ECR International Dunkirk Q90-125 Bedienungsanleitung

Q90 125-200 GAS-FIRED DIRECT VENT

CONDENSING HOT WATER BOILER

P/N 240004826D, Rev. A [10/08]

DUNKIRK BOILERS

85 Middle Rd.

Dunkirk, NY 14048

www.dunkirk.com

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

An ISO 9001-2000 Certied Company

MEMBER: Hydronics Institute

90 125-200 CAST ALUMINUM BOILER

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

TABLE OF CONTENTS

I. Introduction............................................................. 2

II. Safety Symbols...................................................... 2

III. Rules For Safe Installation and Operation.............. 3

IV. Boiler Ratings and Capacities .............................. 4

V. Before Installing The Boiler ................................... 5

VI. Placing The Boiler................................................ 9

VII. Near Boiler Piping ............................................. 10

VIII. Combustion Air and Vent Pipe ......................... 13

IX. Gas Supply Piping.............................................. 15

X. Electrical Wiring .................................................. 16

XI. Controls and Accessories................................... 20

XII. Startup............................................................... 22

XIII. Checkout Procedures and Adjustments............. 26

XIV. Maintenance and Cleaning .............................. 29

XV. Detailed Sequence of Operation....................... 31

XVI. Troubleshooting ............................................... 34

XVII. Installation and Checkout Certicate .............. 43

KEEP THIS MANUAL NEAR BOILER AND

RETAIN FOR FUTURE REFERENCE.

I. INTRODUCTION

This appliance is a gas-red direct vent cast aluminum

hot water boiler. A revolutionary cast aluminum heat

exchanger means better heat transfer and thermal

storage than similarly sized cast iron boilers, which

results in higher efciency. The heating system water

absorbs large amounts of heat from the cast aluminum

heat exchanger, cooling the ue gases and causing

condensation. Sealed combustion, premix gas burner,

and low ame 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 ows into the pre-mix

burner and combusts. The fan then forces the

resulting ue gases from the boiler unit and provides

a positive removal of the ue gases from the building

through inexpensive and readily available PVC and

CPVC vent pipes.

II. SAFETY SYMBOLS

The following dened symbols are used throughout

this manual to notify the reader of potential hazards of

varying risk levels.

IMPORTANT: Read the following instructions

COMPLETELY before installing!

Indicates a potentially hazardous situation

which, if not avoided, could result in death,

serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situa-

tion which, if not avoided, could result in mi-

nor or moderate injury or property damage.

CAUTION

Indicates an imminently hazardous situation

which, if not avoided, will result in death, se-

rious injury or substantial property damage.

DANGER

III. RULES FOR SAFE INSTALLATION AND OPERATION

Figure #1

IMPORTANT:

Failure to follow these instructions could cause

a malfunction of the boiler and result in death,

serious bodily injury, and/or property damage.

For assistance or additional information, consult

a qualied installer, service agency, or the gas

supplier.

1. Check all applicable state and local building codes and

utility company requirements before installation.This

installation must conform with these requirements

in their entirety. In the absence of these codes,

use NFPA installation codes and good industry

practice.

2. Before servicing the boiler, allow it to cool. Always

shut off any electricity and gas supply connected to

the boiler prior to servicing.

3. Inspect gas line for leaks.

4. Be certain gas input rate is correct. Overring may

result in early failure of the boiler components. This

may cause dangerous operation. Underring may

result in too much air for the pre-mix 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 building.

6. Be sure there is adequate outdoor air supply to boiler

for complete combustion.

BOILER JACKETS

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

any and all additional code requirements must be adhered to for installation. This may require

additional controls, including but not limited to a manual reset low water cut off, a manual reset high

temperature limit, and wiring and/or piping modications.

The manufacturer is not responsible for any eld installation changes made to a boiler installation

WHICH ARE NOT DESCRIBED OR ACKNOWLEDGED IN THIS MANUAL.

WARNING

7. Follow a regular service and maintenance schedule

for efcient and safe operation.

