Dunkirk D247 Installation Instructions Manual

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G s-:-ir_: Steam or
VVater
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INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler.
contents
Rules for Safe Installation and Operation .................................................................. 3
Boiler Ratings and Capacities .................................................................................... 4
Boiler Dimensions ...................................................................................................... 5
Combustion Air and Boiler Location ........................................................................... 6
Assembly of Bases ..................................................................................................... 7
Assembly of Sections and Draft Hoods ...................................................................... 7
Connecting Gas Service .......................................................................................... 10
Installing Boiler Jacket ............................................................................................. 11
Boiler Controls .......................................................................................................... 12
Water Boiler Piping .................................................................................................. 13
Steam Boiler Piping .................................................................................................. 15
Flue Connection and Venting ................................................................................... 16
Electrical Wiring ....................................................................................................... 17
Operation and Service ............................................................................................. 21
Checking and Adjusting ........................................................................................... 24
Parts ......................................................................................................................... 26
introduction
Please read our instructions before you install and use your new boiler. This will help assure you of proper installation and help you avoid needless service.
You may plan to install the boiler yourself. You must then realize that the wrong use of any tool can be dangerous, unless you know how to use the tool and equipment
and understand the electrical wiring, piping, and potential hazards involved. The boiler must be installed in accordance with the requirements of the local utility and
those of other authorities.
2
RULES FOR SAFE INSTALLATION
AND OPERATION
1 . Read the Owner's Manual and the Rules for Safe
operation carefully. Failure to follow the rules for safe operation and the instructions could cause a
malfunction of the boiler and result in death, serious bodily injury, and/or property damage.
2. Check your local codes and utility requirements before installation. The installation must be in accordance with their directives.
.
.
Before servicing, allow boiler to cool and always shut off any electricity and gas to boiler when working on it. This will prevent any electrical shocks or burns.
Never test for leaks with an open flame. Use soap suds to check alt connections. This will avoid any possibility of fire or explosion.
Be certain boiler is equipped for type of gas (natural) to be used. Overfiring wilt result in premature failure of the boiler sections and cause dangerous operation.
Never vent this boiler into an enclosed space. Always connect the boiler to a chimney and vent to the outside. Never vent to another room or inside a building.
Be sure there is adequate air supply for complete combustion.
8. Follow a regular service and maintenance schedule for efficient and safe operation.
9. Never install the boiler on carpeting.
10. Keep boiler area clear and free from combustible material such as gasoline and other flammable vapors
and liquids.
WHEN YOUR BOILER ARRIVES
When your boiler arrives be sure to save and refer to the instructions.
First, inspect each item received for visible damage. Ifany parts are damaged, report this to the freight company immediately and request them to call and make an
inspection before you make any installation. Have the inspector prepare a signed report. Send a copy of this report
to the manufacturer and we will send replacements for the damaged parts. But we must have the signed inspection
report of the freight company to prove their liability. Read these instructions carefully before beginning the
installation to be sure all packages have been received. It is recommended that you follow the step-by-step instructions for best assembly results. Before discarding any packing material carefully examine for loose parts. Also store all parts received where they wilt not be lost or damaged.
CODES GOVERNING INSTALLATION
Boiler should be installed in accordance to the latest edition of American National Standard National Fuel Gas Code
Z223.1 (Available from the American Gas Association, 8501 East Pleasant Valley Road, Cleveland, Ohio 44131). Reference should also be made to local gas utility regulations and other codes in effect in the area in which the installation is to be made. The jurisdiction normally covers electrical wiring, gas piping, flue specification, and insulation of adjacent combustible material where required
clearance cannot be maintained. 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.
INSTALLATION
This boiler is designed to provide wide capacity range with multiple burner modules, each equipped with its own set of controls. For purposes of orientation, the manifold side of
the boiler is considered the front. The end sections are so designed that the controls may be placed on either the left
or right end. These instructions are written for the assembling of the boiler starting with the left side and
working to the right side. If the boiler is to be used as a
steam boiler and connected to another steam boiler, the factory designed water lines of the two boilers must be of equal height above the floor.
