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ECR Dunkirk 4 Series Installation, Operation & Maintenance Manual Download Page 1

GAS-FIRED, DIRECT VENT, 

CONDENSING,  

HOT WATER BOILER

INSTALLATION, OPERATION & 

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

 

P/N# 240010121, Rev. C [05/2013]

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com

Models

 

Q90-50

Q90-75

  Q90-100

Q90-50/75/100 Series 4

Summary of Contents for Dunkirk 4 Series

Page 1: ...LLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company P N 240010121 Rev C 05 2013 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com Models Q90 50 Q90 75 Q90 100 Q90 50 75 100 Series 4 ...

Page 2: ...2 DIMENSIONS 2 Figure 1 Boiler Dimensions NOTICE Draft inducer blower may be rotated 90 or 180 to orient vent connection towards right side or rear ...

Page 3: ...ent Pipe 22 Gas Supply Piping 28 Electrical Wiring 30 Controls And Accessories 34 Start Up 36 Operating Instructions 37 Detailed Sequence Of Operation 38 Verification Procedure And Adjustment 42 Differential 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 Hydrosta...

Page 4: ... 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 yo...

Page 5: ...e baseboard cast iron radiators radiant floor etc The difference between Heating Capacity and Net AHRI Rating called piping and pickup allowance establishes reserve for heating volume of water in system and offsetting 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 b...

Page 6: ...h 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 calorific Btu value of supply gas contact local gas utility or dis...

Page 7: ... model 90 75 Propane units only at altitudes above 5 000 ft install 90 75 High Altitude Orifice Kit 550002629 For all other altitudes use sea level orifice 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 Combustion Setting CO2 10 0 11 1 CO 100 ppm Orifice 43331091 43331091 Contact local gas utility or di...

Page 8: ...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 off a manual reset high temperature limit and wiring and or piping modifications 2 Before servicing boiler allow boiler to cool Shut off electricity and gas supply connected to boiler prior to servicing 3 Insp...

Page 9: ...rmit flow through piping systems without restrictions for boiler operation 8 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 9 Keep boiler area clean of debris and free of flammable and combustible materials vapors and liquids 10 Loca...

Page 10: ...y unused openings in the common venting system 2 Visually inspect 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 INSTALLATION 3 In so far as is practical close all building doors and windows and all doors between the space in which the appliances remaini...

Page 11: ...r or pH reading outside acceptable range between 7 0 and 8 0 are indications the system should be cleaned or treated Thoroughly flush system with clean water to remove any sediment or contaminants Sludge and iron oxide deposits can cause rapid breakdown of inhibitors Flushing with clean water If chemical cleaners are used use only those recommended for use with aluminum boilers Follow chemical cle...

Page 12: ...12 NEAR BOILER PIPING Figure 2 Single Zone Boiler Piping SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS ...

Page 13: ...ith 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 heat Primary Secondary Piping is recommended for multi zone systems with more than two zones to insure proper water flow through the boiler at all times See Figures 5 6 and 7 for typical primary secondary piping configurations ...

Page 14: ...14 Figure 4 Two Zone Boiler Piping With Circulators NEAR BOILER PIPING SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS ...

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

Page 16: ...16 NEAR BOILER PIPING Figure 6 Piping 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 Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator ...

Page 18: ...inate 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 expansion tank accordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished Diaphragm type expansion tank see Figure 9 Page 19 See ...

Page 19: ...19 Figure 9 Diaphragm Type Expansion Tank Piping NEAR BOILER PIPING SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS ...

Page 20: ...20 Figure 10 Conventional Closed Type Expansion Tank Piping NEAR BOILER PIPING SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS ...

Page 21: ...ust be manually filled with water Following are the steps 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 vent pipe connector on outlet of induced draft blower 2 Pour about 1 cup of cold tap water into vent drain line with funnel 3 Excess water sho...

Page 22: ...available for visual inspection Specified primers and glues of certified vent system must be from single manufacturer and not intermixed with other manufacturer s vent system parts Components of the certified system must not be interchanged with other vent systems or unlisted pipe and or fittings NOTICE Transition from 2 pipe to 3 pipe must be made in vertical run 3 Boiler combustion air and vent ...

Page 23: ...nate at least 3 ft 0 9m above any forced air inlet except boiler s combustion air inlet within 10 ft 3m COMBUSTION AIR AND VENT PIPE Table 5 Combustion Air And Vent Piping Lengths Total Equivalent Length BOILER SIZE 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 NOTE Follow venting...

