Dunkirk GAS-FIRED BOILERS User manual

DUNKIRK BOILERS
DUNKIRK, NEW YORK 14048 - 716 366-5500
Member: The Hydronics Institute
GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER
BOILERS
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
ARNING
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.

1
TABLE OF CONTENTS INTRODUCTION ............................................................................. 3
BOILER RATINGS AND CAPACITIES .................................................................................. 4
RULES FOR SAFE INSTALLATION AND OPERATION....................................................... 7
BEFORE INSTALLING THE BOILER .................................................................................... 7
A. c des ............................................................................................................................... 7
B. b iler sizing ...................................................................................................................... 8
C. c nsiderati ns f r b iler l cati n ..................................................................................... 8
D. l cating the b iler ............................................................................................................ 8
E. c mbusti n air and vent pipe requirements ..................................................................... 9
F. c ndensate drain requirements...................................................................................... 10
G. f undati n requirements................................................................................................ 11
H. rem ving existing b iler fr m c mm n venting system ................................................. 11
PLACING THE BOILER ....................................................................................................... 11
NEAR BOILER PIPING ........................................................................................................ 12
A. supply and return lines................................................................................................... 12
B. pressure relief valve ....................................................................................................... 16
C. expansi n tank and make-up water ............................................................................... 16
D. c ndensate drain piping ................................................................................................ 19
E. filling c ndensate trap .................................................................................................... 19
F. chilled water piping ........................................................................................................ 20
COMBUSTION AIR AND VENT PIPE .................................................................................. 21
A. c nnecti ns and terminati ns ........................................................................................ 21
B. installati n ...................................................................................................................... 22
GAS SUPPLY PIPING .......................................................................................................... 25
A. check gas supply ........................................................................................................... 25
B. c nnecting the gas piping .............................................................................................. 25
C. checking the gas piping ................................................................................................. 26
ELECTRICAL WIRING ......................................................................................................... 27
A. electric p wer supply ..................................................................................................... 27
B. install y ur therm stat. ................................................................................................... 28
C. field wiring c nnecti ns ................................................................................................. 29
D. schematic wiring diagram .............................................................................................. 30
E. ladder wiring diagram..................................................................................................... 31
CONTROLS AND ACCESSORIES ...................................................................................... 32
A. UT 1013-10 integrated b iler c ntr l ............................................................................ 32
B. gas c ntr l valve ............................................................................................................32
C. h t surface igniter ..........................................................................................................32
D. L4006A high limit aquastat c ntr l ................................................................................ 32
E. draft inducer temperature safety switch ......................................................................... 32
F. casting temperature safety switch .................................................................................. 33
G. differential pressure air pr ving switch .......................................................................... 33

