DUNKIRK Boiler Manual L0612044

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

Open the PDF directly: View PDF .
Page Count: 24

STALLATION INST JCTION

These instructions must be affixed on or adjacent to the boiler

Continuous Pilot

G s-Fi d

These Gas-Fired Water Boilers are low pressure, sectional

cast iron boilers Designed Certified by C.S.A. (Canadian

Standards Association) for use with Natural and Propane

Gases. They are constructed and hydrostatically tested for a

maximum working pressure of 50 psi (pounds per square

inch) in accordance with A.S.M.E. (American Society of

Mechanical Engineers) Boiler and Pressure Vessel Code

Section IV Standards for cast iron heating boilers.

MODEL PWB

Electronic

intermittent ignition

Warning: Improper installation, adjustment, alteration, service or maintenance can cause injury or

property damage, Refer to this manual, For assistance or additional information consult a qualified

installer, service agency or the gas supplier

ASME

RELIEF VENT DAMPER

tll

! 11k"NPT \

DRAIN VALVE

roe

TEMPJPRESS. GAUGE

llh " SUPPLY

ROLLOUT GAS

SWITCH VALVE

11/4"RETURN

INT. PILOT CONTROL

LEFT SIDE FRONT RIGHT SIDE

GAS=FIRED HOT WATER BOILERS

AQUASTAT @

BASIC BOILER UNIT NO.

Electronic Ignition

With

Vent Damper

PWB-2D

PWB-3D

PWB-4D

PWB-5D

PWB-6D

PWB-7D

PWB-8D

PWB-9D

Continuous Pilot

With

Vent Damper

PVWB-2D

PVWB-3D

PVWB-4D

PVWB-5D

PVWB-6D

PVWB-7D

PVWB-8D

PVWB-gD

NO. OF

NATURAL AND PROPANE GAS

AGA/CGA HEATING NET I=B=R

CAPACITY

*MBH

RATING FLUE

*MBH DIAMETER

26 45

50 5

74 6

98 6

123 7

148 7

172 7

197 7

SECTIONS

INPUT

*MBH

37.5

113

142

170

198

226

105

140

175

210

245

28O

DIMENSIONS

(Inches)

IWAl!

WIDTH

11½

14½

17¾

241/4

27½

3O¾

* MBH =1,0O0 Btuh =British Thermal Unit Per Hour

Boilers are equipped for altitudes up to 2,000 feet only

U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level.

Canada Only - Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10% derate.

+ Heating Capacity based on D.O.E. (Department of Energy) test procedure. Add 5½" to height when vent damper is used.

2 section boilers are equipped with a 3" diameter flue collar on the draft diverter, and use a furnished 3" x 4" increaser fitting to install

the furnished 4" vent damper.

New York City MEA Number 39-86=E Vol. IV.

The Ratings marked "Net 1=B=R Ratings" indicate the amount

of remaining heat input that can be used to heat the radiation

or terminal units. The Net I=B=R Ratings shown are based on

an allowance of 1.15 in accordance with the factors shown on

the 1=B=R Standard as published by The Hydronics Institute.

Selection of boiler size should be based upon "Net I=B=R

Rating" being equal to or greater than the calculated heat loss

of the building.

The manufacturer should be consulted bet'orcselecting a boiler

for installations having unusual piping and pickup requirements.

These boilers must stand on a non-combustible floor. If in

stalled on a combustible floor, use Combustible Floor Base

Number 42135-1 or 146-14-031 (2-6 section boilers) or

42135-2 or 146-14-032 (7-9 section boilers).

BOILERS FOR USE AT HIGH ALTITUDE

This boiler is factory equipped for use at altitudes of 0-2,000

feet above sea level. For use at altitudes above 2,000 feet

above sea level, the input ratings are reduced by a change in

main burner orifice size.

U.S.A. Only - For altitudes above 2,000 feet above sea

level, input ratings should be reduced at the rate of 4% for

each 1,000 feet above sea level. Consult the National Fuel

Gas Code (NFPA54/ANSI Z223.1-1atest edition), or the

manufacturer for correct orifice sizing information. High

altitude orifices are available from the boiler manufacturer.

Canada Only - For altitudes in the range of 2,000-4,500

feet above sea level, boilers may be field equipped for use

at high altitude by using a certified field conversion kit. The

change in main burner orifice size results in the boiler's

input rating being reduced by 10%. The conversion shall

be carried out by a manufacturer's authorized

representative, in accordance with the requirements of the

manufacturer, provincial or territorial authorities having

jurisdiction and in accordance with the requirements of the

CSA-B149.1 and CSA-B149.2 Installation Codes. The

certified field conversion kit includes a conversion data

plate, which must be attached to the boiler adjacent to the

rating plate, indicating that the boiler has been converted

for high altitude use. The conversion data plate must be

filled in with the correct conversion information.

Check to be sure you have the right size boiler before starting

the installation. _ See rating and capacity table on previous

page. Also be sure the new boiler is or the type of gas you are

using. Check the rating plate on the right side of the boiler.

You must see that the boiler is supplied with the correct type

of gas, fresh air for combustion, and a suitable 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.

Take the time to complete all of the steps for SAFE and

PROPER operation of the heating system.

If this boiler is installed in a building under construction,

special care must be taken to insure a clean combustion

air supply during the construction process. Airborne

particulates such as from drywall dust and from fiberglass

insulation can clog the burner ports and cause incomplete

combustion and sooting.

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.

The installation must conform to the requirements of the

authority having jurisdiction or, in the absence of such

requirements, to the National Fuel Gas Code, ANSI Z223.1-

latest revision.

In Canada, the boiler shall be installed according to CSA-

13149.1 and .2, Installation Code for Gas Burning

Appliances and Equipment.

Installers - Follow local regulations with respect to

installation of CO detectors. Follow maintenance

recommendations in this instruction manual.

Techniciens Veuillez vous conformer a la

reglementation en vigueur concernant I' installation des

d_tecteurs d'oxyde de carbone. Suivre les consignes

d'entretien figurant dans le manuel dinstruction ci-joint.

GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS

1. Select level location as centralized with piping system, and

as near chimney, as possible.

2. Place crated boiler at selected location, remove crate

by pulling crate sides from top and bottom boards.

Combustible floors: When boiler is to be installed on a

combustible floor, a Special Base Plate must be used -

146-14-031 (2-6 Section) or 146-14-032 (7-9 Section).

This boiler must not be installed on carpeting.

3. Boiler is to be level. Metal shims may be used under

base legs for final leveling.

4. Additional clearances for service may exceed clearances

for fire protection. Always comply with the minimum fire

protection clearances shown on the boiler. An 18 inch

clearance should be maintained on any side where

passage is required to access another side for cleaning,

servicing, inspection or replacement of any part that may

need attention. An 18-inch clearance is recommended

on the control side for servicing.

Figure 2 shows minimum clearances to combustible

construction. Rooms that are large in comparison with

the size of the boiler are defined as rooms having a

volume equal to or greater than 16 times the volume of

the boiler. Where the actual ceiling height of a room is

greater that 8', the volume of a room shall be figured on

the basis of a ceiling height of 8'. Determination of room

size should be based do the total volume of all gas fired

equipment installed in the room. Consult section 6.3.1

of the National Fuel Gas Code for further information,

including approved methods for reducing clearances in

large rooms.

5. Equipment shall be installed in a location in which the

facilities for ventilation permit satisfactory combustion

of gas, proper venting, and maintenance of ambient

temperature at safe limits under normal conditions of use.

