INSTALLATION INSTRUCTIONS
DUNKIRK BOILERS
BOILERS
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ELECTRICAL WIRING
TABLE OF CONTENTS INTRODUCTION
RULES FOR SAFE INSTALLATION AND OPERATION
BEFORE INSTALLING THE BOILER
REPAIR PARTS
CHECK-OUTPROCEDURES AND ADJUSTMENTS
MAINTENANCE AND CLEANING
SERVICE HINTS
INTRODUCTION
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BOILER RATINGS AND CAPACITIES
BOILERS FOR USE AT HIGH ALTITUDE
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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
BEFORE INSTALLING THE BOILER
RULES FOR SAFE INSTALLATION AND OPERATION
A. CODES
C. CONSIDERATIONS FOR BOILER LOCATION
B. BOILER SIZING
81,7
D. LOCATING THE BOILER
E.COMBUSTION AIR AND VENT PIPE REQUIREMENTS
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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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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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D. CONDENSATE DRAIN PIPING
FIGURE 8 CONDENSATE - DRAIN PIPING
F. CHILLED WATER PIPING
COMBUSTION AIR AND VENT PIPE
A. CONNECTIONS AND TERMINATION
917,1
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
TABLE 3 GAS PIPE SIZES
B. CONNECTING THE GAS PIPING
C. CHECKING THE GAS PIPING
NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS
A. ELECTRIC POWER SUPPLY
ELECTRICAL WIRING
FIGURE 12 GAS PIPING
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
B. GAS CONTROL VALVE
CONTROLS AND ACCESSORIES
E. DRAFT INDUCER TEMPERATURE SAFETY SWITCH
A. INTEGRATED BOILER CONTROL IBC
I. CIRCULATOR PUMP
F. CASTING TEMPERATURE SAFETY SWITCH
G. DIFFERENTIAL PRESSURE AIR PROVING SWITCH
H.DRAFT INDUCER
M. OPTIONAL EXTERNAL CONDENSATE PUMP
L. FLAME ROLLOUT SAFETY SHUTOFF
START - UP
K. A.S.M.E. RATED PRESSURE RELIEF VALVE
3.Repeat step 2 for all remaining zones
TO TURN OFF GAS TO APPLIANCE
FOR YOUR SAFETY READ BEFORE OPERATING
D. PLACING BOILER IN OPERATION
OPERATING INSTRUCTIONS
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D. INSPECT SYSTEM PIPING
E. TEST IGNITION SYSTEM SAFETY SHUTOFF DEVICE
B. INSPECT VENTING AND AIR INTAKE SYSTEM
C. INSPECT CONDENSATE DRAIN
3600xheating value from step
F. TEST HIGH LIMIT CONTROL AND ADJUST
G. TEST OTHER SAFETY CONTROLS
I. MEASURE THE NATURAL GAS INPUT RATE
FIGURE 18 GAS VALVE
FIGURE 17 MANIFOLD PRESSURE MEASUREMENT DETAIL
Top view of gas control
K REVIEW ALL INSTRUCTIONS
J. SET THERMOSTAT TO DESIRED ROOM TEMPERATURE
ϒCheckout procedure and adjustments performed
INSTALLATION AND CHECK-OUTCERTIFICATE
Date Installed
ϒInstallation instructions have been followed
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
DETAILED SEQUENCE OF OPERATION
END OF NORMAL SEQUENCE OF OPERATION
INITIAL SERVICE CHECKS
TROUBLE SHOOTING
TROUBLE SHOOTING
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SERIOUS INJURY OR DEATH
TROUBLESHOOTING CHART
TROUBLE SHOOTING
ELECTRICAL SHOCK HAZARD MAY CAUSE
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
6&5,37,21
REPAIR PARTS
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6&5,37,21
CONDENSATE DRAIN TRAP ASSEMBLY
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BOILER BLOCK AND PIPING ASSEMBLY
REPAIR PARTS
6&5,37,21
REPAIR PARTS
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REPAIR PARTS
D.MIXER AND AIR PRESSURE SWITCH ASSEMBLY
6&5,37,21
REPAIR PARTS
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REPAIR PARTS
FLUE ADAPTER AND EXHAUST ASSEMBLY
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