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Dunkirk DCBF-125 Installation, Operation & Maintenance Manual Download Page 2

2

Fully Assembled Boiler

30 PSI Safety Relief Valve

        

Temperature Pressure 

Gauge (2" Shank)

G3/4  NPT  Ball  Gas              

Shutoff Valve

4ea - 17x24x2" Gaskets

4ea - 1/2" AFM Gaskets

Includes Essential           

Documents and Warranty

11x17 Wire Diagrams

DHW  Optional  Pipe               

Heat Only Boiler

Used for  Valve Connections

Document Package

VERIFY CONTENTS RECEIVED

240012564 REV A, [05/15/2019]

Summary of Contents for DCBF-125

Page 1: ...FIRED INSTALLATION OPERATION MAINTENANCE MANUAL Models DCBF 125 DCCF 150 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240012564 R...

Page 2: ...ge 2 Shank G3 4 NPT Ball Gas Shutoff Valve 4ea 17x24x2 Gaskets 4ea 1 2 AFM Gaskets Includes Essential Documents and Warranty 11x17 Wire Diagrams DHW Optional Pipe Heat Only Boiler Used for Valve Conne...

Page 3: ...g 39 9 7 Commissioning For The First Time 39 9 8 Automatic Calibration Function 39 9 9 Manual Calibration Function 40 9 10 De Aeration Function 40 9 11 Commission Set Up Gas Changing The Type Of Gas 4...

Page 4: ...DHW Water Content 0 05 gal 0 23 L SYSTEM When boiler is operating at maximum operating temperature providing heating with all heat emitters operating pressure gauge should not indicate more than 26 11...

Page 5: ...56 in 472 mm 20 50 in 521 mm 24 70 in 628 mm 2 22 in 56 4 mm 9 13 in 232 mm 7 92 in 201 mm 6 63 in 168 mm 4 35 in 111 mm 6 12 in 156 mm 6 12 in 155 mm 7 31 in 186 mm 3 42 in 87 mm 1 80 in 46 mm 43 65...

Page 6: ...requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can scald...

Page 7: ...s Modulates to provide CH Turndown 5 5 1 DHW Turndown 7 1 Maximum output available for domestic hot water DCCF 150 136 000 btu h 40 kW capable of providing 3 5 U S gpm 13 2 liters min with a temperatu...

Page 8: ...9 Pump with Air Separator 10 Boiler Drain Tap 11 Heating Return 12 Gas Inlet 13 Optional Indirect Tank Connection 14 Heating Supply Connection 15 Condensate Connection 16 Low Water Pressure Cutoff 17...

Page 9: ...Inlet 16 DHW Outlet 17 Heating Supply Connection 18 Condensate Connection 19 DHW Heat Exchanger 20 NTC DHW Sensor 21 Low Water Pressure Cutoff 22 3 Way Valve with Motor 23 Gas Valve 24 Water Safety T...

Page 10: ...e 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 si...

Page 11: ...ck of Unit and wall 1 3 4 in 45 mm 13 4 in 45 mm 13 4 in 45 mm 450 mm Front View of Boiler 0in 0 mm 0in 0 mm Top View 0 in 0 mm 0 in 0 mm Combustible Clearances TABLE 1 BOILER CLEARANCES Dimension Com...

Page 12: ...elbow on the top of the boiler is included in equivalent length calculations Use U V stabilized polypropylene when it will be exposed to sunlight wind or prone to freeze ups Manufacturer requires use...

Page 13: ...mmon axis 2 Twin Pipe Exhaust and intake air are separate pipes Figure 5 1 Venting Support 5 COMBUSTION AIR AND VENT PIPING can be terminated using single wall terminals from the vent manufacturer or...

Page 14: ...ational Fuel Gas Code ANSI Z223 1 NFPA 54 1 Venting shall be properly supported 2 Boiler shall not support any type of vent system WARNING Manufacturer recommends this condensing boiler be vented with...

Page 15: ...vents flue and air Verify cut ends are square and free from burrs Insert flue back into intake air vent and pass them through hole in wall Check all measurements before cutting Clearance to combustib...

Page 16: ...ON ALL SIZES Maintain 12 305 mm US 18 457 mm Canada clearance above highest anticipated snow level 24 610 mm above roof or ground Anticipated Snow Line FIGURE 5 5 Coaxial Vertical Exhaust CAN BE USED...

