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