DUNKIRK Boiler Manual L0612123

User Manual: DUNKIRK DUNKIRK Boiler Manual DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides

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Q95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER

_i!i!i

DUNKIRK
BOILERS
85 Middle Rd.
Dunkirk. NY 14048
www. dunkirk, com

An
ECR
An ISO 9001

P/N 240006103D. Rev. 1 1 [04/06.t

INSTALLATION
P/N# 240006103D,

Rev. 1.1 [04/06]

MANUAL
• Printed

in USA • Made In USA

TOP

................
s' ......

AR VENi r;AKE
OPENING
"f ?_'PVC
OP IONAq

LEFTSiDE

FRONT

RIGHT SIDE

Introduction

..........................................

Safety Symbols ....................................

III

Rules for Safe Installation and Operation

Boiler Ratings

.............

Before

The Boiler ..................

Placing The Boiler ................................

VII

Near Boiler Piping ................................

VIII

Combustion

Air and Vent Pipe .............

Gas Supply

Piping ...............................

Wiring ...................................

and Capacities

Installing

Electrical

Controls

XII

Maintenance

XIII

Boiler Wire Diagram ............................

XIV

Piping and Wiring Appendix

and Accessories

....................

and Cleaning ..................

.................

Keep this manual near boiler
and retain for future reference.

o¢÷

/_,47 ,s

BACK

'CONDENSATE
DA[N
OP NING
1/2' PVC

This appliance is a gas-fired direct vent modulating cast aluminum hot water boiler. A revolutionary
cast aluminum monoblock 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 CO and NOx 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 forced draft fan
draws in the outside combustion air to mix with gas,
which flows into the pre-mix burner and combusts.
The fan then forces the resulting 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.

The following defined
of varying risk levels

symbols

are used throughout

this manual to notify the reader of potential

hazards

IAc u,,o.A

ndicates
a potentially
hazardous
situation
I
hich, if not avoided,
may result in minor or I
oderate injury. It may also be used to alert I
gainst

dicates

a potentially

hich, if not avoided,
serious
injury:

hazardous
could result

situation

Failure

ns could cause
d result in death,
operty damage
ormatlon, consult
ency, or the gas

manual.
to follow

4 Be certain gas input rate is correct Overflrmg
may result in early failure of the boiler components
This may cause dangerous operation
Underflrlng
may result in too much air for the pre-mlx burner
causing poor or loss of combustion
5 Never vent the products of combustion from this
boiler to an enclosed space Always vent to the outdoors Never vent to another room or to inside a

J
these

instructlon_

3 Inspect gas line for leaks

applications,
any and all additional
code requirements
must be adhered
to for installation. This may require
additional
controls,
including but not limited to an external
water cut off, a manual reset high temperature
limit, and wiring and/or piping modifications.
The manufacturer
is not responsible
for any
field installation
changes
made to a boiler
installation
which are not described
or ac-

PORTANT:

'-cMoPORTANT:
Read
the following
mpletely before
mstalhngll

2 Before serwcmg the boiler, allow it to cool Always shut off any electricity and gas supply connected to the boiler prior to serwcmg

This appliance
has been equipped
for residential installations.
If used for commercial

in this

practices,

in death I
j/

wAR.I.G
Ai

knowledged

unsafe

building

mstruc-'-_

a malfunction
of the boiler
serious bodily injury, and/or
For assistance or additional
a quahfled installer, service
supplier
,j/

I
I
I
I

his boiler contains
ceramic
fiber materials.
I
se care when handling
these materials
per I
Ithe instructions
specified
under "Modulating
k...Burner' in Section xI of this manual,

I
j)

1 Check all applicable
state and local building
codes and utility company
requirements
before
installation
This installation
must conform with
these requirements
m their enhrety In the absence
of these codes, use NFPA installation codes and
good industry practice

6 Be sure there is adequate outdoor
boiler for complete combustion

air supply to

7 Followa regularserwce
and maintenance
ule for efficient and safe operation

sched-

8 Keep boiler area clean of debris and free of combustible and flammable materials
9
Proper
through-the-wall
or through-the-roof
combustion venting shall be in accordance with the
materials and methods described
in this manual
Installation

must comply with local codes

10 This boiler and related hot water heating systems are not do4t-yourself
items They must be mstalled and serwced by quahfled professionals
Rat-

TABLE1:SEALEVELRATINGS
- NATURAL
ANDPROPANE
GASES

HighFire

200

190

165

Low Fire

95%

I_)1 MBH = 1,000 Btuh (British Thermal Units Per Hour)
12_
Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department

TABLE 2:95M-200

2" CPVC & 3" PVC

of Energy) test procedures.

HiGH ALTITUDE DERATE CHART

High Fire

196

192

188

184

181

177

174

170

Low Fire

78.4

76.8

75.3

73.8

72.3

70.9

69.5

68.1

ings above are for sea level applications. The boiler
automatically derates input at a rate d 2% for every
1000 feet above an elevation of 2000 feet (see Table
2). The boiler wilt also derate relative to the calorific
value of the gas being used. Use the formula specified in "Measure The Natural Gas Input Rate" in Section VII of the Control Manual and Operating Instructions (P/N# 240006104) to determine the proper rate
due to derated gas. No alterations to the boiler are
required for altitudes above sea level.
These low pressure gas-fired hot water boilers are
design certified by CSA International,
for use with
natural and propane gases. The boilers are constructed and hydrostatically
tested for a maximum
working pressure of 50 PSIG (pounds per square
inch gauge) in accordance
with ASME (American
Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating
boilers.
The Boilers are certified in accordance

with ANSI

(American National Standards Institute) Z21.13
standards as gas-fired, direct vent, condensing,
hot water boilers.

Review

the following

before

installing

the boiler.

This boiler product is a gas-fired, direct vent, condensing boiler and must be installed in accordance
with all applicable federal, state and local building
codes including, but not limited to the following:
United

States

284 Ibs.

- Installation

shall

conform

National Fuel Gas Code (NFPA-54/ANSI
latest edition)

with

Z223.1-

The Heating Capacity indicates the amount of heat
available after subtracting the losses up the stack.
Most of this heat is available to heat water. A small
portion is heat loss from the jacket and surfaces of
the boiler, and it is assumed that this heat stays in
the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied
to heat the radiation or terminal units (i.e., finned
tube baseboard,
cast iron radiators, radiant floor,
etc.) The difference between the Heating Capacity
and the Net I=B=R Rating, called the piping and
pickup allowance, establishes a reserve for heating
the volume of water in the system and offsetting
heat losses from the piping. The Net I=B=R Ratings shown are based on a piping and pickup factor
of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net I=B=R
Rating of the boiler selected should be greater than
or equal to the calculated peak heating load (heat
loss) for the building or area(s) served by the boiler
and associated
hot water heating systems. The
manufacturer
should be consulted before selecting
a boiler for installations
having unusual piping and
pickup requirements.

Canada - Installation shall be in accordance
CSA-B149.1
and .2 installation codes.

with

Where required by the authority having jurisdiction,
the installation must conform to the ASME Safety
Code for Controls and Safety Devices forAutomatically Fired Boilers, No.CSD-1.
The installation must conform to the requirements
of the authority having jurisdiction
or, in the absence of such requirements,
to the National Fuel
Gas Code, ANSI Z223.1 -latest revision.

Installers - Follow local regulationswith respect
to installation of Carbon Monoxide Detectors.
Follow maintenance recommendationsin this
manual.

Check to be sure you have selected the
boiler with the proper capacitybeforecontinuingthe installation.The I=B=RRatingof
the boiler selected should be greater than
or equalto the calculatedpeakheatingload
(heat loss)for the buildingor area(s)served
by the boilerand associatedhotwater heating systems.See "Table 1: Sea Level Ratings - Natural and Propane
tion IV of this manual.
•

Heat loss calculations
approved
e

industry
0

Gases"

in Sec-

should

be based

3. The boiler is approved for installation in closets
and on combustible floors. This boiler shall NOT be
installed

on carpeting.

required

clearances

shown

0
Top

Left Side

24"

Right Side

24"

Base

Supplied with the correct type of gas (natural
gas or propane).

