PurePro AGDV3 Installation, Operating And Service Instructions
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PurePro AGDV3 Installation, Operating And Service Instructions

Advantage dv series cast iron gas-fired boiler
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INSTALLATION, OPERATING
SERVICE INSTRUCTIONS
ADVANTAGE DV™ SERIES
CAST IRON GAS-FIRED BOILER
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
AGDV_-H_
Heating Contractor
Address
105248-02 - 9/14
AND
Boiler Serial Number
9700609
Installation Date
Phone Number

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  • Page 1 INSTALLATION, OPERATING SERVICE INSTRUCTIONS ADVANTAGE DV™ SERIES CAST IRON GAS-FIRED BOILER 9700609 For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number Boiler Serial Number Installation Date AGDV_-H_...

  • Page 2: Table Of Contents

    XI. Repair Parts ........31 V. Venting ..........9 VI. Electrical ..........19 Table 1A: Ratings Advantage Gas Ratings Boiler Model Input (MBH) DOE Heating Capacity (MBH) Net AHRI Rating Water (MBH) AFUE (%) AGDV3 60.8 85.5 AGDV4 91.2 85.4 AGDV5 121.6 85.3 AGDV6 152.0...
  • Page 3 Figure 1: Minimum Clearance to Combustible Materials...

  • Page 4: Pre-Installation

    I. PRE-INSTALLATION Provide clearance between boiler jacket and WARNING combustible material in accordance with local fire ordinance. Refer to Figure 1 for minimum clearance Carefully read all instructions before installing from combustible material for closet installation. boiler. Failure to follow all instructions in proper Provide 1/2"...

  • Page 5: Water Piping And Trim

    III. WATER PIPING AND TRIM If boiler is connected to heating coils located in WARNING air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with Failure to properly pipe boiler may result in flow control valves or other automatic means to prevent improper operation and damage to boiler or gravity circulation of boiler water during operation of...

  • Page 8: Gas Piping

    IV. GAS PIPING Size gas piping. Design system to provide adequate gas 4. All above ground gas piping upstream from manual supply to boiler. Consider these factors: shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas 1.

  • Page 9: Venting

    V. Venting WARning CAUtiOn Vent this boiler according to the instructions. install this boiler according to this manual and Failure to do so may cause products of the national Fuel gas Code, AnSi Z223.1/nFPA combustion to enter the building resulting in 54, or applicable provisions of the local building severe property damage, personal injury or codes.
  • Page 10 V. VENTING (continued) 4. If a non-standard length is required, there are two WARNING options: a. Select adjustable length pipe from Table 2. The Do not use this boiler with galvanized, Type 304 pipe adjusts 7” from 12 ¾” to 19 ¾”. Or, or Type 316 stainless steel, non metallic or any ®...
  • Page 11 V. VENTING (continued) WARNING DRAFT HOODS, VENT DAMPERS and other IF USING A CHIMNEY AS A CHASE for the vent, obstructions or openings in the vent system are do not vent any other appliance into the space prohibited. between the chimney wall and the vent. ELIMINATE LOW SPOTS in the vent where flue DO NOT REDUCE THE DIAMETER of the vent pipe.
  • Page 12 V. VENTING (continued) Figure 7: Approved Terminal Locations 13. Vent-Air Intake system may be installed through Horizontal Stainless Steel Vent Installations wall 3" - 24" thick. 1. Install vent and intake piping per Figure 8. Planning Vertical Installations — 2. Where the vent pipe penetrates any combustible 1.
  • Page 13 = equiv. ft. Total* a.+b.+c.+d.+e.= equiv. ft. * Total length cannot exceed 50 equivalent feet length (AGDV3 through AGDV6) . Vent and combustion air terminals do not count towards total equiv. ft. Figure 8: Separate Horizontal – Vent/Air Intake Installation...
  • Page 14 V. VENTING (continued) 5. An optional concentric adapter kit (P/N 61106012) is Vertical Stainless Steel Vent Installations available for 3” & 4” stainless steel vents to provide 1. Install vent and intake piping per Figures 11 thru 13. a single exterior wall penetration accommodating 2.
  • Page 15 V. VENTING (continued) Figure 10: Optional Separate Horizontal Vent Terminal Installation Figure 11: Typical Vertical Stainless Steel Venting...
  • Page 16 V. VENTING (continued) Figure 12: Vertical Vent/Air Termination Details for Stainless Steel Direct Vent Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.
  • Page 17 V. VENTING (continued) Combustion Air If the boiler is a Direct Vent boiler and exchanges all combustion air and combustion products directly with the outdoors, there are no special requirements for providing combustion, ventilation, and dilution air. If the boiler is chimney vented, power vented or induced draft and draws combustion air from within the building, follow the steps below to determine how to provide air to the boiler.
  • Page 18 V. VENTING (continued) 7. Duct this opening vertically or horizontally Do the walls and ceilings exposed to the outside directly to the outdoors, or directly to a space that atmosphere have a continuous water vapor retarder communicates directly with the outdoors, such as an with a rating of 1 perm or less, with openings gasket attic or crawlspace.