Page 24: ...cement is still wet insert pipe into socket with turn twist Be sure pipe is fully inserted into fitting socket COMBUSTION AIR AND VENT PIPE VENT AIR INTAKE 12 305mm 18 12 305mm 18 12 305mm US 18 458mm Canada Minimum Above Anticipated Snow Line 8 203mm Minimum Vertical Separation Between Combustion Air Intake and Vent 10 Wipe excess cement from joint Continuous bead of cement will be visible around...

Page 25: ...nce OVERHANG 12 MINIMUM 90 VENT 12 SEPARATION BETWEEN BOTTOM OF AIR INTAKE AND BOTTOM OF VENT MAINTAIN 12 MIN CLEAR ABOVE HIGHEST SNOW LEVEL OR GRADE 3 MAXIMUM SEPARATION 18 MAXIMUM 15 MAX 12 MINIMUM 12 MINIMUM 36 MIN 90 BRACKET VENT 18 MAXIMUM MAINTAIN 12 MIN CLEAR ABOVE HIGHEST SNOW LEVEL OR GRADE 12 SEPARATION BETWEEN BOTTOM OF AIR INTAKE AND BOTTOM OF VENT 12 MINIMUM OVERHANG 3 MAXIMUM SEPARAT...

Page 26: ...mm Canada 18 457mm clearance above highest anticipated snow level or grade 12 305mm Minimum Must be less than 4 102mm or greater than 24 610mm Horizontal distance between end bells of each air intake to prevent flue gas recirculation 1 25 4mm Maximum Overhang Figure 16 Concentric Vent COMBUSTION AIR AND VENT PIPE Figure 17 Concentric Vent Roof Installation A ELBOW FIELD SUPPLIED B STRAP FIELD SUPP...

Page 27: ... 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 ft 28m maximum total equivalent length for 90 100 models 15 ft 4 6m minimum total equivalent length for 90 100 models 112 ft 34m maximum total equivalent length for 90 50 and 90 75 models 20 ft 6m minimum total equivalent length for 90 50 and 90 75 mo...

Page 28: ...ply 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 Install a manual shutoff valve in the vertical pipe about 5 feet above floor 7 Tighten all joints securely 8 Propane gas connections should only be made by licensed propane installer 9 Two stage regulatio...

Page 29: ...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 20 131 000 216 000 189 000 393 000 40 90 000 145 000 129 000 267 000 60 72 000 121 000 103 000 217 000 Outside diameter GAS SUPPLY PIPING Figure 19 Gas Piping 3 76mm MINIMUM SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS ...

Page 30: ...tem 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 room temperature Set heat anticipator where applicable at 0 7 amps Connect 24 Volt thermostat leads to two 2 yellow wires located in junction box located on outer jacket of boiler See Figure 20 Page ...

Page 31: ...31 Figure 20 Field Wiring Connections ELECTRICAL WIRING SAFETY RELIEF VALVE SEE PAGE 18 FOR REQUIREMENTS ...

Page 32: ...32 ELECTRICAL WIRING Figure 21 Wiring Schematic 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 33: ...33 Figure 22 Ladder Diagram for Figure 22 ELECTRICAL WIRING ...

Page 34: ...nd boiler temperature Refer to limit manufacturer instructions provided with limit control CONTROLS AND ACCESSORIES Figure 23 Indicator Lights A Setting High Limit To adjust turn HI TEMP dial 1 until desired setting is displayed Overall range of High limit setting is from 100 F to 220 F 82 C to 104 C High limit HL on limit control is factory set at 190 F Temperature setting may be varied to suit r...

Page 35: ...IES 7 Differential Pressure Air Proving Switch Blocked Vent Safety Shutoff Differential pressure switch monitors air flow by sensing differential pressure measured in inches of water w c Pressure switch contacts close when draft inducer is running Closed switch indicates there is adequate air flow for combustion Pressure switch shuts off main burner if differential pressure is inadequate due to bl...

Page 36: ...pen until water runs air free for five seconds to rapidly bleed air from boiler then let the relief valve snap shut 2 Open the zone service valve on the supply pipe for the first zone Open the purge valve on the first zone Feed water will fill the zone pushing air out the purge valve Close the purge valve when the water runs air free Close the zone service valve 3 Repeat step 2 for all remaining z...

Page 37: ...he 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 appliance is equipped with an ignition device which automatically lights burner Do NOT try to light this burner by hand Before operating smell all around appliance area for gas Be sure to smell next to floor...