Equipment shall be located so as not to interfere with

proper circulation of air. When normal infiltration does

not provide the necessary air, outside air shall be

introduced (See Page 4 - "Fresh Air for Combustion").

6. Advise owner to keep air passages free of obstructions.

Ventilating and combustion air must enter boiler room

without restrictions.

7. 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.).

Alcove, or Room Not Room Large In

Large in Comparison Comparison

With Boiler With Boiler

2-5 SECT. 6-9 SECT. 2-9 SECT.

Top 6" 6" 6"

Rear 6" 6" 6"

Control Side 8" 24" 6"

Opposite Side 6" 24" 6"

Front 18" 18" 18"

Flue/Vent Connector 6" 6" 6"

Near Boiler Piping 1" 1" 1"

Boiler

Size

2 sect.

3 sect.

4 sect.

5 sect.

6 sect.

7 sect.

8 sect.

9 sect.

Boiler

Volume

(Cu. Ft.)

3.8

5.4

7.0

8.5

10.1

11.7

13.2

14.8

Minimum Room

Volume Required

To Be Large

Room (Cu. Ft)*

61.6

86.6

111.6

136.6

161.7

186.7

211.7

236.7

FOR ROOM WITH SINGLE BOILER ONLY THIS UNIT MUST

BE SET ON A CONCRETE OR OTHER NON-COMBUSTIBLE

MATERIAL BASE OR FLOOR.

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 Z223.14atest revision, or applicable provisions of the local building codes.

WARNING

Be sure to provide enough fresh air for combustion. Enough

air insures proper combustion and assures that no hazard

will develop due to the lack of oxygen.

Youmust providefor enoughfreshairto assurepropercombustion.The

fire inthe boilerusesoxygen.Itmusthavea continuoussupply.Theair in

a house containsonly enoughoxygen to supplythe burnerfor a short

time.Outsideairmustenterthe houseto replacethatusedby the burner.

_udy followingexamples1and2 todetermineyourfreshairrequirements.

EXAMPLE1: BoilerLocatedinUnconfinedSpace

An unconfined space is defined as a space whose volume isnot less

than 50 cubic feet per 1,000 Btu per hour of the total input rating of all

appliances installed inthat space.

If your boiler is in an open area (unpartitioned basement) in a

conventionalhouse,the air that leaksthroughthe cracksarounddoors

and windows will usually be adequate to provide air for combustion.

The doors should not fit tightly. Do not caulk the cracks around the

windows.

Equipmentlocated in buildings of unusuallytight construction shall be

provided with air for combustion,ventilation, and dilution of flue gases

using the methods described in example 2B or shall be specially

engineered. The authority having jurisdiction must approve specially

engineeredinstallations.

EXAMPLE 2: Boiler Located in ConfinedSpace

A. All Air from Inside the Building: The confined space shall be

providedwith two permanentopeningscommunicatingdirectlywith

an additional room(s) of sufficient volume so that the combined

volume of all spaces meets the criteria for an unconfined space.

The total input of all gas utilization equipment installed in the

combined spaceshall beconsidered in makingthis determination.

Each opening shall have a minimum free area of one square inch

per 1,000 Btu per hour of the total input rating of all gas utilization

equipment in the confined space, but not less that 100 square

inches. One opening shall be within 12 inchesof the top and one

within 12 inches of the bottom of the enclosure. The minimum

dimension of air openings shall not be less than 3 inches.

B. All Air from Outdoors: The confined space shall communicate

with the outdoorsinaccordance with methods 1or2. The minimum

dimension of air openings shall not be less than 3 in. Where ducts

are used, they shall be of the same cross-sectional area as the

free area of the openings to which they connect.

1. Twopermanent openings,one commencing within 12inches of

the top. and one commencing within 12 inches of the bottom,

of the enclosure shall be provided. The openings shall

communicate directly, or by the ducts, with the outdoors or

spaces(crawlor attic)thatfreelycommunicatewiththe outdoors.

a) Where directly communicating with the outdoors or where

communicating to the outdoors through vertical ducts, each

opening shall have a minimum free area of 1 sq. in. per 4000

Btu perhouroftotal inputratingof allequipmentinthe enclosure.

(See Figure 3B)

b) Wherecommunicatingwiththe outdoorsthrough horizontalducts.

each opening shall have a minimum free area of I sq. in. per

2000 Btu per hour of total input rating of all equipment in the

enclosure.(See Figure 38.)

NOTE

If you use a fireplace or a kitchen or bathroom exhaust fan,

you should install an outside air intake. These devices will

rob the boiler and water heater of combustion air.

2. One permanent opening commencing with 12 inches of

the top of the enclosure, shall be permitted where the

equipment has clearance of at least 1 inch from the sides

and back and 6 inches from the front of the appliance. The

opening shall directly communicate with the outdoors or

shall communicate through a vertical or horizontal duct to

the outdoors or spaces (crawl or attic) that freely

communicate with the outdoor, and shall have a minimun

free area of:

a) 1 sq. inch per 3000 Btu per hour of the tatal input of all

equipment located in the enclosure ( See Figure 4), and

b) Not less than the sum of the areas of all vent connectors

in theconfined space.

1 Square Inch per 4,000 Btuh

100% Free 75% Free 25% Free

Area Area Area

Fresh Air ¼" Wire Metal Wood

Duct Size Mesh Louvers Louvers

3" x 12" 144,000 108,000 36,000

8"x 8" 256,000 192,000 64,000

8" 12" 384,000 288,000 96,000

8½" x 16" 512,000 384,000 128,000

Square Inch _er2,000 Btuh

100% Free 75% Free 25% Free

Area Area Area

Fresh Air ¼" Wire Metal Wood

Duct Size Mesh Louvers Louvers

3" x 12" 72,000 54,000 18,000

8" x 8" 128,000 96,000 32,000

8" 12" 192,000 144,000 48,000

8½" x 16" 256,000 192,000 64,000

Square Inch _er3,000 Btuh

100% Free 75% Free 25% Free

Area Area Area

Fresh Air ¼" Wire Metal Wood

Duct Size Mesh Louvers Louvers

3" x 12" 108,000 81,000 27,000

8" x 8" 192,000 144,000 48,000

8" 12" 288,000 216,000 72,000

8½" x 16" 384,000 288,000 96,000

1.Placeboilerin theselectedlocation(asnearchimneyas

possible.)Yourboilerisshippedassembled.Youneedonly

toinstalltheReliefValveandadrainlinetocarryanywater

orsteamtoa drain.

2.InstallReliefValveintothe3/4"pipeonthetopoftheboiler.

SeeFigure5.Use3/4"Pipeandanelbow(notfurnished)to

carrythewaterorsteamtoa nearbydrain.Donotconnect

directlyto a drainbutleavean airgap.Noshutoffof any

descriptionshallbeplacedbetweenthesafetyreliefvalve

andtheboiler,orondischargepipesbetweensuchsafety

valvesandtheatmosphere.Installationof thesafetyrelief

valveshallconformtotherequirementsoftheANSI/ASME

Boiler and PressureVessel Code, Section IV. The

manufacturerisnotresponsibleforanywaterdamage.Install

DrainValveinlowerleftsideofboilerasmarked.

3.ConnectSupplyandReturnLinestoboiler.Theconnections

mayrequirecertainadditionalfittingsandparts,asshown

ondiagram(Figs.5and6).

4. This boileris equippedwith 11/4"supplyand return

connectionsonboththeleftandrightsidesoftheboiler.