Front

Back

Connected

Intake/Vent

to a suitable

combustion

air in-

take piping system to supply the correct
amounts of fresh (outdoor) air for combustion
(15' minimum length/60' maximum length).
Connected
to a suitable venting system to
remove the hazardous products of gas combustion (15' minimum
length/60' maximum
length).
Connected
system,

to a suitable

hot water

Supplied with a suitable electrical
all boiler motors and controls.

heating

supply for

Connected to a properly located thermostat or
operating control (not included with boiler).
Placed on level surface
stalled on carpeting).

(must

in Table 3 below indicate

per CSA listing.

TABLE 3: BOILER CLEARANCES*

Before selecting a location for the boiler, the following should be considered.
Each boiler considered
for installation must be:
•

2. Accessibility
clearances,
if more stringent (i.e.
larger clearances)
than required
fire protection
clearances, must be used for the boiler installation.
Accessibility
clearances may be achieved with the
use of removable walls or partitions.

4. The clearances

methods.
O"

1. Select a location which is level, central to the piping systems served and as close to the vent and air
intake terminals as possible.

NOT

be in-

Condensate drain line must be pitched down
to floor drain or external condensate
pump
with reservoir at ¼" per foot (wood frame or
blocks may be used to raise boiler).

Piping

Near Boiler
Water

Hot

Piping

*All distances measured from the cabinet of the boiler.

A minimum
1" clearance must be maintained
between combustible
construction
and each of the
right, top and back surfaces of the boiler. Allow at
least 24" at the front and left side and 8"at the top
for servicing.
No combustible
clearances
are required to venting or combustion
air intake piping.
5. Equipment shall be installed in a location which facilitates the operation of venting and combustion air
intake piping systems as described in this manual.
6. Advise owner of boiler to keep venting and combustion air intake passages free of obstructions.
Both the venting and combustion
air intake piping
systems connected
to the outdoors
must permit
flow through the piping systems without restrictions
for the boiler to operate.
7. The boiler shall be installed

such that the auto-

matic gas ignition system components
are protected from water (dripping, spraying, rain, etc.) during

operation and service (circulator
trol replacement,
etc )

replacement,

8 The boiler must be located where

ambient

con-

room

temperatures
(minimum
possible
temperatures
where boiler is installed assuming boiler is not in
operation and therefore contributes
no heat to the
space) are always at or above 32°F to prevent
freezing of liquid condensate

Figure

1 - Roof Vent/Intake

Terminations

This boiler requires a dedicated direct vent system
In a direct vent system, all air for combustion
is
taken directly from outside atmosphere,
and all flue
products are discharged to outside atmosphere
Combustion
air and vent pipe connections
must
terminate together in the same atmospheric
pressure zone, either through the roof or sidewall (roof
termination preferred)
See Figures 1 and 2 for required clearances
If the concentric vent termination
fer to Figure 3 for proper setup
Figure
I

rl.

3 - Concentric
_lllijii

is being used, re-

Vent Terminations
pO.D=

EP PI - r 1,3

ot°
I
12

/_.

12 I IlNfI, IUM

F llNlr

IUr,

EHT
cor

'BUSTION

rI_INT_EN
l-" IN
_BO E HIGHEST

_,IR

SrdC

2 - Sidewall

Vent/Intake

CLE-P-NCE
.NTICIP.TED

EL D = SPADE

Terminations

t c 0,,o.
Keep boiler area clean of debris and free of I
lammable
and combustible
materials,
va- I
ors, and liquids.
.i)

L LESSTH_I]

Failure to follow
in fire, property
death.

12 CLEAR_I]CE

•

these warnings
could result
damage, personal
injury, or

When vent pipe is exposed
to temperatures below freezing, such as when it passes through an unheated space or when a
chimney is used as a chaseway, vent pipe
must be insulated
with W'Armaflex
or
equivalent.
In extremely
cold climate
eas, use %'Armaflex
or equivalent.

•

,
H-'H

ar-

Combustion
air must be clean outdoor
air. Combustion
air must not be taken
from inside the structure
because that air
is frequently
contaminated
by halogens,
which include fluorides,
chlorides,
phos-

12" ORMORE

CLEARANCE

Figure

LIr

(Continued on next page)j

wAR"'"G
a,l

Figure

5 - Concentric

Vent Roof

(Continued from previous page)

Installation

EIT
I

phates, bromides
and iodides. These elements are found in aerosols,
detergents,
bleaches,
cleaning
solvents,
salts,
air
fresheners,
paints, adhesives,
and other
household
products.

11 T

[rJ

_[.EO
J[i nL :LE_:-n
HL_HL

[rl

_rlTL.L

.p[J
u

E FOOF
TED

:rio,

wuuv
EOOT

Locate combustion
air inlet as far away as
possible
from swimming
pool and swimming pool pump house. All combustion
air and vent pipes must be airtight
and
watertight.
Combustion
air and vent piping must also terminate
exactly as shown
in Figures
1 and 2. if a concentric
vent
termination
is being used, refer to Fig=
ures 3 through
5 for proper setup.
Vent
connections
serving
appliances
vented by natural draft shall not be connected
into any portion
of mechanical
draft systems
operating
under positive
pressure.
.

k,.

Figure

Vent w/Dimensions

LIED

D _=OF
FIELD

ELTU
P

fJJJIll_

L_,I

_:_hc_P_t

I
LiD

[[
I F

[Jh
E

IE*

FLLLI

T[[Jrl

[
F

I-LLLI
IU

I
[

i i

.o lel. TLO'

_[P

At the rear of the unit a ½" PVC pipe nipple with
NPT threads is provided for the attachment of the
condensate
drain line Attach the ½" PVC tee in
the parts bag to act as a vent as shown Attach ½"
PVC from this point to either a drain or an external condensate
pump (not furnished)
If the drain
level is above the condensate trap, a condensate
pump must be used The condensate
pump must
be designed for a flue gas condensate application
The condensate drain line must be pitched down to
the floor at a minimum of 1/4" per foot and must be
routed within the conditioned space to avoid freezing of condensate and blockage of the drain line If
the unit will be started immediately
upon completion of installation,
prime trap by fllhng with water
until water is seen at the vent
f

JELl

I _

4 - Concentric

FLELFI
Ill

HUTE

Solvent
cements are combustible.
Keep
away from heat, sparks,
or open flame.
Use only in well ventilated
areas. Avoid
breathing
in vapor or allowing
contact
with skin or eyes.

FL_'HL

NOTES:
1

Condensate

Wood

trap is integral

_'_

to the boiler

frarne or blocks

maintain
pump
- i

i
I

_,"

S',,,'(} IrJ:!b_,Cc_riLbu_t,ur_

Al_

condensate

reservoir

There _s a 115 volt AC receptacle
provided
trol panel to provide power for an external

pump tlf needed)

,-, F} 41H:-fH

may be used to raise the boiler to

dram pitch or to be above external

on the concondensate
J

Boiler must be placed on level surface.
NOT to be installed on carpeting.
f

Boiler is

NOTES:
1.

If boiler is not level condensate
tion properly.

