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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120,1$/,13870%+        
+($7&$3&,7<0%+        
1(7, % 55$7,1*0%+        
*$625,),&('5,//6,=(        
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35(6685(6:,7&+6(732,17
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7$%/()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

9
1. Select a l cati n which is level, central t the piping systems served and as cl se t the
vent and air intake terminals as p ssible.
2. Accessibility clearances, if m re stringent (i.e. larger clearances) than required fire pr tecti n
clearances, must be used f r the b iler installati n. Accessibility clearances may be achieved
with the use f rem vable walls r partiti ns.
3. The b iler is appr ved f r installati n in cl sets and n c mbustible fl rs. This b iler
shall NOT be installed n carpeting.
4. The clearances sh wn in Table 2 indicate required clearances per IAS listing. A minimum
1" clearance must be maintained between c mbustible c nstructi n and each f the left,
t p and back surfaces f the b iler. A minimum 8" clearance is required n the right side,
t all w r m f r the inlet air pipe. An 18" clearance must be maintained at a side where
passage is required t access an ther side f r cleaning r servicing, inspecti n r
replacement f any parts that n rmally may require such attenti n. All w at least 24" at
the fr nt and left side and 8" at the t p f r servicing. N clearances are required t
venting r c mbusti n air intake piping.
5. Equipment shall be installed in a l cati n which facilitates the perati n f venting and
c mbusti n air intake piping systems as described in this manual.
6. Advise wner f b iler t keep venting and c mbusti n air intake passages free f bstructi ns.
b th the venting and c mbusti n air intake piping systems c nnected t the utd rs must
permit fl w thr ugh the piping systems with ut restricti ns f r the b iler t perate.
7. The b iler shall be installed such that the aut matic gas igniti n system c mp nents are
pr tected fr m water (dripping, spraying, rain, etc.) during perati n and service
(circulat r replacement, c ntr l replacement, etc.).
E. COMBUSTION AIR AND VENT PIPE REQUIREMENTS
This b iler requires a dedicated direct vent system. In a direct vent system, all air f r
c mbusti nis taken directly fr m utside atm sphere, and all flue pr ducts are discharged t
utside atm sphere.
C mbusti n air and vent pipe c nnecti ns must terminate t gether in the same atm spheric
pressure z ne, either thr ugh the r f r sidewall (r f terminati n preferred). See Fig.9 & 10
f r required clearances.
D. LOCATING THE BOILER
&20%867,%/( $&&(66,%,/,7<
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10
CAUTION
KEEP BOILER AREA CLEAN OF DEBRIS AND FREE OF FLAMABLE AND COMBUSTIBLE
MATERIALS, VAPORS AND LIQUIDS
ARNING
When vent pipe is exp sed t temperatures bel w freezing, such as when it passes thr ugh an
unheated space r when a chimney is used as a raceway, vent pipe must be insulated with 1/2
Armaflex r equivalent. In extreme c ld climate areas, use 3/4" Armaflex r equivalent.
C mbusti n air must be clean utd r air. C mbusti n air must n t be taken fr m inside struc-
ture because that air frequently is c ntaminated by hal gens, which include flu rides, chl rides,
ph sphates, br mides and i dides. These elements are f und in aer s ls, detergents, bleaches,
cleaning s lvents, salts, air fresheners, paints, adhesives and ther h useh ld pr ducts.
L cate c mbusti n air inlet as far away as p ssible fr m swimming p l and swimming p l
pump h use.
All c mbusti n air and vent pipes must be airtight and watertight. C mbusti n air and vent
piping must als terminate exactly as sh wn in Fig.9 or 10.
Vent c nnecti ns serving appliances vented by natural draft shall n t be c nnected int any
p rti n f mechanical draft systems perating under p sitive pressure.
S lvent cements are c mbustible. Keep away fr m heat, sparks, and pen flame. Use nly in
well ventilated areas. Av id breathing in vap r r all wing c ntact with skin r eyes.
FAILURE TO FOLLOW THE AFOREMENTIONED WARNINGS COULD RESULT IN FIRE,
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.
F. CONDENSATE DRAIN REQUIREMENTS
C ndensate drain line t be pitched d wn t fl r drain at a minimum f 1/4" per f t. An external
c ndensate pump (n t furnished) may be used if fl r drain is n t available. The c ndensate
pump must be designed f r flue gas c ndensate applicati n
NOTE:1. C ndensate trap is built int the b iler, an external trap is n t required and sh uld n t
be used.
2. W d frame r bl cks may be used t raise the b iler t maintain drain pitch r t be
ab ve external c ndensate pump reserv ir.
3. There is a 115 v lt AC receptacle pr vided n the service switch juncti n b x which
is l cated at the b iler right side, t pr vide p wer f r an external c ndensate
pump (if needed).
G. FOUNDATION REQUIREMENTS
B iler must be placed n level surface. B iler is NOT t be installed n carpeting.

