Dunkirk Q90 125 Installation Manual And Operating Instructions Download

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Summary of Contents for Q90 125

Page 1: ...Q90 125 200 GAS FIRED DIRECT VENT CONDENSING HOT DUNKIRK 85 Middle Rd Dunkirk NY 14048 www dunkirk com ...

Page 2: ...as fired direct vent cast aluminum hot water boiler A revolutionary cast aluminum heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers which results in higher efficiency The heating system water absorbs large amounts of heat from the cast aluminum heat exchanger cooling the flue gases and causing condensation Sealed combustion premix gas burner and l...

Page 3: ...lity company requirements before installation This installation must conform with these requirements in their entirety In the absence of these codes use NFPA installation codes and good industry practice 2 Before servicing the boiler allow it to cool Always shut off any electricity and gas supply connected to the boiler prior to servicing 3 Inspect gas line for leaks 6 Be sure there is adequate ou...

Page 4: ... 000 179 000 159 400 158 200 136 800 134 400 116 000 113 000 7 000 179 000 175 500 156 800 155 400 134 600 131 800 114 500 111 000 8 000 176 000 172 000 154 200 152 600 132 400 129 200 113 000 109 000 9 000 173 000 168 500 151 600 149 800 130 200 126 600 111 500 107 000 10 000 170 000 165 000 149 000 147 000 128 000 124 000 110 000 105 000 Vent Lengths VentLengths Vent Lengths VentLengths Altitude...

Page 5: ...pickup requirements Complete all of the following prior to installing the boiler Oil This boiler product is a gas fired direct vent con densing boiler and must be installed in accordance with all applicable federal state and local building codes including but not limited to the following United States Installation shall conform with National Fuel Gas Code NFPA 54 ANSI Z223 1 latest revision Canada...

Page 6: ...ir intake passages free of obstruc tions Both the venting and combustion air intake piping systems connected to the outdoors must permit flow through the piping systems without restrictions for the boiler to operate 7 The boiler shall be installed such that the automatic gas ignition system components are protected from water dripping spraying rain etc during operation and service circulator re pl...

Page 7: ...t be clean outdoor air Combustion air must not be taken from inside the structure because that air is frequently contaminated by halogens which include fluorides chlorides phosphates bromides and iodides These elements are found in aerosols detergents bleaches cleaning solvents salts air fresheners paints adhesives and other household products Locate combustion air inlet as far away as possible fr...

Page 8: ...afe condition 3 When it is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and oth er 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 ma...

Page 9: ... sign temperature and system water content Boiler contains 2 6 gallons U S Size expansion tank ac cordingly Consult expansion tank manufacturer for proper sizing information Connect properly sized expansion tank not furnished as shown in Figure 6 for diaphragm type expansion tank For diaphragm type expansion tanks adjust the tank air pressure to match the system fill pressure Install air vent furn...

Page 10: ...res for the circulator pump inside the junction box should be taped or wire nutted to prevent short circuits Unplug the circulator pump wiring at the integrated boiler control MULTIZONE BOILER PIPING WiTH ZONE VALVES ZONE SER_CE ZONE F VALVE VALVE ZONES PRESSURE REDUCING VALVE_ VALVE CAN VENT AIR WATER ZONES PRESSURE BACKFLOW PREVEN_R VALVE _ZONE SERVICE VALVE IFlguregb The packaged boiler unit is...

Page 11: ...event the chilled medium from entering the boiler The boiler piping system of a hot water boiler con nected to heating coils located in air handling units where they may be exposed to refrigerated air cir culation must be equipped with flow control valves or other automatic means to prevent gravity circu lation of the boiler water during the cooling cycle I_IPORTANT To prevent damage to the gas _ ...

Page 12: ... vent piping Comply with all clearances required as stated in paragraph 6 below Termination should be positioned where vent vapors wilt not damage plants shrubs air conditioning equipment or siding on the house Termination should be positioned so that it will not be effected by wind eddy air born leaves snow or recircutated flue gases Termination should be positioned where it will not be subjected...