  • Page 19: Electrical

    VI. ELECTRICAL General. Install wiring and electrically bond boiler to For installations using zone valves provide separate ground in accordance with requirements of authority transformer for zone valve wiring. Consult zone valve having jurisdiction, or in absence of such requirements, manufacturer for assistance.
  • Page 20 VI. Electrical (continued) Figure 15: Schematic Ladder Diagram...

  • Page 21: System Start-Up And Checkout

    VII. SYSTEM START-UP AND CHECkOUT IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: •...
  • Page 22 VII. System Start-up and Checkout (continued) CAUTION 11. Test gas piping and connections between Combination Gas Valve and manifold, orifices, and pilot piping for leaks after boiler is operating. Use soap solution or other approved method. Check Gas Input to Boiler 1.
  • Page 23 VII. System Start-up and Checkout (continued) Check Pilot Burner Flame. Combustion Chamber Burn-off 1. See Figure 18. The pilot burner should be lit only 1. The mineral wool combustion chamber panels if thermostat is calling for heat. The pilot burner may contain a cornstarch based binder that must be produces three (3) flames.

  • Page 24: Operation

    VIII. OPERATION Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. Electronic Ignition Module See Figure 19 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. Table 3 cross- references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams.
  • Page 25 VIII. Operation (continued) v. Check the pilot flame. It must be blue, Check the pilot burner operation/ignition steady and envelop the flame sensing rod sequence during ignition cycle: 3/8” to ½”. i. Restore boiler power at circuit breaker or vi. If needed, adjust pilot flame by fuse box.

  • Page 26: Service And Maintenance

    IX. SERVICE AND MAINTENANCE Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 27 IX. Service and Maintenance (continued) Figure 21: Operating Instructions...
  • Page 28 IX. Service and Maintenance (continued) WARNING SERVICE on this boiler should be undertaken TURN OFF ALL GAS AND ELECTRIC power only by trained and skilled personnel from a supplies to the boiler before servicing. Contact qualified service agency. Inspections should be with or release of dangerous flammable gas, performed at intervals specified in this manual.

  • Page 29: Troubleshooting

    X. TROUBLESHOOTING Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. Electronic Ignition Module (see Figure 22)
  • Page 30 X. Troubleshooting (continued) "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.

  • Page 31: Repair Parts

    XI. REPAIR PARTS All Advantage Repair Parts may be obtained through F.W. Webb Company, 1 Bon Terrain Drive, Amherst, NH 03031 or any other F.W. Webb Company location. [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Block Assembly 102287-03 102287-04...
  • Page 32 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Canopy Assembly - Sea Level 105168-03 105168-04 105168-05 105168-06 Canopy Gasket Kit 6206001 Fan Gasket 8206085 102706-01...
  • Page 33 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Base Wrapper 71807031 71807041 71807051 71807061 Base Tray 102543-03 102543-04 102543-05 102543-06 Burner Tray Assembly 61807031 61807041 61807051 61807061 Base Front Panel 102705-03 102705-04 102705-05 102705-06 Burner Access Panel...
  • Page 34 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Gas Valve (Natural Gas), Honeywell 81660282 VR8204P1171 Gas Valve (LP Gas), Honeywell 81660146 VR8204C3015 ½" Gas Manifold 82207031 82207041 82207051 82207061 Burner Orifices - Natural Gas #49 [10] 822709...
  • Page 35 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Air Box Assembly 61807032 61807042 61807052 61807062 Air Box Door 71807034 71807044 71807054 71807064 Combustion Air Diffuser 71807049 71807059 71807069 Pilot Tube Gasket Cover Plate 7096002 Pilot Tube Gasket...
  • Page 36 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Honeywell S8670E EI Module 100959-01 HydroStat 3200 w/Sensor 105161-01 Honeywell Relay Module 80160096 Differential Pressure Switch (Natural Gas) 80160762 104604-01 80160760 Differential Pressure Switch (LP Gas) 104576-01...
  • Page 37 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Jacket Left Side Panel 104249-01 Jacket Right Side Panel 104250-01 Jacket Rear Panel 102569-03 102569-04 102569-05 102569-06 Jacket Vestibule Panel 104246-03 104246-04 104246-05 104246-06 Jacket Top Panel 104247-03...
  • Page 38 XI. Repair Parts (continued) [Quantity] Part Number Description AGDV3 AGDV4 AGDV5 AGDV6 Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 30 PSI Relief Valve 81660363 Drain Valve 102802-01 Vent Terminal 8110701 Vent Connector 8110703 Vent Terminal 8116310 Air Intake Terminal (not shown)

This manual is also suitable for:

Agdv5Agdv6Agdv4

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