Dunkirk DXL-50 Instruction manual

Dt l
i
Hodels
DXL-50
DXL-75
DXL-100
DXL=:L25
DXL--150
DXL-170
DXL-200
DXL SERIES II
CAST IRON GAS FIRED BOILERS
FOR FORCED HOT WATER
iNSTALLATiON,OPERATION&
MAINTENANCE MANUAL
;' T rpr "'US H
Tested For 100 psi.
ASME
Working Pressure
Manufactured by:
ECR International, inc.
220! Dwyer Avenue. Utica NY 13501
web site www ecnnternatlonal corn P/N 2400009041, Rev B [09/2012]

Supply
21/2"
n
50 4" 303/4" 36¾" 6" 1¼"
75 =" 3'_/'' "_/ .... _ "
,., u/4 _u/4 6 1¼
100 6"
...............i2 _..........................'/;; ....................i 8_/;;.... 9'";; 6" 30_/..... /., _,/., 4,/.
•J /2 /8 /2 /4 01/4 i U/2 / /4
171331
150 ;; ½ 18% 9½ 7 30¼ 37¾ 7 1¼
170 _/,, "3"_3/" 44 I/" -7" C, f'_3/" 903/" -7" 41/"
/2 /--_--/4 // /2 t OU/4 OO/4 / / /4 ;
131 ; 3 3 ; 1
200 ½ ,, 22¾ 11½ 8 30¾ ....................................................................................................................8..............................................'1¼

2=SAFETY SYMBOLS &WARNINGS
1= Dimensions ..................................................... 2
2 = Safety Symbols & Warnings ............................. 3
3 = Ratings & Data = Natural Gas & Propane Gas ...... 4
4 = Installation Procedure ..................................... 5
5 = Ventilation & Combustion Air ............................ 6
6 = Supply And Return Piping ................................ 7
7 = Vent Installation ........................................... 12
8 = Vent System Modification ............................... 12
9 = Vent Damper Installation & Instructions ........... 13
10 = Connecting Gas Service ............................... 14
ii = Electrical Section ........................................ 15
12 = Wiring Diagram = Intermittent Ignition ........... 16
13 = Lighting Instructions ................................... 18
14 = Sequence Of Operation ................................ 19
15 = General Instructions .................................... 19
16 = Checking Gas Input Rate To Boiler ................. 21
17 = Setting The Control ..................................... 22
17 = System Start=Up ......................................... 23
17 = Limit Control Troubleshooting ...................... 24
18 - System Troubleshooting ............................... 25
Parts, Kits and Accessories .................................. 27
Warranty .......................................................... 33
Check Out Certificate ......................................... 35
Safety Symbols &Warnings
The following defined symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
Keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors
and liquids.
DO NOT obstruct air openings to the boiler room.
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
TO THE OWNER = Installation and service of this
boiler must be performed by a qualified installer.
TO THE INSTALLER = Leave all instructions with
boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Used to address practices not related to personal
injury.

3'RATINGS &DATA =NATURAL GAS 8t PROPANE GAS/
Table 2 -Ratings and Capacities
(2)
(z) Net AHRI _3)
(1) Heating Rating No. Recommended Water
Boiler Input Capacity Water of Air Cushion Content
No. iVibh Mbh Mbh AFUE Burners Tank (Gais.)
5O 5O
75 75
42
63
High
Altitude
Input
45,000
EXPLANATORY NOTES
-- All boilers are design certified for installation on noncombustible floor.
-- For installation on combustible floors use combustible floor kit.
-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be
reduced to 10 feet. Refer to the latest revision of NFGC part 11.
-- Electric service to be 120 Volts, 15 Amps, 60 Hz.
-- The MEA number for the this boiler is 19-79-E.
(1) Input rating for sea level to 2,000 ft. (610m) above sea level. United States, over 2000 ft (610m) above sea
level. Reduce input rate 4% for every 1000 ft (304m) above sea level.
(2) Net AHRI Water Ratings shown based on piping and pickup allowance of 1.15. Consult manufacturer
before selecting boiler for installations having unusual piping and pickup requirements, such as
intermittent system operation, extensive piping systems, etc.
For forced hot water systems where boiler and all piping within area to be heated, boiler may be selected
on basis of its heating capacity.
(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and
radiation.
STANDARD EQUIPHENT: Boiler ]acket, Cast Iron Boiler Battery, Combination High Limit/Low Water Cutoff
Control, Intermittent Electric Ignition Pilot System, Vent Damper Relay, Temperature/Pressure Gauge, Circulator
With Return Piping To Boiler, Main Gas Burners, Gas Control (Includes Automatic Gas Valve, Gas Pressure
Regulator, Intermittent Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief Valve, Drain Valve,
Spill Switch, Rollout Switch, Combination Gas Control, Automatic Vent Dampen Not Shown Are: Wiring Harness,
Thermocouple, Non=linting Safety Pilot.

