G3 Module 6 - Technical Manuals, Drawings & Graphs

Gas Technician III
Learning Package
Module 6 – Technical Manuals,

Drawings & Graphs
Contents
Learning Outcomes: ....................................................................................................................... 3
Manufacturer's Installation Literature........................................................................................... 4
Gas-Fired Equipment: .................................................................................................................... 4
“Receiving Equipment” and “General Specifications” Sections: .................................................. 5
Precautions Section: ...................................................................................................................... 8
Installation Procedures .................................................................................................................. 9
Air Supply Section: ....................................................................................................................... 11
Venting Section: ........................................................................................................................... 14
Piping Section: ............................................................................................................................. 16
Sequence of Operation Section: .................................................................................................. 19
Trouble-Shooting Section: ........................................................................................................... 21
Electrical Wiring Diagrams: .......................................................................................................... 22
Mechanical Drawings: .................................................................................................................. 26
Service Bulletins: .......................................................................................................................... 29
Charts Graphs & Tables: .............................................................................................................. 30
For use with Instructor facilitated © 2021. Gas Technician III Learning Package by Clarke Petty Version 6.0
G3 Fanshawe Online course only
2
 In Module 4, it was stated that Codes, Standards,
Acts and Regulations control every aspect of our work
and referencing skills were gained by locating specific
Learning
Outcomes: information in the B149.1 Natural Gas and Propane
Installation Code Book.
It is equally important to reference and interpret

information from other sources such as:
manufacturer's installation and service manuals,
service bulletins, and safety directives.
After completion of this module you will be able to:
Familiarize yourself with important sections of a gas appliance manufacturer's

installation and service manual.
Understand the association between the manufacturer's installation

instructions and the B149.1 Natural Gas and Propane Installation Code.
Interpret electrical drawings and components of electrical drawings.
Interpret mechanical drawings and components of mechanical drawings.
Identify and understand the purpose of various charts, graphs and tables.
3
Manufacturer's  Manufacturer's installation and service
Installation manuals contain information that is specifically
Literature
related to their appliance.
Gas-Fired
Equipment:
In this module, we will examine seven sections of a Raypak Type H Residential Boiler
installation manual. This will allow you to gain insight into how a manufacturer
typically describes installation, start-up, operation, and trouble-shooting procedures
associated with their product.
Manufacturer's installation manuals must always be thoroughly reviewed before

installing a gas-fired appliance. Installation manuals generally include the following
information:
Model and serial numbers

Appliance clearance requirements
Appliance combustion and ventilation air requirements
Gas piping practices
Venting requirements
Mounting base requirements
Start-up procedures
Service information
Repair parts lists
Start-up and performance check list
Troubleshooting checklists and flowcharts
Pictorial drawings
Voltage supply and fuse requirements
Wiring and schematic diagrams
Motor/fan sizes
4
“Receiving  In this example, we will examine the “Receiving
Equipment” Equipment” and the “General Specifications”
and “General sections of the manufacturer’s installation
Specifications”
manual.
Sections:
These sections are typically found at the beginning of an installation manual. In these
sections, the manufacturer provides the following information:
Recommendations for inspecting equipment upon

delivery.
Limitations surrounding damaged material.
The various certification and test standards that

