ECR Dunkirk Q90-125 Page 50 Installation, Operation & Maintenance Manual Download

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Summary of Contents for Dunkirk Q90-125

Page 1: ...ER BOILER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company P N 240009431 Rev C 07 2013 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 ...

Page 2: ...ould 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 ope...

Page 3: ...aximum 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 avail...

Page 4: ...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 ...

Page 5: ...ourself 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 48 Boiler Sizing Verify you have selected the boiler with proper capacity before continuing installatio...

Page 6: ...circulator replacement condensate trap control replacement etc 8 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 above freezing temperature 9 If boiler is not level condensate drain lines will not function properly Adjustable feet are located on b...

Page 7: ... venting system common venting system should be re sized 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 boil...

Page 8: ...two zone systems with adequate flow do not require primary secondary piping Systems with more zones or low flow require primary secondary piping 4 NEAR BOILER PIPING Dielectric Isolation 1 Two 2 1 1 4 X 1 1 4 female to female dielectric isolation unions are supplied Install dielectric isolation unions at boiler supply line and return line Install isolation fittings nearest boiler prior to system p...

Page 9: ...e 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 2 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 A Use or larger pipe B Use pipe suita...

Page 10: ...10 4 NEAR BOILER PIPING Figure 4 Diaphragm Type Expansion Tank Piping Figure 5 Single Zone Boiler Piping DIELECTRIC UNIONS DIELECTRIC UNIONS DIELECTRIC UNION ...

Page 11: ... Zone Boiler Piping With Zone Valves SUPPLY TO ZONE SERVICE FLOW CHECK VALVE VALVE RETURN FROM ZONE SERVICE ZONE SERVICE VALVE ZONES ZONES VALVE VALVE FLOW CHECK ZONE SERVICE VALVE CIRCULATORS AIR SCOOP EXPANSION TANK REDUCED PRESSURE BACKFLOW PREVENTER GATE VALVE FEED WATER PRESSURE REDUCING VALVE CAN VENT DIELETRIC UNION CIRCULATOR SUPPLY TO ZONE SERVICE VALVE ZONE SERVICE RETURN FROM ZONE SERVI...

Page 12: ...f 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 1 Pour about 1 cup of cold tap water into condensate trap vent 2 Excess water will go thr...

Page 13: ...r natural gravity type installations or any other open type system General Guidelines When Using Antifreeze Use only antifreeze products recommended for use with aluminum boilers See Table 5 page 14 Continuous addition of make up water will dilute power of antifreeze and change buffers ability to maintain pH Flush old antifreeze from system Flush boiler and system separately Do not use antifreeze ...

Page 14: ...i 11 Hydronic Agencies Ltd Fernox North Distributor 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...

Page 15: ...ion Air 12 305mm Minimum Above Anticipated Snow Line Vent 3 76mm Minimum Separation 12 305mm Minimum From Overhang 12 305mm Separation Between Bottom of Combustion Air Intake And Bottom of Vent See Snow Ice Page 19 Combustion Air Vent 12 305mm Minimum Separation Combustion Air Figure 11 Concentric Vent Terminations Combustion Air 1 26mm Maximum Maintain 12 clearance above highest anticipated snow ...

Page 16: ... instructions in this manual for combustion air and vent piping termination Use of concentric vent termination refer to Figures 10 11 and 12 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 Fully support all vent piping Use hangers at intervals to prevent pipe from sagg...

Page 17: ... to 3 Due to potential for flue gas temperatures over 155 F first 5 feet of vent pipe must be CPVC furnished remaining vent pipe can be PVC This requirement is not required when using PP If any elbows are employed within first 2 of vent they must be CPVC Two 30 pieces of 2 CPVC pipe and one 2 CPVC coupling are furnished with boiler See Figure 13 Length of pipe is counted from boiler jacket air int...

