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GAS-FIRED, DIRECT VENT, 

CONDENSING,  HOT WATER BOILER

INSTALLATION, OPERATION & 

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

DUNKIRK BOILERS

85 Middle Rd.
Dunkirk, NY 14048

www.dunkirk.com

 P/N# 14683301, Rev. C [12/2010]

Summary of Contents for 90-100

Page 1: ...D DIRECT VENT CONDENSING HOT WATER BOILER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company DUNKIRK BOILERS 85 Middle Rd Dunkirk NY 14048 www dunkirk com P N 14683301 Rev C...

Page 2: ...d all instructions carefully before starting the installation Save this manual for reference WARNING Improper installation adjustment alteration service or maintenance can cause injury or property dam...

Page 3: ...es information which should be followed to ensure proper installation and operation H Warnings and Safety Symbols 3 Introduction 4 Boiler Ratings Capacities 5 Boilers For Use At High Altitude 6 Rules...

Page 4: ...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 fro...

Page 5: ...t of this heat is available to heat water A small portion is heat 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...

Page 6: ...boilers with the exception of the 90 75 LP product are factory equipped for operation at altitudes ranging from 0 10 000 feet above sea level No changes to the factory settings are required for instal...

Page 7: ...331096 For model 90 75 LP units only at altitudes above 5 000 ft install 90 75 High Altitude Orifice Kit 550001810 For all other alti tudes use factory installed orifice Series 90 100 Stock Factory Bt...

Page 8: ...the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors Read the entire installation manual before beginning the instal 1 lation Failure to follow...

Page 9: ...ed hot water heating systems See the table BOILER RATINGS AND CAPACITIES page 5 of this document Heat loss calculations should be based on approved industry meth ods Considerations For Boiler Location...

Page 10: ...clearances BEFORE INSTALLING THE BOILER CAUTION Keep boiler area clean of debris and free of flamable and combustible materials vapors and liquids WARNING When vent pipe is exposed to temperatures be...

Page 11: ...oors and windows 3 and all doors between the space in which the appliances remain ing connected to the common venting system are located and other spaces of the building Turn on clothes dryer and any...

Page 12: ...ply and return piping from top access The boiler unit can also be piped from the left side by turning the supply elbow and from the rear of the unit by removing plugs in the rear boiler section Near B...

Page 13: ...13 Figure 3 Multi zone Boiler Piping With Zone Valves Near Boiler Piping...

Page 14: ...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 nut...

Page 15: ...content Boiler contains 2 6 gallons U S Size expansion tank accordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished as shown i...

Page 16: ...16 Figure 6 Diaphragm Type Expansion Tank Piping Near Boiler Piping...

Page 17: ...17 Figure 7 Conventional closed type Expansion Tank Piping Near Boiler Piping...

Page 18: ...to remove condensate to a drain line sanitary line above boiler if a floor drain is not available or its in accessible Figure 8 Condensate Drain Piping Near Boiler Piping Filling Condensate Trap With...

Page 19: ...on boiler are sized 3 for 2 pipe Any pipe size change to 3 must be made outside of the boiler casing in a vertical run of pipe to allow for proper drainage of vent condensate Due to potential for flu...

Page 20: ...d Locate or guard the vent to prevent accidental contact with people or pets Terminate the vent above normal snowline Avoid locations where snow may drift and block the vent Ice or snow may cause the...

Page 21: ...istance of 15ft 9 5m Vent shall not terminate within 3 ft 900mm of a window or door that can be opened in any building or any non mechanical air supply inlet to any building or of the combustion air i...

Page 22: ...Wall Vent Intake terminations Less Than 12 Clearance Above Grade Figure 10B Side Wall Vent Intake Terminations 12 Or More Clearance Above Grade Combustion Air and Vent Pipe Less Than 12 Clearance 12...

Page 23: ...23 Figure 11 Combustion Air and Vent Piping Combustion Air and Vent Pipe...

Page 24: ...ent 9 will be visible around perimeter of a properly made joint Handle pipe joint carefully until cement sets 10 Support combustion air and vent piping a minimum of 11 every 5 feet using pre formed me...

Page 25: ...ipe 5 8 3 4 1 2 3 4 20 131 000 216 000 189 000 393 000 40 90 000 145 000 129 000 267 000 60 72 000 121 000 103 000 217 000 Outside diameter Gas Supply Piping Checking The Gas Piping The boiler and its...

Page 26: ...adian Electrical Code Part 1 CSA C22 1 Electrical Code Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service panel or a properly driven and electrically grounde...

Page 27: ...27 Figure 13 Field Wiring Connections Electrical Wiring...

Page 28: ...LLOW G GREEN R RED V VIOLET BR BROWN PUR PUPPLE 24 VOLT WIRING 24 VOLT FIELD WIRING 120 VOLT WIRING 120 VOLT FIELD WIRING INDUCER GAS VALVE BLOWER TEMPERATURE SAFETY SWITCH DIFFERRENTIAL AIR PRESSURE...