In connectingthecoldwatersupplyto thewaterinletvalve,

makesurethata cleanwatersupplyis available.Whenthe

watersupplyisfromawellorpump,asandstrainershouldbe

installedatthepump.

A hotwaterboilerinstalledaboveradiationlevelmustbe

equippedwitha lowwatercutoffdevice.A periodicinspection

is necessary,as is flushingof float type devices, per

manufacturersspecificinstruction.

FOR USE WITH COOLING UNITS

A. This boiler, when used in connection with chilled water

systems, must be installed so that the chilled water is piped

in parallel with the heating boiler. Appropriate valves must

be used to prevent the chilled water from entering the heating

boiler (Fig. 6).

B. When this boiler is connected to heating coils located in air

handling units where they may be exposed to refrigerated

air circulation, the 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.

LOW DESIGN WATER TEMPERATURE

SYSTEMS (BELOW 140 °)

If the boiler is to be used in a heating system where design

water temperatures below 140° F are desired (e.g. radiant floor

heating), a 3-way or 4-way mixing valve or suitable alternative

is required to prevent low temperature return water from

entering the boiler. Follow the mixing valve manufacturer's

installation instructions.

The minimum design return water temperature to the boiler to

prevent condensation in the boiler and venting is 120° F. The

minimum high limit setting is 140° F.

CAUTION

THE ISOLATION BALL VALVES CONTAIN TEFLON

SEATS AND SEALS, OVERHEATING THIS VALVE MAY

CAUSE PREMATURE FAILURE.

TO SYSTEM

_/ALVES A 8_ S

OPEN FOR HEATINGj

CLOSE FOR COOLING

_/ALVES C 8_ D

CLOSE -OR HEATINGj

OPEN FOR COOLING

WATER

CHILLER

Z223.1=latest revision and applicable provisions of the local building codes.

CHECK YOUR CHIMNEY

This is a very important part of your heating system. It must be

clean, the right size, properly constructed and in GOOD

CONDITION. No boiler can function properly with a bad

chimney. Fig. 7 gives typical chimney sizes. Fig. 8 gives you

an idea how a boiler might be vented to a chimney. Note that

the height (HT) is measured from the vent pipe to the top.

CHIMNEY SIZING

Chimney sizing, and all other aspects of the vent installation

must be in accordance with Part 7 of the National Fuel Gas

Code, ANSI Z223.1 latest revision, and applicable provisions

of the local building codes.

In Canada, follow CAN/CGA B149.1 and B149.2, Installation

Codes for Gas Burning Appliances and Equipment.

CONNECTING THE VENT DAMPER AND VENT

CONNECTOR

Refer to Fig. 1 flue diagram for the size and location of the vent

(flue opening). Use a 28 gauge (minimum) galvanized pipe to

connect to the chimney.

IMPORTANT - The damper blade on the furnished vent damper

has a 1/2 square inch hole (approximately3/4 diameter). On

boilers equipped with standing pilot, the hole must be left open.

On boilers equipped with intermittent ignition, the hole should

be plugged by using the plug supplied with the vent damper.

1. Position furnished vent damper on top of flue outlet collar.

Fasten damper securely to flue outlet collar with sheet

metal screws. Make sure damper blade has clearance to

operate inside of diverter.

On 2 section boilers equipped with vent damper, the

supplied 4-inch vent damper is equipped with a 3- to 4-

inch adapter so that the 4-inch vent damper may be

installed on the boiler's 3-inch flue outlet collar. Fasten all

fittings securely.

As An Option (U.S.A. Only)

The damper may be installed in any horizontal or vertical

position, closer to the flue outlet collar preferred. Follow

the diagrams - Figures 9, 10 and 11.

2. Install the vent damper to service only the single boiler for

which it is intended. The damper position indicator shall

be in a visible location following installation. Locate the

damper so that it is accessible for servicing.

3. The damper must be in the open position when appliance

main burners are operating.

4. The boiler is equipped with a factory wired harness that

plugs into the vent damper.

5. Vent pipe must be same size as the flue outlet collar, except

2 section boilers with vent damper as noted above.

6. Slope pipe up from boilerto chimney not less than 1/4" perfoot.

7. Run pipe as directly as possible with as few elbows as

possible.

8. Do not connect to fireplace flue.

9. End of vent pipe must be flush with inside face of chimney

flue. Use a sealed-in thimble for the chimney connection.

10. Horizontal run should not be longer than s/4 the

chimney height (HT) (Fig, 8).

The sections of vent pipe should be fastened with sheet metal

screws to make the piping rigid. Horizontal portions of the vent

system must be supported to prevent sagging. Use stovepipe

wires every 5' to support the pipe from above If the vent pipe

must go through a crawl space, double wall vent pipe should

be used Where vent pipe passes through a combustible wall

or partition, use a ventilated metal thimble. The thimble should

be 4 inches larger in diameter than the vent pipe.

Boiler Input

Btuh

Up to 100,000

Up to 155,000

Up to 230,000

Up to 350,000

FLUE AREA IN INCHES

*HT.

10-15 Ft.

6x6

6x7

7x8

9x9

*HT. *HT.

10-25Ft. 25Ft. UP

6x5 5x5

6x6 6x5

7x7 6x7

8x9 8x8

HT = top of thimble to top of flue. See Fig. 8

For boiler input refer to table, page 2.

For information only - not meant to imply minimum sizes.

MiNiMUM VENT PiPE CLEARANCE

Wood and other combustible materials must not be closer than

6" from any surface of single wall metal vent pipe. Listed Type

B vent pipe or other listed venting systems shall be installed in

accordance with their listing.

REMOVING EXiSTiNG BOILER FROM

COMMON VENTING SYSTEM

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 to the common venting system

are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion and other deficiencies which

could cause an unsafe condition.

3.Insofarasispractical,closeallbuildingdoorsandwindows

andalldoorsbetweenthespaceinwhichtheappliances

remainingconnectedtothecommonventingsystemare

locatedandotherspacesofthebuilding.Turnonclothes

dryersandanyappliancenotconnectedto thecommon

ventingsystem.Turnonanyexhaustfans,suchasrange

hoodsand bathroomexhausts,so theywilloperateat

maximumspeed.Donotoperatea summerexhaustfan.

Closefireplacedampers.

4. Placeinoperationtheappliancebeinginspected.Follow

thelightinginstructions.Adjustthermostatsoappliance

willoperatecontinuously.

5. Testfor spillageat thedrafthoodreliefopeningafter5

minutesofmainburneroperation.Usetheflameofamatch

orcandle,orsmokefromacigarette,cigarorpipe.

6.Afterit hasbeendeterminedthateachapplianceremain-

ing connectedto thecommonventingsystemproperly

ventswhentestedasoutlinedabove,returndoorswindows,

exhaustfans,fireplacedampersandanyothergas-burning

appliancetotheirpreviousconditionsof use.

7.Anyimproperoperationof thecommonventingsystem

shouldbecorrectedsotheinstallationconformswiththe

NationalFuelGasCode,ANSIZ223.1-1atestrevision.

Whenresizinganyportionofthecommonventingsystem,

thecommonventingsystemshouldberesizedtoapproach

theminimumsizeasdeterminedusingthe appropriate

tablesin Part11in theNationalFuelGasCode,ANSI

Z223.l-latestrevision.

\MU£T SLOPE UP AT LEAST

£/4 !qCU PER FLIBT

Vent connectors serving appliances vented by natural draft

shall not be connected into any portion of mechanical draft

systems operating under positive pressure.

