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Dunkirk D249 Series, Installation, Operation & Maintenance Manual

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Dunkirk D249 Series Installation, Operation & Maintenance Manual Download Page 1

 P/N# 240010347, Rev. B [02/2014]

D249 Series

Cast Iron Commercial 

Natural Gas Steam Boiler

INSTALLATION, OPERATION & 

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Summary of Contents for D249 Series

Page 1: ...eries Cast Iron Commercial Natural Gas Steam Boiler INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501...

Page 2: ...sult in minor or moderate injury WARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and understand all requi...

Page 3: ...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 ASHRAE HVAC Systems and Equipment Handbook Chimney Ga...

Page 4: ...LOW WATER CUTOFF JACKET END PANEL CARTON BASE END PANEL CARTON 300 400 500 Model SECTIONS STEAM TRIM CARTON ACCESSORY CARTON LEFT 41154051 INNER 41154052 RIGHT 41154050 KIT 550002861 KIT 550002862 KI...

Page 5: ...24 28 32 36 40 44 48 52 56 60 5 8 Flat Washer 14695306 12 16 20 24 28 32 36 40 44 48 52 56 60 Non Asbestos Furnace Cement Pint 1440001 2 2 2 2 2 2 2 2 2 2 2 2 2 FB 1 Fitting Bag 41200051 1 1 1 FB 2 F...

Page 6: ...combustible flooring such as carpeting or wood flooring Failure to follow these instructions could result in death or serious injury 6 DO NOT install boiler on non combustible flooring such as carpeti...

Page 7: ...n the same room Installing contractor must provide ventilated foundation for boiler when installing Over a room Over electrical wiring or cables of any kind If concrete floor is not cured or water is...

Page 8: ...200 3 300 1200 300 600 1300 3 325 1300 325 650 1400 3 350 1400 350 700 1500 3 375 1500 375 750 Unconfined area A space whose volume is not less than 50 cubic feet per 1000 Btu per hour of all applianc...

Page 9: ...o 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 sha...

Page 10: ...ose 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...

Page 11: ...nt 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...

Page 12: ...ly 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 commo...

Page 13: ...2 50 29 1 2 34 3 4 38 42 1 4 46 1 2 10 3 8 10 3 8 12 1 2 12 1 2 14 5 8 12 3 4 14 7 8 17 19 1 8 21 1 4 10 3 8 12 1 2 12 1 2 14 5 8 14 5 8 300 300 400 400 500 300 400 400 500 500 x x x x x 1100 1200 13...

Page 14: ...base end panels Install end panels before assembling sections See Figure 7B NOTICE Verify bases are level after assembly Section Assembly 1 Start sections from left or right end of base 2 Place end se...

Page 15: ...ie rods in alternating pairs of upper and lower holes between adjacent sections See Figure 11 6 Be sure both ends of completed section assembly are resting evenly on both ends of base 7 Apply furnace...

Page 16: ...hood clean out covers Attaching Draft Hoods 1 Attach draft hoods to boiler sections after applying boiler Hercules Grrip to top of boiler sections where hoods and sections meet 2 Use J bolts to attach...

Page 17: ...re 14 2 Attach middle jacket end panel left to lower jacket end panel with middle laying over lower Line up holes Use 5 10 x screws See Figure 15 3 Attach upper jacket end panel left to middle jacket...

Page 18: ...s See Figure 17 5 Attach top front intermediate panel to lower base brackets through four slotted holes in panel Use 4 10 x screws See Figure 18 6 On multiple base boilers each additional top front in...

Page 19: ...ted Skip step 7 proceed to step 8 7 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: ...sembled jacket can be assembled as follows See Figures 22A and 22B 8 Attach middle jacket end panel right to upper jacket end panel with middle laying over upper Line up holes Use 6 10 x screws See Fi...

Page 21: ...ermediate jacket panel s 15 Attach control access jacket panel to front jacket Use 2 10 x screws See Figure 25 16 Each boiler base includes Factory installed lighting Instruction Labels Factory instal...

Page 22: ...ssembly to jacket end panel Align with holes in end panel Use 4 10 x screws See Figure 27 2 Attach control panel to front jacket panel align with predrilled holes Use 4 10 x screws Secure harness to c...

Page 23: ...es See Figure 29 6 On multiple base boilers mount remaining control panels to intermediate jacket panels following steps 4 5 7 On each base connect gas valve harness Refer to Wiring Diagram page 30 8...

Page 24: ...und in section on Checking and Adjustments page 33 STEAM TRIM 1 Low Water Cut Off mounted externally with blow off valve 2 High Pressure Limit Control 3 Pressure Gauge 4 Water Gauge Glass Set 5 Siphon...

Page 25: ...ounts in Gauge Glass Tappings NOTE For multiple boiler installation with gravity return use feeder Cutoff Combination or separate feeder and separate cutoff on each boiler FOR CLOSED HEATING SYSTEMS D...

Page 26: ...to both ends of Boiler Area of Return Header should be equal to total area of Return Mains or larger Pipe steam cross headers with swing joints or equipped with slip joint connector to prevent expansi...

Page 27: ...27 BOILER PIPING Figure 35 High Steam Quality Drop Header Piping Arrangement 20 MIN Note Single Main Riser May Be Used Optional Location for Make up Water Connections...

Page 28: ...t use matches candles open flames or other methods that can provide ignition source Correct leaks immediately and retest Chart 5 Minimum Operating Gas Supply Pressure Models 5 0 inches w c 300 500 600...

Page 29: ...anticipator setting per thermostat manufacture instructions 2 Follow thermostat manufacture instructions for final adjustment 3 When set above temperature indicated on thermometer boiler burners shou...

Page 30: ...30 LOW VOLTAGE WIRING WIRING DIAGRAMS Commercial Boiler 1 2 3 Base...

Page 31: ...ot burner 3 Senses pilot burner flame 4 Shuts off spark after pilot flame is lit 5 Opens and closes second main operator Functions occur in two stages trial for pilot ignition and main burner operatio...

Page 32: ...call qualified service technician Force or attempted repair may result in a fire or explosion G Do not use this appliance if any part has been under water Immediately call a qualified service technici...

Page 33: ...t burners and boiler base frame 3 Clean boiler base interior and exterior Verify Burner Input Check boiler for proper Btu input rate Do not exceed Input rate stamped on nameplate of boiler located on...

Page 34: ...5 After boiler has cooled fill and flush out several times 6 Fill to proper water level and ready for normal service Do not use soda or any alkali vinegar or acid for cleaning heating boilers it is d...

Page 35: ...c across PV MV PV terminals on module If voltage is okay replace gas control if not replace module NOTE If the control goes into lockout reset system Spark Stops When Pilot Lit Check continuity of ign...

Page 36: ...verride which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIO...

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