DUNKIRK BOILERS
INSTALLATION INSTRUCTIONS
BOILERS
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BEFORE INSTALLING THE BOILER
TABLE OF CONTENTS INTRODUCTION
RULES FOR SAFE INSTALLATION AND OPERATION
ELECTRICAL WIRING
SERVICE HINTS
CHECK-OUTPROCEDURES AND ADJUSTMENTS
MAINTENANCE AND CLEANING
REPAIR PARTS
INTRODUCTION
BOILER RATINGS AND CAPACITIES
7$%/6$/9/5$7,1*61$785$/$13523$1*$66
BOILERS FOR USE AT HIGH ALTITUDE
7$%/$02/1$785$/*$6+,*+$/7,785$7,1*6
7$%/%02/3523$1*$6+,*+$/7,785$7,1*6
7$%/02/1$785$/*$6+,*+$/7,785$7,1*6
7$%/&02/1$785$/*$6+,*+$/7,785$7,1*6
7$%/02/3523$1*$6+,*+$/7,785$7,1*6
7$%/02/3523$1*$6+,*+$/7,785$7,1*6
RULES FOR SAFE INSTALLATION AND OPERATION
BEFORE INSTALLING THE BOILER
A. CODES
B. BOILER SIZING
C. CONSIDERATIONS FOR BOILER LOCATION
2,/5&/$5$1&6
D. LOCATING THE BOILER
E.COMBUSTION AIR AND VENT PIPE REQUIREMENTS
81,7
F. CONDENSATE DRAIN REQUIREMENTS
G.FOUNDATION REQUIREMENTS
PLACING THE BOILER
NEAR BOILER PIPING
A. SUPPLY AND RETURN LINES
FIGURE 2 SINGLE ZONE BOILER PIPING
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FIGURE 5 SINGLE ZONE BOILER PIPING
B.PRESSURE RELIEF VALVE
C.EXPANSION TANK AND MAKE-UPWATER
FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING
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FIGURE 8 CONDENSATE - DRAIN PIPING
D. CONDENSATE DRAIN PIPING
COMBUSTION AIR AND VENT PIPE
F. CHILLED WATER PIPING
A. CONNECTIONS AND TERMINATION
0$ ,080
4.Combustion air and vent piping lengths
0,1,080
917,1
FIGURE 9 ROOF VENT/INTAKE TERMINATIONS
FIGURE 10 SIDEWALL VENT/INTAKE TERMINATIONS
FIGURE 11 COMBUSTION AIR AND VENT PIPING
B.INSTALLATION
GAS SUPPLY PIPING
A. CHECK GAS SUPPLY
NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS
B. CONNECTING THE GAS PIPING
C. CHECKING THE GAS PIPING
TABLE 3 GAS PIPE SIZES
ELECTRICAL WIRING
A. ELECTRIC POWER SUPPLY
FIGURE 12 GAS PIPING
B. INSTALL YOUR THERMOSTAT
C. Connect Circulator Pump Wiring
FIGURE 13 FIELD WIRING CONNECTIONS
D.FIGURE 14 SCHEMATIC WIRING DIAGRAM
FIGURE 15 LADDER WIRING DIAGRAM
A. INTEGRATED BOILER CONTROL IBC
CONTROLS AND ACCESSORIES
E. DRAFT INDUCER TEMPERATURE SAFETY SWITCH
B. GAS CONTROL VALVE
H.DRAFT INDUCER
F. CASTING TEMPERATURE SAFETY SWITCH
G. DIFFERENTIAL PRESSURE AIR PROVING SWITCH
I. CIRCULATOR PUMP
K. A.S.M.E. RATED PRESSURE RELIEF VALVE
L. FLAME ROLLOUT SAFETY SHUTOFF
START - UP
M. OPTIONAL EXTERNAL CONDENSATE PUMP
3.Repeat step 2 for all remaining zones
OPERATING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
D. PLACING BOILER IN OPERATION
TO TURN OFF GAS TO APPLIANCE
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C. INSPECT CONDENSATE DRAIN
E. TEST IGNITION SYSTEM SAFETY SHUTOFF DEVICE
B. INSPECT VENTING AND AIR INTAKE SYSTEM
D. INSPECT SYSTEM PIPING
I. MEASURE THE NATURAL GAS INPUT RATE
F. TEST HIGH LIMIT CONTROL AND ADJUST
G. TEST OTHER SAFETY CONTROLS
3600xheating value from step
FIGURE 17 MANIFOLD PRESSURE MEASUREMENT DETAIL
FIGURE 18 GAS VALVE
Top view of gas control
J. SET THERMOSTAT TO DESIRED ROOM TEMPERATURE
K REVIEW ALL INSTRUCTIONS
ϒInstallation instructions have been followed
INSTALLATION AND CHECK-OUTCERTIFICATE
Date Installed
ϒCheckout procedure and adjustments performed
MAINTENANCE AND CLEANING
A. BEGINNING OF EACH HEATING SEASON
B.DAILY DURING HEATING SEASON
2.Cleaning Flue passages between boiler sections
C. MONTHLY DURING HEATING SEASON
D.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
END OF NORMAL SEQUENCE OF OPERATION
DETAILED SEQUENCE OF OPERATION
TROUBLE SHOOTING
INITIAL SERVICE CHECKS
1,&$76
6 67067$786
67$786
TROUBLE SHOOTING
ELECTRICAL SHOCK HAZARD MAY CAUSE
TROUBLESHOOTING CHART
TROUBLE SHOOTING
SERIOUS INJURY OR DEATH
TROUBLE SHOOTING
TROUBLESHOOTING CHART
TROUBLE SHOOTING
TROUBLESHOOTING CHART
TROUBLE SHOOTING
TROUBLESHOOTING CHART
TROUBLE SHOOTING
TROUBLESHOOTING CHART
TROUBLE SHOOTING
TROUBLESHOOTING CHART
DIFFERENTIAL AIR PRESSURE SWITCH CHECK
REPAIR PARTS
JACKET AND BASE ASSEMBLY
70180%5
REPAIR PARTS
$&.7$1%$6$660%
6&5,37,21
70180%5
CONDENSATE DRAIN TRAP ASSEMBLY
2116$75$,175$3$660%
6&5,37,21
REPAIR PARTS
BOILER BLOCK AND PIPING ASSEMBLY
70180%5
REPAIR PARTS
2,/5%/2&.$13,3,1*$660%
6&5,37,21
D.MIXER AND AIR PRESSURE SWITCH ASSEMBLY
REPAIR PARTS
70180%5
REPAIR PARTS
0, 5$1$,53566856 ,7&+$660%
6&5,37,21
8$$375$1 +$8675$660%
REPAIR PARTS
FLUE ADAPTER AND EXHAUST ASSEMBLY
70180%5