DUNKIRK Boiler Manual L0611128

User Manual: DUNKIRK DUNKIRK Boiler Manual DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides

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Steam
or
VVater
|OIL|R

INSTALLATION
These instructions

INSTRUCTIONS

must be affixed on or adjacent to the boiler.

contents
Rules for Safe Installation

and Operation

Boiler Ratings and Capacities
Boiler Dimensions
Combustion

..................................................................

....................................................................................

......................................................................................................

Air and Boiler Location

...........................................................................

Assembly

of Bases .....................................................................................................

Assembly

of Sections

Connecting
Installing

and Draft Hoods ......................................................................

Gas Service
Boiler Jacket

..........................................................................................

.............................................................................................

Boiler Controls ..........................................................................................................

Water Boiler Piping ..................................................................................................

Steam

Boiler Piping ..................................................................................................

Flue Connection

and Venting

Electrical

.......................................................................................................

Wiring

Operation

and Service

Checking

and Adjusting

...................................................................................

16
17

.............................................................................................

...........................................................................................

Parts .........................................................................................................................

introduction
Please read our instructions before you install and use your new boiler. This will help
assure you of proper installation and help you avoid needless service.
You may plan to install the boiler yourself. You must then realize that the wrong use
of any tool can be dangerous, unless you know how to use the tool and equipment
and understand the electrical wiring, piping, and potential hazards involved. The
boiler must be installed in accordance with the requirements of the local utility and
those of other authorities.

CODES

RULES FOR SAFE INSTALLATION
AND OPERATION
1 . Read the Owner's

Manual and the Rules for Safe

operation carefully. Failure to follow the rules for safe
operation
and the instructions
could cause a
malfunction of the boiler and result in death, serious
bodily injury, and/or property damage.
2.

Check your local codes and utility requirements before
installation. The installation must be in accordance with
their directives.
Before servicing, allow boiler to cool and always shut
off any electricity and gas to boiler when working on it.
This will prevent any electrical shocks or burns.

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

INSTALLATION
This boiler is designed to provide wide capacity range with
multiple burner modules, each equipped with its own set of
controls. For purposes of orientation, the manifold side of
the boiler is considered the front. The end sections are so
designed that the controls may be placed on either the left
or right end. These instructions
are written for the
assembling of the boiler starting with the left side and
working to the right side. If the boiler is to be used as a
steam boiler and connected to another steam boiler, the
factory designed water lines of the two boilers must be of
equal height above the floor.

Never vent this boiler into an enclosed space. Always
connect the boiler to a chimney and vent to the outside.
Never vent to another room or inside a building.
Be sure there is adequate
combustion.

air supply for complete

Follow a regular service and maintenance
for efficient and safe operation.

Never install the boiler on carpeting.

schedule

A hot water boiler installed above radiation level must be
provided with a low water cutoff device either as a part of
the boiler or at the time of boiler installation.

10. Keep boiler area clear and free from combustible
material such as gasoline and other flammable vapors
and liquids.

The boiler

WHEN

YOUR

INSTALLATION

Where required by the authority having jurisdiction, the
installation
must conform to American
Society of
Mechanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, No. CSD-1.

Be certain boiler is equipped for type of gas (natural)
to be used. Overfiring wilt result in premature failure of
the boiler sections and cause dangerous operation.
.

GOVERNING

Boiler should be installed in accordance to the latest edition
of American National Standard National Fuel Gas Code
Z223.1 (Available from the American Gas Association, 8501
East Pleasant Valley Road, Cleveland, Ohio 44131).
Reference should also be made to local gas utility
regulations and other codes in effect in the area in which
the installation is to be made. The jurisdiction normally
covers electrical wiring, gas piping, flue specification, and
insulation of adjacent combustible material where required
clearance cannot be maintained.

and its individual

shutoff

valve must

disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psig (3.5 kPa).

BOILER ARRIVES

When your boiler arrives be sure to save and refer to the
instructions.

The boiler must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 psig (3.5 kPa)

First, inspect each item received for visible damage. If any
parts are damaged, report this to the freight company
immediately
and request them to call and make an
inspection before you make any installation. Have the
inspector prepare a signed report. Send a copy of this report
to the manufacturer and we will send replacements for the
damaged parts. But we must have the signed inspection
report of the freight company to prove their liability.
Read these instructions carefully before beginning the
installation to be sure all packages have been received. It
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 wilt not be lost or
damaged.

@
RATINGS
CHART

AND CAPACITIES

BOILER

A.G.A.*

MODEL

INPUT

OUTPUT

Steam

Water

NO.

Bitu Mbh

Btu Mbh

Sq. Ft.$

Btu Mbh

JC 300

3O0

240

NET I=B=R RATINGSt

750

180

209

FLUE OUTLET
NO. & SIZE
8"

10"

12"

JC 400

400

320

1000

240

278

JC 500

5O0

400

1250

300

348

JC 600

600

480

1500

360

417

JC 700

7O0

560

1750

420

487

JC 800

8OO

640

2000

480

JC 900

900

720

2250

JC1000

1000

800

JC1100

1100

880

JC1200

1200

JC1300

FLUE

HORSE-

PRESSURE

CHIMNEY

COLLECTOR

POWER

DROP THRU

SIZE$$

SIZE TO

GROSS

WATER BOILERI-I-

I.D. x Ht.

CHIMNEY

OUTPUT**

8"x 20'
1

7.16

10'x 20'

9.55

12" x 20'

11.94

12" x 20'

14.33

12" x 20'

16.72

557

14"x 20'

19.10

540

626

14"x 20'

21.49

2500

600

696

2750

660

765

960

3000

720

835

1300

1040

3250

780

904

JC1400

1400

1120

3500

840

974

JC1500

1500

1200

3750

900

1043

JC1600

1600

1280

4008

962

1113

JC1700

1700

1360

4283

1028

1183

JC1800

1800

1440

4563

1095

JC1900

1900

1520

4838

JC2000

2000

1600

JC2100

2100

JC2200

2200

JC2300

14"x 20'

23.88

16"x 20'

26.27

16"x 20'

28.66

16"x 20'

31.04

18"x 20'

33.43

18"x 20'

35.82

18"x 20'

38.21

1
1

4
1

GPM

In. Water

18.9

0.10

37.8

0.50

25.2
50.4
31.5
63.0

0.27
0.86
0.40
1.20

37.8

0.50

75.6
44.1
88.2
50.4

1.70
0.70
2.50
0.88

100.8

2.90

56.7
113.4
63.0
126.0
69.3

1.10
3.80
1.30
4.00
1.50

138.6

5.00

75.6
151.2
81.9
163.8
88.2
176.4

1.80
6.00
2.00
5.60
2.40
7.00

94.5

2.60

189.0
100.8

8.30
2.80

201.0

9.60

187.1
214.2
113.4
226.8
119.7
239.4
126.0
252.0
132.3
264.6

3.15
10.30
3.50
11.00
4.00
12.50
4.50
14.00
4.95
16.00

18"x 20'

40.60

1252

20"x 20'

42.99

1161

1322

20"x 20'

45.37

5117

1228

1391

20"x 20'

47.76

1680

5392

1294

1461

20"x 20'

50.15

1760

5671

1361

1530

22"x 20'

52.54

2300

1840

5942

1426

1600

22"x 20'

54.93

JC2400

2400

1920

6213

1491

1670

22"x 20'

57.31

JC2500

2500

2000

6471

1553

1739

22"x 20'

59.70

JC2600

2600

2080

6729

1615

1809

22"x 20'

62.09

163.8

7.00

327.6

22.00

7.50
24.00
8.00

352.8

26.00

138.6

5.40

277.2
144.9
289.8
151.2
302.4
157.5
315.0

18.00
5.70
17.00
6.00
19.00
8.00
20.50

24"x 20'

64.48

1948

24"x 20'

66.87

170.1
340.2
176.4

2017

24"x 20'

69.25

182.75

JC2700

2700

2160

6988

1677

1878

JC2800

2800

2240

7246

1739

JC2900

2900

2320

7504

1801

365.5

JC3000

3000

2400

7763

1863

2087

are at sea level to 2,000 feet. For altitudes
based on selection factors recommended

24"x 20'

Ratings
Ratings

based on an allowance of 1.15, and net steam boiler ratings are based on an allowance
high piping and pickup requirements,
use steam rating.
Ratings in square feet are computed at 240 Btuh/square
toot for steam boilers.

**
lt

Ratings based on 33,500 Btuh per horsepower.
Pressure drop based on given flow from a single

71.64

8.50
27.50

189.1

9.00

378.2

9.00

above 2,000 feet, reduce all ratings 4% for each 1,000 feet above sea level
by Hydronics institute for piping and pickup. Net water boiler ratings are

outlet and returning

to a single

of 1.33. For water

inlet at the opposite

applications

with

end of the boiler.

:I::I: Chimney sizes shown are one option based on a typical venting system as shown in Figure 21, 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 page 16. For further chimney design and sizing information,
consult the National Fuel Gas Code, ANSI
Z223.1/NFPA
54-latest revision, or ASHRAE-1996
HVAC Systems and Equipment
Handbook,
Chapter 30, Chimney, Gas
Vent, and Fireplace Systems, or the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances.
NFPA
211 -latest revision. Follow standard engineering
practice.