A hot water boiler installed above radiation level must be
provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation.
The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).
The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 kPa)
3
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®
CHART 1
BOILER MODEL
NO.
JC 300 JC 400 JC 500 JC 600
JC 700 JC 800 JC 900
JC1000 JC1100 JC1200 JC1300
JC1400 JC1500
JC1600 JC1700 JC1800 JC1900
JC2000 JC2100 JC2200 JC2300
JC2400 JC2500 JC2600
JC2700 JC2800 JC2900
JC3000
RATINGS AND CAPACITIES
A.G.A.*
INPUT
Bitu Mbh
3O0 400 5O0 600
7O0 8OO 900
1000 1100 1200 1300
1400 1500
1600 1700 1800 1900
2000 2100 2200
2300 2400 2500 2600
2700 2800 2900
3000
A.G.A.* NET I=B=R RATINGSt
OUTPUT Steam Steam Water
Btu Mbh Sq. Ft.$ Btu Mbh Btu Mbh
240 750 180 209 320 1000 240 278 400 1250 300 348
480 1500 360 417
560 1750 420 487 640 2000 480 557
720 2250 540 626 800 2500 600 696 880 2750 660 765 960 3000 720 835
1040 3250 780 904 1120 3500 840 974 1200 3750 900 1043
1280 4008 962 1113 1360 4283 1028 1183 1440 4563 1095 1252
1520 4838 1161 1322 1600 5117 1228 1391 1680 5392 1294 1461 1760 5671 1361 1530
1840 5942 1426 1600 1920 6213 1491 1670 2000 6471 1553 1739
2080 6729 1615 1809 2160 6988 1677 1878 2240 7246 1739 1948 2320 7504 1801 2017
2400 7763 1863 2087
FLUE OUTLET CHIMNEY
NO. & SIZE SIZE$$
8" 10" 12" I.D. x Ht.
1 8"x 20'
1 10'x 20'
1 12" x 20'
2 12" x 20'
1 1 12" x 20'
2 14"x 20' 1 1 14"x 20'
2 14"x 20'
1 2 16"x 20'
3 16"x 20'
1 2 16"x 20'
1 2 18"x 20'
3 18"x 20'
4 18"x 20'
1 1 2 18"x 20'
2 2 20"x 20' 1 3 20"x 20'
4 20"x 20'
2 3 20"x 20'
3 2 22"x 20' 2 3 22"x 20'
1 4 22"x 20'
5 22"x 20'
2 4 22"x 20'
1 1 4 24"x 20'
2 4 24"x 20' 1 5 24"x 20'
6 24"x 20'
FLUE
COLLECTOR
SIZE TO
CHIMNEY
8 10 12 12
12 14 14
14 16 16 16
18 18
18 18
20 20
20 20 22 22
22 22 22
24 24 24
24
HORSE-
POWER
GROSS
OUTPUT**
7.16
9.55
11.94
14.33
16.72
19.10
21.49
23.88
26.27
28.66
31.04
33.43
35.82
38.21
40.60
42.99
45.37
47.76
50.15
52.54
54.93
57.31
59.70
62.09
64.48
66.87
69.25
71.64
PRESSURE
DROP THRU
WATER BOILERI-I-
GPM In.Water
18.9 0.10
37.8 0.50
25.2 0.27
50.4 0.86
31.5 0.40
63.0 1.20
37.8 0.50
75.6 1.70
44.1 0.70
88.2 2.50
50.4 0.88
100.8 2.90
56.7 1.10
113.4 3.80
63.0 1.30
126.0 4.00
69.3 1.50
138.6 5.00
75.6 1.80
151.2 6.00
81.9 2.00
163.8 5.60
88.2 2.40
176.4 7.00
94.5 2.60
189.0 8.30
100.8 2.80
201.0 9.60
187.1 3.15
214.2 10.30
113.4 3.50
226.8 11.00
119.7 4.00
239.4 12.50
126.0 4.50
252.0 14.00
132.3 4.95
264.6 16.00
138.6 5.40
277.2 18.00
144.9 5.70
289.8 17.00
151.2 6.00
302.4 19.00
157.5 8.00
315.0 20.50
163.8 7.00
327.6 22.00
170.1 7.50
340.2 24.00
176.4 8.00
352.8 26.00
182.75 8.50
365.5 27.50
189.1 9.00
378.2 9.00
Ratings are at sea level to 2,000 feet. For altitudes above 2,000 feet, reduce all ratings 4% for each 1,000 feet above sea level
1 Ratings based on selection factors recommended by Hydronics institute for piping and pickup. Net water boiler ratings are
based on an allowance of 1.15, and net steam boiler ratings are based on an allowance of 1.33. For water applications with high piping and pickup requirements, use steam rating.
