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Dunkirk Q90-100, Installation, Operation & Maintenance Manual

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INSTALLATION AND CHECK-OUT CERTIFICATE

Boiler Model 

Serial # 

Date Installed___________

Measured BTU/HR input____________



Installation instructions have been followed 



Checkout procedure and adjustments performed



Maintenance and Service issues reviewed with owner/ maintenance person



Installation booklet affi xed on or adjacent to boiler

 Installer 

(Company)

 Address

 Phone

 Installer’s 

Name

 Signature

 INSTALLATION AND CHECK-OUT CERTIFICATE

Summary of Contents for Q90-100

Page 1: ...ER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company P N 240009298 Rev A 06 2012 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13504 4729 web site www ecr...

Page 2: ...2 DIMENSIONS 2 Figure 1 Boiler Dimensions...

Page 3: ...Piping 11 Combustion Air And Vent Pipe 22 Gas Supply Piping 28 Electrical Wiring 30 Controls And Accessories 35 Start Up 37 Operating Instructions 38 S9381a Integrated Boiler Control Operation And Adj...

Page 4: ...o 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 i...

Page 5: ...minal units i e finned tube baseboard cast iron radiators radiant floor etc The difference between Heating Capacity and Net AHRI Rating called piping and pickup allowance establishes reserve for heati...

Page 6: ...LLATIONS 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 i...

Page 7: ...0 5 000 5 000 10 000 Normal Input MBH 75 Manifold Pressure In W C 2 5 3 5 3 5 3 5 3 3 Orifice 43331093 43331096 For model 90 75 Propane units only at altitudes above 5 000 ft install 90 75 High Altitu...

Page 8: ...may be used to raise boiler 1 Boiler is equipped for residential installations If used for commercial applications any additional code requirements must be adhered to for installation This may require...

Page 9: ...through piping systems without restrictions for boiler operation 7 Install boiler such that the automatic gas ignition system components are protected from water dripping spraying rain etc during ope...

Page 10: ...the venting system for proper size and horizontal pitch and determine there is no blockage or restrictions leakage corrosion and other deficiencies which could cause an unsafe condition BOILER INSTALL...

Page 11: ...of radiation units panels radiators baseboard or tubing and supply and return mains After all heating system piping and components have been installed make final connection of system piping to boiler...

Page 12: ...12 NEAR BOILER PIPING Figure 2 Single Zone Boiler Piping...

Page 13: ...ly to have small zones with very low heat and flow requirements compared to full heating capacity of the boiler This can result in very low flow in the boiler if only one small zone is calling for hea...

Page 14: ...14 Figure 4 Two Zone Boiler Piping With Circulators NEAR BOILER PIPING...

Page 15: ...15 NEAR BOILER PIPING Figure 5 Primary Secondary Piping And Wiring With Circulators And Domestic Hot Water...

Page 16: ...16 NEAR BOILER PIPING Figure 6 Piping and Wiring Primary Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water With Zone Valve...

Page 17: ...17 NEAR BOILER PIPING Figure 7 Piping And Wiring Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator...

Page 18: ...nate pipe with plain end not threaded Expansion Tank And Make Up Water Determine required system fill pressure system design temperature and system water content Boiler contains 2 6 gallons U S Size e...

Page 19: ...19 Figure 9 Diaphragm Type Expansion Tank Piping NEAR BOILER PIPING...

Page 20: ...20 Figure 10 Conventional Closed Type Expansion Tank Piping NEAR BOILER PIPING...

Page 21: ...required to initially fill condensate trap for start up Steps are only required at initial start up or if maintenance requires draining of condensate trap 1 Disconnect vent condensate drain line from...

Page 22: ...condensate Due to potential for flue gas temperatures over 155 F first five 5 feet of vent pipe must be CPVC the remain ing vent pipe can be PVC If any elbows are employed within the first 5 feet of...

Page 23: ...ZE 2 PIPE MINIMUM VENTING 2 PIPE MAXIMUM VENTING 3 PIPE MINIMUM VENTING 3 PIPE MAXIMUM VENTING 100 2 FEET 21 FEET 15 FEET 92 FEET 75 50 2 FEET 26 FEET 20 FEET 112 FEET Vent shall not terminate underne...

Page 24: ...24 Figure 12 Roof Vent Intake Terminations COMBUSTION AIR AND VENT PIPE VENT AIR INTAKE...

Page 25: ...Wall Vent Intake terminations Less Than 12 Clearance Above Grade Figure 14 Side Wall Vent Intake Terminations 12 Or More Clearance Above Grade COMBUSTION AIR AND VENT PIPE Less Than 12 Clearance 12 O...

Page 26: ...imum Overhang VENT COMBUSTION AIR COMBUSTION AIR 1 MAXIMUM NOTE SECURING STRAP MUST BE FIELD INSTALLED TO PREVENT MOVEMENT OF TERMINATION KIT IN SIDE WALL ELBOW FIELD SUPPLIED A A B B C C STRAP FIELD...