LINE
SUPPLY_

--'dATER

38"
47_"

EZZZ] EZ_

EZB

33.__

89 _

_FLFIOR

Z_................................

LINE

LEFT SIDE VIEW
FRONT VIEW

ICT]_

RETURN

7F_

F_G

I_" 1

_FLUE

HUTLETS

_JJRETURN

ALL SUPPLY AND RETURN
CONNECTIONS, 4IN.
]
SUPPLY

SUPPLY

TOP VIEW
Boiler
Model
No.
JC 300
JC 400
JC 500
JC 600
JC 700
JC 800
JC 900
JC1000
JC1100
JC1200
JC1300
JC1400
JC1500
JC1600
JC1700
JC1800
JC1900
JC2000
JC2100
JC2200
JC2300
JC2400
JC2500
JC2600
JC2700
JC2800
JC2900
JC3000

Water Content Shipping
In Gallons
Weight
.3team Water
Lbs.
20
26
922
25
33
1133
30
40
1344
35
46
1555
40
52
1766
45
58
1977
50
65
2188
55
71
2399
60
78
2610
65
84
2821
70
91
3032
75
97
3243
80
104
3454
85
110
3665
90
117
3876
95
123
4087
100
130
4298
105
136
4509
110
143
4720
115
149
4931
120
156
5142
125
162
5353
130
169
5564
135
175
5775
140
182
5986
145
188
6197
150
195
6408
155
201
6619

A
Jacket Width
L to R
18 3/4
23
27 1/4
31 1/2
35 3/4
40
44 1/4
48 1/2
52 3/4
57
61 1/4
65 1/2
69 3/4
74
78 1/4
82 1/2
86 3/4
91
95 1/4
99 1/2
103 3/4
108
112 1/4
1161/2
120 3/4
125
129 1/4
133 1/2

AA
Base & Battery
Length
16 3/4
21
25 1/4
29 1/2
34 3/4
38
42 1/4
46 1/2
50 3/4
55
59 1/4
63 1/2
67 3/4
72
76 1/4
80 1/2
84 3/4
89
93 1/4
97 1/2
101 3/4
106
110 1/4
1141/2
118 3/4
123
127 1/4
131 1/2

9 3/8
11 1/2
13 5/8
9 3/8
9 3/8
11 1/2
11 1/2
13 5/8
9 3/8
11 1/2
9 3/8
11 1/2
13 5/8
11 1/2
9 3/8
11 1/2
11 1/2
13 5/8
9 3/8
11 1/2
11 1/2
11 1/2
13 5/8
93/8
9 3/8
11 1/2
11 1/2
13 5/8

omit
4
4
12 3/4
14 7/8
17
19 1/8
21 1/4
14 7/8
17
17
19 1/8
21 1/4
17
14 7/8
17
19 1/8
21 1/4
12 3/4
17
17
19 1/8
21 1/4
123/4
14 7/8
17
19 1/8
21 1/4

E
omit
4
4
4
4
4
4
4
17
17
21 1/4
21 1/4
21 1/4
17
19 1/8
19 1/8
21 1/4
21 1/4
17
17
19 1/8
21 1/4
21 1/4
17
19 1/8
19 1/8
21 1/4
21 1/4

omit
4
4
4
4
4
4
4
4
4
4
4
4
17
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
19 1/8
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4

omit
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4

omit
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
21 1/4
21 1/4
21 1/4
21 1/4
21 1/4

9 3/8
11 1/2
13 5/8
9 3/8
11 1/2
11 1/2
13 5/8
13 5/8
11 1/2
11 1/2
13 5/8
13 5/8
13 5/8
11 1/2
13 5/8
13 5/8
13 5/8
13 5/8
13 5/8
13 5/8
13 5/8
13 5/8
13 5/8
135/8
13 5/8
135/8
135/8
13 5/8

COMBUSTION AIR

LOCATING

Provision for combustion and ventilation air must be in
accordance with Section 5.3, "Air for Combustion and
Ventilation", of the National Fuel Gas Code. ANSI Z223.1
latest revision, and applicable provisions of the local
building codes. Consult the code books or boiler
manufacturer for specific requirements.

Locate the boiler on a level, non-combustible foundation
as near chimney or flue as possible. Allow 24 inches at
front and sides of boiler for servicing and cleaning. When
installed in a 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.
When the boiler is installed over a room below, or over
electrical wiring or cables of any kind, or if the concrete
floor is "green," or water is channeled under the concrete,
the installing contractor must provide a ventilated foundation
for the boiler.

WARNING
ENOUGH AIR ENSURES PROPER
COMBUSTION AND ASSURES THAT
NO HAZARD WlLL DEVELOP DUE TO
THELACK OF OXYGEN

CHIMNEY

AND

VENT

PIPE

THE BOILER

The boiler shall be installed such that the automatic gas
ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation
and service (condensate trap, control replacement, etc.)

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 Page 16 for specific venting instructions.

INSTALLATION

The flue pipe should be the same size as draft hood outlet
from boiler to flue collector. See Page 4 for typical chimney
size. Maintain 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.

This boiler is designed to provide a wide capacity range
with multiple burner modules, each equipped with its own
set of controls. For purposes of orientation, the manifold
side of the boiler is considered the front, The end sections
are so designed that the controls may be mounted on either
the left or right end. These instructions are written for the
assembling of the boiler starting with the left side and
working to the right side.

MINIMUM

If the boiler is to be used as a steam boiler and connected

VENT

PIPE

CLEARANCE

If the vent pipe must go through a crawl space, double walt
vent pipe should be used. Where vent passes through a
combustible walt 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.

to another steam boiler, the factory designed water lines of
the two boilers must be of equal height above the floor
level.
Boilers with Inputs above 500,000 BTU Per Hour are made
up of a combination of the 300,000,400,000 and 500,000
BTU Per Hour Input Module Bases. Each base is equipped
with its own gas valve and gas ignition system.
When connecting the cold water supply to the boiler, make
sure that a clean water supply is available. When the water
supply is from a welt, a sand strainer should be installed at
the pump.

FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY, MINIMUM CLEARANCES TO
COMBUSTIBLE CONSTRUCTION ARE.

Top ......................................................

54 inches

Front ........................................................

Alcove

Flue Connector .....................................

6 inches

Rear ....................................................

18 inches

Sides ...................................................

18 inches

Greater clearances for access should supersede
protection clearances.

fire

ASSEMBLY

OF BASES

parallel as they go together. When all sections are pulled
up locate the tie rods in alternating pairs of upper and lower
holes between adjacent sections, and back off nuts so that
they are only finger tight. (See Figure 7). Be sure both
ends of completed section assembly are resting evenly on
both ends of base.

The 300, 400 and 500 boilers are the basic models. The
300 model has (6) burners, the 400 model has (8) burners
and the 500 model has (10) burners. Combinations of the
basic models are used to assemble the 600 through 3000
models. See Chart No. 2 for the proper order of assembly
When two or more bases are used to assemble the boiler,
be sure the top angles of the bases are even. (See Figure
No. 6). The bases are fastened together with 5/16 cap
screws and nuts. Insert two screws in the front posts and
two in the rear posts as shown in Figure No. 1. After bases
are fastened together, install the base end panels. These
end panels must be installed before assembling sections.
Important: After bases are assembled check to be sure
they are level.

STARTING

SECTION

Apply boiler putty at the joints of the sections front, top and
back. Putty should also be applied where the sections join
the base.
Place the necessary plugs and control wells in the correct
locations. Plug alt other tappings, leaving an air vent in the
top of one of the end sections, and connect water. Fitl the
boiler with water until it runs out the air vent. Then
hydrostatically test the boiler in accordance with applicable
codes. Check for leaks before continuing with the assembly
Drain and remove unnecessary plugs.

ASSEMBLY

The sections may be started from either the left or right
end of the base. Place the end section on the base with
the parting line of the section directly over the joint of the
base and base end closure. With boilers having two or more
bases, as you progress be sure the parting line (center-line
of section) of the intermediate sections falt on the junction
of the two bases. Install a top cover support bracket on the
draw bolts of the intermediate sections at each base
junction.

PULLING SECTIONS
WITH TIE RODS

TOGETHER

Before beginning, clean nipples and nipple ports. Coat
nipples and nipple ports with pipe joint compound furnished
or other good sealant and keep them clean. Place nipples
in ports taking care to seat them squarely to prevent
cocking. (See Figure 2). When pulling sections together
with tie rods, always insert tie rods in holes nearest to
nipple ports. Move tie rods to proper location, if necessary,
only after sections are fully pulled together. Oil or lubricate
threads, insert tie rods in lugs with washers under nuts
and tighten uniformly and evenly so that sections are pulled
END

TIE
TOP

COVER

SUPPI]RT _

FIGURE 2

TOP

CLOSING

ANGLE

CAP SCREWS
AND NUTS

BURNERS

FIGURE 1
BASE

ASSEHBLIES

THIS PAGE INTENTIONALLY

LEFT BLANK

LEFT

END

BASE

BATTERY

ASSEMBLY

FIGURE 6

END
ATTACH

DRAFT

HOODS

PLATE

WARNING:

Attach the draft hood(s) to the boiler sections after applying boiler putty to the top of the boiler sections where the
hoods and sections meet. Use (J) bolts to attach front of
draft hood to slots in sections flange.

