Dunkirk Q90 150 Document technique

Q90 125-200 GAS-FIRED DIRECT VENT

CONDENSING HOT

DUNKIRK

85 Middle Rd.

Dunkirk, NY 14048

www. dunkirk, com

INSTALLATION MANUALAND OPERATING INSTRUCTIONS

P/N# 240004826D, Rev. 1.3 [01/06] •Printed in USA •Made In USA

I. Introduction ........................................................ 2

II. Safety Symbols ................................................ 2

III. Rules For Safe Installation and Operation ......... 3

IV. Boiler Ratings and Capacities ......................... 4

V. Before Installing The Boiler .............................. 5

VI. Placing The Boiler ........................................... 9

VII. Near Boiler Piping .......................................... 9

VIII. Combustion Air and Vent Pipe .................... 11

IX. Gas Supply Piping ........................................ 13

X. Electrical Wiring ............................................. 15

XI. Controls and Accessories ............................. 17

XII. Startup ......................................................... 19

XIII. Checkout Procedures and Adjustments ........ 23

XIV. Maintenance and Cleaning ......................... 26

XV. Detailed Sequence of Operation .................. 28

XVl. Troubleshooting .......................................... 33

XVlI. Installation and Checkout Certificate ......... 40

forces the resulting flue gases from the boiler unit

and provides a positive removal of the flue gases

from the building through inexpensive and readily

available PVC and CPVC vent pipes.

The following defined symbols are used throughout

this manual to notify the reader of potential hazards

of varying risk levels.

KEEP THIS MANUAL NEAR BOILER AND

RETAIN FOR FUTURE REFERENCE.

This appliance is a gas-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 low

flame temperature means drastically reduced CO

and NOx emissions, which contribute to a cleaner

and healthier environment.

i:ndicates a potential hazardous situation I

hich, if not avoided, MAY result in minor or I

oderate injury. It may also be used to alert I

gainst unsafe practices. J

MPORTANT: Read the following instructionsj_

OMPLETELY before instatlingH

This appliance, unlike normal residential atmospheric

and induced draft units, takes its combustion air

directly from the outdoors (sealed combustion) and

does not compete with building occupants for fresh

air. Sealed combustion (also known as "direct vent")

is the safest and best way to obtain plenty of clean

combustion air. The forced draft fan draws in the

outside combustion air to mix with gas, which flows

into the pre-mix burner and combusts. The fan then c@:s

®@

OPENING FOR AIR VENT

OPENING FOR RELIEF VALVE AND EXPANSION TANK

DISCHARGE PIPE CONNECTION

_t _ STANDARD

SUPPLY & RETURN OPENINGS

1 1/4 NPT CONNECTIONS

t,+,+,,+,o,oo,+,c++.

JUNCTION BOX FOR 120V+ POWER

& 2,€ V. THERktOSTAT LEADS

_ _ TOP

COMBUSTION AIR INTAKE FITTING

(2" PVC)

GAS SUPPLY _ X_ _ '/+

OPENING _ \

(1/2" NPT)

r_l

FITTING (1/2" PVC)

LEVELING FEET

IMPORTANT: Failure to follow these instructions

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

VENT CONNECTION (2" CPVC)--

may result in too much air for the pre-mix burner

causing poor or loss of combustion.

5. 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

inside a building,

1. 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 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 outdoor air supply

to boiler for complete combustion.

7. Follow a regular service and maintenance

schedule for efficient and safe operation.

8. Keep boiler area clean of debris and free of

combustible and flammable materials.

9. Proper through-the-watt or through-the-roof

combustion venting shall be in accordance with the

materials and methods described in this manual.

Installation must comply with local codes.

4. Be certain gas input rate is correct. Overfiring

may result in early failure of the boiter components.

This may cause dangerous operation. Underfiring

10. This boiler and related hot water heating

systems are not do-it-yourself items. They must be

installed and serviced by qualified professionals.

125 125 112.5

150 150 135

175 175 157.5

200 200 180

(1)1MBH=1,000 Btuh(British ThermalUnits PerHour)

117

137

157

284

2" CPVC & 3" PVC

(2)AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on Department of Energy test procedure.

Ratings shown are for sea level applications. The boiler automatically derates input as altitude increases.

No alterations to boiler are required for altitudes above sea level.

Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000

2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000 121,000

3,000 191,000 189,500 167,200 166,600 143,400 142,200 120,500 119,000

4,000 188,000 186,000 164,600 163,800 141,200 139,600 119,000 117,000

5,000 185,000 182,500 162,000 161,000 139,000 137,000 117,500 115,000

6,000 182,000 179,000 159,400 158,200 136,800 134,400 116,000 113,000

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

0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 195,900 195,750 171,900 171,200 146,900 146,700 123,050 122,250

2,000 191,800 191,500 168,800 167,400 143,800 143,400 121,100 119,500

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

8,000 167,200 166,000 150,200 144,600 125,200 123,600 109,400 103,000

9,000 163,100 161,750 147,100 140,800 122,100 120,300 107,450 100,250

10,000 159,000 157,500 144,000 137,000 119,000 117,000 105,500 97,500

These low pressure gas-fired hot water boilers are design certified by CSA International, for use with

natural and propane gases. The boilers are constructed and hydrostatically tested for a maximum work-

ing pressure of 50 psig (pounds per square inch gauge) in accordance with A.S.M.E. (American Society

of Mechanical Engineers) Boiler and Pressure Vessel Code, Section IV Standards for heating boilers.

The Boilers are certified in accordance with ANSI (American National Standards Institute) Z21.13

standards as gas-fired, direct vent, condensing, hot water boilers.

The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack.

Most of this heat is available to heat water. A small portion is heat loss from the jacket and surfaces of

the boiler, and it is assumed 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 pickup allowance, establishes a reserve for heating the volume

of water in the system and offsetting heat losses from the piping. The Net I=B=R Ratings shown are

based on a piping and pickup factor of 1.15 in accordance with the I=B=R Standard as published by the

Hydronics Institute. The Net I=B=R Rating of the boiler selected should be greater than or equal to the

calculated peak heating load (heat loss) for the building or area(s) served by the boiler and associated hot

water heating systems. The manufacturer should be consulted before selecting a boiler for installations

having unusual piping and 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 - Installation shall be in accordance

with CSA-B149.1 and .2 installation codes.

• Check to be sure you have selected the boiler

with the proper capacity before continuing the in-

stallation. The I=B=R Rating of the boiler selected

should be greater than or equal to the calculated

peak heating load (heat loss) for the building or

area(s) served by the boiler and associated hot

water heating systems. See Section IV, "Boiler

Ratings and Capacities, " for more information.

• Heat loss calculations should be based on

approved industry methods.

Where required by the authority having jurisdiction,

the installation must conform to the American Soci-

ety of Mechanical Engineers Safety Code for Con-

trols and Safety Devices for Automatically Fired

Boilers, No.CSD-1.

The installation must conform to the requirements

of the authority having jurisdiction or, in the ab-

sence of such requirements, to the National Fuel

Gas Code, ANSI Z223.1 -latest revision.

Before selecting a location for the boiler, the follow-

ing should be considered. Each boiler considered

for installation must be:

• Supplied with the correct type of gas (natural

gas or propane).

• Connected to a suitable combustion air intake pip-

ing system to supply the correct amounts of fresh

(outdoor) air for combustion (max. length 60').

Installers - Follow local regulations with re- • Connected to a suitable venting system to re-

spect to installation of CO (Carbon Monox- move the hazardous products of gas combus-

ide) Detectors, Follow maintenance recom- tion (max, length 60'),

mendations in this manual,

• Connectedto a suitablehot water heating

system.

• 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 in-

stalled on carpeting)

• Condensate drain line must be pitched down

to floor drain or external condensate pump with

reservoir at ¼"per foot (wood frame or blocks

may be used to raise boiler).

1. Select a location which is level, central to the

piping systems served and as close to the vent

and air intake terminals as possible.

2. Accessibility clearances, if more stringent (i.e.

larger clearances) than required fire protection

clearances, must be used for the boiler installa-

tion. Accessibility clearances may be achieved

with the use of removable walls or partitions.

3. The boiler is approved for installation in clos-

ets and on combustible floors. This boiler shall

NOT be installed on carpeting.

the front where passage is required for cleaning or

servicing, inspection or replacement dany parts

that normally may require such attention. Allow at

least 24" at the front and left side and 8" at the top

for servicing. No combustible clearances are re-

quired to venting or combustion air intake piping.

5. Equipment shall be installed in a location

which facilitates the operation of venting and

combustion air intake piping systems as de-

scribed in this manual.

6. Advise owner of boiler to keep venting and

combustion air 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-

placement, control replacement, etc.).

8. The boiler must be located where ambient

temperatures (minimum possible room temper-

atures where boiler is installed assuming boiler

is not in operation and therefore contributes no

heat to the space) are always at or above 32°F

to prevent freezing of liquid condensate.

