Dunkirk is leading the way in technology with its innovative condensing boiler designs.
The boiler features a patent pending stainless steel heat exchanger. Each heat exchanger is hydro tested at 225 psi which is one and a half times the maximum working pressure. This testing is witnessed by an independent ASME representative, and the ASME rating plate is then applied with a unique serial number and bar code.
The heat exchanger is constructed from one continuous stainless steel helix coil and has a large diameter waterway which inhibits the buildup of scale. The heat exchanger is vertically positioned in the boiler preventing debris from settling inside. This is truly a self-cleaning design. Heavy duty construction and no internal welded joints ensure long life.
After the heat exchanger has been tested and approved, the assembly process begins.
The flexible connector is attached to the corrosion resistant Polypropylene Plastic flue collector. The Flue collector will then attach to a large diameter clear internal trap assembly. The blower is assembled and attached to the gas valve
The upper and lower pipe assembly are put together featuring copper tree piping with low water cut off. The probe type Low Water Cut off features a manual test button to easily verify proper operation.
The patent pending, helical fin tube heat exchanger is made of stainless steel. Gaskets are installed, then the blower and flue assembly are attached.
The 5 to 1 turn down ratio control board is connected to the easy to understand English text digital display. Wire harnesses and transformer are attached to the lower jacket assembly.
Primary and secondary piping and pump is installed inside the chassis. This eliminates material and labor costs during installation. Next the vertically mounted, self-cleaning heat exchanger is connected. The contents are secured with banding and affixed to the chassis.
The control board and wiring is installed.
Each unit is test fired and electrical, plumbing, pressure vessel and combustion set up parameters are fine-tuned and verified. CO levels are analyzed. Testing under 50 psi pressure verifies that there are no system leaks. Red dots are applied to the unit to show that the unit has been fully tested and passed inspection.
At the end of the line, the unit is packaged with warning label, literature, parts bag, accessories, wall mount bracket, and final labeling. Each unit is barcode scanned and uniquely labeled for quality assurance.