CLEAN
COVER

CLOSING

DO NOT ALTER OR MODIFY DRAFT HOOD
FURNISHED WITH BOILER.

OUT
PANEL

DRAFT

HOOD

APPLY
BOILER
PUTTY

FIGURE 7

CONNECTING GAS SERVICE

CHART 3
TABLE OF PIPE SIZES IN INCHES FOR GAS MAINS

Connect gas service from meter to control assembly(s) in
accordance with ANSI Z223.1 1984 and local codes or utility
On multiple base boilers, connect gas service with branch
lines from common main. Individual branch lines must be
the same size as the inlet to the gas valve. A ground joint
union should be installed in each branch line for easy
servicing of gas controls. A drip leg or trap should be
installed at the bottom of a vertical section of piping at the
inlet to the control chain, Figure 8. A pipe compound
resistant to the action of liquefied petroleum gases must
be used on all threaded pipe connections.

(NATURAL GAS)
Boiler
No.
300

20'
1¼

30'
1¼

40'
1¼

50'
1¼

60' 80' 100'
1¼ 1¼ 1½

125' 150'
1½ 1½

400
500

1¼
1¼

1¼
1½

1½ 1½
1½ 1½

1½
2

2
2

600
700

1¼
1¼

1½
1½

1½
2

2
2

2
2½

800

1½

2½

900

1½

2½

The main gas supply line should be adequate to prevent
undue pressure drop. See Chart No. 3 for pipe sizes for
gas mains.

1000

1½

2½

1100

2½

1200

2½ 2½

2½

To check for leaks in gas piping, use a soap and water
solution or other approved method, DO NOT USE AN
OPEN FLAME.

1300

2½

2½ 2½

2½

1400

2½

2½ 2½

1500

2½

2½ 2½

The boiler must be disconnected from the gas supply piping
system during any pressure testing of that system. Test
the gas connection to the boiler before placing the boiler in
operation.

1600
1700

2
2

2
2½

2½
2½

2½ 2½
2½ 3

3
3

1800

2½

1900
2000

2
2

2½
2½

3
3

2100

2½

2200

2½

2300

2½

2400
2500

2½
2½

2½
3

3
3

3
4

4
4

2600

w.c.

2700
2800

3
3

3
4

4
4

w.c.

2900

3000

Minimum Gas Supply Pressure
Models 300,500,600, 1000, 1300, 5.0 inches
1500,2000,2100,2500,
2600,3000
5.3 inches
Models 400, 700, 800,900, 1100,
1200,1400,1600,1700,
1800, 1900, 2200, 2300,
2400, 2700, 2800, 2900
Maximum Gas Supply Pressure
All Models
14.0 inches
Manifold Pressure
All Models
3.5 inches

w.c.

GAS SUPPLY

SECURE MANIFOLD FROM
BVER HEAD FRAMING
SEE CHART # 3 FRR GAS
MAIN MANIFRLD
SIZING

DRIP

LEG
PROVIDE
DISCONNECT
MEANS AND OVERLOAD
PROTECTION
AS REQUIRED

1202V

INSTALL MANUAL
VALVES
5 FEET ABOVE
FLOOR
WHERE
REQUIRED
BY
LOCAL
CODES

GOHz

4x4x5/8
JUNCTION
BOX
(BY INSTALLER)
MOUNT IN
CONVENIENT
LOCATION
ADJACENT
TO BOILER
TYPICAL ISOMETRIC WIRING
AND GAS MAIN PIPING
NOT FURNISHED,
BOILERS ARE FIELD WIRED
AND ASSEMBLED.

ALL WIRING TB CONFORM
TO
NEC FOR TEMPERATURE
LIMITATION FOR TYPE "T*
WIRE (63F RISE)

FIGURE 8

SUGGESTED

WIRING

AND GAS MAIN PIPING

ALL WIRING MUST COMPLY
WITH ALL
APPLICABLE
CODES, REGULATIONS
AND

ORDINANCES

INSTALLING
.

BOILER

JACKET

Attach the Jacket End Panels to the two Z-bars on the
Base End Closures through the two slotted holes on
the bottom of Jacket End Panels. Use (2)#10 x 1/2"
self-tapping screws each Panel.
Use (2) #8 x 3/4" Hex Head Screws to attach Jacket
End Panels to rear side of Draft Hood, (1) each end.
Position top of Rear Jacket Panel(s) to Draft Hood
Baffle Flange and secure with (2) #10 x 1/2" self-tapping
screws. Secure bottom of Rear Jacket Panel to bracket
on boiler base using (2) #10 x 1/2" self-tapping screws.

JACKET
END
PANEL

MANIFOU') BRACKET
FIGURE

TOP
JACKET
PANELS

ADJUSTABLE

On multiple base boilers the intermediate Top Panels
are bolted at the front through the jacket Top Support
Bracket(s) previously installed with the sections. Use
the #10-32 x 1/2" slot-head screws and 10-32 Hex Nuts.

CLIPS

Attach jacket door knobs with #8-32 x 1/4" hex head
screws. Slide Jacket Front Panel(s) into groove in front
of Jacket Top Panel(s), then insert Bottom of Front
Panel(s) in slots on top of manifold brackets.
Lighting Instruction Plates are provided with each boiler
base. Each boiler base also includes a data plate
indicating the required gas type, firing rate, and gas
pressure for that base. These plates are located on
the Jacket Front Panels. Boilers also have a rating plate
showing the total Input and Output Ratings. This rating
plate is shipped in the AC Carton and is to be mounted
on the right side Jacket End Panel by the installing
contractor.

JACKET
END

@
JACKET TOP
SUPPORT BRACKET

Attach
Local
manufacturer.)

FIGURE 10

DRAFT

HOOD

BAFFLE

Position Top Jacket Panel(s) on adjustable clips on
front of Draft Hood(s). Then using a #10 x 1/2"
selftapping screw secure Top Jacket Panel to Jacket
End Panel at front.

JACKET

E
REAR PANELS

FIGURE 11

Code

Label

(not

provided

STEAM

Figure No. 12 below shows the End Section and the various
tappings provided. Tappings are the same in both Right
and Left End Sections, except for the drain valve tapping
which is 1 ½" Left End, and ¾" Right End.

TRIM ASSEMBLY

Assemble Steam Trim, Low Water Cut-Off, High Pressure
Limit Control, Pressure Gauge, Water Gauge Glass Set
and Siphon Loop, as shown in FIGURE 13. See FIGURE
12 for location of controls.

I=_HIGH

PRESSURE

LIMIT

STEAM

FIGURE 12
OPENING

SIZE

STEAM

WATER

Supply and Return

1½.

Primary LWCO and

Plugged

GAUGE

Gauge Glass Set
C

1 1½,,

Drain, Left End

¾"

Drain, Right End

Plugged

Limit Control

Accessories

Pop Safety Valve

Pressure Relief Valve

Tie Rod Holes

Plugged or Electronic

Plugged

G
H

¾"

(Probe Type) LWCO

BOILER

FIGURE 13

TRIM

The following controls are supplied as standard equipment.
Details of their function and operation will be found in the
section on Controls and Adjustments.

STEAM

Low Water Cut-Off (mounted externally) with blow-off
valve.

High Pressure Limit Control.

Pressure Guage.

Water Gauge Glass Set.

Siphon Loop.

Pop Safety Valve (15 Ibs.).

TRIM ASSEMBLY

Locate Water Trim Controls per Chart in FIGURE 12.

TRIM

WATER

POP SAFETY
VALVE
RELIEF VALVE.

AND

PRESSURE

*If opening F shown in FIGURE 12 is to be used for
something other than the Pop Safety Valve or Pressure
Relief Valve, or the Safety/Relief valve is larger than 1",
the Safety/Relief Valve must be installed in the Header
Piping as near the boiler as possible.

NOTE
No shutoff of any description shall be placed between the
pop safety valve or safey relief valve and the boiler, or on
discharge pipes between such safety valves and the
atmopshere. Installation of the pop safety or safety relief
valve shall conform to the requirements of the AN SI/ASM E
Boiler and Pressure Vessel Code, Section IV.

TRIM

Water Temperature High Limit Control.

Combination Temperature-Pressure

Safety Relief Valve (30 Ibs.).

Gauge.

BOILERS USED WITH
REFRIGERATION
SYSTEM

SYSTEM

When the boiler is installed in connection with a refrigeration
system, it must be piped so that the chilled medium is piped
in parallel with the heating boiler with appropriate valves to
prevent the chilled medium from entering the heating
system. An example of such piping is shown in Figure 14.
Valve A and B open for heating, closed for cooling. Valves
C and D closed for heating, open for cooling.
When hot water boilers are connected to heating coils
located in air handling units where they may be exposed to
refrigerated air circulation on the boiler piping, the boiler
piping system shall be equipped with flow control valves or
other automatic means to prevent gravity circulation of the
boiler water during the cooling cycle.

WATER

BOILER

PIPING

(Figure

15)

Supply and Return connections to the hot water boiler
should be located so that the water will thoroughly circulate
throughout the entire boiler. Each installation has a
preferred piping arrangement according to the requirements
of the particular system and choice of arrangements and
sizes of headers should be decided upon by the installer's
heating engineer or with standard engineering practice.
When using only one supply and one return connection,
return must be connected at opposite end of boiler from
flow connection, on all boilers 600,000 Btu/hr input and
larger.

