Dunkirk D248 Series Installation Operation & Maintenance

D248 Series

i Ln

Cast

Iron Commercial

Steam Boiler

INSTALLATION1 OPERATION &

MAINTENANCE MANUAL

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Manufactured by:

ECR International, Inc.

220! Dwyer Avenue. Utica NY 13501 web site www ecnnternatlonal coin

P/N# 240009137, Rev B [06/2013]

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

TABLE OF CONTENTS

Safety Symbols .................................................. 2

Boiler Ratings & Capacities .................................. 3

Rules For Safe Installation & Operation .................. 4

Locating The Boiler ............................................. 5

Combustion Air, Chimney & Vent Pipe Connection ... 5

Minimum Vent Pipe CLearance, ............................. 5

Installation ........................................................ 5

Ventilation And Combustion Air ............................ 6

Vent Installation ................................................. 8

Assembly Of Bases, Starting Section Assembly ...... 12

Attaching Draft Hoods ......................................... 13

Installing Boiler Jacket Panels .............................. 14

Control Mounting And Installation ......................... 17

Tappings ........................................................... 19

Boiler Trim, Water Trim, Water Trim Assembly ........... 19

Boiler Piping ...................................................... 20

Boilers Used With Refrigeration System .................. 20

Boiler Piping, High Limit, Pipe Sizing ...................... 20

Piping Diagrams ................................................ 21

Connecting Gas Service ...................................... 23

Electrical Wiring ................................................. 24

Installing Thermostat .......................................... 24

Adjust Thermostat Heat Anticipator ....................... 24

Stage Firing Multiple Base Boilers .......................... 24

Wiring Diagrams ................................................ 25

Operation and Service ......................................... 27

Functions & Operation, Trial/Pilot Ignition .................. 27

Main Burner Operation, System Troubleshooting ......... 27

Component & Spark Ignition Check ........................ 27

Startup & Checkout, Start system .......................... 28

Pilot Flame Adjustment, Check Burner Input ............ 28

Pilot System Troubleshooting Table ............................ 29

Checking & Adjusting ......................................... 30

Cleaning And Maintenance .................................. 31

SAFETY SYMBOLS

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates information which should be followed to ensure proper installation and operation.

KEEP THIS MANUAL NEAR BOILER,

RETAIN FOR FUTURE REFERENCE.

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand

all requirements before beginning installation.

Input/size

(Mbh)

Output (1)

Net AHRI

Ratings (2)

Flue Outlet No.

& Size

Chimney

Size (6) Flue

Collector

Size to

Chimney

Horsepower

Gross

Output (4)

Pressure Drop

Therrn. Boiler (5) Eft.

Thru Water

300 233

400 310

500 388

700 543

800 620

900

1000 775

11OO 853

1200 930

1300 1008

1400 1085

1500 1163

1700 1318

i800 i395

i900 i473

2000 1550

8"x20' 8

10"x2O' 10

12"x20' 12

12'x20! 12

14'x20' 14

14"x201 i4

16"x20' 16

18"x20' 18

18"x20 18

18',X2Oi i8

18!'x20' 18

20,x20' 20

20"x20!

20'!x20 20

16;21

6.96

9.25

11.58

13.88

18.51

20184

23,13

25.46

27.76

30.09

32.39

34.72

37.0i

39.34

4i]64

46.27

77.5

77;5

77.5

77:5

77.5

77:5

77.5

77:5

77.5

77:5

2100 1628

2200 1705

2300 1783

2400 1860

2500 1938

2600 . 2015

2700 2093

2800 2i70

2900

3000 2325

1) 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

2) Net steam ratings based on an allowance of 1.333 (300-1600), 1.327 (1700), 1.319 (1800), 1.313 (1900), 1.307 (2000), 1.301 (2100), 1.296 (2200),

1.292 (2300), 1.290 (2400), and 1.288 (2500-3000). Contact Technical Support before selecting boiler for installations having unusual piping and pick-up factors, such as intermittent system operations, extensive piping systems, etc.

3) Ratings in square feet are computed at 240 Btuh/square foot for steam boilers.

4) Ratings based on 33,500 Btuh per horsepower.

5) Pressure drop based on given flow from single outlet and returning to single inlet at the opposite end of the boiler.

