DUNKIRK Boiler Manual L0611475

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

Open the PDF directly: View PDF .
Page Count: 42

Download
Open PDF In Browser	View PDF

EV SERIES CAST IRON PRESSURE-FIRED
WET BASE HOT WATER BOILERS

DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www. ecrinternationaL com

P/N# 14683010,

Rev. 3.1 [09/05]

• Printed in USA.

Made In USA

Boiler Ratings and Capacities .............................
4
Rules for Safe Installation and Operation ............ 8
Indoor Boiler Installation ....................................
10
Jacket Assembly

(Indoor

Boilers)

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

System Piping (Indoor Boilers) ..........................
Weatherproof
(Outdoor) Boiler Installation ........
Normal Sequence of Operation .........................
Lighting Instructions for Gas Burners ................

11
12
23
30
30

Typical Vent Safety Switch Installation .............. 32
Maintenance ......................................................
34
Service Hints and Troubleshooting
....................
Repair Parts ......................................................

KEEP THIS MANUAL NEAR BOILER
BETA!N EOB EUTUBE BBEEBENCE

36
37

The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels.

ndJcates
a potential
hazardous
situation
J
hJch, if not avoided,
MAY result in minor orJ
oderate injury. It may also be used to alert J
gainst

unsafe

cMoPORTANT:

practices.
Read

the following

MPLETELY before insta!!ingH

3
instructions'%}

/9""ii7", '

',4:dy,,
C.S.A. Certified
For Natural Gas Or Propane

¢@@
Tested For 100 LBS
ASME

Working Pressure

FIG, 1 - INDOOR BOILER DIMENSIONS

L
i

0
±
REA_

81DE

5_OE

INDOOR OIL-FIRED HOT WATER BOILERS

62
129

54
I12

87.6
82.9

88.40
83.77

DPFO-4T

80
169

70
I47

87.5
83.3

88.35
84.24

14_A''

DPFO-5T

99
208

86
I82

87.5
83.8

88.31
84.72

17½"

DPFO-7T

117
250

I02
217

87.5
84.3

88.26
85.20

24"

DPFO-9T

154
324

134
282

87.4
__5)

88.15
__(5)

30½"

DPFO-3T

I1"

DPFO-3

.45
.90

56
105

48
91

87.5
82.8

88.22
83.19

I1"

DPFO-4

1.605

74
159

64
I38

87.5
83.3

88.23
83.91

14_A"

DPFO-5

I!#0

93
199

81
I73

87.5
83.9

88.23
84.63

17½"

DPFO-7

1.05
2.35

130
276

I13
240

87.6
__(5)

88.24
__(5)

24"

1.35
3.00

167
353

I46
307

87.6
__(5)

88.26
__(5)

30½"

DPFO-9

Firing rates of 2.00 gph or less use a Beckett Model AFG oil burner Firing rates over 2.00 gph use a Beckett Model CF375 oil burner. Optional Riello 40 Series
oil burners also available.

iNDOOR GAS-FIRED HOT WATER BOILERS

DPFG-3T

70
I54

60
127

52
110

85.0
81.5

85.73
82.18

11"

DPFG-4T

91
I83

78
151

68
131

85.0
81.8

85.68
82.46

14¼"

DPFG-5T

I12
212

96
175

83
153

85.0
82.1

85.64
82.75

17½"

DPFG-7T

I33
240

114
199

99
173

85.0
82.4

85.60
83.04

24"

DPFG-9T

I75
240

150
201

130
175

85.0
82.9

85.52
83.62

30½"

DPFG-3

63
I26

54
104

47
90

84.7
81.6

85.73
82.19

11"

DPFG-4

84
I89

72
156

63
136

84.8
81.9

85.70
82.45

14¼"

DPFG-5

105
211

90
175

78
152

84.8
82.1

85.67
82.7I

17½"

I47

128

109

84.9

85.61

DPFG-7

240

200

174

82.5

83.23

24"

DPFG-9

189
240

162
201

141
175

84.9
83.0

85.55
83.75

30½"

(1) D.O.E. Heating capacity is indicated in thousands of Btu per hour. Use of antifreeze
efficiency by a significant amount.
(2) Net ratings are indicated in thousands
(3) Annual Fuel Utilization
Trade Commission.

in any boiler can reduce capacity, net output and

of Btu per hour based on a piping and pickup allowance of 1.15.

Efficiency based on tests performed

under U.S. Department

of Energy standards

and reported to the Federal

(4) Chimney size is 8" x 8".
(5) Capacity greater than that requiring testing under F.T.C. regulations.

As an Energy Star Partner, ECR International

has determined that this product meets the Energy Star guidelines for energy efficiency.

It is strongly recommended that, before selecting a boiler model for a specific installation, the installer familiarize himself with the supplemental
venting instruction included with this boiler.