1: Ratings in square feet are computed at 240 Btuh/square toot for steam boilers. ** Ratings based on 33,500 Btuh per horsepower.
lt Pressure drop based on given flow from a single outlet and returning to a single inlet at the opposite end of the boiler. :I::I: Chimney sizes shown are one option based on a typical venting system as shown in Figure 21, and sized according to the
National Fuel Gas Code, assuming Type B double wall vent and vent connectors, Other venting system designs are accept- able as shown on page 16. For further chimney design and sizing information, consult the National Fuel Gas Code, ANSI
Z223.1/NFPA 54-latest revision, or ASHRAE-1996 HVAC Systems and Equipment Handbook, Chapter 30, Chimney, Gas
Vent, and Fireplace Systems, or the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances. NFPA
211 -latest revision. Follow standard engineering practice.
4
EZZZ] EZ_ EZB _ _ _-
AA
A
SUPPLY_ --'dATER
38"
89 _
J
LINE
47_" 33.__
; L
_FLFIOR LINE
FRONT VIEW
ICT]_ 7F_ F_G T H7 I_" 1 _FLUE HUTLETS
RETURN _ _ 0 0 _ _ _JJRETURN
SUPPLY SUPPLY
TOP VIEW
Z_............................................
LEFT SIDE VIEW
ALL SUPPLY AND RETURN
CONNECTIONS, 4IN. ]
Boiler Water Content Shipping A AA Model In Gallons Weight JacketWidth Base & Battery C D E F G H I
No. .3team Water Lbs. L to R Length
JC 300 20 26 922 18 3/4 16 3/4 9 3/8 omit omit omit omit omit 9 3/8 JC 400 25 33 1133 23 21 11 1/2 4 4 4 4 4 11 1/2 JC 500 30 40 1344 27 1/4 25 1/4 13 5/8 4 4 4 4 4 13 5/8 JC 600 35 46 1555 31 1/2 29 1/2 9 3/8 12 3/4 4 4 4 4 9 3/8 JC 700 40 52 1766 35 3/4 34 3/4 9 3/8 14 7/8 4 4 4 4 11 1/2
JC 800 45 58 1977 40 38 11 1/2 17 4 4 4 4 11 1/2 JC 900 50 65 2188 44 1/4 42 1/4 11 1/2 19 1/8 4 4 4 4 13 5/8 JC1000 55 71 2399 48 1/2 46 1/2 13 5/8 21 1/4 4 4 4 4 13 5/8 JC1100 60 78 2610 52 3/4 50 3/4 9 3/8 14 7/8 17 4 4 4 11 1/2 JC1200 65 84 2821 57 55 11 1/2 17 17 4 4 4 11 1/2 JC1300 70 91 3032 61 1/4 59 1/4 9 3/8 17 21 1/4 4 4 4 13 5/8
JC1400 75 97 3243 65 1/2 63 1/2 11 1/2 19 1/8 21 1/4 4 4 4 13 5/8 JC1500 80 104 3454 69 3/4 67 3/4 13 5/8 21 1/4 21 1/4 4 4 4 13 5/8 JC1600 85 110 3665 74 72 11 1/2 17 17 17 4 4 11 1/2 JC1700 90 117 3876 78 1/4 76 1/4 9 3/8 14 7/8 19 1/8 21 1/4 4 4 13 5/8
JC1800 95 123 4087 82 1/2 80 1/2 11 1/2 17 19 1/8 21 1/4 4 4 13 5/8 JC1900 100 130 4298 86 3/4 84 3/4 11 1/2 19 1/8 21 1/4 21 1/4 4 4 13 5/8 JC2000 105 136 4509 91 89 13 5/8 21 1/4 21 1/4 21 1/4 4 4 13 5/8 JC2100 110 143 4720 95 1/4 93 1/4 9 3/8 12 3/4 17 21 1/4 21 1/4 4 13 5/8 JC2200 115 149 4931 99 1/2 97 1/2 11 1/2 17 17 19 1/8 21 1/4 4 13 5/8 JC2300 120 156 5142 103 3/4 101 3/4 11 1/2 17 19 1/8 21 1/4 21 1/4 4 13 5/8
JC2400 125 162 5353 108 106 11 1/2 19 1/8 21 1/4 21 1/4 21 1/4 4 13 5/8 JC2500 130 169 5564 112 1/4 110 1/4 13 5/8 21 1/4 21 1/4 21 1/4 21 1/4 4 13 5/8 JC2600 135 175 5775 1161/2 1141/2 93/8 123/4 17 21 1/4 21 1/4 21 1/4 135/8 JC2700 140 182 5986 120 3/4 118 3/4 9 3/8 14 7/8 19 1/8 21 1/4 21 1/4 21 1/4 13 5/8
