ROYALL 6130NS, Instruction Manual

Page 1: ...ation INDOOR PRESSURIZED BOILER Models 6130NS 6150NS 6200NS 6300NS 6490NS OUTDOOR PRESSURIZED BOILER Models 6150 6200 6300 6490 www royallfurnace com 325 South Park Street Reedsburg WI 53959 Phone 608 768 8508 ...

Page 2: ...or substantial property damage OBSERVE AND FOLLOW ALL SAFETY INSTRUCTIONS The following defined terms are used throughout this manual to bring attention to the presence of hazards of serious risk levels or important information concerning the life of the product HAZARD DEFINITIONS DANGER Dictates presence of hazards that WILL CAUSE SERVER personal injury death or substantial property damage WARNIN...

Page 3: ...over other brands __Price __Features __Safety __Previously owned Royall __Recommended to you __Other PRODUCT REGISTRATION CARD Warranty is in effect from the date of purchase upon receipt of this card NAME STREET ADDRESS CITY STATE ZIP CODE PHONE EMAIL ADDRESS DATE OF PURCHASE MODEL NUMBER SERIAL NUMBER DEALER CITY STATE Reason for choosing Royall over other brands __Price __Features __Safety __Pr...

Page 4: ...325 South Park Street Reedsburg WI 53959 OWNER S REGISTRATION CARD MUST BE COMPLETED AND RETURNED T0 ROYALL AT TIME OF INSTALLATION Brand Products Place Stamp Here 325 South Park Street Reedsburg WI 53959 Brand Products ...

Page 5: ...BOILER INSTALLATION VENTING Pg 13 PLUMBING CONNECTIONS Pg 15 COMPONENT ASSEMBLY Pg 16 ELECTRICAL Pg 18 AQUASTAT CONTROL SETTING Pg 20 ELECTRICAL DIAGRAMS Pg 21 SYSTEM PLUMBING Pg 22 TYPICAL SYSTEM SCHEMATICS Pg 23 START UP INITIAL SYSTEM FILL Pg 26 FIRST FIRE Pg 28 OPERATION BOILER CONTROL Pg 28 BURNING WITH WOOD Pg 29 BURNING WITH COAL Pg 30 EMERGENCY ACTIONS Pg 32 MAINTENANCE Pg 33 TROUBLE SHOOT...

Page 6: ... NEVER use automotive anti freeze or ethylene glycol in the system Using these glycols can destroy rubber pump and valve seals leading to hazardous leakage and system damage Monitor and inspect the system and appliance regularly for leakage NEVER operate without a properly installed pressure relief valve watts M335 or Apllo 407 1035 or equiva lent which discharge water and relieve pressure at 30 p...

Page 7: ... fuel to these units with an automatic stoker device DO NOT attempt to supply fuel to these units with an automatic stoker device PRESSURIZED BOILER SPECIFICATIONS 6 MODEL NUMBER 6130 6150 INDOOR OUTDOOR 6200 INDOOR OUTDOOR 6300 INDOOR OUTDOOR 6490 INDOOR OUTDOOR 130 000 780 6 25 cubic ft 26 10 X 14 150 000 905 8 1 cubic ft 26 10 X 14 200 000 1250 13 0 cubic ft 26 17 X 17 300 000 1650 17 7 cubic f...

Page 8: ...shut off during fuel loading and fire box maintenance A two position safety latch is installed on the fuel door and the ash pan door Initial release of the latch should be followed by a brief hesitation to allow ignition of unburned gases Force from the unburned gases igniting can cause the door to abruptly swing open to the 2nd position of the latch which stops further opening forcing the ignitio...

Page 9: ...aced without draining the system It is recommended that isolation ball valves be installed at the boiler to assist in maintenance WATER SUPPLY A tee and additional drain valve installed in the system will assist in filling the appliance Typically the existing boiler system has a keep fill connection already installed The boiler should be filled the first time according to the initial fill manual s...

Page 10: ... GASOLINE OR OTHER FLAMMABLE VAPORS ARE LIKELY TO BE PRESENT The Indoor boil is designed to be installed inside the building being heated either as a stand alone unit or in combination with another boiler All installations must be in accordance with local and state codes which may differ from this manual FOUNDATION The Indoor boiler must be located on a 2 minimum thickness concrete foundation pad ...

