ECR International Dunkirk II Series Gebrauchsanweisung

Q90 125-200 SERIES II

GAS-FIRED DIRECT VENT

CONDENSING HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

P/N 240009431, Rev. A [03/2012]

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13504-4729

web site: www.ecrinternational.com

Models

Q90-125

Q90-150

Q90-175

Q90-200

1 - Boiler Ratings & Capacities..............................................................................................3

2 - Safe Installation And Operation .......................................................................................5

3 - Locating The Boiler ........................................................................................................6

5 - Combustion Air/ Vent Requirements...............................................................................11

6 - Combustion Air And Vent Pipe .......................................................................................13

7 - Gas Supply Piping........................................................................................................15

8 - Electrical Wiring ..........................................................................................................16

9 - Controls And Accessories..............................................................................................20

10 - Startup.....................................................................................................................22

11 - Detailed Sequence Of Operation...................................................................................27

12 - Sequence Of Operation Diagnostics..............................................................................28

13 - Checkout Procedure & Adjustments..............................................................................29

14 - Troubleshooting - High Limit Control And LWCO..............................................................31

15 - Troubleshooting.........................................................................................................33

16 - Maintenance And Cleaning ..........................................................................................42

Appendix A - Dielectric Isolation & Antifreeze Protection .....................................................44

TABLE OF CONTENTS

Safety Symbols & Warnings

The following deﬁned symbols are used throughout this

manual to notify the reader of potential hazards of varying

risk levels.

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

IMPORTANT: Read following instructions

COMPLETELY before installing!!

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

WARNING

Keep boiler area clear and free from combustible

materials, gasoline and other ﬂammable vapors

and liquids.

DO NOT obstruct air openings to the boiler room.

Modiﬁcation, substitution or elimination of factory

equipped, supplied or speciﬁed components may

result in personal injury or loss of life.

TO THE OWNER - Installation and service of this

boiler must be performed by a qualiﬁed installer.

TO THE INSTALLER - Leave all instructions with

boiler for future reference.

When this product is installed in the

Commonwealth of Massachusetts the installation

must be performed by a Licensed Plumber or

Licensed Gas Fitter.

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.

1 -BOILER RATINGS & CAPACITIES

- SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)Table 1

Model Input

(MBH)(1) Heating Capacity

(MBH)(1)(2) Net AHRI Rating

(MBH)(1) Shipping

Weight (lbs.) AFUE

(2) Flue Diameter

125 125 113 98 284 90.0 2” CPVC & 3” PVC

150 150 134 117 284 90.0 2” CPVC & 3” PVC

175 175 158 137 284 90.0 2” CPVC & 3” PVC

200 200 180 157 284 90.0 2” CPVC & 3” PVC

(1) 1 MBH = 1,000 Btuh (British Thermal Units Per Hour)

(2) AFUE (Annual Fuel Utilization Efﬁciency) and Heating Capacity is based on Department of Energy test procedure.

- Boiler JacketsFigure 1

These low pressure gas-ﬁred hot water boilers are design certiﬁed by CSA International, for use with natural and propane

gases. Boilers are constructed and hydrostatically tested for maximum working pressure of 50 psi (pounds per square

inch) in accordance with A.S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code, Section IV

Standards for heating boilers.

Boilers are certiﬁed in accordance with ANSI (American National Standards Institute) Z21.13 standards as gas-ﬁred, direct

vent, condensing, hot water boilers.

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

to heat water. Small portion is heat loss from jacket and surfaces of boiler, it is assumed this heat stays in the structure.

Net AHRI Rating represents portion of remaining heat applied to heat radiation or terminal units (i.e. Finned tube

baseboard, cast iron radiators, radiant ﬂoor, etc.). Difference between Heating Capacity and Net AHRI Rating, called piping

and pickup allowance, establishes reserve for heating volume of water in the system and offsetting heat losses from

piping. Net AHRI Ratings shown are based on piping and pickup factor of 1.15. Net 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. Manufacturer should be consulted before selecting boiler for installations having unusual

piping and pickup requirements.

1 - BOILER RATINGS & CAPACITIES

This is gas-ﬁred direct vent cast aluminum hot water boiler. Cast aluminum heat exchanger means better heat transfer

and thermal storage than similarly sized cast iron boilers, which results in higher efﬁciency. Heating system water

absorbs large amounts of heat from cast aluminum heat exchanger, cooling ﬂue gases and causing condensation. Sealed

combustion, premix gas burner, and low ﬂame temperature means drastically reduced CO and NOx emissions, which

contribute to cleaner and healthier environment.

