Installation, Operating and Service Instructions for Frontier Models: • Steam Boiler • Cast Iron • Chimney Vent • Gas Fired ! WARNING • FTR-3-069A • FTR-4-103A • FTR-5-138A • FTR-6-172A • FTR-7-207A • FTR-8-241A • FTR-9-276A Attention Installer - Affix these instructions adjacent to boiler. Provide model number and serial number when seeking information and support. Attention Building Owner - Retain these instructions for future reference.
The Massachusetts Board of Plumbers and Gas Fitters has approved these boilers. See the Massachusetts Board of Plumbers and Gas Fitters website for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.
! WARNING Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.
I Product Description The FTR series boilers are low pressure cast iron gas fired steam boilers designed for use in closed steam heating systems at steam pressures below 15psi. These boilers are Category I draft diverter equipped appliances, which must be vented by natural draft using a lined masonry or listed metal chimney system. An adequate supply of air for combustion, ventilation and dilution of flue gases must be available in the boiler room.
III Pre-Installation ! WARNING Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. 1) Inspect shipment carefully for signs of damage. Any claim for damage or shortage in shipment must be filed immediately against carrier by consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment.
IV Locating the Boiler ! WARNING Failure to observe the following location requirements could result in a fire, explosion or Carbon Monoxide (CO) hazard. 1) Clearances: • Observe minimum clearances shown below to avoid potential fire hazard. Except as noted, these clearances apply to all combustible construction as well as noncombustible walls, ceilings and doors. Also see Figure 4.1.
V Air for Combustion and Ventilation ! WARNING • This boiler is not designed for use in a space that is depressurized relative to the outdoors. Operating this boiler in a depressurized space may cause severe personal injury or death. • INSUFFICIENT COMBUSTION AIR SUPPLY may result in the production and release of deadly Carbon Monoxide (CO) into the home. • PROVIDE ENOUGH AIR to ventilate the boiler room, and sustain combustion.
• • per 1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input. The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no finer than ¼” (4 x 4) mesh. If providing openings into adjacent rooms is undesirable, use the Outdoor Combustion Air Method.
FIGURE 5.2: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC 6” FIGURE 5.3: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC Using the Outdoor Combustion Air Method 1) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl space, which communicates directly with the outdoors. 2) Two openings are required. The top edge of the upper opening must be within 6 inches of the ceiling.
• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are used, they must be no finer than ¼” (4 x 4) mesh. • If motorized louvers are installed in the openings to the outdoors, they must be interlocked to prevent operation of the fuel burning appliances in the boiler room unless the louvers are open.
VI Venting ! WARNING • Improper venting may result in property damage and/or the release of flue gases, which contain deadly Carbon Monoxide (CO), into the home, which can cause severe personal injury or death. • Do not use plastic venting materials (such as CPVC, PVC and RADEL) to vent this boiler. • Inspect existing chimney before installing boiler. Failure to clean or replace damaged pipe or tile lining will cause severe injury or death.
4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. The National Fuel Gas Code prescribes two conditions under which an exterior chimney may be used: • In some very restrictive cases, this boiler may be vented into an exterior ceramic lined masonry chimney. See the National Fuel Gas Code for information on when exterior chimneys may be used. • An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system.
Removing an Existing Boiler from a Common Chimney In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances. At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
VII Steam Piping ! WARNING • Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh water supply to boiler upstream of a water softener. • Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Check for and correct system leaks. NOTICE: Do not use copper for steam piping for the following reasons: 1.
7) The single most important factor in determining expected life cycle of a steam boiler is the amount of fresh water added to boiler during operation. Fresh water brings minerals and oxygen into the boiler. These contaminants greatly accelerate corrosion of cast iron boiler sections. Assure all system radiators, piping and vents are absolutely leak tight. • If system contains hidden piping (hidden behind walls, buried in concrete, etc.) pressure test this piping and repair any leaks found.