Page 18: ...S636 Intake Air ONLY Pipe and Fittings PVC ASTM D2665 DWV CSA B181 2 SCH 40 CSA B137 3 ABS ASTM D3965 ASTM D2661 CSA B181 1 Pipe Cement And Primer PVC ULC S636 ASTM D2564 ULC S636 Exhaust Air Intake CSA B137 3 Air Intake ONLY CSA B181 2 Air Intake ONLY CPVC ULC S636 ASTM F493 ULC S636 Exhaust Air Intake CSA B137 6 Air Intake ONLY CSA B181 2 Air Intake ONLY ABS ASTM D2235 ULC S636 Exhaust Air Intak...

Page 19: ...ler to shut down if vent becomes obstructed G Under certain conditions flue gas will condense forming moisture and may be corrosive In such cases take steps to prevent building materials at vent from being damaged by exhaust of flue gas Every outside wall penetration shall be permanently sealed to prevent entry of combustion products into building Venting that discharges flue gases perpendicular t...

Page 20: ...cket and end of pipe to insertion mark Quickly apply approved cement to end of pipe and fitting socket over primer Apply cement in light uniform coat on inside of socket to prevent buildup of excess cement Apply second coat 11 While cement is still wet insert pipe into socket with turn twist Be sure pipe is fully inserted into fitting socket 12 Wipe excess cement from joint Continuous bead of ceme...

Page 21: ... absence of such requirements National Fuel Gas Code ANSI Z223 1 NFPA 54 2 Use pipe joint compound suitable for liquefied petroleum gas on male threads only 3 Use ground joint unions 4 Install sediment trap upstream of gas controls 5 Use two pipe wrenches when making connection to gas valve to keep it from turning 6 Install manual main shutoff valve in vertical pipe about 5 feet 1 5m above floor o...

Page 22: ...t Service switch is pre wired and located on exterior boiler jacket See Figure 15 for location of service switch junction box and power supply connection points Connect black hot lead from power supply to either of unused brass screws on service switch Connect white neutral lead from power supply to white screw on service switch Connect green ground lead from power supply to ground green screw on ...

Page 23: ... at 0 7 amps Connect 24 volt thermostat leads to the two 2 yellow wires located in service switch junction box located on outer jacket of boiler See Figure 15 Page 22 for service switch junction box and thermostat field wiring connections Connect Circulator Pump Wiring NOTICE Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Ver...

Page 24: ... If any of the original wire as supplied with this appliance must be replaced it must be replaced with type 150 C Thermoplastic wire or its equivalent 9 ELECTRICAL WIRING Figure 17 Schematic Wiring Connections ...

Page 25: ...OTE If any of the original wire as supplied with this appliance must be replaced it must be replaced with type 150 C Thermoplastic wire or its equivalent 9 ELECTRICAL WIRING Figure 18 Ladder Wiring Diagram ...

Page 26: ...ing failure mode as lack of flame signal C Manually reset IBC from lockout by removing and re establishing thermostat s call for heat or turn service switch off then back on See Figure 19 High Limit Control NOTICE Maximum set point of limit control must not exceed 190 F High limit control determines maximum boiler water temperature and provides means for protecting boiler and heating system from u...

Page 27: ...rge with same size as valve discharge opening to open drain tub or sink or other suitable drainage point Do not subject to freezing in accordance with A S M E Failure to provide pressure relief valve with piping as described may cause water damage and or serious bodily injury Blocked Vent Safety Shutoff Boiler equipped with blocked vent safety shutoff shuts off main burner gas in event airflow of ...

Page 28: ...TUP Water Treatment And Freeze Protection Filling Boiler With Water And Purging Air For Systems With Diaphragm Type Expansion Tanks Refer to the appropriate diagrams Near Boiler Piping on pages 10 and 11 1 Close all zone service valves on supply and return piping Open feed valve and fill boiler with water Verify air vent is open Hold relief valve open until water runs air free for five seconds to ...

Page 29: ...fire department 11 STARTUP Operating Instructions 1 STOP Read the safety information on this page before operating this appliance 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the appliance 4 This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do NOT try to light this burner by hand 5 Remove the front jac...