the equipment was tested under.
Boiler Components.
Dimensions of unit.
Input and heating capacity of various models.
1. RECEIVING EQUIPMENT
Figure 6-1 Raypak Boiler
On receipt of your equipment it is suggested that you visually check for external damage to the
carton. If the carton is damaged, it is suggested that a note be made on the Bill of Lading when
signing for equipment. Remove the boiler from the carton and if it is damaged report the
damage to the carrier immediately.
Be sure that you receive the number of packages indicated on the Bill of Lading. Claims for
shortages and damages must be filed with carrier by consignee. Purchased parts are subject to
replacement only under the manufacturer's warranty.
5
Debits for defective replacement parts will not be accepted and defective parts will be
replaced in kind only per our standard warranties.
When ordering parts, you must specify Model and Serial Number of boiler. When ordering
under warranty conditions, you must also specify date of installation. Raypak recommends that
this manual be reviewed thoroughly before installing your Raypak Boiler. If there are any
questions which this manual does not answer, please contact your local Raypak representative.
2. GENERAL SPECIFICATIONS
The Raypak hydronic boilers are design certified by the American Gas Association, and tested
under the requirements of the American National Standard, ANSI Z21.13. Each boiler has been
constructed and pressure tested in accordance with the requirements of Section IV of the
American Society of Mechanical Engineers Code, and factory fire tested.
The boilers are designed for indoor installation with a built-in drafthood, and a built-in sub-
base for combustible flooring. Models are available with standing pilot, or with intermittent
ignition device (I.I.D.).
The boilers are equipped with the following components: water circulation pump, pressure
relief valve, temperature/ pressure gauge,
adjustable high limit switch, drain valve,
fast response temperature sensor, 40 VA
transformer, pump relay, vent thermal
switch, flame roll-out switch, and
redundant combination gas valve for use with either natural or propane gases.
Two-staged gas valve (50% firing on 1st stage) is standard on models H-0090, H-0135 and H-
0180.
The automatic ignition models and some standing pilot models are provided with a plug-in
connector that is compatible with the Honeywell D80D vent damper.
6
Similar type vent dampers made by other
manufacturers, and design certified by a nationally-
recognized testing Agency, under the ANSI Z21.66
standards, may also be used.
Follow the installation instructions furnished with the

vent damper package. The plug-in connector can also
be used with power venters. Refer to the specific
installation instructions supplied by the power vent
manufacturer.
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always refer to the actual
installation instructions associated with the appliance you’re installing.
7
 In this example, we will examine the
Precautions “Precautions” section of the manufacturer’s
Section: installation manual.
In this section, the manufacturer provides the following information:
Code requirements.
Mounting base requirements.
Clearance requirements.
Appliance protection measures.
Warnings about conditions created by mechanical exhaust vents of other

equipment.
★ Notice the manufacturer’s references regarding compliance with current Codes, such
as the B149.1 Gas Installation Code, Canadian Electrical Code, and others.
Gas Appliances must be installed in accordance with the manufacturers certified instructions
and the B149.1 Natural Gas and Propane Installation Code (B149.1 Gas Code Clause 4.1.3).
8
Installation Procedures
CODE REQUIREMENTS.
Installation must be in accordance with local codes, or, in the absence of local codes, with the
latest editions of the National Fuel Gas Code, ANSI Z223.1, and the National Electrical Code,
ANSI/NFPA 70. In Canada installations must conform with the current CAN/CGA B149.1 or .2
and the Canadian Electrical Code Part 1 CSA C22.2 No.1. Where required by the authority
having jurisdiction, the installation must conform to American Society of Mechanical Engineers
Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.
MOUNTING BASE Boiler should be mounted on a level surface. Each boiler is designed with a
built-in sub-base approved for mounting the boiler on combustible flooring. Boiler must NOT
be installed on carpet flooring.
NOTE: The boiler should be located in an

area where water leakage will not result in
damage to the area adjacent to the
appliance or to the structure. When such
locations cannot be avoided, it is
recommended that a suitable drain pan,
adequately drained, be installed under the
appliance. The pan must not restrict air
flow.
In addition, the boiler shall be installed such

that the gas ignition system components are
protected from water (dripping, spraying,
rain, etc.) during appliance operation and service (circulator replacement, control replacement,
etc.).
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always refer to the actual
9
CLEARANCE REQUIREMENTS
1) Minimum Clearances From Combustible Materials