FIGURE 14

PIPE SIZING
Piping connection sizes are important to control proper
water velocity at the inlet and outlet connections to the water
boiler. It is recommended that the following pipe sizes be
used for flow rates shown and that the boiler be headered
to tappings at both ends of boiler where one pipe connection
will not be adequate to hold water velocities below 3.33
feet per second.

HIGH LIMIT
The immersion well for the High Limit Control must be
mounted at flow outlet of boiler. This may be either right or
left hand.

HIGH
SUPPLY

FLOW RATE GPM

PIPE SIZE

35 - 50

2½"

51 - 76

77 - 131

132 - 205

206 - 300

LIHIT

CONTROL

HEADER

1
__

CBMBI
PRESSURE,
TEMPERATURE
& ALTITUDE
GAUGE

(_
_RETURN
HEADER

F----]

F----1

F-----1 I-----]

VALVE

PRESSURE
RELIEF

STEAM

BOILERS

- SERIES

BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS
CITY ',CATER
SUPPLy

CITY

SHOWN

_,/ATgR

SUPPLy

_AT R

TB RET_N

-_-_-_
.........

TDRETURN

L j
67

McDONNELL FEEDER CUTOFF
COMBINATION

BOILER SIZE
300
THRU

USE
NO. 47-2"
Control Mounts in

1500
1600
THRU

SEPERATE
SEPERATE

BOILER SIZE
300
THRU
1500
1600
THRU
3000

Gauge

Glass Tappings
No. 51.2"
Control Mounts in

3000

1-inch Tappings
FOR CLOSED HEATING SYSTEMS
DIMENSION A = 2 • 2 '/2

NOTE: For multiple
boiler
feeder Cutoff Combination
cutoff on each boiler,
*These

items

available

your

_'_

FEEDER AND
LOW-WATER

McDONNELL PUMP CONTROL AND LOWWATER CUTOFF USED WITH CONDESATE
RECEIVER AND ELECTRIC BOILER FEED PUMP

USE
NO. 247 mechanical feeder or No,
101-24V electric feeder with transformer

NOTE: For multiple
installation
with
condesate tank and single boiler feed
pump, use No, 93 on each boiler to
operate motorized
feed line.

for use on closed heatin 9 systems only.

valve in each boiler

No. 51.2*

FOR CLOSED
DIMENSION

installation with gravity return, use
or seperate
feeder and seperate

through

McDONNEL
McDONNEL
CUTOFF

SERIES

FOR PROCESS

HEATING SYSTEMS
A _ 2 = 2 V= inches

OR PARTIAL

DIMENSION

PROCESS

SYSTEMS

A _ 1 = 1 V= inches

Distributor.

FIGURE 16

WATER BOILERS - SERIES W
BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS
WITH EXCEPTION
OF NO. 764 WHICH MOUNTS IN PIPING

SHOWN
ND, 764

CITy
_ATER
SUPF_Y

_PPLY

McDONNELL

FEEDER CUTOFF COMBINATION

For boilers
30-psi

relief

McDONNELL
For boilers

valve setting

7540 100_psi relief

1500
1600
THRU
3000

FIGURE 17

must

CUTOFF

valve

For all boilers upto
50_psi relief valve setting

setting

I BO,LERS,ZE
I USE I

No 247_

I ALLSIZESI NolSO I

5%2*

*These

USE
I No 53-2

exceed

with

USE

For boilers with up to
75_psi relief valve setting**

** Water supply pressure
least 20 psi,

OW-WATER

with

BOILER SIZE
300
THRU

I BOILER
IALL SIZES
SIZE

LINE_

relief

valve

setting by at

items

available

through

your

Distributor.

ALL SIZES
BOILER
SIZE
ALL SIZES

No 63*
NOUSE
764*

STEAM

CROSS
WATER
CUT-OFF
SEE PAGE
12

HEADER

LINE

FLUSH

POP SAFETY

VALVE

SHOULD

PIPING

(Figure

rET
RETURN

BE FIELD INSTALLED

AS CLOSE

AS POSSIBLE

TO BOILER

FIGURE 18

STEAM

BOILER

18)

A full Steam Header is recommended on all steam systems
as shown above. On Boiler Models 300,400 and 500 the
full header may be eliminated and a single steam header
taken off either side of the boiler provided the system is
clean and properly designed.

WARNING
NEVER INSTALL A SHUT-OFF OR
STEAM VALVE BETWEEN THE POP
SAFETY VALVE AND THE BOILER.

Risers should be a full 4" and at least 20" in height. Use
skimmer tee as shown.
The area of the Main Steam Cross Header Pipe should be
equal to or larger than the total area of the Steam Supply
Mains leading from the Header and should never be smaller
than Supply tappings on Boiler. The Return Header should
be piped to both ends of the Boiler. The area of the Return
Header should be equal to the total area of the Return Mains
or larger.

EQUALIZING

Steam cross headers must be piped with swing joints, or
be equipped with a slip joint connector, in order to prevent
expansion and contraction of steam header from damaging
boiler.
Each installation has a preferred piping arrangement
according to the requirements of the particular system and
choice of arrangements and sizes of Headers should be
decided upon by the installer's heating engineer or with
standard engineering practice.

LINE SIZE

MODEL NUMBERS

SIZE

300 to 900

1000 to 1900

2½"

2000 to 2500

2600 to 3000

FLUE CONNECTION

elbow in this run as shown.

AND VENTING

Consult local codes and gas company requirements.
Adhere to the following standard practice recommendations
for installing the flue pipe:

For installations where the required minimum 4-foot vertical
rise cannot be maintained, the diameter of the horizontal
run must be increased one inch for each foot of riser
reduction. This procedure wilt reduce the resistance of the
system, and if the chimney is adequate the boiler wilt vent
properly.

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.

In certain cases where these short rises of less than 4 feet
have been used, spillage of combustion products has
occurred at the drafthoods 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 drafthoods. DO NOT
BAFFLE ENOUGH TO CAUSE SPILLAGE. The use of
fixed baffles in the short risers above the boiler drafthood
are acceptable as spelled out in American National
Standard NFPA 54/ANSI Z223.1 National Fuel Gas Code,
latest revision.

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.
4. Insulate flue pipe where it passes near combustible
material.
5. Rigidly support pipe with hangers and straps.
6. Extend chimneys at least 2 feet above any object within
radius of 15 feet, including roof.

Fabricate these fixed baffles, using 20-gauge steel. See
Figure 22. 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 drafthood 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.

7. Install a hood on all flue pipes which extend through
roof.
In most locations, the venting of a boiler relies on natural
draft. Inasmuch as the 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, the vertical risers must be at least as large as the
vent openings on the drafthood.

i
/

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

FIGURE

A simple vent system consists of a 6-foot minimum vertical
rise immediately off the drafthood, as shown in Figure 19.
Terminate this vertical flue above the building roof with a
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-drafthood
boilers ONLY, and has limited practical use, because it is
restricted to single-story boiler rooms and because of the
problems encountered in roof flashing.

-RODFLINE -PANTLEG

BOILER

BBILER

The vertical venting system shown in Figure 19 cannot be
used on multiple-base boilers because of the physical
interference of multiple rain caps.
For multiple-base boilers, the pant leg venting system
shown in Figure 20 can be applied, if desired.

FIGURE 21
R DIAMETER

The vent system shown in Figure 21 is commonly used.
With the vent diameters sized to match the flue outlets, a
minimum vertical rise of 4 feet above the drafthood must
be maintained for proper operation. See Page 4 for typical
chimney sizes. Requirements for this type of system are:
an adequately sized chimney, adequate combustion air,
and the outlet end of the horizontal run must be no more
than 6 feet from the chimney with no more than one 90 °

, !_I

_¸_........ i_1_

_ P_A.
_ viE_
ENLARGED

FIGURE 22
Baffle Size (Inches)
Shown is suggested size of fixed
baffle for different size risers.

REMOVING
COMMON

EXISTING
BOILER
VENTING SYSTEM

FROM

When an existing boiler is removed from a common venting
system, the common venting system is likely to be too large for
proper venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected to
the common venting system placed in operation, while the other
appliances remaining connected tothe common venting system
are not in operation.

INSTALLING

Dead Spots:Behind Doors
Corners and Alcoves
Hot Spots:

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.
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
wilt 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. l-latest issue. 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 Part 11 in the National Fuel Gas Code, ANSI Z223.1
-latest issue.

ELECTRICAL

WIRING

Wiring connections are to be made in accordance with the
National Electrical Code, ANSI/NFPA 70-1984 and/or local
authority having jurisdiction. When an external electrical source
is utilized, the boiler must be electrically grounded in accordance
with these requirements. Install a fused disconnect switch
between boiler and electrical panel in a convenient location.
The wiring from high temperature limit control should be secured
to the boiler jacket or gas piping to prevent an accidental
disconnect from controls.
All wiring to gas valves must be taped securely to the gas supply
lines or run in an appropriate conduit.

WARNING
TURN OFF ELECTRIC POWER AT FUSE
BOX BEFORE MAKING ANY LINE
VOLTAGE CONNECTION.
FOLLOW
LOCAL ELECTRICAL
CODES.