8. Keep boiler area clean of debris and free of

combustible and ammable materials.

9. Proper through-the-wall or through-the-roof

combustion venting shall be in accordance with the

III. RULES FOR SAFE INSTALLATION AND OPERATION

materials and methods described in this manual.

Installation must comply with local codes.

10. This boiler and related hot water heating systems

are not do-it-yourself items. They must be installed

and serviced by qualied professionals.

IV. BOILER RATINGS & CAPACITIES

TABLE #1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)

Model Input

(MBH)(1)

Heating Capacity

(MBH)(1)(2)

Net I=B=R Rating

(MBH)(1)

Shipping

Weight (lbs.)

AFUE

(2) Flue Diameter

125 125 112.5 98 284 90 2” CPVC & 3” PVC

150 150 135 117 284 90 2” CPVC & 3” PVC

175 175 157.5 137 284 90 2” CPVC & 3” PVC

200 200 180 157 284 90 2” CPVC & 3” PVC

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

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

TABLE #2 - NATURAL GAS

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. The boiler automatically derates input as altitude increases.

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

IV. BOILER RATINGS & CAPACITIES

TABLE #3 - LP GAS

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

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

sign certied 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 accor-

dance with A.S.M.E. (American Society of Mechanical

Engineers) Boiler and Pressure Vessel Code, Section

IV Standards for heating boilers.

The Boilers are certied in accordance with ANSI

(American National Standards Institute) Z21.13

standards as gas-red, direct vent, condensing,

hot water boilers.

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 oor, 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 pip-

ing. 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 In-

stitute. 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 be-

fore selecting a boiler for installations having unusual

piping and pickup requirements.

V. BEFORE INSTALLING THE BOILER

Complete all of the following prior to installing the boiler.

CODES

This boiler product is a gas-red, direct vent, condens-

ing boiler and must be installed in accordance with all

applicable federal, state and local building codes in-

cluding, but not limited to the following:

United States - Installation shall conform with

National Fuel Gas Code (NFPA-54/ANSI Z223.1

- latest revision)

Canada - Installation shall be in accordance with

CSA-B149.1 and .2 installation codes.

Where required by the authority having jurisdiction, the

installation must conform to the American Society of Me-

chanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, No.CSD-1.

V. BEFORE INSTALLING THE BOILER

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.

In the State of Massachusetts:

This product must be installed by a licensed plumb-•

er or gas tter.

When exible connectors are used, the maximum •

length shall not exceed 36 inches.

When lever type gas shut-offs are used, they shall •

be T-handle type.

Installers - Follow local regulations with respect

to installation of CO (Carbon Monoxide) Detec-

tors. Follow maintenance recommendations in

this manual.

BOILER SIZING

• Check to be sure you have selected the boiler with

the proper capacity before continuing the installation.

The 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.

See Section IV, “Boiler Ratings and Capacities,” for

more information.

• Heat loss calculations should be based on approved

industry methods.

CONSIDERATIONS FOR BOILER LOCATION

Before selecting a location for the boiler, the follow-

ing should be considered. Each boiler considered for

installation must be:

• Supplied with the correct type of gas (natural gas

or propane).

• Connected to a suitable combustion air intake piping

system to supply the correct amounts of fresh (outdoor)

air for combustion (max. length 60’).

• Connected to a suitable venting system to remove

the hazardous products of gas combustion (max.

length 60’).

• Connected to a suitable hot water heating system.

• Supplied with a suitable electrical supply for all boil-

er motors and controls.

• Connected to a properly located thermostat or op-

erating control. (Not included with boiler)

• Placed on level surface (must NOT be installed on

carpeting)

• Condensate drain line must be pitched down to

oor drain or external condensate pump with res-

ervoir at ¼” per foot (wood frame or blocks may be

used to raise boiler).

LOCATING THE BOILER

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.

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

clearances) than required re protection clearanc-

es, must be used for the boiler installation. Acces-

sibility clearances may be achieved with the use of

removable walls or partitions.

