American Standard Aerozen G2 User manual

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G-2 GAS BOILER
by
AMERICAN -$tandattd
INSTALLATION -OPERATION
AND
MAINTENANCE MANUAL
SUPPLEMENT
NON- PACKAG . ED
FOR STEAM
BOILERS WITH
FLUSH OR DELUXE JACKETS
APPROVED BY AMERICAN GAS ASSOCIATION
NOTICE TO INSTALUI AND OPEIATOI
THIS IOOKlET MUST II AFFIXED ON
Ol ADJACENT TO THE HEATING ~MENT
_AmRICAN-$taftdattef
..................................
BP-5-G2 Sup. 11EV. 11 ~rl
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STANDARD HEATER IO
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13
G-2 STEAM GAS BOn.ER
2" FLOW
Fig. 1
Boiler with Deluxe Jacket
t
1
BOILER No. OF No. OF
A B c 0
NUMBER
SECTIONS BURNERS
G-230 3 2
13 Va
6~6
4
11
5
1!
G-240
4 3
16~
8~6
5 19"2
G-250
5 4
19%
91~6
5 19"2
G-260
6 5 22Ys
11~6
6 19
G-270 7 6
26 Va
13 !-;
6 6
19
G-280
8 7
29~ 141ks
7
19~
G-290
9 8
32~
16 ~6
7
19\
G-2100 10
9 35Ys 171~6
8
19~
G-211 0 II 10
39 Va
19 ~6
8
19Ve
NOTE-: EXTERNAL DRAFT HOOD IS ONLY
PROVIDED FOR
G-23-D BOILER
p::;~:;;=~::;- d __ r~~:~
BOILER No. OF No. OF A B c 0 E
NUMBER
SECTIONS BURNERS
G-23F
3 2 II
51/2
4
13 7
G-24F
4 3 14
1
/4 7Va 5
13
3
~
7
G-25F
5 4
11 v2
8~4
5 133/4
7
G-26F
6 5
20~4
10~
8
6
16
1
/2 9
G-27F
']
6 24
12 6 16 y2
9
G-28F
8 7
27~
13~
8
7 203/4 12
G-29F
9 8
30V
2
15~
7
20
3
/4
12
G-210F
10 9
33~4
16'V
8 8 253
/4
16
G-211 F
II 10 37
18Y
2 8
25
3
/4
16
SIDE
FRONT VIEW
Fig. 2 Boiler with Flush Japket

•
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3
4
5
G-2 STEAM GAS BOILER
c 2•
FLOW
c
2' RETURN
SIDE VIEW FRONT VIEW
SECTION ASSEMBLY
SHOWING TAPPINGS
FOR STEAM BOILER
CONTROL APPLICATION
LOCATION SIZE OF
CONTROLS
ON BOILER TAPPING
A 3"
BLOW-OFF
B I "
"2
PRESSURE GAGE
c 3 "
~
SAFETY VALVE
Fig. 3 - Location of Tappings for Boiler Controls
2" SUPPLY __ _
CONNECTION
FOR HARTFORD
RETURN
EQUALIZER PIPE
I ~,FOR G-23 THRU G-27
2"FOR G-28 T HRU G-211
2 1
Fig. 4 - Boiler with Flush
Fig. 5 - Boiler with Deluxe
Type Jacket
Type Jacket
1. Junction Box
4. Siphon Fitting
2. Safety Valve
5. Low Water Cutoff
3. Steam Limit Control
6. Water Gauge
2