Adjustable

Wood

frame

maintain
pump

or blocks

drain lines will not func-

feet are located

make up for minor surface
2.

irregularities

on the boiler to
or tilt,

may be used to raise boiler

drain pitch or to be above external

condensate

reservoir,

When an existing boiler is removed from a common venting system, the common venting system
is likely to be too large for proper venting of the
appliances
remaining connected to it. At the time
of removal of an existing boiler, the following steps
shall be followed with each appliance
remaining
connected to the common venting system placed
in operation, while the other appliances
remaining
connected to the common venting system are not
in operation.
1. Seal any unused
venting system.

openings

2. Visually inspect the venting
size and horizontal pitch and
no blockage or restrictions,
and other deficiencies which
safe condition.

in which the appliances
remaining
connected
to the common venting system are located and
other spaces of the building. Turn on clothes
dryer and any appliance not connected to the
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhaust, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close
fire dampers.

in the common

system for proper
determine there is
leakage, corrosion
could cause an un-

3. When it is practical, close all building doors
and windows and all doors between the space

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliances will operate continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use
the flame of a match or candle, or the smoke
from a cigarette, cigar or pipe.
6. After it has been determined
that each appliance remaining
connected
to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans and any other gas-burning
appliance
to
their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation conforms
with the National Fuel Code,
NFPA-54/ANSI
-Z223.1-tatest
revision, or section 5 of CSA-B149
for Canadian
standards.
When resizing any portion of the common venting system, the common venting system should
be resized to approach the minimum size as determined using the appropriate tables in part 11
in the National Fuel Gas Code, NFPA-54/ANSIZ223.1 -latest revision, or section 5 of CSA-B 149
for Canadian standards.

may be moved into position with an appliance dolly or 2-wheel hand truck. The dolly or hand truck
should be inserted under the right hand side of the
boiler. It is possible to slide the boiler for a short
distance on a smooth floor or surface.
The boiler should be placed to provide the most
direct connections
to the combustion
air, vent and
system piping as possible.

nual for required clearances
for servicing
and mainteJ
NmaOTE: Refer to "Locating
The Boiler" in Section V of this'_
ce.

Place

crated

as possible

boiler

as close to selected

and uncrate

location

boiler. The uncrated

boiler

--'JsMPORTANT: For piping examples
ee the Piping Appendix in Section

using the Gas-Fired
XIV of this manual.

Direct Vent Modulating

Hot Water Boiler,

ter supply is from a well or pump,
should be installed at the pump.
Copper supply and return piping must NOT be
installed directly into aluminum
boiler section
castings
due to galvanic
corrosion
between
dissimilar
metals. Iron or steel bushings
or
pipe nipples should be used between copper
system piping and boiler to make final connection to boiler. Also, the use of dielectric
unions is acceptable.
The packaged
boiler is
furnished
with iron piping where necessary
k.for the supply
When

the

and return

installation

connections.

of the boiler

Figure

6 - Diaphragm

Expansion

a sand strainer

Type

Tank Piping ..... o.........
/

i SU :'i>LY

EX'AN

I)r,

TANK Db/IE
{ATE

VALVE
8ALL

FJLL

YAL_E

is for a new
COL}

REDUCEC
BACKFLO,k

PRESSURE
PREVE
TER

2NO

boiler

installed

above

radiation

level

must be equipped with a low water cut off device.
A periodic inspection is necessary, as is flushing
of float type devices, per low water cut off manufacturers specific instructions. This boiler is factory
equipped with a manual reset probe-type low water
cut off.

Figure

ANSI)N

_,boiler.

water

only

piped

directly

OPTION

F(;R

FOR

FEED

_yATE{,

FEE}

W#TE:_

TANK

7 - Relief Valve
/

I Non-potable

iIi1{

\'AL_'E
O_

heating system, first install all of the radiation units
(panels, radiators, baseboard,
or tubing) and the
supply and return mains. After all heating system
piping and components
have been installed, make
final connection of the system piping to the boiler.
A hot water

v EN]

Discharge

Piping

,PRESSURE RELIEF DEVCE

Determine
required system fill pressure,
system
design temperature,
and system water content.
Boiler contains 2.6 gallons (US). Size expansion
tank accordingly. Consult expansion tank manufacturer for proper sizing information.
Connect properly sized expansion tank (not furnished) as shown
in Figure 6 for diaphragm type expansion tank. For
diaphragm type expansion
tanks, adjust the tank
air pressure to match the system fill pressure. Install air vent (furnished)
as shown for diaphragm
type expansion tank system only. Install make-up
water connections
as shown and per local codes.
If a pressure
reducing valve is used, adjust to
match the system fill pressure. In connecting
the
cold make-up water supply to the boiler, make sure
that clean water supply is available. When the wa-

The boiler

is furnished

with a relief

valve

in the

boiler parts bag. Provide ¾" piping from the supplied relief valve to a local floor drain, but leave
an air gap between piping and drain. No shutoff of
any description shall be placed between safety relief valve and the boiler, or on the discharge pipes

between such safety valve and the atmosphere.
Installationof the safetyrelief valveshall conform
to ANSI/ASMEBoiler and PressureVesselCode,
SectionIV.The manufactureris not responsiblefor
anywater damage.

The packaged boiler unit is set up to receive 1¼"
NPT return piping from the rear of the unit with an
option for left or right return connections.
1¼" NPT
supply piping exits the boiter jacket at the top of the
unit.
/_OTE:
[within

Circulator
a carton

_,a! the installer

pump

and isolation

inside the boiler cabinet
preferred

valves

are furnished_

and can be installed

location.

,,,j/

lrMaPORTANT: On initial start up the condensate_
p must be manually filled with water.
1/'
The following are the steps required to initially fill
the condensate
trap for start up, these steps are
only required at the initial start up or if maintenance
requires draining of the condensate trap:
1. Pour about 1 cup of cold tap water
vent drain line.

2. Excess water should go through the overflow
and out through the condensate drain line. Verify proper operation of the drain line (or external
condensate pump if used).
3. Reinstall

The condensate

trap is integral

½" diameter

schedule

40 PVC

condensate

drain piping and pipe fittings must conform to ANSI
standards and ASTM D1785. Schedule 40 PVC cement and primer must conform to ASTM D2564.
In Canada, use CSA or ULC certified schedule 40
PVC drain pipe and cement.
A condensate pump with a reservoir (not furnished)
may be used to remove condensate to a drain line
(sanitary line) above boiler if a floor drain is not
available or is inaccessible.

For boilers connected to gas vents or chimneys,
vent installations
shall be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1-1atest
revision, CSA-B149.1
and B149.2, and applicable provisions of the local
building codes.
Provisions

for combustion

the vent drain line.

to the boiler.

Provide ½" pipe and fittings for PVC condensate
drain line. Condensate
drain line to be pitched
down to floor drain at a minimum of ¼" per foot.
The

into the

and ventilation

air must

be in accordance
with Section 5.3, Air For Combustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1-tatest
revision, CSA-B149.1
and B149.2, or applicable provisions of the local
building code.

The boiler, when used in connection with a refrigeration system, must be installed so the chiller medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from
entering the boiler.
The boiler piping system of a hot water boiler connected to heating coils located in air handling units
where they may be exposed to refrigerated
air circulation must be equipped with flow control valves
or other automatic means to prevent gravity circulation of the boiler water during cooling cycle.

These boilers require a dedicated direct vent system. All air for combustion
is taken directly from
outdoors through the combustion
air intake pipe.
All flue products are discharged
to the outdoors
through the vent pipe. Insulate lengths of combustion pipe in unconditioned
areas.
1. See Figures 1 through 5 for combustion
air
and vent pipe roof and sidewall termination (roof
termination
is preferred).
Combustion
air and
vent pipes must terminate together in same atmospheric pressure zone as shown. Construction through which vent and air intake pipes may
be installed is a maximum 24" and a minimum
¼" thickness.

2. Combustionair and vent pipe fittings must
conformto American NationalStandards Institute (ANSI) standards and American Society
for Testing and Materials (ASTM) standards
D1784(schedule-40CPVC),D1785(schedule40 PVC),D2665(PVC-DWV),D2241(SDR-21
andSDR-26PVC),D2661(ABS-DWV),or F628
(schedule-40ABS). Pipe cement and primer
mustconformtoASTMstandardsD2564(PVC)
or D2235(ABS).
In Canada

construct

all combustion

1. Combustion
air piping to be pitched back to
boiler at minimum ¼" per foot from vent terminals
so that all moisture in vent piping drains to boiler•
Pipes must be pitched continuously with no sags
or low spots where moisture can accumulate and
block the flow of flue gas. Combustion
air and
vent pipes must be airtight and watertight.
2. Consideration for the following should be used
when determining an appropriate location for termination of combustion air and vent piping:

air and vent

pipes for this unit of CSA or U LC certified schedule-40 CPVC, schedule-40
PVC, PVC-DWV
or
ABS-DWV pipe and pipe cement• SDR pipe is
NOT approved
in Canada.
3. Combustion air and vent pipe connections on
boiler are 2" but must increase to 3". Due to potential for flue gas temperatures
above 155°F,
the first 30" of supplied vent pipe is CPVC while
the remaining vent pipe can be PVC. Any replacement of the first 30" of vent pipe must be
made with CPVC.
NOTE:

The exhaust

made
• (See

transition

in a vertical
Figure

from

run. Transition

2" pipe to 3" pipe must_
pieces

are not includ-

8 for details.)