FIG, 2 - WEATHERPROOF
2Z_

BOILER DIMENSIONS

38Y_

L
REAR

_ _'_

SIDE
WEATHERPROOF

FRONT

OIL BOILERS

m
NO.
_EC.
DPFO4W

.60
1.35

71
I51

61
I31

82.9
78.6

88.23
83.19

DPFO7W

1.05
2.35

I24
276

I07
240

82.9
__(4)

88.24
__<4)

DPFO9W

1.35
3.00

159
309

138
268

82.5
__(4)

88.26
__<4)

WEATHERPROOF

GAS BOILERS

m m
'MULTI:
PASS1
,6:O1_i

NO,

DPFG4W

70
93

61
81

80.8
80.2

85.7
84.7

Less

28½"

DPFG7W

I22
I49

I06
I30

80.9
80.0

85.6
85.0

Less

37½"

DPFG9W

I56
I98

I36
I72

80.9
80.4

85.5
85.1

Less

44%"

iMPORTANT: ANTIFREEZE

ADDED TO WEATHERPROOF

(1) D.O.E Heating capacity is indicated in thousands
efficiency by a significant amount.
(2) Net ratings are indicated in thousands
(3) Annual Fuel Utilization Efficiency
Trade Commission.

BOILERS

of Btu per hour. Use of antifreeze

MUST BE NON-TOXIC!!

in any boiler can reduce capacity, net output and

of Btu per hour based on a piping and pickup allowance of 1.15.

based on tests performed

under U.S. Department

of Energy standards

and reported to the Federal

(4) Capacity greater than that requiring testing under F.T.C. regulations. Firing rates of 2.00 gph or tess use a Beckett Model AFG oil
burner. Firing rates over 2.00 gph use a Beckett Model CF375 oil burner.

IMPORTANT
Standard

indoor EV Series

boilers are furnished

as knockdown
boilers and are shipped as four
components (w/o DES) or five components
(with
DES) are shown below:
The optional DES is to be used in conjunction
with the EV boiler for indoor installations
requiring
through the wall venting, The DES is designed as
an integral part of the EV boiler,
need for a power venter.

eliminating

the

4 to 9 sections

Oil

boiler

6W'

FDVS 6

8½"

FDVS

DES

kits

include

an oil

basic boiler assembly (oil and gas identical)
boiler jacket (oil and gas identical)
accessory kit (oil and gas identical)
burner (oil or gas, without post purge)

• DES parts (include
oil-fired burners)

_iiiiii_iii_i_iiiIHi_iiiiiijiiii_i_iiii_i1iii_i_iiiIiii_iiiiit_iiiiii_i_iiii_i_i_iii!iiI_i_!iiii!!iiii1iii

3 sections

•
•
•
•

burner

post purge oil burner for

Weatherproof
(outdoor) EV Series boilers are
furnished
as knockdown
boilers only and are
shipped

with

adjustable
post purge timer and solenoid valve.
For through the wall venting, this post purge burner
must be used in place of the standard burner that is
furnished with the boiler.

as five components

• basic boiler assembly (oil and gas identical)
• weatherproof
boiler jacket (oil and gas
identical)
• exhaust cap, pipe, and weather collar
and gas identical)
• accessory kit (oil and gas identical)
• burner (oil or gas)
On knockdown

Selection of boiler size should be based upon "Net
I=B+R Rating MBH being equal to or greater than
the calculated heat loss of the building.
These boilers are low pressure
sectional
cast
iron boilers constructed
and hydrostatically
tested
for a maximum
working
pressure
of 50 psi in
accordance
with A.S.M.E.
(American
Society of
Mechanical
Engineers)
Section IV Standards
for
cast iron heating boilers. They are capacity rated
in accordance
with the code of the Hydronics
Institute.
These boilers operate on #2 Heating Oil, Natural
Gas, or Propane Gas, with the proper burner.

as shown below:

oil burners,

is not included. Correctly
installed prior to startup.

(oil

the oil burner nozzle
sized nozzle

must be

Indoor oil-fired models DPFO (3, 4, 5, 3T, 4T,
5T) without direct exhaust system are available
as packaged boilers, in which case an oil burner
nozzle for one of three specified firing rates wilt
be factory installed in the oil burner.
Gas

boilers,

knockdown

or packaged,

may be

ordered to have their burners equipped for either
natural or propane gas with the proper flame
retention head and orifice to match the input
specified by the purchaser. However, a boiler
drawn from the stock of a wholesale distributor will
normally be equipped with a burner with a G-O
flame retention head and an orifice to fire natural
as in the minimum

input range of a G-O head.