4. =INSTALLATION PROCEDURE
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
1. Installation must conform to requirements of authority
having jurisdiction or, in absence of such requirements,
to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
2. Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
and Safety Devices for Automatically fired Boilers,
ANSI/ASME CSD-1.
3. Boiler series is classified as Category I. Vent
installation shall be in accordance with "Venting of
Equipment ," of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of local
building codes.
4. Boiler has met safe lighting and other performance
criteria with gas manifold and control assembly on
boiler per latest revision of ANSI Z21.13/CGA 4.9.
5. Boiler shall be installed such that gas ignition system
components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service, (circulator replacement, condensate trap,
control replacement, etc.).
6. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
7. Allow 24 inches (610mm) at front and right side for
servicing and cleaning.
8. When installed in utility room, door should be wide
enough to allow largest boiler part to enter, or to
permit replacement of another appliance such as water
heater.
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
9_ FOR INSTALLATION ON NON=COMBUSTIBLE
FLOORS ONLY =For installation on combustible
flooring special base must be used. (See Replacement
PartsSection.)Boilercan not be installedon
carpeting,Minimum clearances to combustible
construction are:
TOP ....................................18 IN. (457mm)
FRONT ......................................... ALCOVE _<
FLUE CONNECTOR ................. 6 IN. (152mm)
REAR ................................... 4 IN. (102mm)
CONTROL SIDE ..................... 9 IN. (229mm)
OTHER SIDE ........................... 3 IN. (76mm)
HOT WATER PIPING ................ Per Local Code
NOTE: Greater clearances for access should supersede fire
protection clearances.
Definition of Alcove is three sided space with no wall in
front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.
Figure 2 -Clearance to Combustibles
Hinimum Clearancesto Combustible
Construction(as seen from above.)
!1

5- VENTILATION & COMBUSTION AIR
Provide combustion air and ventilation air in accordance
with the section "Air for Combustion and Ventilation," of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or
applicable provisions of local building codes.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
• Engineered Installations. Must be approved by
authority having jurisdictions.
Mechanical Air Supply. Provide minimum of 0.35
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.
• All Indoor Air. Calculate minimum volume for all
appliances in space. Use a different method if
minimum volume not available.
Standard Method. Cannot be used if known air
infiltration rate is less than 0.40 air changes per
hour. See Table 3 for space with boiler only. Use
equation for multiple appliances.
Volume > 50 ft 3 x Total Input [Mbh]
Known Air Infiltration Rate. See Table 3 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate
(ACH) greater than 0.60.
Volume > 21 ftB/ACH x Total Input [Mbh]
o Refer to National Fuel Gas Code for opening
requirements between connection indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom
enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in2 per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in_ per 2
Mbh of total input rating of all appliances in
enclosure.
One Permanent Opening Method. Provide opening
commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides
and back and 6 inches on front of boiler (does not
supersede clearance to combustible materials).
o Combination Indoor and Outdoor Air. Refer to
National Fuel Gas Code for additional requirements
for louvers, grilles, screens and air ducts.
• Combination Indoor and Outdoor Air. Refer to
National Fuel Gas Code for application information.
National Gas and Propane Installation Code Requires
providing air supply in accordance with:
• Section 8.2 and 8.3 when combination of appliances
has a total input of up to and including 400 Mbh (120
kW).
•Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW),
Refer to Natural Gas and Propane Installation Code
for specific air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.
200 10000 42000 21000 14000 10500 8400 7000

6=SUPPLY AND RETURN PIPING ...........................
Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.
Discharge line shall:
• Connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from floor or allowable safe point of discharge.
• Be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge
line.
• Have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug
or place any obstruction in discharge line.
• Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.
• Allow complete drainage of the valve and the discharge line.
• Be independently supported and securely anchored to avoid applied stress on the relief valve.
• Be as short and straight as possible.
• Terminate with plain end (not threaded).
• Be constructed of material suitable for exposure to temperatures of 375°F (191°C); or greater.
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.
Figure 3 -Safety Relief Valve
RELIEF VALVE
DISCHARGE
LINE
Check local
codes for
maximum
distance
from floor
or allowable
safe point of
discharge,

