Dunkirk 90-50 Installation, Operation & Maintenance Manual
  1. Manuals
  2. Brands
  3. Dunkirk Manuals
  4. Boiler
  5. 90-50
  6. Installation, operation & maintenance manual

Dunkirk 90-50 Installation, Operation & Maintenance Manual

Gas-fired, direct vent, condensing, hot water boiler
Hide thumbs Also See for 90-50:
Table of Contents

Advertisement

Quick Links

See also: Installation Manual
GAS-FIRED, DIRECT VENT,
CONDENSING, HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www.dunkirk.com
P/N# 14683301, Rev. C [12/2010]
An ISO 9001-2008 Certified Company

Advertisement

Table of Contents
loading

Related Manuals for Dunkirk 90-50

Summary of Contents for Dunkirk 90-50

  • Page 1 GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL DUNKIRK BOILERS 85 Middle Rd. Dunkirk, NY 14048 www.dunkirk.com P/N# 14683301, Rev. C [12/2010] An ISO 9001-2008 Certified Company...
  • Page 2 90-50-100 GAS-FIRED BOILER Model No. 90-50 90-75 90-100 These instructions must be affixed on or adjacent to the boiler. WARNING Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or the gas supplier.

  • Page 3: Table Of Contents

    Table of ConTenTs Warnings and Safety Symbols ....................... 3 Introduction ..........................4 boiler Ratings & capacities ......................5 boilers For use At high Altitude ..................... 6 Rules For Safe Installation And Operation ..................8 before Installing The boiler ......................8 Placing The boiler ........................11 Near boiler Piping ........................12 combustion Air and Vent Pipe ......................19...

  • Page 4: Introduction

    inTroduCTion This appliance is a gas-fired direct vent hot water boiler with cast (sealed combustion) and does not compete with building occupants aluminum boiler sections. A revolutionary cast aluminum heat for fresh air. Sealed combustion (also known as “direct vent”) is the exchanger means better heat transfer and thermal storage than safest and best way to obtain plenty of clean combustion air.

  • Page 5: Boiler Ratings & Capacities

    Net I=B=R Rating Shipping Model Flue Dia. *(MBH) *(MBH) Weight (lbs.) *(MBH) 90-50 2” CPVC & PVC 90-75 2” CPVC & PVC 90-100 2” CPVC & PVC * 1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour...

  • Page 6: Boilers For Use At High Altitude

    Table #1 for natural gas applications and Table #2 for LP gas ap- plications. Instructions on how to adjust the gas manifold pressure settings are shown in Figures 17 & 18. TABLE #1: SERIES 90 NATURAL GAS SERIES 90-50 Stock Factory Btu Value of Natural Gas++ Settings...
  • Page 7 For model 90-75 LP units only at altitudes above 5,000 ft., install 90-75 high Altitude Orifice Kit #550001810*. For all other altitudes use factory installed orifice. TABLE #2: SERIES 90 PROPANE GAS SERIES 90-50 Stock Factory Btu Value of LP Gas++ Settings 2300...

  • Page 8: Rules For Safe Installation And Operation

    rules for safe insTallaTion and operaTion Read the entire installation manual before beginning the instal- Follow a regular service and maintenance schedule for efficient lation. Failure to follow these rules for safe installation and and safe operation. operation and these instructions could cause a malfunction Keep boiler area clean of debris and free of combustible and of the boiler and result in death, serious bodily injury, and/or flammable materials.
  • Page 9 before insTalling THe boiler In the event that the side wall horizontally vented gas Considerations for boiler location fueled equipment is installed in a crawl space or an attic, Before selecting a location for the boiler, the following should be the hard wired carbon monoxide detector with alarm and considered.
  • Page 10 before insTalling THe boiler Advise owner of boiler to keep venting and combustion air sphere, and all flue products are discharged to outside atmosphere. intake passages free of obstructions. both the venting and com- Combustion air and vent pipe connections must terminate together bustion air intake piping systems connected to the outdoors in the same atmospheric pressure zone, either through the roof must permit flow through the piping systems without restric-...

  • Page 11: Placing The Boiler

    before insTalling THe boiler moval of an existing boiler, the following steps shall be followed with Condensate drain requirements each appliance remaining connected to the common venting system Condensate drain line to be pitched down to floor drain at a mini- placed in operation, while the other appliances remaining connected mum of ¼”...

