DUNKIRK Boiler Manual L0611128

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

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INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler.

contents

Rules for Safe Installation and Operation .................................................................. 3

Boiler Ratings and Capacities .................................................................................... 4

Boiler Dimensions ...................................................................................................... 5

Combustion Air and Boiler Location ........................................................................... 6

Assembly of Bases ..................................................................................................... 7

Assembly of Sections and Draft Hoods ...................................................................... 7

Connecting Gas Service .......................................................................................... 10

Installing Boiler Jacket ............................................................................................. 11

Boiler Controls .......................................................................................................... 12

Water Boiler Piping .................................................................................................. 13

Steam Boiler Piping .................................................................................................. 15

Flue Connection and Venting ................................................................................... 16

Electrical Wiring ....................................................................................................... 17

Operation and Service ............................................................................................. 21

Checking and Adjusting ........................................................................................... 24

Parts ......................................................................................................................... 26

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.

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.

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.

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 air supply for complete

combustion.

8. Follow a regular service and maintenance schedule

for efficient and safe operation.

9. Never install the boiler on carpeting.

10. Keep boiler area clear and free from combustible

material such as gasoline and other flammable vapors

and liquids.

WHEN YOUR BOILER ARRIVES

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

instructions.

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.

CODES GOVERNING INSTALLATION

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.

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.

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.

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.

The boiler and its individual shutoff valve must be

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).

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)

@®

CHART 1

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

RATINGS AND CAPACITIES

A.G.A.*

INPUT

Bitu Mbh

3O0

400

5O0

600

7O0

8OO

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

A.G.A.* NET I=B=R RATINGSt

OUTPUT Steam Steam Water

Btu Mbh Sq. Ft.$ Btu Mbh Btu Mbh

240 750 180 209

320 1000 240 278

400 1250 300 348

480 1500 360 417

560 1750 420 487

640 2000 480 557

720 2250 540 626

800 2500 600 696

880 2750 660 765

960 3000 720 835

1040 3250 780 904

1120 3500 840 974

1200 3750 900 1043

1280 4008 962 1113

1360 4283 1028 1183

1440 4563 1095 1252

1520 4838 1161 1322

1600 5117 1228 1391

1680 5392 1294 1461

1760 5671 1361 1530

1840 5942 1426 1600

1920 6213 1491 1670

2000 6471 1553 1739

2080 6729 1615 1809

2160 6988 1677 1878

2240 7246 1739 1948

2320 7504 1801 2017

2400 7763 1863 2087

FLUE OUTLET CHIMNEY

NO. & SIZE SIZE$$

8" 10" 12" I.D. x Ht.

1 8"x 20'

1 10'x 20'

1 12" x 20'

2 12" x 20'

1 1 12" x 20'

2 14"x 20'

1 1 14"x 20'

2 14"x 20'

1 2 16"x 20'

3 16"x 20'

1 2 16"x 20'

1 2 18"x 20'

3 18"x 20'

4 18"x 20'

1 1 2 18"x 20'

2 2 20"x 20'

1 3 20"x 20'

4 20"x 20'

2 3 20"x 20'

3 2 22"x 20'

2 3 22"x 20'

1 4 22"x 20'

5 22"x 20'

2 4 22"x 20'

1 1 4 24"x 20'

2 4 24"x 20'

1 5 24"x 20'

6 24"x 20'

FLUE

COLLECTOR

SIZE TO

CHIMNEY

HORSE-

POWER

GROSS

OUTPUT**

7.16

9.55

11.94

14.33

16.72

19.10

21.49

23.88

26.27

28.66

31.04

33.43

35.82

38.21

40.60

42.99

45.37

47.76

50.15

52.54

54.93

57.31

59.70

62.09

64.48

66.87

69.25

71.64

PRESSURE

DROP THRU

WATER BOILERI-I-

GPM In.Water

18.9 0.10

37.8 0.50

25.2 0.27

50.4 0.86

31.5 0.40

63.0 1.20

37.8 0.50

75.6 1.70

44.1 0.70

88.2 2.50

50.4 0.88

100.8 2.90

56.7 1.10

113.4 3.80

63.0 1.30

126.0 4.00

69.3 1.50

138.6 5.00

75.6 1.80

151.2 6.00

81.9 2.00

163.8 5.60

88.2 2.40

176.4 7.00

94.5 2.60

189.0 8.30

100.8 2.80

201.0 9.60

187.1 3.15

214.2 10.30

113.4 3.50

226.8 11.00

119.7 4.00

239.4 12.50

126.0 4.50

252.0 14.00

132.3 4.95

264.6 16.00

138.6 5.40

277.2 18.00

144.9 5.70

289.8 17.00

151.2 6.00

302.4 19.00

157.5 8.00

315.0 20.50

163.8 7.00

327.6 22.00

170.1 7.50

340.2 24.00

176.4 8.00

352.8 26.00

182.75 8.50

365.5 27.50

189.1 9.00

378.2 9.00

Ratings are at sea level to 2,000 feet. For altitudes above 2,000 feet, reduce all ratings 4% for each 1,000 feet above sea level

1 Ratings based on selection factors recommended by Hydronics institute for piping and pickup. Net water boiler ratings are

based on an allowance of 1.15, and net steam boiler ratings are based on an allowance of 1.33. For water applications with

high piping and pickup requirements, use steam rating.

1: Ratings in square feet are computed at 240 Btuh/square toot for steam boilers.