2) A front clearance of at least 24" is recommended for adequate service of burner-tray and
controls.
3) Except for carpeted flooring, boilers are certified for installation on combustible floors.
4) For un-insulated hot water pipes,
maintain a 2"clearance, or consult local
authority having jurisdiction.
COMBUSTION/VENTILATION AIR
The boiler must be provided with adequate supply of air for proper combustion and ventilation
in accordance with Sec. 5.3, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, or
applicable provisions of the local building codes.
WARNING: Air supply to the boiler room must not be affected by mechanical exhaust vents
located in other parts of the house, such as kitchen or bathroom fans, or attic blowers.
Mechanical exhaust vents may create a negative pressure condition in the boiler room that can
become a hazard of asphyxiation, explosion or fire.
CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can
damage the boiler. Measures must be taken to prevent the entry of corrosive chemical fumes
to the combustion and ventilation air supply. Such chemicals include, but are not limited to,
chlorinated and/or fluorinated hydrocarbons such as found in refrigerants, aerosol propellants,
dry- cleaning fluids, degreasers, and paint removers. Other harmful elements may come from
bleaches, air fresheners, or mastics. Vapors from these types of products can form corrosive
acid compounds when burned in a gas flame. The resulting acid condensate can damage or
substantially reduce the life of the heater. It may be necessary to provide outside air directly to
the heater in order to avoid this problem.
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always refer to
the actual installation instructions associated with the appliance you’re installing.
10
Air Supply  In this example, we will examine the “Air
Supply” section of the manufacturer’s installation
Section:
manual.

Venting information.
Combustion and ventilation air requirements.
AIR SUPPLY
When the boiler is installed in a confined space such as a utility room or closet (Models
0030, 0042 and 0066 only), where all air is supplied from inside the building, the boiler
room must be provided with two openings, each one having a minimum net free area, in
square inches as follows:
One opening shall be within 12 inches of the top, and the other opening within 12 inches of
the floor. If additional gas appliances are installed in the same space, the total input of all
gas appliances installed in the same space, must be considered in the calculation. Refer to
Sec. 5.3.5 of the latest edition of the National Fuel Gas Code for additional requirements.
NOTE: If louvers, grills or screens are used on the openings, obtain the net free area from
their supplier or manufacturer. If the design free
area of a louver is not known nor available, it shall
be assumed that wood louvers will have 20-25
percent free area and metal louvers will have 60-75
percent free area as shown in Sec. 5.3.5 National
Fuel Gas Code.
Note: Raypak technical literature on this form is furnished solely for

Gas Technician III training purposes. Always refer to the actual
11
If the boiler room is located against an outside wall and air openings can
communicate directly with the outdoors, the two openings on the outside wall must
each have a net free area, in square inches as follows:
Location of the openings is the same as in the previous case - that is, within 12 inches of the
top, and within 12 inches of the bottom of the enclosure. If horizontal ducts are used, the
area must be doubled and the duct area shall not be less than the area of the openings they
connect, and in no case shall the smallest dimension be less than 3 inches.
VENTING CONNECTIONS
These boilers have built-in drafthoods. Vent piping the same size or larger than the draft
hood outlet is recommended; however, when the total vent height (drafthood outlet to
vent terminal) is at least ten (10) feet, the vent pipe size may be reduced by one size only as
specified in Part 11, Note 2 and in Appendix G of the latest edition of the National Fuel Gas
Code, ANSI Z 223.1. As much as possible avoid horizontal runs of vent pipe and too many
elbows. If installation requires horizontal runs, the vent pipe must have a minimum of 1/4
inch per foot rise and should be supported at not less than five foot intervals. Maximum
vent connector horizontal length shall be 1-1/2 feet (18 inches) for each inch of connector
diameter as follows.
12
Gas Vents supported only by the flashing and extending above the roof more than five feet
should be securely guyed or braced to withstand snow and wind loads. We recommend use
of insulated vent pipe spacer through the roofs and walls.
For protections against rain or blockage by snow, the vent pipe must terminate with a listed
vent cap which complies with the local codes or, in the absence of such codes, to the latest
edition of the National Fuel Gas Code, ANSI Z 223.1.
The discharge opening must be a minimum of two feet vertically from the roof surface and
at least two (2) feet higher than any part of the building within ten (10) feet. Vent stack
shall be at least five (5) feet in vertical height above the drafthood outlet. The vent cap
location shall have a minimum clearance of four (4) feet horizontally from, and in no case
above or below, unless a 4-foot horizontal distance is maintained, from electric meters, gas
meters regulators and relief equipment.
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always refer to the
actual installation instructions associated with the appliance you’re installing
13
 In this example, we will examine the “Venting”
Venting
Section: section of the manufacturer’s installation manual.
Vent support and height information.
Common venting.
Inspection and maintenance provisions.
The weight of the vent stack or chimney must

