ECR Dunkirk Q95M-200 Page 3 Installation Manual Download

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III - RULES fOR SafE INSTaLLaTION aND OPERaTION

ImPORTaNT:

Failure to follow these instruc-

tions 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 qualified installer, service

agency, or the gas supplier.

II - SafETy SymBOLS aND waRNINGS

This  appliance  has  been  equipped  for  resi-
dential  installations.  If  used  for  commercial
applications, any and all additional code  re-
quirements  must  be  adhered  to  for  installa-
tion.  This  may  require  additional  controls,
including  but  not  limited  to  an  external  wa-
ter cut off, a manual reset high temperature

limit, and wiring and/or piping modifications.

The manufacturer is not responsible for any

field installation changes made to a boiler

installation which are not described or ac-
knowledged in this manual.

WARNING

ndicates an imminently hazardous situation

which, if not avoided, will result in death,
serious injury or substantial property dam-
age.

DANGER

Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property dam-
age

WARNING

Indicates a potentially hazardous situation

which, if not avoided, could result in minor or

moderate injury or property damage

CAUTION

Indicates special instructions on installation,

operation or maintenance which are important

but not related to personal injury hazards.

NOTICE

The following defined symbols are used throughout this manual to notify the reader of potential

hazards of varying risk levels.

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 ab-

sence of these codes, use NFPA installation

codes and good industry practice.

Before servicing the boiler, allow it to cool. Al-

ways shut off any electricity and gas supply con-

nected to the boiler prior to servicing.
Inspect gas line for leaks.

Be certain gas input rate is correct. Overfiring

may result in early failure of the boiler compo-

nents. This may cause dangerous operation.

Underfiring may result in too much air for the pre-

mix burner causing poor or loss of combustion.
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 in-

side a building.
Be sure there is adequate outdoor air supply to

boiler for complete combustion.
Follow a regular service and maintenance sched-

ule for efficient and safe operation.
Keep boiler area clean of debris and free of com-

bustible and flammable materials.
Proper through-the-wall or through-the-roof com-

bustion venting shall be in accordance with the

materials and methods described in this manual.

Installation must comply with local codes.

Summary of Contents for Dunkirk Q95M-200

Page 1: ...INSTALLATION MANUAL Q95M 200 GAS FIRED DIRECT VENT MODULATING HOT WATER BOILER DUNKIRK BOILERS 85 Middle Rd Dunkirk NY 14048 www dunkirk com An ISO 9001 2000 Certified Company P N 240006103D Rev A 05 08 ...

Page 2: ...ger means better heat transfer and thermal storage than similarly sized cast iron boilers which results in higher efficiency The heating system wa ter absorbs large amounts of heat from the cast aluminum heat exchanger cooling the flue gases and causing con densation Sealed combustion premix gas burner and low flame temperature means drastically reduced CO and NOx emissions which contribute to a c...

Page 3: ... installation operation or maintenance which are important but not related to personal injury hazards NOTICE The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels Check all applicable state and local building 1 codes and utility company requirements before installation This installation must conform with these requirements in...

Page 4: ...rtion is heat loss from the jacket and surfaces of the boiler and it is as sumed 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 floor etc The difference between the Heating Capacity and the Net I B R Rating called the piping and ...

Page 5: ...f completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detec tor with an alarm shall be installed Approved carbon monoxide detectors 2 Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be...

Page 6: ...ctions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the in stallation Supplied with a suitable electrical supply for all boiler motors and controls Connected to a properly located thermostat or operating control not included with boiler Placed on level surface must NOT be installed on carpeting Con...

Page 7: ...n air intake piping systems connected to the outdoors must permit flow through the piping systems without restrictions for the boiler to operate The boiler shall be installed such that the automatic 7 gas ignition system components are protected from water dripping spraying rain etc during operation and service circulator replacement control replace ment etc The boiler must be located where ambien...

Page 8: ...ROM INSIDE CORNERS VENT TERMINATION MUST BE INSTALLED WITH A CLEARANCE OF AT LEAST 12 INCHES 31 CM FROM ANY AIR OPENING INTO A BUILDING 12 MAX Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation ...

Page 9: ...ler to maintain drain pitch or to be above external condensate pump reservoir There is a 115 volt AC receptacle provided on the control panel to provide power for an external condensate pump if needed Failure to follow these warnings could result in fire property damage personal injury or death Locate combustion air inlet as far away as possible from swimming pool and swim ming pool pump house All...

Page 10: ... the space in which the appliances remaining connected to the common venting system are located and other spaces 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 exhaust fan Close fireplace dampers Foundation Requirements ...

Page 11: ...connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans and any other gas burn ing appliance to their previous condition of use Any improper operation of the common venting sys 6 tem 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 stan...