G-2 STEAM GAS BOILER
REFER TO WATER BOILER INSTALLATION MANUAL (Form BP-5-G2) PACKED IN PLATEJWRK AND
CONTROL BOX FOR DETAILS NOT INCLUDED IN THIS SUPPLEMENT.
INSTALLATION OF JACKET - Proceed as directed in the Installation Manual for water
boilers, with the following exceptions:
3
FLUSH TYPE JACKET - Select L.H. Side Panel (has 7-5/0
11
diameter knockout) and remove
this knockout for all steam boilers also two knockouts for water gauge connections.
Assemble steam gauge to right end section with 3/4" x 1/2" pipe bushing before
assembling jacket.
DELUXE TYPE JACKEl' - Select L.H. Side Panel (has 4" diameter knockout within a 7-5/8
11
diameter knockout) and remove the 4
11
knockout .for all steam boilers. Remove two
knockouts for water gauge connections. Assemble steam gauge to right end section
with 3/4
11
pipe nipple and coupling before assembling the jacket.
INSTALLATION OF HATER COLlJMN TRIM AND CONTROLS: -
1. After assembly of the jacket install a 1/2
11
x 4-1/2
11
brass pipe nipple in the
lower 1/2" water gauge tapping.
2. Install the low water cutoff on this nipple before connecting any piping to the
return tapping.
4.
5.
6.
7.
Install a 1/2
11
x 4-1/2
11
brass nipple together with the tee connecting fitting
from the low water cutoff in the upper 1/2" water gauge tapping.
Install the brass tube and connectors as illustrated in the instruction sheet
provided with the low water cutoff.
Install the water gauge fittings and gauge glass.
Install the syphon fitting in the 1/4
11
pipe tapping on top of the low water
cutoff and assemble the steam limit control to the syphon.
Install the safety valve in the 3/4" tapping on top of the boiler using the
nipple and coupling provided also install the drain cock in the 3/4
11
tapping
at the left side of the boiler.
NOTE - In case of Massachusetts boilers where 1" safety valve is required,
it should be installed by means of a reducing bushing in the 3" tapping
provided in the cover plate on the left side.
8. Mount the junction box on the jacket side panel with the sheet metal screws
provided. Connect wiring to accord with applicable installation shown on the
wiring diagram for steam boilers.
Refer to Figure 4 for steam boiler with Flush jacket.
Refer to Figure 5 for steam boiler with Deluxe jacket.
Figures 4 and 5 show a typical method of connecting the supply and return piping
t.o the steam boiler. Return connections should be - made through a Hartford loop.
ALL SUPPLY AND RETURN PIPING SHOWN IS NOT SUPPLIED BY A.R. and S.S. CORP. THIS
APPLIES ALSO TO THE DRIP LEG PIPING SHOWN Bi!:LOW THE GAS SHUTOFF VALVE.
Bottom pan (floor shield) is provided on all steam boilers. Refer to Page 11 in the
Installation Manual for assembly view.