  • Page 12: Near Boiler Piping

    near boiler piping When the installation of the boiler is for a new heating system, first NOTICE install all of the radiation units (panels, radiators, baseboard, or tub- ing) and the supply and return mains. After all heating system piping The circulator pump and isolation valves are and components have been installed, make final connection of the furnished within a carton inside the boiler...
  • Page 13 near boiler piping figure 3 - multi-zone boiler piping With Zone Valves...
  • Page 14 near boiler piping figure 4 - multi-Zone boiler piping With Circulators NOTICE 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.
  • Page 15 near boiler piping figure 5 - single Zone boiler piping pressure relief Valve expansion Tank and make-up Water The boiler is furnished with a factory installed relief valve in the top Determine required system fill pressure, system design temperature, of the boiler. Provide ¾” piping from the supplied relief valve to a and system water content.
  • Page 16 near boiler piping figure 6 - diaphragm Type expansion Tank piping...
  • Page 17 near boiler piping figure 7 - Conventional (closed type) expansion Tank piping...
  • Page 18 near boiler piping figure 8 - Condensate drain piping Condensate drain piping filling Condensate Trap With Water The condensate trap is built into the boiler, an external trap is not On The Initial Start Up The Condensate Trap Must Be Manually required and should NOT be used.

  • Page 19: Combustion Air And Vent Pipe

    near boiler piping The boiler piping system of a hot water boiler connected to heat- Chilled Water piping ing coils is located in air handling units where they may be exposed The boiler, when used in connection with a refrigeration system, to refrigerated air circulation must be equipped with flow control must be installed so the chiller medium is piped in parallel with the valves or other automatic means to prevent gravity circulation of the...

  • Page 20: Combustion Air And Vent Piping Lengths

    CombusTion air and VenT pipe Combustion air and vent piping lengths: COMBUSTION AIR AND VENT PIPING LENGTHS BOILER 2” PIPE MINIMUM 2” PIPE MAXIMUM 3” PIPE MINIMUM 3” PIPE MAXIMUM SIZE VENTING VENTING VENTING VENTING 2 FEET 21 FEET 15 FEET 92 FEET 75 &...
  • Page 21 CombusTion air and VenT pipe figure 9 - roof Vent / intake terminations • Vent shall not terminate with 6 ft. (1.8m) of a mechanical air-supply inlet to any building. • Vent shall not terminate above a regulator within 3 ft. (900 mm) horizontally of the vertical centerline of the regulator vent outlet to a maximum vertical distance of 15ft (9.5m).
  • Page 22 CombusTion air and VenT pipe figure 10a - side Wall Vent / intake terminations - less Than 12” Clearance above grade Less Than 12” Clearance figure 10b - side Wall Vent / intake Terminations - 12” or more Clearance above grade 12”...
  • Page 23 CombusTion air and VenT pipe figure 11 - Combustion air and Vent piping...

  • Page 24: Gas Supply Piping

    CombusTion air and VenT pipe After pipes have been cut and pre-assembled, apply cement installation primer to pipe fitting socket and end of pipe to insertion mark. Attach combustion air intake piping to supplied Fernco 2” cou- Quickly apply approved cement to end of pipe and fitting pling on mixer.
  • Page 25 gas supply piping Checking The gas piping WARNING The boiler and its gas connection must be leak tested before placing Never use a match or open flame to test for the boiler in operation. Open the manual shutoff valve. Test for leaks leaks.

  • Page 26: Electrical Wiring

    eleCTriCal Wiring grounded ground rod. Connect Circulator pump Wiring WARNING See Figure 13 (following page) for service switch junction box and Turn off electrical power at fuse box before circulator pump field wiring connections. A 5 feet wiring harness making any line voltage connections. Follow with flexible metal conduit is supplied to connect the circulator local electrical codes.
  • Page 27 eleCTriCal Wiring figure 13 - field Wiring Connections...
  • Page 28 eleCTriCal Wiring figure 14 - d - schematic Wiring diagram 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...
  • Page 29 eleCTriCal Wiring figure 15 - e - ladder Wiring diagram 120 VOLT POWER SUPPLY ON/OFF SWITCH P7-2 P7-1 P7-3 P4-3 P4-1 P10-1 CIRCULATOR MOTOR P5-3 P5-1 P10-2 DRAFT INDUCER HOT SURFACE IGNITER P6-1 P12-1 P12-2 P6-2 P1-3 P1-1 TRANSFORMER P2-1 P2-2 CASTING TEMPERATURE SAFETY SWITCH...

