Dunkirk Q95M-200 Installation, Operation & Maintanance Manual
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Dunkirk Q95M-200 Installation, Operation & Maintanance Manual

Gas-fired direct vent modulating hot water boiler
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Q95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTANANCE MANUAL
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www.dunkirk.com
An ISO 9001-2000 Certified Company
P/N 240006103D, Rev.C [04/2009]
R

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Summary of Contents for Dunkirk Q95M-200

  • Page 1 Q95M-200 GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER INSTALLATION, OPERATION & MAINTANANCE MANUAL DUNKIRK BOILERS 85 Middle Rd. Dunkirk, NY 14048 www.dunkirk.com An ISO 9001-2000 Certified Company P/N 240006103D, Rev.C [04/2009]...

  • 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 I - Introduction ............2 III - Rules For Safe Installation and Operation ..3 This appliance is a gas-fired direct vent modulating cast aluminum IV - Boiler Ratings and Capacities ......4 hot water boiler.

  • Page 3: Rules For Safe Installation And Operation

    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 an imminently hazardous situation which, if not Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial avoided, may result in injury or property damage.

  • Page 4: Boiler Ratings And Capacities

    iv - boiler ratinGs and capacities TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES Boiler Input Rate Heating Capacity Net I=B=R Rating (MBH) AFUE Flue Diameter Shipping (1)(2) (MBH) (MBH) High Fire 2” CPVC & 3” PVC 284 lbs. Low Fire 1 MBH = 1,000 BTUH (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
  • Page 5 v - before installinG the boiler less than seven (7) feet above finished grade in the area of the vent- the installation. ing including but not limited to, decks and porches, the following requirements shall be satisfied: boiler sizing Installation of carbon monoxide detectors: At the time •...
  • Page 6 v - before installinG the boiler The clearances shown in Table 3 indicate required clearances per CSA listing. A minimum 1” clearance must be maintained between combustible construction and each of the right, top and back surfaces of the boiler. Allow at least 24” at the front figure 1 - roof vent/intake terminations and left side and 8”at the top for servicing.
  • Page 7 v - before installinG the boiler If the concentric vent termination is being used, refer to Figure 3 for proper setup. figure 3 - concentric vent terminations VENT COMBUSTION AIR figure 3a - clearances to other residential features 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.
  • Page 8 v - before installinG the boiler When utilizing two or more boilers, each termination must have at least 12 inches of clearance from any adjacent termination. See diagrams below. OVERHANG 12" MINIMUM 12" MINIMUM 12" SEPARATION 12" BETWEEN BOTTOM OF MINIMUM COMBUSTION AIR INTAKE AND BOTTOM OF VENT...
  • Page 9 v - before installinG the boiler condensate drain requirements figure 4 - concentric vent w/ dimensions At the rear of the unit a ½” PVC pipe nipple with NPT threads is provided for the attachment of the condensate drain line. Attach Concentric Vent w/Dimensions the ½”...

  • Page 10: Placing The Boiler

    v - before installinG the boiler exhaust fan. Close fireplace dampers. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Place in operation the appliance being inspected. Follow the Code, NFPA-54/ANSI -Z223.1-latest revision, or section 5 of lighting instructions.
  • Page 11 vii - near boiler pipinG pressure relief valve / temperature pressure Gauge The boiler is furnished with a relief valve in the boiler parts bag. Pro- figure 6 - diaphragm type expansion tank piping vide ¾” piping from the supplied relief valve to a local floor drain, but leave an air gap between piping and drain.

  • Page 12: Combustion Air And Vent Pipe

    vii - near boiler pipinG Excess water should go through the overflow and out through must be installed so the chiller medium is piped in parallel with the of the drain boiler with appropriate valves to prevent the chilled medium from the condensate drain line.
  • Page 13 viii - combustion air and vent pipe should be taken to prevent building materials at the vent figure 8 - combustion air & vent piping from being damaged by exhaust of flue gas. 3” INTAKE AND EX- FIELD INSTALL 2” BY 3” The venting system shall terminate at least 3’...

  • Page 14: Gas Supply Piping

    viii - combustion air and vent pipe While cement is still wet, insert pipe into socket with a ¼ turn NOTICE twist. Be sure pipe is fully inserted into fitting socket. NOTE: It is recommended that all pipes be cut, prepared, Wipe excess cement from joint.

  • Page 15: Electrical Wiring

    iX - Gas supply pipinG Use pipe joint compound suitable for liquefied petroleum gas on male threads only. figure 9 - Gas piping Use ground joint unions. Install a sediment trap upstream of gas controls. Use two pipe wrenches when making the connection to the gas valve to keep it from turning.
  • Page 16 X - electrical wirinG Route all wires and conduits to the openings in the right jacket low voltage connections panel. Connect low voltage wiring to low voltage terminal strip as shown in the boiler wiring diagram. line voltage monitor Route all low voltage wires through opening on the right This boiler is factory equipped with a line voltage monitor that and jacket panel.

  • Page 17: Controls And Accessories

    Xi - controls and accessories This section provides a brief description of the key controls and modulating blower accessories found in this boiler. See the Repair Parts Manual The modulating blower provides a means of introducing the gas/ (P/N# 240006107) for illustrations and the Control Manual and air mixture through the burner and into the combustion chamber Operation Instructions (P/N# 240006104) for a detailed sequence where combustion can begin and then out the exhaust vent where...
  • Page 18 Xi - controls and accessories condition. The LWCO senses water through a probe at the top before resetting this switch. of the boiler that sends a signal through the water to ground. If the signal is not sensed through the ground, the LWCO enters taco pump curve a lockout mode that disables the appliance.