THERMOSTAT

The thermostat location has an important effect on the operation
of the boiler system. Be sure to follow the instructions included
with the thermostat. Locate the thermostat about 5 feet above
the floor on an inside wall. It should be sensing average
temperature, so avoid the following:

Concealed Pipes
Fireplaces
TV Sets
Lamps
Direct Sunlight
Kitchens

Cold Spots: Concealed Pipes or Ducts
Stairwells
Drafts
Unheated Rooms on other side of walt
Keep thermostat(s) at desired room temperature. If windows
are to be opened or heat is not needed, set thermostat(s) pointer
to a lower setting.

ADJUST

THERMOSTAT

HEAT ANTICIPATOR

Suggested heat anticipator settings are shown in the wiring
diagrams (Figures 26, 27 and 28). Set accordingly Then follow
instructions packaged with thermostat for the final adjustment,
checking thermostat operation. When set above temperature
indicated on the thermometer, boiler bumers should ignite. Make
certain the thermostat(s) turns off the boiler when room
temperature reaches the selected setting and starts the boiler
operating when room temperature falls a few degrees.
Finally, set the thermostat for the desired temperature. Special
conditions in building and the location of the thermostat witl
govem this setting.
STAGE
FIRING MULTIPLE
1 . STEAM BOILERS

BASE

BOILERS

Multiple base steam boilers should not be stage fired due
to fluctuations in water line between fired and unfired bases.
The boiler should be all bases on or all bases off. When
more precise control than a single thermostat offers is
required, a weather responsive duty cycle control such as
the Honeywell model ZG-54 or the Heat Timer model MPC
or model EPU or a similar type of control should be used.
These controls determine boiler run time based on outdoor
temperature. Consult the various control manufacturers. It
stage firing is required, consult the boiler manufacturer.
2. HOT WATER BOILERS
Multiple base hot water boilers are ideal for stage firing.
Many controls are available for sequencing or stage firing
multiple base hot water boilers. We offer a W7100J Outdoor
Reset Stage Fire Control Package that wilt sequence up
to six bases, with lead/lag, soft start, adjustable reset ratio
and setpoint, and microprocessor control. This control will
fire bases as required to maintain supplywater temperature
at a desired set point, which is automatically varied based
on outdoor air temperature. Consult the boiler manufacturer
for more information.

CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.

L!
UNIT
CBNTR_LLER

DN-Df'F
SVITCH

(NIT)
I

r......._-t--F_--q---;
I
I
I
TI-IERM_TAT DR
CUNTRBLLER

r
24V
TR_FDRNER

F----'-I
J L
...... @--L-_2,__
j ......................................

ARE

SENSGR
IGNITER

PILDT i I

'°

BURNER

MAIN

Ig|

!K2

----A,r....
@

POWER

SUPPLY

ALTERNATE

PROVIDE

DISCONNECT

LIMIT CONTROLLER

AND OVERLOAD

PROTECTIONAS

J__
VALVE.....

I
_a_

REQUIRED

INTERNAL

LOCATION

SCHEMATIC

FIGURE 23

MEANS

___

"_F

P LDT

2K2
A

VALVE

WIRING DIAGRAM FOR S8600M

WIRING

EXTERNAL

WIRING

INTERI,41TTENT
PILOT

7
_II

INTERMITTENT
GROUND
TO PILOT

754 NARNESS_
PILOT

CONTROL
TH

_OT

GROUND
MAIN VALVE

Rv:_v
PILOT VALVE

Robertshaw
7O0O
DERHC
Gas Valve
Wiring
HONEYWELL

CONTROL

VR8304M

GAS VALVE WIRING

GREEN
RED
WHITE
FIGURE 25

FIGURE 24

STEAM OR HOT WATER SINGLE BASE BOILERS WITH HONEYWELL
WHERE

THERMOSTAT

INTERMITTENT
CIRCULATOR
PUMP

DOES NOT CONTROL

PILOT

120V
60Hz
SUPPLY
H

TH-I

SUPPLY
TR-1

120V

(OPTIONAL)
MAN RESET

PS/HL

SUPPLIED
Lr_
WITH AC CARTON I

-rlPTIONAL-

SET HEAT
ANTICIPATOR
AT 90 AMPS

60Hz

TR-2 E

SUPPLIED BY
INSTALLER

24VG

F4v .PIo

LWCD

WIRING TD GAS VALVEFACTORY INSTALLED

rlpT.PS/HL

EWF

TH-I

WIRING
PS/HL

LWCB

Trl GAS

FACTORY

VALVE-

TR-I

Ill_

INSTALLED

60Hz

_II_ SUPPLY

FIGURE 26

SUGGESTED
WIRING
INTERMITTENT

FOR FORCED HOT WATER SINGLE BASE BOILER WITH HONEYWELL
PILOT WHERE THERMOSTAT
CONTROLS CIRCULATOR
PUMP

TH-I
SET HEAT
ANTICIPATOR
AT .90 AMPS

R845A (NOT SUPPLIED)

°T

WIRING
TO GAS VALVEFACTORY
INSTALLED

120V GOHz
SUPPLY
CIRCULATOR
iTR_I

FIGURE 27

FOR WIRE COLOR

CODE BETWEEN

GAS VALVE AND MODULE

COMPONENT
TH-1
TR-1
TR-2
PS/HL

NAN, RESET
(OPTIONAL>
HL

THERMOSTAT (24 VOLT)
TRANSFORMER (120V-24V)
TRANSFORMER (120V-24V 50VA)
PRESSURE SWITCH (STEAM)
HIGH LIMIT (WATER)

CODING
-O--eLWCO
EWF
IP

SEE ABOVE

CONTROL TERMINAL
WIRING CONNECTION
OPTIONAL CONTROLS
LOW WATER CUT-OFF
ELECTRIC WATER FEEDER
INTERMITTENT PILOT MODULE

SUGGESTED

WIRING

FOR STEAM OR HOT WATER MULTIPLE BASE BOILERS WITH HONEYWELL
WHERE THERMOSTAT
DOES NOT CONTROL CIRCULATOR
PUMP

INTERMITTENT

PILOT,

RB222A
RELAY
OPTIONAL

MAN. RESET

PS/HL

[

SET HEAT
ANTICIPATOR
AT .40 AMPS

0_)

T
°
I i_rn
I

NNo

O_
4 I
4

2
2

o--_
I

I
EWF

LWL:

__.___

_,PROVIDE
DISCONNECT
_ MEANS & OVERLOAD

IIII
LU-I
TR-2
(SUPPLIED

HERMDSTAT_

'PROTECTInN
-

AS REO'D. _

OPTIONAL

TR-]

PPLIE

WITH

AC CARTON)

BY INSTALLER)

7 _4v

MYr- _

-I _4v

MVr_A

_r_" £

24VG

PV[__

GAS VALVE

MV/PV

WIRING

PV[_

TO
$8600
0

MODULES GAS
SEE VALVE
PAGE
BETWEEN

_:_ FlI

_,.T-

FIGURE

]8
AND

GAS

VALVE

MODULE

INSTALLED

VIRES- DO NOTREMOVE
FOR'dIRECOLOR
CODE

zoo;o

$8600
FACTORY

Z ;:Om
m 0
--

MODULE

VIRES

CTDRY INSTALLED
- DO NOT REMOVE

FOR VIRE COLOR CODE
BETVEEN
GAS VALVE
AND
MODULES
SEE PAGE 18

OPERATION
S8600

FUNCTIONS

AND SERVICE

AND OPERATION

SYSTEM

TROUBLESHOOTING

The S8600 control module performs the following basic
functions:

Start the system by setting the thermostat or controller
above room temperature and observe the system response.

1 . Opens and closes the first (pilot) operator of the gas
valve.

Establish the type of system malfunction or deviation from
normal operation by using the $8600 Intermittent Pilot
System Troubleshooting Table, page 23.

2. Provides a spark for igniting pilot burner.

Use the table by following the questions in the boxes. If the
condition is true (answer is yes), go down to next box. If
the condition is not true (answer is no), go to the box
alongside.

3. Senses the pilot burner flame.
4. Shuts off the spark after pilot flame is lit.
5. Opens and closes the second (Main) operator.

TRIAL FOR PILOT IGNITION

Continue checking and answering conditions in each box
until a problem and/or the repair is explained. Use the
Component Checks section, see below, as necessary, to
perform system checks.

On every call for heat (System start), the $8600 performs
an internal safe-start check. Ifa flame simulating condition
is present, the system will not start.

After any maintenance or repair, the troubleshooting
sequence should be repeated until the procedure ends with
normal system operation.

During a normal start, the $8600 opens the first (pilot) valve
operator of the gas control, which allows gas to flow to the
pilot burner. At the same time, the electronic spark
generator in the $8600 produces a 15,000 volt spark pulse
output (open circuit). This voltage produces a spark at the
igniter sensor rod which ignites the pilot burner. If the pilot
flame does not light or the presence of the pilot flame is not
detected back through the flamerod, the $8600 will not open
the second (Main) valve operator of the gas control. The
$8600F will continue to try to ignite the pilot burner until
either a flame is detected or the thermostat (controller) is
set down below a call for heat.

COMPONENT
CHECKS
CHECK SPARK IGNITION

These functions occur in two stages - trial for pilot ignition
and main burner operation as described below.