** Ratings based on 33,500 Btuh per horsepower.

lt Pressure drop based on given flow from a single outlet and returning to a single inlet at the opposite 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 accept-

able 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. 4

EZZZ] EZ_ EZB _ _ _-

SUPPLY_ --'dATER

38"

89 _

LINE

47_" 33.__

; L

_FLFIOR LINE

FRONT VIEW

ICT]_ 7F_ F_G TH7 I_" 1 _FLUE HUTLETS

RETURN _ _ 0 0 _ _ _JJRETURN

SUPPLY SUPPLY

TOP VIEW

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

LEFT SIDE VIEW

ALL SUPPLY AND RETURN

CONNECTIONS, 4IN. ]

Boiler Water Content Shipping A AA

Model In Gallons Weight Jacket Width Base &Battery CDE F GH I

No. .3team Water Lbs. L to R Length

JC 300 20 26 922 18 3/4 16 3/4 9 3/8 omit omit omit omit omit 9 3/8

JC 400 25 33 1133 23 21 11 1/2 4 4 4 4 4 11 1/2

JC 500 30 40 1344 27 1/4 25 1/4 13 5/8 4 4 4 4 4 13 5/8

JC 600 35 46 1555 31 1/2 29 1/2 9 3/8 12 3/4 4 4 4 4 9 3/8

JC 700 40 52 1766 35 3/4 34 3/4 9 3/8 14 7/8 4 4 4 4 11 1/2

JC 800 45 58 1977 40 38 11 1/2 17 4 4 4 4 11 1/2

JC 900 50 65 2188 44 1/4 42 1/4 11 1/2 19 1/8 4 4 4 4 13 5/8

JC1000 55 71 2399 48 1/2 46 1/2 13 5/8 21 1/4 4 4 4 4 13 5/8

JC1100 60 78 2610 52 3/4 50 3/4 9 3/8 14 7/8 17 4 4 4 11 1/2

JC1200 65 84 2821 57 55 11 1/2 17 17 4 4 4 11 1/2

JC1300 70 91 3032 61 1/4 59 1/4 9 3/8 17 21 1/4 4 4 4 13 5/8

JC1400 75 97 3243 65 1/2 63 1/2 11 1/2 19 1/8 21 1/4 4 4 4 13 5/8

JC1500 80 104 3454 69 3/4 67 3/4 13 5/8 21 1/4 21 1/4 4 4 4 13 5/8

JC1600 85 110 3665 74 72 11 1/2 17 17 17 4 4 11 1/2

JC1700 90 117 3876 78 1/4 76 1/4 9 3/8 14 7/8 19 1/8 21 1/4 4 4 13 5/8

JC1800 95 123 4087 82 1/2 80 1/2 11 1/2 17 19 1/8 21 1/4 4 4 13 5/8

JC1900 100 130 4298 86 3/4 84 3/4 11 1/2 19 1/8 21 1/4 21 1/4 4 4 13 5/8

JC2000 105 136 4509 91 89 13 5/8 21 1/4 21 1/4 21 1/4 4 4 13 5/8

JC2100 110 143 4720 95 1/4 93 1/4 9 3/8 12 3/4 17 21 1/4 21 1/4 413 5/8

JC2200 115 149 4931 99 1/2 97 1/2 11 1/2 17 17 19 1/8 21 1/4 413 5/8

JC2300 120 156 5142 103 3/4 101 3/4 11 1/2 17 19 1/8 21 1/4 21 1/4 413 5/8

JC2400 125 162 5353 108 106 11 1/2 19 1/8 21 1/4 21 1/4 21 1/4 413 5/8

JC2500 130 169 5564 112 1/4 110 1/4 13 5/8 21 1/4 21 1/4 21 1/4 21 1/4 413 5/8

JC2600 135 175 5775 1161/2 1141/2 93/8 123/4 17 21 1/4 21 1/4 21 1/4 135/8

JC2700 140 182 5986 120 3/4 118 3/4 9 3/8 14 7/8 19 1/8 21 1/4 21 1/4 21 1/4 13 5/8

JC2800 145 188 6197 125 123 11 1/2 17 19 1/8 21 1/4 21 1/4 21 1/4 135/8

JC2900 150 195 6408 129 1/4 127 1/4 11 1/2 19 1/8 21 1/4 21 1/4 21 1/4 21 1/4 135/8

JC3000 155 201 6619 133 1/2 131 1/2 13 5/8 21 1/4 21 1/4 21 1/4 21 1/4 21 1/4 13 5/8

COMBUSTION AIR

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.

WARNING

ENOUGH AIR ENSURES PROPER

COMBUSTION AND ASSURES THAT

NO HAZARD WlLL DEVELOP DUE TO

THELACK OF OXYGEN

CHIMNEY AND VENT PIPE 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.

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.

MINIMUM 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.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY, MINIMUM CLEARANCES TO

COMBUSTIBLE CONSTRUCTION ARE.

LOCATING THE BOILER

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.

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.)

INSTALLATION

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.

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

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.

Top ...................................................... 54 inches

Front ........................................................ Alcove

Flue Connector ..................................... 6 inches

Rear .................................................... 18 inches

Sides ................................................... 18 inches

Greater clearances for access should supersede fire

protection clearances.

ASSEMBLY OF BASES

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 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 TOGETHER

WITH TIE RODS

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 CLOSING

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.

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.