FIGURE 7.1: INSTALLATION OF FACTORY SUPPLIED FITTINGS BOILER MODEL FTR-3-069A FTR-4-103A FTR-5-138A FTR-6-172A MINIMUM PIPE DIA. (IN NPT) "A" "B" "C" "D" * 2 1 1/2 1 1/4 * 2 1 1/2 1 1/4 * 2 1 1/2 1 1/4 * 2 1 1/2 1 1/4 * SECOND 2" SUPPLY RISER OPTIONAL FIGURE 7.
BOILER MODEL FTR-3-069A FTR-4-103A FTR-5-138A FTR-6-172A FTR-7-207A FTR-8-241A FTR-9-276A MINIMUM PIPE DIA. (IN NPT) "A" "B" "C" "D" 2 2 1 1/2 1 1/4 2 2 1 1/2 1 1/4 2 2 1 1/2 1 1/4 2 2 1 1/2 1 1/4 2 3 1 1/2 1 1/4 2 3 2 1 1/2 2 3 2 1 1/2 * SECOND 2" SUPPLY RISER OPTIONAL FIGURE 7.3: STEAM BOILER PIPING FOR GRAVITY RETURN, DUAL RISER BOILER MODEL FTR-3-069A FTR-4-103A FTR-5-138A FTR-6-172A FTR-7-207A FTR-8-241A FTR-9-276A MINIMUM PIPE DIA.
FIGURE 7.
VIII INDIRECT WATER HEATER PIPING NOTICE: • Some indirect water heaters may not be suitable for use with a steam boiler. Consult the water heater manufacturer’s guidelines before installing it in this type of system. • Boiler water temperatures and flow rates in this type of system may be considerably lower than those upon which the water heater manufacturer’s ratings are based. This may result in substantially longer water heater recovery times.
IX Gas Piping ! WARNING • Shut off gas supply before servicing the boiler. • All gas piping must be gas tight. Use thread compound that is listed for gas service on all threaded joints to avoid leaks, which may result in fire or explosion. • Size gas piping, regulators, valves and meters so as to provide an adequate gas flow and pressure to the boiler during operation. Failure to do so may cause poor combustion, noise, injury or death.
FIGURE 9.
X Wiring ! WARNING • All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70). • Electrical power may be supplied from more than one circuit. Disconnect electrical power to the boiler and heating system before servicing. Positively assure that no voltage is present.
FIGURE 10.
FIGURE 10.
Indirect Water Heater Wiring Figure 10.3 shows field wiring for an indirect water heater. A Honeywell R845A or equivalent DPST relay and transformer is required. The high limit described in Part VIII must also be supplied by the installer. A call for heat from the indirect water heater thermostat will energize the relay making both sets of contacts. One set of these contacts then energizes the circulator.
XI Start-up and Checkout ! WARNING Do not leave the boiler in service if it fails any of the following start-up checks. Doing so may result in fire, explosion, or Carbon Monoxide (CO) poisoning. ! WARNING • Gas leaks may result in fire or explosion. • Never use a flame to check for gas leaks. • Make sure that the area around the boiler is clear and free from combustible materials, gasoline and other flammable vapors and liquids. • Water leaks may cause extensive property damage.
FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. If you cannot reach your gas supplier, call the fire department. C. Use only your hand to push in or turn the gas control knob. Never use tools.
12) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: m) Connect a manometer to the inlet pressure tap on the gas valve (see Figure 11.2). n) Check the inlet line pressure with all gas appliances on and off. The inlet pressure at the boiler must be within the following limits regardless of what combination of appliances is firing: Inlet Press (inches w.c.) Natural Gas LP Gas Minimum 5.0 11.0 Maximum 14.0 14.
17) Check LWCO Operation – Verify low water cutoff operation while the boiler is running. Slowly open drain valve and drain boiler until the water level drops below low water cutoff line. Water still should be visible in the gauge glass when the low water cutoff shuts down the main burners. Both pilot burner and main burners should stop firing. Make sure pressure limit, thermostat or other controls have not shut off the boiler and the amber LED on LWCO is illuminated.
i) If using buckets, continue to skim until the first bucket is almost full. Remove the full bucket and switch to the second bucket while you dump the first. Do not shut off the ball valve while doing this. j) Keep skimming until the water is cool enough to touch (approximately 110F). k) When done skimming stop adding water. Drain the water to the proper fill level. l) Remove 1-1/4” ball valve and temporary skimmer piping. Replace the 1-1/4” cap removed in (b).
