Dunkirk DPFO-3, Installation Manual And Operating Instructions

Page 1: ...EV SERIES CAST IRON PRESSURE FIRED WET BASE HOT WATER BOILERS DUNKIRK BOILERS 85 Middle Rd Dunkirk NY 14048 www ecrinternationaL com ...

Page 2: ... 32 Maintenance 34 Service Hints and Troubleshooting 36 Repair Parts 37 KEEP THIS MANUAL NEAR BOILER BETA N EOB EUTUBE BBEEBENCE J 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 un...

Page 3: ... 15 DPFO 9T 30 324 282 __5 __ 5 DPFO 3 45 56 48 87 5 88 22 5 I1 90 105 91 82 8 83 19 DPFO 4 1 605 74 64 87 5 88 23 159 I38 83 3 83 91 6 14_A DPFO 5 I 0 93 81 87 5 88 23 6 17 199 I73 83 9 84 63 DPFO 7 1 05 130 I13 87 6 88 24 7 24 2 35 276 240 __ 5 __ 5 1 35 167 I46 87 6 88 26 DPFO 9 3 00 353 307 __ 5 __ 5 8 30 Firing rates of 2 00 gph or less use a Beckett Model AFG oil burner Firing rates over 2 0...

Page 4: ...acity is indicated in thousands of Btu per hour Use of antifreeze in any boiler can reduce capacity net output and efficiency by a significant amount 2 Net ratings are indicated in thousands of Btu per hour based on a piping and pickup allowance of 1 15 3 Annual Fuel Utilization Efficiency based on tests performed under U S Department of Energy standards and reported to the Federal Trade Commissio...

Page 5: ...MPORTANT ANTIFREEZE ADDED TO WEATHERPROOF BOILERS MUST BE NON TOXIC 1 D O E Heating capacity is indicated in thousands of Btu per hour Use of antifreeze in any boiler can reduce capacity net output and efficiency by a significant amount 2 Net ratings are indicated in thousands of Btu per hour based on a piping and pickup allowance of 1 15 3 Annual Fuel Utilization Efficiency based on tests perform...

Page 6: ...as knockdown boilers and are shipped as four components w o DES or five components with DES are shown below 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 post purge oil burner for oil fired burners Weatherproof outdoor EV Series boilers are furnished as knockdown boilers onl...

Page 7: ...er 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 air supply for complete combustion 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 through the walt venting re...

Page 8: ...dictional requirements must be met This may require wiring and or piping modifications The manufacturer is not responsible for any changes to the original design DO NOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING k GASOLINE Check to be sure you have the right size boiler before starting the installation See rating and capacity tables on preceding pages Check the rating plate on the righ...

Page 9: ...National Fire Protection Association as follows N F RA 31 Section 4 4 1 5 Appliances may be placed on combustible floors although not listed for such installation provided the floor under the appliance is protected in accordance with the requirements of accepted building code practice A water wall type heating boiler operating not in excess of 250 F for water boilers may be placed on a combustible...

Page 10: ...re available at Battery Park Quincy MA 02269 CONSULT FIRE AUTHORITIES J FOR LOCAL REQUIREMENTS FIG 5 JACKETASSEMBLY INDOOR BOILERS 4 Hold panels 1 and 1A against burner end of boiler and insert necessary piping through jacket openings into boiler casting 5 Screw acorn nuts onto stand off bolts 6 Screw 1 nipple and sight glass holder into hole above burner 7 Screw the plug into tapping on upper lef...

Page 11: ... may reduce capacity by 10 or more and increase fuel consumption Tanktess coil performance will fall as concentration of antifreeze is increased See below for water volumes of boilers and piping 3 Because antifreeze forms slush rather than hard ice it is safe to protect only to 10 degrees above coldest temperature anticipated provided slush formed can move towards expansion tank BOILER WATER VOLUM...

Page 12: ...2 00 gph or less It is equipped with an F3 flame retention head the size most commonly used It is possible the head must be changed to match the nozzle firing rate required and it is recommended the installer carry a complete assortment of Beckett flame retention heads When head rating overlap a smaller head with air shutter fairly well open will generally provide better combustion than a larger h...