Page 17: ...the top of the boiler to Twin Pipe polypropylene venting an adapter kit is available C Twin Pipe Separated Flue Exhaust and combustion air intake are not located in same general location D Twin Pipe C...

Page 18: ...the pipe 4 Insert the male end of of the second pipe into the clamp on the up etched side Force the two pipes together 5 Verify the two pipes are secure together with clamp in place 5 9 Securing Twin...

Page 19: ...liance 12 305 mm Min 84 2 2 m Max vertical separation between combustion air intake and vent of different appliances 15 381 mm Max horizontal length of vent Min vent intake between different appliance...

Page 20: ...ir of other boilers required in all multiple boiler installations FIGURE 5 22 2 50 mm 3 80 mm Twin Pipe Side Wall Vent CAN BE USED ON ALL SIZES 3 77 mm Min 24 610 mm Max Separation See Grade Snow Ice...

Page 21: ...ions Flexible venting installations use single wall polypropylene to pass flue gasses to base of chimney then flexible venting to get them to termination at the top Combustion air is not supplied thro...

Page 22: ...h side of center line extended above meter regulator assembly 3 ft 0 9 m within a height of 15 ft 4 5 m above the meter regulator assembly 3 ft 0 9 m I Clearance to service regulator vent outlet 3 ft...

Page 23: ...ump designated for use with condensing boiler if boiler located below disposal point Condensate pump should have overflow switch Condensate from Boiler is slightly acidic and may cause property damage...

Page 24: ...heat exchange surfaces and accumulate in pump cavities causing reduced efficiency and premature wear Flush system to remove any solid objects such as metal chips fibers or Teflon tape etc Flush syste...

Page 25: ...Safety relief valve could discharge steam or hot water during operation Use pipe suitable for temperatures of 375 F 191 C or greater DO NOT use plastic pipe Install discharge piping per these instruct...

Page 26: ...LVE BEFORE TEE OR LWCO Note To Drain Check Local Codes for Maximum Distance to Floor Arrange piping to prevent water dripping onto boiler 1 Return Purge Valve Magnetic Dirt Separator Position Temperat...

Page 27: ...O sensing device in the supply piping above the minimum height of boiler See Figure 6 2 Piping Diagram Position control in HORIZONTAL piping to assure proper boiler protection upright or 90 rotation F...

Page 28: ...tion and debris from your water supply piping from entering the boiler Debris carried from the water supply will clog DHW water flow sensor potentially resulting in significant operation issues Locate...

Page 29: ...ensors will send a signal to the control board allowing the control board to increase decrease the speed of the fan The combustion fan will in turn modulate the gas rate accordingly When the domestic...

Page 30: ...on external to the boiler Boiler shall be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of gas supply piping system at test pres...

Page 31: ...d acceptable to authority having jurisdiction Do not use matches candles open flames or other methods that can provide ignition source Correct leaks immediately and retest 7 3 Gas Orifice See Figure 7...

Page 32: ...ent latter from overheating Model Size 125 150 Power Supply 120V 60Hz Power Consumption 133 W 142 W Internal Fuse Qty 2 F3 15 A Electrode Spark Gap 1 8 to 3 16 3 1 mm to 4 7 mm DANGER Electrocution Ha...

Page 33: ...hich is high voltage 120V 60Hz Fuses 3 15 A are incorporated in the power supply terminal block To check or replace fuse pull out black fuse carrier TERMINAL BLOCK M1 L Live brown N Neutral light blue...

Page 34: ...ELECTRICAL CONNECTIONS 8 7 Optional Electrical Connections A 1K Ohm 1K Outdoor Temperature Sensor To connect this accessory see figure 8 5 terminals 4 5 and instructions supplied with 1K sensor B Set...

Page 35: ...n terminal block M2 Insert 10K NTC sensor element in the sensor well of indirect storage tank Verify exchange capacity of the storage boiler coil is appropriate for boiler power Adjust DHW temperature...

Page 36: ...TING ONLY WITH OPTIONAL INDIRECT DHW CONNECTION DCBF 125 HEATING ONLY WITHOUT OPTIONAL INDIRECT DHW CONNECTION 9 2 Central Heating System Connections Combi DCCF 150 COMBI LEGEND 150 A Heating supply c...

Page 37: ...e drain as soon as water appears Systems using radiators to remove air Vent each radiator in turn starting with lowest in the system It is important the pump is properly vented to avoid running it dry...