6) Chimney sizes shown are one option based on a typical venting system as shown in Figure 6, and sized according to the National Fuel Gas Code, assuming Type B double wall vent and vent connectors, Other venting system designs are acceptable as shown on Flue Connection And Venting section of this manual. For further chimney design and sizing information, consult the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest revision, or ASHRAE6 HVAC Systems and Equipment Handbook,

Chimney, Gas Vent, and Fireplace Systems, or the Standard for Chimneys, Fireplaces, Vents, and Sotid Fuet Burning Appliances. NFPA 211. Follow standard engineering

practice.

20"x20' 20

22"x20' 22

22"x20 22

24"x20'

24'!x201

24,x20' 24

24'!x20 24

48.60

50.90

53.22

55.52

57.85

60ii5

62.48

64178

67:10

69,40

77.5

77 5

77.5

77:5

Safety Information

iMPORTANT: Read the following COMPLETELY before installing!!

Fire, explosion, asphyxiation and electrical shock

instructions

hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

When Your Boiler Arrives

When boiler arrives be sure to save and refer to instructions,

Inspect each item received for visible damage. If any parts are damaged, report this to freight company

immediately and request them to call and make inspection before you make any installation. Have

inspector prepare a signed report. Send copy of report to manufacturer.

We must have the signed inspection report of the freight company to prove their liability.

Keep boiler area clear and free from combustible

materials, gasoline and other flammable vapors and liquids.

DO NOT obstruct air openings to the boiler room.

Modification, substitution or elimination of factory equipped, supplied or specified components may

result in personal injury or loss of life. TO THE OWNER = Tnstallation and service of this

boiler must be performed by a qualified installer. TO THE INSTALLER = Leave all instructions with

boiler for future reference. When this product is installed in the

Commonwealth of Massachusetts the installation

must be performed by a Licensed Plumber or

Licensed Gas Fitter.

1. Never test for leaks with an open flame, Use soap suds to check all connections, This will avoid any possibility of fire or explosion,

2. Boiler is configured for operation with natural gas, Over-firing will result in premature failure of boiler sec- tions and cause dangerous operation, Verify there is adequate gas supply piping,

3. Never vent this boiler into enclosed space, Always con- nect boiler to chimney and vent to outside, Never vent to another room or inside abuilding,

4. Verify there is adequate air supply for complete com- bustion,

5. Follow regular service and maintenance schedule for efficient and safe operation,

Read these instructions carefully before beginning the installation to be sure all packages have been

received. ]:t 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 will not be lost or damaged.

CODES GOVERNING INSTALLATION

Installation must conform to the requirements of the authority having jurisdiction or, in the absence of

such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA54.

Where required by the authority having jurisdiction, the installation must conform to the standard for Controls

and Safety Devices for Automatically Fired Boilers,

ANS_/ASME CSD=I,

Installation Boiler is designed to provide wide heating capacity range

with multiple burner modules, each equipped with its own set of controls. For purposes of orientation, gas manifold side of boiler is considered front. Instructions are written

for assembly of boiler starting with left side and working to right side.

Hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be

provided with a low water cutoff device at the time of boiler installation.

Fire hazard. Do not install boiler carpeting. Failure

to follow these instructions could result in death or serious injury.

6. Never install boiler on carpeting.

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Boiler Location Locate boiler on level, non=combustible foundation as near

to chimney or flue as possible. Allow 24 inches at front and sides of boiler for servicing and cleaning. When installed in 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.

Tnstalling contractor must provide ventilated foundation for boiler when installing:

• Over a room

• Over electrical wiring or cables of any kind

• Tf concrete floor is "green," or water is channeled under concrete floor

Combustion Air

Provide combustion and ventilation air in accordance with the section "Air for Combustion and Ventilation", of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.

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 Pages 6-::L0for specific venting instructions.

Flue pipe should be same size as draft hood outlet from boiler to flue collector. See Chart 1 for Typical Chimney Size. Main-

rain 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

wall vent pipe should be used. Where vent passes through a combustible wall 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.

Top 52" 52"

Front Alcove Alcove

Flue Collector 6 " 6"

Rear 18" 24"

Sides 18" 24"

Steam/Water 1" 1"

Piping

Greater clearances (24") for access should supersede fire protection clearances.

Asphyxiation hazard. Ensure enough air is available

for proper combustion, avoiding hazard due to lack

of oxygen.

300 i 75 300 75 150

500 i 125 500 125 250

700 2 175 700 175 350

900 2 225 900 225 450

ii!ii ii; i

1100 3 275 1100 275 550

Air openings to combustion area must not be

obstructed. Follow Chart 2 to insure adequate combustion air is maintained.