15 ft. equivalent

INSTALL

FIELD

2' BY 3'

TRANSITION

THF

VERTICA_

vent length

SUPPLIED
IN

POS_T_ON

2' {50 8_ 'M)
NTAKE

PIPING

(FURNISHED)

ONLY

Termination should be positioned where vent
vapors will not damage plants/shrubs
or air
conditioning
equipment•

Termination should be positioned so that it
will not be effected by wind eddy, air born
leaves, snow, or recircutated flue gases•

Termination
should be positioned
where it
wilt not be subjected to potential damage by
foreign objects, such as stones, balls, etc.

Termination should be positioned
vapors are not objectionable•

•

Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to prevent accidental contact with people or pets.

length J

The length of pipe is counted from the end of the
supplied 2" CPVC pipe exiting the boiler• The combustion air supply pipe must terminate at the same
location as the exhaust pipe.

Figure 8 - Combustion

Comply

with all clearances

required•

where vent

length J 60 ft. equivalent

Reduce the maximum
90 ° elbow•

•

by 5' per each

Air and Vent Piping

Terminate

the vent above

normal

snowline.

Avoid locations where snow may drift and
block the vent. Ice or snow may cause the
boiler to shut down if the vent becomes obstructed.
Under certain conditions, flue gas will condense, forming moisture, and may be corrosive• In such cases, steps should be taken
to prevent building materials at the vent from
being damaged by exhaust of flue gas.
3. The venting system shall terminate at least 3'
above any forced air inlet (except boiler's combustion air inlet) within 10'. The venting system
shall terminate at least 12" from any air opening
into any building• The bottom of the vent shall be
located at least 12" above grade• Termination of
the vent shall be not less than 7' above an adjacent public walkway• The vent terminal shall not
be installed closer than 3' from the inside corner
of an "L" shaped structure• Termination of the
vent should be kept at least 3' away from vegetation. The venting system shall terminate at
least 4' horizontally from, and in no case above

or below, electric meters,
tors, and relief equipment.

gas meters,

regula-

If multiple terminations
are used, there must be
a minimum of 12" between the exhaust of one
termination and the air intake of the next termination. See Figures

1-3 for illustrations.

7. After pipes have been cut and pre-assembled, apply cement primer to pipe fitting socket
and end of pipe to insertion mark. Quickly apply
approved cement to end of pipe and fitting socket (over primer). Apply cement in light, uniform
coat on the inside of socket to prevent buildup of
excess cement. Apply second coat.

NaOTE: Primer

and cement will discolor jacket. Take
u!ions !o pro!ec!
!acke! whi!e cemen!ing ven! p!pe:

MrVPORTANT: When

transitioning

from CPVC to_

C it is recommended to use Weld-On CPVC 724 I
other cement approved for CPVC and PVC. ,_
1. Attach combustion
air intake piping to supplied 2" PVC Intake Connector. Attach vent piping to furnished 2" CPVC vent pipe.
_NOTE:

All pipe joints

are to be water

8. While cement is still wet, insert pipe into socket with a ¼ turn twist. Be sure pipe is fully inserted into fitting socket.
9. Wipe excess cement from joint. A continuous
bead of cement will be visible around perimeter
of a properly made joint.

tight.

10. Handle pipe joint carefully
2. Working from the boiler
pipe to required length(s).

to the outside,

3. Deburr inside and outside

of pipe.

to be joined.

6. Check dry fit of pipe and mark insertion
on pipe.

depth

NrOTE: It is recommended
that all pipes be cut, prepared,
e-assembled
before permanently cementing any joint.

until cement sets.

cut

4. Chamfer outside edge of pipe for better distribution of primer and cement.
5. Clean and dry att surfaces

pre-_

and_

11. Support combustion
air and vent piping a
minimum
of every 5' using pre-formed
metal
hanging
straps. Support combustion
air and
vent piping so no weight is resting on the boiler
jacket. Do not rigidly support pipes. Allow movement due to expansion and contraction.
12. Slope combustion air and vent pipes toward
boiler a minimum of ¼" per linear foot with no
sags between hangers.
13. Use appropriate
methods
ings where vent and combustion
through roof or side wall.

to seat openair pipes pass

TABLE 4: GAS PIPING SIZES
The gas pipe to your boiler must be the correct size
for the length of run and for the total BTU per hour
input of all gas utilization equipment connected to
it. See Table 4 at right for proper size. Be sure your
gas line complies with local codes and gas company requirements.
The boiler and its individual

20'

92,000

190,000

350,000

625,000

40'

63,000

130,000

245,000

445,000

60'

50,000

105,000

195,000

365,000

20'

131,000

216,000

393,000

40'

90,000

145,000

267,000

60'

72,000

121,000

shutoff valve must be

disconnected
from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of ½ psig (3.5kPa).
The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff
valve during any pressure testing of the gas supply
piping system at test pressures equal to or greater
than ½ psig (3.5kPa).

103,000

The _ng_ ofp_eortub_g
should be measu_dfrom
meterorpropaneseconds_geregu#_

217,000
me gas

In order for proper operation of the boiler, it is recommended that the line pressure be within the minimum and maximum values in Table 5.

2. Use pipe joint compound suitable for liquefied
petroleum gas on male threads only.
3. Use ground joint unions.

TABLE 5: GAS SUPPLY PRESSURE

4-m,o.
w.c. lO-m x.
w.o.
J
10- o.w.o. 14"

4. Install a sediment
trols.

w.o.I

trap upstream

of gas con-

Please check line pressure while unit is running.

5. Use two pipe wrenches when making the connection to the gas valve to keep it from turning.
Refer to
er, which
shipped,
rear but,
ther the

Figure 9 for the general
shows the basic fittings
the gas line enters the
as an option, it can be
right or left side panel.
Figure

6. Install

layout at the boilyou will need. As
boiler through the
routed through ei-

9 - Gas Piping

a manual

shutoff

valve

in the vertical

pipe about 5' above floor outside the boiler jacket in addition to the shutoff valve supplied with
the boiler.

7. Tighten

all joints securely.

8. Propane
gas connections
should
made by a licensed propane installer.
9. Two stage regulation
propane installer.

should

10. Propane gas piping should
by the propane installer.

only

be used by the

be checked

out

3AS CONNECTION,

11. In addition to the components
supplied with
the boiler, it is recommended
to use a ½" union
and ball valve suitable for natural and propane
gas upstream of the furnished ½" NPT ball valve
to facilitate service on the unit.
The boiler is equipped with a ½" NPT connection
on the gas valve for supply piping and ½" NPT ball
valve for manual shut off. The following rules apply
for boiler piping:
1. Use only those piping materials and joining
methods listed as acceptable
by the authority
having jurisdiction,
or in the absence of such
requirements,
by the National Fuel Gas Code,
ANSI Z223.1- latest revision. In Canada, follow
the CAN/CGA B149.1 and .2 Installation Codes
for Gas Burning Appliances

and Equipment.