JC2800 145 188 6197 125 123 11 1/2 17 19 1/8 21 1/4 21 1/4 21 1/4 135/8 JC2900 150 195 6408 129 1/4 127 1/4 11 1/2 19 1/8 21 1/4 21 1/4 21 1/4 21 1/4 135/8 JC3000 155 201 6619 133 1/2 131 1/2 13 5/8 21 1/4 21 1/4 21 1/4 21 1/4 21 1/4 13 5/8
5
COMBUSTION AIR
Provision for combustion and ventilation air must be in accordance with Section 5.3, "Air for Combustion and
Ventilation", of the National Fuel Gas Code. ANSI Z223.1
latest revision, and applicable provisions of the local building codes. Consult the code books or boiler manufacturer for specific requirements.
WARNING
ENOUGH AIR ENSURES PROPER
COMBUSTION AND ASSURES THAT
NO HAZARD WlLL DEVELOP DUE TO
THELACK OF OXYGEN
CHIMNEY AND VENT PIPE CONNECTION
This is a very important part of the heating system. It must be clean, the right size, properly constructed and in GOOD
CONDITION. No boiler can function properly with a bad chimney. See Page 16 for specific venting instructions.
The flue pipe should be the same size as draft hood outlet from boiler to flue collector. See Page 4 for typical chimney size. Maintain a minimum upward slope of 1/4 inch per linear foot from boiler to the chimney Fasten joints together
with sheet metal screws to prevent sagging.
MINIMUM VENT PIPE CLEARANCE
If the vent pipe must go through a crawl space, double walt vent pipe should be used. Where vent passes through a
combustible walt or partition, use a ventilated metal thimble. The thimble should be 4 inches larger in diameter than
vent pipe. If boiler is installed with single wall galvanized type vent pipe, it must have 6 inches clearance between its surface and any combustible material. If UL listed type B (Insulated) vent pipe is used, clearance between it and combustible material to be as listed by pipe manufacturer.
FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY, MINIMUM CLEARANCES TO
COMBUSTIBLE CONSTRUCTION ARE.
LOCATING THE BOILER
Locate the boiler on a level, non-combustible foundation as near chimney or flue as possible. Allow 24 inches at
front and sides of boiler for servicing and cleaning. When installed in a utility room, the door should be wide enough to allow the largest boiler parts to enter, or permit replacement of any other appliance in the same room.
When the boiler is installed over a room below, or over electrical wiring or cables of any kind, or if the concrete floor is "green," or water is channeled under the concrete, the installing contractor must provide aventilated foundation
for the boiler. The boiler shall be installed such that the automatic gas
ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (condensate trap, control replacement, etc.)