not rest on boiler draft hood. Support must be
provided in compliance with applicable codes.
The boiler top and draft hood must be readily

removable for maintenance and inspection.
Vent pipe should be adequately supported to
maintain proper clearances from combustible
construction. Type "B" double wall (or
equivalent vent pipe is recommended).
However single wall metal vent pipe may be

used as specified in the latest edition of the
National Flue Gas Code ANSI Z 223.1.
For connections to gas vents or chimneys, vent installations shall be in accordance with Part 7,
Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, or applicable provisions of
the local building codes.
14
COMMON VENTS
Manifolds that connect more than one boiler to a common chimney must be sized to handle
the combined load. Consult available guides for proper sizing of the manifold and the
chimney. At no time should the area be less than the area of the largest outlet.
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always
refer to the actual installation instructions associated with the appliance you’re installing.
15
In this example, we will examine the “Piping”
Piping section of the manufacturer’s installation manual..
Section:
Gas supply information.
Gas pressure specifications.
Water connections and system piping.
Minimum water temperature and flow information.
GAS SUPPLY CONNECTIONS
The inlet gas connection of the boiler gas valve is 1/2". Provide an adequate gas piping
supply line no smaller than 1/2", according to the chart below:
Maximum Equivalent Pipe Length (Feet)
CAUTION: The boiler and its manual shut off valve must be disconnected from the gas
supply during any pressure testing of that system at test pressures in excess of 1/2 psig
(3.45 KPA). Dissipate test pressure in the gas supply line before reconnecting the boiler and
its manual shut off valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. OVER PRESSURED GAS VALVES ARE NOT COVERED BY
WARRANTY.
16
The boiler and its gas connections shall be leak tested before placing the appliance in
operation. Use soapy water for leak test. DO NOT use open flame.
NOTE: Do not use Teflon tape on gas line pipe thread. A flexible sealant suitable for use with
Natural and Propane gases is recommended. The gas valve is provided with pressure taps to
measure gas pressure upstream of the gas valve and downstream which is the same as the
manifold pressure.
WATER CONNECTIONS & SYSTEM PIPING

