ECR International Dunkirk Q95M-200 Installation Manual
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ECR International Dunkirk Q95M-200 Installation Manual

Gas-fired direct vent modulating hot water boiler
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Q95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
DUNKIRK BOILERS
An ISO 9001-2000 Certified Company
85 Middle Rd.
Dunkirk, NY 14048
P/N 240006103D, Rev. B [06/08]
www.dunkirk.com

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Summary of Contents for ECR International Dunkirk Q95M-200

  • Page 1 Q95M-200 GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER DUNKIRK BOILERS An ISO 9001-2000 Certified Company 85 Middle Rd. Dunkirk, NY 14048 P/N 240006103D, Rev. B [06/08] www.dunkirk.com...

  • Page 2: Table Of Contents

    GaS-fIRED DIRECT vENT mODULaTING hOT waTER BOILER INSTaLLaTION maNUaL Printed in USA • Made In USA TaBLE Of CONTENTS I - INTRODUCTION This appliance is a gas-fired direct vent modulating cast I - Introduction.............2 aluminum hot water boiler. A revolutionary cast aluminum II - Safety Symbols and Warnings ......3 monoblock heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers,...

  • Page 3: Safety Symbols And Warnings

    II - SafETy SymBOLS aND waRNINGS The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. DANGER CAUTION Indicates a potentially hazardous situation ndicates an imminently hazardous situation which, if not avoided, could result in minor or which, if not avoided, will result in death, moderate injury or property damage .

  • Page 4: Boiler Ratings And Capacities

    Iv - BOILER RaTINGS aND CaPaCITIES This boiler and related hot water heating sys- sure The Natural Gas Input Rate” in Section VII tems are not do-it-yourself items. They must be of the Control Manual and Operating Instructions installed and serviced by qualified profession- (P/N# 240006104) to determine the proper rate als.

  • Page 5: Before Installing The Boiler

    v - BEfORE INSTaLLING ThE BOILER Review the following before installing the boiler Installation of carbon monoxide detectors: This boiler product is a gas-fired, direct vent, condensing the time of installation of the side wall horizontal vent- boiler and must be installed in accordance with all appli- ed gas fueled equipment, the installing plumber or cable federal, state and local building codes including, but gasfitter shall observe that a hard wired carbon mon-...
  • Page 6 v - BEfORE INSTaLLING ThE BOILER A product-ap- • Supplied with a suitable electrical supply for all Product-approved vent/air intake: proved vent terminal must be used and, if applicable, a boiler motors and controls. product-approved air intake must be used. Installation •...
  • Page 7 v - BEfORE INSTaLLING ThE BOILER Equipment shall be installed in a location which fa- Figure 2 - Sidewall Vent/Intake Terminations cilitates the operation of venting and combustion air intake piping systems as described in this manual. OVERHANG 12" MINIMUM Advise owner of boiler to keep venting and combus- tion air intake passages free of obstructions.
  • Page 8 v - BEfORE INSTaLLING ThE BOILER NOTE: IF THERE IS A POTENTIAL FOR EXCESSIVE WINDS, SPECIAL CONSIDERATION SHOULD BE GIVEN TO LOCATE THE VENT TERMINATION AWAY FROM THE WINDWARD SIDE OF THE BUILDING. 12” MOUNT VENT TERMINATION AT LEAST 3 FT (92 CM) FROM INSIDE CORNERS VENT TERMINATION MUST BE AT LEAST 12”...
  • Page 9 v - BEfORE INSTaLLING ThE BOILER CAUTION WARNING Keep boiler area clean of debris and failure to follow these warnings could result in free of flammable and combustible fire, property damage, personal injury, or death. materials, vapors, and liquids. • Locate combustion air inlet as far away as possible from swimming pool and swim- ming pool pump house.
  • Page 10 v - BEfORE INSTaLLING ThE BOILER foundation Requirements Figure 5 - Concentric Vent Roof Installation Boiler must be placed on level surface. Boiler is NOT to be installed on carpeting. NOTES: If boiler is not level condensate drain lines will not function properly.

  • Page 11: Placing The Boiler

    v - BEfORE INSTaLLING ThE BOILER standards. When resizing any portion of the common Place in operation the appliance being inspected. Fol- venting system, the common venting system should be low the lighting instructions. Adjust thermostat so appli- resized to approach the minimum size as determined ances will operate continuously.