Top 1" 8"

Left Side 8" 24"

Right Side 1"

Base 1"

Front 0" 24"

Back 1"

Intake/Vent 0"

Piping

Near Boiler Hot 1"

Water Piping

Aft distances measured from the cabinet of the boiler.

4. The clearances shown in Table 4 indicate re-

quired clearances per CSA listing. A min. 1" clear-

ance must be maintained between combustible

construction and each of the right, top and back

surfaces of the boiler. A min. 8" clearance is re-

quired on the left side, to allow room for the inlet

air pipe. An 18" clearance must be maintained at

This boiler requires a dedicated direct vent system.

In a direct vent system, all air for combustion is

taken directly from outside atmosphere, and all flue

)roducts are discharged to outside atmosphere.

ROOF VENTIINTAKE TERMINATIONS

I Figure 1]

Combustion air and vent pipe connections must

terminate together in the same atmospheric pres-

sure zone, either through the roof or sidewall (roof

termination preferred). See Figures 1 and 2 for re-

quired clearances.

SIDEWALL VENTIINTAKE TERMINATIONS

I LESS THAN 12 CLE;,R;,riCE J

12" OR MORE CLEARANCE

If the concentnc vent termination is being used, re-

fer to Figure 3 for proper setup

CONCENTRIC VENT TERMINATIONS

12_ P IlNll 1UP 1

COt 1EUSTIOH AIR

_1 PCOF

3 E_=H-IIG

12 I11PJRIIJ[ _

ENT r1-ff4T_in IC irl CLE-_-NCE

:BC E H;GHEST .NTIC_P-TED

SI_ 'LE ELOF = SP-DE

eep boiler area clean of debris and free of I

ammable and combustible materials, vapors, I

nd liquids, i,)

FAILURE TO FOLLOW THESE WARNINGS

COULD RESULT IN FIRE, PROPERTY

DAMAGE, PERSONAL INJURY, OR DEATH.

When vent pipe is exposed to temperatures

below freezing, such as when it passes through

an unheated space or when a chimney is used

as a chaseway, vent pipe must be insulated

with l/2"Armaflex or equivalent. In extremely

cold climate areas, use 3/4"Armaflex or

equivalent.

Combustion air must 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 from swimming pool and swimming

pool pump house. All combustion air and

vent pipes must be airtight and watertight.

Combustion air and vent piping must also

terminate exactly as shown in Figures 1-2. If

aconcentric vent termination is being used,

refer to Figures 3-5 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.

Solvent cements are combustible. Keep away

from heat, sparks, or open flame. Use only in

well ventilated areas. Avoid breathing in vapor

k.or allowing contact with skin or eyes. J

CONCENTRIC VENT

CONCENTRICVENTROOFINSTALLATION

VENT

I MAINTAIN 12 IN

(i8 IN FD_ CANADA>

MINI_UN CLEARANCE

SNO_

MAXINUM OF

IN A_DVE NOOF

NOTE, SbPPORT WUST BE FIELD INSTALLED

TO SECC_RE TERMINAT[0N K!I /O STR/JCTURE

3" Diameter PVC Vent/Exhaust

1W' ,¢"_1d1_'

46% _

3" Diameter PVC Intake/Combustion Air

[ Figure 5 I

Boiler must be placed on level surface. Boiler is

NOT to be installed on carpeting.

NOTES

1. If boiler is not level condensate drain lines will not function

properly. Adjustable feet are located on the boiler to make

up for minor surface irregularities or tilt.

2. Wood frame or blocks may be used to raise boiler to maintain

Wa!np!!chor!obeabovee erna!condensa!epump

When an existing boiler is removed from a common

venting system, the common venting system is likely

to be too large for proper venting of the appliances

remaining connected to it. At the time of removal of

an existing boiler, the following steps shall be fol-

lowed with each appliance remaining connected to

the common venting system placed in operation,

while the other appliances remaining connected to

the common venting system are not in operation.

1. Seal any 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 restriction, leakage, corrosion or

other deficiencies which could cause an unsafe

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 maximum speed. Do not operate

a summer exhaust fan. Close fire dampers.

4. Place in operation the appliance being in-

spected. Follow the lighting instructions. Adjust

thermostat so appliances will operate continu-

ously.

5. Test for spillage at the draft hood relief open-

ing after 5 minutes of main burner operation. Use

the flame of a match or candle, or the smoke

from a cigarette, cigar or pipe.

6. After it has been determined that each ap-

pliance remaining connected to the common

venting system properly vents when tested as

outlined above, return doors, windows, exhaust

fans and any other gas-burning appliance to their

previous condition of use.