Page 11: ... TO BACKWALL 18 FLUE TO SIDEWALL 30 FLOOR PROTECTION FOR INSTALLATION ON NON COMBUSTIBLE FLOOR ONLY MAXIMUM DRAFT 0 06 IN WATER COLUMN ELECTRICAL RATING 120 V 0 5 AMP 60 HZ OPERATION MAINTENANCE FUEL BURN SOLID WOOD OR COAL ONLY LOAD FUEL CAREFULLY OR DAMAGE MAY RESULT DO NOT STORE FUEL OR COMBUSTIBLES NEAR UNIT DO NOT USE CHEMICALS OR FLUIDS TO START FIRE DO NOT BURN GARBAGE GASOLINE NAPTHA OR EN...

Page 12: ...e is in place directly behind the blower mounting opening GRATES all boilers The unit comes with grates installed inside the fire box Verify that the grates are in place and operate freely DOOR GASKETS all boilers The unit comes with the door gaskets installed in both the fuel door and ash pan door Verify that they are in place SMOKE DAMPER all boilers The unit comes with the smoke damper assembly...

Page 13: ...IT 1 Attach Shroud mount corners to Boiler using supplied hardware Each corner is designed to fit a specific corner of the unit 2 Attach Shroud side panels to corners Panels will fit inside the corners 3 Install Shroud top Top must be installed before aquastat is installed Attach with supplied hardware SHROUD MOUNTING CORNER SHROUD SIDE SHROUD TOP ...

Page 14: ...eat for 2nd side MODEL 6150 6200 12 Full 2 Cut Bricks Starting in the BACK of the unit place brick on end then add 4 full brick on end Last lay 2 full bricks side down Repeat for 2nd side MODEL 6300 18 Full Bricks 2 Cut Bricks Starting in the BACK stand 1 cut brick then 7 full brick side by side Then lay 2 bricks stacked side to side in the front Repeat for 2nd side MODEL 6490 36 Full Bricks Start...

Page 15: ...aintain 2 clearance to combustibles 2 Boiler must be the only heating appliance connected to a single chimney flue 3 Keep the connector as straight and short as possible A Minimize elbows B Maximum horizontal distance between boiler and chimney 6 Ft C Male end should point back to boiler D Horizontal runs must be pitched back to the boiler in accordance with local Building Codes typically 1 4 pitc...

Page 16: ...nd Chimney height may have to be raised to overcome downdraft conditions Improper use or failure to maintain the boiler may cause nuisance conditions Persons operating this solid fuel boiler are responsible for operation so as not to cause nuisance conditions Even proper use and maintenance of the boiler and meeting the distance and stack height recommendations and requirements in State and local ...

Page 17: ...September 2012 Page 15 PLUMBING CONNECTIONS SIZE OF BOILER FITTINGS Front View 2 6 5 4 Back View 8 3 1 7 ...

Page 18: ...RE RELIEF VALVE 3 A Apply pipe sealer and Teflon tape to threads B Install in threaded coupling in upper center back of boiler C Tighten pressure relief valve with proper wrench D Do not over tighten Before filling the system ensure the pressure relief valve is installed Use only a boiler relief valve set to limit pressure to 30 psi Failure to comply with these guidelines could result in failure o...

Page 19: ...st water If an auto fill valve is installed it is recommended that a routine system check for leaks be established Also careful monitoring of the relief valve discharge area should be conducted If a feed water line and valve are incorporated a back flow preventer is required to preclude heating system water from entering the domestic system INSTALLATION ELECTRICALS BASIC ELECTRICALS For your safet...

Page 20: ...power 115 V 60 Hz 15 Amp to the junction box 4 Connect the MASTER switch Connect power Hot Black to one side Wire nut a lead from the other side to both the FAN switch and to the pump 5 Route power from the other side of the FAN switch to the aquastat attach to R 6 Route power from the aquastat B to the blower Connect Black wire to Black wire on blower Connect White wire to one White wire on blowe...

Page 21: ...rew in the top of the unit 4 Replace cover ADDITIONAL SAFETY CONTROLS HIGH TEMPERATURE LIMIT CONTROL If installation is to comply with ASME or Canadian requirements an additional high temperature limit is required Install control in supply piping close to the appliance Set second control to approx 20 F above set point of first control Maximum set point should be established to protect weakest comp...