After all connections
have been made, check immediately for leaks. Open the manual shutoff valve.
Test for leaks by applying soap suds (or a liquid
detergent) to each joint. Bubbles forming indicate
leak. Correct even the smallest
leak at once.
_

WARNING

_i_

IflMPORTANT:

Wiring diagrams

for the Gas-Fired

Direct Vent Modulating

Hot Water Boiler can be

ound in Section XIII of this manual.
,_

WARNING

2. Route all low voltage wires through
ed opening on the right jacket panel.

grommet-

1. Connect room thermostat or end switch (isolated contact only) between terminals TI and T2.
_iPORTANT:

Wiring

must be N.E.C.

Class

1._

original boiler wiring must be replaced, use I
ly type 105°C wire or equivalent.
Boiler must I
electrically grounded as required by National I
ectrical Code ANSI/NFPA 70 - latest edition..1/

2. Install thermostat on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sunrays, or fireplaces.
3. Thermostat

anticipator

A. If connected
amps.
Installations
must comply with National Electrical
Code, any other national, state, provincial, or local codes or regulations, and, in Canada, with CSA
C22.1 Canadian Electrical Code (Part 1) and any
local codes.

1. Connect 120 VAC power wiring to line voltage
terminal strip on boiler control panel.
2. Provide

and install a fused disconnect

vice switch (15 amp recommended)
by code.

or ser-

as required

directly

loose. Wire boiler
diagram label on

4. When connecting a DHW circulator, connect
wiring to line voltage terminal strip on boiler control panel.
5. Route all wires and conduits
in the right jacket panel.

to the openings

1. Connect low voltage wiring to low voltage
terminal strip as shown in the boiler wiring diagram.

to boiler,

set for 0.1

B. If connected to relays or other devices, set
to match total electrical power requirements
of connected devices. See device manufacturers' specifications
tions for details.

and thermostat

instruc-

1. Connect outdoor temperature
sensor between
terminals A1 and A2 to enable outdoor reset operation of the boiler. If fixed temperature
operation is
required, do not install outdoor sensor.
2. Mount sensor on exterior

3. Boiler circulator is shipped
circulator
as shown in wire
boiler side panel.

(if applicable):

rect sunlight
sources.

watt, shielded

or flow of heat or cooling

from di-

from other

3. If desired, install a summer/winter
switch across
terminals A1 and A2. When the switch is closed,
the boiler (space heating) circulator is disabled.
4. Route sensor wires through the holes provided
on the right jacket panel of the boiler.

Connect storage indirect water heater (DHW) aquastat between terminals DHW T1 and DHW T2.

This sectionprovidesa brief descriptionof the key
controlsandaccessoriesfoundinthis boilerSeethe
RepairPartsManual(P/N#240006107)for illustrationsandthe ControlManualandOperationInstructions (P/N#240006104)for a detailedsequenceof
operationandtroubleshootingprocedures

This applianceemploysa cast aluminumheat exchanger that features a monoblockdesign The
monoblockdesigneliminatesthe need for mating
sections and therefore eliminatesleaks between
sections Since the heat exchangeris cast of aluminum instead of iron, it has better heat transfer
propertieswhich in turn lead to higher efficiency
andcoolerexhausttemperaturesThesecoolerexhausttemperaturescreatecondensationofthe flue
gas,whichwouldcausecorrosionintraditionalcast
iron heatexchangers

Thisappliancefeaturesa mainpowerswitchlocated
on the displaypanel The main powerswitch is illuminatedwhen it is receivingpowerand in the ON
position Theonlytimethatthe switchshouldnot be
illuminatedoncethe boileris readyfor use is when
the casting temperaturesafety switch has been
trippedor whenthe switchis in the OFFposition

This applianceincorporatesan integratedmodulating controlthat sensesthe load necessaryto heat
a structureandthereforeuseslessfuelthan a conventionalfixedfiringrate bollerwhenthereis a lower than peakdemandfor heat The controlsenses
the supplywater,returnwater,andoutsideair temperaturesandcalculatesthe loadon the system It
then adjuststhe firingrate to deliverthe amountof
heatthat is neededatthat particulartime
o_t
The NTCsensorsusedwiththis appliancefor measuring supply water, returnwater, and outside air
temperature are specially configuredto operate
withthe modulatingboilercontrol

The modulating blower provides a means of introduclng the gas/air mixture through the burner and

intothecombustionchamberwherecombustioncan
beginandthenout the exhaustventwherethe combustionproductsaredischargedtothe outdoorsThe
bloweris designedto communicatewiththe modulating controlto run at variablespeedsdependent
onthe heatloadexperiencedbythe heatingsystem
Thevariablespeedscreatepressuresfelt bythe gas
valveandgas/airmixerthatdictatehowmuchfuelis
introducedto the combustionprocess

Thegascontrolsinthis boilerhavebeendeveloped
for domesticheatingapplianceswith premixburners and automaticdirect burner ignitionand are
suitablefor naturaland LP gas The gas controls
performallthe functionsrequiredto safelyregulate
gas flow to the main burner of the boiler The gas
valveis directlyconnectedto the gas/airmixer

The ventundesignof the gas/airensuresthatthere
is alwaysthe correctmixtureof air and gas

Thisburneris designedtooperateoverthefull range
of inputfor this boilerThe burnercanoperateunder
normal(blueflame)andinfraredconditions

The burner
bers which

in this unit contains ceramic fi=
can be converted
to a cancer-

causing substance called cristobalite
in very
high temperature
applications.
When removing the burner, avoid breathing
dust by using
a NIOSH (National
Institute for Occupational
Safety and Health) certified dust respirator
and wear long-sleeved,
loose fitting clothing,
gloves, and eye protection to avoid contact
with skin and eyes. In case of contact with
skin or eyes, wash or irrigate affected
area
immediately,
then wash potentially contaminated clothing separately
and rinse clothes
washer thoroughly
before reusing.
For addi=
tional information,
see the NIOSH homepage

at www.cdc.gov/niosh/homepage.html,

This appliance uses a direct spark igniter to ignite
the fuel/air mixture in the combustion chamber and

senseflameduringoperation.The DSIis a durable,
reliable componentthat resists breakagedue to
handlingor inadvertentimpactwith otherobjects. Inthe event of lack of or lossof water in the boiler,
the castingtemperaturesafetyswitch (230°Fsetpoint) installedon the top of the aluminumboiler section behind the supply piping shuts off the
This applianceemploysa factoryinstalledintegral boiler by shutting off power to the boiler control
low water cut off (LWCO)that has to be manually and causesa failure code to be displayedon the
reset if there is a low water condition.The LWCO digital readout.This fault requiresmanualreset of
senseswaterthrougha probeatthe topof the boiler the castingtemperaturesafetyswitchto restartthe
thatsendsa signalthroughthewatertoground.Ifthe boiler and the resetto be pressedon the user insignalis not sensedthroughthe ground,the LWCO terfacepanel.Verifythatthe boileris properlyfilled
entersa lockoutmodethatdisablesthe appliance. with water beforeresettingthis switch.
If the LWCOis in normalmodea red indicatorlight
is illuminatedon the LWCOpanelin the boiler.Duringa lowwatercondition,the red lightgoesout and
the LWCOand controlresetbuttonson the display
panelmustbedepressedto resetthe LWCO.

Thisswitchis normallyclosedandspringloadedso
that, when depressed,it opens,and closesagain
when pressureis removed.The switch is usedas
the manualresetfor the LWCO.Whentripped the
LWCOwilt remain in lockoutuntil the water level
reachesthe probe and the switch is depressedto
an open stateand then releasedto a closedstate,
whichsendsa signalto the LWCOto resumenormal operation.The boilercontrolreset buttonmust
then be pressedto reset from a low water condition.The LWCOswitchandcontrolresetbuttonare
locatedon the displaypanelof the boiler.

