fu

rthe

r in

form

atio

n is

req

uire

d.

We

have

fou

r di

ffere

nt t

ypes

of

stan

doffs

,de

sign

ed t

o co

nnec

t ci

ruci

t bo

ards

to

pane

ls

Top

Vie

w

Sid

e V

iew

Bot

tom

Vie

w

1/16

”S

tand

off

1/8”

Sta

ndof

fR

etro

fitS

tand

off

Cir

cuit

Bo

ard

Sta

ndof

fS

cre

w M

ou

nt

Sta

ndof

f

1/16

”1/

8”

Sta

nd

off

sS

tan

do

ffs

Sta

nd

off

sS

tan

do

ffs

Sta

nd

off

s

Dim

ensi

on

al D

raw

ing

Dim

ensi

on

al D

raw

ing

Dim

ensi

on

al D

raw

ing

Dim

ensi

on

al D

raw

ing

Dim

ensi

on

al D

raw

ing

à

TTTT Tra

nsf

orm

erra

nsf

orm

erra

nsf

orm

erra

nsf

orm

erra

nsf

orm

er

à

à

Su

pp

ort

Sta

nd

off

Lo

catio

n

à

à

1-3/

4” (

4.44

cm

)

4” (

10.1

6 C

M)

4-3/

8” (

11.1

1

1-5/8” (4.13 cm)à

2-1/2” (6.35 cm)

1” (

2.54

cm

)

à

à

3-1/

4” (

8.25

cm

) 3/16

” (0

.48

cm) à

à11/16”(1.75 cm)

à

à

WWWW War

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4TPN

˝2/1-2TPN

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the

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sig

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500

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rass

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s.s

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prov

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File

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M

Serie

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1644

Dim

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Serie

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App

licat

ions

• Op

en T

anks

• Cl

osed

Ves

sels

• W

ater

• Di

lute

d Co

rros

ive

Liqu

ids

How

to O

rder

Use

the

Bold

cha

ract

ers

from

the

char

t bel

ow to

co

nstru

ct a

pro

duct

cod

e.

Note

:1.

3N

feat

ures

up

to th

ree

prob

es o

nly.

Pum

p or

Mot

orize

d Va

lve

Circ

uit R

atin

g (A

mpe

res)

Volta

geFu

ll Lo

adLo

cked

Rot

orPi

lot D

uty

120

VAC

7.4

44.4

345

VA a

t24

0 VA

C3.

722

.212

0 or

240

VAC

Appr

oxim

ate

Dist

ance

Abo

veCa

st L

ine

Diffe

rent

ial

Setti

ngIn

. (m

m)

In.

(mm

)

Pum

p Of

f15

/16

(24)

5 /16

(8)

Pum

p On

5 /8

(16)

Burn

er O

n5 /

8(1

6)3 /

8(1

6)Bu

rner

Off

1 /4

(6.4

)

Pum

p Of

f13

/8(4

1)3 /

4(1

9)Pu

mp

On5 /

8(1

6)

Burn

er O

n7 /

8(2

2)7 /

8(2

2)Bu

rner

Off

0(0

)

BU

RN

ER

“CU

T-O

FF

LE

VE

L”

AT C

AS

T LI

NE

7 /8"

BU

RN

ER

OF

F

(22m

m)

BU

RN

ER

ON

PU

MP

OF

F

BU

RN

ER

OF

FB

UR

NE

R“C

UT-

OF

F L

EV

EL”

AT

CA

ST

LIN

E

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

13/8

"(3

5mm

)

PU

MP

OF

FP

UM

P O

N

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

3 /4"

(19m

m)

PU

MP

OF

FP

UM

P O

N

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

(19m

m)

3 /4"

PU

MP

OF

F

BU

RN

ER

OF

FB

UR

NE

R “C

UT-

OF

F L

EV

EL”

3 /

8" (

9.5m

m)

BE

LOW

CA

ST

LIN

ENO

RM

AL

BO

ILE

RW

ATE

R L

INE

113 /

16"

(46m

m)

OP

ER

AT

ION

Max

imu

m P

ress

ure

:150

psi

(10

.5 k

g/cm

2 )

Ele

ctri

cal R

atin

gs

Set

tin

gs

and

Dif

fere

nti

al P

ress

ure

s

Val

ues

are

±8

” (3

.2m

m).

Ser

ies

150/

157

and

150

S/1

57S

150

psi

(10

.5 k

g/c

m2 )

Lev

els

150

psi

(10

.5 k

g/c

m2 )

Lev

els

0 ps

i(0

kg/

cm2 )

150

psi

(10.

5 kg

/cm

2 )

Appr

oxim

ate

Dist

ance

Abo

veCa

st L

ine

Diffe

rent

ial

Setti

ngIn

. (m

m)

In.

(mm

)

Pum

p Of

f15

/16

(24)

3 /8

(16)

Pum

p On

9 /16

(14)

Burn

er O

ff0

(0)

N/A

Pum

p Of

f17

/16

(37)

3 /4

(19)

Pum

p On

11/1

6(1

7)

Burn

er O

ff- 3

/8(-

16)

N/A

Mo

del

s 15

0-M

D/1

57-M

D a

nd

150

S-M

D/1

57S

-MD

0 ps

i(0

kg/

cm2 )

150

psi

(10.

5 kg

/cm

2 )

Pres

sure

Pres

sure

Alar

m C

ircui

t Rat

ing

Volta

geAm

ps

120

VAC

1

240

VAC

1/2

Mot

or H

orse

pow

erVo

ltage

Hp

120

VAC

1/3

240

VAC

1/3

2

Ser

ies

150

and

157

(Mer

cury

Sw

itch)

Ser

ies

150S

and

157

S(S

nap

Switc

h,A

ll M

odel

s ex

cept

157

S-R

B-P

)

Low

Wat

er C

ut-O

ff/P

ump

Con

trol

lers

For S

team

Boi

lers

and

Oth

er L

evel

Con

trol A

pplic

atio

ns

Typi

cal A

pplic

atio

ns:

– P

rim

ary

or s

econ

dary

pum

p co

ntro

ller/

low

wat

er fu

el c

ut-o

fffo

r st

eam

boi

lers

– M

otor

ized

val

ve c

ontr

olle

r

– Lo

w w

ater

cut

-off

– H

igh

wat

er c

ut-o

ff

– A

larm

act

uato

r •B

efo

re u

sin

g t

his

pro

du

ct r

ead

an

d u

nd

erst

and

inst

ruct

ion

s.

•S

ave

thes

e in

stru

ctio

ns

for

futu

re r

efer

ence

•A

ll w

ork

mu

st b

e p

erfo

rmed

by

qu

alif

ied

per

son

nel

tra

ined

in t

he

pro

per

ap

plic

atio

n,i

nst

al-

lati

on

,an

d m

ain

ten

ance

of

plu

mb

ing

,ste

am,a

nd

ele

ctri

cal e

qu

ipm

ent

and

/or

syst

ems

in

acco

rdan

ce w

ith

all

app

licab

le c

od

es a

nd

ord

inan

ces.

•To

pre

ven

t se

rio

us

burn

s,th

e b

oile

r m

ust

be

coo

led

to

80˚

F (

27˚C

) an

d t

he

pre

ssu

re m

ust

be

0 p

si (

0 b

ar)

bef

ore

ser

vici

ng

.

•To

pre

ven

t el

ectr

ical

sh

ock

,tu

rn o

ff t

he

elec

tric

al p

ower

bef

ore

mak

ing

ele

ctri

cal c

on

nec

tion

s.

•T

his

low

wat

er c

ut-

off

mu

st b

e in

stal

led

in s

erie

s w

ith

all

oth

er li

mit

an

d o

per

atin

g c

on

tro

ls

inst

alle

d o

n t

he

bo

iler.

