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Quantum GAS-FIRED BOILERS installation instructions Dunkirk Boilers, Installation Instructions

Models: GAS-FIRED BOILERS

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BOILERS

GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER

BOILERS

INSTALLATION INSTRUCTIONS

These instructions must be affixed on or adjacent to the boiler

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 gas supplier.

DUNKIRK BOILERS

DUNKIRK, NEW YORK 14048 - 716 366-5500

Member: The Hydronics Institute

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Quantum GAS-FIRED BOILERS installation instructions Dunkirk Boilers, Installation Instructions

Contents

INSTALLATION INSTRUCTIONS DUNKIRK BOILERSBOILERS Page RULES FOR SAFE INSTALLATION AND OPERATION TABLE OF CONTENTS INTRODUCTIONBEFORE INSTALLING THE BOILER ELECTRICAL WIRINGMAINTENANCE AND CLEANING CHECK-OUTPROCEDURES AND ADJUSTMENTSSERVICE HINTS REPAIR PARTSINTRODUCTION 7$%/6$/9/5$7,1*61$785$/$13523$1*$66 BOILER RATINGS AND CAPACITIESBOILERS FOR USE AT HIGH ALTITUDE 7$%/%02/3523$1*$6+,*+$/7,785$7,1*6 7$%/$02/1$785$/*$6+,*+$/7,785$7,1*67$%/02/3523$1*$6+,*+$/7,785$7,1*6 7$%/&02/1$785$/*$6+,*+$/7,785$7,1*67$%/02/1$785$/*$6+,*+$/7,785$7,1*6 7$%/02/3523$1*$6+,*+$/7,785$7,1*6BEFORE INSTALLING THE BOILER RULES FOR SAFE INSTALLATION AND OPERATIONA. CODES C. CONSIDERATIONS FOR BOILER LOCATION B. BOILER SIZINGE.COMBUSTION AIR AND VENT PIPE REQUIREMENTS D. LOCATING THE BOILER2,/5&/$5$1&6 81,7G.FOUNDATION REQUIREMENTS F. CONDENSATE DRAIN REQUIREMENTSPLACING THE BOILER A. SUPPLY AND RETURN LINES NEAR BOILER PIPINGFIGURE 2 SINGLE ZONE BOILER PIPING Page Page B.PRESSURE RELIEF VALVE FIGURE 5 SINGLE ZONE BOILER PIPINGC.EXPANSION TANK AND MAKE-UPWATER FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING Page D. CONDENSATE DRAIN PIPING FIGURE 8 CONDENSATE - DRAIN PIPINGF. CHILLED WATER PIPING COMBUSTION AIR AND VENT PIPEA. CONNECTIONS AND TERMINATION 0,1,080 4.Combustion air and vent piping lengths0$ ,080 917,1FIGURE 9 ROOF VENT/INTAKE TERMINATIONS FIGURE 10 SIDEWALL VENT/INTAKE TERMINATIONS FIGURE 11 COMBUSTION AIR AND VENT PIPING GAS SUPPLY PIPING B.INSTALLATIONA. CHECK GAS SUPPLY C. CHECKING THE GAS PIPING B. CONNECTING THE GAS PIPINGNEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS TABLE 3 GAS PIPE SIZESA. ELECTRIC POWER SUPPLY ELECTRICAL WIRINGFIGURE 12 GAS PIPING C. Connect Circulator Pump Wiring B. INSTALL YOUR THERMOSTATFIGURE 13 FIELD WIRING CONNECTIONS D.FIGURE 14 SCHEMATIC WIRING DIAGRAM FIGURE 15 LADDER WIRING DIAGRAM E. DRAFT INDUCER TEMPERATURE SAFETY SWITCH CONTROLS AND ACCESSORIESA. INTEGRATED BOILER CONTROL IBC B. GAS CONTROL VALVEG. DIFFERENTIAL PRESSURE AIR PROVING SWITCH F. CASTING TEMPERATURE SAFETY SWITCHH.DRAFT INDUCER I. CIRCULATOR PUMPSTART - UP L. FLAME ROLLOUT SAFETY SHUTOFFK. A.S.M.E. RATED PRESSURE RELIEF VALVE M. OPTIONAL EXTERNAL CONDENSATE PUMP3.Repeat step 2 for all remaining zones D. PLACING BOILER IN OPERATION FOR YOUR SAFETY READ BEFORE OPERATINGOPERATING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCEPage B. INSPECT VENTING AND AIR INTAKE SYSTEM E. TEST IGNITION SYSTEM SAFETY SHUTOFF DEVICEC. INSPECT CONDENSATE DRAIN D. INSPECT SYSTEM PIPINGG. TEST OTHER SAFETY CONTROLS F. TEST HIGH LIMIT CONTROL AND ADJUSTI. MEASURE THE NATURAL GAS INPUT RATE 3600xheating value from stepFIGURE 18 GAS VALVE FIGURE 17 MANIFOLD PRESSURE MEASUREMENT DETAILTop view of gas control K REVIEW ALL INSTRUCTIONS J. SET THERMOSTAT TO DESIRED ROOM TEMPERATUREDate Installed INSTALLATION AND CHECK-OUTCERTIFICATEϒInstallation instructions have been followed ϒCheckout procedure and adjustments performedA. BEGINNING OF EACH HEATING SEASON MAINTENANCE AND CLEANINGB.DAILY DURING HEATING SEASON C. MONTHLY DURING HEATING SEASON 2.Cleaning Flue passages between boiler sectionsD.PERIODICALLY DURING HEATING SEASON l.Connect gas line to gas valve d.Reinstall and connect the condensate trap, using the hose clamps to secure the various condensate lines to their fittings SERVICE HINTS DETAILED SEQUENCE OF OPERATION DETAILED SEQUENCE OF OPERATION DETAILED SEQUENCE OF OPERATION END OF NORMAL SEQUENCE OF OPERATIONINITIAL SERVICE CHECKS TROUBLE SHOOTING67$786 6 67067$7861,&$76 TROUBLE SHOOTINGTROUBLE SHOOTING TROUBLESHOOTING CHARTELECTRICAL SHOCK HAZARD MAY CAUSE SERIOUS INJURY OR DEATHTROUBLESHOOTING CHART TROUBLE SHOOTINGTROUBLESHOOTING CHART TROUBLE SHOOTINGTROUBLESHOOTING CHART TROUBLE SHOOTINGTROUBLESHOOTING CHART TROUBLE SHOOTINGTROUBLESHOOTING CHART TROUBLE SHOOTINGDIFFERENTIAL AIR PRESSURE SWITCH CHECK JACKET AND BASE ASSEMBLY REPAIR PARTS$&.7$1%$6$660% REPAIR PARTS70180%5 6&5,37,212116$75$,175$3$660% CONDENSATE DRAIN TRAP ASSEMBLY70180%5 6&5,37,21BOILER BLOCK AND PIPING ASSEMBLY REPAIR PARTS2,/5%/2&.$13,3,1*$660% REPAIR PARTS70180%5 6&5,37,21REPAIR PARTS D.MIXER AND AIR PRESSURE SWITCH ASSEMBLY0, 5$1$,53566856 ,7&+$660% REPAIR PARTS70180%5 6&5,37,21FLUE ADAPTER AND EXHAUST ASSEMBLY REPAIR PARTS8$$375$1 +$8675$660% 70180%5