1300 3 325 1300 325 650

1500 3 375 1500 375 750

1700 4 425 1700 425 850

1900 4 475 1900 475 950

2100 5 525 2100 525 1050

2300 5 575 2300 575 1150

2500 5 625 2500 625 1250

2700 6 675 2700 675 1350

2900 6 725 2900 725 1450

* Unconfined area: A space whose volume is not less than 50 cubic feetper 1000 Btu

per hour of all appliances installed in that space (cubic feet of space = height x width x length).

** Confined area: A space whose volume is less than 50 cubic feet per 1000 Btu per

hour of all appliances installed in that space (cubic feet of space = height x width x length).

Figure I Figure 2

Combustion

Air

_ _, ODeninas

Combustion Air supplied from

outside the building

Important Vent=Piping Note: Sloped vent pipe at least 1/4" for every 1" to the vent terminal.

Provide combustion and ventilation air in accordance

with the section "Air for Combustion and Ventilation", of the National Fuel Gas Code, ANSI Z223.:[/NFPA 54, or applicable provisions of the local building codes.

Boiler is located in unconfined space in building or conventional construction frame, masonry or metal building, infiltration normally is adequate to provide a_r for combustion and ventilation. However, if equipment is located in building of tight construction (See National

Fuel Gas Code, ANSI Z223.:[), boiler area should be considered as confined space. If there is any doubt, install air supply provisions in accordance with latest

revision of National Fuel Gas Code.

Boiler is installed in unconfined space, in building of tight construction, air for combustion and ventilation must be obtained from outdoors or from spaces freely communicating with outdoors. Permanent opening or openings having total free area of not less than 1 square inch per 5,000 Btu per hour of total input rating of all appliances shall be provided. Ducts may be used to convey makeup air from outdoors and shall have same cross-sectional area of openings to which they

are connected.

4. When air for combustion and ventilation is from inside buildings, confined space shall be provided with two

permanent openings, one starting 12 inches from top and one 12 inches from bottom of enclosed space. Each opening shall have minimum free area of 1 square inch per one thousand (1000) Btu per hour of total input rating of all appliances in enclosed space, but must not be less than one hundred (100) square inches. Openings must freely communicate directly with other spaces of sufficient volume so combined volume of all spaces meets criteria for unconfined space. Figure 1.

5. When boiler is installed in confined space and all air is provided from outdoors confined space shall be provided with one or two permanent openings according to methods A or B (listed below). When ducts are used, they shall be of same cross sectional area as free area of area of openings to which they connect. Minimum dimension of rectangular air ducts shall be not less than 3 x 3 inches or 9 square inches.

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A. When installing two openings, one must commence B.

within 12 inches from top and other within 12 inches from bottom of enclosure. Openings shall communicate directly, or by ducts, with outdoors or spaces (:crawl or attic) that freely communicate with outdoors. One of following methods must be used to provide adequate air for ventilation and

combustion.

1) When directly communicating with outdoors,

each opening shall have minimum free area of

1 square inch per 4,000 Btu per hour of total

input rating of all equipment in enclosure. Refer to Figure 2 on previous page.

2) When communicating with outdoors by means of vertical ducts, each opening shall have minimum free area 1 square inch per 4,000 Btu per hour of total input rating of all

appliances in the enclosed space.

3) If horizontal ducts are used, each opening and duct shall have minimum free area 1

square inch per 2,000 Btu per hour of total input rating of all appliances in the enclosed

space.

In calculating free area using louvers, grilles or

screens for above, consideration shall be given to their blocking effect. Screens used shall not be smaller than 1/4 inch mesh. If free area through design of louver or grill is known, it should be used in calculating size opening required to provide free area specified. If design and free area is not known, it may be assumed that wood louvers will have 20= 25% free area and metal louvers and grilles will have 60-75% free area. Louvers and grilles should be fixed in open position or interlocked with boiler so they are opened automatically during boiler operation.

One permanent opening, commencing within 12 inches of top of enclosure, shall be permitted where equipment has clearances of at least 1 inch from sides, 1 inch from back, and 6 inches from front of boiler. Opening shall directly communicate with

outdoors or shall communicate through vertical or horizontal duct to outdoors or spaces (:crawl

or attic) that freely communicate with outdoors. Openings must have minimum free area of 1

square inch per 3000 Btu per hour of total input rating of all equipment located in enclosure. Free

area must be no less than sum of areas of all vent connectors in confined space.

