Page 1: ...llh I _ i I Cast D248 Series Iron Commercial Steam Boiler INSTALLATION1 OPERATION MAINTENANCE MANUAL US H Manufactured by ECR International Inc 220 Dwyer Avenue Utica NY 13501 web site www ecnnternatl...
Page 2: ...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...
Page 3: ...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...
Page 4: ...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...
Page 5: ...o 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...
Page 6: ...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 1300 3 325 1300 325 650 1500 3 375 1500 375 750 1700 4 425 1700 425 850 1900 4 475 1900 475 950...
Page 7: ...ing 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 outdo...
Page 8: ...nch 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 as...
Page 9: ...th 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...
Page 10: ...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 hor...
Page 11: ...i_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii_ii_ ii_ii_ii _ii_ii_i i_ii...
Page 12: ...i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i...
Page 13: ...oints of the sections front top and back Putty should also be applied where the sections join the base Figure 12 Place necessary plugs and control wells in correct locations Plug all other tappings le...
Page 14: ...ng up holes Use 6 10 x 1 2 screws Ensure bare metal plate is inserted between casting ridge and draft hood This will hold panel in place Figure 16 4 Position top front intermediate panel so back edge...
Page 15: ...lower jacket end panel right to middle jacket end panel with lower behind middle and lining up holes Use 5 0 x 1if screws Attach lower jacket end panel to two Z bars on base end closures through two...
Page 16: ...each boiler base Each boiler base also includes data plate indicating required gas type firing rate and gas pressure for that base These plates are located on Jacket Top Front Panels Boilers also have...
Page 17: ...along top of bracket and 2 along lower edge of bracket Figure 26A Remove cover 2 screws from box then remove knockout left or right side Connect plug of harness from transformer to plug on j box Figu...
Page 18: ...Control Mounting And Installation Figure 27A Figure 29A Figure 27B Figure 29B Figure 28...
Page 19: ...operation will be found in section on Controls and Adjustments 1 Water temperature high limit control 2 Combination temperature pressure gauge 3 Safety relief valve 30 psi WATER TRIM ASSEMBL Y Locate...
Page 20: ...uirements of the particular system and choice of arrangements and sizes of headers should be decided upon by the installer s heating engineerorwith standard engineering practice When using only one su...
Page 21: ...transformer for use on closed heating systems only 1600 THRU 3000 No 51 2 FOR CLOSED HEATING SYSTEMS DIMENSION A 2 e 2 1 z These items available through your Distributor FOR CLOSED HEATING SYSTEMS DI...
Page 22: ...i_i_i __i_i_i_i_i_i_i_i __i_i_i_i_i_i_i_i __i_i_i_i_i_i_i_i _ _i_i_i_i_i_i_i_i __i_i_i_i_i_i_i __i_i_i_i_i_i_ __i_i_i_i_i_ _ _i_i_i_i_i_i __i_i_i_i_ __i_i_i_i_ __i_i_i_ _ _i_i_i_ __i_i_ _ Figure 35 ST...
Page 23: ...all threaded pipe connections Main gas supply line should be adequate to prevent undue pressure drop See hart 5 for pipe sizes for gas mains Boiler and its gas connection must be leak tested before pl...
Page 24: ...temperature reaches selected setting and starts boiler operating when room temperature falls few degrees Finally set thermostat for desired temperature Special conditions in building and location of t...
Page 25: ...0 BERHC VHT _i i u GAS VALVE GAS VALVE I WIRING WIRING r t TL PRIIT i o _ TMFR I _mmmm_ r_J _ t I FIELD INSTALLED WIRING SCHEMATIC HIGH VOLT POWER SUPPLY _Evrk _ 3_ 7 LVCO Q_ RELAY i LVCB PS HL PS HL...
Page 26: ...IONAL BOILER BASE S I f x P _ R_ _ _ _ TMFR I r_J sE_C _ II I i IFIELD INSTALLED RELAY WIRING SCHEMATIC HIGH VOLT POWER SUPPLY 4 EWF I I 2 J 3 4 6 woo i o T g _ _ T iT L_ CO PS HL PS HL MANUAL RESET O...
Page 27: ...should be made before troubleshooting and after maintenance 1 Check power switch 2 Manual shutoff valves in gas line to boiler must be open 3 Make sure all wiring connections are clean and tight 4 Re...
Page 28: ...after adjustment to prevent possible gas leakage Check Grounding A common ground is required for the pilot burner igniter sensor mounting bracket and the GND terminal of the control If the ground is p...
Page 29: ...electrical connections between flame rod and module Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If roblem ersists re...
Page 30: ...INPUT RATE NOTE The adjustment screw is plastic and may require sfightly greater turning force than metal threads Be sure to replace Regulator Cap High Limit Control While boiler is operating set high...
Page 31: ...grease or oil used to lubricate the cutting tools or push nipples during the erection of new piping systems picks up sand and dirt causing a scum of fine particles and grease to accumulate on the surf...
Page 32: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com...