INSTALLATION
This boiler is designed to provide a wide capacity range
with multiple burner modules, each equipped with its own
set of controls. For purposes of orientation, the manifold side of the boiler is considered the front, The end sections are so designed that the controls may be mounted on either the left or right end. These instructions are written for the assembling of the boiler starting with the left side and
working to the right side.
If the boiler is to be used as a steam boiler and connected to another steam boiler, the factory designed water lines of
the two boilers must be of equal height above the floor level.
Boilers with Inputs above 500,000 BTU Per Hour are made up of a combination of the 300,000,400,000 and 500,000
BTU Per Hour Input Module Bases. Each base is equipped
with its own gas valve and gas ignition system.
When connecting the cold water supply to the boiler, make sure that a clean water supply is available. When the water supply is from a welt, a sand strainer should be installed at the pump.
Top ...................................................... 54 inches
Front ........................................................ Alcove
Flue Connector ..................................... 6 inches
Rear .................................................... 18 inches
Sides ................................................... 18 inches
Greater clearances for access should supersede fire protection clearances.
6
ASSEMBLY OF BASES
The 300, 400 and 500 boilers are the basic models. The 300 model has (6) burners, the 400 model has (8) burners
and the 500 model has (10) burners. Combinations of the basic models are used to assemble the 600 through 3000 models. See Chart No. 2 for the proper order of assembly
When two or more bases are used to assemble the boiler, be sure the top angles of the bases are even. (See Figure
No. 6). The bases are fastened together with 5/16 cap screws and nuts. Insert two screws in the front posts and two in the rear posts as shown in Figure No. 1. After bases are fastened together, install the base end panels. These end panels must be installed before assembling sections. Important: After bases are assembled check to be sure they are level.
STARTING SECTION ASSEMBLY
The sections may be started from either the left or right end of the base. Place the end section on the base with
the parting line of the section directly over the joint of the base and base end closure. With boilers having two or more
bases, as you progress be sure the parting line (center-line of section) of the intermediate sections falt on the junction
of the two bases. Install a top cover support bracket on the draw bolts of the intermediate sections at each base
junction.
PULLING SECTIONS TOGETHER
WITH TIE RODS
Before beginning, clean nipples and nipple ports. Coat nipples and nipple ports with pipe joint compound furnished or other good sealant and keep them clean. Place nipples in ports taking care to seat them squarely to prevent
cocking. (See Figure 2). When pulling sections together
with tie rods, always insert tie rods in holes nearest to
nipple ports. Move tie rods to proper location, if necessary, only after sections are fully pulled together. Oil or lubricate
threads, insert tie rods in lugs with washers under nuts and tighten uniformly and evenly so that sections are pulled
END CLOSING
parallel as they go together. When all sections are pulled up locate the tie rods in alternating pairs of upper and lower
holes between adjacent sections, and back off nuts so that they are only finger tight. (See Figure 7). Be sure both
ends of completed section assembly are resting evenly on both ends of base.
Apply boiler putty at the joints of the sections front, top and
back. Putty should also be applied where the sections join the base.
Place the necessary plugs and control wells in the correct locations. Plug alt other tappings, leaving an air vent in the top of one of the end sections, and connect water. Fitl the
boiler with water until it runs out the air vent. Then hydrostatically test the boiler in accordance with applicable
codes. Check for leaks before continuing with the assembly Drain and remove unnecessary plugs.
TIE
TOP COVER SUPPI]RT _
FIGURE 2
TOP ANGLE
CAP SCREWS
AND NUTS
FIGURE 1
BASE ASSEHBLIES
7
BURNERS
I
THIS PAGE INTENTIONALLY LEFT BLANK
I
8
LEFT END BATTERY
BASE ASSEMBLY
FIGURE 6
ATTACH DRAFT HOODS Attach the draft hood(s) to the boiler sections after apply-
ing boiler putty to the top of the boiler sections where the hoods and sections meet. Use (J) bolts to attach front of draft hood to slots in sections flange.