MAIN BURNER

The Electronic module and step-up transformer in the
$8600 provides spark ignition at 15,000 V (open circuit).
This circuit can be checked at the $8600 module as follows:
.

Turn off manual gas cock to prevent the flow of gas.
Disconnect the ignition cable at the $8600 stud ter
minal to isolate the circuit from the pilot burner/
igniter-sensor, and prepare a short jumper lead using
heavily insulated wire, such as ignition wire.
Energize the $8600 and touch one end of the jumper
firmly to the $8600 ground terminal (GND). (Do not
disconnect the existing ground lead.) Move the free
end slowly toward the stud terminal to establish a spark
and then pull the lead wire slowly away from the stud.
Not the length of the gap at which arcing discontinues.

OPERATION

When the pilot flame is established, a flame rectification
circuit is completed to the burner ground. The $8600 flame
sensing circuit detects the flame current, shuts off the spark
generator and opens the second (Main) valve operator to
allow gas to flow to the main burners. The pilot flame ignites
the main burner conventionally.

IMPORTANT
The electronic $8600 control module cannot be repaired.
If the troubleshooting procedure indicates a malfunction in
the $8600, the S8600 must be replaced. Intermittent Pilot
systems should be serviced only by trained, experienced
service technicians.

PRELIMINARY

CIRCUIT

An arc length of 1/8 inch (3.2 mm) or more indicates
satisfactory voltage output. If no arc can be established
or the maximum gap is less than 1/8 inch (3.2 ram)
fuse was okay, and power to the S8600 input terminal
was proved, replace the $8600.

CHECK
CAUTION
DO NOT TOUCH EITHER END OF JUMPER
OR STUD TERMINAL.
THIS IS A VERY
HIGH VOLTAGE CIRCUIT AND
ELECTRICAL
SHOCK CAN RESULT.

The following visual checks should be made before
troubleshooting and after maintenance.
1.

Check power switch.

Manual shutoff cocks in the gas line to the boiler must
be open.

Make sure all wiring connections are clean and tight.

Review the $8600 normal sequence of operation.

IGNITION CABLE CHECK

PILOT FLAME ADJUSTMENT

Cable must not run in continuous contact with a metal
surface or spark voltage will be greatly reduced.
Connections to the stud terminal on the $8600 and on the

The pilot flame should envelop 3/8 to 1/2 inch of the tip of
the insulated rod on the igniter-sensor. If adjustment is
required, remove the pilot adjustment cover screw and turn
the inner adjustment screw clockwise to decrease or
counterclockwise to increase the pilot flame. Be sure to
replace cover screw after adjustment to prevent possible
gas leakage.

igniter-sensor must be clean and tight. Loose connections
may not conduct a flame current even though the ignition
spark is satisfactory. Check the electrical continuity of the
cable.

CHECK

GROUNDING

A common ground is required for the pilot burner/
igniter-sensor mounting bracket, and the GND terminal of
the $8600. If the ground is poor or erratic, safety shutdown
may occur occasionally even though operation is normal
at the time of the checkout. Therefore,
if nuisance
shutdowns occur, be sure to check the grounding.

STARTUP

AND CHECKOUT

NOTE: If any component in the system fails, the system
will not operate. If the system does not perform as outlined
in Start System, below, refer to the $8600 Intermittent Pilot
System Trouble-shooting Table.

START

PROPER FLAME ADJUSTMENT

SYSTEM

1. Turn on power to the $8600(s) and turn off gas supply.
2. Check $8600(s) operation as follows:
a. Set the Thermostat
or controller
temperature to call for heat.

CHECK
above

room

BURNERINPUT

Checkboiler_rproperBTUinputrate.

b. Watch for spark at the pilot burner(s). 3. Turn on
gas supply.

CAUTION
Do not exceed the Input rate stamped on the nameplate of
the boiler located on the End Jacket Panel.

4. Set thermostat or controller above room temperature to
call for heat.

Make certain primary air supply to the Main burners is
properly adjusted for complete combustion.

5. System should start as follows:
a. Spark will turn on and pilot gas valve will open at
once. Pilot burner(s) should ignite after gas reaches
the pilot burner(s).

If boiler is shut down for service, the gas and electric must

I be off for 5 minutes before
WARNING
relighting.

b. Spark ignition should cut off when pilot flame is
established.
c. Main gas valve should open and main burners
should ignite after gas reaches the burner ports.

To check boiler for proper BTU Input proceed as follows.
With main burners operating, measure the gas Input to the
boiler by reading the meter. Be sure all other appliances
connected to the same meter are shut off. Rate of gas flow
(cu. ft. per hour) multiplied by the BTU value of the gas
should check with the BTU Input shown on the nameplate
of the boiler. If it is within 5%, adjust Pressure Regulator to
obtain the desired flow (stem for adjustment is under the
cap in the top of the regulator). TURN CLOCKWISE TO
INCREASE INPUT AND COUNTERCLOCKWISE
TO
DECREASE THE INPUT RATE.

NOTE: Lightoff may not be satisfactory until the gas input
and combustion air have been adjusted.

WARNING
DO NOT OMIT THIS TEST
With main burners in operation, paint pipe joints, pilot tubing,
connections, screws, and valve(s) gaskets with a rich soap
and water solution. Bubbles indicate gas leakage. To stop
leak, tighten joints and screws or replace gaskets. Never
use a flame to check for gas leaks.

NOTE: The adjustment screw is plastic and may require
slightly greater turning force than metal threads.
Be sure to replace Regulator Cap.
22

S8600 INTERMITTENT

PILOT SYSTEM

TROUBLESHOOTING

TABLE

START
I

TURN GAS SUPPLY OFF.
TURN THERMOSTAT
(CONTROLLER) TO CALL
FOR HEAT

familiarize

yourself with the startup and check procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) I
and wiring. Also, check air proving switch on combustion air blower system (if used) and
that vent damper (if used) is open and end switch is made.

POWER TO MODULE
(24V MODULE)

NOTE: Before troubleshooting,

YES ,
SPARK ACROSS
IGNITER/SENSOR GAP

Pull ignition
lead and check
spark
module.
Spark at
okay?
YES

,,_ _
_f

•

been installed, then removed.
On models
with damper
vent damper
plug,
make
sure
vent
has not
Replace
vent
damper if necessary.
On other models, replace module.

¥
YES

•
•

Check boot of the ignition cable for signs of melting or bucking. Take protective
Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
action to shield cable and boot from excessive temperatures.

•

PILOT BURNER LIGHTS?

•
•

gas
open,
pressures
Check
that pilot
all manual
valves
are
good, and
burner orifice
is notare
blocked. supply tubing and
Check electrical connection between module and pilot operator on gas control.
Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control: if not, replace module.

1
NOTE: If S8600B, H goes into lockout, reset system.
for retry or reset system.

SPARK STOPS WHEN
PILOT IS LIT?
YES

For S8600M, wait 6 min. nom.

•
•
•
•

Check
Clean
Check
Check

continuity of ignition cable and ground wire.
flame rod.
electrical connections between flame rod and module.
for cracked ceramic flame rod insulator.

•
•
•

Check that pilot flame covers flame rod and is steady and blue.
Adjust pilot flame.
If problem persists, replace module.

I
I

•
•

MAIN BURNER LIGHTS?

Check for 24 Mac across MV-MV/PV terminals. If no voltage, replace module.
Check electrical connections between module and gas control. If okay, replace
gas control or gas control operator.

NOTE: If S8600B, H; $8610B, H goes into lockout, reset system.
6 min. nom. For retry or reset system.
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS

•

YES
•
•

•
•

CALL
FORSHUTS
HEAT OFF?
ENDS
SYSTEM

Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally
even though operation is normal at the time of checkout.
Check that pilot flame covers flame rod and is steady and blue.
If checks okay, replace module.

Check for proper thermostat (controller) operation.
Remove MV lead at module: if valve closes, recheck temperature
wiring: if not, replace gas control.

YES
J,
TROUBLESHOOTING
ENDS

Repeat procedure

For S8600M, wait

I
I

TURN GAS SUPPLY ON

YES

until trouble free operation is obtained.

controller and

CHECKING

AND ADJUSTING

HIGH LIMIT CONTROL

qualified service technician to replace the relief valve and
inspect the heating system to determine the cause, as this
may indicate an equipment malfunction.

While the boiler is operating, set the high limit control below
boiler water temperature and the main burners should shut
off. Return the control to the normal setting and the main
burners should start again.

PRESSURE

This valve should be tested every month during periods of
boiler operation, and at the beginning and end of any
extended non-service period. Prior to testing, make certain
discharge pipe is properly connected to valve outlet and
arranged so as to contain and safely dispose of boiler
discharge. Test at normal system operating pressure. Hold
the trip lever fully open for at least five seconds in order to
flush free any sediment that may lodge on the valve seat.
Then permit the valve to snap shut.

LIMIT CONTROL

While the boiler is operating, set the pressure limit control
below the pressure in boiler and the main burners should
shut off. Return the control to the normal setting and the
main burner should start again.

LOW WATER

CUT-OFF

The Low Water Cut-Off will interrupt the electrical current
to the burners when the water line in the boiler drops to a
low level. It is very important to keep the float chamber
free from sediment, a condition essential to dependability
To keep any accumulation from interfering with float action
is to "BLOW DOWN" or flush out the control regularly Do it
while the boiler is in operation. First note water level in
gauge glass. Open blow-off valve at bottom of control-,
water wilt pour out, flushing away sediment. Drain until water
is clear, about a pail, then close valve. If water level in
gauge glass has dropped, add water to boiler to restore
level.