FLB%"

TO FUF,_L_CE [_

OR _OILER

ACTUATOR NAY BE

34_TALL[_ IN _NY F_ZT_N

CAUT[BNE DD NOT [NSTALL NO

THE VENT DAMPER

WITHIN 6 hq, <[52 ram) OF %

CBMBUSTA_LE MATERIAL

CHIMNEY

_01LER

V'ERTICAL INSTALLATION

INS_#_L lYE}IT DANPE_ _TH

_CTU_TORTO _]_ OF VZNT

DNLY, D0 NOT _[]UNT A_O_/E

OR DELO'_ VENT,

TO FI_N&CE

OR E_LER _/ENT ]_4F_'F3_ _o OI[NNE(

HORIZONTAL INSTALLATION

TYPICAL iNSTALLATiON FOR VENT DAMPER

NOT CAUTION AND FOOTNOTES

1. Install the vent damper to service only the single

appliance for which it is intended. If improperly

installed, a hazardous condition, such as an explosion

or carbon monoxide poisoning, could result.

2. Do not install the vent damper on pipe curve.

3. Do not run wires near high temperature surfaces. Use

stand-off brackets if necessary.

For safe, efficient operation, the vent damper and all flue product

carrying areas of the appliance must be checked annually by

you, with particular attention given to deterioration from

corrosion or other sources. If you see corrosion or other

deterioration, contact yourheating contractorfor repairs. Check

vent damper operation as follows:

1. When the boiler is off, check that the vent damper positions

indicator points to the closed position, Fig. 11.

2. Turn the thermostat or controller up to call for heat and

check the vent damper indicator points to the open

position, Fig. 11.

3. Turn the thermostat or controller down again and check

that the damper position indicator returns to the closed

position.

MANUAL OPERATION OF THE VENT DAMPER

The vent damper may be placed in the open position to permit

burner operation by using the "HOLD DAMPER OPEN" switch,

located on the damper controller. The thermostat will control

the burner firing as before, while the damper will remain open.

DO NOT turn damper open manually or motor damage will

result. Set switch to "AUTOMATIC OPERATION" to close vent

damper during burner off cycle.

For further information, and for a vent damper troubleshooting

guide, refer to the manual that was packaged with the vent

damper.

The vent damper must be inspected at least once a year

by a trained, experienced service technician. The name of

the person who originally installed your vent damper is

shown on the installation label.

DANPER CLOSFD _AHPER OPEN

SHOWING OPEN AN_ CLBSEB POS[TION

NOTES FOR CANADA ONLY

1. Canadian Standard CAN1-2.28-M81 prohibits the use of

vent dampers on propane fired appliances equipped with

intermittent ignition.

2. In Canada, the vent damper must be attached directly to

the flue outlet collar, with the exception of the 2 section

boiler, where the 3- to 4-inch adapter is supplied with the

vent damper.

No other interconnectng pieces are allowed between the

boiler and the vent damper.

In Canada, vent dampers are not an option. Boilers are

either factory built for use with a vent damper and the vent

damper is supplied with the boiler, or they are factory built

for use without a vent damper. In the second case a vent

damper cannot be installed later.

CHECK GAS SUPPLY

The gas pipe to your boiler must be the correct size for the

length of the run and for the total Btu per hour input of all gas

utilization equipment connected to it. See Fig. 12 for the proper

size. Be sure your gas line complies with local codes and gas

company requirements.

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 pres-

sure testing of the gas supply piping system at test pressures

equal to or less than 1/2 psig (3.5 kPa).

CONNECTING THE GAS PiPiNG

Refer to Fig. 13 for the general layout at the boiler. It shows

the basic fittings you will need. The gas line enters the boiler

from the right side.

The following rules apply:

1. Use only those piping materials and joining methods listed

as acceptable by the authority having jurisdiction, or in

the absence of such requirements, by the National Fuel

Gas Code, ANSI 223.I-latest revision. In Canada, follow

the CAN/CGA B149.1 and .2 Installation Codes for Gas

Burning Appliances and Equipment.

2. Use pipe joint compound suitable for LP gas on male

threads only.

3. Use ground joint unions.

4. Install a sediment trap upstream of gas controls.

5. Use two pipe wrenches when making the connection to

the gas valve to keep it from turning.

6. Install a manual shut-off valve in vertical pipe about 5

feet above floor.

7. Tighten all joints securely.

8. Propane gas connections should only be made by a

licensed propane installer.

9. Two-stage regulation should be used by the propane

installer.

10. Propane gas piping should be checked out by the

propane installer.

CHECKING THE GAS PiPiNG

Upon completion of piping, check immediately for gas leaks.

Open the manual shut-off valve. Test for leaks by applying soap

suds (or a liquid detergent) to each joint. Bubbles forming indicate

a leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE.

NATURAL GAS

Pipe Capacity - Btu Per Hour Input

Length of Includes Fittings

Pipe - Ft. 1/2" 3/4" 1" 1¼"

20 92,000 190,000 350,000 625,000

40 63,000 130,000 245,000 445,000

60 50,000 105,000 195,000 365,000

PROPANE GAS

Pipe Capacity - Btu Per Hour Input

Length of Includes Fittings

Pipe - Ft. Copper Tubing* Iron Pipe

5/8" 3/4" 1/2" 3/4"

20 131,000 216,000 189,000 393,000

40 90,000 145,000 129,000 267,000

60 72,000 121,000 103,000 217,000

* Outside diameter

The lenght of pipe or tubing should be measured from the gas

meter or propane second stage regulator.

AUTOHATIC

GA3

VALVE_

\\\x

MANIFOLD

f- f -_

J _ J

FLOOR LINE

All electrical work must conform to local codes as well as the

National Electrical Code, ANSI/NFPA-70, latest revision. In

Canada, electrical wiring shall comply with the Canadian Elec-

trical Codes, CSA-C22.1 and.2.

ELECTRIC POWER SUPPLY

Run a separate 120 Volt circuit from a separate overcurrent

protective device in the electrical service entrance panel.

This should be a 15 ampere circuit. Locate a shut-off switch

at the boiler. It must be turned offduring any maintenance.

Connect 120 Volt power supply to aquastat terminals L1

(HOT) and L2.

The boiler, when installed, must be electrically grounded in

accordance with the requirements of the authority having ju-

risdiction or, in the absence of such requirements, with the

National Electrical Code, ANSI/NFPA No. 70-latest revision.

Run a 14 gauge or heavier copper wire from the boiler to a

grounded connection in the service panel or a properly driven

and electrically grounded ground rod.

WARNING

Turn off electric power at fuse box before making any line

voltage connections. Follow local electrical codes.

INSTALL YOUR THERMOSTAT

The thermostat location has an important effect on the operation

of your boiler system. BE SURE TO FOLLOW THE

INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT.

a vertically mounted outlet box. It should be sensing average

room temperature, so avoid the following:

DEAD SPOTS:

Behind doors

Corners and alcoves

HOT SPOTS:

Concealed pipes

Fireplace

TV sets

Radios

Lamps

Direct sunlight

Kitchens

COLD SPOTS:

Concealed pipes or ducts

Stairwells - drafts

Doors - drafts

Unheated rooms on other side of wall

Set heat anticipator at .2 amps. 24 Volt thermostat connects

to aquastat terminals T and TV.

VENT DAMPER WIRING

The boiler is equipped with a factory wired harness with 4 pin

molex plug, that plugs into a 4 pin molex receptacle inside the

vent damper operator.

The vent damper must be connected for the boiler to

operate.