Page 38: ...S FOR 20 SEC IGNITER WARMUP BRIGHT YELLOW ORANGE GLOW OF THE HOT SURFACE IGNITER CAN BE OBSERVED THRU THE OBSERVATION PORT IN FRONT OF BOILER SECTION JUST ABOVE IGNITER IGNITOR LIGHT IS ON GAS VALVE ENERGIZED THRU 3K1 AND 4K1 CONTACTS VALVE LIGHT IS ON GAS VALVE OPENS FOR 5 SEC TRIAL FOR IGNITION BLUE ORANGE GLOW OF THE BURNER CAN BE SEEN THRU OBSERVATION PORT 2 SEC INTO THE 5 SEC IGNITION TRIAL P...

Page 39: ...ion Thermostat ends call for heat Gas valve and circulator pump are de energized valve and flame lights go out Blower runs for 30 seconds post purge purge light is on Blower is de energized after 30 seconds purge light shuts off Boiler stand by for next call for heat ...

Page 40: ...on port on boiler A B C D E 6 After igniter warm up period integrated boiler control energizes gas valve initiating 6 second trial for ignition mode indicated by illumination of Lamp D Lamp C extinguishes after 2 second delay Integrated boiler control stops sending power to hot surface igniter A B C D E 7 Low level illumination of Lamp E indicates initiation of flame proving During last 2 seconds ...

Page 41: ...rol automatically resets after 1 hour HIGH LIMIT CONTROL If boiler water temperature reaches high limit setpoint high limit n c contacts open immediately closing gas valve Valve and flame lights go out Draft inducer continues to run for 30 second post purge and switch OFF Circulator runs as long as thermostat calls for heat When high limit contacts connect before end of call for heat control goes ...

Page 42: ...te Correct input rate is essential for proper and efficient operation of the burner and boiler 1 Determine elevation at installation site 2 Table 1 and Table 2 Page 6 to determine correct input rate for the local elevation 3 Obtain yearly average heating value of local gas supply from gas utility At sea level elevation it should be approximately 1000 Btu s per standard cubic foot 4 Operate boiler ...

Page 43: ...cturer for information on correct orifice sizing The specific gravity G and the higher heating value HHV of the local natural gas must be obtained from the local gas utility in order to determine the proper orifice size Set Thermostat To Desired Room Temperature Observe several operating cycles to verify proper operation Review All Instructions Review all instructions shipped with this boiler with...

Page 44: ...R ADJUSTMENT UNDER CAP SCREW INLET PRESSURE TAP VR8205 WIRING TERMINALS 2 OUTLET PRESSURE TAP Figure 25 Manifold Pressure Measurement Detail Figure 26 Gas Valve VERIFICATION PROCEDURE AND ADJUSTMENT Refer to Differential Air Pressure Switch Check all models on page 45 when reading manifold pressure When measurement is complete disconnect U Tube Manometer or Differential Pressure Gauge Be sure to r...

Page 45: ...R STATUS DIFFERENTIAL PRESSURE W C PRESSURE SWITCH CONTACTS Not Running 0 Normally Open 1 80 for Model 100 1 80 for Model 75 2 10 for Model 50 Running Without Blockage Greater Than Setpoints Closed Running With Blockage Less Than or Equal to Setpoints Open If manometer readings do not correspond to chart above check for possible causes Blockage or moisture in suction lines Blockage in air intake o...

Page 46: ...line as shown to inclined manometer or differential pressure gauge with ability to read 0 01 to 5 0 w c Turn on service switch and set thermostat to call for heat If manometer readings do not correspond to chart check for possible causes A Blockage in air intake B Undersized air intake C Loose blower wheel or motor shaft D Incorrect pressure switch or pressure switch setpoint When pressure reading...

Page 47: ...s and check for piping leaks around relief valve and other fittings Repair if found DO NOT use stop leak compounds J Check igniter for cracks and deterioration Replace if necessary K Check for water in pressure switch tubing Drain if necessary 2 Check boiler area is free from combustible materials gasoline and other flammable vapors and liquids 3 Circulator pump and blower motor furnished with boi...

Page 48: ...vent 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 Close manual gas valve to turn gas supply OFF to boiler Failure to comply will result in death or serious injury NOTICE Have qualified service agency perform the following service procedures Boiler ow...

Page 49: ... problem an electrical short burning out a transformer for example Initial 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 all appropriate manual shutoff valves and at the gas control valve D Make sure that the thermostat is calling for heat E Check ...