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Vent connectors serving appliances vented by

natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

1. The vent pipe must slope upward from the boiler not less than 1/4" for every 1' to the vent terminal.

Figures 1 & 2,

2. Horizontal portions of the venting system shall be

supported rigidly every 5 feet and at the elbows. No portion of the vent pipe should have dips or sags.

Flue Connection And Venting

Vent installations shall be in accordance with "Venting of Equipment", of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or applicable provisions of the local building

codes.

1. Consult dimensional drawing for number and size of flue pipes required for each size boiler.

2. Maintain minimum upward slope of 1/4 inch per linear foot from the boiler to chimney.

3. Run flue pipe directly as possible. Keep turns to a minimum. Insert flue pipe into, but not beyond, inside wall of chimney. Do not connect into a chimney serving an open fireplace.

Insulate flue pipe where it passes near combustible material.

Rigidly support pipe with hangers and straps.

Extend chimneys at least 2 feet above any object within radius of 15 feet, including roof.

Install hood on all flue pipes which extend through roof. In most locations, venting of boiler relies on natural

draft. In as much as energy available from natural draft is quite low, serious thought should be given to vent system design, i.e., adequate size, use of gradual transitions, tees, elbows, etc., close proximity of boiler and chimney. On all boilers, vertical risers must be at least as large as vent openings on draft=hood. Boiler

manufacturer makes no specific recommendations regarding application of draft inducers that may be used with this boiler. If draft inducer is used, it is up to installing contractor and draft inducer manufacturer to determine proper application.

Flue Connection And Venting - Continued Simple vent system consists of 6-foot minimum vertical

rise immediately off draft-hood, as shown in Figure 3.

Terminate this vertical flue above building roof with suitable

rain cap at least 2 feet above surrounding obstructions, i.e., parapets, adjacent buildings, penthouses, etc. This type of vent system applies to single draft-hood boilers ONLY, and has limited practical use, because it is restricted to single-story boiler rooms and because of problems encountered in roof flashing.

Vertical venting system shown in Figure 3 cannot be used on multiple=base boilers because of physical interference of multiple rain caps.

For multiple=base boilers, pant leg venting system shown in

Figure 4 can be applied, if desired.

Figure 3

IMPORTANT: Extend chimneys at least 2 feet above any

object within radius of 15 feet, including roof.

Vent system shown in Figure 5 is commonly used. With vent diameters sized to match flue outlets, minimum

vertical rise of 4 feet above draft=hood must be maintained for proper operation. Refer to Chart 1 for typical chimney

sizes. Requirements for this type of system are: an adequately sized chimney, adequate combustion air, and

outlet end of horizontal run must be no more than 6 feet from chimney with no more than one 90° elbow in this run

as shown.

For installations where required minimum 4-foot vertical rise cannot be maintained, diameter of horizontal run must

be increased one inch for each foot of riser reduction. This procedure will reduce resistance of system, and if chimney

is adequate boiler will vent properly.

Figure 4

Figure 5

IMPORTANT: Extend chimneys at least 2 feet above any

object within radius of 15 feet, including roof.

IMPORTANT: Extend chimneys at least 2 feetabove any

object within radius of 15 feet, including roof.

Figure 6

Shown is suggested size of fixed baffle for different size risers.

IMPORTANT; Extend chimneys at least 2 feet above any

object within radius of 15 feet, including roof.

Flue Connection And Venting = Continued

In certain cases where these short rises of less than 4 feet have been used, spillage of combustion products has

occurred at the draft-hoods farthest from the chimney. Assuming the chimney is adequately sized, one acceptable method to correct this spillage problem is to permanently baffle the riser(s) closest to the chimney to reduce the excess of room air entering those draft-hoods. DO NOT

BAFFLE ENOUGH TO CAUSE SPILLAGE. The use of fixed

baffles in the short risers above the boiler draft-hood are acceptable as spelled out in American National Standard

NFPA 54/ANSI Z223.1 National Fuel Gas Code, latest

revision.

Fabricate these fixed baffles, using 20-gauge steel. See

Figure #6. Permanently attach the baffle to the inside of the riser(s). Trial and error will dictate the degree to which each should be positioned to avoid draft-hood spillage at the far end of the boiler. Be careful to avoid bending the fixed baffle so it will obstruct the flue gas flow in the horizontal collector.

Removing Existing Boiler From Common Venting

System

When existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.

At time of removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which

could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected

to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with

the National Fuel Gas Code, ANSI Z223.1/NFPA 54. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

+ 22 hidden pages

Dunkirk D248 Series Installation Operation & Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual