Table of Contents
Related Manuals for Dunkirk DCBF-125
Summary of Contents for Dunkirk DCBF-125
- Page 1 CONDENSING GAS FIRED INSTALLATION, OPERATION & MAINTENANCE MANUAL Models DCBF-125, DCCF-150 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 240012564 REV. A [05/15/2019]...
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Page 2: Verify Contents Received
VERIFY CONTENTS RECEIVED Temperature Pressure G3/4 NPT Ball Gas Fully Assembled Boiler 30 PSI Safety Relief Valve Gauge (2" Shank) Shutoff Valve Includes Essential 4ea - 17x24x2" Gaskets Documents and Warranty 4ea - 1/2" AFM Gaskets 11x17 Wire Diagrams DHW Optional Pipe Used for Valve Connections Document Package Heat Only Boiler... -
Page 3: Table Of Contents
TABLE OF CONTENTS Verify contents received ..........2 9.12 Chimney Sweep Function (CO2 Adjust) ....9.13 Combustion Adjustment Function (CO2%) .... Table of contents ............3 9.14 Check Firing Rate ..........41 Physical Data..............4 9.15 Description Of Parameters: Factory Settings ..1 - Important Information ..........6 9.16 Adjusting Maximum Heating Power ...... -
Page 4: Physical Data
PHYSICAL DATA Dimensions DIMENSIONS 125 & 150 Height (Bottom of boiler top of safety Valve) 43.65" [1.09 m] Overall Width with Manifold 24.70" [628 mm] Depth 17.46" [444 mm] Condensate Trap Connection 3/4" NPT System Supply 11/4” Sweat Connection (125) (150) DHW Outlet (125 Optional) 3/4”... - Page 5 PHYSICAL DATA Top View All Models 10.44 in. [266 mm] 6.87 in. [175 mm] 18.56 in. [472 mm] 20.50 in. [521 mm] 24.70 in. [628 mm] Left Side View Front View Right Side View All Models All Models All Models 17.46 in.
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Page 6: Important Information
1 - IMPORTANT INFORMATION 1. Safety Information FOR YOUR SAFETY READ BEFORE OPERATING DANGER Boiler installation shall be completed by qualified agency. See glossary for additional information. WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. -
Page 7: Introduction
• DCCF-150 provide both central heating and domestic 2.1 Installation shall conform to requirements of authority hot water. having jurisdiction or in absence of such requirements: • DCBF-125 central heating only. UNITED STATES • Indoor installation. • National Fuel Gas Code, ANSI Z223.1/NFPA 54 •... -
Page 8: Component Listing
3 - COMPONENT LISTING DUNKIRK - DCBF 125 Dunkirk ITEM DCBF-125 Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator Boiler Drain Tap Heating Return Gas Inlet Optional Indirect Tank... - Page 9 3 - COMPONENT LISTING DUNKIRK DCCF-150 Dunkirk ITEM DCCF-150 Coaxial Connector Flue Sensor Heat Exchanger Burner (not shown) Flame Detection Electrode Air/Gas Blend Manifold Venturi Pump with Air Separator DHW Priority Sensor Flow Sensor with Water Filter and Flow Restrictor...
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Page 10: Locating Boiler
4 - LOCATING BOILER WARNING WARNING Fire Hazard! Do not install on carpeting. Failure to Fire, explosion, and asphyxiation hazard. Improper follow these instructions could result in death or installation could result in death or serious serious injury. injury. Read these instructions and understand all requirements before beginning installation. - Page 11 4 - LOCATING BOILER 4.3 Clearances TABLE 1: BOILER CLEARANCES Manufacturer Combustible Dimension Recommended for Materials Service (1)(2) 0" (0 cm) 8-5/8" (220 mm) Left Side 1-3/4" (45 mm) 12" (305 mm) Right Side 1-3/4" (45 mm) 1-3/4" (45 mm) Front 17-3/4"(450 mm) 0"...