TIE

TOP COVER SUPPI]RT _

FIGURE 2

TOP ANGLE

CAP SCREWS

AND NUTS

FIGURE 1

BASE ASSEHBLIES

BURNERS

ITHIS PAGE INTENTIONALLY LEFT BLANK I

LEFT END BATTERY

BASE ASSEMBLY

FIGURE 6

ATTACH DRAFT HOODS

Attach the draft hood(s) to the boiler sections after apply-

ing 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.

END CLOSING PLATE

WARNING:

DO NOT ALTER OR MODIFY DRAFT HOOD

FURNISHED WITH BOILER.

CLEAN OUT

COVER PANEL

DRAFT HOOD

APPLY BOILER

PUTTY

FIGURE 7

CONNECTING GAS SERVICE

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.

The main gas supply line should be adequate to prevent

undue pressure drop. See Chart No. 3 for pipe sizes for

gas mains.

To check for leaks in gas piping, use a soap and water

solution or other approved method, DO NOT USE AN

OPEN FLAME.

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.

Minimum Gas Supply Pressure

Models 300,500,600, 1000, 1300,

1500,2000,2100,2500,

2600,3000

Models 400, 700, 800,900, 1100,

1200,1400,1600,1700,

1800, 1900, 2200, 2300,

2400, 2700, 2800, 2900

Maximum Gas Supply Pressure

All Models

Manifold Pressure

All Models

GAS SUPPLY

5.0 inches w.c.

5.3 inches w.c.

14.0 inches w.c.

3.5 inches w.c.

SECURE MANIFOLD FROM

BVER HEAD FRAMING

DRIP LEG

INSTALL MANUAL VALVES

5 FEET ABOVE FLOOR

WHERE REQUIRED BY

LOCAL CODES

TYPICAL ISOMETRIC WIRING

AND GAS MAIN PIPING

NOT FURNISHED,

BOILERS ARE FIELD WIRED

AND ASSEMBLED.

FIGURE 8

SUGGESTED WIRING AND GAS MAIN PIPING

CHART 3

TABLE OF PIPE SIZES IN INCHES FOR GAS MAINS

(NATURAL GAS)

Boiler

No. 20' 30' 40' 50' 60' 80' 100' 125' 150'

300 1¼ 1¼ 1¼ 1¼ 1¼ 1¼ 1½ 1½ 1½

400 1¼ 1¼ 1¼ 1¼ 1½ 1½ 1½ 1½ 2

500 1¼ 1¼ 1¼ 1½ 1½ 1½ 2 2 2

600 1¼ 1½ 1½ 1½ 2 2 2 2 2

700 1¼ 1½ 1½ 2 2 2 2 2 2½

800 1½ 1½ 2 2 2 2 2 2½ 2½

900 1½ 2 2 2 2 2 2½ 2½ 2½

1000 1½ 2 2 2 2 2½ 2½ 2½ 2½

1100 2 2 2 2 2 2½ 2½ 2½ 2½

1200 2 2 2 2 2½ 2½ 2½ 2½ 3

1300 2 2 2 2½ 2½ 2½ 2½ 3 3

1400 2 2 2 2½ 2½ 2½ 3 3 3

1500 2 2 2½ 2½ 2½ 2½ 3 3 3

1600 2 2 2½ 2½ 2½ 2½ 3 3 3

1700 2 2½ 2½ 2½ 2½ 3 3 3 3

1800 2 2½ 2½ 2½ 2½ 3 3 3 3

1900 2 2½ 2½ 2½ 3 3 3 3 3

2000 2 2½ 2½ 2½ 3 3 3 3 3

2100 2½ 2½ 2½ 3 3 3 3 3 4

2200 2½ 2½ 2½ 3 3 3 3 4 4

2300 2½ 2½ 3 3 3 3 3 4 4

2400 2½ 2½ 3 3 3 3 3 4 4

2500 2½ 3 3 3 3 3 4 4 4

2600 3 3 3 3 3 4 4 4 4

2700 3 3 3 3 4 4 4 4 4

2800 3 3 3 4 4 4 4 4 4

2900 3 3 4 4 4 4 4 4 4

3000 3 4 4 4 4 4 4 4 4

SEE CHART # 3 FRR GAS

MAIN MANIFRLD SIZING

PROVIDE DISCONNECT

MEANS AND OVERLOAD

PROTECTION AS REQUIRED

1202V GOHz

4x4x5/8

JUNCTION BOX

(BY INSTALLER)

MOUNT IN

CONVENIENT LOCATION

ADJACENT TO BOILER

ALL WIRING TB CONFORM TO

NEC FOR TEMPERATURE

LIMITATION FOR TYPE "T*

WIRE (63F RISE)

ALL WIRING MUST COMPLY WITH ALL

APPLICABLE CODES, REGULATIONS

10 AND ORDINANCES

MANIFOU') BRACKET

FIGURE 9

TOP

JACKET

PANELS

JACKET TOP

SUPPORT BRACKET

FIGURE 10

ADJUSTABLE CLIPS

JACKET

END

PANEL

JACKET

END

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.

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.

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.

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.

Attach Local Code Label (not provided by

manufacturer.)

DRAFT HOOD

BAFFLE

FIGURE 11

®E

JACKET REAR PANELS

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.

STEAM 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.

