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Summary of Contents for ECR International D250 Series
- Page 1 Cast Iron Commercial Natural Gas Steam & Water Boiler D250, JF, 41L INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured by: ECR International Inc. 2260 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com PN 240013851 REV. B [11/20/2024]...
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Page 2: Table Of Contents
CAST IRON STEAM BOILER Contents Ratings And Capacities ....................3 Shipment Check List ....................... 4 Accessory Carton Check List..................... 5 Safety Information ......................6 Before Installing ......................7 Ventilation And Combustion Air..................8 Vent Installation ......................10 Boiler Dimensions ......................13 Installation –... -
Page 3: Ratings And Capacities
RATINGS AND CAPACITIES PN 240013851 Rev. B [11/20/2024]... -
Page 4: Shipment Check List
SHIPMENT CHECK LIST PN 240013851 Rev. B [11/20/2024]... -
Page 5: Accessory Carton Check List
ACCESSORY CARTON CHECK LIST ACCESSORY CARTON BOILER MODEL NUMBERS AND QUANTITIES PARTS PART NO. DESCRIPTION 1000 1100 1200 1300 1400 1500 4” Push Nipples 43300977 5/8” - 11NC x 7 14695304 Stud 5/8” - 11NC Hex 1330005 5/8” Flat Washer 14695306 Non-Asbestos Furnace Cement... -
Page 6: Safety Information
SAFETY INFORMATION Safety Information When Your Boiler Arrives When boiler arrives be sure to save and refer to IMPORTANT: Read the following instructions instructions. COMPLETELY before installing!! Inspect each item received for visible damage. If any WARNING parts are damaged, report this to freight company immediately and request them to call and make Fire, explosion, asphyxiation and electrical shock inspection before you make any installation. -
Page 7: Before Installing
BEFORE INSTALLING Minimum Vent Pipe Clearance Boiler Location If the vent pipe must go through a crawl space, double Locate boiler on level, non-combustible foundation as near wall vent pipe should be used. Where vent passes through to chimney or flue as possible. Allow 24 inches at front and a combustible wall or partition, use a ventilated metal sides of boiler for servicing and cleaning. -
Page 8: Ventilation And Combustion Air
VENTILATION AND COMBUSTION AIR WARNING WARNING Asphyxiation hazard. Ensure enough air is available Air openings to combustion area shall not be for proper combustion, avoiding hazard due to lack obstructed. Follow Chart 3 to insure adequate of oxygen. combustion air is maintained. COMBUSTION AIR REQUIREMENTS –... - Page 9 VENTILATION AND COMBUSTION AIR Figure 1 Figure 2 Combustion Air Combustion Openings with Motorized Dampers Openings Vent-Piping Vent-Piping Combustion Air supplied from Combustion Air supplied from inside the building 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 When air for combustion and ventilation is from inside with the section “Air for Combustion and Ventilation”,...
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Page 10: Vent Installation
VENTILATION AND COMBUSTION AIR A. When installing two openings, one must commence B. One permanent opening, commencing within 12 within 12 inches from top and other within 12 inches of top of enclosure, shall be permitted where inches from bottom of enclosure. Openings shall equipment has clearances of at least 1 inch from communicate directly, or by ducts, with outdoors sides, 1 inch from back, and 6 inches from front... - Page 11 VENT INSTALLATION Flue Connection And Venting - Continued Figure 3 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.
- Page 12 VENT INSTALLATION Removing Existing Boiler From Common Venting Figure 6 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...
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Page 13: Boiler Dimensions
BOILER DIMENSIONS Left Side View Front View Supply Supply Water Line 38” 29½” Floor Line Top View Flue Outlets Return Return ALL SUPPLY AND RETURN CONNECTIONS ARE 4 INCH Supply Supply Chart 4 Water Content *Boiler Modules Boiler Shipping A Jacket in Gallons Base &... -
Page 14: Installation & Assembly
INSTALLATION – ASSEMBLY Base Assembly Figure 7A 300, 400 and 500 boilers are the basic models. Figure #7A • 300 model has (6) burners • 400 model has (8) burners • 500 model has (10) burners Combinations of basic models are used to assemble 600 through 1500 models. - Page 15 INSTALLATION – ASSEMBLY When starting section assembly, clean nipples and Figure 9 nipple ports. Coat nipples and nipple ports with Hercules Grrip or other good sealant. See Figure 9. Place nipples in ports. Take care to seat them squarely Figure 10 to prevent cocking.
- Page 16 INSTALLATION – ASSEMBLY Attaching Draft Hoods Figure 13 Draft Hood Attach draft hoods to boiler sections after applying boiler furnace cement to top of boiler sections where hoods and sections meet. Use J-bolts to attach front of draft hoods to slots in section flanges.
- Page 17 INSTALLATION – ASSEMBLY Installing Boiler Jacket Panels Figure 14 NOTICE Start jacket assembly at left side. Attach lower jacket end panel (left) to two Z-bars on base end closures through two slotted holes on bottom of jacket end panel. Use (2) #10 x ½” screws. See Figure 14.
- Page 18 INSTALLATION – ASSEMBLY Figure 17 Position top/front intermediate panel so back edge of top hangs on adjustable clips on front of draft hood(s); Adjustable Clips A. Left edge hangs on bracket on left upper jacket end panel, B. Right edge with integral bracket hangs on tie Bracket rod(s).
- Page 19 INSTALLATION – ASSEMBLY Figure 19 NOTICE Manufacture recommends assembling jacket panels after piping is completed. Skip step 7 proceed to step 8. Attach upper jacket end panel (right) so left edge hangs on bracket on top/front intermediate panel. Insert bare metal plate in same manner as left panel. See Figure 19.