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Page 12: Combustion Air And Vent Piping
5 - COMBUSTION AIR AND VENT PIPING • Support horizontal sections of vent pipe to prevent sags WARNING capable of accumulating condensate. Fire, explosion, and asphyxiation hazard. Improper • Assemble vent materials in accordance with venting installation could result in death or serious manufacturer’s instructions. -
Page 13: Definitions
5 - COMBUSTION AIR AND VENT PIPING Figure 5-1 - Venting Support 5.3 Definitions Coaxial piping – Exhaust and air intake pipe have a common axis. Twin Pipe – Exhaust and intake air are separate pipes, can be terminated using single wall terminals from the vent manufacturer or field built configuration using elbows or tees. -
Page 14: Approved Venting Materials
5 - COMBUSTION AIR AND VENT PIPING All piping, glue, solvents, cleaners, fittings and 5.4 Approved Venting Materials components must conform to ASTM and ANSI standards. In Canada ULC S636 and in the USA UL 1738 schedule 40 WARNING CPVC are the only approved vent system to be used as an Manufacturer recommends this condensing boiler be alternative to polypropylene venting for the exhaust pipe. -
Page 15: Coaxial Venting Instructions
5 - COMBUSTION AIR AND VENT PIPING 5.6 Coaxial Venting Instructions WARNING Maximum equivalent flue lengths for Coaxial venting are: Asphyxiation hazard. Before securing the screws Coaxial Pipe Vent Lengths ensure the pipe has been pushed in a minimum of (Includes first elbow and termination) 1-3/4"... - Page 16 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-4 Roof Mount Coaxial Venting FIGURE 5-6 Side Wall Coaxial Venting CAN BE USED ON ALL SIZES CAN BE USED ON ALL SIZES Maintain 12"(305 mm) US (18"(457 mm) Canada) clearance above highest anticipated snow level Anticipated 18"...
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Page 17: Twin Pipe Systems
5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-8 - 3"/ 80 mm Twin Pipe Separated WARNING Horizontal Flue Termination Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe Installation Instructions completely and understand all This requirements before beginning installation. -
Page 18: Securing Twin Pipe Polypropylene Venting
Figure 5-11 - Natalini Clamp WARNING Asphyxiation hazard! Improper installation could result in death or serious injury. Read Twin Pipe Installation Instructions completely and understand all requirements before beginning installation. NOTICE Venting manufacturer's use a device to secure single wall twin pipe polypropylene vent pieces to each other. - Page 19 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-14 - (2" / 50 mm & 3" / 80 mm) Twin Pipe 12" (305 mm) Min. horizontal separation Roof Vent CAN BE USED ON ALL SIZES between combustion air intake and vent of same appliance.
- Page 20 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-17 -( 3" / 80 mm ONLY) Twin Pipe Side FIGURE 5-20 - 2" /50 mm & 3" / 80 mm Vent Pipe Wall Vent (Multiple Appliances) with T CAN BE USED ON ALL SIZES This Note: 3"...
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Page 21: 3" /80 Mm Only) Flexible Vent System
5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-24 - (3" / 80 mm Only) Flexible Venting 5.10 (3" /80 mm Only) Flexible Vent System System CAN BE USED ON ALL SIZES Flexible Pipe Vent Lengths Boiler Size 125/150 3” [80 mm] Diameter Pipe Vent Size Vent Terminal Minimum... - Page 22 5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-25 - Flue Terminal Location All vent pipe and combustion air pipe and fittings shall comply with the following: Use only manufacturer approved venting materials or venting materials primer and glue approved to: ULC S636 in Canada, or UL 1738 in the U.S.