FIGURE 12

OPENING SIZE STEAM

A 4" Supply and Return

B 1½. Primary LWCO and

Gauge Glass Set

C 1 1½,, Drain, Left End

C ¾" Drain, Right End

DW' Plugged

E 1" Accessories

*F 1" Pop Safety Valve

G Tie Rod Holes

H ¾" Plugged or Electronic

(Probe Type) LWCO

WATER

Supply and Return

Plugged

Drain, Left End

Drain, Right End

Limit Control

Accessories

Pressure Relief Valve

Tie Rod Holes

Plugged

BOILER 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 TRIM

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

valve.

2. High Pressure Limit Control.

3. Pressure Guage.

4. Water Gauge Glass Set.

5. Siphon Loop.

6. Pop Safety Valve (15 Ibs.).

WATER TRIM

1. Water Temperature High Limit Control.

2. Combination Temperature-Pressure Gauge.

3. Safety Relief Valve (30 Ibs.).

I=_HIGH PRESSURE LIMIT

STEAM

GAUGE

FIGURE 13

WATER TRIM ASSEMBLY

Locate Water Trim Controls per Chart in FIGURE 12.

POP SAFETY VALVE AND PRESSURE

RELIEF VALVE.

*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.

BOILERS USED WITH

REFRIGERATION SYSTEM

When the boiler is installed inconnection 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.

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.

TB SYSTEM

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.

FLOW RATE GPM

35 - 50

51 - 76

77 - 131

132 - 205

206 - 300

PIPE SIZE

2½"

SUPPLY HEADER

CBMBI

PRESSURE,

TEMPERATURE

& ALTITUDE

GAUGE (_

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

HIGH LIHIT CONTROL

_RETURN

HEADER

__ PRESSURERELIEF

VALVE

STEAM BOILERS - SERIES S

BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS SHOWN

CITY',CATER

SUPPLy

TB RET_N

CITY _,/ATgR

SUPPLy

TDRETURN

_AT R

67 SERIES _'_

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

McDONNELL FEEDER CUTOFF

COMBINATION

BOILER SIZE USE

300 NO. 47-2"

THRU Control Mounts in

1500 Gauge Glass Tappings

1600 No. 51.2"

THRU Control Mounts in

3000 1-inch Tappings

FOR CLOSED HEATING SYSTEMS

DIMENSION A = 2 • 2 '/2

NOTE: For multiple boiler installation with gravity return, use

feeder Cutoff Combination or seperate feeder and seperate

cutoff on each boiler,

*These items available through your Distributor.

SEPERATE McDONNEL FEEDER AND McDONNELL PUMP CONTROL AND LOW-

SEPERATE McDONNEL LOW-WATER WATER CUTOFF USED WITH CONDESATE

CUTOFF RECEIVER AND ELECTRIC BOILER FEED PUMP

BOILER SIZE USE

300 NO. 247 mechanical feeder or No,

THRU 101-24V electric feeder with transformer

1500 for use on closed heatin 9 systems only.

1600

THRU No. 51.2*

3000

NOTE: For multiple installation with

condesate tank and single boiler feed

pump, use No, 93 on each boiler to

operate motorized valve in each boiler

feed line.

FOR CLOSED HEATING SYSTEMS

DIMENSION A _ 2 = 2 V= inches

FOR PROCESS OR PARTIAL PROCESS SYSTEMS

DIMENSION A _ 1 = 1 V=inches

FIGURE 16

WATER BOILERS - SERIES W

BOILER TAPPINGS ARE AVAILABLE FOR ALL CONNECTIONS SHOWN

WITH EXCEPTION OF NO. 764 WHICH MOUNTS IN PIPING

CITy _ATER

SUPF_Y

McDONNELL FEEDER CUTOFF COMBINATION

For boilers with

30-psi relief valve setting

_PPLY LINE_

BOILER SIZE USE

300

THRU No 247_

1500

1600

THRU No 5%2*

3000

For boilers with up to

75_psi relief valve setting**

USE

IBOILER SIZE INo 53-2IALL SIZES

** Water supply pressure must exceed relief valve setting by at

least 20 psi,

FIGURE 17 14

ND, 764

McDONNELL OW-WATER CUTOFF

For boilers with

7540 100_psi relief valve setting

IBO,LERS,ZEI USE I

IALLSIZESINolSO II

For all boilers upto

50_psi relief valve setting

BOILER SIZE I USE I

ALL SIZES No 63*

ALL SIZES NO 764*

*These items available through your Distributor.

STEAM

STEAM CROSS

HEADER

LINE

FLUSH rET

RETURN

WATER

CUT-OFF

SEE PAGE 12

POP SAFETY VALVE SHOULD BE FIELD INSTALLED AS CLOSE AS POSSIBLE TO BOILER

FIGURE 18

STEAM BOILER PIPING (Figure 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.

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.

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.

WARNING

NEVER INSTALL A SHUT-OFF OR

STEAM VALVE BETWEEN THE POP

SAFETY VALVE AND THE BOILER.

EQUALIZING LINE SIZE

MODEL NUMBERS

300 to 900

1000 to 1900

2000 to 2500

2600 to 3000

SIZE

2½"

FLUE CONNECTION AND VENTING

Consult local codes and gas company requirements.

Adhere to the following standard practice recommendations

for installing the flue pipe:

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.

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.

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.

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.

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.

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.

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°

elbow in this run as shown.

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.

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.

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.