3. The boiler is approved for installation in closets and

on combustible oors. This boiler shall NOT be in-

stalled on carpeting.

TABLE #4 - BOILER CLEARANCES

Unit Combustible

Clearance

Accessibility, Cleaning,

and Servicing

Top 1” 8”

Left Side 8” 24”

Right Side 1” -

Base 1” -

Front 0” 24”

Back 1” -

Intake/Vent

Piping 0” -

Near Boiler Hot

Water Piping 1” -

All distances measured from the cabinet of the boiler.

4. The clearances shown in Table 4 indicate required

clearances per CSA listing. A min.. 1” clearance must

be maintained between combustible construction and

each of the right, top and back surfaces of the boiler.

A min.. 8” clearance is required on the left side, to al-

low room for the inlet air pipe. An 18” clearance must

be maintained at the front where passage is required

for cleaning or servicing, inspection or replacement

of any parts that normally may require such attention.

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.

Keep boiler area clean of debris and free of ammable

and combustible materials, liquids and vapors.

CAUTION

OVERHANG

12" MINIMUM

90°

VENT

12" SEPARATION

BETWEEN BOTTOM OF

COMBUSTION AIR INTAKE

AND BOTTOM OF VENT

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL OR

GRADE

MAXIMUM

SEPARATION

18"

MAXIMUM

15"

MAXIMUM

LESS THAN 12" CLEARANCE

12"

MINIMUM

12"

MINIMUM

V. BEFORE INSTALLING THE BOILER

5. Equipment shall be installed in a location which fa-

cilitates the operation of venting and combustion air

intake piping systems as described in this manual.

6. Advise owner of boiler to keep venting and combus-

tion air intake passages free of obstructions. Both

the venting and combustion air intake piping sys-

tems connected to the outdoors must permit ow

through the piping systems without restrictions for

the boiler to operate.

7. The boiler shall be installed such that the automatic

gas ignition system components are protected from

water (dripping, spraying, rain, etc.) during opera-

tion and service (circulator replacement, control

replacement, etc.).

8. The boiler must be located where ambient tempera-

tures (minimum possible room temperatures where

boiler is installed assuming boiler is not in opera-

tion and therefore contributes no heat to the space)

are always at or above 32°F to prevent freezing of

liquid condensate.

COMBUSTION AIR/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.

Combustion air and vent pipe connections must termi-

nate together in the same atmospheric pressure zone,

either through the roof or sidewall (roof termination

preferred). See Figures #1 and #2 for required clear-

ances.

8" MINIMUM

VERTICAL SEPARATION

BETWEEN COMBUSTION

AIR INTAKE AND VENT

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL

3'' MAXIMUM

SEPARATION

15'' MAXIMUM

COMBUSTION

AIR

12''

MIMIMUM

ROOF VENT / INTAKE TERMINATIONS

Figure #1

SIDEWALL VENT/INTAKE TERMINATIONS

Figure #2

12" OR MORE CLEARANCE

90°

BRACKET

VENT

18"

MAXIMUM

MAINTAIN 12" MINIMUM

CLEARANCE ABOVE HIGHEST

ANTICIPATED SNOW LEVEL OR

GRADE

12" SEPARATION

BETWEEN BOTTOM OF

COMBUSTION AIR INTAKE

AND BOTTOM OF VENT

12" MINIMUM

OVERHANG

MAXIMUM

SEPARATION

12"

MINIMUM

12"

MINIMUM

Less Than 12” Clearance

12” or More Clearance

If the concentric vent termination is being used, refer

to Figure #3 for proper setup.

CONCENTRIC VENT TERMINATIONS

Figure #3

V. BEFORE INSTALLING THE BOILER

FAILURE TO FOLLOW THESE WARNINGS COULD

RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL

INJURY, OR DEATH.

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 1/2”Armaex or equivalent.

In extremely cold climate areas, use 3/4”Armaex or

equivalent.