11
NOTE: 1. If b iler is n t level c ndensate drain lines will n t functi n pr perly. Adjustable
feet are l cated n the b iler t make up f r min r surface irregularities r tilt.
2. W d frame r bl cks may be used t raise b iler t maintain drain pitch r t be
ab ve external c ndensate pump reserv ir.
H. REMOVAL OF EXISTING BOILER FROM COMMON VENT SYSTEM
When an existing b iler is rem ved fr m a c mm n venting system, the c mm n venting
system is likely t be t large f r pr per venting f the appliances remaining c nnected t it.
At the time f rem val f an existing b iler, the f ll wing steps shall be f ll wed with each
appliance remaining c nnected t the c mm n venting system placed in perati n, while the
ther appliances remaining c nnected t the c mm n venting system are n t in perati n.
1. Seal any unused penings in the c mm n venting system.
2. Visually inspect the venting system f r pr per size and h riz ntal pitch and determine
there is n bl ckage. r restricti ns, leakage, c rr si n and ther deficiencies which c uld
cause an unsafe c nditi n.
3. Ins far as is practical, cl se all. building d rs and wind ws and all d rs between the
space in which the appliances remaining c nnected t the c mm n venting system are
l cated and ther spaces f the building. Turn n cl thes dryer and any appliance n t
c nnected t the c mm n venting system. Turn n any exhaust fans, such as range
h ds and bathr m exhaust, s they will perate at maximum speed. D n t perate a
summer exhaust fan. Cl se fire dampers.
4. Place in perati n the appliance being inspected. F ll w the lighting instructi ns. Adjust
therm stat s appliances will perate c ntinu usly.
5. Test f r spillage at the draft h d relief pening after 5 minutes f main burner perati n.
Use the flame f a match r candle, r the sm ke fr m a cigarette, cigar r pipe.
6. After it has been determined that each appliance remaining c nnected t the c mm n venting
system pr perly vents when tested as utlined ab ve, return d rs, wind ws, exhaust fans
and any ther gas-burning appliance t their previ us c nditi n f use.
7. Any impr per perati n f the c mm n venting system sh uld be c rrected s the
installati n c nf rms with the Nati nal Fuel C de, NFPA-54/ANSI -Z223.1-latest revisi n,
r secti n 5 f CSA-B 149 f r Canadian standards. When resizing any p rti n f the
c mm n venting system, the c mm n venting system sh uld be resized t appr ach the
minimum size as determined using the appr priate tables in part 11 in the Nati nal Fuel
Gas C de, NFPA-54/ANSI- Z223.1-latest revisi n, r secti n 5 f CSA-B 149 f r
Canadian standards.
The b iler sh uld be placed t pr vide the m st direct c nnecti ns t the c mbusti n air, vent
and system piping as p ssible.
Place crated b iler as cl se t selected l cati n as p ssible and uncrate b iler. The uncrated
b iler may be m ved int p siti n with an appliance d lly r 2-wheel hand truck. The d lly r hand
truck sh uld be inserted under the left ha d side f the b iler. It is p ssible t slide the b iler f r a
sh rt distance n a sm th fl r r surface.
NOTE: Refer t manual secti n LOCATING THE BOILER f r required clearances f r servic
ing and maintenance.
PLACING THE BOILER