The highlimitaquastatcontrolis a redundantsafety
limitcontrolthatdeterminesthe maximumboilerwater temperatureand alsoprovidesa meansfor protectingthe boilerand heatingsystemfrom unsafe
operatingconditionswhichcoulddamagethe boiler.
The aquastatis mountedin the ½" NPTcontrolwell
and ¾" x ½" bushingon the top of the front boiler
sectionat the hot wateroutlet.The aquastatis tied
in with the boilercontroland is factoryset at 200°F
watertemperature.The highlimitsetpointis fieldadjustableand may be set anywherebetween100°F
and200°F,with the maximumhighlimitsetpointnot
exceeding200°F.The field high limit setpointadjustmentfor each installationdependson heating
system requirements.The aquastatautomatically
resetswhenthe boilerwatertemperaturedecreases
ten degreesbelowthe highlimitsetpointvalue.
NatTE:

Boiler operating

culated

temperature

and set in the parameters

(temperature

curve)

of the boiler control.

is_
J

Every forced hot water system requires at least one
circulating pump. The circulating pump imparts the
necessary energy to move water through the closed
loop supply and return piping systems, terminal
heating equipment (finned tube radiators, etc.) and
back through the boiler for reheating. To provide the
required hot water flow rates, the circulator pump
must be properly sized to overcome frictional losses
(usually measured in feet of water, also referred to
as "pump head loss") of the supply and return piping
systems and boiler. The circulator pump is furnished
in a carton within the boiler cabinet. The circulator(s)
should always be located
on the downstream
("pumping away") side of the expansion tank.

I
-

i:,
+/

The air proving blocked vent safety assembly incorporates two pressure switches that are wired in series to discontinue operation of the appliance if there
is a problem with the blower or venting system. The
normally open switch closes upon the initiation of the
blower and functions as an air proving switch. The

normally closed switch opens if there is a blockage
in the combustion air intake or exhaust vent pipes.

The manual drain valve provides a means of draining the water in the heating system, including the
boiler and hot water supply and return piping systems installed above the drain valve. This drain
valve is installed in the return piping at the bottom
front of the boiler section. Any piping installed below
the elevation of this drain valve will require additional
drain valves to be installed at low points in the piping
systems in order to drain the entire system.

Each boiler must have a properly sized and installed American Society of Mechanical Engineers
rated pressure relief valve. Water expands as it is
heated by the burner/boiler
sections. If there is no
place for the water to expand its volume,
(i.e., a
properly sized and properly functioning
expansion
tank) pressure on the inside of the boiler and heating system wilt increase. The furnished relief valve
wilt automatically
open at 30 psig pressure to relieve the strain on the boiler and heating system
from the increasing pressure. The pressure relief
valve discharge must be piped with the same size

'_bNyOTE: Maintenance
the owner unless

as outlined below
otherwise
noted.

can be 3erformed'_

The acidic nature of flue gases condensing
on the
aluminum boiler sections wilt cause the formation
of aluminum oxide. This oxide formation is normal,
is generally uniform throughout the boiler sections,
and represents
a negligible
mass of aluminum
that is consumed by oxidation during the life of the
boiler. If left unchecked,
this buildup may eventually cause blockage of the flue gas passages in the
boiler sections, reducing efficiency, and ultimately
shutting down the boiler due to lack of combustion
air flow.
Regular
service
and maintenance
by a qualified service agency must be performed
at least
once every 12 months
to assure safe, trouble
free operation
and maximum
efficiency.

1. Schedule an annual service call by a qualified
service agency which includes:

pipe as the valve discharge
opening to an open
drain, tub or sink, or other suitable drainage point
not subject to freezing, in accordance with ASME
specifications.
Failure to provide the pressure relief
valve with piping as herein described
may cause
water damage and/or serious bodily injury. The
boiler manufacturer
is not responsible for any water
damage or personal injury.

For installations

where there is no floor drain or oth-

er appropriate drainage receptacle available to receive condensate from the boiler, an external float
activated condensate
pump with integral sump is
required. The condensate
pump can be piped to
a remote tie in point to a sanitary sewer system.
For this application, the boiler must be installed so
that proper pitch of piping to the external condensate reservoir (sump) can be accomplished.
Use
wood frame or blocks to raise boiler as required for
proper installation.

The optional
concentric
vent/air intake termination utilizes a single opening per each appliance
through the walt or roof of a structure.

Examining
flue passages
between
boiler
sections, burner, and condensate lines, and
cleaning (if necessary)
by following the instructions in "Annual Examination and Cleaning of Boiler Components"

in this section.

Visually inspecting the venting and air intake
system for proper operation, immediately repairing or replacing any sign of deterioration
or leakage, and insuring proper reassembty
and reseating of the system.
Checking for and removing any obstruction
to the flow of combustion
air or venting of
flue gases,
Following the instructions in Sections V and
VII of the Control Manual and Operating Instructions (P/N# 240006104),
"Putting The
Boiler In Operation" and "Checkout Procedures And Adjustments. "
Visually inspecting the condensate drain line
for proper operation and checking for deteriorated or plugged condensate drain line.

•

Checking all gasketed joints for leakage
and tighteningboltsor replacinggasketsas
needed.
Removingjacketfrontandtop panels,checkingfor piping leaksaround reliefvalve and
other fittings,and repairing if found WITHOUT USINGSTOPLEAKCOMPOUNDS.

2. Checkthat boiler area is free from combustible materials,gasoline,and other flammable
vaporsand liquids.
3. Circulator pump and blower motor furnished
with boiler are permanently
lubricated from the
factory and require no further lubrication. Additional or non-factory supplied pumps and/or motors should be lubricated according to the pump
and/or motor manufacturer's
instruction.

including flushing of float type devices. Refer to
low water cut off manufacturer's
specific instructions.

1. Turn off gas to boiler as described
"To Turn
Off Gas To Appliance" in Section V of the Control Manual and Operating
Instructions
(P/N#
240006104).
2. If heating system is to remain out of service
during freezing weather and does not contain
antifreeze, drain system completely. If boiler will
be exposed to freezing temperatures,
drain condensate lines. Otherwise,
do not drain system
or boiler.

1. Check for and remove any obstruction
to the
flow of combustion air or venting of flue gases.
2. Check that boiler area is free from
tible materials, gasoline,
vapors and liquids.

and other

combusflammable

1. Remove jacket front and top panels and check
for piping leaks around relief valve and other fittings. If found, contact a qualified service agency. DO NOT USE STOP LEAK COMPOUNDS.
2. Test relief valve. Refer to valve manufacturers
instructions

packaged

with relief valve.

3. Visually inspect the venting and air intake
system for proper operation. If the vent or air intake show any signs of deterioration
or leakage,
contact a qualified service agency to repair or
replace them immediately
and to insure proper
reassembty and resealing of the system.
4. Visually inspect the PVC condensate
drain
pipe for proper operation. If the drain pipe shows
any signs of blockage, leakage, or deterioration
contact a qualified service agency to clean, repair, or replace it immediately.

1. Before servicing, turn off electrical power to
boiler at service switch. Close manual gas valve
to turn off gas supply to boiler.
2. Examine flue passages by removing blower
assembly from casting. The procedure for examining and cleaning the burner is described
below.
Any buildup of sediment
or aluminum
oxide
(white powdery or flaky substance)
in the flue
passages must be cleaned as follows:
•

jacket front and top panels.

Confirm that manual gas valve is closed and
disconnect
gas line to gas valve at union.
Then disconnect
pressure switch hoses to
gas valve and air inlet.
•

Disconnect

•

Loosen

•

wires to gas valve and igniter.

but do not remove

ing blower

5. Check air vent(s) for leakage.
6. Where low water cut offs are used, a periodic
inspection of the low water cut off is necessary,

Remove

adapter

assembly

Remove two igniter screws
fully remove the igniter.

five nuts attachto boiler.
and very care-

•

Removefive nutsandremovebloweradapter assembly,burner,andgaskets.

stall five nuts but do not tighten. Reinstall
igniter and igniter gasket and fasten with
two screws. Tighten five nuts holding blower
adapter assembly.

Aluminum oxide deposits are water soluble
and may be rinsed away by inserting a hose
into the burner opening of the casting and
slowly running water through the flue side of
the boiler and out the condensate drain.

c o,,o. I
ebris rinsed away by this method will e×it I
hrough
the condensate
drain. Be wary of I
rain lines getting clogged and causing wa= I
er to back up in the bottom

of the casting.