Page 22: ...September 2012 Page 20 AQUASTAT CONTROL SETTING ...

Page 23: ...tly mounted The motor canister must be horizontal C Body has an arrow on the casting that indicates direction of flow D To rotate the motor canister remove the four motor bolts rotate 4 8 Max motor and replace bolts Ensure the junction box is NOT located underneath the circulator E When boiler is operating pump will feel hot to the touch This is normal 3 PRIMARY SECONDARY PIPING A Primary Secondar...

Page 24: ...n a system pump is not necessary All pumps must be sized properly based on flow requiems EXPANSION TANK Hydronic heating systems require an expansion tank to allow water to expand contract as it heats or cools without adversely affecting system pressure A diaphragm type expansion tank is recommended The tank must be installed vertically Typically it is attached to the bottom of an air scoop An exi...

Page 25: ...oiler 2 Set 150 higher than aquastat on solid fuel boiler but never over 2000 F 3 Wiring installation a Route low voltage wire from R screw and W spade on safety limit aquastat into the existing relay on boiler or to the zone valve b If you have several zones in your heating system wire a safety aquastat to allow circulation through the largest zone Wire a safety limit in parallel with the thermos...

Page 26: ...ition closely spaced Tees 4 to 8 inches apart 3 For the zone pump use either a zoning circulator with built in relay or a regular pump with a zone pump control panel WIRING A ZONING CIRCULATOR 1 Route wire from thermostat to R on safety limit aquastat 2 Route wire from W on safety limit aquastat to 1 on zoning circulator 3 Route wire from 2 on zoning circulator to thermostat SAFETY LIMIT AQUASTAT ...

Page 27: ...y the solid fuel boiler MIXING VALVE DETAILS The mixing valve MUST be piped such that a pump pulls water through it The best location for the pump is 10 to 12 down stream of the Mixed port of the mixing valve Multiple pumps in parallel require check valves on the outlet of each pump MIXED TEMPERATURE SYSTEMS Follow the instructions for high temperature systems as modified by the diagrams below Cal...

Page 28: ...scharge if pressure exceeds 30 psi The person pressurizing the appliance must either be able to see the pressure gauge or must be in direct communications with someone who can see the pressure gauge DO NOT EXCEED 45 PSI Failure can result in severe personal injury death or substantial property damage I Test for no longer than 10 minutes at 29 psi Ensure constant gauge pressure has been maintained ...

Page 29: ...ped at the top of the boiler C Crack open drain valve C and repeat purging D Slowly open Drain Valve G until Boiler pressure indicates 10 psi E Open Isolation Valves B and C F Verify that solid fuel boiler pump isolation flanges are open and start the solid fuel boiler pump Verify that it is running by placing the blade of a screw driver against the pump motor and the butt against your ear G Open ...

Page 30: ... of wood to form a stable base for the coal It will take ten to twenty minutes before they are thoroughly ignited and ready for the coal Adding the coal too soon could cut the air supply and smother the fire B Add a thin layer of coal preferably smaller chunks to the wood fire being careful not to disturb it too much or cut off the draft C After the coal is ignited and burning well add a second he...

Page 31: ... weight The following are general guidelines for wood selection Hardwoods burn better than softwoods Larger pieces burn better than small pieces 25 moisture content is optimum Higher moisture content wastes energy boiling off water Lower moisture content burns rapidly and inefficiently The type of wood will determine how often the unit will have to be refueled It may take a week of close attention...

Page 32: ...ELING 1 Place the FAN switch in the OFF position 2 Pull smoke bypass damper rod out and wait one minute 3 Open the fuel loading door slowly 4 Pull the glowing coal to the front of the fire box Try not to disturb the fire too much 5 Add new coal to the back of the fire box being careful not to seal off the top It is important to leave a red spot of glowing coals visible after adding new coal to ens...

Page 33: ...ould be inspected at least twice monthly during the heating season to determine if a creosote buildup has occurred 6 If creosote has accumulated it should be removed to reduce the risk of a chimney fire Note hotter fires deposit less creosote Creosote formation can be high during fall and spring thus require more frequent cleaning compared to the coldest months Be prepared to handles a chimney fir...