Appliance, unlike normal residential atmospheric and induced draft units, 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. Forced draft fan draws in outside combustion air to

mix with gas, which ﬂows into pre-mix burner and combusts. Fan forces resulting ﬂue gases from boiler unit and provides

positive removal of ﬂue gases from building through PVC and CPVC vent pipes.

- LP GASTable 3

Nominal

Input 200,000 175,000 150,000 125,000

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude Min. Max Min. Max Min. Max Min. Max

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 195,900 195,750 171,900 171,200 146,900 146,700 123,050 122,250

2,000 191,800 191,500 168,800 167,400 143,800 143,400 121,100 119,500

3,000 187,700 187,250 165,700 163,600 140,700 140,100 119,150 116,750

4,000 183,600 183,000 162,600 159,800 137,600 136,800 117,200 114,000

5,000 179,500 178,750 159,500 156,000 134,500 133,500 115,250 111,250

6,000 175,400 174,500 156,400 152,200 131,400 130,200 113,300 108,500

7,000 171,300 170,250 153,300 148,400 128,300 126,900 111,350 105,750

8,000 167,200 166,000 150,200 144,600 125,200 123,600 109,400 103,000

9,000 163,100 161,750 147,100 140,800 122,100 120,300 107,450 100,250

10,000 159,000 157,500 144,000 137,000 119,000 117,000 105,500 97,500

- NATURAL GASTable 2

Nominal

Input 200,000 175,000 150,000 125,000

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude Min Max Min. Max Min. Max Min. Max

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000

2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000 121,000

3,000 191,000 189,500 167,200 166,600 143,400 142,200 120,500 119,000

4,000 188,000 186,000 164,600 163,800 141,200 139,600 119,000 117,000

5,000 185,000 182,500 162,000 161,000 139,000 137,000 117,500 115,000

6,000 182,000 179,000 159,400 158,200 136,800 134,400 116,000 113,000

7,000 179,000 175,500 156,800 155,400 134,600 131,800 114,500 111,000

8,000 176,000 172,000 154,200 152,600 132,400 129,200 113,000 109,000

9,000 173,000 168,500 151,600 149,800 130,200 126,600 111,500 107,000

10,000 170,000 165,000 149,000 147,000 128,000 124,000 110,000 105,000

Ratings shown are for sea level applications. Boiler automatically derates input as altitude

increases. No alterations to boiler are required for altitudes above sea level.

Boiler is equipped for residential installations. If used for

commercial applications; additional code requirements

must be adhered to. This may require additional controls,

including but not limited to manual reset low water cut off,

manual reset high temperature limit, and wiring and/or

piping modiﬁcations.

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/NFPA 54.

Where required by authority having jurisdiction,

installation must conform to the Standard for Controls

and Safety Devices for Automatically ﬁred Boilers,

ANSI/ASME CSD-1.

Be certain gas input rate is correct. Over-ﬁring may

result in early failure of boiler components; this may

cause dangerous operation. Under-ﬁring 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.

Verify adequate outdoor air supply to boiler for

complete combustion.

Follow regular service and maintenance schedule for

efﬁcient and safe operation.

Keep boiler area clean of debris and free from

combustible materials, gasoline and other ﬂammable

vapors and liquids.

Proper through-the-wall or through-the-roof

combustion venting shall be in accordance with

materials and methods described in this manual.

Installation must comply with local codes.

Boiler and related hot water heating systems are

not do-it-yourself items. Installation and service by

qualiﬁed professionals are required.

2 - SAFE INSTALLATION AND OPERATION

Installers

-Follow local regulations with respect to

installation of CO (Carbon Monoxide) Detectors. Follow

maintenance recommendations in this manual. See

“Maintenance And Cleaning” on page 42.

Boiler Sizing

Verify you have selected the boiler with proper capacity• before continuing 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

“Boiler Ratings & Capacities” on page 3.

Heat loss calculations should be based on approved• industry methods.

Considerations For Boiler Location

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 amount of fresh (outdoor) air

for combustion. See “Combustion Air And Vent Pipe” on

page 13.

Connected to suitable venting system to remove• hazardous products of gas combustion. See “Combustion

Air And Vent Pipe” on page 13.

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)

WARNING

Fire hazard. Do not install boiler on carpeting.

Failure to follow these instructions could result in

death or serious injury.

Placed on level surface (DO NOT install on carpeting)•

Condensate drain line must be pitched down to ﬂoor• drain or external condensate pump with reservoir at ¼”

per foot (21 mm/m) (wood frame or blocks may be used

to raise boiler).

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

Locating The Boiler

Select level location, central to piping systems served

and close to vent and air intake terminals as possible.