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Page 23: Condensate Piping
5 - COMBUSTION AIR AND VENT PIPING FIGURE 5-26 - Condensate Drain 5.11 Condensate Piping • Use materials acceptable to authority having jurisdiction. In absence of such authority: • USA - PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493. •... -
Page 24: Hydronic Piping
6 - HYDRONIC PIPING • It is necessary to semi-annually check the water quality of WARNING central heating systems. • Poison hazard. Ethylene glycol is toxic. Do not use • Manufacturer recommends installation of magnetic dirt ethylene glycol. separator in the hydronic system where there are cast iron or steel components, or where the previous boiler was a cast •... -
Page 25: Safety Relief Valve And Air Vent
6 - HYDRONIC PIPING FIGURE 6-1 Safety Relief Valve WARNING Safety Relief Burn and scald hazard. Safety relief valve could Valve discharge steam or hot water during operation. Use pipe suitable for temperatures of 375°F (191°C) or greater. DO NOT use plastic pipe. Install discharge piping per these instructions. - Page 26 6 - HYDRONIC PIPING FIGURE 6-2 - Piping Diagram - LWCO Location Arrange piping to prevent Note water dripping onto boiler. Illustrations are meant to Note show system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction.
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Page 27: External Optional Low Water Cut Off
6 - HYDRONIC PIPING 6.6 External Optional Low Water Cut Off FIGURE 6-3 - Low Water Cutoff - Detail These guidelines are supplied when necessary to install an additional Low Water Cut Off (LWCO), for sensing a low water level condition in a boiler, as required by the Authority Having Jurisdiction. - Page 28 6 - HYDRONIC PIPING 6.5 Manufacturer Recommendation - Strainer Potable water Potable water Manufacturer Recommendation Manufacturer strongly recommends the use of a strainer filtering potable water before entering the boiler. The strainer prevents any sedimentation and debris from your water supply piping from entering the boiler.
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Page 29: Central Heating System
The combustion fan will in turn modulate the gas rate accordingly. 6.8 Domestic Hot Water Mode • When the domestic hot water demand ceases the burner Dunkirk Boiler DCCF-150 and DCBF-125 with indirect will extinguish, unless there is a demand for central heating. WARNING Burn, Scald Hazard! Water temperature over 125°F... -
Page 30: Gas Supply Piping
Gas Supply Required appliance. Model Natural Gas (A) Liquid Propane (E) Do not use this boiler if any part has been under DCBF-125 118 ft3/h (3.30m3/h) 51 ft3/h (1.48m3/h) water. Call a qualified service technician before use. DCCF-150 143 ft3/h (4.00 m3/h) 61.15 ft3/h (1.72 m3/h) -
Page 31: Leak Check Gas Piping
7 - GAS SUPPLY PIPING Figure 7-1 - Gas Piping NOTICE Sediment trap shall be located upstream of gas controls. NOTICE If overheating occurs or gas supply fails to shut off, do not turn off or disconnect electrical supply to pump. Shut off gas supply at location external to the boiler. -
Page 32: Electrical Connections
8 - ELECTRICAL CONNECTIONS DANGER Model Size Power Supply 120V - 60Hz Electrocution Hazard! HIGH VOLTAGE - Connections in terminal block M1 are high voltage (120V / 60Hz). 133 W 142 W Power Consumption Before making connections, verify appliance is Internal Fuse (Qty. -
Page 33: Access To Connection Block
Place jumper back on terminals 1-2 of boiler terminal block Terminals 9 - 10: Indirect storage tank connection for M1 if room thermostat is not used or if Remote Control is Dunkirk Models DCBF-125. not installed. 240012564 REV A, [05/15/2019]... -