Page 13: ...2 Working from the boiler to the outside cut pipe to required length s 3 Deburr inside and outside of pipe Remove all chips and shavings 4 Chamfer outside edge of pipe for better distri bution of primer and cement 5 Clean and dry all surfaces to be joined 9 Wipe excess cement from joint A continuous bead of cement wilt be visible around perimeter of a properly made joint 10 Handle pipe joint caref...

Page 14: ...hut off The following rules apply 3 Use ground joint unions 4 Install a sediment trap upstream of gas con trols 5 Use two pipe wrenches when making the con nection to the gas valve to keep it from turning 6 Install a manual shutoff valve in the vertical pipe about 5 feet above floor outside the boiler jacket 7 Tighten all joints securely 8 Propane gas connections should only be made by a licensed ...

Page 15: ...ower supply to the ground green screw on the service switch The recepta cle on the service switch is always powered regard less of whether the switch is on or off and could be used as a power supply for an external condensate pump if one is used f _K 1 _ _ 12o volt wi_ co_R CODE _ CmCIII_TOR BK 13Ia_ _ W wIlrrE y _ GIVEN _ 24 VOLT Y l_l LO_ G 60 IIZ i _ ZN _ BO _ _ GROUl_ pOI_I_ SUPpLy s_eE _ Figu...

Page 16: ...ITOR _ VALW NOTE USE COPPER CON UCTORS ONLY LADDER WIRING DIAGRAM t20 VOLt POWER SUPPLY NO1E USE COPPER CONDUC1 ORS ONLY HOT ON OFF BLK WHT SWITCH LWCO K1 P10 I CIRCULATOR FIELD WIRED P10 2 P5 3 PIO 35K2 5K1 P6 1 P12 1 BLOWER HOT SURFACE IGNITER P12 2 P6 2 i20 VAC SAFETY SWITCH GAS VALVE M _NUAL RESET _ K_ 13K_ i _ _ p_ AIR PRSSSURE M_CROPROCESSOR SW TCH N O _ _ _ DIFFERENT AL AIR _L gTRO_ wCF R S...

Page 17: ... water temperature and also provides a means for protecting the boiler and heating system from unsafe operating conditions which could dam age the boiler The aquastat is mounted in the NPT control well and 3A x bushing on the top of the front boiler section at the hot water outlet The aquastat is tied in with the IBC and is factory set at 180 F water temperature The high limit setpoint is field ad...

Page 18: ...ld always be located on the downstream i e pumping away side of the expansion tank The manual drain valve provides a means d draining the water in the heating system including the boiler and hot water supply and return piping systems in stalled above the drain valve This drain valve is in stalled in the tapping at the bottom of the boiler Any piping installed below the elevation of this drain valv...

Page 19: ...rom year to year Improperly maintained antifreeze solu tions will gradually lose their ability to protect the aluminum boiler from corrosion d The recommended premi ed antifreeze solution is INTERCOOL NFP 50 This prod uct is sold direct to distributors by the manu facturer Please contact Interstate Chemical Company at 1 800 422 2436 or your distribu tor for more information c In older systems obvi...

Page 20: ...lve and fill boiler with water Make sure air vent is open Hold relief valve open 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 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...

Page 21: ...ser vice technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water 10 Turn on all electrical power to the appliance 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions in To Turn Off Gas To Appliance below and call your service technician or gas supplier 1 Set the thermostat to the ...

Page 22: ...upply Piping in this manual 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 the air intet pipe may need to be disconnected to allow the boiler to start in order to verify the bolter firing rate and combustion properties The inlet air pipe can be disconnected by remowng the PVC inlet air piping ...

Page 23: ...control energizes thegasvalve initiating a 6 second trialforignition mode whichisindicated bytheillumination of Lamp D Twoseconds later LampC will extinguish whenthe integrated boilercontrolstops sending power tothehotsurface igniter 7 A lowlevelillumination of LampEindicates theinitiation offlame proving During thelast2seconds ofthetrialforignition mode main burner flameisproven byflamerectificat...