Page 13: ... 60 W m 170 155 150 150 m 3 40 3 75 5 00 5 00 mF3 F3 F3 F5 60 60 W 155 5 2 25 F5 85 60 W 170 2 0 3 00 F5 1 35 60 W 160 1 5 3 00 F10 1 10 60 W 165 3 5 3 80 F5 1 65 60 W 165 2 5 3 40 F10 2 50 60 B 150 5 0 7 80 F10 50 60 W 170 5 3 40 F3 75 60 A 160 3 0 4 50 F3 1 20 60 A 150 4 0 4 30 F5 75 60 W 175 1 5 2 80 F5 1 20 60 W 170 3 5 5 00 F5 1 75 60 W 170 2 5 4 50 F10 1 All Burners fired at an over fire pre...

Page 14: ...ents verify that all fuel water and electrical connections have been made in accordance with the regulations of the National Fire Prevention Association the National Electrical Code and or local regulations See L8151 Control Settings in this manual for more information 11 START UP AND ADJUSTMENT Start and adjust burner according to manufacturer s instructions contained in burner carton or included...

Page 15: ... 1 35 1 20 70 A 2 00 1 65 40 B 3 00 2 50 60 B 65 60 80 B 1 00 85 80 B 1 45 1 25 80 B 95 85 80 B 1 45 1 20 80 B 2 10 1 75 60 B B Yes No No m 10 10 10 m 1 0 0 m AFG AFG AFG F3 I_A Yes 10 1 AFG F6 I_A No 10 1 AFG F12 I_A No 10 3 AFG F6 1_ 8 No 10 2 AFG SV1 1 No 6 5 0 CF375 SV1 5 No 10 4 CF375 F0 1_ 8 Yes 10 1 AFG F3 I_A No 10 1 AFG F6 I_A No 10 2 AFG F3 1_ 8 No 10 2 AFG F6 1_ 8 No 10 3 AFG SV1 2 No 1...

Page 16: ...s above a specific limit set by the homeowner When outside thermostat is not used Jumper T T Terminals on relay These settings may be altered based on the heating system response During very cold weather if the heating system does not provide quite enough heat the high limit control setting may be raised to a maximum of 200 F If more domestic hot water is required the low limit control setting may...

Page 17: ...ht of burner using sheet metal screws in holes located in jacket Wiring harness is provided When welt is used at the rear of a larger boiler it might be necessary to relocate the control with longer wiring not provided 7 If boiler has a tanktess coil insert well for the L8151 remote bulb in coil plate Run capillary tube through sight glass opening in jacket 8 If a tankless coil is not used install...

Page 18: ...as the boiler water Adjust the post purge timer to nearest time interval always rounding up if possible For example if the time measured is 3 minutes and 20 seconds then set the post purge timer at 4 minutes Whenever the nozzle is removed for service check for varnish forming on the outside of the nozzle If carbon and varnish do not wipe off easily increase the post purge time 15 LIMITED RECYCLEAN...

Page 19: ...t be provided upstream of the gas controls and location of manual main shutoff valve must be outside the jacket when codes require 1 The gas line should be of adequate size to prevent undue pressure drop and never smaller than the pipe size of the main gas control valve See chart below Maximum Pipe Capacity in Cubic Feet of Gas Hour Gas pressure O 5 psig or less pressure drop w c IN J 1 Foradditio...

Page 20: ... the burner to change or enlarge gas orifices See orifice change out diagram below FIG 11 ORIFICE CHANGEOUT PROCEDURE _ _ _ _l_ T_ _ _ TP_R _R_AR_ _1_ t_ TH_ 110 000 120 000 130 000 140 000 150 000 160 000 170 000 180 000 190 000 200 000 210 000 220 000 230 000 240 000 D 246 F 257 I 272 K 281 M 295 N 300 5 16 312 P 323 Q 332 S 350 23 64 360 3 8 375 25 64 391 Z 413 9 3 2 15 64 C 1 4 G I J K M N 5 1...