6= SUPPLY AND RETURN PIPING ...........................
IHPORTANT: Circulators in the following illustrations are mounted on the system supply side, but
mounting on the system return side is also acceptable practice.
Figure 4 -Circulators Hounted on Supply System, Boiler Used In Configuration to Chiller System.
See Special Conditions, Page 9
SUPPLY PIPING
TO HEATING
AND COOLING
ELEMENT
RETURN PIPING
FROM HEATING
AND COOLING
ELEMENT
AIR
GATE _ i//_EPARATO R
©/
WATER DEVICE TANK
D
CHECK
VALVE
PRESSURE -
REDUCING
VALVE
B
l>,<::l
PURGE
VALVE
U
1. Boiler, used in connection with a refrigeration system,
must be installed so chilled medium is piped in parallel
with boiler with appropriate valves to prevent chilled
medium from entering boiler. See Figure 4.
2. Boiler piping system of hot water boiler connected to
heating coils located in air handling units where they
may be exposed to refrigerated air circulation must be
equipped with flow control valves or other automatic
means to prevent gravity circulation of boiler water
during cooling cycle.
3. Hot water boilers installed above radiation level or
as required by authority having jurisdiction must be
provided with a low water cut-off device.
4. When a boiler is connected to a heating system that
utilizes multiple zoned circulators, each circulator must
be supplied with a flow control valve to prevent gravity
circulation.
5. Hot water boilers and system must be filled with water
and maintained to a minimum pressure of 12 psi.
,Bypass piping is an option which gives the ability to
adjust the supply boiler water temperature to fit the
system or the condition of the installation. This method
of piping, however, is not typically required for base-
board heating systems. Typical installations where
bypass piping is used are as follows:
A. This method is used to protect boilers from con-
densation forming due to low temperature return
water. Generally noticed in large converted grav-
ity systems or other large water volume systems.
Figure 5 & 6, Page 9,
B. These methods are used to protect systems using
radiant panels and the material they are encased in
from high temperature supply water from the boiler
and protect the boiler from condensation.
NOTE#l: When using bypass piping, adjust
valves Vl & V2 until desired system temperature
Js obtained.
NOTE#2: Bypass loop must be same size piping
as the supply and return piping.

6=SUPPLY AND RETURN PIPING ...........................
Figure 5
Figure 6
-Bypass Piping Automatic Mixing Valve
TO SYSTEM
WATER INLET
EXPANSION
TANK
z
FROM SYSTEM
_\ iii
_ER "_ JALTERNATE
CIRCULATOR
LOCATION
(_ C,ROOLATOR_ P"ESSUREREoUOERVALVE_ BAL'VA'VE01A'RSEPARATORE::
VA_vESRO_OFFt'q CHECKVALVE_ VA_vESWAYMIX'NG_ HOSEBIB
-Bypass Piping -Fixed Low Temp Only Manual Mixing Valve
TO SYSTEM S_
CIRCULATOR 0 .......
WATER INLET
EXPANSION
TANK
©
V2
FROM SYSTEM
i5--
_,,,,')
ER _- _JALTERNATE
CIRCULATOR
LOCATION
.Installation using circulators and zone valves are
shown in Figure 7, 8, 9 and 10 Pages 10, and 11. For
further piping information refer to AHRI Installation
and Piping Guide.
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
8. Install discharge piping from safety relief valve. See
Warning, Page 7.

6=SUPPLY AND RETURN PIPING ...........................
Figure 7 - Single Zone System With DHW Priority
CH CIRCULATOR
BOILER
WATER INLET
)q
DHW
CIRCULATOR
tip,.-.-
PRiORiTY ZONE
Figure 8 - Multi Zone System With Circulators And DHW Priority
ZOO'4E 4
C_RC 4 ...... _ ZONE 3
CiRC 3 ...............................ZONE 2
C{RC 2
DHW CIRCULATOR
ZONE '_(PRK')RI?Y ZONE}
;EXPANSION
TANK