FIGURE 19 -RODFLINE -PANTLEG

BOILER BBILER

FIGURE 21

R DIAMETER

, !_I _ i_1_¸_........ _ P_A._viE_

ENLARGED

FIGURE 22

Baffle Size (Inches)

Shown is suggested size of fixed

baffle for different size risers.

REMOVING EXISTING BOILER FROM

COMMON VENTING SYSTEM

When an existing boiler is removed from a common venting

system, the common venting system islikelyto 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 inoperation, while the other

appliances remaining connected tothe common ventingsystem

are not in operation.

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 beelectricallygrounded inaccordance

with these requirements. Install a fused disconnect switch

between boiler and electrical panel in a convenient location.

The wiring from hightemperature limitcontrol should be secured

to the boiler jacket or gas piping to prevent an accidental

disconnect from controls.

All wiring to gas valves must betaped 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.

INSTALLING THERMOSTAT

The thermostat locationhas 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:

Dead Spots:Behind Doors

Corners and Alcoves

Hot Spots: 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, setthermostat(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

indicatedon the thermometer, boilerbumers 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 BASE BOILERS

1 . STEAM BOILERS

Multiple base steam boilers should not be stage fired due

to fluctuations inwater linebetween 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 orthe HeatTimer 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

multiplebase hot water boilers.We offera 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 airtemperature. Consult the boilermanufacturer

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.

FIGURE 23

(NIT) L_UNIT DN-Df'F

CBNTR_LLER SVITCH I

r......._-t--F_--q---;

TI-IERM_TAT DR

CUNTRBLLER _24V

_TR_FDRNER

F----'-I JL

...... @--L-_2,__j ......................................

_ARE

IGNITER

SENSGR

'°

PILDT i I

BURNER

MAIN

Ig| !K2 @ VALVE "_F

t----A,r....

PLDT I

2K2 @ VALVE _

___ J__ ..... _a

A POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTIONAS REQUIRED

_ ALTERNATE LIMIT CONTROLLER LOCATION

INTERNAL WIRING

SCHEMATIC WIRING DIAGRAM FOR S8600M EXTERNAL WIRING

1 2 3 4 56 7

"Rv:_v

_II INTERMITTENT

PILOT CONTROL

GROUND

_OT

HONEYWELL VR8304M GAS VALVE WIRING

FIGURE 24

754 NARNESS_

Robertshaw

7O0O DERHC

Gas Valve

Wiring

RED

GREEN

WHITE

FIGURE 25

PILOT VALVE

INTERI,41TTENT

PILOT CONTROL

GROUND

TO PILOT

MAIN VALVE

STEAM OR HOT WATER SINGLE BASE BOILERS WITH HONEYWELL INTERMITTENT PILOT

WHERE THERMOSTAT DOES NOT CONTROL CIRCULATOR PUMP

H G

1_ 120V 60Hz

SUPPLY

TR-1

SUPPLIED Lr_

WITH AC CARTON I

24VG

F4v .PIo

SET HEAT

ANTICIPATOR

AT 90 AMPS

WIRING TD GAS VALVE-

FACTORY INSTALLED

(OPTIONAL)

TH-I PS/HL MAN RESET

LWCD

TR-2 E

120V 60Hz

SUPPLY

-- -rlPTIONAL-

_ SUPPLIED BY

INSTALLER

EWF

FIGURE 26

rlpT.PS/HL TH-I IP TR-I

WIRING Trl GAS VALVE- _ Ill_ 60Hz

PS/HL LWCB FACTORY INSTALLED _II_ SUPPLY

SUGGESTED WIRING FOR FORCED HOT WATER SINGLE BASE BOILER WITH HONEYWELL

INTERMITTENT PILOT WHERE THERMOSTAT CONTROLS CIRCULATOR PUMP

FIGURE 27

TH-1

TR-1

TR-2

PS/HL

TH-I

SET HEAT

ANTICIPATOR

AT .90 AMPS

120V GOHz

SUPPLY

°T

iTR_I

R845A (NOT SUPPLIED)

WIRING TO GAS VALVE-

FACTORY INSTALLED

CIRCULATOR

(OPTIONAL>

NAN, RESET

HL HL

FOR WIRE COLOR CODE BETWEEN GAS VALVE AND MODULE SEE ABOVE

THERMOSTAT (24 VOLT)

TRANSFORMER (120V-24V)

TRANSFORMER (120V-24V 50VA)

PRESSURE SWITCH (STEAM)

HIGH LIMIT (WATER)

COMPONENT CODING

-O-

--e-

LWCO

EWF

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 INTERMITTENT PILOT,

WHERE THERMOSTAT DOES NOT CONTROL CIRCULATOR PUMP

RB222A

RELAY

OPTIONAL

MAN. RESET PS/HL PS/HL [

lHERMDSTAT_

__.___

O_ o--_ [I _,PROVIDE DISCONNECT

/2 4 I I I IIII _ MEANS & OVERLOAD

I T ° I I I LU-I 'PROTECTInN AS REO'D. _

Ii_rn EWF TR-2 - OPTIONAL TR-] PPLIE WITH AC CARTON)

0_) =i I LWL: (SUPPLIED BY INSTALLER)

NNo _-

7 _4v MYr- _ -I _4v MVr-

"1 _ 24VG MV/PV E

_r_" £ _ H PV[__ Tn GAS VALVE U PV[_

$8600 MODULE $8600 MODULE

0 0 _ FACTORY INSTALLED

Z;:Om VIRES-DO NOTREMOVE

m0FOR'dIRECOLORCODE

-- _:_ FlI BETWEEN GAS VALVE AND

MODULES SEE PAGE ]8

zoo;o

oZZ_ m FIGURE 28

_,.T-

SET HEAT

ANTICIPATOR

AT .40 AMPS

_A WIRING

TO GAS VALVE

CTDRY INSTALLED

VIRES - DO NOT REMOVE

FOR VIRE COLOR CODE

BETVEEN GAS VALVE AND

MODULES SEE PAGE 18

OPERATION AND SERVICE

S8600 FUNCTIONS AND OPERATION

The S8600 control module performs the following basic

functions:

SYSTEM TROUBLESHOOTING

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.