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LOW WATER
CUT OFF
WIRING DIAGRAI.A
AMERICAN -STANDARD C-2 GAS BOILER
STEAM SYST EM WITH AUTOMAT IC WAT[R FEEDER
ELECTRIC•
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SWITCH
LOW WATER
CUT OFF
S.t.FETY
SWITCH
LEGEND :
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SAFETY
SWITCM
LIMIT
CONTROL
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BOX
1
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SWITCH WITH IGNITER COIL.
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WIAI'IIG OIAGRAirol FOR ELECTRIC IGNITION
AMERICAN·STA~ G-2 Got.S BOILER
STEAM SYSTfW
VALV! ONLY 1
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AUTOMATIC
GAS VALliE
®
OPERATING
CONTROL
LOW WAT(R
CuT orr
LIMIT
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GAS BOILER
LOW W!<TER
CUT OFF
LIMIT
CONTROL
_..-NOTE W 1! A BLIND
TERMINAL
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WIRING OI...GRAit;l
AMERICAN - STANDARD C.·Z GAS 801\.EA
STEAM BO I LER
PILOT
S AFETY
SWITCH
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CLASS Ill
.....,.._ WIRE
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PILOT
S•FETY
SWITCH
LEG[NO;
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1\o!AINTAINING CONSTANT STE AM PRESSURE -NO RQQ t.A THERM OSTAT
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LOW WATER
CUT OFF
OUTDOOR
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24¥-SOV,O. f"EEOER
T(o";i;~~~~R AMERICA"' STANDARD G 2 G~:T:~~R
DUAL GAS C ONTROLS
WlfHNG DIAGRAM FOR N"T a. PROP ANE G ASES
SH AU SYST£j,j
LEGEND:
CLASS •1
_.,.,.,. WIRE
PIL-OT GENERATOR
GENERAL CONTROLS
PG-9A03
Tt-~ERMOPILOT VALVE
PtL.OT GENERATOR I.IO OEL.
GENERAL CONTRQI..S UA-2
{FOR ~ SHUTOFF ONLY)
THEIWOST.o.T
G
LNERAL COtiiTROLS
T·80A
AUTOMATIC
GAS VALVE
GENER"L CON TRO LS
B-60
[rij!]
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LEGEND:
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-a::ASS •1 WIRE
FEEDER
(OPTIONA~
WIRING DIAGRAM FOR SELf· ENERGIZING SYSTEM
USING GENERAL COf4TI'IOl.$
FOR STEAU SYSTEM ®
8G -13355-D
THESE WIRING DIAGRAMS FOR STEAM BOILERS ONLY
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G-2 STEAM GAS BOILER
FILLING SYSTEI,:
CAUTION: Never start boiler unless it is properly filled. Steam boilers should be filled
until water is visible approximately half way up in the water gauge glass. After boiler
is in operation make-up water should be added slowly.
CHECK-UP OF LO'J ~TATER CUTOFF
1. Light pilot in accordance with applicable instructions shown in the installation
manual for water boilers. Turn thermostat to highest temperature. Automatic gas
valve should open.
2. Open blow-off valve on bottom of cutoff and drain water until the water level in
the boiler drops to approximately 1/4
11
visible in the gauge glass. Automatic
gas valve should close.
3. Refill until water level is approximately half way up in the water gauge glass.
Automatic gas valve should open.
MAINTENANCE OF BOILER lf'HILE IN OPERATION
1. Check level regularly and add water slowly when needed.
2. This boiler is fired automatically.
3. Test safety valve at beginning of season and once a month, thereafter: -
a. Fasten cord or wire to valve lever.
b. Vthen pressure is up, stand safe distance away and pull cord.
(Steam should be released)
CLEANING BOILERS - The grease used to lubricate the cutting tools during erection
of new piping systems serves as a carrier for dirt, with the result that a scum of
fine particles and grease accumulates on the surface of the water in all new boilers,
while heavier particles may settle to the bottom of the boiler and form sludge.
These impurities tend to cause foaming, preventing the generation of steam and
causing an unsteady water line.
This unavoidable accumulation of oil and grease should be removed by blowing-off
the boiler as follows;
Blow-off
Val.ve
'
To Drain
Sai'et:r Val.n
If not already provided, install a surface
blow connection of at least 1-1/4
11
nominal
pipe size with outlet extended to within
18 inches of the floor or to sewer,
inserting a valve in line close to boiler.
Bring the water line to center of outlet,
raise steam pressure, and while fire is
burniHg briskly open valve in blow-off line.
When pressure recedes, close valve and repeat
process adding water at intervals to maintain
proper level. As a final operation bring the
pressure in the boiler to about 10 lbs. close
blow-off and manual shutoff valvea,then open
drain valve. After boiler has cooled, partly
fill and flush out several times before filling
it to proper water level for normal service.
The use of soda or any alkali, vinegar or any
acid is not recommended for cleaning heating
boilers because of the difficulty of complete
removal an~ the possibility of subsequent
injury after the cleaning process has been completed. Illustration shows piping
arrangement for blowing-off steam boilers.
CAUTION - After blow-off operation, a checkup should be made of the low water cutoff
as directed above.

Plumbing and Heating Division
AMERICAN RADIATOR 8c STANDARD SANITARY CORPORATION
40 WEST 40TH STREET, NEW YORK 18, N.Y.
,•