Page 50: ...n during this condition Important System must be checked by qualified service agency prior to resuming operation 4 ACTIVE Indicates that thermal targeting function is active and control reduces boiler temperature to conserve fuel Economy feature is activated using the ECONOMY dial 5 TARGET When feature is active control continually sets target temperatures below high limit setting to maximize fuel...

Page 51: ...Sensing Low Water Control is Sensing High Temperature Boiler Reached Target Temperature Boiler in Purge Mode and will not fire until temperature drops to 140 F See Purge page 36 Both red and yellow LEDs are off and there is call to fire burner there will be 120 VAC in terminals B1 and B2 120 VAC is not present replace control CAUTION ALWAYS ALLOW BOILER TO COOL BEFORE ADDING WATER Burner will not ...

Page 52: ...52 Troubleshooting Chart 1 TROUBLESHOOTING ...

Page 53: ...53 Troubleshooting Chart 2 TROUBLESHOOTING ...

Page 54: ... PUDDLE AND BLOCK THE VENT YES CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY NO CLEAN OUT SAMPLING LINES OR REPLACE DEFECTIVE SWITCH YES CHECK FLUE PASSAGES IN BOILER PER MAINTENACE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN NO CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTIONS YES CHECK DRAFT INDUCER MOTOR RPM I...

Page 55: ...ER LIGHT CHECK FOR 24 VAC ACROSS TERMINALS MV ON THE GAS CONTROL WHILE VALVE FLAME INDICATOR LIGHT IS ON NO NO CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON IBC WHILE THE VALVE FLAME LED IS LIT NO REPLACE IBC YES REPAIR REPLACE WIRING BETWEEN IBC AND GAS CONTROL YES CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER RESTORE IGNITER SENSOR TO CORRECT POSITION DO NOT ...

Page 56: ...INTENANCE AND CLEANING INSTRUCTIONS CHECK AIR ORIFICE AT BURNER INLET FOR CORRECT SIZE SEE REPAIR PARTS DIAGRAM IS ORIFICE CORRECT SIZE REPLACE BURNER NO CHART 4 YES DOES MAIN BURNER RUN UNTIL CALL FOR HEAT ENDS OR HI LIMIT AQUASTAT CONTACTS OPEN NO 1 NO 2 NO 3 RUNS SMOOTHLY FOR ABOUT 6 SECONDS THEN SHUTS OFF INDICATES POOR FLAME SIGNAL CHECK IGNITER SENSOR POSITION TIP SHOULD BE SLANTED TOWARDS B...

Page 57: ...FIC INSTRUCTIONS REQUIRES SPECIFIC TOOLS NO YES REPLACE BURNER REPLACE IBC BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT ARE HI LIMIT AQUASTAT CONTACTS CLOSED NO BOILER OFF ON HIGH LIMIT IS ACTUAL BOILER WATER TEMP GREATER THAN HI LIMIT SET POINT MINUS 30 F CONTROL DIFFERENTIAL NO NO REPLACE AQUASTAT OK YES SEE TROUBLESHOOTING PATH 2 ABOVE CHART 5 NO 3 CHART 5 YES SET THERMOSTAT BELOW ROOM TEMPERAT...

Page 58: ...ry Install boiler so gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement etc DIELECTRIC ISOLATION Two 2 1 1 4 X 1 1 4 Female to female dielectric isolation unions are shipped loose in boiler parts bag Install Dielectric Isolation unions at boiler supply line and return line Install isolation fittings neare...

Page 59: ...s 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 hardness Filling with chlorinated potable water is acceptable DO NOT fill boiler with water containing chlorine in excess of 100 ppm DO NOT use inhibitors or other additives that are not listed in th...

Page 60: ...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 boiler check pH and chemistry of boiler solution and consult the antifreeze manufacturer for recommendations Recommend taking pH reading annually and adjusted as necessary Follow antifreeze inhibitor ...

Page 61: ...istributor 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 2797 Freedland Road P O Box 1600 Hermitage PA 16148 0600 www interstatechemical com Tel 800 422 2436 Fax 724 981 8383 Hercules Cryo tek 100 Al Hercules Chemical Company Inc 111 South Street Passaic NJ ...

Page 62: ..._____ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed on or adjacent to boiler Installer Company Address Phone Installer s Name Signature INSTALLATION AND CHECK OUT CERTIFICATE ...

Page 63: ...NOTES ...

Page 64: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

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