Page 34: ...se of the overheating Refill the system if necessary CHIMNEY FIRE 1 CALL 911 INDOOR UNITS ONLY 2 EVACUATE THE BUILDING INDOOR UNITS ONLY 3 Manually turn off the draft fan at the FAN switch and close damper plate 4 Leave the doors securely closed 5 DO NOT TURNOFF THE SWITCH MASTER The pump must have power to remove heat from the appliance LOSS OF ELECTRICAL POWER 1 Shut blower damper plate fully 2 ...

Page 35: ...s a result creosote residue accumulates on the flue lining When ignited this creosote makes an extremely hot fire When burning wood the chimney connector and chimney should be inspected every 2 4 weeks through out the season and build up removed MONTHLY Examine door gasket and draft fan shutter Ensure airtight seal Replace as required EVERY THREE MONTHS Clean heat exchanger and baseboard radiators...

Page 36: ...is running Aquastat Inspect and test the aquastat Verify operation by turning aquastat temperature below the appliance temperature The boiler should cycle off Return aquastat to original setting Air Vents Inspect automatic air vents The cap must be unscrewed one turn to allow air to escape If the air vent is leaking remove cap and briefly push valve and then release to clean the valve seat Replace...

Page 37: ...F NOWATER FLOWS VALVE IS INOPERATIVE SHUT DOWNTHE APPLIANCE UNTIL A NEW RELIEFVALVE HAS BEEN INSTALLED AT LEAST ONCE EVERY THREE YEARS Safety Relief Valves should be re inspected by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tam...

Page 38: ...g If pump is not running or an isolation valve is shut or an air lock is stopping circulation appliance can overheat 3 PROBLEM NOT ENOUGH HEAT OUT OF THE APPLIANCE If the appliance reaches operating temperature and draft fan shuts off it is working properly If draft fan does not shut off see Problem 4 Check the following A System water flow rate too low This can be caused by The circulating pump m...

Page 39: ...air bubbles allowing them to more readily move to the air vents B Pump is not running You should be able to feel the vibration of pump when it s running Defective pump check if installed properly If installed incorrectly pump will burn out With 180 water circulating through pump it will be hot to the touch Pump is not wired correctly Refer to wiring diagram See page 20 C Pump flanges are closed Fl...

Page 40: ...t be possible to correct with a Chimney cap 8 PROBLEM EXCESSIVE SMOKE OR FLAMES COMING OUT OF LOADING DOOR DURING REFUELING A Fully open the smoke damper rod prior to opening the fuel loading door B Open fuel door 1 2 then wait 30 seconds for draft to increase prior to fully opening the door SLOWLY C Chimney could have insufficient draft 1 Ensure that chimney draft is 06 w c or greater 2 Check len...

Page 41: ...Cast Baffle Rocker Grate 3 8 16x1 1 2 HHCS 3 8 16 Nut 1 4x1 1 3 4 Clevis Pin 1 6x1 1 4 Cotter Pin SS Rear Grate Frame Cast Z Bar Shaker Handle 3 8 16x1 1 2 HHCS 3 8 16 Nut 1 4 20x1 HHCS 1 4 20 Center Lock Nut Rocker Flat Bar A B C E F G Front Grate Frame D ...

Page 42: ...TS LISTING CONT Damper Plate 3 16x2 1 2 Cotter Pin Damper Rod Spring Handle J I H Ref Name Royall Part Number Notes H Spring Handle HAR HAN Spring I Damper Rod RB Damper Rod LRG MED SML J Damper Plate RB Damper Plate Standard or Large 6490 ...

Page 43: ...Ref Name Royall Part Number Notes K Pressure Relief Valve RBPRESS REL L Pressure Temp Gauge RBPRESS Gauge M Aquastat RBAQL4081 Aquastat Wall PIN RB Aquastat Well N Fuel Door Cas Door Specify size when ordering 10x14 17x17 O Positive Shut Off BL POS Please specify stove model P Draft Blower W H Gasket Unit Specific B160 BL100 B1148 Gasket Q Ash Door CAS Door Ash R Ash Pan Unit Specific Ash Pan 30 A...

Page 44: ...ormation is in the installation manual and other printed technical information provided with the product or direct from ROYALL NOTE THE WARRANTY DESCRIBED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY ROYALL EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL INCI...