SG Series Boilers – Installation and Service Manual
44
INDEX Section 8
Section Page
Dimensions and Specifications – For Models SG-135 to SG-270................................................................ 2
Dimensions and Specifications – For Models SG-315 to SG-495................................................................ 3
Boiler Water Flow Data ................................................................................................................................. 4
About Our Manuals ....................................................................................................................................... 5
1 Lighting Instructions......................................................................................................................... 5
1.1 Safety Instructions............................................................................................................................... 5
1.2 Lighting Instructions ............................................................................................................................ 5
1.3 Lighting Instructions for Intermittent Electronic ignition with Combination Gas Valve ........................ 6
1.4 Lighting Instructions for Intermittent Electronic Ignition with Non-Combination Gas Valve................ 6
1.5 To Turn off Gas to the Boiler or Emergency Shut-Off.........................................................................7
1.6 Controller Programming and Service Codes ...................................................................................... 7
1.7 BC-1 Controller (For 2 stage boilers only) ........................................................................................ 12
2 Installation Instructions.................................................................................................................. 17
2.1 Receiving........................................................................................................................................... 17
2.2 Installation Codes and Requirements ............................................................................................... 17
2.3 Location............................................................................................................................................. 17
2.4 Gas Service Piping............................................................................................................................ 18
2.5 Air Supply for Combustion and Ventilation ....................................................................................... 18
2.6 Corrosive Atmospheres..................................................................................................................... 18
2.7 Venting .............................................................................................................................................. 19
2.8 Automatic Vent Damper .................................................................................................................... 20
2.9 Blocked Vent and Flame Roll-out Safety Switches........................................................................... 20
2.10 Boiler Piping System ......................................................................................................................... 21
2.11 Corrosion Prevention (Internal)......................................................................................................... 21
2.12 System Operating Requirements...................................................................................................... 21
2.13 Pressure Relief Valve........................................................................................................................ 22
2.14 Electrical Wiring................................................................................................................................. 22
3 Startup Instructions ........................................................................................................................ 23
3.1 Pre-startup......................................................................................................................................... 23
3.2 Startup ............................................................................................................................................... 23
3.3 Check Burner System ....................................................................................................................... 24
3.4 Aquastat Adjustment ......................................................................................................................... 25
3.5 Gas Manifold Pressure...................................................................................................................... 25
3.6 Check Input & Orifices....................................................................................................................... 25
3.7 Check for Draft Hood Spillage........................................................................................................... 26
3.8 Check of Controls.............................................................................................................................. 26
3.9 Check for Gas Leaks......................................................................................................................... 27
3.10 Installer’s Checklist............................................................................................................................ 27
4 Service & Maintenance Instructions ............................................................................................. 28
4.1 Service & Maintenance Instructions.................................................................................................. 28
4.2 Cleaning Procedure........................................................................................................................... 28
4.3 Service Checklist............................................................................................................................... 29
4.4 Caution: Water Replenishment ......................................................................................................... 30
4.5 Refractory Handling Procedure......................................................................................................... 30
5 Replacement Parts .......................................................................................................................... 31
6 Wiring Diagrams.............................................................................................................................. 34
7 Troubleshooting Guide................................................................................................................... 42
8 Index ................................................................................................................................................. 44
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