2
H. draft inducer...................................................................................................................... 33
I. circulat r pump..................................................................................................................33
J. drain valve......................................................................................................................... 33
K. relief valve........................................................................................................................ 34
L. flame r ll ut safety shut ff................................................................................................ 34
M. external c ndensate pump............................................................................................... 34
START-UP.............................................................................................................................. 34
A. water treatment and freeze pr tecti n.............................................................................. 34
B. filling b iler with water and purging air with diaphragm type expansi n tanks.................. 35
C. filling b iler with water and purging air with c nventi nal cl sed type expansi n tanks.... 35
D. b iler in placing.................................................................................................................. 36
I. f r y ur safety read bef re perating
II. perating instructi ns
III. t turn ff gas t appliance
CHECK-OUT PROCEDURES AND ADJUSTMENTS............................................................ 37
A. verify pr per sequence f perati n.................................................................................. 37
B. inspect venting and air intake system................................................................................ 38
C. inspect c ndensate drain................................................................................................... 38
D. inspect system piping.........................................................................................................38
E. test igniti n system safety shut ff...................................................................................... 38
F. test high limit c ntr l and adjust.........................................................................................38
G. test ther safety c ntr ls....................................................................................................39
H. set therm stat heat............................................................................................................ 39
1. measure the gas input rate................................................................................................39
J. set therm stat t desired r m temperature......................................................................41
K. review all instructi ns........................................................................................................ 41
L. installati n and check- ut certificate.................................................................................. 41
MAINTENANCE AND CLEANING.......................................................................................... 43
A. beginning f each seas n.................................................................................................. 43
B. daily during heating seas n............................................................................................... 43
C. m nthly during heating...................................................................................................... 44
D. peri dically during heating................................................................................................. 44
E. end f each heating seas n -annual shut d wn pr cedure............................................... 44
F. annual examinati n and cleaning f b iler c mp nents.................................................... 44
SERVICE HINTS...................................................................................................................... 47
A fl w chart/detailed sequence f perati n......................................................................... 47
B. tr uble sh ting................................................................................................................. 50
C. differential air pressure switch check................................................................................. 58
REPAIR PARTS.......................................................................................................................59
A. jacket and base..................................................................................................................59
B. c ndensate drain trap assembly ....................................................................................... 61
C. bl ck and piping assembly.................................................................................................62
D. mixer and air pressure switch assembly............................................................................ 64
E. flue adapter and exhauster assembly................................................................................ 66

This appliance is a gas-fired direct vent hot water boiler with cast aluminum boiler sections. A
revolutionary cast aluminum heat exchanger means better heat transfer and thermal storage than
similarly sized cast iron boilers, which results in higher efficiency. The heating system water absorbs large
amounts of heat from the cast aluminum heat exchanger, cooling the flue gases and causing
condensation. Sealed combustion, premix gas burner, and low flame temperature means drastically
reduced C and N x emissions, which contribute to a cleaner and healthier environment.
This appliance, unlike normal residential atmospheric and induced draft units, takes its combustion air
directly from the outdoors (sealed combustion) and does not compete with building occupants for fresh
air. Sealed combustion (also known as direct vent) is the safest and best way to obtain plenty of clean
combustion air. The induced draft fan draws in the outside combustion air, then takes the cooler flue
gases from the boiler unit and provides a positive removal of the flue gases from the building through
inexpensive and readily available PVC and CPVC pipes.
3
FIGURE 1
INTRODUCTION