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

clearances) than required ﬁre protection clearances,

must be used for boiler installation. Accessibility

clearances may be achieved with use of removable

walls or partitions.

Clearances shown in Table 4 indicate required

clearances per CSA listing. Minimum 1” (25 mm)

clearance must be maintained between combustible

construction and each of the right, top and back

surfaces of boiler. Minimum 8” (203 mm) clearance is

required on left side, to allow room for inlet air pipe.

18” (457 mm) clearance must be maintained at front

where passage is required for cleaning or servicing,

inspection or replacement of any parts that normally

require such attention. Allow 24” (610 mm) at front

and left side and 8” (203 mm) at top for servicing.

No combustible clearances are required to venting or

combustion air intake piping.

- BOILER CLEARANCESTable 4

Unit Combustible

Clearance Accessibility, Cleaning,

and Servicing

Top 1” (25 mm) 8” (203 mm)

Left Side 8” (203 mm) 24” (610 mm)

Right Side 1” (25 mm) -

Base 1” (25 mm) -

Front 0” (0 mm) 24” (610 mm)

Back 1” (25 mm) -

Intake/Vent

Piping 0” (0 mm) -

Near Boiler Hot

Water Piping 1” (25 mm) -

All distances measured from boiler cabinet.

Keep boiler area clean of debris and free of ﬂammable

and combustible materials, liquids and vapors.

Install equipment in location which facilitates operation

of venting and combustion air intake piping systems as

described in this manual.

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 ﬂow through piping systems

without restrictions for boiler to operate.

Boiler shall be installed such that automatic gas

ignition system components are protected from water

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

service (circulator replacement, condensate trap,

control replacement, etc.).

Boiler must be located where ambient temperatures

(minimum possible room temperatures where boiler

is installed assuming boiler is not in operation and

therefore contributes no heat to space) are always

at or above 32°F (0°C) to prevent freezing of liquid

condensate.

If boiler is not level condensate drain lines will not

function properly. Adjustable feet are located on boiler

to make up for minor surface irregularities or tilt.

Wood frame or blocks may be used to raise boiler

10.

to maintain drain pitch or to be above external

condensate pump reservoir.

3 - LOCATING THE BOILER

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 restriction, leakage, corrosion or other deﬁciencies

which could cause an unsafe condition.

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 ﬁre dampers.

Place in operation appliance being inspected. Follow

lighting instructions. Adjust thermostat so appliances

operate continuously.

Test for spillage at draft hood relief opening after 5

minutes of main burner operation. Use ﬂame of match

or candle, or smoke from cigarette, cigar or pipe.

After it has been determined each appliance remaining

connected to 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.

Any improper operation of common venting system

should be corrected so installation conforms with the

National Fuel Code, ANSI Z223.1/NFPA 54. When

resizing any portion of common venting system,

common venting system should be resized to approach

minimum size as determined using appropriate tables

in chapter 13 of the National Fuel Code, ANSI Z223.1/

NFPA 54.

Placing The Boiler

Place boiler to provide most direct connections to• combustion air, vent, and system piping as possible.

Place crated boiler as close to selected location as• possible and uncrate boiler.

Move uncrated boiler into position with appliance dolly• or 2-wheel hand truck.

Insert dolly or hand truck under• right hand side of

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

smooth ﬂoor or surface.

3 - LOCATING THE BOILER

Do not install copper supply and return piping directly

into aluminum boiler section castings due to galvanic

corrosion between dissimilar metals.

Use iron, steel bushings or pipe connectors between

copper system piping and boiler to make ﬁnal

connection to boiler.

Use of dielectric unions is acceptable, installer supplied.

Packaged boiler is furnished with iron piping in front

boiler section for supply and return connections.

Install all of radiation units (panels, radiators,

baseboard, or tubing) and supply and return mains

ﬁrst, when installation of boiler is for new heating

system.

After installation of all heating system piping and

components; make ﬁnal connection of system piping to

boiler.

Hot water boiler installed above radiation level or

as required by authority having jurisdiction must be

equipped with low water cut off device (included with

boiler).

Periodic inspection is necessary, as is ﬂushing of ﬂoat

type devices, per low water cut off manufacturers

speciﬁc instructions.

Expansion Tank And Make-Up Water

Determine required system ﬁll pressure, design• temperature, and water 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)• See Figure 2, for diaphragm type expansion tank.

For diaphragm type expansion tanks, adjust tank air

pressure to match 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 pressure reducing valve is used, adjust to match• system ﬁll pressure. Verify clean water supply is

available when connecting cold make-up water supply

to boiler. When water supply is from well or pump,

install sand strainer at pump.