The pipe size for water connections is shown on page 3. Typical piping systems are shown
on pages 11 to 13.
The boiler is supplied as standard with a circulator and a built-in by-pass to insure the
required minimum water flow in the boiler. The by-pass on models H-0135 and H-0180 is
provided with an adjustable valve that is factory set in the full open position.
The handle is shipped loose. The full open position is appropriate for most systems, and
insures adequate flow through the boiler. If system flow is inadequate, (indicated by
excessive temperature drop through the system) the by-pass valve can be throttled slightly.
Care must be taken against over throttling which may lead to inadequate flow through the
boiler and boiler harmonics (a humming sound from the heat exchanger). If adequate
system flow cannot be obtained without causing harmonics, an additional pump is required.
17
The factory-mounted circulator will provide adequate water flow for systems designed at a
20°F temperature drop, and system pressure drop or head
not exceeding that is shown below.
When the total system head exceeds the available head pressures, a primary/secondary
pumping system is recommended. The minimum boiler operating temperature should be
105°F. When operating at low temperature applications, ÐT (temperature rise) must be
20°F or less. Propylene glycol solution is commonly used in the heating system when freeze
protection is required. This will affect the system design and pump performance. As a "rule
of thumb", 50% solution of propylene glycol will require the system flow (GPM) to increase
by 14%, and the system head (Ft/Wtr) by 23% in order to maintain the same heat transfer
load.
TYPICAL SINGLE ZONE PIPING
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always refer to
the actual installation instructions associated with the appliance you’re installing
18
 In this example, the manufacturer explains the
Sequence of
sequence of operation and general location of
Operation
Section: controls associated with their appliance. Notice
the special instructions for resetting the ignition
control module.
SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE (IID)
Boilers equipped with the IID system will automatically light the pilot burner first and then the
main burner, each time there is a call for heat from the room thermostat.
Whenever the room thermostat is calling for heat, the circulator supplied with the boiler, will
be energized and should be running. The ignition control module will also be energized to
initiate the pilot ignition by opening the first main valve (pilot). At the same time, the
electronic spark generator in the module produces a high voltage spark pulse output that lights
the pilot burner.
If the pilot burner does not light, the module will not energize the second main valve and the
burners will not light. Ignition spark continues only until the timed trial for ignition period ends.
Then, the module goes into safety shutdown or lockout. Lockout de-energizes the first main
valve operator and closes the first main (pilot) valve in the gas control, stopping pilot gas flow.
The ignition control system must be reset by setting the thermostat below room temperature
for one minute or by turning off power to the module for one minute.
19
When the pilot flame is established, flame rectification circuit is completed between the sensor
and burner ground. The flame sensing circuit in the module detects the flame current, shuts off
the spark generator and energizes the second main valve operator, which opens the second
main valve. This allows gas to flow to the burners where it is ignited by the pilot burner flame.
When the thermostat is satisfied, the
valve operators are de-energized
shutting off the pilot and main burners,
and also the circulator.
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always
refer to the actual installation instructions associated with the appliance you’re installing.
20
In this example, we will examine how a
Trouble-
manufacturer typically organizes a troubleshooting
Shooting
Section: guide to help solve operating problems.
Troubleshooting guides are useful in quickly
diagnosing and solving problems.
A troubleshooting guide will generally list a problem (or symptom), a possible cause, and then
suggest a solution to the problem.
Trouble-Shooting Guide Example:

PROBLEM(S) CAUSE(S) SOLUTION(S)
1)Check circuit breakers,
1) When room thermostat is 1) No power to the boiler. disconnect switch. Make
turned on, boiler does not 2) Defective room sure power is on.
operate. thermostat or disconnected 2) Check continuity on
wire in thermostat circuit. thermostat and wiring
3) Defective transformer. circuit. Replace thermostat,
4) Defective pump relay. or repair wiring
5) Defective pump connections.
3) Check secondary
voltage. If no 24V, replace
transformer.
4) Check relay coil or
contacts. Replace as
required.
5) Replace pump.
Note: Raypak technical literature on this form is furnished solely for Gas Technician III training purposes. Always refer to the
actual installation instructions associated with the appliance you’re installing
21
 Electrical diagrams are drawings that are
Electrical intended to show electrical components and their
Wiring related connections. They are not generally drawn to
Diagrams: scale, and show only the electrical association
between the components and controls.
Electrical drawings include supply voltage, internal wiring, required field wiring, and the
location of controls.
In electrical diagrams, symbols are used extensively to represent the various pieces
of electrical equipment. Lines, representing wires, are used to connect the
symbols.
A dotted or broken line on a wiring diagram generally indicates required field

wiring, such as wiring to a thermostat (Figure 6-2).
Figure 6-2 Dotted Line
Indicates Field Wiring
A small dot at the intersection of two or more wires indicates
an electrical connection. (Figure 6-4)
Figure 6-4 Wires Figure 6-5 Wires