Aft

er in

stal

lati

on

,ch

eck

for

pro

per

op

erat

ion

of

all o

f th

e lim

it a

nd

o

per

atin

g c

on

tro

ls,b

efo

re le

avin

g t

he

site

.

•To

pre

ven

t se

rio

us

per

son

al in

jury

fro

m s

team

blo

w d

own

,co

nn

ect

a d

rain

pip

e to

th

e co

ntr

ol

op

enin

g t

o a

void

exp

osu

re t

o s

team

dis

char

ge.

•To

pre

ven

t a

fire

,do

no

t u

se t

his

low

wat

er c

ut-

off

to

sw

itch

cu

rren

ts o

ver

7.4A

,1/3

Hp

at

120

VAC

or

3.7A

,1/3

Hp

at

240

VAC

,un

less

a s

tart

er o

r re

lay

is u

sed

in c

on

jun

ctio

n w

ith

it.

Failu

re t

o f

ollo

w t

his

war

nin

g c

ou

ld c

ause

pro

per

ty d

amag

e,p

erso

nal

inju

ry o

r d

eath

.

WAR

NING

CAUT

ION

!W

AR

NIN

G

Ser

ies

150

and

150

S

Ser

ies

157

and

157

S

Appro

ved

®

Insta

llation &

Main

tenance

Instr

uctions M

M-2

17(E

)

4

If t

he

con

tro

l will

be

the

pri

mar

y lo

ww

ater

fu

el c

ut-

off

,siz

e th

e st

eam

(to

p)an

d w

ater

(bo

ttom

) eq

ualiz

ing

pipe

leng

ths

so t

hat

the

horiz

onta

l cas

t lin

e on

the

bod

yis

1a

”(3

5mm

) b

elo

wth

e bo

iler’s

no

rmal

wat

er le

vel,

but

no

t lo

wer

th

an t

he

low

-es

t,sa

fe p

erm

issi

ble

wat

er le

vel,

asd

eter

min

ed b

y th

e b

oile

r m

anu

fact

ure

r.

OR

If t

he

con

tro

l will

be

the

seco

nd

ary

low

wat

er f

uel

cu

t-o

ff,s

ize

the

stea

m (

top)

and

wat

er (

botto

m)

equa

lizin

g pi

pe le

ngth

s so

that

the

hor

izon

tal c

ast

line

on t

he b

ody

isat

or

abov

e,th

e lo

wes

t,sa

fe p

erm

issi

-b

le w

ater

leve

l,as

det

erm

ined

by

the

bo

iler

man

ufa

ctu

rer.

a.U

sing

a p

ipe

wre

nch,

uns

crew

the

pla

stic

flo

atbl

ocki

ng p

lug

(A)

from

the

low

wat

er c

ut-o

ffbo

dy (

B).

ST

EP

2 -

Inst

allin

g t

he

Lo

w W

ater

Cu

t-O

ff

ST

EP

1 -

Det

erm

ine

the

Ele

vati

on

at W

hic

h t

he

Lo

w W

ater

Cu

t-O

ff/P

um

p C

on

tro

ller

Mu

st b

e In

stal

led

INS

TAL

LA

TIO

N –

TOO

LS

NE

ED

ED

:Tw

o (2

) pi

pe w

renc

hes,

one

(1)

fla

thea

d sc

rew

driv

er,

and

pipe

sea

ling

com

poun

d.

IMP

OR

TAN

T:F

ollo

w th

e bo

iler

man

ufac

ture

r'sin

stru

ctio

ns a

long

with

all

appl

icab

le c

odes

and

ordi

nanc

es fo

r pi

ping

, blo

w d

own

valv

e an

d w

ater

gaug

e gl

ass

requ

irem

ents

.

13/8

"

ST

EA

M E

QU

ALI

ZIN

G P

IPE

VE

RT

ICA

L E

QU

ALI

ZIN

G P

IPE

BLO

W D

OW

N V

ALV

E

NO

RM

AL

BO

ILE

R W

ATE

R L

INE

AS

A P

RIM

AR

YLO

W W

ATE

R C

UT-

OF

F/P

UM

P C

ON

TR

OLL

ER

BU

RN

ER

“CU

T-O

FF

LE

VE

L” A

T C

AS

T LI

NE

LOW

ES

T P

ER

MIS

SIB

LE

WAT

ER

LE

VE

L

(35m

m)

WAT

ER

EQ

UA

LIZ

ING

PIP

E

ST

EA

M E

QU

ALI

ZIN

G P

IPE

VE

RT

ICA

L E

QU

ALI

ZIN

G P

IPE

BLO

W D

OW

N V

ALV

E

AS

A S

EC

ON

DA

RY

LOW

WAT

ER

CU

T-O

FF

/PU

MP

CO

NT

RO

LLE

R

BU

RN

ER

“CU

T-O

FF

LE

VE

L” A

T C

AS

T LI

NE

LOW

ES

T P

ER

MIS

SIB

LE

WAT

ER

LE

VE

L

BU

RN

ER

OF

F

WAT

ER

EQ

UA

LIZ

ING

PIP

E

B AB

A

B

A

Ser

ies

150

and

150

S(e

xcep

t M

od

el 1

50-B

an

d15

0S-B

)

Mo

del

s 15

0-B

an

d 1

50S

-BS

erie

s 15

7 an

d 1

57S

Appr

oxim

ate

Dist

ance

Abo

veCa

st L

ine

Diffe

rent

ial

Setti

ngIn

. (m

m)

In.

(mm

)

Mot

orize

d15

/16

(24)

Valv

e Cl

osed

5 /16

(8)

Mot

orize

d5 /

8(1

6)Va

lve

Open

Burn

er O

n5 /

8(1

6)3 /

8(1

6)Bu

rner

Off

1 /4

(6.4

)

Mot

orize

d13

/8(4

1)

3 /4

(19)

Valv

e Cl

osed

Mot

orize

d5 /

8(1

6)Va

lve

Open

Burn

er O

n7 /

8(2

2)7 /

8(2

2)Bu

rner

Off

0(0

)

BU

RN

ER

“CU

T-O

FF

LE

VE

L”

AT C

AS

T LI

NE

7 /8"

BU

RN

ER

OF

F

(22m

m)

BU

RN

ER

ON

MO

TOR

IZE

DVA

LVE

CLO

SE

D

BU

RN

ER

OF

FB

UR

NE

R“C

UT-

OF

F L

EV

EL”

AT

CA

ST

LIN

E

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

13/8

"(3

5mm

)

MO

TOR

IZE

DVA

LVE

CLO

SE

D

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

(19m

m)

3 /4"

MO

TOR

IZE

DVA

LVE

OP

EN

PU

MP

#1

OF

FP

UM

P #

1O

N

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

(19m

m)

3 /4"

PU

MP

#2

ON

AT C

AS

T LI

NE

7 /8"

PU

MP

#2

ON

(22m

m)

PU

MP

#2

OF

F

PU

MP

#1

OF

FP

UM

P #

2O

NP

UM

P #

2 O

NAT

CA

ST

LIN

E

NO

RM

AL

BO

ILE

RW

ATE

R L

INE

13/8

"(3

5mm

)

Set

tin

gs

and

Dif

fere

nti

al P

ress

ure

s (c

on

tin

ued

)

Val

ues

are

±8

” (3

.2m

m).

No

te:

Due

to

the

slow

er o

pera

tion

of s

ome

mot

oriz

ed v

alve

s, c

ompl

ete

valv

e op

enin

gor

clo

sing

will

occ

ur a

t sl

ight

ly d

iffer

ent

leve

ls t

han

indi

cate

d ab

ove.

Mo

del

s 15

8 an

d 1

58S

150

psi

(10

.5 k

g/c

m2 )

Lev

els

150

psi

(10

.5 k

g/c

m2 )

Lev

els

0 ps

i(0

kg/

cm2 )

150

psi

(10.