Wiring diagrams follow for the various different models.

Locate the thermostat about five feet above the floor on an

inside wall. It may be mounted directly on the wall or on CAUTION

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous

operation. Verify proper operation after servicing.

The pump does not come pre-installed on the boiler. It must

be connected to the circulator harness in the field according to

the pump manufacturer's instructions and the wiring diagrams

in this manual.

INTERMITTENT IGNITION

RE _ D E

I)tl I ER I:,:B[ E

I I ' :,

--L I _ISL : E I

[',', ',, )[ A, [

I :'_,, ', I T Aq E

I I ,I IJ

_[ I _ I £ I'I J 17

£I:S t I T ST

i/'!i ',m

r ,,i,,' ! ,

i:'! i

,I I,

i i i

=il i

!_E_ ¸ s_, o,F _

i¸ _:_, ' I

ic} i

i1< I ,<

t_ L_

:t I

,i: if J

iJ][,kl i] _:1 :bit:

! ' ,_ ,v i - o_5 vALVE

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR ITS EQUIVALENT.

NOTE: THE CIRCULATOR HARNESS IS FACTORY WIRED TO THE AQUASTAT. THIS HARNESS

NEEDS TO BE CONNECTED TO THE CIRCULATOR IN THE FIELD.

STANDING PILOT

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR ITS EQUIVALENT.

NOTE: THE CIRCULATOR HARNESS IS FACTORY WIRED TO THE AQUASTAT. THIS HARNESS

NEEDS TO BE CONNECTED TO THE CIRCULATOR IN THE FIELD.

RELIEF VALVE

You must have a relief valve on your boiler. Water expands as

it is heated. If there is no place for the water to expand into,

water pressurewilJbuild up inside the boiler and system. Should

this happen, the relief valve will automaticalJy open at a

predetermined pressure. This will relieve the strain on the boiler

and system. Run a pipe from the relief valve outlet (pipe must

be same size as outlet and the open end must not be threaded)

to an open drain, tub or sink, or other suitable drainage point

not subject to freezing. Failure to do so may cause water

damage or injury should relief valve release.

EXPANSION TANK

In a properly assembled system, the expanding water flows

into a expansion tank. This tank should be of the correct size.

The tank is filled with air. As the water expands it compresses

the air in the tank to form an air pressure cushion. This "spring-

like" cushion serves to maintain correct operating water

pressure regardless of water temperature. This assures a "full

measure" of a water, even in the highest radiation unit of the

system. It also prevents blowing off of the relief valve.

The air in the tank in the beginning (with system filled with cold

water) is sufficient for proper operation. The tank also serves

as a trap for excess air in the system. The air would cause

gurgling in the pipes and inefficient circulation in the radiators

if left in the system .It is possible for a tank to become

"waterlogged" (filled with water). It can also become overfilled

with air. This can happen after filling the system with new water.

Fittings provided on the tank and in the line to the tank are for

bleeding off excess water or air.

When installing this tank, it is important:

1) That the tank be higher than the boiler top.

2) That the pipe to the tank continuously rises up to the tank

(so that air can "bubble" up to it).

DIAPHRAGM TYPE EXPANSION TANK

The diaphragm type expansion tank (EX-TROL) takes the place

of the conventional expansion tank. Carefully read the

instructions packed with your EX-TROL tank assembly.

The EX-TROL tank comes to you with a 10-12 pounds per square

inch air charge. This is the same as the pressure produced in

the system by the automatic fill valve. When the system is first

filled, the EX TROL tank will contain little or no water.

As the water is heated its pressure increases. It expands into

the EX-TROL tank, compressing the air in the tank. This

compressed air cushion permits the water in the system to

expand as the temperature changes.

The diaphragm type tank can be mounted on the air purger

fitting or at any convenient place in the supply or return line.

AIR ELIMINATING FITTING (AIR PURGER)

An air purger is used to remove excess air from the system. It

is installed in the supply line. It will eliminate air from the water

before it reaches the radiators and bleed off this air.

MAiN AiR VENT FOR DOWN FLOW SYSTEMS

OR DIAPHRAGM TYPE EXPANSION TANK

Before a system is filled with water, there is air in the pipes and

radiation units. Some of it will be trapped as the system is filled.

It is possible to eliminate most of this air through the air vents

on the radiation units. A main air vent will speed and simplify

this. It should be installed on the highest point in the supply

main when all radiation is below top of boiler.

AUTOMATIC FILL VALVE

For safe, efficient operation, a hot water system must be

completely filled with water. Adding new water, when needed

can be done manually (by use of a hand valve in the water

supply line). This requires regular attention to the system's

needs. An automatic fill valve accomplishes this without

attention. It is installed in the supply line on hot water boilers

only. The valve operates through water pressure differentials.

It does not require an electrical connection.

DRAIN VALVE

This manual valve Provides a means of draining all water from

the boiler and system. It is often installed in the 3/4" tapping at

the bottom of the end boiler section. Or it can be installed in a

tee where the return line enters the boiler.

WATER TEMPERATURE CONTROL

The water temperature limit control in the relay is adjustable

and may be set as necessary. It may be set as low as 140°F,

or as high as 240°F. This depends on the type and amount of

radiation involved and weather conditions.

CIRCULATING PUMP

Every forced hot-water system requires a circulating pump. A

separate pump or zone valve is required for each zone, if you

have a two or more zone system. This pump must have the

capacity to provide the circulation required by your system.

VENT DAMPER

This product is an automatic, motorized stack damper that has

been developed to increase the efficiency of heating system

by reducing standby losses from the heating apparatus and

the conditioned air space. The damper closes the chimney

vent when the burner is off and fully opens it when combustion

is required.

ROLLOUT SWITCH

(FLAME ROLLOUT SAFETY SHUTOFF)

The rollout switch is a temperature-sensitive fuse link device.

It is located on the boiler base just outside the fire box. In the

event of heat exchanger flueway blockage causing flame to

roll out of the fire box, the fuse will blow, shutting clown the flow

of gas to the main burners. The fuse does not change in

appearance when blown.

If the rollout switch blows, it must be replaced with an exact

replacement. Check heat exchanger flueways for blockage

when restoring system to operating condition. DO NOT operate

system without a rollout switch.

SPILL SWITCH

(BLOCKED VENT SAFETY SHUTOFF)

The spill switch isa manual reset discthermostat with a fixed setpoint

(340°F), and normally closed contacts. It is located at the relief

opening of the integral draft diverter. In the event of chimney or

venting system blockage causing products of combustion to spill

out of the relief opening, the spill switch disc heats up and the spill

switch contacts open, shutting down the flow of gas to the main

burners by removing power to the gas valve.

In the event that the spill switch contacts open, the reset button

on the back of the switch will pop up. The spill switch must be

reset manually, after the switch has cooled off, by pushing the

reset button down. Check the venting system and chimney for

blockage when restoring the system to operating condition. DO

NOT operate the boiler without a spill switch.

HOW AHOT-WATER SYSTEM OPERATES

Your entire heating system (boiler, piping and radiation units)is

filled with water. As the water in the boiler is heated, it is pumped

from the top of the boiler through the supply main to the radia-

tion units. The cooler water in them flows back through the re-

turn main to the boiler. This provides positive and rapid response

to the thermostat.