4 - NEAR BOILER PIPING

- Diaphragm Type Expansion TankFigure 2 Piping

- Relief Valve Discharge PipingFigure 3

WARNING

Burn and scald hazard. Safety relief valve could

discharge steam or hot water during operation.

Install discharge piping per these instructions.

Check local codes

for maximum

distance from

ﬂoor or other

allowable safe

point of discharge

RELIEF VALVE

DISCHARGE

PIPING

Safety Relief Valve / Temperature Pressure Gauge

Boiler is furnished with safety relief valve and temperature

pressure gauge.

Install safety relief valve using pipe ﬁttings provided• with boiler. Figure 3, Page 8.

Install safety relief valve with spindle in vertical position.• Do not install shutoff valve between boiler and safety• relief valve.

Install discharge piping from safety relief valve.• Use ¾” or larger pipe.A. Use pipe suitable for temperatures of 375°FB. (191°C) or greater.

Individual boiler discharge piping shall beC. independent of other discharge piping.

Size and arrange discharge piping to avoidD. reducing safety relief valve relieving capacity below

minimum relief valve capacity stated on rating

plate.

Run pipe as short and straight as possible toE. location protecting user from scalding and properly

drain piping.

Install union, if used, close to safety relief valveF. outlet.

Install elbow(s), if used, close to safety relief valveG. outlet and downstream of union (if used).

Terminate pipe with plain end (not threaded).H.

NOTE:

When zoning with

circulators, use furnished

circulator pump as one of

zone pumps. Tape or wire

nut each stripped end of

electrical wire for circulator

pump inside junction box

to prevent short circuits.

Unplug circulator pump

wiring at integrated boiler

control.

Supply And Return Lines

Packaged boiler receives 1¼” NPT supply and return piping

from top access.

4 - NEAR BOILER PIPING

- Single Zone Boiler PipingFigure 4

- Multi Zone Boiler Piping With ZoneFigure 5 Valves

- Multi-zone Boiler Piping withFigure 6 Circulators

Condensate Drain Requirements

Pitch condensate drain line down to ﬂoor drain

at minimum of ¼” per foot (21mm/m). External

condensate pump (not furnished) may be used if

ﬂoor drain is not available. Condensate pump must be

designed for ﬂue gas condensate application.

Condensate trap is proved with boiler.

Build condensate trap in the ﬁeld. See Figure 7.

Wood frame or blocks may be used to raise boiler

to maintain drain pitch or to be above external

condensate pump reservoir.

115 volt AC receptacle provided on service switch

junction box which is located at boiler right side,

to provide power for external condensate pump (if

needed).

Condensate Drain Piping

Condensate trap is to be ﬁeld installed as shown in•

Figure 7.

Provided are ½” PVC ﬁttings for condensate drain• trap (assembled in ﬁeld).

The ½” diameter schedule 40 PVC condensate• drain piping and pipe ﬁttings must conform to ANSI

standards and ASTM D1785 or D2846.

Schedule 40 PVC cement and primer must conform• to ASTM D2564 or F493. In Canada, use CSA or ULC

certiﬁed schedule 40 PVC drain pipe and cement.

Condensate pump with reservoir (not furnished) may• be used to remove condensate to drain line (sanitary

line) above boiler if ﬂoor drain is not available or is

inaccessible

Filling Condensate Trap With Water

Manually ﬁll condensate trap at initial start up with water.

Following steps are required to ﬁll condensate trap for

start up. Steps are only required at initial start up or if

maintenance requires draining of condensate trap:

Pour about 1 cup of cold tap water into condensate trap

vent.

Excess water will go through condensate drain line.

Verify proper operation of drain line (and external

condensate pump if used).

Chilled Water Piping

Install boiler used in connection with refrigeration system,

so chiller medium is piped in parallel with boiler with

appropriate valves to prevent chilled medium from entering

boiler.

Boiler piping system of 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 boiler water during cooling

cycle.

4 - NEAR BOILER PIPING

- Condensate Trap and VentFigure 7

To Exhaust Vent

(2” CPVC)

½” Adapter

Male NPT x Socket

Weld PVC Piping

1 3/8” Long

To Boiler Flue Outlet (2” CPVC)

2” Unthreaded Male x 2” NPT Male PVC Bushing

1/2” Unthreaded PVC Elbow

1/2” Unthreaded PVC Piping 3 3/4” Long

1/2” Unthreaded PVC Elbow

1/2” Unthreaded PVC Piping 2” Long

1/2” Unthreaded PVC Piping 3 3/4” Long

1/2” Unthreaded PVC Tee

To Condensate Drain (Field Supplied)

2” NPT Male PVC Bushing

1/2” Unthreaded PVC Piping 12” Long

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