- Page 20 INSTALLATION – ASSEMBLY If boiler piping is preassembled jacket can be assembled as Figure 22A follows. See Figures 22A and 22B. Attach middle jacket end panel (right) to upper jacket end panel with middle laying over upper. Line up holes. Use (6) #10 x ½”...
- Page 21 INSTALLATION – ASSEMBLY Attach burner door knobs with #8-32 x ¼” screws and Figure 24 #8-32 hex nuts. Slide bottom of lower access door(s) in slots on top of manifold brackets. See Figure 24. Attach control panel to front jacket. Use (2) #10 x ½” Figure 25 screws.
- Page 22 INSTALLATION – ASSEMBLY Attach control panel to front jacket panel align with Figure 27A predrilled holes. Use (4) #10 x ½” screws. Secure harness to control panel with zip-ties. Attach wire clips to side and front panels (3). Route wires through clips. See Figure 27A.
- Page 23 INSTALLATION – ASSEMBLY Figure 28B Attach control access jacket panel to front jacket. Use (2) #10 x ½” screws. See Figure 28B. Connect pilot spark wire after control panel installation. See Figure 29. Each boiler base includes: • Factory installed lighting Instruction Labels. NOTE: Attachment of control access jacket panel can •...
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Page 24: Boiler Trim
TAPPINGS Figure 31 shows end section and provided tappings. Figure 31 Tappings are same in both right and left end sections. OPENING SIZE STEAM WATER 4” Supply and Return Supply and Return Primary LWCO and ½” Plugged Gauge Glass Set ¾”... -
Page 25: Boiler Piping
BOILER PIPING Figure 33 - Boiler Tappings STEAM BOILERS - SERIES S BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS SHOWN NOTE: Mount electrical supply on opposite side. CITY WATER SUPPLY CITY WATER SUPPLY WATER WATER WATER LINE LINE LINE 1.1/2 TO RETURN TO RETURN NO. - Page 26 BOILER PIPING Figure 35 STEAM BOILER PIPING Steam Piping Size WARNING Model Header Riser Equalizer Do not install shut-off or steam valve between 400 to 900 4” 4” 2” safety valve and boiler. 1000 to 1200 4” 4” 2 ½” Install Safety Valve As Close To Boiler As Possible 1300 to 1500 4”...
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Page 27: High Limit
BOILER PIPING may be the opposite and of the high limit control. BOILERS USED WITH REFRIGERATION SYSTEM When the boiler is installed in connection with a PIPE SIZING refrigeration system, it must be piped so that the Piping connection sizes are important to control proper chilled medium is piped in parallel with the heating water velocity at the inlet and outlet connections to boiler with appropriate valves to prevent the chilled... - Page 28 BOILER PIPING Figure 38 MULTIPLE STEAM BOILER PIPING - GRAVITY RETURN OPTIONAL STOP VALVE SYSTEM TRAP TO RETURN SYSTEM RETURN OPTIONAL BLOW DOWN VALVE PN 240013851 Rev. B [11/20/2024]...
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Page 29: Connecting Gas Service
CONNECTING GAS SERVICE Chart 5 CAUTION Minimum Operating Gas Supply Pressure WHAT TO DO IF YOU SMELL GAS 5.0 inches w.c. Models • Do not try to light any appliance. 1000 1300 1500 • Do not touch any electrical switch; do not use 5.3 inches w.c. -
Page 30: Electrical Wiring
ELECTRICAL WIRING Adjust Thermostat Heat Anticipator WARNING Set heat anticipator setting per thermostat Electrical shock hazard. Turn OFF electrical power manufacture instructions. supply at service panel before making any line Follow thermostat manufacture instructions for final voltage connections. Failure to do so could result adjustment. -
Page 31: Wiring Diagrams
WIRING DIAGRAMS Commercial Boiler, 1, 2 & 3 Base LOW VOLTAGE WIRING PN 240013851 Rev. B [11/20/2024]... -
Page 32: Operation And Service
OPERATION AND SERVICE Control Functions And Operation System Troubleshooting Control module performs following basic functions: Set thermostat or controller above room temperature and observe system response. Opens and closes first (pilot) operator of gas valve. Establish of system malfunction or deviation from Provides spark for igniting pilot burner. - Page 33 OPERATION AND SERVICE G. Do not use this appliance if any part has been CAUTION under water. Immediately call a qualified service technician to inspect the appliance and to replace WHAT TO DO IF YOU SMELL GAS any part of control system and any gas control Do not try to light any appliance.
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Page 34: Checking And Adjusting
CHECKING AND ADJUSTING Burner And Pilot Flame Verify Burner Input Manufacture recommends visual check of burners and Check boiler for proper Btu input rate. Do not exceed Input rate pilot flame monthly during heating season by owner stamped on nameplate of boiler located on end jacket panel. and once year by service technician. -
Page 35: Cleaning And Maintenance
CLEANING AND MAINTENANCE Cleaning The Steam Boiler Boiler Water Treatment In closed water heating systems, negligible amounts Steam boilers must be cleaned prior to use in order to of make up water are used, and water treatment is not ensure efficient operation. required. -
Page 36: Pilot System Troubleshooting Table
PILOT SYSTEM TROUBLESHOOTING TABLE NOTE: Before troubleshooting, familiarize yourself with startup and check Turn gas supply OFF. Turn thermostat procedure. (controller) to call for heat. Check line voltage power, low voltage transformer, limit controller, thermostat Power to module (24V module) (controller) and wiring. - Page 37 NOTES PN 240013851 Rev. B [11/20/2024]...
- Page 38 NOTES PN 240013851 Rev. B [11/20/2024]...
- Page 39 NOTES PN 240013851 Rev. B [11/20/2024]...
- Page 40 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. 2260 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 325 5479 ©2024 ECR International, Inc. www.ecrinternational.com...
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