FILLING SYSTEM WITH WATER

Close the air vents on all radiation units. Open the valves to

these units. Make sure the boiler and expansion tank drain

cocks are closed. The air bleed screw on the tank drain fitting

should be closed. Open the valve in the line from the boiler to

the expansion tank. Open the water inlet to your boiler and

leave it open. Start with the lowest radiation unit. Open the air

vent on this unit. When all the air has escaped and water starts

to flow from the vent, close it. Go to the next radiation unit, and

repeat this process. Repeat until you have covered every

radiation unit in the system (ending up at the highest unit in the

system). If your units have automatic vents, this manual venting

is unnecessary but it will speed up the proper filling of your

system.

If your system is a closed expansion tank system, you may

leave it open to refill the system automatically as needed. Check

the temperature pressure gauge. Not the position of the hand

indicating pressure. This should be between 10 and 15 Ibs.

Any lowering of this movable hand below 10 Ibs. Will indicate

loss of water due to leakage. The automatic fill valve should

compensate for this. Instructions are packages with the valve.

WARNING

Never run water into a hot empty boiler.

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

A. Some boilers are equipped with an intermittent ignition

device which automatically lights the pilot. Do not try to

light the pilot by hand.

Some boilers are equipped with a continuous pilot and must

be manually lighted. (See operating instructions on page

16-18.) A match holder is included in the parts bag.

B. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell next to the floor because

some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone

in your building.

* Immediately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire

department.

Use only your hand to push in or turn the gas control knob.

Never use tools. If the knob will not push in or turn by hand,

don't try to repair it, call a qualified service technician. Force

or attempted repair may result in a fire or explosion.

Do not use this appliance if any part has been underwater.

Immediately call a qualified service technician to inspect

the appliance and to replace any part of the control system

and any gas control which has been under water.

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to

light the pilot by hand.

7. Wait five (5) minutes to clear out any gas. Then smell for

gas, including near the floor. If you smell gas, STOP! Follow

"B" in the safety information on page 19 If you don't smell

gas, go to next step.

8. Rotate the gas control knob counterclockwise

to "ON."

9. Replace lower front panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions "To

Turn Off Gas To Appliance" and call your service technician

or gas supplier.

[NLE i I_

GAS CiqNTRDL KNDB

SHOWN IN "E]N" PDS_TIDN

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to

be performed.

3. Push in gas control knob slightly and turn clockwise_

to "OFF" Do not force.

5. Remove lower front panel.

6. Rotate the gas control knob clockwise,,_

to"OFF"

1.STOP!Readthesafetyinformationonpage16.

2.Setthethermostattolowestsetting.

3.Turnoffallelectricpowertotheappliance.

4. Removelowerfrontpanel.

5.Rotategascontrolknobslightlyandturnclockwise

to"OFF"

GAS --_ _J!]!

INLET

--GAS CONTROL KNOB

SHOWN IN "Oil_ POSZT[DN

6. Wait five (5) minutes to clear out any gas. Then smell for

gas, including near the floor. If you smell gas, STOP! Follow

"B" in the safety information on page 19 If you don't smell

gas, go to next step.

7. Find pilot - follow metal tube from gas control. The pilot is

between two burner tubes as shown in Fig. 14 on page 18.

8. Turn knob on gas control counterclockwise to f"_--,

"PILOT"

9. Rotate the gas control knob counterclockwise

to "PILOT" Push down and hold the red reset button while

you light pilot burner with a match.

After about one minute, release reset button. Pilot should

remain lit. If it goes out, turn gas control knob clockwise

to OFF To relight, repeat steps 5-9.

• If button does not pop up when released, stop and

immediately call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the gas

control knob to "OFF" and call your service technician or

gas supplier.

10. After pilot remains lit when red reset button is released,

turn gas control knob counterclockwise to "ON."

11. Replace lower front panel.

12. Turn on all electric power to the appliance.

13. Set thermostat to desired setting.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to

be performed.

3. Push in gas control knob slightly and turn clockwise

to "OFF" Do not force.

AUTOMATIC GAS VALVE

The Automatic Gas Valve opens or closes according to the

heat requirements of the thermostat and temperature limit

control. It closes if the pilot goes out. Each individual control

must be operating correctly before any gas can pass to the

burners. Any one control can hold the gas supply from burner

regardless of the demand of any other control.

SAFETY PILOT

Safety Pilot prevents the flow of gas to burner if the pilot goes

out, or will not ignite.

GAS VALVE SAFETY SHUTDOWN TEST

1. For boilers equipped with continuous pilot, with main burners

firing, disconnect the thermocouple from the gas valve. The

gas valve should immediately shut off the main burners and

the pilot.

2. For boilers equipped with intermittent ignition, with main

burners firing, disconnect the ignition cable from the

intermittent pilot control box. The gas valve should shut off

the main burners.

TURN OFF ELECTRIC POWER to boiler before

reconnecting ignition cable, to prevent electric shock.

RELIGHT

The electric and gas shall be offfor 5 minutes before relighting.

THERMOSTAT

Keep it set at a desired room temperature. If windows are to

be opened or heat is not needed, move thermostat pointer to a

lower setting.

NOTE

In the event of failure of any component, the system will not

operate or will go into safety lockout. The system is

completely self-checking. On every call for heat, each

component must be functioning properly to permit operation.

On safety lockout the system has to be reset by turning the

thermostat to the lowest setting for one minute, then back

to the normal setting.

Safe lighting and other performance criteria were met with

the gas manifold and control assembly provided on the boiler

when the boiler underwent tests specified in ANSI Z21.13 -

latest revision.

INLET I_

PRESSURE REGULATOR CBNVEN_NCE

TERMINAIS (2)

ADJUSTHENT (OPTIONAL)

(UNDER CAP ¸SCREW)

\ (2>

INLFT

PRESStJR_ TAP

[NLETI_i I_DUTLET

CUTLET

\PiLDI ADJUS[MENI

CONNECTION

(UNDER CAR SCREW)

GAS CONTROL

RED RESET KNOB

BUTTON

m/- OUTER MANTEL

ADJUST PILOT BURNER

Pilot flame should surround 3/8" to 1/2" of the pilot sensor.

Refer to Fig. 18. If flame needs adjusting, do it as follows:

1. Remove screw cover over pilot adjusting screw.

2. Insert small screwdriver and adjustflame as needed. Turn screw

counterclockwise to increase flame, clock-wise to decrease.

3. Replace screw cover over pilot adjusting screw.

MAiN BURNER(S)

The main burners do not require primary air adjustment and

are not equipped with primary air shutters. Main burner flames

should form sharp blue inner cones in a softer blue outer mantel,

with no yellow. Puffs of air from blowing on the flame or

stamping on the floor will cause the flames to turn orange

momentarily. This is not unusual. Remain still when observing

the main burner flames. If the flame appearance is not correct,

check main burner orifices and the burner throat and flame

ports for dust and lint obstruction. It may be necessary to

remove the rollout shield to observe the main burner flames.

Replace rollout shield after observation. Refer to Figure 17.

ADJUST LIMIT CONTROLS

Instructions for each control are included with the controls.

These settings can be changed after you have had some

RECOMMENDED BOILER WATER TEM PERATU RES

Type of Heating Unit Limit Control Setting

Standing Radiators ................................... 180° F.

Baseboard and Convector Radiators ........200 ° F.

idea how the system works. Example: If your system does not

give quite enough heat in very cold weather, you can raise the

limit setting to 220 ° F Use the boiler gauge to check your

settings. Make the adjustments according to its readings. Check

thermostat operation. When set above temperature indicated

on the thermometer, boiler should ignite. Make certain the

thermostat turns off the boiler when room temperature reaches

the selected setting and starts the boiler operating when room

temperature falls a few degrees.