  • Page 12: Near Boiler Piping

    vII - NEaR BOILER PIPING ImPORTaNT: For piping examples using the Gas-Fired Direct Vent Modulating Hot Water Boiler, see the Piping Appendix in Section XVI of this manual. CAUTION and per local codes. If a pressure reducing valve is used, adjust to match the system fill pressure.
  • Page 13 vII - NEaR BOILER PIPING A condensate pump with a reservoir (not furnished) Pressure Relief valve / Temperature Pressure Gauge may be used to remove condensate to a drain line The boiler is furnished with a relief valve in the boiler parts (sanitary line) above boiler if a floor drain is not avail- bag.

  • Page 14: Combustion Air And Vent Pipe

    vIII - COmBUSTION aIR aND vENT PIPE Connections & Terminations For boilers connected to gas vents or chimneys, vent in- Combustion and vent Piping Length stallations shall be in accordance with Venting Require- maximum allowable Temperatures TaBLE #4 ments of the National Fuel Gas Code, ANSI Z223.1-latest Of Typical Non-metallic vet material revision, CSA-B149.1 and B149.2, and applicable provi- material...
  • Page 15 vIII - COmBUSTION aIR aND vENT PIPE ture. Termination of the vent should be kept at least 3’ air supply pipe must terminate at the same location as the away from vegetation. The venting system shall termi- exhaust pipe. nate at least 4’ horizontally from, and in no case above Reduce the maximum vent length by 5’...

  • Page 16: Gas Supply Piping

    vIII - COmBUSTION aIR aND vENT PIPE Wipe excess cement from joint. A continuous bead of NOTE: It is recommended that all pipes be cement will be visible around perimeter of a properly cut, prepared, and pre-assembled before per- made joint. manently cementing any joint.
  • Page 17 IX - GaS SUPPLy PIPING Use pipe joint compound suitable for liquefied petro- Connecting the Gas Piping leum gas on male threads only. Refer to figure 9 for the general layout at the boiler, which shows the basic fittings you will need. As shipped, Use ground joint unions.

  • Page 18: Electrical Wiring

    X - ELECTRICaL wIRING ImPORTaNT: Wiring diagrams for the Gas-Fired Direct Vent Modulating Hot Water Boiler can be found in Section XIV of this manual. Low voltage Connections WARNING Connect low voltage wiring to low voltage terminal for your safety, turn off electrical power strip as shown in the boiler wiring diagram.

  • Page 19: Controls And Accessories

    XI - CONTROLS aND aCCESSORIES This section provides a brief description of the key controls haust vent where the combustion products are discharged and accessories found in this boiler. See the Repair Parts to the outdoors. The blower is designed to communicate Manual (P/N# 240006107) for illustrations and the Control with the modulating control to run at variable speeds de- Manual and Operation Instructions (P/N# 240006104) for...
  • Page 20 XI - CONTROLS aND aCCESSORIES Normally Closed LwCO Switch Taco Pump Curve This round button switch located next to the digital dis- play is normally closed and spring loaded so that, when depressed, it opens, and closes again when pressure is removed.
  • Page 21 XI - CONTROLS aND aCCESSORIES on Cam Vent at the heat exchanger) before reset- aSmE Rated Pressure Relief valve ting this switch. Each boiler must have a properly sized and installed WARNING American Society of Mechanical Engineers (ASME) rat- ed pressure relief valve. Water expands as it is heated Never run cold water into a hot, empty boiler.

  • Page 22: Water Treatment & Freeze Protection

    XII - waTER TREaTmENT & fREEZE PROTECTION When filling the boiler water is the preferred heating solution. Most • Maintain water hardness below 7 grains hardness. potable water supplies may be used to charge and re-fill provided • Filling with chlorinated fresh water should be acceptable the chlorine and chloride ions levels are less than 100 ppm.
  • Page 23 XII - waTER TREaTmENT & fREEZE PROTECTION freeze Protection NOTICE aluminum Safe antifreeze, Treatments and additive Antifreeze solutions can breakdown over time. Failure to Guidelines: check antifreeze chemistry, including inhibitors, annually Antifreeze, if required, must be one of the antifreeze manufac- may result in accelerated corrosion of boiler and other sys- turers listed in this manual.
  • Page 24 Testing Services: Each of the recommended antifreeze manufacturers have developed a sampling pro- gram available to the homeowner and contractor. Contact the antifreeze manufacturer regarding their sampling plan procedure. Consult the antifreeze manufacturer for details on sample requirements and recommendations. ECR International reserves the right to make changes without notice.