5 kg

/cm

2 )

Pres

sure

Appr

oxim

ate

Dist

ance

Abo

veCa

st L

ine

Diffe

rent

ial

Setti

ngIn

. (m

m)

In.

(mm

)

Pum

p #1

Off

15/1

6(2

4)5 /

16(8

)Pu

mp

#1 O

n5 /

8(1

6)

Pum

p #2

Off

5 /8

(16)

3 /8

(16)

Pum

p #2

On

1 /4

(6.4

)

Pum

p #1

Off

13/8

(41)

3 /4

(19)

Pum

p #1

On

5 /8

(16)

Pum

p #2

Off

7 /8

(22)

7 /8

(22)

Pum

p #2

On

0(0

)

Mo

del

s 15

9 an

d 1

59S

0 ps

i(0

kg/

cm2 )

150

psi

(10.

5 kg

/cm

2 )

Pres

sure

3

6ST

EP

4 -

Ele

ctri

cal W

irin

g

•To

pre

ven

t el

ectr

ical

sh

ock

,tu

rn o

ff t

he

elec

tric

al p

ower

bef

ore

mak

ing

ele

ctri

cal c

on

nec

tion

s.•

Th

is lo

w w

ater

cu

t-o

ff m

ust

be

inst

alle

d in

ser

ies

wit

h a

ll o

ther

lim

it a

nd

op

erat

ing

co

ntr

ols

inst

alle

d o

n t

he

bo

iler.

Aft

er in

stal

lati

on

,ch

eck

for

pro

per

op

erat

ion

of

all o

f th

e lim

it a

nd

op

erat

ing

co

ntr

ols

,bef

ore

leav

ing

th

e si

te.

•M

od

ifica

tion

of

the

switc

h a

ssem

bly

bef

ore

or

afte

r in

stal

latio

n c

ou

ld c

ause

dam

age

to t

he

bo

iler

and

/or

bo

iler

syst

em.

Failu

re t

o f

ollo

w t

his

war

nin

g c

ou

ld c

ause

ele

ctri

cal s

ho

ck,a

n e

xplo

sio

n a

nd

/or

a fi

re,w

hic

h c

ou

ld r

esu

lt in

pro

per

ty d

amag

e,p

erso

nal

inju

ry o

r d

eath

.

!W

AR

NIN

G

Sw

itch

Op

erat

ion

Fo

r al

l Mo

del

s ex

cep

t 15

8/15

8S a

nd

159

/159

S

Fo

r M

od

els

158

and

158

S

Boi

ler

feed

pum

p of

f,bu

rner

on,

ala

rm o

ff.B

oile

r fe

ed p

ump

on,

burn

er o

n, a

larm

off.

Boi

ler

feed

pum

p on

,bu

rner

off,

ala

rm o

n.

12

4 5

6 1

2 4

5 6

12

4 5

6

Mot

oriz

ed v

alve

clo

sed,

burn

er o

n, a

larm

off.

Mot

oriz

ed v

alve

ope

n,bu

rner

on,

ala

rm o

ff.M

otor

ized

val

ve o

pen,

burn

er o

ff, a

larm

on.

4 5

6 1

2 3

4 5

12

3 4

5 1

2 3

6 6

Fo

r M

od

els

159

and

159

S

Pum

p #1

off,

pum

p #2

off.

Pum

p #1

on,

pum

p #2

off.

Pum

p #1

on,

pum

p #2

on.

12

5 6

12

5 6

12

5 6

Ka.

Usi

ng a

flat

head

scr

ewdr

iver

, rem

ove

the

junc

tion

box

cove

r (K

).

5

CA

A

C

F

G

E

D

c.M

ount

and

pip

e th

e lo

w w

ater

cut

-off

(D)

ona

vert

ical

equ

aliz

ing

pipe

(E

) at

the

req

uire

del

evat

ion

leve

l, as

det

erm

ined

in S

tep

1.

Inst

all a

full

port

ed b

low

dow

n va

lve

(G)

dire

ctly

bel

ow th

e lo

wer

cro

ss o

f the

wat

ereq

ualiz

ing

pipe

(F

).

No

te:

1” N

PT

tapp

ings

are

pro

vide

d, w

ith t

heex

cept

ion

of s

ome

157

and

157S

mod

els

whi

ch a

re 14

” N

PT.

b.F

or

Mo

del

s 15

0-B

an

d 1

50S

-B a

nd

Ser

ies

157

and

157

S(F

or a

ll ot

her

mod

els,

pr

ocee

d to

Ste

p 3)

.

Scr

ew t

he w

” N

PT

stee

l plu

g (C

) (p

rovi

ded)

in t

appi

ng (

A).

Ser

ies

157

and

157

SM

od

els

150-

B a

nd

150

S-B

b.I

nsta

ll a

wat

er g

auge

gla

ss (

J).

Not

e:G

auge

gla

ss a

nd tr

i-coc

ks n

otin

clud

ed w

ith p

rodu

ct.

J

J

Ha.

Inst

all a

wat

er c

olum

n (H

) (n

ot in

clud

ed w

ithpr

oduc

t) f

or a

ll m

odel

s ex

cept

Ser

ies

157

and

157S

(w

ith in

tegr

al w

ater

col

umn)

.

ST

EP

3 -

Inst

allin

g a

Wat

er G

aug

e G

lass

(Req

uir

ed o

n a

ll st

eam

bo

ilers

)

Ser

ies

157

and

157

SA

ll O

ther

Mo

del

s

No

te:

For

Mod

els

159

and

159S

, us

e te

rmin

als

5 an

d 6

for

pum

p #2

.

WIR

ING

DIA

GR

AM

SF

or M

otor

ized

Val

ves,

ref

er t

o th

e va

lve

man

ufac

ture

r's w

iring

inst

ruct

ions

.

Lo

w W

ater

Cu

t-O

ff O

nly

1.M

ain

Line

Sw

itch

- F

or b

urne

r ci

rcui

ts w

ithin

the

sw

itch’

s el

ectr

ical

rat

ing.

Pu

mp

Co

ntr

ol O

nly

1.M

ain

Line

Sw

itch

- F

or p

ump

mot

ors

with

in t

he

switc

h’s

elec

tric

al r

atin

g.

1.M

ain

Line

Sw

itch

- F

or b

urne

r ci

rcui

ts w

ithin

th

e sw

itch’

s el

ectr

ical

rat

ing.

2.

Pilo

t S

witc

h -

To

hold

ing

coil

of a

sta

rter

whe

n th

e bu

rner

circ

uit

exce

eds

the

switc

h’s

elec

tric

al

ratin

g.

2. P

ilot

Sw

itch

- T

o ho

ldin

g co

il of

a s

tart

er w

hen

the

pum

p ci

rcui

t ex

ceed

s th

e sw

itch’

s el

ectr

ical

ra

ting.

LIN

ELO

AD

12

45

6

LIN

ELO

AD

12

45

6

12

45

6

ALA

RM

NE

UT

RA

L

HO

T

ALA

RM

NE

UT

RA

L

HO

T

12

45

6

12

45

6

SE

E P

UM

PC

ON

TR

OL

CIR

CU

IT

TO

NE

UT

RA

L

TO

BU

RN

ER

CO

NT

RO

L C

IRC

UIT

HO

TA

LAR

M

12

45

6LO

AD

LIN

E (

3 P

HA

SE

)S

EE

PU

MP

CO

NT

RO

LC

IRC

UIT

ALA

RM

12

45

6LO

AD

LIN

E

12

45

6LO

AD

LIN

E

OR

OR

OR

OR

Co

mb

inat

ion

Pu

mp

Co

ntr

ol,

Lo

w W

ater

Cu

t-O

ff a

nd

Ala

rm

Ala

rm C

ircu

it O

nly

1.Lo

w W

ater

Ala

rm2.