  • Page 30: Controls And Accessories

    ConTrols and aCCessories This section provides a brief description of the key controls and NOTICE accessories found in this boiler. See the Troubleshooting section (page 47 of the of this installation The maximum setpoint of the Aquastat must not exceed 200 °F. manual) for detailed sequences of operation and troubleshooting procedures.

  • Page 31: Circulator Pump

    ConTrols and aCCessories draft inducer blocked Vent safety shutoff The draft inducer (blower) provides a means for pulling combustion This boiler is equipped with a blocked vent safety shutoff means, air into and through the mixer, the burner, the flue ways of the which shuts off main burner gas in the event that the flow of cast aluminum boiler sections and the flue adapter before being combustion products through the flueways is reduced.

  • Page 32: Water Treatment & Freeze Protection

    WaTer TreaTmenT & freeZe proTeCTion When filling the boiler water is the preferred heating solution. Most Cleaning the Hydronic system potable water supplies may be used to charge and re-fill provided the IMPORTANT: Do not mix different manufacturers’ chlorine and chloride ions levels are less than 100 ppm. products.
  • Page 33 WaTer TreaTmenT & freeZe proTeCTion If the system has leaked for some reason, the water and antifreeze freezing temperature needed and use the correct amount of anti- chemistry will need to be adjusted. To avoid damage to the boiler, freeze. Never exceed 50% antifreeze by volume. check the pH and chemistry of the boiler solution and consult the •...

  • Page 34: Start Up

    sTarT up filling boiler With Water and purging air for systems placing boiler in operation With diaphragm Type expansion Tanks WARNING Refer to the appropriate diagrams in Section VII, “Near Boiler Pip- ing, ” for more information. If you do not follow these instructions Close all zone service valves on the supply and return piping.

  • Page 35: Operating Instructions

    operaTing insTruCTions STOP! Read the safety information above on this label. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” Set thermostat to lowest setting. in the safety information above on this label.

  • Page 36: Check Out Procedure And Adjustment

    CHeCk ouT proCedure and adjusTmenT Verify proper sequence of operation The sequence can be followed via the diagnostic indicator lamps on the Honeywell S9301A integrated boiler control in Figure #16. This is the normal sequence of operation. A more detailed sequence of operation containing potential faults can be found in the service hints section.
  • Page 37 CHeCk ouT proCedure and adjusTmenT SEQUENCE OF OPERATION “DIAGNOSTIC INDICATOR LAMPS” A.  After pre purge, Lamp B goes out and Lamp C illuminates, in- dicating the hot surface igniter is powered for the 20 second B.  C.  igniter warm-up period.
  • Page 38 CHeCk ouT proCedure and adjusTmenT Set up U-tube manometer or differential pressure gauge for Test High limit Control and adjust measuring manifold pressure, see Figure #17. While burner is operating, move indicator on high limit control Manometer or gauge must be able to read at least 0.0 to 3.0 below actual boiler water temperature.
  • Page 39 CHeCk ouT proCedure and adjusTmenT The following steps and diagram indicate the location of the Refer to “CHECK OUT PROCEDURE AND ADJUSTMENTS” in connection points required to measure the manifold pressure. this manual when reading the manifold pressure. The manifold pressure may be measured using a U-Tube Manometer When measurement is completed, disconnect the U-Tube or a Differential Pressure Gauge.

  • Page 40: Installation And Check-Out Certificate

    insTallaTion and CHeCk-ouT CerTifiCaTe insTallaTion and CHeCk-ouT CerTifiCaTe Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________  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...

  • Page 41: Maintenance And Cleaning

    mainTenanCe and Cleaning Check that boiler area is free from combustible materials, Maintenance as outlined below can be performed by the gasoline, and other flammable vapors and liquids. owner unless otherwise noted. The acidic nature of flue gasses condensing on the aluminum boiler Circulator pump and blower motor furnished with boiler are permanently lubricated from factory and require no further sections will cause the formation of aluminum oxide.
  • Page 42 mainTenanCe and Cleaning NOTICE The following service procedures must be monthly during Heating season performed only by a qualified service agency. 1. Remove jacket front and top panels and check for piping boiler owner should not attempt these leaks around relief valve and other fittings. If found, contact procedures.
  • Page 43 mainTenanCe and Cleaning Inspection of the flue connector requires the following steps (Refer to Reinstall burner and mixer gasket and position mixer the repair parts diagram.) assembly over studs. Install five (5) nuts but do not tighten. Loosen the clamp on the draft inducer end of the 2” Reinstall igniter and igniter gasket and fasten with two flexible coupling that connects the vent tee to the draft (2) screws.