  • Page 25: Putting The Boiler In Operation

    XIII - PUTTING ThE BOILER IN OPERaTION free. Close the zone service valve. filling boiler with water and purging air (For each of the following systems, refer to the Repeat step 2 for all remaining zones. appropriate piping diagrams in the Installation Open the expansion tank service valve and the tank Manual P/N# 240006103.) vent.
  • Page 26 XIII - PUTTING ThE BOILER IN OPERaTION CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switches; do not use any phones in your building. • Immediately call your gas supplier from a neigh- bor’s phone.

  • Page 27: Maintenance And Cleaning

    XIv - maINTENaNCE aND CLEaNING Circulator pump and blower fan motor furnished with The acidic nature of flue gases condensing on the alumi- boiler are permanently lubricated from the factory and num boiler sections will cause the formation of aluminum require no further lubrication.
  • Page 28 XIv - maINTENaNCE aND CLEaNING If heating system is to remain out of service during CAUTION freezing weather and does not contain antifreeze, Debris rinsed away by this method will exit drain system completely. If boiler will be exposed to through the condensate drain.

  • Page 29: Boiler Wiring Diagram

    Xv - BOILER wIRING DIaGRam...

  • Page 30: Piping And Wiring Appendix

    XvI - PIPING aND wIRING aPPENDIX Basic Wiring Diagram BOILER CONTROL PANEL CH T1 120 VAC T-STAT CH T2 CH C1 DHW T1 CH C2 DHW T2 DHW C1 DHW C2 CIRC OUTDOOR AIR SENSOR Note: The CH & DHW Circulator connections on the boiler will only support a pump with a 1 amp rating or less.
  • Page 31 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 1 CH CIRCULATOR WATER INLET EXPANSION TANK CIRCULATOR BOILER PRIORITY ZONE PRESSURE BALL VALVE CIRCULATOR HOSE BIB REDUCER VALVE AIR SEPARATOR FLOW CONTROL SHUT-OFF ZONE VALVE VAVLE CHECK VALVE VALVE Single Zone system with domestic hot water priority NOTE: NOT RECOmmENDED fOR aNTIfREEZE aPPLICaTIONS Wiring Diagram 1 Hotline indirect water heater...
  • Page 32 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 2 ZONE 4 ZONE 3 ZONE 2 CH & DHW SYSTEM CIRCULATOR ZONE 1 (PRIORITY ZONE) WATER INLET *USE FULL PORT ZONE BOILER VALVE. FOR OPTIMUM TANK EXPANSION PERFORMANCE, CONSIDER TANK USING ZONE CIRCULATOR (SEE FIGURE 5) FLOW CONTROL PRESSURE...
  • Page 33 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 2 SWITCH LEGEND INDIRECT WATER TANK HEATER AQUASTAT CONTROL OR THERMOSTAT T-STAT T-STAT ARGO AZ-4CUP CONTROL Yellow 24VAC Yellow STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP ZONE VALVE/PUMP X-X CONTACT ZR ON PRIORITY ZC ON ZR-ZC...
  • Page 34 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 3 ZONE 4 ZONE 3 *USE FULL PORT ZONE VALVE. ZONE 2 CIRCULATOR ZONE 1 (PRIORITY ZONE) WATER INLET CIRCULATOR BOILER EXPANSION TANK PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE FLOW CONTROL SHUT-OFF ZONE VALVE CHECK VALVE...
  • Page 35 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 3 SWITCH LEGEND INDIRECT WATER TANK HEATER AQUASTAT CONTROL OR THERMOSTAT T-STAT T-STAT ARGO AZ-4CP CONTROL Yellow 24VAC Yellow STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP ZONE VALVE/PUMP X-X CONTACT ZR ON PRIORITY ZC ON ZR-ZC...