Hig

h W

ater

Ala

rm

2.P

ilot

Sw

itch

- To

hol

ding

coi

l of

a st

arte

r w

hen

the

burn

er c

ircui

t ex

ceed

s th

e sw

itch’

s el

ectr

ical

ratin

g.

8

b.F

ollo

win

g th

e ap

prop

riate

wiri

ng d

iagr

am,

(ref

erto

pag

e 9)

bas

ed o

n yo

ur a

pplic

atio

n re

quire

-m

ents

, an

d us

ing

BX

arm

ored

cab

le o

r T

hinw

all

elec

tric

al m

etal

tub

ing

conn

ecto

r fit

tings

, m

ake

elec

tric

al c

onne

ctio

ns t

o th

e ju

nctio

n bo

x (L

).

PU

MP

SW

ITC

H

PU

MP

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

AN

DA

LAR

M S

WIT

CH

ALA

RM

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

TE

RM

INA

LS

L

PU

MP

#1

SW

ITC

H

PU

MP

#1

CIR

CU

ITT

ER

MIN

ALS

PU

MP

#2

SW

ITC

H

PU

MP

#2

CIR

CU

ITT

ER

MIN

ALS

L

MO

TOR

IZE

DVA

LVE

SW

ITC

H

MO

TOR

IZE

DVA

LVE

TE

RM

INA

LS

LOW

WAT

ER

CU

T-O

FF

AN

DA

LAR

M S

WIT

CH

ALA

RM

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

TE

RM

INA

LS

L

12

34

56

MO

TOR

IZE

DVA

LVE

SW

ITC

H

MO

TOR

IZE

DVA

LVE

TE

RM

INA

LS

LOW

WAT

ER

CU

T-O

FF

AN

DA

LAR

M S

WIT

CH

ALA

RM

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

TE

RM

INA

LS

L

12

34

56

PU

MP

SW

ITC

H

PU

MP

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

AN

DA

LAR

M S

WIT

CH

ALA

RM

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

TE

RM

INA

LS

L

IMP

OR

TAN

T:T

here

mus

t be

a m

inim

um s

pace

of

1/2”

(13m

m)

betw

een

conn

ecto

rfit

tings

and

ele

ctric

al li

vem

etal

par

ts.

Au

tom

atic

Res

et(A

ll m

od

els

exce

pt

158S

an

d 1

59S

)A

uto

mat

ic R

eset

Mo

del

158

S

Man

ual

Res

etM

od

el 1

58S

-M

Au

tom

atic

Res

etM

od

el 1

59S

Man

ual

Res

et(A

ll m

od

els

exce

pt

158S

)

Sn

ap S

wit

ches

(S

erie

s 15

0S a

nd

157

S)

NO

. 1 P

UM

PC

IRC

UIT

NO

. 2 P

UM

PC

IRC

UIT

12

56

L

TOE

LEC

TR

ICVA

LVE

TOLO

W W

ATE

RA

LAR

M

TOLO

W W

ATE

RC

UT-

OF

F

12

34

56

L

PU

MP

SW

ITC

H

PU

MP

CIR

CU

ITT

ER

MIN

ALS

CU

T-O

FF

A

ND

ALA

RM

S

WIT

CH

ALA

RM

CIR

CU

ITT

ER

MIN

ALS

LOW

WAT

ER

CU

T-O

FF

TE

RM

INA

LS

L

(All

mo

del

s ex

cep

t 15

8an

d 1

59)

Mer

cury

Sw

itch

es (

Ser

ies

150

and

157

)

Mo

del

158

Mo

del

159

7

H

G

e.

To p

reve

nt

seri

ou

s p

erso

nal

inju

ry f

rom

ste

am p

ipe

blo

w d

ow

n,c

on

nec

t a

pip

e to

avo

id e

xpo

sure

to

stea

m d

isch

arg

e.

Failu

re t

o f

ollo

w t

his

cau

tio

n c

ou

ld c

ause

per

son

al in

jury

.

!C

AU

TIO

N

Whe

n th

e w

ater

leve

l is

at it

s no

rmal

leve

lan

d th

e bu

rner

is o

n. S

low

lyop

en t

he b

low

dow

n va

lve

(G)

until

it is

ful

ly o

pen.

W

atch

the

gaug

e gl

ass

(H)

to s

ee t

hat

the

wat

erle

vel d

rops

. C

lose

the

val

ve a

fter

verif

ying

that

the

pum

p co

mes

on

and

the

burn

ersh

uts

off.

For

Mod

els

158

and

158S

, cl

ose

the

blow

dow

n va

lve

afte

r th

e m

otor

ized

valv

e op

ens

and

the

burn

er s

huts

off.

For

Mod

els

159

and

159S

, cl

ose

the

blow

dow

nva

lve

afte

r bo

th p

umps

com

e on

. If

this

doe

sno

t oc

cur,

imm

edia

tely

shu

t of

f th

e bo

iler

and

corr

ect

the

prob

lem

and

ret

est. IN

STA

LLAT

ION

CO

MP

LETE

13/8"

M

(35m

m)

J

c.F

or

auto

mat

ic r

eset

mo

del

s o

nly

.Whe

n th

e w

ater

leve

l rea

ches

app

roxi

mat

ely d

” (2

2mm

) ab

ove

the

horiz

onta

l cas

t lin

e (lo

wer

for

MD

mod

els)

the

bur

ner

shou

ld c

ome

on (

pum

p #2

sho

uld

shut

off

with

Mod

els

159

and

159S

).

OR

Fo

r m

anu

al r

eset

mo

del

s o

nly

.Whe

n th

e w

ater

leve

lre

ache

s ap

prox

imat

ely d

” (2

2mm

) ab

ove

the

horiz

onta

lca

st li

ne p

ress

the

res

et b

utto

n (N

). T

he b

urne

r sh

ould

then

com

e on

.

d.

Con

tinue

wat

chin

g th

e ga

uge

glas

s (J

) to

see

that

the

wat

er c

ontin

ues

to r

ise

toap

prox

imat

ely

1a”

(35m

m)

(17 /

16”

(37m

m)

for

MD

mod

els)

abo

ve t

he h

oriz

onta

l cas

tlin

e (M

). T

he p

ump

shou

ld s

hut

off

(the

mot

oriz

ed v

alve

sho

uld

clos

e w

ith M

odel

s15

8 an

d 15

8S,

or w

ith M

odel

s 15

9 an

d15

9S,

pum

p #1

sho

uld

shut

off)

.

10

N

Sn

ap S

wit

ch M

od

els

Mer

cury

Sw

itch

Mo

del

s

N

Kc.

Re-

atta

ch th

e ju

nctio

n bo

x co

ver

(K).

ST

EP

5 -

Tes

tin

g

OF

F

ON

a.Tu

rn o

n th

e el

ectr

ic p

ower

to

the

boile

r. W

ith t

hebo

iler

empt

y th

e pu

mp

shou

ld g

o on

and

the

bur

ner

mus

t re

mai

n of

f.

IMP

OR

TAN

T:F

ollo

w t

he b

oile

r m

anuf

actu

rer’s

sta

rt-u

p an

d op

erat

ing

inst

ruct

ions

alo

ng w

ith a

ll ap

plic

able

code

s an

d or

dina

nces

. N

ote

:W

ater

leve

ls s

tate

d be

low

are

onl

y fo

r 15

0 ps

i (10

.5 k

g/cm

2 ) o

pera

tion.