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

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 exactly as shown in Figures #1 – #2. If a

concentric vent termination is being used, refer to Figures

#3 – #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.

Solvent cements are combustible. Keep away from

heat, sparks, or open ame. Use only in well ventilated

areas. Avoid breathing in vapor or allowing contact with

skin or eyes.

COMBUSTION AIR/VENT PIPE REQUIREMENTS Continued

CONCENTRIC VENT ROOF INSTALLATION

CONCENTRIC VENT

Figure #5

Figure #4

WARNING

V. BEFORE INSTALLING THE BOILER

FOUNDATION REQUIREMENTS

Boiler must be placed on level surface. Boiler is NOT

to be installed on carpeting.

NOTES:

1. If boiler is not level condensate drain lines will

not function properly. Adjustable feet are locat-

ed on the boiler to make up for minor surface

irregularities or tilt.

2. Wood frame or blocks may be used to raise

boiler to maintain drain pitch or to be above ex-

ternal 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 com-

mon venting system placed in operation, while the

other appliances remaining connected to the common

venting system are not in operation.

1. Seal any unused openings in the common venting

system.

2. Visually inspect the venting system for proper size

and horizontal pitch and determine there is no block-

age or restriction, leakage, corrosion or other de-

ciencies which could cause an unsafe condition.

3. When it is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the com-

mon venting system are located and other spac-

es 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 ex-

haust fan. Close re dampers.

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 af-

ter 5 minutes of main burner operation. Use the

ame 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-latest revision, or section 5 of

CSA-B149 for Canadian standards. When resiz-

ing 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/ANSI- Z223.1-latest

revision, or section 5 of CSA-B149 for Canadian

standards.

VI. PLACING THE BOILER

The boiler should be placed to provide the most direct

connections to the combustion air, vent and system

piping as possible.

Place crated boiler as close to selected location as

possible and uncrate boiler. The uncrated boiler 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 oor or surface.

NOTE: Refer to “Locating The Boiler” in Section

V for required clearances for servicing and main-

tenance.

VII. NEAR BOILER PIPING

Copper supply and return piping must NOT be in-

stalled 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

nal connection to boiler. Also, the use of dielectric

unions is acceptable. The packaged boiler is fur-

nished with iron piping in the front boiler section for

the supply and return connections.

When the installation of the boiler is for a new heat-

ing system, rst install all of the radiation units (panels,

radiators, baseboard, or tubing) and the supply and re-

turn mains. After all heating system piping and compo-

nents have been installed, make nal connection of the

system piping to the boiler.

A hot water boiler installed above radiation level must

be equipped with a low water cut off device (included

with boiler). A periodic inspection is necessary, as is

ushing of oat type devices, per low water cut off man-

ufacturers specic instructions.

EXPANSION TANK AND MAKE-UP WATER

Determine required system ll pressure, system de-

sign temperature, and system water content. Boiler

contains 2.6 gallons (U.S.). Size expansion tank ac-

cordingly. Consult expansion tank manufacturer for

proper sizing information. Connect properly sized ex-

pansion 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 ll 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, ad-

just to match the system ll pressure. In connecting the

cold make-up water supply to the boiler, make sure that

clean water supply is available. When the water sup-

ply is from a well or pump, a sand strainer should be

installed at the pump.

PRESSURE RELIEF VALVE / TEMPERATURE

PRESSURE GAUGE

The boiler is furnished with a relief valve and temper-

ature pressure gauge in the boiler parts bag. Install

vent relief valve as shown in Figure #7. Provide ¾”

piping from the relief valve to a local oor drain, but

leave an air gap between piping and drain. No shut-

off 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. In-

stallation of the safety relief valve shall conform to

ANSI/ASME Boiler and Pressure Vessel Code, Sec-

tion IV. The manufacturer is not responsible for any

water damage.

Figure #6

Figure #7

RELIEF VALVE DISCHARGE PIPING

DIAPHRAGM TYPE EXPANSION TANK PIPING

CAUTION

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