Dunkirk D249 Series Installation, Operation & Maintenance Manual
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Dunkirk D249 Series Installation, Operation & Maintenance Manual

Cast iron commercial natural gas steam boiler
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D249 Series
Cast Iron Commercial
Natural Gas Steam Boiler
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
An ISO 9001-2008 Certified Company
P/N# 240010347, Rev. B [02/2014]

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  • Page 1 D249 Series Cast Iron Commercial Natural Gas Steam Boiler INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com An ISO 9001-2008 Certified Company P/N# 240010347, Rev. B [02/2014]...

  • Page 2: Table Of Contents

    CAST IRON HOT WATER OR 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 ......................

  • Page 3: Ratings And Capacities

    RATINGS AND CAPACITIES Ratings and Capacities - Chart 1 Net AHRI Flue Outlet No. & Chimney Horse- Output (1) Flue Ratings (2) Size Size (6) power Input/Size Collector Therm. Gross Gross Steam (Mbh) Size to Eff. Steam Output Output 8” 10”...

  • Page 4: Shipment Check List

    SHIPMENT CHECK LIST...

  • Page 5: Accessory Carton Check List

    ACCESSORY CARTON CHECK LIST ACCESSORY CARTON BOILER MODEL NUMBERS AND QUANTITIES PARTS 1000 1100 1200 1300 1400 1500 DESCRIPTION PART NO. COMPLETE ACCY CRTN # 4” Push Nipples 43300977 5/8” - 11NC x 7 14695304 Stud 5/8” - 11NC Hex 1330005 5/8”...

  • Page 6: Safety Information

    SAFETY INFORMATION Safety Information When Your Boiler Arrives IMPORTANT: Read the following instructions When boiler arrives be sure to save and refer to COMPLETELY before installing!! instructions. WARNING Inspect each item received for visible damage. If any parts are damaged, report this to freight company Fire, explosion, asphyxiation and electrical shock immediately and request them to call and make hazard.

  • 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”,...

  • 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...

  • 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 Boiler Water Shipping A Jacket *Boiler Modules 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. Figure 10 Place nipples in ports. Take care to seat them squarely to prevent cocking.
  • Page 16 INSTALLATION – ASSEMBLY Attaching Draft Hoods Figure 13 Draft Hood Attach draft hoods to boiler sections after applying boiler Hercules Grrip 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 See Figure 21. Figure 22A If boiler piping is preassembled jacket can be assembled as 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. Position control access jacket panel(s) so tabs slide into slots on top/front intermediate jacket panel(s).
  • Page 22 INSTALLATION – ASSEMBLY Control Mounting And Installation Figure 27 Electrical controls, J-box, etc. can be mounted on either left or right jacket end panel. Boiler safeties (LWCO, etc.) and respective piping must be mounted on opposite end of boiler electrical controls. Attach J-box assembly to jacket end panel.
  • Page 23 INSTALLATION – ASSEMBLY Connect plugs on harnesses. See Figure 29. Figure 29 On multiple base boilers, mount remaining control panels to intermediate jacket panels following steps 4 & 5. On each base, connect gas valve harness. Refer to Wiring Diagram page 30. Figure 30 Connect pilot spark wire after control panel installation.

  • Page 24: Tappings

    TAPPINGS Figure 31 shows end section and provided tappings. Figure 31 Tappings are same in both right and left end sections. OPENING SIZE STEAM 4” Supply and Return Primary LWCO and Gauge ½” Glass Set ¾” Drain, Left End ¾” Drain, Right End ½”...

  • Page 25: Boiler Piping

    BOILER PIPING Figure 33 - Boiler Tappings...

  • Page 26: Steam Boiler Piping

    BOILER PIPING Figure 34 STEAM BOILER PIPING SKIM TEE 29½” Optional Location for Make-up Water Connections Install Safety Valve As Close To Boiler As Possible WARNING Do not install shut-off or steam valve between STEAM BOILER PIPING See Figure 34 safety valve and boiler.
  • Page 27 BOILER PIPING Figure 35 - High Steam Quality Drop Header Piping Arrangement...

  • Page 28: 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 29: 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 30: Wiring Diagrams

    WIRING DIAGRAMS Commercial Boiler, 1, 2 & 3 Base LOW VOLTAGE WIRING...

  • Page 31: 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 32 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.

  • Page 33: Checking And Adjusting

    CHECKING AND ADJUSTING BOILER FLUE PASSAGE Verify Burner Input Burner And Pilot Flame Check boiler for proper Btu input rate. Do not exceed Input rate Manufacture recommends flue passages, burner stamped on nameplate of boiler located on end jacket panel. adjustments and operation of boiler controls be checked Verify primary air supply to main burners is properly once a year by a service technician.

  • Page 34: Cleaning And Maintenance

    CLEANING AND MAINTENANCE Cleaning The Steam Boiler Boiler Water Treatment In steam systems where system is tight, free from leaks, Steam boilers must be cleaned prior to use in order to and all steam is returned to boiler as condensate, amount ensure efficient operation.

  • Page 35: 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 36 • 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. DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...

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