Use a flexible handle nylon brush to loosen
sediment and aluminum oxide on all accessible heating surfaces of the boiler. Be sure
not to get brush stuck in heat exhanger!
•

After brushing and rinsing, remove
maining loosened sediment
using
vacuum with a snorkel attachment.

Connect
gas line to gas valve, pressure
switch hose to gas valve and air inlet assembly, igniter wires, and gas valve wires.
3. Visually
inspect the condensate
trap. Any
foreign material visible in the condensate
lines
needs to be cleaned out as described below:
•

Inspect for sediment

•

Flush out with water or vacuum.

•

Follow the instructions in Section VII, "Filling
The Condensate
Trap With Water."

4. Inspect the flue connector

any rea shop

Reinstall burner and gaskets and position
blower adapter assembly
over studs. In-

as follows:

Loosen the clamp on the vent tee side of the
2" flexible coupling that connects the vent
tee to the exhaust port.

Inspect burner for any foreign matter in the
flame ports or inside the burner. Any foreign
matter should be removed by blowing with
compressed
air or vacuuming.
•

or blockage.

Inspect interior of vent tee. Any buildup of
sediment
on the inside surface must be
cleaned.
•

Reconnect

2" flexible coupling

to vent tee.

ELECTRICAL

WIRING

DIAGRAM

(DIAGRAHHE

CABLAGE

_-LECTRIQUE)

_w_#m

120 VOLT POWER SUPPLY
l

DISPLAY

ODD

DDD

USE

COPPEiONDUCTORS

ONLY)

RESET(7
L2(_)

LO_(6

_°
OOOOO

I[_IIL_y

x_-_

...........

....

--_

22:::::2

_4 t

I-z

xl._

[]

_._

_ --_-_-

__.-- ,_

X_
X_-_
X_-_
sw_rc_
24 VOLT

----_vf--

THER_DSTAT

pU_P

G_,SV_LV[

et v_c

x_-_
xe-_

SLPPLy
S NS@R

m_H

FILe ]NST_LL_

HIGH
e4V
LINIT
BLI]_ER
TIDN

-- ..--_R OUT

x_-_

m-L
X+,-,4
Xm,._

x_-t

41R P_OVING

X_-e

X_-_
m_mrmmm
_t_dRN

S_,F_Ty
SVlTCH
CAST

CDHPDNENT
TH-I
TIP2

THERMOSTAT
THERMOSTAT

IN-3

THERMOSTAT
(LINE VOLTAGE)
(VOLTAGE
DE LIGNE)
TRANSFBRNER
(120V/R4V
4OVA)
TRANSFBRNATEUR
(I_OV/
_AV 4OVA)

TR-I
TR-2
NOV

(N]I.LIVOLT)
(24
VOLT)

TRANSFORMER
(120V/_4V
5OVA)
TRANSF[i_NATEUR
(120V/
2'$V 5OVA)
_LLIVOLT
GAS VALVE
SOU_APE
_ OAZ MILL_VOLT

LOV

LGV-I

SOUPAPE
_ GAZ 24 VOLT
24 VOLT
GAS VALVE

snuPAPE
_ GAZ 24
PRESSURE
SWITCH

VOLT

GAS

INTERRUPTEUR
NOT[:

VALVE

VOLT

MR-PS

CODING

MANUAL
RESET
PRESSURE
SW,
ROMISE EN NARCHE MANU_L
DE
L'INTERRUPTEUR
DE PRESSION
SD
ST_CK
DAMPER
REGISTRE
DE LA CHENIN_E
--0-CONTROL]IER_INAL
BORNE
DU CONTR_LE
I K
RELA_
CElL
BOBINE DU RELAYS
1 K1
RELAY
CONTACTS
CONTACTS
DU k_LAIS
1K£
RELAY
CONTACTS
CONTACTS
_U RELAIS
LS
LIMIT
SWITCH
INTERRUP'_UR
_E LINITE
r
FLAME
SENSING
FLAMNE
SENSING

(CODE

DES
MS

COMPIqSANTES)

N_NUAL
SWITCH
INTERRUPTEUR
MANUEL
C_R
CINCULATDR
CIRCULATEUR
ECO
ENERGY
CUT-OFF
COUPE-CIRCUIT
LVCO
LOW VOTER
CUT-OFF
POUR
FERNER L'EAU
EWF
ELECTRIC
WATER
FEEDER
ALIHENTEUR
_LECTRIOUE
D'EAU
PG
POWER
GENERA]I]R
G _N¢::RATEUR
PSC
pllnT
SAFETY
CB@L
_DBINE
DE Si_R_T
IOE LA
VEILLEUSE
V_E
CONNECT_N
RACCORD
DES FILS

NOT ALL COMPONENTSLISTED ARE USED IN ALL CONTROl
SYSTEMS,
(LEg COMPOSANTES_zNUN_RtES NE SONT PAS TBUTES
UTILIS{ES DANg TOUS LOS SYST_:NES DE CONTROLES.)
WIRING (CADLAGE)
m

LINE VOLTAGE

_Y FACTORY

LIGNE DE VOLTAGE POR L'USINE
--

LOW VOLTAGE BY FACTORY
BAg VOLTAGE PAR L'USINE

m_mmmmm

LINE VOLTAGE _'( INSTALLER
LIGNE DE VOLTAGE PAR L'INSTAGLATEUR

.......

PRESSIBN

LOW VOLTAGE BY INSTALLER
BAS VOLTAGE pAR L'INSTALLATEUR

l, SWITCHES ARE SHOWN IN POSITION TAKEN DURING HEATING CYCLE,
(LEg ]NTERRUPTEURS SONT NONTR_'SEN POSITION DE CYCLE DE CHAUFFANT,)
2. IF ANY BF THE ORIGINAL WIRING SUPPLIED Vlll4 THE I_OILER IS REPLACED, _
MUST :BE REPLACED WITH L_E WIRE SIZE AND TYPE BF ]NSULAT_N OR EQUIVALENT.
(SI AUCUN _ES FILS ORIQINAUX FDURNIS AVOC LA CM&UD_RE EST REMPLAC{, IL DOIT _TRE RENPLAC£ OAR UN AUTRE FIL DE N_NE GROSSEURET DU R_NE TYPE D'ISOLATION
OU L'_'OU]VALE NT.)

/
_40005L03_

REV

SINGLE

ZONE SYSTEM

WITH

DOMESTIC

HOT WATER

CH CIRCULATOR

C_RCULATOR
DHW

BO_LER
PRiORiTY

ZONE

PRIORITY

SINGLE

ZONE SYSTEM

Ho_Ut_e
_qu_

WITH

lmd_rec_
or

DOMESTIC

w_er

HOT WATER

he_;er

_hermos_

Boiter

AR822_!1

i l
i I
I

PRIORITY

Control

Panel

CH T1

0 °._

CH CI

OD'#N

0_.'-, T_ °" °_ 0
0

20
L! (HOT)

_._°_Q

MULTIZONE
AND DOMESTIC

PIPING WITH

HOT WATER

ZONE VALVES

PRIORITY

(WITH

ZONE VALVE)

ZONE

ZONE 3

ZONE2

BOILER

"USE FULL _RT ZONE
VALVE, FOR OPTIMUM TANK
PE_FOR_,_NCE,
CONSIDER
USING ZONE C_RCU_TOR

MULTIZONE
AND DOMESTIC

PIPING WITH

HOT WATER

ZONE VALVES

PRIORITY

(WITH

ZONE VALVE)

HEATER AQUASTAT
OR THERMOSTAT

1--

I{ _
24

B_G

POWER
SUPPLY

120

INDIRECT

VOLT

WATER

COMFORT-TROL,

I._-

SPARCO

TACO TYPE
ZONE VALVE

HONEYWELL,

ERIE

SUPERIOR TYPE
ZONE VALVE

VAC_

-::::::Mol_,0__MOo _0
_® x_]
_4 _®'ll_
RInRIT_{_

!°]

[

0___

Boi [eP Corttr'ot

BJTgOD_
AIR SENSOR

CH C1

{

P_t_tt

- "":181
: -0°ol

ZO;_

! 1
i

I I

ZONE

I_®_i_!_®__®_

AR822_11

', 121_t'2:gz_

_ _,,'.