BOILER RATINGS AND CAPACITIES
4
These l w pressure gas-fired h t water b ilers are design certified by CSA Internati nal f r use
with natural and pr pane gases. The b ilers are c nstructed and hydr statically tested f r a
maximum w rking pressure f 50 psig (p unds per square inch gage) in acc rdance with
A.S.M.E. (American S ciety f Mechanical Engineers) B iler and Pressure Vessel C de Secti n
IV Standards f r heating b ilers.
++ AFUE (Annual Fuel Utilizati n Efficiency) and Heating Capacity is based n the D.O.E.
(Department f Energy) test pr cedure.
The B ilers are certified in acc rdance with ANSI (American Nati nal Standards Institute)
Z21.13 standards as gas-fired, direct vent, c ndensing, h t water b ilers.
The Heati g Capacity indicates the am unt f heat available after subtracting the l sses up the
stack. M st f this heat is available t heat water. A small p rti n is heat fr m the jacket and
surfaces f the b iler, and it is assumed that this heat stays in the structure. The Net I=B=R
Rati g represents the p rti n f the remaining heat that can be applied t heat the radiati n r
terminal units (i.e. finned tube baseb ard, cast ir n radiat rs, radiant fl r, etc.). The difference
between the Heating Capacity and the Net I=B=R Rating, called the piping and pickup
all wance, establishes a reserve f r heating the v lume f water in the system and ffsetting
heat l sses fr m the piping. The Net I=B R Ratings sh wn are based n a piping and pickup
fact r f 1.15 in acc rdance with the I=B=R Standard as published by the Hydr nics Institute.
The Net I=B=R Rating f the b iler selected sh uld be greater than r equal t the calculated
peak heating l ad (heat l ss) f r the building r area(s) served by the b iler and ass ciated h t
water heating systems. The manufacturer sh uld be c nsulted bef re selecting a b iler f r
installati ns having unusual piping and pickup requirements.
BOILERS FOR USE AT HIGH ALTITUDE
The b ilers are fact ry equipped f r perati n at altitudes ranging fr m 0-2,000 feet ab ve sea
level. F r use f these b ilers at altitudes ab ve 2,000 feet ab ve sea level, the gas input
ratings (MBH) must be reduced.
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5
U.S.A. ONLY: F r altitudes ab ve 2,000 feet ab ve sea level, input ratings sh uld be reduced
as sh wn in tables IA, C, & E f r natural gas b ilers r in tables 1B, D & F f r pr pane fired
b ilers. Reduced input ratings are achieved by the natural derati n f the gas at higher
elevati ns and fine tuned by adjusting the manif ld pressure.
CANADA ONLY: F r altitudes in the range f 2,000-4,500 feet ab ve sea level, b ilers may be
field equipped f r use at high altitude by using a certified high altitude c nversi n kit. The change
in main burner rifice size results in a 10% reducti n f the b iler gas input rating (MBH).
The c nversi n shall be carried ut by a manufacturers auth rized representative, in
acc rdance with the requirements f the manufacturer, pr vincial r territ rial auth rities having
jurisdicti n, and in acc rdance with the requirements f the CSA-B 149.1 and CSA-B 149.2
Installati n C des. The certified field c nversi n kit includes a c nversi n data plate, indicating
that the b iler has been c nverted f r high altitude use. The c rrect c nversi n inf rmati n must
be entered n the c nversi n data plate.
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6
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+($7&$3&,7<0%+        
1(7, % 55$7,1*0%+         
*$625,),&('5,//6,=(        
0$1,)2/'35(6685(
,1&+(6:$7(5&2/801        
35(6685(6:,7&+6(732,17
,1&+(6:$7(5&2/801        
(/(9$7,21)((7        
120,1$/,13870%+        
+($7&$3&,7<0%+        
1(7, % 55$7,1*0%+        
*$625,),&('5,//6,=(        
0$1,)2/'35(6685(
,1&+(6:$7(5&2/801        
35(6685(6:,7&+6(732,17
,1&+(6:$7(5&2/801        
7$%/()02'(/3523$1(*$6+,*+$/7,78'(5$7,1*6
7$%/((02'(/1$785$/*$6+,*+$/7,78'(5$7,1*6
7$%/('02'(/3523$1(*$6+,*+$/7,78'(5$7,1*6
7$%/(&02'(/1$785$/*$6+,*+$/7,78'(5$7,1*6