Page 29: ...PPER DIFFERENTIAL AIR P3 9 HIGH LIMIT MANUAL RESET PRESSURE SWITCH 4 5 1 3 VR8205A P12 1 P12 2 LOCATION OF CONNECTOR PLUG BETWEEN SCHEMATIC AND BLK WHT AND THE UNIT RECEPTACLE IS LIVE WHEN CAUTION ON...

Page 30: ...fferential The differential can be adjusted with the white Differential Adjustment Wheel on the aquastat and gives the flexibility for boiler operation The larger the differential the longer the run c...

Page 31: ...f 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 will increase The furnished...

Page 32: ...re outside the stated ranges Cleaning the Hydronic System IMPORTANT Do not mix different manufacturers products Doing so will void the warranty of the boiler Consideration MUST be given to cleaning th...

Page 33: ...r Suppliers Recommended Products Interstate Chemical 2797 Freedland Road P O Box 1600 Hermitage PA 16148 0600 www interstatechemical com Tel 800 422 2436 Fax 724 981 8383 Intercool NFP 30 40 50 AA Int...

Page 34: ...e Repeat step 2 for all remaining zones 3 Open the expansion tank service valve and the tank vent Fill 4 the tank to the proper level and close the tank vent Remove the handle from the expansion tank...

Page 35: ...l for gas 7 including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go on to next step Turn the gas control knob counterclockwise 8...

Page 36: ...ting 2 Volt power is being supplied to the inte grated control A B C m D m E m Thermostat calls for heat energizing system circulator A l B m C m D m E m Integrated boiler control goes through self ch...

Page 37: ...es in dicating the hot surface igniter is powered for the 20 second igniter warm up period The bright yellow orange glow of the hot surface igniter can be observed through the observation port in the...

Page 38: ...sured input rate should be within 2 of the input rating 8 from step 2 If within 2 go to step 9 If not adjustment is required proceed as follows Turn boiler off A Set up U tube manometer or differentia...

Page 39: ...KNOB PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW INLET PRESSURE TAP VR8205 WIRING TERMINALS 2 OUTLET PRESSURE TAP Figure 17 Manifold Pressure Measurement Detail Figure 18 Gas Valve Check Out Procedu...

Page 40: ...____ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed on or...

Page 41: ...ses Check the air baffle located inside 1 x 2 flexible coupling on the mixer clean it if necessary and make sure to put it back Refer to repair parts diagram of mixer and pressure switch assembly for...

Page 42: ...ower to boiler at service 1 switch Close manual gas valve to turn off gas supply to boiler NOTICE The following service procedures must be performed only by a qualified service agency Boiler owner sho...

Page 43: ...ough C the condensate lines to thoroughly flush out any sediment or debris in the lines Reinstall and connect the condensate trap using the hose D clamps to secure the various condensate lines to thei...

Page 44: ...44 Service Hints Detailed Sequence Of Operation...

Page 45: ...or heat or turning the service switch off and back on or b waiting for the control to automatically reset after 15 minutes for loss of combustion airflow or one hour for loss of flame Draft Inducer Te...

Page 46: ...ENDS CALL FOR HEAT GAS VALVE AND CIRCULATOR PUMP ARE DE ENERGIZED AND FLAME LIGHTS GO OUT BLOWER RUNS FOR 30 SECONDS POST PURGE PURGE LIGHT IS ON BLOWER IS DE ENERGIZED FOR 30 SECONDS PURGE LIGHT SHUT...

Page 47: ...it is being damaged by some other problem an electrical short burning out a transformer for example Initial Service Checks Before troubleshooting 1 Make sure that circuit breaker is on or fuse is ok...

Page 48: ...OWERED OR AIR FLOW IS NOT PROVEN OFF DURING IGNITER AND RUN CYCLE NORMAL OPERATION PURGE CYCLE COMPLETE BLINKING IBC IS LOCKED OUT PROBLEM COULD INDICATE FALSE POSITIVE PROOF OF AIR FLOW BLOCKED VENT...

Page 49: ...low the gas supplier s instruction If you can not reach your gas supplier call the fire department Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electri...

Page 50: ...50 TROUBLESHOOTING CHART 2 Troubleshooting...

Page 51: ...CONDENSATE MAY PUDDLE AND BLOCK THE VENT YES CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY NO CLEAN OUT SAMPLING LINES OR REPLACE DEFEC...

Page 52: ...ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON NO NO CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT NO REPLACE IBC YES REPAI...

Page 53: ...53 TROUBLESHOOTING CHART 5 Troubleshooting...

Page 54: ...SPECIFIC TOOLS NO YES REPLACE BURNER REPLACE IBC BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT AQUASTAT CONTACTS CLOSED NO BOILER OFF ON HIGH LIMIT IS ACTUAL BOILER WATER TEMP GREATER THA...

Page 55: ...heat Boiler Status Differential Pressure w c Pressure Switch Connects Not Running 0 Normally Open Setpoint 1 00 for Model 100 1 35 for Model 75 1 55 for Model 50 Running Without Blockage Greater Than...

Page 56: ...85 Middle Rd Dunkirk NY 14048...

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