6'SUPPLY AND RETURN PIPING ...........................
Figure 9-Hulti Zone System With Zone Valves And DHW Priority (With Circulator)
BOILER
*USE FULL PORT ZONE
VALVE
CH
WATER _NLET
)
ZONE 4
_ LL_]_i _!i.__.:_w_j._
-_ ';/"_ lill IIIIIIii I lllil!Ill II II
ZONE 3
ZONE 2
DHW
CIRCULATOR
ZONE 1 (PRIORITY ZONE)
Figure 10 -Multi Zone System With Zone Valves And DHW Priority (With Zone Valve)
ZONE 4
BOILER EXPANSION
TANK
CH & DHW
SYSTEM
ZONE 3
ZONE 2
*USE FULL PORT ZONE
VAWE FOR OPTIMUM TANK
PERFORMANCE CONSIDER
USING ZONE CfRCULA]OR
ZONE 1 (PR{ORITY ZONE)

7-VENT INSTALLATION ...................
Boiler and venting installations shall be performed
by a qualified expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to fire or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
1.
2.
The vent pipe must slope upward from the boiler not
less then 1/4inch for every 1 foot (21mm/m) to vent
terminal.
Horizontal portions of the venting system shall be
supported rigidly every 5 feet and at the elbows. No
portion of the vent pipe should have any dips or sags.
3. This boiler series is classified as a Category I. Vent
installation shall be in accordance with "Venting of
Equipment," of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of the local
building codes.
4. Inspect chimney to make certain it is constructed
according to NFPA 211. The vent or vent connector
shall be Type B or metal pipe having resistance to heat
and corrosion not less than that of galvanized sheet
steel or aluminum not less than 0.016 inch thick (No.
28 Ga).
5. Connect flue pipe from draft hood to chimney. Bolt or
screw joints together to avoid sags. Flue pipe should
not extend beyond inside wall of chimney. Do not
install manual damper in flue pipe or reduce size of
flue outlet except as provided by the latest revision of
ANSI Z223.13.. Protect combustible ceiling and walls
near flue pipe with fireproof insulation. Where two or
more appliances vent into a common flue, the area of
the common flue must be at least equal to the area
of the largest flue plus 50 percent of the area of each
additional flue.
8= VENT SYSTEM MODIFICATION .................
When an existing boiler is removed from a common
venting system, the system is likely to be too large for the
proper venting of the appliances sill connected to it. If
this situation occurs, the following test procedure must be
followed:
REMOVAL OF BOILER FROM VENTING SYSTEM
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 an unused opening 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. Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any other appliance not
connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they operate at maximum speed. Do
not operate a summer exhaust fan. Close fireplace
dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
6. After it has been determined that each appliance
remaining connected to a common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas burning appliances to their previous
condition of use.
7. Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel gas Code, ANSI Z223.1/NFPA 54.
When re-sizing any portion of the common venting
system, the common venting system should be re-sized
to approach the minimum size determined using the
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.

9= VENT DAMPER INSTALLATION & INSTRUCTIONS
DAMPER INSTALLATION
NOTE: Referto Figure 10 forstepsi-6.
Figure 11 -Damper Motor Wiring
DAMPER INSTRUCTIONS
Figure 12 - Vent Damper Placement
\
Vent Damper
Vent Outlet
Damper Motor
"iOF V#ATk H_ At_ _k
1. Place vent damper on or as close to vent outlet of
boiler as possible. See Figure 12,
2. Remove vent damper motor cover.
3. Feed damper wire harness connector through bracket
hole on damper motor frame.
4. Tighten Iocknut onto damper wire harness connector.
5. Plug damper connector into socket on damper motor
frame.
6. Replace damper motor cover and wire damper. See
Figure 11.
1. Verify only boiler is serviced by vent damper, See
Figure 12.
2. Clearance of not less than 6 inches between vent
damper and combustible material must be maintained,
Additional clearance should be allowed for service of
vent damper,
3. Vent damper must be in the open position when
appliance main burners are operating,
4. Vent damper position indicator must be in a visible
location following installation,
5. The thermostat's heat anticipator must be adjusted to
match the total current draw of all controls associated
with boiler during heating cycle,