BURNER

AND PILOT FLAME

We recommend that you make a periodic visual check of
the burners and pilot flame (see page 22). During this visual
check look for any deterioration from corrosion or other
sources of the burners, pilot burners and boiler base frame.
Also be sure the boiler base interior and exterior are clean.
This visual check should be made once every month during
the heating season by the owner and once a year by a
competent
Service Technician
to assure safe and
trouble-free operation.

NOTE: Opening blow-off valve checks cut-off operation
too. As float drops with falling water level, burners will shut
off. After valve is closed and normal operating conditions
are restored, burners will resume firing.

SPECIAL

FLUSHING

INSTRUCTIONS

For new boilers installed in old systems. The installation of
a new boiler in an old system may break loose a heavy
accumulation of sediment and scale from old piping and
radiators. It is extremely important to blow down the low
water cut-off more frequently the first week.

_DUTER

MANTLE

_DUTER

CONE
BURNER

FIRST WEEK - 2 or 3 times
THEREAFTER

PRESSURE

- At least once a week

RELIEF VALVE

BOILER

You must have a pressure relief valve on the boiler. Steam
and water expand as they are heated. It there is no place
for the steam or water to expand into, pressure will build
up inside the boiler and system. Should this happen, the
pressure relief valve will relieve the strain on the boiler and
system by automatically opening at a predetermined
pressure. (The Pop Safety Valve on steam boilers is set at
15 psig and the Relief Valve on water boilers is set at 30
psig, 50 psig optional.) Run a pipe from the pressure relief
valve outlet to an open drain. This pipe must be of same
size as outlet on valve and open end must not be threaded.
This drain must be run in an area not subject to freezing.
Failure to do so may cause water damage or injury should
valve release.
If valve discharge occurs, or if valve fails to open as
described above, contact an authorized contractor or

FLUE PASSAGES

Under normal operating conditions, with the burners
adjusted properly, it should not be necessary to clean the
boiler flue gas passages. However, to assure trouble-free
operation, we recommend that you have the flue passages,
burner adjustments and operation of the boiler controls
checked once each year by a competent
Service
Technician. If it becomes necessary to clean flue passages,
first remove the burners and pilot(s) from the boiler. Next
refer to page 9 of these instructions and remove the
cleanout cover panel on the Draft Hood. This wilt expose
the flue passages. Clean flue passageways between the
sections with flexible handle wire brush. Remove all dirt
from bottom of boiler and reassemble all parts. Be sure to
check tightness of pilot connection(s) and adjustment of
pilot(s) and burner flames after reassembly

VENTING

SYSTEM
joints and fittings. There should be at least two (2) sheet
metal screws per joint.

The vent system is a very important part of the heating
system. No boiler, however efficient its design, can perform
satisfactorily if the chimney that serves it is inadequate.
Check your chimney to make sure that it is the right size,
properly constructed, clean and in good condition to ensure
proper combustion
and THAT NO HAZARD WILL
DEVELOP You must also provide enough FRESH AIR FOR
COMBUSTION.
LACK OF ENOUGH OXYGEN WILL
CREATE A HAZARD. If your building is of tight construction,
it may be necessary to add a FRESH AIR DUCT to provide
the OXYGEN required (see page 6).

Check to see that the vent pipe slopes at least 1/4" per foot
up from the boiler to the chimney. The vent pipe should be
securely fastened to prevent sagging.
The Vent Pipe should also be checked for any deterioration
from corrosion
or any other sources. See venting
instructions on page 16.

AT LEAST ONCE A MONTH DURING HEATING SEASON
check to see that the sections of vent pipe are secure at all

CLEANING

THE NEW STEAM

BOILER

New steam boilers must be cleaned previous to or during
the first few days of use in order to ensure efficient
operation. The 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 surface of the
water in all new boilers, The heavier particles carried in
the grease may settle to the bottom of the boiler and form
sludge. This condition, if permitted to remain in the boiler,
tends to prevent the generation of steam, produces foaming
and causes an unsteady water line. This unavoidable
accumulation of oil and grease should be removed by
blowing off the boiler as follows:

Close valves in boiler feed line and skim line.

Bring the pressure in the boiler to about 10 Ibs.

Install a surface blow-off connection of at least 11/4'

nominal pipe size in boiler using the Skimming Tee
shown on page 15. The blow-off line should extend to
within 18" of the floor or to the sewer.

After the boiler has cooled-, fill and flush out several
times.

Fill to proper water level and ready for normal service.

b. While the burners are on, open the valve in the skim
line and then slowly feed clean water into the boiler
adjusting the inlet water so that the boiler water
remains hot.
c. Continue skimming until the water is clean.

a. Turn off the burners.
b. Open the bottom drain valve permitting all the water
to drain from boiler.

NOTE: Use of soda or any alkali, vinegar or any acid is not
recommended for cleaning heating boilers because it is
difficult to completely remove them and injury may occur
after the cleaning process has been completed.

a. Insert a valve in the line close to the boiler.
2.

Bring the water line to the center of the outlet.
a. Raise the temperature to a point just below steaming.

BOILER

WATER

TREATMENT

BETWEEN

In closed hot water heating systems, negligible amounts
of make up water are used, and water treatment is not
required.

HEATING

SEASONS

Boilers should not be drained between heating seasons.
Boilers in closed hot water heating systems may be left as
is. Steam boilers should be entirely filled with water during
the summer months to exclude air.

In steam systems where the system is tight, free from leaks,
and all the steam is returned to the boiler as condensate,
the amount of make up water is small. Again, water
treatment is not required.
On steam systems with less than 90% of the steam being
returned as condensate, or with very hard or corrosive make
up water, treatment
may be desirable.
Follow the
recommendations
of the ASME (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code,
Section Vl, latest version.

COMPLETE BOILER MATERIAL
SECTIONS

COMPONENT

CART.

MODEL

300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000

INNER

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

QTY.
300
1

QTY.
400

QTY.
500

1
1
2
1

1
2
1

4
1
2
1

2
3
2
1
2
1

1
2

2
3

1
2
1

LIST

2
2
3
2
2
3
4
3
2
3
4
5
4
4
4
5
6

WATER
TRIM
CARTON
WA-1
WA-1
WA-1
WA-1
WA-2
WA-2
WA-2
WA-2
WA-2
WA-3
WA-3
WA-3
WA-3
WA-3
WA-4
WA-4
WA-4
WA-4
WA-4
WA-4
WA-4
WA-4
WA-4
WA-4
WA-5
WA-5
WA-5
WA-5

STEAM
TRIM
CARTON
SA-1
SA-1
SA-1
SA-2
SA-2
SA-3
SA-3
SA-3
SA-3
SA-3
SA-3
SA-3
SA-4
SA-4
SA-4
SA-4
SA-4
SA-4
SA-4
SA-4
SA-4
SA-5
SA-5
SA-5
SA-5
SA-5
SA-5
SA-5

AC
CARTON
3OO
4OO
5OO
6OO
7OO
8OO
9OO
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000

JACKET
END
PANEL
CARTON
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

BASE
END
PANEL
CARTON
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

PILOT
BURNER

MAiN GAS VALVE

",\:

IBURNERS

BURNER ORIFICES
AND AIR SHU'Fi-ERS

ELECTRONIC

IGNITION

PARTS DESCRIPTION

BASE MATERIAL

STOCK
NO.
1
300 Base
425-57-123
2
400 Base
425-57-124
3
500 Base
425-57-125
425-57-133
4t
300 Fire Door
425-57-134
51400 Fire Door
425-57-135
61
500 Fire Door
146-15-310
71Orifice 30
8
300 Manifold
146-16-303
9
400 Manifold
146-16-304
10
500 Manifold
146-16-305
11
5/16" - 18 x ¾" Hex Head Machine Crew - ZP 146-95-302
12
5/16"- 18 Nuts-ZP
146-95-013
13
Main Burner
146-15-302
14
Main Burner with Pilot Bracket
146-15-301
15
Q348A1275 Electronic Pilot Burner
146-62-301
425-57-029
1
Pilot Mounting Bracket
146-62-074
16
#394800-25 I,qnition Cable x 25" x Lon,q
146-95-301
17A1- #10-32 x 3/16" Hex Head Screw
146-95-311
17B1- #6-32 x 5/16" Hex Head Screw
146-15-005
18
1/8" OD Aluminum Tubin,q x 24" Lon,q
19
¾" 90 ° Street Elbow Black
146-93-040
20A
7000 DERHC ¾" H.C. Electronic Gas Valve
146-63-001
20B
VR8304M ¾" x ¾" Electronic Gas Valve
146-62-315
20C
VR8304M ½" x ¾" Electronic Gas Valve
146-62-058
21A
S8600M-1000 Intermittent Pilot Module
146-62-071
21B
$8600H-1014 Intermittent Pilot Module
146-62-304
22
#10-32 x ½" Machine Screw
146-95-307
23
#10-32 Hex Nut
146-95-308
433-00-942
24A
Wirin,q Harness 14" Lon,q
433-00-949
24B
Wiring Harness 14" Long
433-00-938
25
Ground Wire 4" Long
146-91-002
26
Cable Tie 3.7/8" Long
1 Not Shown

LIST
UNIT
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.