Page 24: ...r 4 seconds gas valve closes lamp D goes out as integrated boiler control senses that flame is not present 2 See Table 2 in Section IV of this manual to determine the correct approximate input rate for the local elevation 6 To restart system follow operating instruc tions in Section XlI Start Up 3 Obtain the yearly average heating value of the local gas utility At sea level elevation it should be ...

Page 25: ...n step 2 above about halfway into the exhaust gas stream Take a flue gas reading and observe the CO 2 value Adjust the throttle screw until the CO 2 value is between 8 5 and 10 Turning the throttle screw counter clockwise increases the rate and the CO 2 value Turning the throttle screw clockwise decreases the rate and the CO 2 value Allow the apphance to sta bdJze for approximately 1 minute after ...

Page 26: ...and cleaning instructions in paragraph F below b Visually inspect venting and air intake system for proper operation If the vent or air intake show any signs of deterioration or leakage repair or replace them immediately Insure proper reas sembly and resealing of the vent and air intake system c Check for and remove any obstruction to the flow d combustion air or venting of flue gases d Follow ins...

Page 27: ...blower adapter assembly over studs Install five nuts but do not tighten Reinstall igniter and ig niter gasket and fasten with two screws The ig niter element is very sensitive Do not touch the igniter element with your fingers or hands as oils or debris wil_ jl cause premature failure Tighten five nuts holding blower adapter assembly m Connect gas line to gas valve air inlet as sembly to gas valve...

Page 28: ... AS LONG AS THERMOSTAT CONTINURES TO CALL FOR HEAT __ PURGE LIGHT IS ON AIRFLOW PROVED DRAFT INDUCER RUNS FOR 15 SEC PREPURGE DOES MAIN BURNER PROVE _ED FLAME WITHIN INITIAL TRIAL FOR IGNITION PERIOD DURING THE LAST 2 SEC OF THE 5 SEC IGNITION TRIAL MAIN BURNER FLAME IS PROVED BY FLAME RECTIFICATION A FLAME SIGNAL TO IBC GAS VALVE REMAINS ENERGIZED BOILER RUNS t 2 SEC INTO THE 6 SEC IGNITION TRIAL...

Page 29: ... TROL LOCKOUT PROBLEM WITH COMBUSTION AIRFLOW PURGE LIGHT BLINKS CONTROL WILL I AUTOMAT CALLY RESETAFTER 15 M NUTES J CASTING TEMPERATURE SAFETY SWITCH IF BURNER OPERATES WHEN BOILER HAS NO WA i ER ALUMINUM BOILER SECTIONS HEAT UP RAPIDLY J CASTING TEMPERATURE SAFETY SWITCH CON TACTS WILL OPEN BREAKING 24 VOLT POWER TO IBC POWER INDICATOR LIGHT GOES OUT REQUIRES MANUAL RESET TO RECLOSE CON TACTS P...

Page 30: ...DS CALL FOR HEAT GAS VALVE AND CIRCULATOR PUMP ARE DE ENER GIZED 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 31: ...be hap pening chances are that either there is nothing wrong with the control or it is being damaged by some other problem for example an electrical short burning out a transformer 1 Before troubleshooting a Make sure that circuit breaker is on or fuse is okay ay electrical panel b Make sure that service switch is on c Make sure that gas is on at the gas me ter at all appropriate manual shutoff va...

Page 32: ...nes 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 pres sure switch setpoint Gas valve out of adjustment 6 When pressure reading is proper and the pressure switch is operating prop erly remove testing lines and reinstall vinyl caps to Tee and 3 way connector This diagram indicates the locations of th...

Page 33: ...due to broken igniter or lack of low flame signal or no gas On Bright Flame proven FLAME On Dim Checking for flame signal during trial for ignition Off Flame unproven ELECTRICAL SHOCK HAZARD MAY CAUSE SERIOUS iNJURY OR DEATH The following procedures may expose you to dangerous line voltage Use caution to avoid touching live electrical contacts Service must be performed by a trained experienced ser...