:10-CONNECTING GAS SERVICE
CAUTION
WHAT TO DO IF YOU SHELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow gas supplier's
instructions.
• If you cannot reach your gas supplier, call the fire
department.
Figure 13 -Gas Piping
VAWE WiTH _N
6 fl (183cm)OF
THE BOILER AND
5 ft (152cm)
ABOVETHE FLOOR
WHERE REQUIRED
BY LOCAL CODES
3_ (8 cm)
TO GAS CONTROL INLET
IAXIHUH CAPACITY OF PIPE IN CUBIC FEET OF GAS/HOUR
(Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in. w/c)
20 120 250 465 950
General
• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements of National Fuel gas Code, ANSI Z223.1/
NFPA 54
• Size and install gas piping system to provide sufficient
gas supply to meet maximum input at not less than
minimum supply pressure. See Table 5.
• Support piping with hooks straps, bands, brackets,
hangers, or building structure components to prevent or
dampen excessive vibrations and prevent strain on gas
connection. Boiler will not support piping weight.
• Use thread (joint) compound (pipe dope) suitable for
liquefied petroleum gas.
• Install field sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve.
See Figure 13.
Table 5-Gas Pressure
13.5" w.c.
3.5" w.c.
13.5"w.c.
10.5"w.c.
Fire Hazard. Do not use matches, candles, open
flames, or other methods providing ignition source.
Failure to comply will result in death or serious
injury.
Leak Check Gas Piping
Pressure test boiler and gas connection before placing
boiler in operation,
• Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas
supply system.
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve,
Locate leakage using gas detector, noncorrosive
detection fluid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open flames, or other methods
providing ignition source.
•Correct leaks immediately and retest.
For additional information refer to the National Fuel Gas
Code Handbook.

1=ELECTRICAL SECTION
Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.
Electrical Wiring
See wiring diagrams on the following two pages for
details,
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to
National Electrical Code, ANSI/NFPA 70.
Thermostat Installation
1. Thermostat should be installed on an inside wall about
four feet above the floor.
2. NEVER install a thermostat on an outside wall.
3. Do not install a thermostat where it will be affected
by drafts, hot or cold pipes, sunlight, lighting fixtures,
televisions, a fireplace, or a chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop the
burners.
5. Instructions for the final adjustment of the thermostat
are packaged with the thermostat (adjusting heating
anticipator, calibration, etc.)

BY_ALUER
t
(R_O_@ENDED)1
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%3' LIGHTING INSTRUCTIONS
If you do not follow these instructions
exactly, a fireor explosion may result
causing property damage, personal injury
or loss of life.
•This appliance is equipped with an ignition device
which automatically lights burner. Do NOT try to
lightthis burner by hand.
•Before operating smell all around appliance area
for gas. Be sure to smell next to floor because
some gas is heavier than air and will settle to the
floor.
• Use only your hand to turn the gas shutoff
valve. Never use tools.Ifvalve willnot turn by
hand, do not try to repair it, call a qualified ser-
vice technician. Force or attempted repair may
result in fire or explosion.
• Do not use this appliance if any part has
been under water, Immediately call a quali-
fied service technician to inspect appliance and to
replace any part of control system and any gas
control which has been under water.
Before lighting any type of pilot burner (standing or
intermittent), verify the hot water boiler and system
are full of water to minimum pressure of 12 psi in
the system, also verify system is vented of air. Set
operating control of thermostat to "below" normal
setting. Refer to following appropriate lighting
instruction.
LIGHTING PROCEDURE FOR BOILER WITH
INTERHITTENT PILOT SYSTEM
For Your Safety, Read Before Operating!!
A. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
appliance by hand.
ACAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switches; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• Ifyou cannot reach your gas supplier, call the fire
department.
OPERATING INSTRUCTIONS FOR INTERHITTENT
PILOT SYSTEM
I. STOP! Read the safetyinformationtothe left.
2. Set thethermostattolowestsetting.
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.
Figure 16 -Intermittent Pilot
GAS
CO_,_'TROL
KI',JOB
PI LO _'" _ LO VV
A©], SCREW
BENEATH
COV R
SCREVV
GA_,
_NLET
ooi i!
_L...................
.. ? /4 o
GAN
OUTLET
INLET
PR;ESSURE
TAP
PRESSU_'.E
_ RE:GU L A_©R
BBNEATH
C©VER SC R E'Vv'
OU [ LET
, PRESSURE
TAP
A
5. Turn gas control knob clockwise 4r _ to "OFF."
6. Wait (5) minutes to clear out any gas. If you then smell
gas, STOP! Follow "What To Do If You Smell Gas" in the
safety information to the left. If you don't smell gas, go
on to the next step.
7. Turn gas control knob counterclockwise _'_ to "ON."
F"
I
8. Turn on all electric power to the app _ance.
9. Set thermostat to desired setting.
10. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance", and call qualified
service technician or your gas supplier.
TO TURN OFF GAS TO THE 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.
4. Call qualified service technician.