7
l. Read the entire installati n manual bef re beginning the installati n. Failure t f ll w these
rules f r safe installati n and perati n and these instructi ns c uld cause a malfuncti n f
the b iler and result in death, seri us b dily injury, and/ r pr perty damage.
2. Check all applicable state and l cal building c des and utility c mpany requirements
bef re installati n. The installati n must c nf rm with these requirements in their
entirety. In the absence f these c des, use NFPA Installati n C des and g d
industry practice.
3. Bef re servicing the b iler - all w the b iler t c l. Always shut ff any electricity and
gas supply c nnected t the b iler pri r t servicing.
4. Inspect gas line f r leaks.
5. Be certain gas input rate is c rrect. Over firing may result in early failure f the b iler
secti ns. This may cause danger us perati n. Under firing may result in t much air
f r the pre-mix burner causing p r r l ss f c mbusti n.
6. Never vent the pr ducts f c mbusti n fr m this b iler t an encl sed space. Always
vent t the utd rs. Never vent t an ther r m r t inside a building.
7. Be sure there is adequate utd r air supply t b iler.f r c mplete c mbusti n.
8. F ll w a regular service and maintenance schedule f r efficient and safe perati n. 9.
Keep b iler area clean f debris and free f c mbustible and flammable materials.
10. Pr per thr ugh the wall r thr ugh the r f c mbusti n venting shall be in acc rdance with the
materials and meth ds described in this manual. Installati n must c mply with l cal c des.
11. This b iler and related h t water heating systems are n t d it y urself items. They
must be installed and serviced by qualified pr fessi nals.
ARNING
This b iler has been equipped f r residential installati ns. If used f r c mmercial applicati ns, any
additi nal c de requirements must be adhered t f r installati n. This may require additi nal
c ntr ls including but n t limited t a l w water cut ff, a manual reset high temperature limit, and
wiring and/ r piping m dificati ns. The manufacturer is n t resp nsible f r any field installati n
changes made t a b iler installati n which are n t described r ackn wledged in this manual.
C mplete all f the f ll wing pri r t installing the b iler.
A. CODES
This b iler pr duct is a gas-fired, direct vent, c ndensing b iler and must be installed in
acc rdance with all applicable federal, state and l cal building c des including, but n t
limited t the f ll wing:
U ited States -Installati n shall c nf rm with Nati nal Fuel Gas C de (NFPA-54/ANSI
Z223.1-latest editi n)
Ca ada - Installati n shall be in acc rdance with CSA B 149.1 and .2. installati n
c des.
RULES FOR SAFE INSTALLATION AND OPERATION
BEFORE INSTALLING THE BOILER

Where required by the auth rity having jurisdicti n, the installati n must c nf rm t the
American S ciety f Mechanical Engineers Safety C de f r C ntr ls and Safety Devices
f r Aut matically Fired B ilers, N .CSD-1.
The installati n must c nf rm t the requirements f the auth rity having jurisdicti n r, in the
absence f such requirements, t the Nati nal Fuel Gas C de, ANSI Z223.1 - latest revisi n.
Installers - F ll w l cal regulati ns with respect t installati n f CO (Carb n
M n xide) Detect rs. F ll w maintenance rec mmendati ns in this manual.
Techniciens -Veuillez v us c nf rmer à la réglementati n en vigueur c ncernant 1'
installati ns des détecteurs d' xyde de carb ne. Suivre les c nsignes
d'entretien figurant dans le manuel d'instructi n ci-j int.
B. BOILER SIZING
•Check t be sure y u have selected the b iler with the pr per capacity bef re starting
the installati n. The I=B R Rating f the b iler selected sh uld be greater than r equal
t the calculated peak heating l ad (heat l ss) f r the building r area(s) served by the
b iler and ass ciated h t water heating systems. See the table "BOILER RATINGS
AND CAPACITIES".
•Heat l ss calculati ns sh uld be based n appr ved industry meth ds.
C. CONSIDERATIONS FOR BOILER LOCATION
Bef re selecting a l cati n f r the b iler, the f ll wing sh uld be c nsidered. Each b iler
c nsidered.
•Supplied with the c rrect type f gas (natural gas r pr pane).
•C nnected t a suitable c mbusti n air intake piping system t supply the c rrect
am unts f fresh ( utd r) air f r c mbusti n. (maximum length 80' f r the M del-100
b iler, and maximum length 100' f r the M del-75 and M del-50 b ilers).
•C nnected t a suitable venting system t rem ve the hazard us pr ducts f gas
c mbusti n (maximum length 80' f r the M del-100 b iler, and maximum length 100' f r
the M del-75 and M del-50 b ilers).
•C nnected t a suitable h t water heating system
•Supplied with a suitable electrical supply f r all b iler m t rs and c ntr ls.
•C nnected t a pr perly l cated therm stat r perating c ntr l. (n t included with
b iler)
•Placed n level surface (must NOT be installed n carpeting)
•C ndensate drain line must be pitched d wn t fl r drain r external c ndensate
pump with reserv ir at ¼" per f t (w d frame r bl cks may be used t raise b iler).
8