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