Thi

s co

ntro

l is

fact

ory

calib

rate

d fo

r sp

ecifi

c ap

plic

atio

ns. T

he f

ollo

win

g te

stin

g pr

oced

ure

is o

nly

mea

nt t

ose

rve

as a

ver

ifica

tion

of p

rope

r op

erat

ing

sequ

ence

.D

imen

sion

s pr

ovid

ed a

re t

ypic

al f

or a

boi

ler

not

bein

g fir

ed a

nd/o

r no

t at

pre

ssur

e. A

ctua

l ope

ratin

g ra

nges

are

show

n on

pag

e 2

in t

he "

Ope

ratio

n" s

ectio

n.

If th

e bu

rner

co

mes

on

,im

med

iate

ly t

urn

th

e b

oile

r o

ff a

nd

mak

e th

en

eces

sary

co

rrec

tion

s.

Failu

re t

o f

ollo

w t

his

war

nin

g c

ou

ld c

ause

an

exp

losi

on

or

fire

an

dre

sult

in p

rop

erty

dam

age,

per

son

al in

jury

or

dea

th.

!W

AR

NIN

G

7 /8"

M

J (22m

m)

b.

The

boi

ler

shou

ld b

egin

to fi

ll w

ith w

ater

.W

atch

the

gau

ge g

lass

(J)

unt

il th

e w

ater

leve

l rea

ches

app

roxi

mat

ely d

” (2

2mm

)ab

ove

the

horiz

onta

l cas

t lin

e (M

) on

the

low

wat

er c

ut-o

ff.

IMP

OR

TAN

T:If

wat

er d

oes

not

star

t fil

ling

the

boile

r, im

med

iate

ly t

urn

off

the

the

boile

r an

dm

ake

the

nece

ssar

y co

rrec

tions

.

9

3500 N

. S

pauld

ing A

venue

Chic

ago,

Illin

ois

60618

tel:

77

3 2

67

-16

00

fax:

773 2

67-0

991

ww

w.m

cd

on

ne

llmill

er.co

m

©2001 I

TT

Industr

ies I

nc.

Printe

d in U

.S.A

.

4-0

1

210341

11

MA

INT

EN

AN

CE

SC

HE

DU

LE

:•

Blo

w d

ow

n c

on

tro

l as

follo

ws

wh

en b

oile

r is

in

op

erat

ion

.–

Dai

ly if

op

erat

ing

pre

ssu

re is

ab

ove

15 p

si.

– W

eekl

y if

op

erat

ing

pre

ssu

re is

bel

ow

15

psi

.

•D

isas

sem

ble

an

d in

spec

t an

nu

ally

.Rep

lace

th

e lo

w w

ater

cu

t-o

ff/p

um

p c

on

tro

ller

if it

is

wo

rn,c

orr

od

ed,o

r if

co

mp

on

ents

no

lon

ger

o

per

ate

pro

per

ly.

•In

spec

t th

e fl

oat

ch

amb

er a

nd

eq

ual

izin

g p

ipin

g

ann

ual

ly.R

emov

e al

l sed

imen

t an

d d

ebri

s.•

Rep

lace

hea

d m

ech

anis

m e

very

5 y

ears

.M

ore

freq

uent

rep

lace

men

t m

ay b

e re

quire

d w

hen

seve

re c

ondi

tions

exi

st s

uch

as r

apid

sw

itch

cycl

ing,

su

rgin

g w

ater

leve

ls,

and

use

of w

ater

tre

atm

ent

chem

ical

s.•

We

reco

mm

end

hea

d m

ech

anis

m r

epla

cem

ent

wh

en t

he

swit

ch(e

s) n

o lo

ng

er o

per

ate

pro

per

ly.

If yo

u ch

oose

to

repl

ace

the

switc

h(es

), o

rder

the

pr

oper

McD

onne

ll &

Mill

er r

epla

cem

ent

switc

h or

sw

itch

asse

mbl

y an

d fo

llow

the

Rep

air

Pro

cedu

re

prov

ided

.

PR

OC

ED

UR

E:

1.B

low

dow

n th

e lo

w w

ater

cut

-off

whe

n th

e w

ater

leve

l is

at it

s no

rmal

leve

l and

the

bu

rner

is o

n. S

low

lyop

en t

he b

low

dow

n va

lve

until

it is

ful

ly o

pen

and

obse

rve

the

wat

er le

vel f

all i

n th

e ga

uge

glas

s. C

lose

the

va

lve

afte

r ve

rifyi

ng t

hat

the

pum

p co

ntac

ts

have

clo

sed

and

the

burn

er s

huts

off.

For

M

odel

s 15

8 an

d 15

8S,

clos

e th

e bl

ow d

own

valv

e af

ter

the

mot

oriz

ed v

alve

ope

ns a

nd t

he

burn

er s

huts

off.

For

Mod

els

159

and

159S

, cl

ose

the

blow

dow

n va

lve

afte

r bo

th p

umps

co

me

on.

If th

is d

oes

not

happ

en,

imm

edia

tely

sh

ut o

ff th

e bo

iler

and

corr

ect

the

prob

lem

.

To p

reve

nt

seri

ou

s p

erso

nal

inju

ry f

rom

ste

amp

ipe

blo

w d

ow

n,c

on

nec

t a

dra

in p

ipe

to t

he

con

tro

l op

enin

g t

o a

void

exp

osu

re t

o s

team

dis

char

ge.

Failu

re t

o f

ollo

w t

his

cau

tio

n c

ou

ld c

ause

per

son

al in

jury

.

!C

AU

TIO

N

Sn

ap s

wit

ches

mu

st b

e re

pla

ced

as

anas

sem

bly

.

!C

AU

TIO

N

Rep

lace

men

t S

wit

ch A

ssem

bly

Rep

lace

men

t M

ercu

ry T

ub

es

2-W

ire

Pu

mp

3-W

ire

Bu

rner

NO

TE

Mo

re f

req

uen

t b

low

-do

wn

may

be

nec

essa

ry d

ue

to d

irty

bo

iler

wat

er a

nd

/or

loca

l co

des

.

2

OF

F

ON

a.To

pre

vent

ele

ctric

al s

hock

tur

n of

f al

l ele

ctric

al

pow

er t

o th

e bo

iler.

CA

UT

ION

:T

here

may

be

mor

e th

an o

ne s

ourc

e of

pow

er t

o th

e bo

iler.

STE

P 1

- P

repa

ratio

n

b.

Rel

ease

all

pres

sure

fro

m t

he b

oile

r an

d le

t it

cool

dow

n to

80˚

F (

27˚C

). D

rain

the

wat

er le

vel

dow

n be

low

the

flo

at c

ham

ber.

c.R

emov

e th

e fo

ur s

crew

s th

at h

old

the

cove

r on

the

sw

itch

hous

ing

(A)

and

rem

ove

the

cove

r. M

ark

all

elec

tric

al s

uppl

y w

ires

so t

hey

can

be r

etur

ned

to

the

prop

er te

rmin

als.

Rem

ove

the

wire

s an

d co

ndui

t co

nnec

tions

fro

m s

witc

h ho

usin

g (A

).

E D

A

F

C

B

d.

Rem

ove

eigh

t he

x he

ad b

olts

hol

ding

hea

d m

echa

nism

(B

) to

flo

at c

ham

ber.

Car

eful

ly r

emov

e he

ad m

echa

nism

(B

) fr

om f

loat

cha

mbe

r an

d pl

ace

in a

vis

e.

e.H

oldi

ng f

loat

(C

) fir

mly

, un

scre

w A

llen®

or T

orx®

fast

ener

(D

). (

Uni

ts w

ith d

ate

code

s of

E99

or

earli

erw

ill h

ave

Alle

n®he

ad f

aste

ners

. Tho

se w

ith c

odes

of

F99

or

late

r w

ill h

ave

Torx

®fa

sten

er).

Uns

crew

flo

at

and

float

rod

(C

). F

or s

nap

switc

h un

its s

ee S

tep

3a.