Page 34: ...ICH INDICATOR LIGHT IS BLINKING RESET SYSTEM BY TURNING SERVICE SWITCH OFF THEN ON IF NOT LOCKED OUT SET THERMOSTAT TO CALL FOR HEAT CIRCULATOR STARTS YES FALSE POSITIVE PROOF OF AIRFLOW CHECK AIR PRESSURE SWITCH CONTACTS IF CONTACTS ARE CLOSED WITH NO AIRFLOW REPLACE PRESSURE SWITCH CLOSED CHART2 _r MALLY OPEN AI_ CH CONTACTS OPEN CHART3 ...

Page 35: ...DARY NO V YES 24 VAC AT WIRING HARNESS PLUG CN2 NO _YES REPLACE IBC I CHECK FOR 120 VAC BETWEEN TERMINALS t NO 1 AND 3 AT CONNECTOR CN5 ON IBC YES CHECK FOR 120 VAC AT CIRCULATOR t NO r YES REPAiR REPLACE CIRCULATOR I l CHECK WATER LEVEL IN BOILER CHECK FOR AIR TRAPPED IN TOP OF BOILER CONTACTS WILL NOT STAY CLOSED UNTIL BOILER COOLS OFF REPLACE REPAIR WIRING FROM SERVICE I SWITCH TO IBC REPLACE I...

Page 36: ...E ORIFICE IN NEGATIVE PRESSURE HOSE CLEAR YES ARE VENT PIPE AND AIR INTAKE PIPE CLEAR NO BLOCKAGE YES CHECK AIR PRESSURE SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY YES CHECK FLUE PASSAGES IN BOILER PER MAINTENACE AND CLEANING ARE FLUE PASSAGES IN BOILER CLEAN YES CHECK DRAFTINDUCER MOTOR RPM ISIT 3400 3600 YES CHECKFOR BROKEN OR LOOSEIMPELLER ON DRAF...

Page 37: ...L WHILE VALVE FLAME INDICATOR LIGHT IS ON _ REPLACEIBC ___ REPAIR REPLACE WIRING FROM IBC TO IGNITER SENSOR REPLACE IGNITER SENSOR YES y CHECK FOR 24 VAC ACROSS TERMINALS CN6 2 AND CN6 5 ON tgc WHILE THE VALVE FLAME LED IS LIT YES REPAIR REPLACE WiRiNG BETWEEN IBC AND GAS CONTROL CHECKIFIGNITER H SENSOR POSITIONIS OK TIP SHOULD BE SLANTED TOWARDSBURNER YES CHECK GAS SUPPLY II PRESSURE ATINLET PRES...

Page 38: ...USE CORRECT GAS VENTURI VALVE SIZE CLEAN BOILER FLUE PASSAGES PER MAINTENANCE AND CLEANING INSTRUCTIONS CLEAN MIXER AND BURNER PER MAINTENANCE AND 1 CLEANING INSTRUCTIONS REPLACE BURNER DOES MAIN BURNER RUN UNTIL CALL FOR HEAT ENDS OR HI LIMIT AQUASTAT CONTACTS OPEN r CHART 6 NO 1 NO 2 NO 3 IF THE ANSWER IS NO CHOOSE THE APPROPRIATE PATH _ 2 OR 3 BASED ON SYMPTOMS SHOWN CHART 6 CHART 6 RUNS SMOOTH...

Page 39: ...OINT MINUS 30 F CONTROL DIFFERENTIAL REPLACE GAS CONTROL rYES CHECK GAS ORFICICE SIZE IS GAS ORIFICE StZE CORRECT CHECK REPAIR PARTS LIST FOR CORRECT SIZE IS GAS ORIFICE CLEAR OF BLOCKAGE rYES DOES THE UNIT USE LP GAS NO ADJUSTRATEASDESCRIBEDINTHE CHECK OUT PROCEDURE AND ADJUSTMENT SECTION OF THE MANUAL REPLACE WITHCORRECT AIR BAFFLE REPLACEBURNER REPLACEIBC NNNo_ REPLACE AQUASTAT OK I I I I I I S...

Page 40: ...ion instructions have been followed o Checkout procedure and adjustments performed o Maintenance and Service issues reviewed with owner maintenance person o Installation booklet affixed on or adjacent to boiler Installer Company Address Phone Installer s Name Signature ...

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