ECR International Dunkirk 4 Series Gebrauchsanweisung

GAS-FIRED, DIRECT VENT,

CONDENSING,

HOT WATER BOILER

INSTALL ATION, OPER ATION &

MAINTENANCE MANUAL

Models

Q90-50

Q90-75

Q90-100

Q90-50/75/100 Series 4

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 325 5479

www.ecrinternational.com

PN240010121 REV. F [10/15/2021]

DIMENSIONS

Figure 1 - Boiler Dimensions

NOTICE

Draft inducer (blower) may be

rotated 90° or 180° to orient

vent connection towards right

side or rear.

PN 240010121 Rev. F [10/15/2021]

INTRODUCTION

Introduction

• This appliance is a gas-red direct vent hot water boiler

with cast aluminum boiler sections.

• The heating system water absorbs large amounts of

heat from the cast aluminum heat exchanger, cooling

ue gases and causing condensation.

• Sealed combustion, premix gas burner, and low ame

temperature means reduced CO and NOx emissions,

which contribute to cleaner and healthier environment.

• This appliance takes its combustion air directly from

outdoors (sealed combustion) and does not compete

with building occupants for fresh air.

• Sealed combustion (also known as “direct vent”)

is safest and best way to obtain plenty of clean

combustion air.

Dimensions....................................................................................................................2

Introduction...................................................................................................................3

Important Safety Information...........................................................................................4

Boiler Ratings & Capacities ..............................................................................................5

Boilers For Use At High Altitude - United States Installations ................................................6

Before Installing The Boiler ..............................................................................................8

Boiler Installation ...........................................................................................................9

Near Boiler Piping ......................................................................................................... 11

Combustion Air And Vent Pipe ........................................................................................ 22

Gas Supply Piping......................................................................................................... 28

Electrical Wiring ........................................................................................................... 30

Controls And Accessories ............................................................................................... 34

Start Up ...................................................................................................................... 36

Operating Instructions................................................................................................... 37

Detailed Sequence Of Operation ..................................................................................... 38

Verication Procedure And Adjustment ............................................................................ 42

Dierential Air Pressure Switch Check - All Models ............................................................ 45

Negative Pressure Switch Check ..................................................................................... 46

Maintenance And Cleaning ............................................................................................. 47

Troubleshooting............................................................................................................ 49

Troubleshooting - High Limit Control And LWCO ............................................................... 50

Troubleshooting - Hydrostat High Limit Control And LWCO ................................................. 51

Appendix A - Water Quality, Water Treatment And Freeze Protection ........................58

Installation And Check-Out Certicate ............................................................................. 62

• Induced draft fan draws in outside combustion

air, takes cooler ue gases from boiler unit and

provides positive removal of ue gases from the

building through readily available PVC, CPVC and PP

(Polypropylene) pipes.

• These low pressure gas-red hot water boilers are

design certied by CSA International for use with

natural gas and propane gas.

• Boilers are constructed and hydrostatically tested for

maximum working pressure of 50 psig (pounds per

square inch gage) in accordance with A.S.M.E. Boiler

and Pressure Vessel Code Section IV Standards for

heating boilers.

PN 240010121 Rev. F [10/15/2021]

Installation shall conform to requirements of

authority having jurisdiction or in absence of such

requirements:

•

United States

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, NFPA 70.

Where required by authority having jurisdiction,

installation shall conform to Standard for Controls

and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1.

Additional manual reset low water cuto and/or manual

reset high limit may be required.

Requirements for Commonwealth of

Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not

limited to:

• Installation by licensed plumber or gas tter.

Installers - Follow local regulations with respect to

installation of CO (Carbon Monoxide) Detectors. Follow

maintenance recommendations“Maintenance And Cleaning”

on page 47.

NOTICE

Used to address practices not related to personal

injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

This is the safety alert symbol. Symbol alerts you toThis is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.following this symbol to avoid possible injury or death.

Become familiar with symbols identifyingBecome familiar with symbols identifying

potential hazards.potential hazards.

General

Boiler installation shall be completed by qualied agency.

See glossary for additional information.

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death

or serious injury. Read this manual and understand

all requirements before beginning installation.