2. Provides a spark for igniting pilot burner.

3. Senses the pilot burner flame.

4. Shuts off the spark after pilot flame is lit.

5. Opens and closes the second (Main) operator.

These functions occur in two stages - trial for pilot ignition

and main burner operation as described below.

TRIAL FOR PILOT IGNITION

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.

Establish the type of system malfunction or deviation from

normal operation by using the $8600 Intermittent Pilot

System Troubleshooting Table, page 23.

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.

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.

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 CIRCUIT

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.

MAIN BURNER 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.

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.

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.

PRELIMINARY CHECK

The following visual checks should be made before

troubleshooting and after maintenance.

1. Check power switch.

2. Manual shutoff cocks in the gas line to the boiler must

be open.

CAUTION

DO NOT TOUCH EITHER END OF JUMPER

OR STUD TERMINAL. THIS IS A VERY

HIGH VOLTAGE CIRCUIT AND

ELECTRICAL SHOCK CAN RESULT.

3. Make sure all wiring connections are clean and tight.

4. Review the $8600 normal sequence of operation. 21

IGNITION CABLE CHECK

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

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 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 above room

temperature to call for heat.

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

gas supply.

4. Set thermostat or controller above room temperature to

call for heat.

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).

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.

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.

PILOT FLAME ADJUSTMENT

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.

PROPER FLAME ADJUSTMENT

CHECK BURNERINPUT

Checkboiler_rproperBTUinputrate.

CAUTION

Do not exceed the Input rate stamped on the nameplate of

the boiler located on the End Jacket Panel.

Make certain primary air supply to the Main burners is

properly adjusted for complete combustion.

I WARNING I

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

be off for 5 minutes before relighting.

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: The adjustment screw is plastic and may require

slightly greater turning force than metal threads.

Be sure to replace Regulator Cap.

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

FOR HEAT

POWER TO MODULE

(24V MODULE)

S8600 INTERMITTENT PILOT SYSTEM TROUBLESHOOTING TABLE

START

I NOTE: Before troubleshooting, 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. I

YES ,

SPARK ACROSS

IGNITER/SENSOR GAP

YES 1

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES 1

SPARK STOPS WHEN

PILOT IS LIT?

YES

MAIN BURNER LIGHTS?

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

YES

I CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

IYESJ,

TROUBLESHOOTING

ENDS

Pull ignition lead and check ,,_ _ '_ • On models with vent damper plug,

spark at module. _f make sure vent damper has not

been installed, then removed.

Spark okay? Replace vent damper if necessary.

YES Jr On other models, replace module.

I • Check ignition cable, ground wiring, ceramic insulator and gap, and correct. I

• Check boot of the ignition cable for signs of melting or bucking. Take protective Iaction to shield cable and boot from excessive temperatures.

• Check that all manual valves are supply tubing and are

gas open, pressures

good, and pilot burner orifice is not blocked.

• 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.

NOTE: If S8600B, H goes into lockout, reset system. For S8600M, wait 6 min. nom.

for retry or reset system.

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

• Check 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 problem persists, replace module.

• 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. I

NOTE: If S8600B, H; $8610B, H goes into lockout, reset system. For S8600M, wait

6 min. nom. For retry or reset 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 controller and

wiring: if not, replace gas control. I

I Repeat procedure until trouble free operation is obtained.

CHECKING AND

HIGH LIMIT CONTROL

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 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.

ADJUSTING

qualified service technician to replace the relief valve and

inspect the heating system to determine the cause, as this

may indicate an equipment malfunction.

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.

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.

FIRST WEEK - 2 or 3 times

_DUTER MANTLE

_DUTER CONE

BURNER _

THEREAFTER - At least once a week

PRESSURE RELIEF VALVE

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

BOILER 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

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).

AT LEAST ONCE A MONTH DURING HEATING SEASON

check to see that the sections of vent pipe are secure at all

joints and fittings. There should be at least two (2) sheet

metal screws per joint.

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.

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:

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.

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.

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.

3. Close valves in boiler feed line and skim line.

4. Bring the pressure in the boiler to about 10 Ibs.

a. Turn off the burners.

b. Open the bottom drain valve permitting all the water

to drain from boiler.

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

times.

6. Fill to proper water level and ready for normal service.

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.

BOILER WATER TREATMENT

In closed hot water heating systems, negligible amounts

of make up water are used, and water treatment is not

required.

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.

BETWEEN 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.

COMPLETE BOILER MATERIAL LIST

MODEL

SECTIONS

L INNER R

300 1 2 1

400 1 3 1

500 1 4 1

600 1 5 1

700 1 6 1

800 1 7 1

900 1 8 1

1000 1 9 1

1100 1 10 1

1200 1 11 1

1300 1 12 1

1400 1 13 1

1500 1 14 1

1600 1 15 1

1700 1 16 1

1800 1 17 1

1900 1 18 1

2000 1 19 1

2100 1 20 1

2200 1 21 1

2300 1 22 1

2400 1 23 1

2500 1 24 1

2600 1 25 1

2700 1 26 1

2800 1 27 1

2900 1 28 1

3000 1 29 1

COMPONENT CART.