After setting limit control to limit setting, check to see if it shuts

off the gas supply to the burners. Turn your thermostat up to call

for heat and let your boiler run until the temperature of the water

reaches the limit setting. The gas valve should shut off and the

circulator keep running until the thermostat is satisfied, or the

water cools enough to restart the burners through the limit control.

Finally, set the thermostat for the desired temperature. Special

conditions in your home and the location of the thermostat will

govern this setting.

BURNERS

A visual check of the pilot end main burner flames should be

made at least once each year, preferably at the beginning of

the heating season. See page 21

RELIEF VALVE

This valve should open automatically if the system pressure

exceeds the pressure rating (usually 30 psi) of the relief valve.

Should it ever fail to open under this condition, shut down your

system. Drain the system until system pressure is reduced

below the relief valve pressure rating. If valve discharge oc-

curs, or if valve fails to open as described above, contact an

authorized contractor or 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 con-

tain and safely dispose of boiler discharge. Test at normal sys-

tem 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.

EXPANSION TANK

As previously noted, this tank may become waterlogged, or

may receive an excess of air. Frequent automatic opening of

the relief valve indicates water logging. A high boiler tempera-

ture accompanied by unusually low radiation unit temperature

(and "knocking") indicates excess air in tank.

To correct either condition, close the valve between the boiler

and the tank. Drain the tank until it is empty. Check all the tank

plugs and fittings. Tighten as necessary. Open the valve be-

tween the boiler and tank. Water will rise to the normal height

in the tank if you have an automatic fill valve (otherwise, manu-

ally refill the system).

BOILER FLUE PASSAGES

Under normal operating conditions, with the burners properly

adjusted, it should not be necessary to clean the boiler flue

gas passages. However, to assure trouble-flee operation, we

recommend that you have the flue passages, burner

adjustment, and operation of the controls checked once each

year by a competent Service Technician.

Before the start of each season (or whenever system has

been shut down for some time) recheck the whole system for

leaks.., and recheck the boiler and vent pipe for leaks. Replace

or patch any boiler seals that are faulty.

VENT PIPE

The venting of this unit is very important and the piping

should be checked at least once aseason, if the vent piping

shows any sign of leaking, replace it immediately.

WATER SYSTEM

If system is to remain out of service during freezing weather,

always drain it completely (water left in to freeze will crack the

pipes and/or boiler).

CLEANING YOUR BOILER AND BURNERS

Flue passages between sections should be examined yearly

and cleaned if necessary. To clean, remove burners, pilot, and

vent pipe, Remove top and front jacket panels. Remove the

two screws attaching the intermediate front panel to the left

and right side jacket panels. Remove the draft diverter and

intermediate front panel as a unit. Carefully remove the cerafelt

gasket strips. Clean passageways between sections with a

flexible handle wire brush. Remove dirt from bottom of boiler

and from between sections by vacuuming. Make sure all flame

ports in burners are open and clear. Shake out or blow out all

loose dirt in burners. Reseal seams between adjacent sections

as necessary with 400 F RTV silicone sealant. Reassemble

all parts. Be sure to check tightness of pilot connections and

condition of burner flames after reassembly (see Figures 17

and 18). Be sure vent pipe connections to chimney are secure

and no obstructions are present.

CIRCULATOR PUMP ISOLATION VALVES

The isolation valves in the circulator pump flanges should be

operated manually once or twice per year to prevent the valves

from becoming stuck in the open position Rotate the valves

from the open position to the closed position and back to the

open position.

No electric power to boiler

Controls out of adjustment

Radiators not heating

Circulating pump not running

Poor electrical contact

Rollout switch blown

Spill switch blown

Vent damper not operating

You may avoid inconvenience and service calls by checking these points before you call for service.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS

1. Do Not try to light any appliance.

2. Do not touch any electric switch, do not use the phone.

3. Leave the building immediately, then call your gas supplier.

4. If you cannot reach the gas supplier, call the fire department.

Possible Cause What to do

Thermostat is not set correctly Reset thermostat above room temperature

Burner is not operating properly Check flame. If it is yellow, the burner is not getting enough air.

Or, if flame is blue and noisy and seems to lift off the burner, the

burner is getting too mush air. Contact your service technician.

Check overcurrent protection. Check to be sure electric power

supply circuit is "ON".

Reset according to instructions.

Open radiator vents to excess air. Check flow control valve (if

used). It may be in closed position.

Check overcurrent protection. Check relay operation.

Check all control terminals and wire joints.

Have your service technician check heat exchanged for blockage.

Replace rollout switch with exact replacement.

Have your service technician check venting system and chimney

for blockage, or down draft condition. Reset spill switch.

Consult troubleshooting guide in Effikal manual, packaged with

vent damper.

Possible Cause

Gas input amount is incorrect

Possible Cause

Dirt on seat

Water logged expansion tank

What to do

Contact your service technician.

What to do

Open valve manually. Allow water to run and clear valve seat.

Drain tank, see instructions.

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

GAS = FIRED HOT WATER BOILERS

-IMPORTANT-

READ THESE INSTRUCTIONS BEFORE ORDERING

All parts are listed in the following Parts List may be

ordered through your nearest supplier.

When ordering parts, first obtain the Model Number from the

data plate on your boiler, than determine the Part No. (not

the Key No.) and the Description of each part from the

following illustrations and list. Be sure to give us all this

information:

The Part No. - The Part Description - The Boiler Model No.

t3\

12_\

17_

7\1

KEY

NO.

DESCRIPTION

Jacket, Right Side Panel

#10 x 1/2 Sheet Metal Screw

Rating Plate

Base Insulation - Base Sides (2)

- Base Front

- Base Rear

5 Base Baffle

6 Base

7 Jacket Tie Bar

8 Push Nipple

9 Jacket, Left Side Panel

10 Knob, Service Door (Pair)

11 Jacket, Service Door

12 Jacket, Int'd. Panel

13 Jacket, Front Panel

14 1/4" Tie Rod, Nat

15 Boiler Section, Left

16 Boiler Section, Middle

17 Jacket, Top Panel

18 Draft Diverter

19 Boiler Section, Right

20 Jacket, Back Panel

$ Jacket Complete

$ Btock Assembty (19, 16, 15, 14, 8)

$ Combustabte Floor Plate

$ Cerafelt Gasket

21 Vent Damper

$ Base Assembly (6, 5, 4)

JACKET- SECTION AND BASE PARTS

THIS IS A REPAIR PARTS LIST - NOT A PACKAGING LIST

2SECTION

PaN No.

425-00-901

146-95-074

146-80-901

146-14-020

146-14-112

146-14-122

425-00-642

425-00-662

425-00-652

433-00-976

425-45-900

137-02-513

425-00-912

425-00-812

425-00-810

146-05-008

410-00-020

425-45-842

425-00-672

410-00-021

425-00-902

425-00-922

410-00-213

146-14-031

146-14-018

118-20-04

433-00-662

3SECTION

Part No.

425-00-901

146-95-074

146-80-901

146-14-130

146-14-113

146-14-123

425-00-643

425-00-663

425-00-653

433-00-976

425-45-900

137-02-513

425-00-913

425-00-813

425-00-811

146-05-001

410-00-020

410-00-021

425-45-843

425-00-673

410-00-021

425-00-903

425-00-923

410-00-313

146-14-031

146-14-018

118-20-05

433-00-663

4SECTION

PaN No.