Connected Not Connected
22
It is essential in our field that we are able to identify the name, contact position, and action of
the following electrical symbols:
Symbol Name Contact Position Action
Temperature Opens on a rise in

actuated switch Normally Closed N.C. temperature
Temperature Closes on a rise in

actuated switch Normally Open N.O. temperature
Pressure actuated Opens on a rise in

switch Normally Closed N.C. Pressure
Pressure actuated Closes on a rise in

switch Normally Open N.O Pressure
Opens on a rise in
Liquid level switch
Normally Closed N.C liquid level
Closes on a rise in
Liquid level switch
Normally Open N.O liquid level
Flow switch - liquid Open on liquid or

or air. air flow
Normally Closed N.C
Flow switch - liquid Closes on liquid

or air. Normally Open N.O or air flow
Table 6-1 Electrical Symbols
23
Contact symbols are used to indicate an open or closed path of current flow. Contacts
are shown as normally open (NO) or normally closed (NC). Contacts shown by this
symbol require another device such as a control relay to activate them.
“CR” often designates a control relay. The contacts that are

associated with the relay have the same identifying letter and are
Figure 6-6 Contact
Positioning numbered CR1, CR2, CR3 etc.
There can be a single contact or many contacts associated with a relay. The associated
contacts can be either normally open or normally closed. When the relay is energized,
all of the associated contacts change position.
Figure 6-7 Contacts Associated with Control Relay
24
Schematic diagrams show more detailed information than wiring diagrams. They show
how a system works.
Below is a schematic diagram of a Honeywell RA890G flame safeguard control relay; the
operation of which is examined closely in the Gas Technician I course. The diagram
provides more detailed information by showing both external and internal wiring and
components.
Figure 6-8 Honeywell Schematic Diagram RA 890G
25
 Mechanical drawings are used to represent three-
dimensional objects on a two-dimensional piece of
Mechanical
Drawings: paper. Mechanical drawings can show the mechanical
layout of heating, ventilation and air-conditioning
equipment associated with a building. Mechanical
drawings often include the address of the building,
layout of piping and ductwork, ductwork sizing, and the
location of electrical panels.
Other common types of drawings used in our trade include assembly, orthographic and
pictorial drawings.
Assembly drawings refer to the all of the necessary parts needed to assemble a
product and show how the individual parts fit together.
The dimensions in an assembly drawing usually refer to the relationship among

parts and not the size of the individual parts. An assembly drawing may be a multi-
view or a single profile view.
Figure 6-9 Assembly

Drawing Solenoid Valve
Figure 6-10 Assembly Drawing Raypak Boiler
26
Orthographic drawings are individual views of the
front, rear, sides, top, and bottom of an object. It
takes several views to show the entire object.
Pictorial drawings show several sides at the same

time. Many find pictorial drawings easier to
understand, however they do not provide as much
information as orthographic views. Figure 6-11 Orthographic Drawing
Honeywell Gas Valve
The most commonly used pictorial drawing for technical information is called an
isometric drawing. Isometric drawings were developed to approximate
perspective.
An Isometric drawing of a piping system can show a horizontal and vertical view at
the same time.
In order to do this, the vertical lines remain vertical, while the horizontal lines are
drawn at a 30o angle.
These drawings are made using a single line

technique, which assumes the line to be
the center of the pipe. Short cross lines
indicate fittings.
Note: In the practical assessment mechanical

module of this course, you will assemble and test a
gas piping/tubing system using the isometric
drawing shown (Figure 6-12).
Figure 6-12 Isometric Drawing Gas
Tech III Shop Project
27
Common mechanical symbols used in drawings associated with our trade include the following:
Symbol Name Symbol Name
Manual Shut Off Gas Over Pressure

Valve Relief Valve
High Pressure
Diaphragm Valve
Modulating Valve
Pounds to Ounces
(LBS to OZ) Gas
Automatic Safety
Pressure Regulator
Shutoff Valve
Pounds to Pounds
Low Pressure Gas
(LBS – LBS) Gas
Regulator
Pressure Regulator
Tee Union
90o Elbow 45o Elbow
Cap
Table 6-2 Mechanical Symbols
28
 Appliance manufacturers will issue service bulletins or
Service
reports on special problems, often indicating required
Bulletins
& Safety field repairs, when a problem with an appliance is
Orders: recognized. Safety orders are issued by the TSSA. Below
is a copy of a safety order previously issued by TSSA.
29
Charts, graphs, and tables are used to visually
Charts
illustrate, compare, and relate items. Charts,
Graphs &
Tables: graphs and tables are used extensively in our
field. The circle graph, bar graph, and line graph
are three principal types of graphs.
The circle graph, which looks like a pie cut into unequal slices, is used to show how a
whole is divided into parts. The circle represents the
whole, and the "slices" represent the relationship of
the parts to the whole.
Figure 6-13 Circle Graph
The bar graph is used to compare the quantity of Items.
The bars can be drawn straight