  • Page 36 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 4 ZONE 4 CIRC 4 ZONE 3 CIRC 3 ZONE 2 CIRC 2 ZONE 1 (PRIORITY ZONE) DHW CIRCULATOR WATER INLET EXPANSION TANK BOILER PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE SHUT-OFF ZONE VALVE FLOW CONTROL...
  • Page 37 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 4 Hotline indirect water heater aquastat or thermostat NOTE: IN PLACE OF 115 T-STAT VOLT ISOLATION RELAY, T-STAT OPTIONAL CONTROL T-STAT ARGO AR822II THERMOSTATS TERMINAL 5 & 6 N.O. DATA PORT PRIORITY ZONE 2 ZONE 3 ZONE 4...
  • Page 38 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 5 ZONE 4 CIRC 4 ZONE 3 CIRC 3 ZONE 2 CIRC 2 ZONE 1 (PRIORITY ZONE) CIRCULATOR 12" MAX APART (TO PREVENT FORCED FLOW IN SECONDARY) WATER INLET CH & DHW EXPANSION BOILER TANK...
  • Page 39 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 5 INDIRECT HOT WATER HEATER AQUASTAT OR THERMOSTAT NOTE: IN PLACE OF 115 VOLT ISOLATION RELAY, OPTIONAL CONTROL ARGO AR822II TERMINAL 5 & 6 N.O. TO DHW T1 & DHW T2 T-STAT TORQUE TERMINAL AR822-TT SCREWS...
  • Page 40 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 6 ZONE 4 ZONE 3 ZONE 2 ZONE 1 (PRIORITY ZONE) *USE FULL PORT ZONE VALVE. FOR OPTIMUM TANK PERFORMANCE, CONSIDER USING ZONE CIRCULATOR (SEE FIGURE 13) SYSTEM CIRCULATOR 12" MAX APART (TO PREVENT FORCED FLOW IN SECONDARY) WATER INLET...
  • Page 41 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 6 INDIRECT WATER SWITCH LEGEND TANK HEATER AQUASTAT CONTROL OR THERMOSTAT T-STAT T-STAT ARGO AZ-4CP CONTROL Yellow Yellow STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP ZONE VALVE/PUMP X-X CONTACT ZR ON PRIORITY ZC ON ZR-ZC Black...
  • Page 42 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 7 *USE FULL PORT ZONE ZONE 4 VALVE. ZONE 3 ZONE 2 CH CIRCULATOR ZONE 1 (PRIORITY ZONE) DHW CIRCULATOR 12" MAX APART (TO PREVENT FORCED FLOW IN SECONDARY) WATER INLET BOILER EXPANSION CIRCULATOR TANK...
  • Page 43 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 7 INDIRECT WATER HEATER AQUASTAT SWITCH LEGEND TANK OR THERMOSTAT CONTROL T-STAT T-STAT ARGO AZ-4CP CONTROL Yellow Yellow STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP ZONE VALVE/PUMP X-X CONTACT ZR ON PRIORITY ZC ON ZR-ZC Black...
  • Page 44 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 8 TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE SHUT-OFF 3 WAY MIXING CHECK VALVE HOSE BIB VALVE VALVE Bypass piping (automatic mixing valve) Piping Diagram 9 FROM SYSTEM TO SYSTEM...
  • Page 45 XvI - PIPING aND wIRING aPPENDIX Piping Diagram 10 TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE 4-WAY MIXING SHUT-OFF FLOW CONTROL CHECK VALVE VALVE HOSE BIB VALVE VALVE Bypass piping (4-way valve option with circulator on supply) Piping Diagram 11...
  • Page 46 XvI - PIPING aND wIRING aPPENDIX Wiring Diagram 8: Multiple Boiler Wiring (AMB-4) AMB-4 WATER SENSOR OUTSIDE SENSOR IF USING EXTERNAL DAY/NIGHT FEATURE CONNECT HERE (DRY CONTACT) IF USING REQ/ACK CONNECT HERE (TT/THERMOSTAT DRY CONTACT) TO PRIORITY IF USING (DRY CONTACT) CH T1 CH T2 DWH T1...
  • Page 47 NOTES _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________ _____________________________________________________________...
  • Page 48 SERvICE RECORD 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...

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