Page 30: ...oper gas line sizing to boiler Refer to Check Gas Supply on page 22 3 Check for orifice in negative pressure hose at gas valve and 2 air intake pipe upstream of gas valve 4 Relight boiler 5 If boiler still does not light A Disconnect air inlet pipe Allow boiler to start verify boiler firing rate and combustion properties B Disconnect inlet air pipe by removing PVC inlet air piping from coupler loc...

Page 31: ... resets after 1 hour HIGH LIMIT CONTROL REFER TO PAGE 37 FOR MORE INFO 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...

Page 32: ...t 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 12 DETAILED SEQUENCE OF OPERATION ...

Page 33: ...HT 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 POWER IS TURNED OFF TO THE HOT SU...

Page 34: ... through observation 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 Duri...

Page 35: ...ot proven Off during igniter and run cycle normal operation purge cycle complete Blinking IBC is locked out Problem could indicate false positive proof of air flow Blocked vent intake air pipe flue way or orifice in negative pressure hose IGNITER ON IBC is energizing igniter OFF Igniter is not energized VALVE ON IBC is energizing gas control valve to open OFF Gas control valve is closed Blinking I...

Page 36: ...ecific features of high limit control Test Other Safety Controls If boiler is equipped with low water cut off manual reset high limit or additional safety 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 re ignite Set Thermostat Heat Anticipator If Used And Verify Th...

Page 37: ... pressure between 4 and 10 w c natural gas between 10 and 14 w c propane gas 2 Drill hole in plastic CPVC pipe for combustion analyzer 3 Turn thermostat to closed position to activate boiler 4 Allow boiler to run for 5 minutes 5 Insert combustion analyzer sample probe into hole just drilled about halfway into exhaust gas stream A Take flue gas reading and observe CO2 value B Adjust throttle screw ...

Page 38: ...peration during this condition Important System must be checked by qualified service agency prior to resuming operation 4 ECONOMY 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 ECONOMY TARGET When feature is active control continually sets target temperatures below high limit s...

Page 39: ...ing 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 fire...

Page 40: ...plosion or shock hazard may cause death or serious injury Do not attempt to modify physical or electrical characteristics of this boiler in any way In reset from lockout condition all electrical meter readings at gas control valve 24 vac must be taken within trial for ignition period If any component dose not function properly make sure it is correctly installed and wired before replacing Static e...

Page 41: ...41 Troubleshooting Chart 1 15 TROUBLESHOOTING ...

Page 42: ...42 Troubleshooting Chart 2 15 TROUBLESHOOTING ...

Page 43: ...UDDLE 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 IS ...

Page 44: ... 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 RE...

Page 45: ...45 Troubleshooting Chart 5 15 TROUBLESHOOTING ...

Page 46: ...IC 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 TEMPERATU...

Page 47: ... suction lines to switch Blockage or moisture in orifice installed in suction lines to switch Blockage in air intake or vent pipes Undersized air intake or vent pipes Loose blower wheel on motor shaft Incorrect pressure switch or pressure switch set point Gas valve out of adjustment 6 When pressure reading corresponds to Table 11 and pressure switch is operating properly remove testing lines and r...

Page 48: ...ssary H 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 free from combustible materials gasoline and other flammable vapors and liquids 3 Circulator pump and blower motor furnished with boiler are permanently lubricated from factory and require no further lubrication Lubricate...

Page 49: ...inside burner Remove any foreign matter by blowing with compressed air or vacuuming L Install burner and gaskets Position blower adapter assembly over studs Install five nuts do not tighten Install igniter and igniter gasket and fasten with two screws Do not touch igniter element with your fingers or hands as oils or debris will cause premature failure Tighten five nuts holding blower adapter asse...

Page 50: ...50 NOTES ...

Page 51: ...51 Company Address Phone Company Name Tech Initials Service Performed Date SERVICE RECORD ...

Page 52: ...creases This feature is equipped with an override which is provided primarily to permit 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 system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used f...

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