14' SEQUENCE OF OPERATION
Thermostat actuates on call for heat,
completing circuit to control. Completed
circuit to control will first activate circulator
and damper which will close end switch inside
damper. Completes circuit to ignition system,
ignition takes place.
Integral Draft
In event boiler water temperature exceeds
high limit setting on boiler mounted high limit
control, power is interrupted between control
system and ignition system. Power remains
off until boiler water temperature drops below
high limit setting. Circulator continues to
operate under this condition until thermostat is
satisfied.
Burner
Blocked Vent
Safety Switch
In event flow of combustion products through
boiler venting system becomes blocked, blocked
vent safety switch shuts main burner gas off.
Similarly, if boiler flue-way becomes blocked,
flame rollout safety switch shuts main burner
gas off. See Figure 17. If either of these
conditions occur, do not attempt to place boiler
back into operation. Contact certified service
agency. Orifices Manifold
Rollout Switch
4 Section Boiler
Base Rollout Switch
2,3,5
]acket Base Section Boiler
Panel
:&5 =G EN ERJ_L INSTRUCTIONS
Before seasonal start=up, have a certified service agency
check boiler for soot and scale in flues, clean burners and
check gas input rate to maintain high operating efficiency.
Label all wires prior to disconnection when servicing
controls. Wiring errors could cause improper and
dangerous operation.
Verify proper operation after servicing
Service agency will verify system is filled with water to
minimum pressure and open air vents, if used, to expel any
air accumulated in the system. Check entire piping system
and, if any leaks appear, have them repaired.
Circulators need to be checked and maintained,
Refer to circulatormanufacturer's instructions.
Inspect venting system at the start of each heating
season. Check vent pipe from boiler to chimney for signs of
deterioration by rust or sagging joints. Repair if necessary.
Remove vent pipe at base of chimney or flue and using a
mirror, check vent for obstruction and verify vent is in good
working order.
Boiler flue gas passageways may be inspected by a light
and mirror. Remove burner door. See Figure 20, Page 20.
Place trouble lamp in flue collector through draft relief
opening. With mirror positioned above burners, flue gas
passageways can be checked for soot or scale.
This procedure should be followed to clean flue gas
passageways:
1. Remove burners from combustion chamber by raising
burners up from manifold orifices and pulling toward
front of boiler. See Figure 17.
2. Disconnect vent pipe from draft hood.
3. Remove top jacket panel.
4. Remove combination flue collector and draft hood from
boiler castings by loosening nuts on hold down bolts
located on each side of collector. See Figure 17.
5. Place sheet of heavy paper or similar material over
bottom of base and brush down flue passageways. Soot
and scale will collect on paper and is easily removed
with the paper.
6. With paper still in place in base, clean top of boiler
castings of boiler putty or silicone used to seal between
castings and flue collector. Verify chips are not lodged
in flue passageways.
When cleaning process is complete, restore boiler
components to their original position. Use IS-808 GE
silicone (available from distributor) to seal around flue
collector and boiler castings.

Makevisualcheckofmainburnerandpilotflamesatstart
ofheatingseasonandagaininmid-season.Mainburner
flameshouldhavewelldefinedinnerbluemantelwith
lighterblueoutermantel.Checkburnerthroatsandburner
orificesforlintor dustobstruction.SeeFigures17and19.
Figure 20
BURNERS,
-Combustion Chamber
GAS VALVE
ORIFICES
Figure 19 - Gas Burner Pilot
Pilot flame should envelop 3/8to 1/2inch of tip of pilot
thermocouple, ignition/sensing electrode or mercury
sensor. See Figure 19.
PROPER
FLAME
ADJUSTMENT 3/8TO1/2 iNCH
(95 TO1Z7 MILUMETRE
t
iNSULATED
ELECTRODE
To adjust pilot flame, remove pilot adjustment cover screw
and turn inner adjustment screw counterclockwise _ to
ir
increase or clockwise _ to decrease pilot flame.
Be sure to replace cover screw after adjustment to prevent
possible gas leakage. See Figure 14, Page 16.
Burners and pilot should be checked for signs of corrosion,
rust or scale buildup.
Area around boiler must be kept clear and free of
combustible materials, gasoline and other flammable
vapors and liquids.
Free flow of combustion and ventilating air to boiler and
boiler room must not be restricted or blocked.
Inspect field sourced low water cutoffs annually, or as
recommended by low water cutoff manufacturer. Flush
float type low water cutoffs per manufacturer's instructions.
Employ a qualified service agency to make annual
inspection of boiler and heating system. They are
experienced in making the inspections outlined above,
and, in event repairs or corrections are necessary, trained
technicians can make the proper changes for safe operation
of the boiler.