Page 34: Install Room Thermostat
8 - ELECTRICAL CONNECTIONS FIGURE 8-4 Thermostat Connections 8.6 Install Room End Switch Install room end switch on inside wall. Do not install where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, sun rays or near a fireplace. Dry contact only - do not apply 24 volts between 6 and 7. -
Page 35: Indirect Storage Tank
8 - ELECTRICAL CONNECTIONS 8.8 Indirect Storage Tank Boilers DCBF-125 can be electrically connected to indirect storage tank as follows: 10K Ω • Connect DHW priority sensor NTC to terminals 9-10 on terminal block M2. 10K Ω • Insert NTC sensor element in the sensor well of indirect storage tank. -
Page 36: Start Up Procedure
9 - START UP PROCEDURE 9.1 Central Heating System Connections - Heat Only 9.2 Central Heating System Connections - Combi DCBF-125 HEATING ONLY DCCF-150 COMBI WITH OPTIONAL INDIRECT DHW CONNECTION DCBF-125 HEATING ONLY WITHOUT OPTIONAL INDIRECT LEGEND DHW CONNECTION 11/4” sweat... -
Page 37: System Start Up
9 - START UP PROCEDURE FIGURE 9-1 Condensate Drain Assembly 9.3 System Start Up Follow all codes and regulations when filling the boiler. Use drain taps to allow system to completely drain. Thoroughly flush the heating system before boiler is connected Pour and again after first heating season. -
Page 38: Control Panel
9 - START UP PROCEDURE 9.5 Control Panel Press and hold for 1 second, to display information as shown in the table below. Press to exit. DESCRIPTION DESCRIPTION Secondary fault internal code Setpoint Central Heating (°F/°C) 10/11 Heating flow temperature (°F/°C) Manufacturing information Outdoor temperature (°F/°C) Flue sensor temperature (°F/°C) -
Page 39: Prior To Commissioning
9 - START UP PROCEDURE Boiler must not shutoff during calibration. NOTICE Note Open all heating zones in heating or DHW mode to ensure boiler does not shutoff. All connections shall be made and water added before performing this function. 9.8 Automatic Calibration Function Before performing this function verify there are no heat NOTICE... -
Page 40: Manual Calibration Function
9 - START UP PROCEDURE FIGURE 9-3 - Gas Inlet Tap - Pi 9.9 Manual Calibration Function: Manual Calibration phase starts at the end of the Automatic Calibration. The Display shows the boiler power and adjustment of the CO2 value (parameter setting) during Manual Calibration sequence. -
Page 41: Chimney Sweep Function (Co2 Adjust)
) in the combustion flue must be within tolerances indicated in table below. COMBUSTION TABLE Gas A Gas A (Natural Gas) (Natural Gas) Gas E (LPG) DCBF-125 DCCF- 150 CO2 % O2 % CO2 % O2 % CO2 % O2 % Nominal value 10.0... -
Page 42: Description Of Parameters: Factory Settings
9 - START UP PROCEDURE For Natural Gas : Table 9-2 Input Rate @ High Fire (MBH) 3600 x cu ft Input (MBH) seconds Approximate Rate @ Example: Natural Gas - Gas flow from 100% Fire (MBH) Meter = 2 cu ft Size Measured time = 72 seconds 3600 x 2 cu ft... - Page 43 9 - START UP PROCEDURE FACTORY SETTINGS 9.16 Description Of Parameters: Factory Settings conti. Outdoor temperature sensor input configuration 00= with outdoor temperature sensor connected, external temperature value has influence to calculate heating flow temperature set-point 01= with outdoor temperature sensor connected, display shows external temperature value (no influence) 02…05 = no function is associated 00..02 = No function is associated 03 = This is an input contact for CH request (e.g.