]____
.__)
SYSTEM
CIRCULATOR

_T_l

N_:'

J/_I"PaJlr

MULTIZONE
DOMESTIC

SYSTEM

HOT WATER

WITH

ZONE VALVES

PRIORITY

(WITH

AND

CIRCULATOR)

ZONE 4

*USE FULL PORT ZONE
VALVE
ZONE2
CH
'CIRCULATOR

ZONE 1 (PRIORITY ZONE)
iDHW
CIRCULATOR

MULTIZONE
DOMESTIC

SYSTEM

HOT WATER

WITH

ZONE VALVES

PRIORITY

(WITH

AND

CIRCULATOR)

INDIRECT WATER
HEATER AQUAS'rAT
F--_-_
t
VOLT

[

POWER
SUPPLY

120

OR THERMOSTAT

B&G COMFORT-TROL,
]

VAC_

SPARCO

SUPERIOR TYPE
ZONE VALVE

HONEYWELL, ERIE

TACO TYPE
ZONE VALVE

-'aT4T®_I'®ll'®' _ '®' _®T

_;0'--24VAC

_-_
x_i_-2
_

BolteP

CH TI
T2
I LI_c.
L -_

[

AIR SEN_

_=I_III
=:,=_.'_

T=I,','
I Ill'I

-___9Hw

Controt

P(_rmt

.,_ OHO_QI
AI

I=1

LI O_
L2

_
C1
CH CI

1
t

AR822-11

@,_
4VALVE
WIRE ONLY

\\
N\

)
I

_:o_

:=_,'o_:°

[@-'J

_!:_:,::,,:a.

MULTIZONE

SYSTEM

WITH CIRCULATORS

AND

DOMESTIC

HOT WATER

ZONE4

ZONE 3

,ZONE 2

PRIORITY

MULTIZONE

SYSTEM

WITH CIRCULATORS

AND

DOMESTIC

HOT WATER

PRIORITY

Ho_Ine IndlPe_k woq_er heo+er
oquorko+
or+ t_r_ot

NOTE: IN PLACE OF 115
VOLT ISOLATION RELAY,
OPTIONAL CONTROL
ARGO AR82211
TERMINAL 5 & 6 N.O.
TO DHW T1 & DHW T2

DATA PORT

PR_RffY ON

L1 & L2 TO ARM L &
N ON PRIORITY ZONE

J I
J
r-

,,_t'

_-,-J

I
I
I
I

115 V COIL / ISDLATIDN
NnRMALY OPEN
Dolter

Controt

RELAY

Panet

|------

OUTDOOR

DHW

AIR SENSOR

--.-L2
®,

20V
L1 (HDT)

ClRC

' 7
1

PRIMARY/SECONDARY

PIPING WITH

CIRCULATORS

AND DOMESTIC

ZONE4

ZONE 2

ZONE 1 (PRIORITY ZONE)

12" MAX APART
J,'_(TO PREVENT FORCED
FLOW IN SECONDARY)

8OILER

_'--y/AETERNATE
_ CIRCULATOR

LOCATION

HOT WATER

NOTE: IN PLACE OF 115
VOLT ISOLATION RELAY,
OPTIONAL CONTROL
ARGO AR82211
TERMINAL 5 & 6 N.O.
TO DHW T1 & DHW T2

m
0

0
Z

[]
L1 & L2 TO ARM L &
N ON PRIORITY ZONE

G)
-4
I

r
AR822-11

i i

I
I

r
I i....

I I
I I

II II

It I

C
tO

115
Bolier
0

CH T2

Control

PQnei

COIL / ISOLATION
NORMALY
OPEN

RELAY

_, CNC,0

OI)HW

o
m
.-t

O0A,

g
-'r

.-t

BOILER ClRC
m

PRIMARY/SECONDARY
ZONE VALVES AND

MULTIZONE

DOMESTIC

SYSTEM

NOT WATER

PIPING

WITH

(WITH ZONE VALVE)

ZONE 4

ZONE 3

ZONE 2

=milD=¸

ZONE 1 (PRIORITY ZONE)

12" MAX APART
(TO PREVENT FORCED |
FLOW IN SECONDARY |

BOILER
f

-_
|

ALTERNATE
CIRCULATOR

LOCATION

O
Z'O

HEATER
AOUASTAT
OR THERMOSTAT
F_
24

VOLT

INDIRECT

POWER
SUPPLY

B&O

WATER
COMFORT-TROL,

L-

SPARCO

HONEYWELL,
ERIE
SUPERIOR
TYPE
ZONE VALVE

TACO TYPE
ZONE VALVE

]

rTI --.

>?>
Z

120 VAC _

oO
o7>

r
i
i

ARSS2F_L_......

-_-® $-: -T_-*2-T®TII T® fiT®* J

131

I
I
---

_o_ let

CH T2

L-_c.,1

.......

Control

Po,net

L, O_

DWH T1

CH C!

DHW T2

0 0

_I i®0i>-

C20I

®y

1111111 ,1111

I _ill I =,::

OUTDODR
AIR

oq
"r'm

SENSOR

_I I IX .-..

a!l

i(g_'_l
L

BOILER ClRC

m o¢ _

and

when

=__

USE1

NXI

4 wiREzo_

133

J I
J

l_tn+p_

n_in_i+\/

Innn

7NnP

\/nlwp

tJ_p_

v,li+h

+hi<

rnn#intJ_n+in_q

133
v

PRIMARY/SECONDARY
AND DOMESTIC

PIPING WITH

HOT WATER

%SE FULL PORT ZONE
VALVE

ZONE

(WITH

ZONE VALVES
CIRCULATOR)

ZONE 3

ZONE 2

ZONE 1 (PRIORITY ZONE)

DHW CIRCULATOR

12" MAX APART
(TO PREVENT FORCED
FLOW _NSECONDARY) ]

BOILER

-,_-" ALTERNATE
/ CIRCULATOR

LOCATION

HEATER
AQUASTAT
OR THERMOSTAT
INDIRECT
WATER

24 VOLT
POWER
SUPPLY

S&G

OOMFORT-TROL,
TACO TYPE
ZONE
VALVE

SPARCO

HONEYWELL,
ERIE
SUPERIOR
TYPE
ZONE VALVE

120 VAC >

--24VAC

COMU

AR832

=rC3

IF ......

r®fl _@
R I TYLA

_3Z

ZONE
123

I
DHW

CIRC

_o_oTl

L
ClRC

BOILER

Note:

a priority

Loop

USE/

CIRC

zone

I
I

Note:
Install
wlre jumper
between
terminals
3
and
4 when
using
zone
volves
without
an
end
switch.

--_N
cm
r-=

o_:
valve

is used

with

this configuration

BYPASS

PIPING

(AUTOMATIC

MIXING VALVE)

FROM SYSTEM
TO SYSTEM

BOILER

"--_ _%LTERNATE
CIRCULATOR
LOCATION

BYPASSPIPING

(FIXED

LOW TEMP. ONLY)

TO SYSTEM

FROM SYSTEM

V2
r

BOILER

\k/

._I
ALTERNATE
| CIRCULATOR

LOCATION

BYPASS

PIPING

(4-WAY VALVE

OPTION

WITH

CIRCULATOR

ON SUPPLY)

FROM SYSTEM

BO_LER

_.%1

-_,., ALTERNATE
C_RCULATOR

LOCATION

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.2
Linearized                      : No
Page Count                      : 37
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 3, 2, 1, 4
Create Date                     : Fri Apr 20 15:51:57 2007
Author                          : 
Title                           : 
Subject                         :

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DUNKIRK Boiler Manual L0612123

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