425-00-901

146-95-074

146-80-901

146-14-130

146-14-114

146-14-124

425-00-644

425-00-664

425-00-654

433-00-976

425-45-900

137-02-513

425-00-914

425-00-814

425-00-804

146-05-002

410-00-020

410-00-021

425-45-844

425-00-674

410-00-021

425-00-904

425-00-924

410-00-413

146-14-031

146-14-018

118-20-06

433-00-664

5SECTION

Part No.

425-00-901

146-95-074

146-80-901

146-14-130

146-14-115

146-14-125

425-00-645

425-00-665

425-00-655

433-00-976

425-45-900

137-02-513

425-00-915

425-00-815

425-00-805

146-05-051

410-00-020

410-00-021

425-45-845

425-00-675

410-00-021

425-00-905

425-00-925

410-00-513

146-14-031

146-14-018

118-20-06

433-00-665

6SECTION

Part No.

425-00-901

146-95-074

146-80-901

146-14-130

146-14-116

146-14-126

425-00-646

425-00-666

425-00-656

433-00-976

425-45-900

137-02-513

425-00-916

425-00-816

425-00-806

146-05-053

410-00-020

410-00-021

425-45-846

425-00-676

410-00-021

425-00-906

425-00-926

410-00-613

146-14-031

146-14-018

118-20-07

433-00-666

7 SECTION

PaN No.

425-00-901

146-95-074

146-80-901

146-14-130

146-14-117

146-14-127

425-00-647

425-00-667

425-00-657

433-00-976

425-45-900

137-02-513

425-00-917

425-00-817

425-00-807

146-05-005

410-00-020

410-00-021

425-45-847

425-00-677

410-00-021

425-00-907

425-00-927

410-00-713

146-14-032

146-14-018

118-20-07

433-00-667

8SECTION

Part No.

425-00-901

146-95-074

146-80-901

146-14-130

146-14-118

146-14-128

425-00-648

425-00-668

425-00-658

433-00-976

425-45-900

137-02-513

425-00-918

425-00-818

425-00-808

146-05-007

410-00-020

410-00-021

425-45-848

425-00-678

410-00-021

425-00-908

425-00-928

410-00-813

146-14-032

146-14-018

118-20-07

433-00-668

:l: Not illustrated

9 SECTION

Part No,

425-00-901

146-95-074

146-80-901

146-14-130

146-14-119

146-14-129

425-00-649

425-00-669

425-00-659

433-00-976

425-45-900

137-02-513

425-00-919

425-00-819

425-00-809

146-05-009

410-00-020

410-00-021

425-45-849

425-00-679

410-00-021

425-00-909

425-00-929

410-00-913

146-14-032

146-14-018

118-20-07

433-00-669

GAS BURNERS AND MANIFOLD PARTS

(FOR USE WiTH NATURAL GAS AND PROPANE)

4 5

NOTE: Actual gas valve may look different than gas valve shown.

24 V Gas Valve, Elect. Ignition-Nat. 146-62-052 146-82-052 146-82-052 146-82-052 !46-62-058 146-62-058 146-62-058 !46-62-058

124VGasVatve, Elect. Ignition-LP 146-62-062 146-82-062 146-82-062 148-82-062 !46-62-059 148-62-059 !46-62-059 146-62-059

2 Pilot Tube w/Fittings 433-00-201 433-00-201 433-00-201 433-00-201 433-00-201 433-00-20! 433-00-200 433-00-200

3 10-32½HexHd. Screw(2) 146-95-307 146-95-307 146-95-307 146-95-307 146-95-307 146-95-307 146-95-307 !46-95-307

Gas Manifold-Nat. 146-16-032 146-16-033 146-16-034 146-16-035 146-16-013 146-16-0!4 146-!6-015 !46-16-0!6

4Gas Manifold-LP 146-16-009 146-16-010 146-16-01! 146-16-012 !46-16-0!3 !46-!6-0!4 !46-!6-0!5 !46-!6-016

Main Burner Orifice - Nat.* !46-!5-041 !46-15-041 146-15-041 146-15-041 146-15-042 146-15-042 146-15-042 146-15-042

5Main BumerOrifice-LP* 146-16-043 146-16-043 146-16-043 146-16-043 146-16-043 146-16-043 146-16-043 146-16-043

6 Main Bumer** --- 146-15-532 146-15-532 146-15-532 !46-15-532 !46-!5-532 !46-!5-532 !46-15-532

6A Main Burner with Pilot Bracket** !46-15-531 146-15-531 146-15-531 146-15-531 146-15-531 146-15-53! 146-15-531 146-15-531

Pilot Burner- Nat. 146-62-095 !46-62-092 146-62-092 146-62-092 146-62-092 146-62-092 146-62-092 146-62-092

7Pilot Burner- LP !46-62-093 !46-62-094 146-62-094 146-62-094 146-62-094 146-62-094 146-62-094 146-62-094

+ Rollout Shield 425-00-932 425-00-933 425-00-934 425-00-935 425-00-936 425-00-937 425-00-938 425-00-939

_'Ill: ;,]_r-,Aud=li#-,I ;;uuF,.I: o] ;,][o,][o]_ idl_il[o].lJ.'-Ruin[o]

_ _ECTI_ _ _ECT!_N

24 V Gas Valve, Continuous Pilot - Nat. 146-62-05! 146-62-051 146-62-05! 146-62-051 !46-62-060 !46-62-060 146-62-060 !46-62-060

124 V Gas Valve, Continuous Pilot - LP --- 146-95-30! 146-95-30! 146-95-301 !46-95-301 !46-95-301 !46-95-301 !46-95-301

Pilot Burner- Nat. 146-62-098 !46-62-098 146-62-098 146-62-098 146-62-098 146-62-098 146-62-098 146-62-098

7Pilot Burner - LP --- !46-62-096 146-62-096 146-62-096 146-62-096 146-62-096 146-62-096 146-62-096

+ Thermocouple-Nat. 146-62-037 146-62-037 146-62-039 146-62-039 !46-62-039 !46-62-039 146-62-036 !46-62-036

Thermocouple-LP --- 146-62-037 146-62-039 146-62-039 !46-62-039 146-62-039 !46-62-036 146-62-036

NOTE: * Requires 1 less than the number of sections.

•* Requires 2 less than the number of sections.

+ Not Illustrated

BOILER CONTROLS AND PiPiNG

Key

No.

Description

¾" ASME Relief Valve

¾" x 7½" Nipple

Temperature Pessure Gauge - 5" Stem

11A,,x ¾,, x 11A,, Tee

Aquastat Relay

Isolation Ball Valve

Grundfos UP15-42F Circulator

Taco 007 Circulator

1!/4'' x 2½" Nipple

11A'' Bent Return Nipple

Intermittent Pilot Control

Spill Switch (36TX16-6281)340 ° F

Rollout Switch

4" Vent Damper (w 3" Adapter)

5" Vent Damper

6" Vent Damper

7" Vent Damper

Vent Damper Operator (Motor)

400 ° F Black Silicone Rubber Adhesive

Sealant (10.3 oz. Cartridge)

Part

No.

146-22-011

146-07-041

146-23-009

151-00-01

101-00-02

146-26-043

Cl-006.01

Cl-001.03

146-07-044

146-07-003

146-62-070

146-60-002

146-29-002

118-20-04

118-20-05

118-20-06

118-20-07

114-00-02

146-06-020

:l: Not illustrated

Note: the circulator and ball valves do not come

pre-installed."

14683002 Rev.3,November2004

DUNKIRK Boiler Manual L0612044

Navigation menu

Versions of this User Manual:

Views

Navigation