  • Page 44: Detailed Sequence Of Operation

    deTailed sequenCe of operaTion service Hints...
  • Page 45 deTailed sequenCe of operaTion DRAFT INDUCER TEMPERATURE SAFETy SwITCH CASTING TEMPERATURE SAFETy SwITCH IF DRAFT INDUCER TEMPERATURE REACHES IF BURNER OPERATES WHEN BOILER HAS NO TEMPERATURE SAFETY SWITCH SETPOINT, WATER, ALUMINUM BOILER SECTIONS HEAT UP SAFETY SWITCH CONTACTS OPEN IMMEDIATELY RAPIDLY.
  • Page 46 deTailed sequenCe of operaTion THERMOSTAT ENDS CALL FOR HEAT GAS VALVE AND CIRCULATOR PUMP ARE DE- ENERGIZED AND FLAME LIGHTS GO OUT BLOWER RUNS FOR 30 SECONDS POST PURGE PURGE LIGHT IS “ON” BLOWER IS DE-ENERGIZED FOR 30 SECONDS PURGE LIGHT SHUTS “OFF” BOILER STANDS BY FOR NEXT CALL FOR HEAT...

  • Page 47: Troubleshooting

    TroublesHooTing Troubleshooting tools: WARNING Voltmeter to check 120 vac and 24 vac Fire, explosion or shock hazard may cause Continuity tester. property damage, severe injury or death. Inclined manometer or pressure gauge with 0-2.0” Range Do not attempt to modify the physical or (0.01”...
  • Page 48 TroublesHooTing system status The indicator lights track the operating sequence. If the system locks out, the lights indicate the point in the sequence of operation where lockout occurs. LIGHT STATUS INDICATES IBC IS ENERGIzED THROUGH 24 VOLT TRANSFORMER. POwER IBC IS NOT ENERGIzED. BLINKING IBC RECEIVES MORE THAN 40 VAC IBC IS ENERGIzING THE DRAFT INDUCER AND AIR FLOW IS PROVEN.
  • Page 49 TroublesHooTing TroublesHooTing CHarT 1 WARNING 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 service technician.
  • Page 50 TroublesHooTing TroublesHooTing CHarT 2...
  • Page 51 TroublesHooTing TroublesHooTing CHarT 3 CHART 1 OPEN CHECK FOR VAC BLOWER STARTS BETWEEN TERMINALS 1 AND 3 REPLACE IBC AT CONNECTOR CN4 ON IBC CHECK FOR 120 VAC AT REPAIR/REPLCE BLOWER LEADS ON WIRING WIRING FROM IBC HARNESS TO BLOWER REPAIR/REPLACE BLOWER PRESSURE SWITCH...
  • Page 52 TroublesHooTing TroublesHooTing CHarT 4 CHART 3 CHECK FOR 120 VAC IGNITER/SENSOR WARMS BETWEEN TERMINALS 1 UP AND GLOWS AND 2 AT CONNECTOR YELLOW/ORANGE REPLACE IBC CN1 ON IBC (DURING DURING 20 SECOND IGNITER WARM UP) WARM UP CHECK FOR 120 VAC AT IGNITER/SENSOR LEADS REPAIR/REPLACE WIRING ON WIRING HARNESS...
  • Page 53 TroublesHooTing TroublesHooTing CHarT 5...
  • Page 54 TroublesHooTing TroublesHooTing CHarT 6 CHART 5 CHART 5 CHART 5 REPLACE GAS CONTROL. NO #3 NO #2 CHECK GAS ORFICICE SIZE. IS GAS ORIFICE SIZE CORRECT. CHECK REPAIR PARTS LIST FOR CORRECT SIZE. IS GAS ORIFICE CLEAR OF BLOCKAGE. RUNS FOR 25-50 SECONDS, THEN TURNS OFF.

  • Page 55: Differential Air Pressure Switch Check

    differenTial air pressure sWiTCH CHeCk What is system status? PRESSURE The following steps and diagram indicate the locations of the con- BOILER DIFFERENTIAL SwITCH nection points required to check the differential air pressure. STATUS PRESSURE (w.C.) CONNECTS The differential air pressure switch is a safety device which will Not Running 0”...
  • Page 56 85 Middle Rd. Dunkirk, NY 14048...

This manual is also suitable for:

90-7590-100

Table of Contents