Page 27: ...for 90 50 and 90 75 models 2 feet minimum total equivalent length for all models TRANSITION FITTING 2 50 8mm to 3 76 2mm IN VERTICAL RUN 3 76 2mm DIAMETER VENT AND COMBUSTION AIR INTAKE PIPING 92 fee...

Page 28: ...ly pressure See Table 7 Page 29 3 Use ground joint unions 4 Provide sediment trap up stream of gas valve 5 Use two pipe wrenches when making the connection to gas valve to keep it from turning 6 Insta...

Page 29: ...000 40 63 000 130 000 245 000 445 000 60 50 000 105 000 195 000 365 000 PROPANE GAS Length of Pipe Ft Pipe Capacity BTU Per Hour Input Includes Fittings Copper Tubing Iron Pipe 5 8 3 4 1 2 3 4 20 131...

Page 30: ...m Follow instructions included with your thermostat Locate thermostat about five feet above floor on inside wall Mount directly on wall or on vertical mounted outlet box It should be sensing average r...

Page 31: ...31 Figure 20 Wiring Schematic ELECTRICAL WIRING NOTICE If any of original wire as supplied with this appliance must be replaced it must be replaced with type 105 C Thermoplastic wire or its equivalent...

Page 32: ...32 Figure 21 Ladder Wiring Diagram ELECTRICAL WIRING...

Page 33: ...33 Figure 22 Suggested Wiring Schematic for Domestic Hot Water Priority Two Zone System with Circulators Using Argo AR822II Pump Relay ELECTRICAL WIRING...

Page 34: ...34 Figure 23 Ladder Diagram for Figure 22 ELECTRICAL WIRING...

Page 35: ...ntroller from thermal purge and allow burner to run in order to maintain comfort in the space Boiler temperature has dropped 10 F from boiler water temperature measured at beginning of the call for he...

Page 36: ...zone or zone valve controlled heating system and should be located on downstream i e pumping away side of expansion tank For pump controlled system where there is a circulator for each zone circulato...

Page 37: ...mediately Purging Air For Systems With Conventional Closed Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on page 11 for more information 1 Close all zone service valves on...

Page 38: ...e front jacket panel OPERATING INSTRUCTIONS WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This applianc...

Page 39: ...Press and release the I button until the parameter requiring adjustment is displayed Then press the UP or DOWN button until the parameter has reached the desired value After 60 seconds without any bu...

Page 40: ...40 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS Table 9 State Code Definitions...

Page 41: ...41 S9381A INTEGRATED BOILER CONTROL OPERATION AND ADJUSTMENTS Figure 26 Sequence of Operation...

Page 42: ...controls test for operation as outlined by control manufacturer Burner should be operating and should go off when controls are tested When safety controls are restored burner should reignite Set Therm...

Page 43: ...fold pressure lower than 2 0 inches w c or higher than 3 0 inches w c when adjusting input rate IV Measure new input rate cover screw must be installed Repeat steps I IV until the input rate is within...

Page 44: ...GULATOR ADJUSTMENT UNDER CAP SCREW INLET PRESSURE TAP VR8205 WIRING TERMINALS 2 OUTLET PRESSURE TAP Figure 27 Manifold Pressure Measurement Detail Figure 28 Gas Valve CHECK OUT PROCEDURE AND ADJUSTMEN...

Page 45: ...place gaskets if necessary I Remove jacket front and top panels and check for piping leaks around relief valve and other fittings Repair if found DO NOT use stop leak compounds 2 Check boiler area is...

Page 46: ...ent pipe connector to draft inducer outlet MAINTENANCE AND CLEANING Annual Examination And Cleaning Of Boiler Components DANGER Before servicing turn off electrical power to boiler at service switch C...

Page 47: ...Service Checks 1 Before troubleshooting A Make sure that circuit breaker is on or fuse is ok at electrical panel B Make sure that service switch is on C Make sure that gas is on at the gas meter at a...

Page 48: ...48 TROUBLESHOOTING Table 10 Error Codes...

Page 49: ...BOILER STATUS DIFFERENTIAL PRESSURE W C PRESSURE SWITCH CONNECTS Not Running 0 Normally Open Setpoint 1 00 for Model 100 1 60 for Model 75 2 10 for Model 50 Running Without Blockage Greater Than Setpo...

Page 50: ...____ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed on or...

Page 51: ...njury Install boiler so gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator re placement etc DIELECTRIC ISOLATION Two 2...

Page 52: ...or any other open type system Fill Water and Chemistry Verify water used to fill system meets these requirements System fluid pH maintained between 7 0 and 8 0 Maintain water hardness below 7 grains...

Page 53: ...ed to maintain a pH within recommended level Follow antifreeze manufacturer s instructions to adjust pH If system has leaked water and antifreeze chemistry will need to be adjusted To avoid damage to...

Page 54: ...stributor 15363 117 Avenue Edmonton AB T5M 3X4 Canada www hydronicagencies com Tel 780 452 8661 Fax 780 488 2304 Fernox www fernox com Intercool NFP 30 40 50 AA Intercool RPH 15 Interstate Chemical 27...

Page 55: ...NOTES...

Page 56: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com...

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