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Page 44: Adjusting Maximum Heating Power
9 - START UP PROCEDURE 9.17 Adjusting Maximum Heating Power Maximum boiler heating power can be reduced to suit requirements of heating system it serves. Table showing parameter P13 values according to desired maximum power model is shown for each single boiler. To access and edit P13 values, proceed as described in Section 9.15 Parameter Settings. -
Page 45: Operating Instructions
10 - OPERATING INSTRUCTIONS 10.3 Central Heating Mode FOR YOUR SAFETY READ BEFORE OPERATING With demand for heating, pump circulates water through WARNING the primary circuit. Combustion fan comes on at ignition speed, closing the air If you do not follow these instructions exactly, pressure switch, allowing power to spark generator and a fire or explosion may result causing property gas valve, creating ignition in the combustion chamber. -
Page 46: General Maintenance And Cleaning
11 - GENERAL MAINTENANCE AND CLEANING • Circulator pump and combustion air blower motor furnished DANGER with boiler are permanently lubricated from factory and require no further lubrication. Lubricate field sourced Before servicing, turn off electrical power to boiler at pumps and/or motors according to pump and/or motor service switch. -
Page 47: Maintenance And Routine Servicing
11 - GENERAL MAINTENANCE AND CLEANING 11.2 Maintenance And Routine Servicing WARNING Check and service boiler as necessary. Following service procedures must be performed by Frequency of servicing will depend upon installation qualified service agent. Boiler owner shall not attempt conditions and usage, manufacturer recommends annually. -
Page 48: Draining The Boiler
11 - GENERAL MAINTENANCE AND CLEANING DANGER Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury. 11.4 Draining the Boiler •... -
Page 49: Hydraulic Unit (Dhw)
11 - GENERAL MAINTENANCE AND CLEANING 11.6 Hydraulic Unit (DHW) Model DCCF-150 For special areas, where water is harder than 200 ppm or 12 grains/ gallon, install polyphosphate dispenser or equivalent treatment system, compliant with current regulations. 11.7 Cleaning The Cold Water Filter Boiler is fitted with cold water filter located on DHW hydraulic assembly (B). -
Page 50: User Information
11 - GENERAL MAINTENANCE AND CLEANING 11.10 User Information 11.13 Replacement Parts Advise and demonstrated to User the following important Perform Automatic Calibration procedure described in section information: 9.8 if one or more of the following components are replaced. Check and adjust CO2% value as indicated in the Combustion A. -
Page 51: Ratings And Capacities
95.0 2,000-4,500 ft (600m-1350m) DCCF-150 95.0 Max CH Supply temp 176° F (80° C) for DCBF-125 and DCCF-150 **DCCF-150 Max DHW Flow rate 3.5 gpm (13.2 l/min) Max DHW temp 140° F (60° C) 12.4 High Altitude Chart Natural Altitude Model 0-2,000 ft. -
Page 52: Trouble Shooting
13 - TROUBLE SHOOTING 13.1 Error Messages And Resetting The Boiler Error Description Operation Gas valve connection fault Check cable PCB/gas valve and gas valve plug Outdoor sensor fault Check sensor and cable Verify all cables. Replace PCB. Gas valve command fault Call authorized SERVICE center Central Heating NTC sensor fault Check sensor and cable... - Page 53 13 - TROUBLE SHOOTING 13.1 Error Messages and Resetting the Boiler - continued Error Description Operation Check pressure switch and cable. Flue pressure switch (contact open) Check obstruction on flue pipe 164/384 Fault flame (parasitic flame). Check correct operation of T. gas valve. 165/385 Input voltage too low.
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Page 54: Anomalies Table For The Installer - Use This Table To Report The Anomaly Values
13 - TROUBLE SHOOTING 13.2 Anomalies Table for the Installer - Use this table to report the anomaly values. SYSTEM STATUS CODES 0 STANDBY 1 DHW "ON" 2 CHIMNEY SWEEP ACTIVE 3 CH "ON" 4 PREHEAT "ON" 5 CH NO FROST "ON" 6 DHW NO FROST "ON"... -
Page 55: Glossary
14 - GLOSSARY • APPLIANCE - Device to convert gas into energy; term • DIRECT VENT BOILER - Boiler constructed and installed so includes any component, control, wiring, piping or tubing all combustion air is derived directly from outdoors and all required to be part of the device. - Page 56 14 - GLOSSARY • METRIC GAS METERS • TWO PIPE SYSTEM - Type of venting that allows for exhaust flue and intake air piping to be separated from each Natural Gas other. Fresh air may be drawn in at a different area from 127,116 x cu meters where flue terminal is located.
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Page 57: Appendix A - Wiring Diagrams
APPENDIX A - WIRING DIAGRAMS A-1 MODELS 125 - Heat Only 240012564 REV A, [05/15/2019]... -
Page 58: Appendix A - Wiring Diagrams
APPENDIX A - WIRING DIAGRAMS A-2 MODELS 150 - Combi 240012564 REV A, [05/15/2019]... - Page 59 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 60 IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. 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.