QTY. QTY. QTY.

300 400 500

1 1

1 2

1 1 2

2 2

1 3

2 3

3 2

2 3

1 4

2 4

1 1 4

2 4

1 5

WATER

TRIM

CARTON

WA-1

WA-2

WA-3

WA-4

WA-5

STEAM

TRIM

CARTON

SA-1

SA-2

SA-3

SA-4

SA-5

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

BASE

END

PANEL

CARTON

MAiN GAS VALVE

",\:

PILOT

BURNER

IBURNERS

BURNER ORIFICES

AND AIR SHU'Fi-ERS

ELECTRONIC IGNITION BASE MATERIAL LIST

PARTS DESCRIPTION

1 300 Base

2 400 Base

3 500 Base

4t 300 Fire Door

51- 400 Fire Door

61 500 Fire Door

71- Orifice 30

8 300 Manifold

9 400 Manifold

10 500 Manifold

11 5/16" - 18 x ¾" Hex Head Machine Crew - ZP

12 5/16"- 18 Nuts-ZP

13 Main Burner

14 Main Burner with Pilot Bracket

15 Q348A1275 Electronic Pilot Burner

1 Pilot Mounting Bracket

16 #394800-25 I,qnition Cable x 25" x Lon,q

17A1- #10-32 x 3/16" Hex Head Screw

17B1- #6-32 x 5/16" Hex Head Screw

18 1/8" OD Aluminum Tubin,q x 24" Lon,q

19 ¾" 90° Street Elbow Black

20A 7000 DERHC ¾" H.C. Electronic Gas Valve

20B VR8304M ¾" x ¾" Electronic Gas Valve

20C VR8304M ½" x ¾" Electronic Gas Valve

21A S8600M-1000 Intermittent Pilot Module

21B $8600H-1014 Intermittent Pilot Module

22 #10-32 x ½" Machine Screw

23 #10-32 Hex Nut

24A Wirin,q Harness 14" Lon,q

24B Wiring Harness 14" Long

25 Ground Wire 4" Long

26 Cable Tie 3.7/8" Long

STOCK UNIT QUANTITY

NO. 300 400 500

425-57-123 Ea. 1

425-57-124 Ea. 1

425-57-125 Ea. 1

425-57-133 Ea. 1

425-57-134 Ea. 1

425-57-135 Ea. 1

146-15-310 Ea. 6 8 10

146-16-303 Ea. 1

146-16-304 Ea. 1

146-16-305 Ea. 1

146-95-302 Ea. 4 4 4

146-95-013 Ea. 4 4 4

146-15-302 Ea. 5 7 9

146-15-301 Ea. 1 1 1

146-62-301 Ea. 1 1 1

425-57-029 Ea. 1 1 1

146-62-074 Ea. 1 1 1

146-95-301 Ea. 2 2 2

146-95-311 Ea. 2 2 2

146-15-005 Ea. 1 1 1

146-93-040 Ea. 1 1 1

146-63-001 Ea. 1

146-62-315 Ea. 1

146-62-058 Ea. 1

146-62-071 Ea. 1 1 1

146-62-304 Ea. Optional

146-95-307 Ea. 2 2 2

146-95-308 Ea. 2 2 2

433-00-942 Ea. 1 1

433-00-949 Ea. 1

433-00-938 Ea. 1

146-91-002 Ea. 1 1 1

1 Not Shown 27

AC-CARTON

PARTS

DESCRIPTION

STOCK

No.

1 AC Carton

2 4" Push Nipples

3 5/8" -11NC x 7 Stud

4 5/8"-11NC Hex Nut

5 5/8" Flatwasher

6 Furnace Cement - Pint

7 FB-1 Fitting Ba.q

8 FB-2 Fitting Bag

9 FB-3 Fitting Bag

10 FB-4 Fitting Ba.q

11 FB-5 Fitting Bag

12 FB-6 Fitting Bag

13 Main Rating Plate

14 12" x 9" Plastic Bag

15 Warning Label

16 User's Information

Manual

17 Installation Instructions

18 Top Support Bkt.

19 ¾" Drain Valve

20 AT87A-1007 Transformer

21 AT88A-1005 Transformer

22 AT92A-1007 Transformer

23 AT92C-1005 Transformer

24 R8222A-1002 Relay

25 129384A Case & Cover

26 Nipple Paste (4 oz.)

27 High Gas

Pressure Switch

28 1" Sq. Head Plugs

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

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. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2

Ea. 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60

Ea. 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 10010410811211612C

Ea. 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 100 104108 112 11612C

Ea. 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4

Ea. 1 1 1

Ea.