Page 21: ... UP AND ADJUSTMENT Start and adjust burner according to manufacturer s instructions contained in burner carton or included with packaged boiler and pay special attention to the following important points a As the name suggests this boiler is designed to produce the ultimate in usable heat from the fuel used A WAR__ NG A carbon monoxide tester must be used n smoke tester b Air Adjustment Is Not Fac...

Page 22: ...ncy boilers care must be taken to minimize condensation Therefore cold standby is not recommended and may be used only with a piping bypass as shown in Figure 6 This requires a change in control wiring Please contact factory prior to making that change When cold standby is not utilized the homeowner might possibly object to the burner starting when space heat is not required To avoid this an optio...

Page 23: ...indoor tanktess coil or indirect water heater An indirect Water Heater is recommended b Without Domestic Water Heating See Figure 15 3 Place control welt in top tapping near burner end of boiler 4 Install a street ell in remaining top tapping Mount relief vatve on street ell using a x 7 nipple Mount overflow pipe not supplied so that it extends downward beside boiler casting and will be covered by...

Page 24: ...ufacturer s instructions included and to Figures 17 oil installation or 18 gas installation on next page 12 Install burner according to manufacturer s instructions with particular attention given to the following IMPORTANT information a Oil Installations See charts below for firing rate head sizing and nozzle sizing instructions The F3 head supplied might not be the correct size to match the firin...

Page 25: ...E TtI RMOSTAT IS NOT U _D NOTE WHEN INDIRECT WATER HEATER IS USED SEE MANUFACTURER S WIRING INSTRUCTIONS FIG 18 WIRING DIAGRAM FOR WEATHERPROOF GAS FIRED BOILER SPACE HEATING 120V 24V 11Kl 1K2 A PROVIDE DISCONNECT MEANS AND OVEgLOAD PROTECTION AS REQUIRED JUMPER T T TERM tqALS WHEN OUTSIDE THERMOSTAT IS NOT USED NOTE WHEN INDIRECT WATER HEATER IS USED_ SEE MA ffUFACTUP ER WIRING INSTRUCTIONS R_ER ...

Page 26: ...gure 16 fasten front jacket panel 9 in position with sheet metal screws and install jacket top 5 19 Install exhaust assembly with parts 6 7 and 8 The exhaust cap is made to spring inside the short length of smoke pipe A tourniquet made of wire or a large hose clamp may be used to reduce the diameter so that it will fit inside the pipe Two or three hose clamps in series may be used when a large one...

Page 27: ...t of Beckett flame retention heads When head ratings overlap a smaller head with air shutter fairly well open will generally provide better combustion than a larger head with air shutter near closed See head size selection chart on page 21 For firing rates under 1 00 gph see page 18 for information on using low firing rate baffles It should be recognized that the description of spray patterns migh...

Page 28: ...ing the correct head and orifice for the Adams gas burner Adams burners supplied from stock with EV Series boilers are equipped with a GO flame retention head and with two orifice plates one inserted at each end of the orifice spring The primary orifice mounted in position ready for firing is the smallest at which the burner should be fired using natural gas The auxiliary orifice stained red in co...

Page 29: ...e pres Do not attempt to place the boiler back into oph sure switch will sense a drop in pressure open _ration Contact a qualified service agency J LT i Before operating make certain the boiler and system are full of water to minimum pressure this is usually 12 Ibs per square inch on most systems and system is vented of air See the k operating and lighting instructions j 1 This appliance is equipp...

Page 30: ...ext step 7 Turn gas control knob counterclockwise to ON 8 Turn on all electric power to the appliance 9 Set thermostat to desired setting 10 If the appliance will not operate follow the in structions To Turn Off Gas To Appliance below and call a qualified service technician or your gas supplier See off burner instructions for nozzle and electrode setting 1 Check oil burner nozzle to make certain i...

Page 31: ...roximately 1 Check to insure minimum 02 w c overfire draft and zero smoke If 02 w c overfire draft can not be maintained changes and or modifications may be required in the venting or the chimney CHECK SAFETY CONTROL CIRCUIT after burner adjustments have been made for satisfactory per formance 1 High Limit Control Remove cover and note temperature setting With the burner operat ing decrease this s...