Page 38: ...temperature F C 16 Manufacturing information 07 Thermo fuse status 000 001 17 Fan speed i17 x100 08 Not used 18 Manufacturing information DHW temperature adjustment to increase the temperature and to...

Page 39: ...itions immediately after installation system will implement a self learning procedure to reach correct ignition level 9 START UP PROCEDURE 9 8 Automatic Calibration Function Before performing this fun...

Page 40: ...restored Press and together and hold at same time for at least 6 seconds B If display shows fault E118 low pressure in hydraulic circuit during gas recognition function open filling tap on appliance a...

Page 41: ...g normal operation boiler performs combustion control cycles In this phase CO values higher than 400 ppm can occur for brief periods of time Automatically calculated from the PCB 9 14 Check Firing Rat...

Page 42: ...lose contact with a room thermostat request other than ECR thermostat 02 close contact with a ECR room thermostat request 03 relay for indicating low water pressure 04 relay for error code display 05...

Page 43: ...put 0 100 00 P16 Maximum CH set point C 00 176 F 80 C 01 113 F 45 C 00 P17 Pump overrun time in heating mode 01 240 minutes 03 P18 Burner ignition delay in CH mode 00 10 minutes 00 10 seconds 03 P19 M...

Page 44: ...proceed as described in Section 9 15 Parameter Settings Boiler Model PARAMETER P13 Heating Output Btu h KW DCB 125 DCC 150 20 400 6 0 0 0 23 800 7 0 4 3 27 200 8 0 7 6 30 700 9 0 11 9 34 100 10 0 15...

Page 45: ...mes on at ignition speed closing the air pressure switch allowing power to spark generator and gas valve creating ignition in the combustion chamber 3 Flame sensor acknowledges presence of flame in co...

Page 46: ...Verify proper operation after servicing Note Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe trouble free operation and maximum efficie...

Page 47: ...Check spark gap positioning and height of electrodes 7 Check fan impeller is clean and free to rotate WARNING Combustion chamber insulation in this product contains ceramic fiber material Ceramic fibe...

Page 48: ...he Boiler turn boiler off isolate electrical supply close boiler gas service cock allow boiler to cool drain boiler through onboard drain if available or external drain valve 11 5 Draining the Heating...

Page 49: ...o achieve temperature difference across heating supply and return pipes at the boiler Check system for proper volume and pressure See page 4 for acceptable volume and pressure Turn off boiler Thorough...

Page 50: ...ient operation C Servicing or replacement of parts shall be carried out by a qualified personnel D Ensure boiler controls and room thermostat if fitted are set to User s requirements E Tell User about...

Page 51: ...onnection Size 1 2 Sweat Cold Water Input Connection Size 1 2 Sweat 12 2 Domestic Hot Water Specifications Max DHW temp 140 F 60 C For elevations between 2000 ft 600 m and 10 000 ft 3048 m use the fol...

Page 52: ...k correct circulation of water and pump 118 Hydraulic pressure too low Refill heating system by opening cold water tap 117 Hydraulic pressure too high Relieve pressure via relief valve or drain Ensure...

Page 53: ...l of the flue duct E69 Combustion level out of range Check flue recirculation and the combustion levels E70 Flame signal problem micro interruption of the flame signal Check cable and integrity of the...

Page 54: ...6 C04 P37 C05 P38 C06 RESET ANOMALY P39 C07 P40 C08 P41 C09 FAILURE CODE NUMBER OF TIMES OCCURRED SYSTEM STATUS CODES 0 STANDBY 1 DHW ON 2 CHIMNEY SWEEP ACTIVE 3 CH ON 4 PREHEAT ON 5 CH NO FROST ON 6...

Page 55: ...wood compressed paper plant fibers or other materials capable of being ignited and burned Such material shall be considered combustible even though flame proofed fire retardant treated or plastered C...

Page 56: ...or servicing of appliances and equipment Experienced in such work Familiar with all precautions required Complies with all requirements of authority having jurisdiction SAFETY RELIEF VALVE Valve desig...

Page 57: ...57 A 1 MODELS 125 Heat Only APPENDIX A WIRING DIAGRAMS 240012564 REV A 05 15 2019...

Page 58: ...58 A 2 MODELS 150 Combi APPENDIX A WIRING DIAGRAMS 240012564 REV A 05 15 2019...

Page 59: ...__________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed...

Page 60: ...mit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management s...

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