For

mer

cury

sw

itch

units

rem

ove

the

two

mer

cury

sw

itche

s. R

emov

e si

x (6

) A

llen®

or T

orx®

scre

ws

(E).

f.R

emov

e sw

itch

hous

ing

(A)

from

hea

d ca

stin

g (B

).

The

bel

low

s as

sem

bly

(F)

may

stic

k to

the

sw

itch

hous

ing

(A).

Rem

ove

bello

w a

ssem

bly

(F)

and

clea

n ga

sket

sur

face

s on

bot

h he

ad c

astin

g (B

) an

d sw

itch

hous

ing

(A).

B

A

Fou

r C

over

Scr

ews

Eig

ht H

exH

ead

Bol

ts

Ser

ies

150,

150S

,157

,157

SB

ello

ws

Rep

lace

men

t

Ser

ies

150

Ser

ies

150S

• B

efo

re u

sin

g p

rod

uct

,rea

d a

nd

un

der

stan

d in

stru

ctio

ns.

• S

ave

thes

e in

stru

ctio

ns

for

futu

re r

efer

ence

.

•A

ll w

ork

mus

t be

per

form

ed b

y qu

alifi

ed p

erso

nnel

tra

ined

in t

he p

rope

r ap

plic

atio

n,in

stal

latio

n,an

d m

aint

enan

ce o

f pl

umbi

ng,s

team

,and

ele

ctri

cal e

quip

men

t an

d/or

sys

tem

s in

acc

orda

nce

with

all

appl

icab

le c

odes

and

ord

inan

ces.

•To

pre

ven

t el

ectr

ical

sh

ock

,tu

rn o

ff t

he

elec

tric

al p

ow

er b

efo

re m

akin

g e

lect

rica

l co

nn

ecti

on

s.

•To

pre

ven

t se

rio

us

burn

s re

leas

e al

l pre

ssu

re a

nd

let

bo

iler

coo

l do

wn

to

80˚

F (

27˚C

).

•D

rain

wat

er le

vel d

ow

n b

elo

w t

he

flo

at b

ow

l ch

amb

er b

efo

re t

akin

g t

he

hea

d m

ech

anis

m

ou

t o

f th

e b

od

y.

Failu

re t

o f

ollo

w t

his

war

nin

g c

ou

ld c

ause

pro

per

ty d

amag

e,p

erso

nal

inju

ry o

r d

eath

.

WAR

NING

CAUT

ION

!W

AR

NIN

G

Repla

cem

ent

Instr

uctions

MM

-711

3500 N

. S

pauld

ing A

venue

Chic

ago,

Illin

ois

60618

tel:

77

3 2

67

-16

00

fax:

773 2

67-0

991

ww

w.m

cd

on

ne

llmill

er.co

m

©1999 I

TT

Industr

ies I

nc.

Printe

d in U

.S.A

.

7-9

9

246765

e.S

crew

flo

at a

nd f

loat

rod

(C

) in

to f

loat

arm

(K

) an

d ha

nd t

ight

en.

Cen

ter

the

float

rod

in t

he f

loat

ro

d gu

ide

(not

sho

wn)

and

tig

hten

Tor

x®sc

rew

(D

) to

125

in.

lbs.

(14

N•m

). M

ake

sure

you

hol

d th

e flo

at in

pla

ce w

hile

tig

hten

ing

scre

w (

D).

Mov

e th

e flo

at u

p an

d do

wn,

mak

ing

sure

the

re is

no

bind

ing

and

that

the

float

rod

is s

till c

ente

red.

Inst

all b

rack

et

(P)

usin

g sc

rew

s (N

), t

ight

en t

o 40

in.

lbs.

(4

.5 N

•m).

a.C

lean

the

gas

ket

surf

ace

on h

ead

cast

ing

(B)

and

the

body

cas

ting.

Usi

ng a

new

gas

ket

(fur

nish

ed)

mou

nt t

he h

ead

mec

hani

sm t

o th

e bo

dy c

astin

g. T

ight

en t

he e

ight

(8)

bol

ts t

o 18

ft.

lbs.

(24

N•m

).

Rea

ttach

con

duit

conn

ecto

rs a

nd c

onne

ct w

ires

to t

he p

rope

r te

rmin

als.

Tur

n on

ele

ctric

al p

ower

to

the

boile

r.

STE

P 4

- A

ssem

blin

g th

e H

ead

to th

e B

ody

and

Test

for

Pro

per

Ope

ratio

n

b.

Run

the

uni

t th

roug

h se

vera

l cyc

les

of o

pera

tion,

not

ing

the

oper

atin

g po

ints

. O

n th

e sn

ap

switc

h co

ntro

ls it

may

be

nece

ssar

y to

rea

djus

t th

e sw

itche

s. I

f th

is is

nec

essa

ry f

ollo

w t

he

encl

osed

inst

ruct

ions

. (S

ee a

ttach

ed f

or r

efer

ence

onl

y, M

M-2

35).

d.

Mak

e su

re t

he t

appe

d ho

le o

n flo

at a

rm (

K)

is

faci

ng t

he c

orre

ct w

ay,

so t

he f

loat

and

flo

at

rod

(C)

can

be s

crew

ed in

to it

whe

n be

llow

s as

sem

bly

is a

ssem

bled

on

the

head

cas

ting.

P

lace

gas

ket

(M)

on h

ead

cast

ing

(B).

Cen

ter

the

gask

et a

nd p

lace

the

bel

low

s as

sem

bly

(F)

and

the

switc

h ho

usin

g (A

) on

hea

d ca

stin

g (B

). I

nser

t an

d tig

hten

the

six

(6)

Tor

x®sc

rew

s (E

) to

125

in.

lbs.

(14

N•m

). M

ake

sure

tha

t tw

o (2

) of

the

scr

ews

capt

ure

the

switc

h br

acke

t (R

).

D H

G JK

E

DR

A

B

P

J

C

H

NL F

K

M

c.Ta

ke t

he n

ew b

ello

ws

asse

mbl

y (F

) an

d di

sass

embl

e it

notin

g th

e or

der

of p

arts

. P

ut s

ealin

g w

ashe

r (J

) on

top

of

float

arm

(K

) an

d in

sert

into

insi

de o

f be

llow

s (F

). P

lace

gas

ket

(L)

over

bel

low

s (F

).

Inse

rt t

his

asse

mbl

y in

to s

witc

h ho

usin

g (A

) an

d br

acke

t (H

). I

f th

e sc

rew

(D

) w

as a

n A

llen®

scre

w,

the

spac

er w

ashe

r (G

) w

ill h

ave

to b

e pu

t in

the

top

ho

le o

f br

acke

t (H

). T

ake

Torx

®sc

rew

(D

) (f

urni

shed

) an

d in

sert

it in

to h

ole

on t

op o

f br

acke

t (H

) an

d sp

acer

was

her

(G)

(if n

eede

d) a

nd s

crew

in

to f

loat

arm

(K

). H

and

tight

en o

nly.

Ste

p 3

- Cha

ngin

g th

e B

ello

ws

for

Sna

p S

witc

h U

nits

(con

t’d)

b.

NO

TE

:O

n un

its t

hat

have

Alle

n®he

ad s

crew

s th

ey

will

be

repl

aced

with

Tor

x®sc

rew

s (f

urni

shed

).

3

C

E

DA L F

J K

B

M

HD H

G JK

STE

P 2

- C

hang

ing

the

Bel

low

s fo

r M

ercu

ry S

witc

h U

nits

(For

Sna

p S

witc

h S

ee S

TEP

3)

c.M

ake

sure

tap

ped

hole

on

float

arm

(K

) is

fac

ing

the

corr

ect

way

, so

the

flo

at a

nd f

loat

rod

(C

) ca

n be

sc

rew

ed in

to it

whe

n be

llow

s as

sem

bly

is a

ssem

bled

on

the

hea

d ca

stin

g. P

lace

gas

ket

(M)

on c

astin

g (B

).