IMPORTANT SAFETY INFORMATION

Keep this manual near boiler

Retain for future reference

CAUTION

Laceration, burn hazard. Metal edges and parts may

have sharp edges and/or may be hot. Use appropriate

personal protection equipment to include safety

glasses and gloves when installing or servicing this

boiler. Failure to follow these instructions could result

in minor or moderate injury.

PN 240010121 Rev. F [10/15/2021]

Table 1 - SEA LEVEL RATINGS – NATURAL AND PROPANE GASES

Model Input

*(MBH)

++ Heating Capacity

*(MBH)

Net AHRI Rating

*(MBH)

Shipping

Weight (lbs.) AFUE

90-50 50 45 39 220 90.0

90-75 75 68 59 220 90.0

90-100 100 90 78 220 90.0

* 1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour

BOILER RATINGS & CAPACITIES

++ AFUE (Annual Fuel Utilization Eciency) and Heating Capacity is based on the D.O.E. (Department of Energy) test

procedure.

Heating Capacity indicates the amount of heat available after subtracting losses up the stack. Most of this heat is available

to heat water. A small portion is heat from jacket and surfaces of the boiler, and it is assumed that this heat stays in the

structure.

Net AHRI rating represents portion of remaining heat that can be applied to heat radiation or terminal units (i.e. nned

tube baseboard, cast iron radiators, radiant oor, etc.). The dierence between Heating Capacity and Net AHRI Rating,

called piping and pickup allowance, establishes reserve for heating volume of water in system and osetting heat losses

from piping.

Net AHRI ratings shown are based on piping and pickup factor of 1.15 in accordance with AHRI Standard as published

by Hydronics Institute. Net AHRI rating of boiler selected should be greater than or equal to the calculated peak heating

load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. Consult manufacturer

before selecting a boiler for installations having unusual piping and pickup requirements.

Boilers for use at high altitude

United States - See “Boilers For Use At High Altitude” on page 6.

PN 240010121 Rev. F [10/15/2021]

Table 2 - NATURAL GAS

MODEL 90-50

Stock Factory Btu Value of Natural Gas++

Settings 750 850 950 1000 1050

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 50 – – – – –

Orice 43331094 43331094

MODEL 90-75

Stock Factory Btu Value of Natural Gas++

Settings 750 850 950 1000 1050

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 75 – – – – –

Orice 43331092 43331092

MODEL 90-100 /

Stock Factory Btu Value of Natural Gas++

Settings 750 850 950 1000 1050

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 100 – – – – –

Orice 43331090 43331090

++Contact local gas utility or distributor for Btu value of gas.

BOILERS FOR USE AT HIGH ALTITUDE - UNITED STATES INSTALLATIONS

• Boilers (with exception of 90-75 propane (LP) product)

are factory equipped for operation at altitudes ranging

from 0-10,000 feet above sea level.

• No changes to factory settings are required for

installations from 0-5,000 feet above sea level.

• For altitudes from 5,000-10,000 feet above sea level

gas manifold pressure needs to be adjusted based upon

caloric (Btu) value of supply gas (contact local gas

utility or distributor for this value).

• For specic settings refer to Table 2 for natural gas

applications and

Table 3, Page 7

for propane (LP) gas

applications.

• Instructions on how to adjust gas manifold pressure

settings see

Figure 25 and Figure 26, Page 44

Note 90-75 propane (LP) applications for 5,000 - 10,000

feet above sea level require orice change as well as gas

manifold pressure adjustment based upon caloric (Btu)

value of supply gas.

Refer to

Table 2

and Table 3 for high altitude orice

part numbers. For replacing an orice refer to specic

instructions included with conversion kit.

PN 240010121 Rev. F [10/15/2021]

Table 3 - PROPANE GAS

MODEL 90-50

Stock Factory Btu Value of Propane Gas++

Settings 2300 2350 2400 2450 2500

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 50

– – – – –

Orice 43331095 43331095

MODEL 90-75*

Stock Factory Btu Value of Propane Gas++

Settings 2300 2350 2400 2450 2500

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 75

– – – – –

Orice 43331093

43331096*

* For model 90-75 Propane units only at altitudes above 5,000 ft., install 90-75 High Altitude Orice Kit #550002629 For all other

altitudes use sea level orice.