QUANTITY
300 400 500
1
1
1
1
1
1
6
8
10
1
1
1
4
4
4
4
4
4
5
7
9
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
Optional
2
2
2
2
2
2
1
1
1
1
1
1
1

AC-CARTON

PARTS
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

AC Carton
4" Push Nipples
5/8" -11NC x 7 Stud
5/8"-11NC Hex Nut
5/8" Flatwasher
Furnace Cement - Pint
FB-1 Fitting Ba.q
FB-2 Fitting Bag
FB-3 Fitting Bag
FB-4 Fitting Ba.q
FB-5 Fitting Bag
FB-6 Fitting Bag
Main Rating Plate
12" x 9" Plastic Bag
Warning Label

16
17

User's Information
Manual
Installation Instructions

18
19
20
21
22
23

Top Support Bkt.
¾" Drain Valve
AT87A-1007 Transformer
AT88A-1005 Transformer
AT92A-1007 Transformer
AT92C-1005 Transformer

24
25
26
27

R8222A-1002 Relay
129384A Case & Cover
Nipple Paste (4 oz.)
High Gas
Pressure Switch

1" Sq. Head Plugs

STOCK
No.

433-00-977
146-95-304
146-95-305
146-95-306
146-91-025
412-00-051
412-00-052
412-00-053
412-00-054
412-00-055
412-00-056
146-80-901
146-84-012
146-80-108
19817

Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.

1
6
6
12
12
2
1

1
8
8
16
16
2
1

1
10
10
20
20
2
1

1
12
12
24
24
2

1
14
14
28
28
2

1
16
16
32
32
2

1
18
18
36
36
2

1
20
20
40
40
2

1
22
22
44
44
2

1
24
24
48
48
2

1
26
26
52
52
2

1
28
28
56
56
2

1
30
30
60
60
2

1
32
32
64
64
2

1
34
34
68
68
2

2
36
36
72
72
4

2
38
38
76
76
4

2
40
40
80
80
4

2
42
42
84
84
4

1
1
1
1

1 1
1 2
1 1
1 1

1
2
1
1

1
3
1
1

1
4
1
1

1
5
1
1

146-83-004
425-57-037
146-22-001
146-62-305
146-62-306
146-62-307
146-62-308
146-62-309
146-62-310
146-91-302
146-62-314

Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.

1
1
1

1
2
1

1
3
1

146-93-055

Ea. 4

2
44
44
88
88
4

2
46
46
92
92
4

2
48
48
96
96
4

2 2 2 2 2 2
50 52 54 56 58 60
50 52 54 56 58 60
10010410811211612C
100 104108 112 11612C
4 4 4 4 4 4

1
5
1
1

11111
1 1
5 5
1 1
1 1

1
5
1
1

1
4
1

1
5
1

11111
11111
11111
11111

1 1 1
11111111

1
1
1

1
5
1

11111
11111

1
1
1

1
1
1
1

1 1
1 1
1 1
1 1
11111

1
1
1
1

STEAM

TRIM CARTON

MATERIAL

LIST

WATER

TRIM CARTON

MATERIAL

LIST

CARTON NO.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

STOCK
UNIT
NO.
67D-1 McDonnell & Miller LWCO
146-26-042 Ea.
PA404-A-1009 Pressuretrol
146-62-015 Ea.
146-22-010 Ea.
#20-104 Water Gau,qe Set
--Ea.
5/8" x 7.3/4" Glass Only for Item #3
--Ea.
3/16" x 10" Lg. Rods for Item #3
146-23-005 Ea.
2.1/2" Round Steam Gauge
146-22-002 Ea.
3/4" x 3/4" Pop Safety Valve
146-22-302 Ea.
1" x 1" Pop Safety Valve
146-22-303 Ea.
1.1/4" x 1.1/2" Pop Safety Valve
146-22-304 Ea.
1.1/2" x 2" Pop Safety Valve
146-22-305 Ea.
2" x 2" Pop Safety Valve
146-43-005 Ea.
1/4" Brass Syphon Loop
1/4" Brass Tee
146-93-057 Ea.
146-07-054 Ea.
1/4" x 2" Brass TBE Nipple
Steam Trim Carton for Items 1 to 14
--Ea.

CARTON NO.
<<<<<

PARTS DESCRIPTION

I-

11111
11111
11111
11111
22222
11111
1
1
1

PARTS DESCRIPTION

1
2
3
4
5
6
7
8
9

1
111
111
111
111

1
1
1
1

1
1
1
1
1

L4006A1017 Aquastat w/Well
Water Temperature/Pressure
Gauge
1/2" x 1/4" Bushing
3/4" x 3/4" Relief Valve
3/4" x 1" Relief Valve
l"x 1.1/4" Relief Valve
1.1/4"x 1.1/2" Relief Valve
1.1/2" x 2" Relief Valve
Water Trim Carton for Items 1 to 8

STOCK
No.
146-62-136
146-23-003
146-93-002
146-22-011
146-22-311
146-22-312
146-22-313
146-22-314
---

UNIT
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.

",-- O,

¢O ,_:l" _

4<44_:
0")0':.0300:,0
11111
11111
11111
1
1
1
1
1
11111

Refer to page 26 for water carton size required for your boiler

COMPONENT

CARTON

MATERIAL

LIST
MODEL

Refer to page 26 for steam carton size required for your boiler

PARTS DESCRIPTION

I-

DO
(D

JACKET END PANEL
Carton - Stock No. 425-57-118
PARTS DESCRIPTION
i_
1 Left End Jacket Panel

425-57-073

UNIT
No.
Ea.

425-57-074

Ea.

Right End Jacket Panel

STOCK

1
2
3
4
5
6
7
8
9
10

Component Carton
300 Base Assembly
400 Base Assembly
500 Base Assembly
300 Inter. Jacket Car.
400 Inter. Jacket Car.
500 Inter. Jacket Car.
300 Draft Hood
400 Draft Hood
500 Draft Hood

BOILER
BASE END PANEL
Carton - Stock No. 425-57-119
LU
I-1
2

PARTS

DESCRIPTION

STOCK

;E
LU

UNIT

No.
Left Base
Right

Base

End Panel
End Panel

425-57-100

Ea.

425-57-101

Ea.

1
2
3

SECTIONS

PARTS DESCRIPTION
Left End Section
Right End Section
Intermediate Section

STOCK
No.
--412-00-103
412-00-104
412-00-105
425-57-103
425-57-104
425-57-105
425-57-113
425-57-114
425-57-115

UNIT
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.
Ea.

MATERIALS
STOCK
Ng,
411-54-051
411-54-050
411-54-052

300 400 500
1
1
1
1
1
1
1
1
1
1
1
1

LIST
UNIT
Ea.
Ea.
Ea.

FITTING
MATERIAL

DESCRIPTION

# 10 x 1/2" Self Tap Screws
#8 x 3/4" Self Tap Screws
# 10-32 x 1/2" Slot Head Screws
# 10-32 Hex Nuts
5/16"- 18NC 3/4" Hex Head Bolts
5/16"- 18NC Hex Nuts
1/4" - 20NC x 1.1/2" J Bolts
1/4" - 20NC Hex Nuts
5" x 8" Plastic Bag
Jacket Door Knobs
Knob Screws

BOILER
MODEL

FITTING
BAG REQ'D.

300
400
5O0

FB-1

BOILER
MODEL
1600
1700
1800
1900
2000

Assembly

FITTING
BAG REQ'D.
FB-4
Assembly

BAGS (MATERIAL
STOCK
146-95-074
146-95-003
146-95-307
146-95-308
146-95-302
146-95-013
146-95-303
146-95-041
146-91-301
137-02-153
137-04-005

FB-1
10
2
none
none
8
8
1
1
1
2
2

BOILER
MODEL
60O
700
800
900
1000

FITTING
BAG REQ'D.

BOILER
MODEL
2100
2200
2300
2400
2500

FITTING
BAG REQ'D.

FB-2
Assembly

FB-5
Assembly

REQUIRED)
FB-2
14
2
2
2
12
12
2
2
1
4
4

FB-3
18
2
4
4
16
16
3
3
1
6
6

FB-4
22
2
6
6
20
20
4
4
1
8
8

FB-5
26
2
8
8
24
24
5
5
1
10
10

FB-6
30
2
10
10
28
28
6
6
1
12
12

BOILER
MODEL
1100
1200
1300
1400
1500

FITTING
BAG REQ'D.

BOILER
MODEL
2600
2700
2800
2900
3000

FITTING
BAG REQ'D.

FB-3
Assembly

FB-6
Assembly

WATER

MATERIAL

& STEAM

DESCRIPTION

TRIM KITS

STOCK

NUMBER

WATER

TRIM WA-1

41200071

WATER

TRIM WA-2

41200072

WATER

TRIM WA-3

41200073

WATER

TRIM WA-4

41200074

WATER

TRIM WA-5

41200075

14683004 (Form 500)

Rev. 3/May, 2003

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.2
Linearized                      : No
Page Count                      : 32
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 3, 2, 1, 4
Create Date                     : Fri Apr 20 15:33:15 2007
Author                          : 
Title                           : 
Subject                         :

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DUNKIRK Boiler Manual L0611128

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