Page 12: ...er is factory equipped with a manual reset probe type low water cut off Expansion Tank Make up Water Non potable water only piped directly to boiler DO NOT connect drinking water to heating system CAUTION Determine required system fill pressure system design temperature and system water content Boiler contains 2 6 gallons US Size expansion tank accordingly Consult expansion tank manufacturer for p...

Page 13: ...g and pipe fittings must conform to ANSI standards and ASTM D1785 Schedule 40 PVC cement and primer must conform to ASTM D2564 In Canada use CSA or ULC certified schedule 40 PVC drain pipe and cement A condensate pump with a reservoir not furnished may be used to remove condensate to a drain line sanitary line above boiler if a floor drain is not avail able or is inaccessible Filling the Condensat...

Page 14: ...t be listed to ULC S636 Do not use cellular core PVC for venting flue gas WARNING Combustion air and vent pipe connections on boiler 4 are 2 but must increase to 3 Due to potential for flue gas temperatures above 155 F the first 30 of sup plied vent pipe is CPVC while the remaining vent pipe can be PVC Any replacement of the first 30 of vent pipe must be made with CPVC NOTE The exhaust transition ...

Page 15: ...xhaust pipe Reduce the maximum vent length by 5 per each 90 el bow Exhaust air piping to be pitched back to boiler at 1 minimum per foot from vent terminals so that all moisture in vent piping drains to boiler Pipes must be pitched continuously with no sags or low spots where moisture can accumulate and block the flow of flue gas Combustion air and vent pipes must be airtight and watertight Consid...

Page 16: ... Primer and cement will discolor jacket Take precautions to protect jacket while cement ing vent pipe While cement is still wet insert pipe into socket with 8 a turn twist Be sure pipe is fully inserted into fitting socket Wipe excess cement from joint A continuous bead of 9 cement will be visible around perimeter of a properly made joint Handle pipe joint carefully until cement sets 10 Support co...

Page 17: ...ing Appliances and Equip ment Use pipe joint compound suitable for liquefied petro 2 leum gas on male threads only Use ground joint unions 3 Install a sediment trap upstream of gas controls 4 Use two pipe wrenches when making the connection 5 to the gas valve to keep it from turning Install a manual shutoff valve in the vertical pipe about 6 5 above floor outside the boiler jacket in addition to t...

Page 18: ...estic Hot Water Route all wires and conduits to the openings in the 5 right jacket panel Low Voltage Connections Connect low voltage wiring to low voltage terminal 1 strip as shown in the boiler wiring diagram Route all low voltage wires through opening on the 2 right jacket panel Use shielded cable Thermostat Connect room thermostat or end switch isolated con 1 tact only between terminals T1 and ...

Page 19: ... The modulating blower provides a means of introducing the gas air mixture through the burner and into the combustion chamber where combustion can begin and then out the ex haust vent where the combustion products are discharged to the outdoors The blower is designed to communicate with the modulating control to run at variable speeds de pendent on the heat load experienced by the heating sys tem ...

Page 20: ...he boiler control and is factory set at 200 F water temperature The high limit setpoint is field adjust able and may be set anywhere between 100 F and 200 F with the maximum high limit setpoint not exceeding 200 F The field high limit setpoint adjustment for each installation depends on heating system requirements The aquastat automatically resets when the boiler water temperature decreases ten de...

Page 21: ...ith ASME specifications Failure to provide the pressure relief valve with piping as herein described may cause water damage and or serious bodily injury The boiler manufacturer is not responsible for any water damage or personal injury Check local codes for maxi mum discharge height from floor External Condensate Pump optional For installations where there is no floor drain or other ap propriate d...

Page 22: ... any other open type system System fluid pH must be maintained between 7 0 and 8 0 Maintain water hardness below 7 grains hardness Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are typically less than 5 ppm Do not fill boiler with water containing chlorine and chloride ions levels greater than 100 ppm Do not use inhibitors or other additives that ar...

Page 23: ...o adjust the pH If the system has leaked for some reason the water and antifreeze chemistry will need to be adjusted To avoid damage to the boiler check the pH and chemistry of the boiler solution and consult the antifreeze manufacturer for recommendations It is recommended that a pH reading is taken annually and adjusted as necessary Follow antifreeze inhibitor manufac turer s instructions for de...

Page 24: ...e In these cases it is recommended to flush the system and refill with untreated water and new boiler manufacturer approved antifreeze suitable for Aluminum heat exchangers IMPORTANT Regardless of antifreeze or inhibitors used be sure to follow the antifreeze manufacturer s instructions for use safe handling and storage of their products Refer to the MSDS Material Safety Data Sheets provided by th...

Page 25: ... from boiler then let the relief valve snap shut Open the zone service valve on the supply pipe for B 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 XIII Putting the Boiler in Operation free Close the zone service valve Repeat step 2 for all remaining zones C Open the expansion tank s...