7. Any improper operation of the common vent-

ing system should be corrected so the installation

conforms with the National Fuel Code, NFPA-

54/ANSI -Z223.1-1atest revision, or section 5 of

CSA-B149 for Canadian standards. When resiz-

ing any portion of the common venting system,

the common venting system should be resized to

approach the minimum size as determined using

the appropriate tables in part 11 in the National

Fuel Gas Code, NFPA-54/ANSI- Z223.1-tatest

revision, or section 5 of CSA-B149 for Canadian

standards.

The boiler should be placed to provide the most

direct connections to the combustion air, vent and

system piping as possible.

Place crated boiler as close to selected location

as possible and uncrate boiler. The uncrated boiler

may be moved into position with an appliance dol-

ly or 2-wheel hand truck. The dolly or hand truck

should be inserted under the right hand side of

the boiler. It is possible to slide the boiler for a short

distance on a smooth floor or surface.

NqNOTE: Refer to "Locating The Boiler" in Section V for re-_

uired clearances for servicing and maintenance. J

r c.o,,o, .,

Copper supply and return piping must NOT be in-

stalled directly into aluminum boiler section castings

due to galvanic corrosion between dissimilar met-

als. Iron or steel bushings or pipe nipples should

be used between copper system piping and boiler

to make final connection to boiler. Also, the use d

dielectric unions is acceptable. The packaged boiler

is furnished with iron piping in the front boiler sec-

k_ion for the supply and return connections. J

When the installation of the boiler is for a new heat-

ing system, first install all of the radiation units (pan-

els, radiators, baseboard, or tubing) and the supply

and return mains. After all heating system piping and

components have been installed, make final con-

nection of the system piping to the boiler.

Determine required system fill pressure, system de-

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

(furnished) as shown for diaphragm type expansion

tank system only. Install make-up water connec-

tions as shown and per local codes. If a pressure

reducing valve is used, adjust to match the system

fill pressure. In connecting the cold make-up water

supply to the boiler, make sure that clean water sup-

ply is available. When the water supply is from a well

or pump, a sand strainer should be installed at the

pump.

A hot water boiler installed above radiation level must

be equipped with a low water cut off device (included

with boiler). A periodic inspection is necessary, as is

flushing of float type devices, per low water cut off

manufacturers specific instructions.

DIAPHRAGM TYPE EXPANSION TANK PIPING

E)G_ANSION TANK SER_ICE VALVE

{OA_ VALVE Of_ FULL

PORT BALL VAL'_)

AUTOMATIC AIR

VENT*

.............\ •

REDUCING VALVE *- FURNISHED IN

pARTS BAG.

REDUCINGVALVE

I_/ .... 1ST Op_cN FOR FEED WA3ER

WA_R 2ND Opllo_ FOR FEED WAER

DIAPHRAGM TfPE-

EXPANSION TANK

RELIEF VALVE DISCHARGE PiPiNG

PRESSURERELIEFDEVICE

Figure 7 ]

The boiler is furnished with a relief valve and tem-

perature pressure gauge in the boiler parts bag. In-

stall vent relief valve as shown in Figure 7. Provide

¾" piping from the relief valve to a local floor drain,

but leave an air gap betweenpiping and drain.

No shutoffof any descriptionshall be placedbe-

tweensafetyreliefvalveandthe boiler,or on the

dischargepipesbetweensuchsafetyvalveandthe

atmosphere.Installationof the safety reliefvalve

shallconformto ANSI/ASMEBoilerand Pressure

VesselCode,SectionIV.Themanufactureris not

responsibleforanywaterdamage.

SINGLEZONEBOILERPiPiNG

SERVI E S[ PPLY [3

VALVE

SE \/Z(?E

'ALVE

MULTIZONE BOILER PiPiNG

WiTH CIRCULATORS

_-ZONE SERVICE

j" VALVE

FLOW CHECK TO

VALVE ZONES

CIRCULATORS

PRESSURE

REDUClNO VALVE_

VALVE

VAL_

NOTE: When zoning with circulators, the furnished circulator pump

should be used as one of the zone pumps. Each stripped end of

the electrical wires 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 FVALVE

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 set up to receive 1¼"

NPT supply and return piping from top access.

COTE: The circulator and isolation valves fur- _

pump are

ished within a carton inside the boiler cabinet and can be]

_installed at the installer preferred location, j'

CONDENSATE DRAIN PIPING

Condensate drain line to be pitched down to floor

drain at a minimum of ¼" per foot. An external con-

densate pump (not furnished) may be used if floor

drain is not available. The condensate pump must

be designed for flue gas condensate application.

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