• Read the installation
manual before beginning
the installation.
Failure to follow the rules for
safe operation and the instructions
can cause a
malfunction
of the boiler and result, serious bodily
injury, and/or property damage.
• Check your local codes and utility requirements
before installation.
The installation
must be in
accordance with their directives, or, in their absence,
follow NFPA Installation
Codes and good industry
practice.
• Before servicing, allow boiler to coot. Always shut
off any electricity and oil to boiler when working on
it. This will prevent any electrical shocks or burns.
• Inspect oil lines and connections

for leaks.

• Be certain oil burner nozzle or gas orifice is size
required. Over-firing
will result in early failure of
the boiler sections.
This will cause dangerous
operation.
• Never vent this boiler into an enclosed space.
Always 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
schedule for efficient and safe operation.
• Keep boiler area clean and free of combustible
material, gasoline,
and other flammable
vapors
and liquids.
• Proper
complete

through-the-walt
venting requires
DES (oil-fired units only).

use of

• Oil and gas burners are not do-it-yourself
items.
This boiler must be installed
and serviced
by
qualified
professionals
using
combustion
test
instruments.
• Be aware when piping the relief valve if the
system pressure exceeds the safe limit of 30 Ibs.
per square inch, the relief valve will automatically
open. Lifting of the relief valve can discharge large
quantities
of steam and hot water, which may
damage
the surroundings.
Before installing
the
relief valve, read the manufacturer's
instructions
and the maintenance
section of the manual on
relief valves.

• Frequent and mysterious lifting of the relief valve
may be a sign of an improperly
sized expansion
tank. Installation
and sizing of the expansion tank
must consider
the heating system's
total water
volume, temperature,
boiler initial fill pressure, and
system arrangement.
For proper installation
and
maintenance
follow the guidelines established
by
ECR and the manufacturer.
• Expansion tank performance
and life expectancy
can be hindered
by overfilling
the boiler. ECR
recommends
an initial fill pressure of 10 - 12 psig.
For higher fill pressures, the expansion
tank's air
charge will need to match the fill pressure. Consult
the manufacturer's
guidelines
for sizing
and
selection.
• Purging the heating system of air and gases
during the boiler's initial commissioning
is critical
for proper circulation and quiet performance.
Once
the air and gases are purged, for boiler installations
using float type vents, the air vents should be closed
for normal operation. If air is heard or noticed by a
loss of heat, purge the system and open the vents
for a short period of time.

iA c o ,o.
Ai

for any

electrical supply. Also, the boiler must be connected
to a suitable venting system and an adequate piping
system. Finally, a thermostat,
properly located, is
needed for control of the heating system. If you
have any doubts as to the various requirements,
check with local authorities and obtain professional
help where needed.
These installation instructions are vital to the proper
and safe operation of the heating system. Take the
time to be sure they are carefully followed.

lways keep the manual fuel supply valve shut I
if the burner is shut down for an extended
r
eriod of time.

NOT

DRAININGS

USE
OR

GASOLINE
ANY

OIL

CRANKCASE
CONTAINING

k..
GASOLINE"

of the burner nozzle

.40
.50
.60
.65
.75
.85
1.10
1.20
1.25
1.35
1.50
1.65
1.75
2.00

Check
before

to be sure you have the right size boiler
starting the installation.
See rating and

THE PUMP PRESSURE
OF THE STANDARD
BECKETT BURNER IS SET AT 140 PSI.

1.00

the

You must see that the boiler is supplied with the
proper fuel, fresh air for combustion, and a suitable

The output

This boiler has been designed for residential
installations. If used for commercial applications,
all jurisdictional
requirements
must be met. This
may require wiring and/or piping modifications.
The manufacturer
is not responsible
changes to the original design.

capacity tables on preceding
pages. Check
rating plate on the right side of the boiler.

2.25
2.50

will be 18% greater

.47
.59
.71
.77
.89
1.01
1.18
1.30
1.42
1.48
1.60
1.77
1.95
2.07
2.37
2.66
2.96

than rated.

FIG. 3 - GENERAL REQUIREMENTS

FOR ATYPICAL

INSTALLATION
k.....

FIG. 4 - RECOMMENDED

FIREPROOF BASE FOR INSTALLATION ON COMBUSTIBLE

2"2GASHBET METAL PAN
WTH I LIPAU.SiDES
(LIP NOT R_QU_R_D POR
GAS _NS_ALL#_I" ONS )

4" HOLLOW

C_
Source Exif Data:
File Type : PDF
File Type Extension : pdf
MIME Type : application/pdf
PDF Version : 1.2
Linearized : No
Page Count : 42
Page Layout : SinglePage
Page Mode : UseNone
Producer : Goby Monitor Application version 3, 2, 1, 4
Create Date : Fri Apr 20 15:43:44 2007
Author :
Title :
Subject :

EXIF Metadata provided by EXIF.tools

DUNKIRK Boiler Manual L0611475

Navigation menu

Versions of this User Manual:

Views

Navigation