Page 26: ...ight this burner by hand Remove the front jacket panel 4 Turn off the gas ball valve Valve handle should be perpen 5 dicular to the gas pipe Wait 5 minutes for any gas to clear Then smell for gas 6 including near the floor If you smell gas STOP Follow instructions on this page under What To Do If You Smell Gas If you do not smell gas go to next step Turn gas ball valve to the on position The handl...

Page 27: ... aluminum oxide This oxide formation is normal is generally uniform throughout the boiler sections and represents a negligible mass of aluminum that is consumed by oxidation during the life of the boiler If left unchecked this buildup may eventually cause blockage of the flue gas passages in the boiler sections reducing efficiency and ultimately shut ting down the boiler due to lack of combustion ...

Page 28: ...ect interior of vent tee Any buildup of sediment on the inside surface must be cleaned Reconnect 2 flexible coupling to vent tee xIV maintenance and cleaning If heating system is to remain out of service during 2 freezing weather and does not contain antifreeze drain system completely If boiler will be exposed to freezing temperatures drain condensate lines Annual examination and cleaning of boile...

Page 29: ...S 1 SWITCHES ARE SHOWN IN POSITION TAKEN DURING HEATING CYCLE LES INTERRUPTEURS SONT MONTRÉS EN POSITION DE CYCLE DE CHAUFFANT 2 IF ANY OF THE ORIGINAL WIRING SUPPLIED WITH THE BOILER IS REPLACED IT MUST BE REPLACED WITH LIKE WIRE SIZE AND TYPE OF INSULATION OR EQUIVALENT SI AUCUN DES FILS ORIGINAUX FOURNIS AVEC LA CHAUDÈRE EST REMPLACÉ IL DOIT ÊTRE REMPLACÉ OAR UN AUTRE FIL DE MÊME GROSSEUR ET DU...

Page 30: ... T2 A2 A1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR BOILER CONTROL PANEL DHW CIRC L1 120 VAC L2 CH CIRC Basic Wiring Diagram Single Zone system with domestic hot water priority Note The CH DHW Circulator connections on the boiler will only support a pump with a 1 amp rating or less ...

Page 31: ...piping and wiring appendix NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Hotline indirect water heater CH C1 L1 T STAT L2 CH C2 DHW C2 DHW C1 DHW T2 A2 A1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR aquastat or thermostat Boiler Control Panel DHW CIRC L1 HOT L2 N 120V AC NO L2 VAC 120 4 4 NC AR822 II TORQUE TERMINAL 6 TO 7 INCH LBS ELECTRONIC FUSE CIRCUIT ON AR822 TT R T TT NO 24V W C T 5 SCREWS NC 6...

Page 32: ...MUM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR SEE FIGURE 5 ZONE 4 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE EXPANSION TANK AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE Piping Diagram 2 Multizone piping with zone valves and domestic hot water priority with zone valve NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS ...

Page 33: ... JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 SWITCH LEGEND OFF ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANSFORMER 24VAC 40 VA L LINE IN N Black White 24VAC N L Yellow Yellow AZ 4CP Boiler Control Panel DHW...

Page 34: ...VE DHW CIRCULATOR CH CIRCULATOR CIRCULATOR FLOW CONTROL VALVE SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB EXPANSION TANK Piping Diagram 3 Multizone system with zone valves and domestic hot water priority with circulator NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS ...

Page 35: ...LVE ONLY 2 1 3 4 JUMPER ZONE VALVE PUMP PRIORITY ON ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 SWITCH LEGEND OFF ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X TRANSFORMER 24VAC 40 VA L LINE IN N Black White 24VAC N L Yellow Yellow AZ 4CP Boile...

Page 36: ...CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK Piping Diagram 4 Multizone system with circulators and domestic hot water priority XVI piping and wiring appendix NOTE NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS ...

Page 37: ...STAT T 3 R ZONE 4 W T 4 R T DHW CIRC L2 CH C2 DHW C2 DHW C1 DHW T2 A2 A1 DHW T1 CH T2 CH T1 OUTDOOR AIR SENSOR aquastat or thermostat Boiler Control Panel 115 V COIL ISOLATION RELAY NORMALY OPEN NOTE IN PLACE OF 115 VOLT ISOLATION RELAY OPTIONAL CONTROL ARGO AR822II TERMINAL 5 6 N O TO DHW T1 DHW T2 L1 L2 TO ARM L N ON PRIORITY ZONE ELECTRONIC FUSE VAC CIRCUIT ON 120 L2 NO 4 NC 4 AR822 TT SCREWS T...

Page 38: ...ENT FORCED FLOW IN SECONDARY ZONE 4 DHW CIRCULATOR CIRC 2 CIRC 3 CIRC 4 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK WATER INLET Piping Diagram 5 Primary secondary piping with circulators and domestic hot water SEE NOTE NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS ...