END CLOSING PLATE
WARNING:
DO NOT ALTER OR MODIFY DRAFT HOOD
FURNISHED WITH BOILER.
CLEAN OUT
COVER PANEL
DRAFT HOOD
APPLY BOILER
PUTTY
FIGURE 7
9
CONNECTING GAS SERVICE
Connect gas service from meter to control assembly(s) in accordance with ANSI Z223.1 1984 and local codes or utility On multiple base boilers, connect gas service with branch
lines from common main. Individual branch lines must be the same size as the inlet to the gas valve. A ground joint
union should be installed in each branch line for easy servicing of gas controls. A drip leg or trap should be installed at the bottom of a vertical section of piping at the inlet to the control chain, Figure 8. A pipe compound resistant to the action of liquefied petroleum gases must be used on all threaded pipe connections.
The main gas supply line should be adequate to prevent undue pressure drop. See Chart No. 3 for pipe sizes for gas mains.
To check for leaks in gas piping, use a soap and water solution or other approved method, DO NOT USE AN
OPEN FLAME. The boiler must be disconnected from the gas supply piping
system during any pressure testing of that system. Test the gas connection to the boiler before placing the boiler in
operation. Minimum Gas Supply Pressure
Models 300,500,600, 1000, 1300,
1500,2000,2100,2500,
2600,3000
Models 400, 700, 800,900, 1100,
1200,1400,1600,1700, 1800, 1900, 2200, 2300,
2400, 2700, 2800, 2900
Maximum Gas Supply Pressure
All Models
Manifold Pressure
All Models
GAS SUPPLY
l
5.0 inches w.c.
5.3 inches w.c.
14.0 inches w.c.
3.5 inches w.c.
SECURE MANIFOLD FROM
BVER HEAD FRAMING
DRIP LEG
INSTALL MANUAL VALVES 5 FEET ABOVE FLOOR
WHERE REQUIRED BY LOCAL CODES
TYPICAL ISOMETRIC WIRING
AND GAS MAIN PIPING
NOT FURNISHED,
BOILERS ARE FIELD WIRED
AND ASSEMBLED.
FIGURE 8
SUGGESTED WIRING AND GAS MAIN PIPING
CHART 3
TABLE OF PIPE SIZES IN INCHES FOR GAS MAINS
(NATURAL GAS)
Boiler
No. 20' 30' 40' 50' 60' 80' 100' 125' 150' 300
400 2 500 2 2 2
600 2 2 2 2 2 700 2 2 2 2 2
800 2 2 2 2 2
900 2 2 2 2 2 1000 2 2 2 2 1100 2 2 2 2 2 1200 2 2 2 2 3 1300 2 2 2 3 3 1400 2 2 2 3 3 3 1500 2 2 3 3 3
1600 2 2 3 3 3 1700 2 3 3 3 3
1800 2 3 3 3 3 1900 2 3 3 3 3 3
2000 2 3 3 3 3 3 2100 3 3 3 3 3 4 2200 3 3 3 3 4 4 2300 3 3 3 3 3 4 4
2400 3 3 3 3 3 4 4 2500 3 3 3 3 3 4 4 4
2600 3 3 3 3 3 4 4 4 4 2700 3 3 3 3 4 4 4 4 4
2800 3 3 3 4 4 4 4 4 4 2900 3 3 4 4 4 4 4 4 4 3000 3 4 4 4 4 4 4 4 4
SEE CHART # 3 FRR GAS
MAIN MANIFRLD SIZING
PROVIDE DISCONNECT
MEANS AND OVERLOAD
PROTECTION AS REQUIRED
1202V GOHz
4x4x5/8
JUNCTION BOX
(BY INSTALLER)
MOUNT IN
CONVENIENT LOCATION
ADJACENT TO BOILER
ALL WIRING TB CONFORM TO
NEC FOR TEMPERATURE
LIMITATION FOR TYPE "T*
WIRE (63F RISE)
ALL WIRING MUST COMPLY WITH ALL
APPLICABLE CODES, REGULATIONS
10 AND ORDINANCES
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