Page 32: ...ejacket usingthe screwsprovidedand is wiredto the T T terminalson the Oil Primaryfor oil firedboilers as shown at left It is mounted in the collar provided and wired to the T T terminals on the Oil Primary for oil fired boilers or the T T terminals on the Adams gas burner for gas fired models see below OIL FIRED Connect the flexible tubing provided from the hose barb on the burner mount ing plate ...

Page 33: ...ighten as necessary Open the valve between the boiler and tank Water will rise to the normal height in the tank if you have an automatic fill valve otherwise manually refill the system If system is to remain out of service during freezing weather and does not contain antifreeze always drain it completely Water left in to freeze will crack the pipes and or boiler Visually inspect the entire venting...

Page 34: ...to maintain the proper amount of air the fuel requires to burn 3 Remove relief valve discharge pipe and top jacket panel 4 Remove the two brass wing nuts holding the flue collector top Remove the collector top 5 Check the gasket on the underside of the flue collector and replace as necessary 6 Remove the burner Service burner per burner manufacturer s instructions 7 Inspect the combustion chamber ...

Page 35: ...OUGH HEAT Burner may be short cycling No power to boiler Controls out of adjustment Radiators not heating Circulating pump not running Poor electrical contact i i ii i iiii i N Air in system RADIATORS NOISY Reset thermostat above room temperature Clean all flue passages and the vent pipe Have burner cleaned i and readjusted i Check nozzle size or orifice size if there is any doubt Have burner adju...

Page 36: ...be ordered through your nearest supplier When ordering parts first obtain the model number from the data plate on your boiler then determine the part number and description of each part from the following illustrations INCLUDED IN THIS SECTION Boiler Parts Indoor Jacket Parts Weatherproof Jacket Parts Direct Exhaust System Parts Boiler Controls and Piping ...

Page 37: ... ...

Page 38: ...113 1330008 43382251 41900004 HW06701 1330007 HW0700I 14695042 14685103 13704007 14695109 43382265 41982002 14630021 14630022 14630031 14630023 41900001 43300976 14605009 42582125 41900002 41900003 14627023 43382255 14627022 43382259 14693065 14619001 14695113 1330008 43382251 41900004 HW06701 1330007 HW07001 14695042 14685103 13704007 14695109 43382266 I 2 2A 3 4 5 6 7 8 9 10 11 I5A I5B 16 17 18 ...

Page 39: ...5 742831003 13702153 42582044 42500654 42582030 42582031 42582032 42582033 42582060 742831004 13702153 42582045 42500655 42582030 42582031 42582032 42582034 42582061 742831005 13702153 42582046 42500656 42582030 42582031 42582032 42582035 42582062 742831006 13702153 42582047 42500657 42582030 42582031 42582032 42582036 42582063 742831007 13702153 42582048 42500659 42582030 42582031 42582032 425820...

Page 40: ...il li 1 Top Panel 14630411 14630412 14630413 2 Jacket 14630402 14630403 14630404 3 Weather Shield 14630421 14630424 14630427 4 Flue Pipe 14630423 14630426 14630429 5 Collar 14630422 14630425 14630428 ...

Page 41: ...m 1 2 3 4 5 4 Exhaust Hood 6 Exhaust Hood Vacuum Relief Draft RegulatorAssembly Pressure Switch Viton Tubing Brass Barb 240005873 240005874 240005625 30705 1230010 Item 2 included with Item 1 ...

Page 42: ...alve x 4 Nipple 14 x 10 Nipple except Models 7TT 8T 9 1 x 12 Nipple Models 7TT 8T 9 14 x x 1 Tee except Models 7TT 8T 9 1 x x 1 Tee Models 7TT ST 9 14 x 2 Nipple except Models 7TT 8 i 9 1 x 2 Nipple Models 7TT 8T 9 Boiler Drain Valve 1 x 14 Bushing except Models 7TT 8T 9 Immersion Well for Aquastat 1 x Bushings 1 Sq Hd Plugs 400 F Black Silicone Rubber Adhesive Sealant 10 3 oz cartridge 500 F Red ...