Cen

ter

the

gask

et a

nd p

lace

the

bel

low

s as

sem

bly

(F)

and

switc

h ho

usin

g (A

) on

hea

d ca

stin

g (B

). I

nser

t an

d tig

hten

six

(6)

Tor

x®sc

rew

s (E

) to

125

in.

lbs.

(14

N•m

).

d.

Scr

ew f

loat

and

flo

at r

od (

C)

into

flo

at a

rm (

K)

and

hand

tig

hten

. C

ente

r th

e flo

at r

od in

the

flo

at r

od

guid

e (n

ot s

how

n) a

nd t

ight

en T

orx

scre

w (

D)

to

125

in.

lbs.

(14

N•m

). M

ake

sure

you

hol

d th

e flo

at

in p

lace

whi

le t

ight

enin

g sc

rew

(D

). M

ove

the

float

up

and

dow

n, m

akin

g su

re t

here

is n

o bi

ndin

g an

d th

at t

he f

loat

rod

is s

till c

ente

red.

b.

Take

the

new

bel

low

ass

embl

y (F

) an

d di

sass

embl

e it

notin

g th

e or

der

of t

he p

arts

. P

ut s

ealin

g w

ashe

r (J

) on

to

p of

flo

at a

rm (

K)

and

inse

rt in

to in

side

of

bello

ws

(F).

P

lace

gas

ket

(L)

over

bel

low

s (F

). I

nser

t th

is a

ssem

bly

into

sw

itch

hous

ing

(A)

and

brac

ket

(H).

If

the

scre

w (

D)

was

an

Alle

n®sc

rew

, th

e sp

acer

was

her

(G)

will

hav

e to

be

put

in t

he t

op h

ole

of b

rack

et (

H).

Tak

e To

rx®

scre

w (

D)

(fur

nish

ed)

and

inse

rt it

into

hol

e on

top

of b

rack

et (

H)

and

spac

er w

ashe

r(G

) (if

nee

ded)

and

scr

ew in

to f

loat

arm

(K

).H

and

tight

en o

nly.

a.N

OT

E:

On

units

tha

t ha

ve A

llen®

head

scr

ews

they

sho

uld

be r

epla

ced

with

Tor

x®sc

rew

s (f

urni

shed

).

B

C

J

F

A

G

D

P

N

R

E

Ste

p 3

- Cha

ngin

g th

e B

ello

ws

for

Sna

p S

witc

h U

nits

a.C

lean

out

sea

lant

and

rem

ove

two

(2)

scre

ws

(N)

and

brac

ket

(P).

Rem

ove

(6)

Alle

n®or

Tor

x®sc

rew

s (E

). R

emov

e sw

itch

hous

ing

(A)

from

hea

d ca

stin

g (B

).T

he s

witc

h br

acke

t (R

) w

ill c

ome

out

with

the

sw

itch

hous

ing

(A).

The

bel

low

s as

sem

bly

(F)

may

stic

k to

th

e sw

itch

hous

ing

(A).

Rem

ove

bello

w a

ssem

bly

(F)

and

clea

n ga

sket

sur

face

s on

bot

h he

ad c

astin

g (B

) an

d sw

itch

hous

ing

(A).

Inst

alla

tion

& M

aint

enan

ceIn

stru

ctio

ns M

M-4

16

Wir

ing

conn

ectio

ns fo

r a

Ser

ies

150E

/157

E w

hen

used

as

a re

plac

emen

t for

a S

erie

s 15

0/15

7 (m

ercu

ry)

or 1

50S

/157

S (s

nap)

sw

itch

unit.

A.

Con

nect

'Hot

'(L1

) w

ire fr

om p

ower

sup

ply

to

Term

inal

'H'.

B.

Con

nect

'Neu

tral

'(L2

) w

ire fr

om p

ower

sup

ply

to T

erm

inal

'N'.

NO

TE:

Pow

er w

ires

conn

ecte

d to

Ter

min

als

'H'

and

'N' o

n 15

0E s

houl

d be

from

the

boile

r's c

ontro

ltra

nsfo

rmer

con

nect

ions

whi

ch a

re u

sual

ly d

esig

-na

ted

'L1'

and

'L2'

.The

150

E S

HO

ULD

NO

Tbe

pow

ered

as

part

of a

ny o

pera

ting

or s

afet

y ci

rcui

t.

C.

Rem

ove

wire

from

Ter

min

al '1

'and

con

nect

to

Term

inal

'PC

OM

'.

D.

Rem

ove

wire

from

Ter

min

al '2

'and

con

nect

to

Term

inal

'PN

O'.

E.

Rem

ove

wire

from

Ter

min

al '4

'and

con

nect

to

Term

inal

'BN

O'.

F.R

emov

e w

ire fr

om T

erm

inal

'5'a

nd c

onne

ct to

Te

rmin

al 'B

CO

M'.

G.

Rem

ove

wire

from

Ter

min

al '6

'and

con

nect

to

Term

inal

'BN

O'.

3500

N. S

paul

ding

Ave

nue

Chi

cago

, Illi

nois

606

18te

l: 7

73 2

67-1

600

fax:

773

267

-099

1w

ww

.mcd

onne

llmill

er.c

om

©20

02 IT

T In

dust

ries

Inc.

Prin

ted

in U

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. 1

0-02

2

1054

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NO

TE

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d an

d fo

llow

inst

alla

tion

inst

ruct

ions

incl

uded

with

150

E/1

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con

trol

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PU

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060

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0

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be C

onne

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otto

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iddl

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llow

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e

0-60

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ond

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ner O

ff D

elay

110

Volt

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tfro

m B

oile

rC

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anua

l Res

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app

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w W

ater

LED

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reen

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itch

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ner

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inal

s

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rmin

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BN

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BN

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PN

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be L

ED

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Ele

ctro

nic

Rel

ays

(Ser

ies

150E

an

d 1

57E

)

Mer

cury

Sw

itch

es (

Ser

ies

150

and

157

)

Sn

ap S

wit

ches

(S

erie

s 15

0S a

nd

157

S)

NO

TE

: D

O N

OT

RE

MO

VE

TH

E F

OU

R “

CO

RN

ER

” T

UB

ES

AS

TH

EY

AR

E

NE

ED

ED

TO

HO

LD

TH

E S

HA

PE

OF

TH

E B

OIL

ER

.

1.

Be

gin

by c

utt

ing

th

e b

ott

om

ro

w o

f b

oile

r tu

be

s.

2.

Cu

t a

ll o

the

r tu

be

s f

rom

bo

th e

nd

s o

f th

e b

oile

r.

Th

e t

ub

es w

ill

fall i

nto

th

e f

ire

bo

x.

Do

no

t d

am

ag

e t

he

bu

rne

r/g

as o

rifi

ce

s.

3.

Usin

g a

du

ll c

his

el

an

d s

led

ge

ha

mm

er,

cri

mp

do

wn

th

e f

lare

d e

nd

of

the

tu

be

th

at

is

left

in

th

e t

ub

e s

he

et

aft

er

cu

ttin

g.

4.

Usin

g t

he

sa

me

ch

ise

l a

nd

ha

mm

er,

kn

ock t

he

re

ma

inin

g p

iece

of

tub

e i

nto

th

e f

ire

bo

x.

5.

Aft

er

rem

ov

ing

th

e tu

be

e

nd

s,

cle

an

a

ll tu

be

s

he

et

ho

les

w

ith

a

g

rin

din

g s

ton

e u

sin

g

ca

uti

on

no

t to

re

mo

ve

to

o m

uch

su

rfa

ce

or

ca

use

ho

les t

o b

eco

me

ou

t o

f ro

un

d.

6.