11111

Ea. 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

Ea. 1 1 1 1 2 2 2 2 3 3 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5

Ea. 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

Ea. 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5

Ea. 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

Ea. 11111111

Ea. 11111

Ea. 1 1 1 1 1 1 1 1 1 1

Ea. 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

Ea. 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

Ea. 11111

146-93-055 Ea. 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

STEAM TRIM CARTON MATERIAL LIST

PARTS DESCRIPTION

1 67D-1 McDonnell & Miller LWCO

2 PA404-A-1009 Pressuretrol

3 #20-104 Water Gau,qe Set

4 5/8" x 7.3/4" Glass Only for Item #3

5 3/16" x 10" Lg. Rods for Item #3

6 2.1/2" Round Steam Gauge

7 3/4" x 3/4" Pop Safety Valve

8 1" x 1" Pop Safety Valve

9 1.1/4" x 1.1/2" Pop Safety Valve

10 1.1/2" x 2" Pop Safety Valve

11 2" x 2" Pop Safety Valve

12 1/4" Brass Syphon Loop

13 1/4" Brass Tee

14 1/4" x 2" Brass TBE Nipple

15 Steam Trim Carton for Items 1 to 14

STOCK UNIT

NO.

CARTON NO.

<<<<<

11111

22222

11111

146-26-042 Ea.

146-62-015 Ea.

146-22-010 Ea.

--- Ea.

146-23-005 Ea.

146-22-002 Ea.

146-22-302 Ea.

146-22-303 Ea.

146-22-304 Ea.

146-22-305 Ea.

146-43-005 Ea.

146-93-057 Ea.

146-07-054 Ea.

--- Ea.

111

1 1

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

JACKET END PANEL

Carton - Stock No. 425-57-118

PARTS DESCRIPTION STOCK UNIT

i_ No.

1Left End Jacket Panel 425-57-073 Ea.

2 Right End Jacket Panel 425-57-074 Ea.

BASE END PANEL

Carton - Stock No. 425-57-119

LU PARTS DESCRIPTION STOCK UNIT

I-

-- No.

1 Left Base End Panel 425-57-100 Ea.

2 Right Base End Panel 425-57-101 Ea.

WATER TRIM CARTON MATERIAL LIST

LU PARTS DESCRIPTION

I-

1 L4006A1017 Aquastat w/Well

2 Water Temperature/Pressure Gauge

3 1/2" x 1/4" Bushing

4 3/4" x 3/4" Relief Valve

5 3/4" x 1" Relief Valve

6 l"x 1.1/4" Relief Valve

7 1.1/4"x 1.1/2" Relief Valve

8 1.1/2" x 2" Relief Valve

9 Water Trim Carton for Items 1 to 8

STOCK UNIT

No.

146-62-136 Ea.

146-23-003 Ea.

146-93-002 Ea.

146-22-011 Ea.

146-22-311 Ea.

146-22-312 Ea.

146-22-313 Ea.

146-22-314 Ea.

--- Ea.

CARTON NO.

",-- O, ¢O ,_:l" _

4<44_:

0")0':.0300:,0

11111

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

COMPONENT CARTON MATERIAL LIST

LU PARTS DESCRIPTION

I-

1 Component Carton

2 300 Base Assembly

3 400 Base Assembly

4 500 Base Assembly

5 300 Inter. Jacket Car.

6 400 Inter. Jacket Car.

7 500 Inter. Jacket Car.

8 300 Draft Hood

9 400 Draft Hood

10 500 Draft Hood

STOCK UNIT

No.

--- Ea.

412-00-103 Ea.

412-00-104 Ea.

412-00-105 Ea.

425-57-103 Ea.

425-57-104 Ea.

425-57-105 Ea.

425-57-113 Ea.

425-57-114 Ea.

425-57-115 Ea.

MODEL

300 400 500

1 1 1

BOILER SECTIONS MATERIALS LIST

LU PARTS DESCRIPTION STOCK UNIT

Ng,

1 Left End Section 411-54-051 Ea.

2 Right End Section 411-54-050 Ea.

3 Intermediate Section 411-54-052 Ea.

FITTING BAGS (MATERIAL REQUIRED)

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

STOCK FB-1 FB-2 FB-3 FB-4 FB-5 FB-6

146-95-074 10 14 18 22 26 30

146-95-003 2 2 2 2 2 2

146-95-307 none 2 4 6 8 10

146-95-308 none 2 4 6 8 10

146-95-302 8 12 16 20 24 28

146-95-013 8 12 16 20 24 28

146-95-303 1 2 3 4 5 6

146-95-041 1 2 3 4 5 6

146-91-301 1 1 1 1 1 1

137-02-153 2 4 6 8 10 12

137-04-005 2 4 6 8 10 12

BOILER FITTING

MODEL BAG REQ'D.

300

400

5O0

FB-1

Assembly

BOILER

MODEL

60O

700

800

900

1000

FITTING

BAG REQ'D.

FB-2

Assembly

BOILER

MODEL

1100

1200

1300

1400

1500

FITTING

BAG REQ'D.

FB-3

Assembly

BOILER

MODEL

1600

1700

1800

1900

2000

FITTING

BAG REQ'D.

FB-4

Assembly

BOILER

MODEL

2100

2200

2300

2400

2500

FITTING

BAG REQ'D.

FB-5

Assembly

BOILER

MODEL

2600

2700

2800

2900

3000

FITTING

BAG REQ'D.

FB-6

Assembly

WATER &STEAM TRIM KITS

MATERIAL DESCRIPTION

WATER TRIM WA-1

WATER TRIM WA-2

WATER TRIM WA-3

WATER TRIM WA-4

WATER TRIM WA-5

STOCK NUMBER

41200071

41200072

41200073

41200074

41200075

14683004 (Form 500) Rev. 3/May, 2003

DUNKIRK Boiler Manual L0611128

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