12
CAUTION
C pper supply and return piping. must NOT be installed directly int aluminum b iler secti n
casings due t galvanic c rr si n between dissimilar metals. Ir n r steel bushings r pipe
nipples sh uld be used between c pper system piping and b iler t make final c nnecti n t
b iler. Als , the use f dielectric uni ns is acceptable. The packaged b iler is furnished with ir n
piping in the fr nt b iler secti n f r the supply and return c nnecti ns.
When the installati n f the b iler is f r a new heating system, first install all f the radiati n
units (panels, radiat rs, baseb ard, r tubing) and the supply and return mains. After all heating
system piping and c mp nents have been installed, make final c nnecti n f the system piping
t the b iler. A h t water b iler installed ab ve radiati n level must be equipped with a l w water
cut ff device. A peri dic inspecti n is necessary us is flushing f fl at type devices, per l w
water cut ff manufacturers specific instructi ns.
A. SUPPLY AND RETURN LINES
The packaged b iler unit is set up t receive 1 1/4" NPT supply and return piping fr m t p
access. The b iler unit can als be piped fr m the left side by turning the supply elb w, and
fr m the rear f the unit by rem ving plugs in the rear b iler secti n.
NOTE: The circulat r pump and is lati n valves are furnished within a cart n inside the b iler
cabinet and can be installed at the installer preferred l cati n.
NEAR BOILER PIPING

FIGURE 2 SINGLE ZONE BOILER PIPING
13

FIGURE 3 MULTI ZONE BOILER PIPING WITH ZONE VALVES
14

N TE: When zoning with circulators, the furnished circulator pump should be used as one of the
zone pumps. Each stripped end of the electrical wires for the circulator pump inside the junction
box should be taped or wire nutted to prevent short circuits. Unplug the circulator pump wiring at
the integrated boiler control.
FIGURE 4 MULTI ZONE BOILER PIPING WITH CIRCULATORS
15

B. PRESSURE RELIEF VALVE
The b iler is furnished with a fact ry installed relief valve in the t p f the b iler. Pr vide ¾
piping fr m the supplied relief valve t a l cal fl r drain, but leave an air gap between piping
and drain. N shut ff f any descripti n shall be placed between safety relief valve and the
b iler, r n the discharge pipes between such safety valve and the atm sphere. Installati n
f the safety relief valve shall c nf rm t ANSI/ASME B iler and Pressure Vessel C de,
Secti n IV. The manufacturer is n t resp nsible f r any water damage.
C. EXPANSION TANK AND MAKE-UP WATER
Determine required system fill pressure, system design temperature, and system water
c ntent. B iler c ntains 2.6 gall ns (U.S.). Size expansi n tank acc rdingly. C nsult
expansi n tank manufacturer f r pr per sizing inf rmati n. C nnect pr perly sized
expansi n tank (n t furnished) as sh wn in Fig. 6 f r diaphragm type expansi n tank and
Fig. 7 f r c nventi nal cl sed type expansi n tanks. F r diaphragm type expansi n tanks,
adjust the tank air pressure t match the system fill pressure. Install air vent (furnished) as
sh wn f r diaphragm type expansi n tank system nly. Install make-up water c nnecti ns
as sh wn per l cal c des. If a pressure reducing valve is used, adjust t match the system
fill pressure. In c nnecting the c ld make-up water supply t the b iler, make sure that clean
water supply is available. When the water supply is fr m a well r pump, sand strainer
sh uld be installed at the pump.
16
FIGURE 5 SINGLE ZONE BOILER PIPING

FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING
17

FIGURE 7 CONVENTIONAL (closed type) EXPANSION TANK PIPING
18