Insta

ll f

ou

r tu

be

s i

nto

th

e t

ub

e s

he

et

ne

are

st

to t

he

re

ma

inin

g f

ou

r co

rne

r tu

be

s a

nd

ro

ll

(exp

an

d)

tho

se

tu

be

s u

sin

g y

ou

r e

xp

an

din

g t

oo

l, s

ocke

t a

nd

dri

ll m

oto

r. N

ow

re

mo

ve

th

e

fou

r “c

orn

er”

tu

be

s,

& t

ub

e e

nd

s a

nd

cle

an

th

e t

ub

e h

ole

s a

s p

er

the

ab

ove

in

str

ucti

on

s.

7.

Th

e r

em

ain

ing

tu

be

s c

an

no

w b

e i

nsta

lle

d i

nto

th

e t

ub

e s

he

et

at

this

tim

e.

8.

Use

a f

lat

en

de

d n

ail o

n o

ne

en

d t

o h

old

th

e t

ub

e a

nd

ke

ep

th

em

fro

m s

pin

nin

g w

hile

rollin

g.

9.

Lig

htl

y g

rea

se

th

e in

sid

e o

f th

e tu

be

b

efo

re ro

llin

g fo

r lu

bri

ca

tio

n o

f th

e ro

lle

r

(exp

an

de

r).

10

.E

xp

an

d (

roll)

all t

ub

es.

11

.A

fte

r e

xp

an

din

g w

ipe

in

sid

e o

f tu

be

to

re

mo

ve

exce

ss g

rea

se

.

12

.C

lea

n i

nsid

e o

f h

ea

de

r a

nd

he

ad

pla

te.

13

.R

ep

lace

ma

gn

esiu

m a

no

de

ro

ds (

if i

nclu

de

d w

ith

bo

ile

r).

14

.In

sta

ll n

ew

ga

ske

ts (

no

ga

ske

t co

mp

ou

nd

is n

ee

de

d).

15

.In

sta

ll h

ea

d p

late

s a

nd

nu

ts.

16

.U

sin

g a

12

" O

AL

ra

tch

et

an

d s

ocke

t, t

igh

ten

th

e h

ea

d p

late

nu

ts.

17

.R

efi

ll b

oile

r w

ith

wa

ter.

18

.P

um

p b

oil

er

pre

ss

ure

no

t to

ex

ce

ed

re

lie

f v

alv

e p

res

su

re.

19

.U

sin

g a

fla

sh

lig

ht,

lo

ok i

nto

th

e f

ire

bo

x a

rea

an

d c

he

ck t

ub

es f

or

lea

ks.

20

.If

le

aks a

re f

ou

nd

, d

rain

bo

ile

r a

nd

fo

llo

w a

bo

ve

pro

ce

du

re t

o r

e-e

xp

an

d t

ub

es(i

t is

no

t

ne

ce

ssa

ry t

o r

em

ove

le

akin

g t

ub

e,

on

ly t

o r

e-r

oll).

21

.C

on

tin

ue

pro

ce

du

re u

nti

l le

aks a

re s

top

pe

d.

Gas

kets

, tu

be

rolle

rs (

exp

and

ers)

& t

ub

e cu

tter

s ar

e av

aila

ble

fo

r sa

le o

r re

nta

l fro

m t

he

fact

ory

. P

leas

e ca

ll

the

par

ts d

epar

tmen

t fo

r d

etai

ls.

YO

UR

LO

CA

LR

EP

RE

SE

NTA

TIV

EIS:

AJAXBOILERINC

. m

ain

tain

s a

po

licy o

f co

nti

nu

ou

s im

pro

vem

en

ts a

nd

there

fore

rese

rves

the r

igh

t to

ch

an

ge s

pecif

ica

tio

ns

wit

ho

ut

no

tice.

AJA

XB

OIL

ER

IN

C.

2701 S

OU

TH

HA

RB

OR

BL

VD. •

SA

NT

AA

NA, C

A 9

2704

PH

ON

E: (7

14)

437-9

050 •

FA

X: (7

14)

437-9

060

http://w

ww

.aboile

rinc.c

om

• E

MA

IL: I

nfo

@aboile

rinc.

com

A.S

.M.E

.U

.L.

Lis

ted

TO

OL

S N

EE

DE

DS

ocket fo

r re

movin

g h

ead p

late

nuts

Curr

ent B

oile

r S

ize

Socket S

ize

100-7

50

1-1

/16"

socket

850-5

000

1-1

/4"

socket

5550-9

500

1-5

/16"

socket

10,0

00 +

larg

er

1-1

/16"

socket

Ste

am

Models

5-4

0 H

P7/8

" socket

50-7

0 H

P

1-1

/16"

socket

Sm

all

pin

ch b

ar

to p

ry h

ead p

late

loose

Sm

all

sle

dge h

am

mer

(appx. 4#)

1"

chis

el 8"

to 1

0"

long

Tube c

uttin

g tool

1"

Socket fo

r square

end o

f tu

be c

uttin

g tool (if used)

12"

OA

L r

atc

het fo

r use w

ith tube c

uttin

g tool or

expander

Exte

nsio

n h

andle

for

levera

ge

Tube e

xpander/

rolle

r-3/4

" socket

Larg

e d

rill

moto

r fo

r expandin

g/r

olli

ng o

f tu

bes

Test pum

p (

if r

equired)

PR

OC

ED

UR

EA

pply

WD

-40 o

r sim

ilar

oil

on the s

tuds b

efo

re r

em

ovin

g n

uts

.

Rem

ove the h

ead p

late

nuts

.

Rem

ove the h

ead p

late

s &

gaskets

.

Open the c

om

bustion c

ham

ber

(fire b

ox)

door.

Rem

ove o

r cover

the b

urn

er

heads (

we feel th

at it is b

etter

to r

em

ove &

cle

an the b

urn

er

heads a

t th

is tim

e for

pro

per

main

tenance o

f your

boile

r).

Gas

kets

, tu

be

rolle

rs (

exp

and

ers)

& t

ub

e cu

tter

s ar

e av

aila

ble

fo

r sa

le o

r re

nta

l fro

m t

he

fact

ory

.

Ple

ase

call

the

par

ts d

epar

tmen

t fo

r d

etai

ls.

IN

ST

RU

CT

IO

NS

F

OR

TU

BE

R

EM

OV

AL

&

RE

PL

AC

EM

EN

T

MA

TE

RIA

L

RE

QU

IRE

D2 -

Repla

cem

ent H

ead G

askets

Boile

r T

ubes:

SA

178 G

rade A

2"

Dia

- 0

.95"

Wall

By B

oile

r R

eq. Length

0

AJAX BOILER INC.2701 S. Harbor Blvd. • Santa Ana, CA 92704 714.437.9050 • Fax 714.437-9060 [email protected]

Copyright 2003 © Ajax Boiler Inc. All rights reserved. Printed in the USA Performance specifications are effective with date of issue and are subject to change without prior notice. The brand and product names contained within this document are trademarks or registered of their respective holders.

SO # Serial No. Model No.

N O T I C E This owners & operation manual provides warnings of risk of harm from improper installation, operation and/or maintenance of Ajax Products. Ajax Boiler, Inc. used ordinary care and complied with UL and ASME Standards in the design and manufacture of Ajax Products. Proper installation, operation and maintenance are covered in the manual supplied with the product. All equipment must comply with local codes.

W A R N I N G THIS PRODUCT CONTAINS CRYSTALLINE SILICA, A CHEMICAL KNOWN TO CAUSE CANCER. CONTAINS NO ASBESTOS.

Rev.3

-3.2

2.20

10

Documents

Operating and Maintenance Manual - Ajax Boiler · PDF fileOperating and Maintenance Manual AJAX BOILER INC. Designed and Manufactured in Accordance with ASME Code Section IV, Heating