XII Operation Sequence of Operation (Refer to Figures 10.1 & 10.2 for connection and ladder diagrams) 1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close.
SERIES 2E Installation, Operating & Service Manual XIII Service and Maintenance 12 Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
! WARNING • Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. ATTENTION. Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Les erreurs de câblage peuvent nuire au bon fonctionnement et être dangereuses. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien terminé.
• For McDonnell & Miller #67 low water cut-offs - Remove and inspect switch and float mechanism. Inspect float bowl for mud accumulation. Clean as required. Replace the switch and float mechanism every five years or 100,000 cycles. Consult the McDonnell and Miller #67 manual for any additional maintenance information. Test the low water cut-off before placing the boiler back into service. 13) Allow the boiler to cool to room temperature.
11) Put a light in the combustion chamber and look through the flue passages from the top to verify that they have been thoroughly cleaned. 12) Replace the flue collector gasket strips. If desired, RTV-732 silicone sealant with a 500F intermittent duty temperature rating may be substituted for this rope gasket. The flue collector must be thoroughly sealed to the heat exchanger. 13) Reassemble the rest of the boiler in reverse order of above.
XIV Troubleshooting The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1) This information is only meant to be used by a professional heating technician as an aid in diagnosing boiler problems. 2) Where applicable, follow all precautions outlined in the Section XI (Start-up and Checkout). 3) In general, these tables assume that there are no loose or miswired electrical connections.
Notes 38
Troubleshooting Chart for Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs and Vent Dampers Caution: Read page 32 before attempting to use this chart START Vent damper open? Is there an audible click as R8225 relay pulls in when the thermostat calls for heat? Thermostat calls for heat Y 120 volts across black and white transformer leads? N N N Y 24 volts across blue and yellow wires inside junction box? Is yellow LED lit on LWCO? N 24 volts between P2 and 2 on CG400 LWCO? N Y Y N
Main burners light? Do burners shut down when pressure exceeds limit setting? Y N Do burners shut down when water level drops below cut-off point? Y N 24 volts across red damper lead and yellow transformer lead? END N * Defective damper * Defective or loose damper harness * Obstruction in path of damper blade N Y * Defective pressure limit control * Blockage in siphon tube Y 24 volts across standing pilot gas valve terminals or terminals 5&6 on S8600 module? Y *Grounded probe or probe lead
Ignition System Troubleshooting Chart Caution: Read page 32 before attempting to use this chart START (24 volts is present across 24V and 24V (GND) on ignition module but main burners do not light) Spark across ignitor/sensor gap? Y Does spark stop when pilot lights? Y Pilot lights? N N N * Defective ignition module Y Y N N Y * Defective ignition module Y END N 24VAC across terminals MV & MV/PV on module? 24 volts across PV & MV/PV at gas valve? * Defective ignition module 24 volts between
XV PARTS All Repair Parts may be obtained through your local Archer Boilers authorized distributor. Should you require assisstance in locating a distributor in your area, or have questions regarding the availability of Archer products or repair parts, please contact Archer Boilers main office: Archer Boilers 888-432-8887 www.archerboiler.
Key No. 1 2 3 4 5 6 Description Heat Exchanger Assembly (Complete) Base Tray Base Wrapper Burner Tray Base Front Panel Assembly (includes insulation) Burner Access Panel Part No.
Key No. 7 8 9 10 11 12 Description Base End Insulation Base Rear Insulation Base Leg Assembly Screw, Self Tapping, Phillips Pan Head, 1/4 -20 x 1/2" 1/2” x 2” Sealing Strip Flame Rollout Switch Bracket Assembly Part No.
Key No. Description Part No.
Key No.
SERVICE RECORD DATE SERVICE PERFORMED
Archer Boilers 888-432-8887 www.archerboiler.