MODEL 90-100 **

Stock Factory Btu Value of Propane Gas++

Settings 2300 2350 2400 2450 2500

Altitude in Ft. 0-5,000 5,000-10,000

Normal Input (MBH) 100

– – – – –

Orice 43331091

43331091

++Contact local gas utility or distributor for Btu value of gas.

BOILERS FOR USE AT HIGH ALTITUDE - UNITED STATES INSTALLATIONS

Model 90-75 propane (LP) units only at altitudes

above 5,000 ft., install 90-75 High Altitude Orice Kit

#550002629*.

For all other altitudes use sea level orice

PN 240010121 Rev. F [10/15/2021]

Boiler Sizing

Check to be sure you have selected boiler with proper

capacity before starting installation. AHRI Rating of boiler

selected should be greater than or equal to calculated

peak heating load (heat loss) for building or area(s) served

by boiler and associated hot water heating systems. See

Table 1, Page 5.

Heat loss calculations should be based on approved

industry methods.

Boiler Location Considerations

Before selecting boiler location consider following.

• Supplied with correct type of gas (natural gas or

propane).

• Connected to suitable combustion air intake piping

system to supply correct amounts of fresh (outdoor)

air for combustion, refer to “Combustion Air and Vent

Pipe” on page 22 for details.

• Connected to suitable venting system to remove

hazardous products of gas combustion, refer to

“Combustion Air and Vent Pipe” on page 22 for details.

• Connected to suitable hot water heating system.

• Supplied with suitable electrical supply for all boiler

motors and controls.

• Connected to properly located thermostat or operating

control. Not included with boiler.

• Placed on level surface.

• Condensate drain line must be pitched down to oor

drain or external condensate pump with reservoir at ¼”

per foot (wood frame or blocks may be used to raise

boiler).

Boiler is equipped for residential installations. If used

for commercial applications, any additional code

requirements must be adhered to for installation.

This may require additional controls including but not

limited to an additional low water cut o, a manual

reset high temperature limit, and wiring and/or piping

modications.

Before servicing boiler - allow boiler to cool. Shut o

electricity and gas supply connected to boiler prior to

servicing.

Inspect gas line for leaks.

Verify gas input rate is correct. Over ring may result

in early failure of boiler sections. This may cause

dangerous operation. Under ring may result in too

much air for pre-mix burner causing poor or loss of

combustion.

Never vent products of combustion from this boiler to

enclosed space. Always vent to outdoors. Never vent to

another room or to inside building.

Be sure there is adequate outdoor air supply to boiler

for complete combustion.

Follow regular service and maintenance schedule for

ecient and safe operation.

Keep boiler area clean of debris and free of combustible

and ammable materials.

Proper through wall or through roof combustion venting

shall be in accordance with materials and methods

described in this manual. Installation must comply with

local codes.

10.

Boiler and related hot water heating systems are not do

it yourself items they must be installed and serviced by

qualied professionals.

BEFORE INSTALLING THE BOILER

Minimum Clearances To Combustible Construction

8”

Boiler

Rear

Front

Control Side

Opposite Side

1”

(26MM)

11”

(280MM)

1”

(26MM)

1”

(26MM)

PN 240010121 Rev. F [10/15/2021]

Table 4 -

Required Clearances

Unit Combustible

Clearance

Accessibility,

Cleaning, and

Servicing

Top 1” (26mm) 8” (204mm)

Left Side 1 “ (26mm) -

Right Side 11” (280mm) -

Base 1” (26mm) -

Front 1” (26mm) 24” (610mm)

Back 1” (26mm) -

Intake/Vent Piping 0 (0) -

All distances measured from the cabinet of the boiler.

Locating The Boiler

Place crated boiler as close to selected location as

possible and un-crate boiler. Boiler may be moved into

position with appliance dolly or 2 wheel hand truck.

Insert dolly or hand truck under left hand side of

boiler. It is possible to slide boiler for short distance on

smooth oor or surface.

Select level location central to piping systems served

and as close to vent and air intake terminals as

possible.

Accessibility clearances, if more stringent (i.e. larger

clearances) than required re protection clearances,

must be used for boiler installation. Accessibility

clearances may be achieved with the use of removable

walls or partitions.

Boiler is approved for installation in closets and on

combustible oors. This boiler shall NOT be installed on

carpeting.