up and down, or they may run
from left to right.
Figure 6-14 Bar Graph
30
The line graph is usually used to show how something is related to time, or how it
changes over a period of time.
Figure 6-15 Line Graph
A troubleshooting chart provides a systematic approach to solving problems

associated with equipment.
To Read Graphs, Tables, & Charts You Should:
Read the title to determine the overall purpose of

the graph, table, or chart.
Read the headings or legend on the graphic.
Determine what items are being compared.
Study the graphic, noticing how the relationship

between the items changes. Figure 6-16 Troubleshooting Chart
**End of Module - Return to Course and Complete Associated Online Test(s)**
31

G3 Module 6 - Technical Manuals, Drawings & Graphs

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G3 Module 6 - Technical Manuals, Drawings & Graphs

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Gas Technician III

Module 6 – Technical Manuals,

It is equally important to reference and interpret

After completion of this module you will be able to:

Familiarize yourself with important sections of a gas appliance manufacturer's

Understand the association between the manufacturer's installation

Interpret electrical drawings and components of electrical drawings.

Interpret mechanical drawings and components of mechanical drawings.

Manufacturer's installation manuals must always be thoroughly reviewed before

Model and serial numbers

Recommendations for inspecting equipment upon

Limitations surrounding damaged material.

The various certification and test standards that

Input and heating capacity of various models.

Follow the installation instructions furnished with the

In this section, the manufacturer provides the following information:

Mounting base requirements.

Appliance protection measures.

Warnings about conditions created by mechanical exhaust vents of other

NOTE: The boiler should be located in an

In addition, the boiler shall be installed such

1) Minimum Clearances From Combustible Materials

In this section, the manufacturer provides the following information:

Note: Raypak technical literature on this form is furnished solely for

In this section, the manufacturer provides the following information:

Vent support and height information.

Inspection and maintenance provisions.

The weight of the vent stack or chimney must

The boiler top and draft hood must be readily

However single wall metal vent pipe may be

In this section, the manufacturer provides the following information:

Gas supply information.

Gas pressure specifications.

Water connections and system piping.

Minimum water temperature and flow information.

GAS SUPPLY CONNECTIONS

Maximum Equivalent Pipe Length (Feet)

WATER CONNECTIONS & SYSTEM PIPING

TYPICAL SINGLE ZONE PIPING

SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE (IID)

Trouble-Shooting Guide Example:

A dotted or broken line on a wiring diagram generally indicates required field

Figure 6-4 Wires Figure 6-5 Wires

Symbol Name Contact Position Action

Temperature Opens on a rise in

Temperature Closes on a rise in

Pressure actuated Opens on a rise in

Pressure actuated Closes on a rise in

Flow switch - liquid Open on liquid or

Flow switch - liquid Closes on liquid

Table 6-1 Electrical Symbols

“CR” often designates a control relay. The contacts that are

Figure 6-7 Contacts Associated with Control Relay

Figure 6-8 Honeywell Schematic Diagram RA 890G

The dimensions in an assembly drawing usually refer to the relationship among

Figure 6-9 Assembly

Figure 6-10 Assembly Drawing Raypak Boiler

Pictorial drawings show several sides at the same

These drawings are made using a single line

Note: In the practical assessment mechanical

Symbol Name Symbol Name

Manual Shut Off Gas Over Pressure

90o Elbow 45o Elbow

End of Module - Return to Course and Complete Associated Online Test(s)