Page 39: ...4 CIRC 3 ZONE 4 ZONE 4 ZONE 3 ZONE 2 N 2 L N 3 L ZONE 3 ZONE 2 120 VAC 4 N L N PRIORITY ON INDIRECT HOT WATER HEATER AQUASTAT OR THERMOSTAT W T STAT DATA PORT X X ZR ZC W T PRIORITY T 1 ZONE T R ZONE 4 THERMOSTATS ZONE 3 T ZONE 2 2 W T R 3 T TW R TO EXTRA ZONE MODULE T 4 R 1VA 24 VAC COMMON T STAT T STAT 15 VA 2 7K SILKSCREEN 1 2K L1 L2 TO ARM L N ON PRIORITY ZONE ELECTRONIC FUSE VAC CIRCUIT ON 12...

Page 40: ...ONE 4 USE FULL PORT ZONE VALVE FOR OPTIMUM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR SEE FIGURE 13 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK Piping Diagram 6 Primary secondary multizone system piping with zone valves and domestic hot water with zone valve NOTE RECOMMENDED FOR ANTIFREEZE APPLICAT...

Page 41: ...ER VAC CIRCUIT ON 120 L2 N O 4 N C 4 AR822 TT TT T T R W 24V C 5 6 6 RELAY TRANSFORMER N O N C 24VAC 15 VA 24VAC L1 3 FACTORY INSTALLED JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FR...

Page 42: ...LOCATION ZONE 4 USE FULL PORT ZONE VALVE DHW CIRCULATOR CH CIRCULATOR WATER INLET CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE HOSE BIB FLOW CONTROL VALVE EXPANSION TANK Piping Diagram 7 Primary secondary piping with zone valves and domestic hot water with circulator NOTE RECOMMENDED FOR ANTIFREEZE APPLICATIONS SEE NOTE ...

Page 43: ...UIT ON 120 L2 N O 4 N C 4 AR822 II T T R W 24V C 5 6 6 RELAY TRANSFORMER N O N C 24VAC 15 VA 24VAC L1 3 FACTORY INSTALLED JUMPER ZONE VALVE PUMP PRIORITY ZR ZC DPM 2 OPTION SWITCH ZC ON STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X X CONTACT ZR ON T T T T T T T T 1 2 3 4 PRI ZONE 1 2 3 4 ZONE 2 1 2 3 4 ZONE 3 1 2 3 4 ZONE 4 ON N L N L N L ZR ZC 120 VAC PRIORITY PUMP PRIMARY PUMP FROM BOILER X X ...

Page 44: ...ALVE 3 WAY MIXING VALVE AIR SEPARATOR HOSE BIB EXPANSION TANK Piping Diagram 8 Bypass piping automatic mixing valve BOILER ALTERNATE CIRCULATOR LOCATION TO SYSTEM FROM SYSTEM V2 V1 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE AIR SEPARATOR ZONE VALVE EXPANSION TANK WATER INLET SYSTEM CIRCULATOR Piping Diagram 9 Bypass piping fixed low temp only ...

Page 45: ...VE EXPANSION TANK BOILER 1 BOILER 1 CIRC BOILER 2 CIRC WATER INLET ALTERNATE CIRCULATOR LOCATION BOILER 1 TO SYSTEM FROM SYSTEM BOILER 2 12 MAX ALTERNATE CIRCULATOR LOCATION BOILER 2 CIRCULATOR SHUT OFF VALVE PRESSURE REDUCER VALVE CHECK VALVE BALL VALVE 3 WAY MIXING VALVE AIR SEPARATOR HOSE BIB EXPANSION TANK 12 MAX Piping Diagram 10 Piping Diagram 11 Bypass piping 4 way valve option with circula...

Page 46: ...VICE TO BOILER T T TO BOILER T T TERMINALS 1 2 Wiring Diagram 8 Multiple Boiler Wiring AMB 4 TRANSFORMER 24VAC 40 VA Black White Yellow Yellow DHW C1 DHW C2 CH C2 CH C1 A2 DWH T1 DHW T2 A1 BOILER CONTROL PANEL CH T1 CH T2 L1 L2 120 V WHITE BLACK BOILER 1 CIRC DHW C1 DHW C2 CH C2 CH C1 A2 DWH T1 DHW T2 A1 BOILER CONTROL PANEL CH T1 CH T2 L1 L2 BOILER 2 CIRC AMB 8 BOILER 1 BOILER 2 IF USING REQ ACK ...

Page 47: ...__________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _______________________________________________________...

Page 48: ...formed Company Name Tech Initials Company Address Phone For technical assistance with this product call toll free 1 800 325 5479 ECR International PO Box 4729 Utica NY 13504 4729 www ecrinternational com Service RECORD ...

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