Clearances shown in Table 4

indicate required

clearances. Maintain minimum 1” clearance between

combustible construction and each of left, top and

back surfaces of the boiler. Minimum 11” clearance is

required on right side, to allow room for induced draft

blower. Allow 24” at front and 8” at top for servicing.

No clearances are required to venting or combustion air

intake piping.

Install equipment in location which facilitates operation

of venting and combustion air intake piping systems

as described in this manual. Draft inducer (blower)

may be rotated 90° or 180° to orient vent connections

towards right side or rear. Remove blower mounting

screws. Orient blower and install mounting screws. Do

not overtighten screws.

Advise owner to keep venting and combustion air

intake passages free of obstructions. Both venting

and combustion air intake piping systems connected

to outdoors must permit ow through piping systems

without restrictions for boiler operation.

Install boiler such that the automatic gas ignition

system components are protected from water

(dripping, spraying, rain, etc.) during operation and

service (circulator replacement, condensate trap,

control replacement, etc.).

Keep boiler area clean of debris and free of ammable

and combustible materials, vapors and liquids.

10.

Locate boiler where minimum possible room

temperature where boiler is installed, assuming boiler

is not in operation and therefore contributes no heat

to space, is always at or above 32°F (0°C) to prevent

freezing of liquid condensate.

Combustion Air And Vent Pipe Requirements

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 ue products are

discharged to outside atmosphere.

Terminate combustion air and vent pipe connections in

same atmospheric pressure zone, through roof or sidewall

(roof termination preferred). See Figure 12 thru Figure 14,

pages 24 and 25 for required clearances.

WARNING

Solvent cements are combustible. Keep away

from heat, sparks, and open ame. Use only in

well ventilated areas. Avoid breathing in vapor or

allowing contact with skin or eyes. Failure to follow

these instructions could result in re, serious injury,

or death.

• Combustion air must be clean outdoor air. Combustion

air must not be taken from inside structure because

that air frequently is contaminated by halogens, which

include uorides, chlorides, phosphates, bromides

and iodides. These elements are found in aerosols,

detergents, bleaches, cleaning solvents, salts, air

fresheners, paints, adhesives and other household

products.

• 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 as shown in

“Combustion Air and Vent

Pipe”

section.

• Vent connections serving appliances vented by

natural draft shall not be connected into any portion

of mechanical draft systems operating under positive

pressure.

BOILER INSTALLATION

PN 240010121 Rev. F [10/15/2021]

Condensate Drain Requirements

• Pitch condensate drain line down to oor drain at

minimum of ¼” per foot. External condensate pump

(not furnished) may be used if oor drain is not

available. Installation shall conform to requirements

of authority having jurisdiction, check local codes for

requirements.

• Condensate pump must be designed for ue gas

condensate application.

• Condensate trap provided with boiler, an additional trap

is not required and should not be used.

• Wood frame or blocks may be used to raise boiler

to maintain drain pitch or to be above external

condensate pump reservoir.

Foundation Requirements

• Install boiler on level surface.

WARNING

Fire hazard. Shall not install boiler on carpeting.

Failure to follow these instructions could result in

death or serious injury.

• Boiler is NOT to be installed on carpeting.

• If boiler is not level condensate drain lines will not

function properly. Adjustable feet are located on the

boiler to make up for minor surface irregularities or tilt.

• Wood frame or blocks may be used to raise boiler

to maintain drain pitch or to be above external

condensate pump reservoir.

Removal of Existing Boiler From Common Vent

System

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.

Seal any unused openings in the common venting

system.

Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage, or

restrictions, leakage, corrosion and other deciencies

which could cause an unsafe condition.

BOILER INSTALLATION

In-so-far as is practical, close all building doors and

windows and all doors between the space 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 re dampers.

Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so

appliances will operate continuously.

Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the ame of a

match or candle, or the smoke from a cigarette, cigar

or pipe.

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, re place dampers,

and any other gas-burning appliance to their previous

condition of use.

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 and/

or the Natural Gas and Propane Installation Code,

CAN/CSA B149.1. When re-sizing any portion of the

common venting system, the common venting system

should be re-sized to approach the minimum size as

determined using the appropriate of the National Fuel

Gas Code, NFPA-54/ANSI- Z223.1 and/or the Natural

Gas and Propane Installation Code, CAN/CSA B149.1.

PN 240010121 Rev. F [10/15/2021]

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