  • Page 19: Water Treatment & Freeze Protection

    Xi - controls and accessories asme rated pressure relief valve WARNING Each boiler must have a properly sized and installed American Never run cold water into a hot, empty boiler. Society of Mechanical Engineers (ASME) rated pressure relief valve. Water expands as it is heated by the burner/boiler sections. If there is no place for the water to expand its volume, (i.e., a properly sized circulator pump and properly functioning expansion tank) pressure on the inside...
  • Page 20 Xii - water treatment & freeze protection leak will become obvious if boiler pressure decreases when Measure total capacity of the system including the piping, tanks, make up valve is closed. boiler, collector plates, etc. The most accurate method of mea- suring fluid capacity is to fill the system and then completely •...
  • Page 21 Xii - water treatment & freeze protection • Using the antifreeze manufacturer’s instructions to deter- NOTICE mine the freezing temperature needed and use the correct amount of antifreeze. Never exceed 50% antifreeze by Antifreeze solutions can breakdown over time. Failure to volume.

  • Page 22: Putting The Boiler In Operation

    Xiii - puttinG the boiler in operation filling boiler with water and purging air NOTICE NOTE: Do not use stop leak compounds. Leaks in For each of the following systems, refer to the appropriate piping threaded connections in the aluminum boiler sections diagrams in the Installation Manual must be repaired immediately.

  • Page 23: Xiv- Maintenance And Cleaning

    Xiii - puttinG the boiler in operation operatinG instructions NOTICE STOP! Read the safety information above before operating this appliance. Set the thermostat to the lowest setting. Turn off all electrical power to the appliance. This appliance does not have a pilot. It is equipped with an igni- Control Valve “ON”...
  • Page 24 Xiv - maintenance and cleaninG and Freeze Protection section of manual 240006104. annual examination and cleaning of boiler components Check that boiler area is free from combustible materials, gaso- line, and other flammable vapors and liquids. WARNING Circulator pump and blower fan motor furnished with boiler are permanently lubricated from the factory and require no The following service procedures must be performed by further lubrication.
  • Page 25 Xiv - maintenance and cleaninG ened sediment using a shop vacuum with a snorkel attach- ment. • Inspect burner for any foreign matter in the flame ports or inside the burner. Any foreign matter should be removed by blowing with compressed air or vacuuming. If the burner cannot be cleaned, it must be replaced.

  • Page 27: Boiler Wiring Diagram

    Xv - boiler wirinG diaGram...

  • Page 28: Piping And Wiring Appendix

    Xvi - pipinG and wirinG appendiX boiler control wiring diagram: single zone system with domestic hot water priority 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...
  • Page 29 Xvi - pipinG and wirinG appendiX piping diagram 1: single zone system with domestic hot water priority 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 CHECK VALVE VAVLE...
  • Page 30 Xvi - pipinG and wirinG appendiX piping diagram 2 : multizone piping with zone valves and domestic hot water priority (with zone valve) ZONE 4 ZONE 3 ZONE 2 CH & DHW SYSTEM CIRCULATOR ZONE 1 (PRIORITY ZONE) WATER INLET *USE FULL PORT ZONE BOILER VALVE.
  • Page 31 Xvi - pipinG and wirinG appendiX wiring diagram 2: multizone wiring with zone valves and domestic hot water priority (with zone valve) 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...
  • Page 32 Xvi - pipinG and wirinG appendiX piping diagram 3 : multizone system with zone valves and domestic hot water priority (with circulator) ZONE 4 ZONE 3 *USE FULL PORT ZONE VALVE. ZONE 2 CIRCULATOR ZONE 1 (PRIORITY ZONE) WATER INLET CIRCULATOR BOILER EXPANSION...
  • Page 33 Xvi - pipinG and wirinG appendiX wiring diagram 3: multizone system with zone valves and domestic hot water priority (with circulator) 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...
  • Page 34 Xvi - pipinG and wirinG appendiX piping diagram 4: multizone system with circulators and domestic hot water priority 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...
  • Page 35 Xvi - pipinG and wirinG appendiX wiring diagram 4: multizone system with circulators and domestic hot water priority 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 &...
  • Page 36 Xvi - pipinG and wirinG appendiX piping diagram 5 : primary/secondary piping with circulators and domestic hot water ZONE 4 ZONE 3 ZONE 2 ZONE 1 (PRIORITY ZONE) DHW PUMP 12" MAX APART (TO PREVENT FORCED FLOW IN SECONDARY) WATER INLET Piping Diagram 5 EXPANSION PRIMARY...
  • Page 37 Xvi - pipinG and wirinG appendiX wiring diagram 5 : primary/secondary wiring with circulators and domestic hot water 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 &...
  • Page 38 Xvi - pipinG and wirinG appendiX piping diagram 6 : primary/secondary multizone system piping with zone valves and domestic hot water (with zone valve) 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)
  • Page 39 Xvi - pipinG and wirinG appendiX wiring diagram 6 : primary/secondary multizone system wiring with zone valves and domestic hot water (with zone valve) INDIRECT WATER SWITCH LEGEND TANK HEATER AQUASTAT CONTROL OR THERMOSTAT T-STAT T-STAT ARGO AZ-4CP CONTROL Yellow Yellow STATUS PRIORITY ON...
  • Page 40 Xvi - pipinG and wirinG appendiX piping diagram 7 : primary/secondary piping with zone valves and domestic hot water (with circulator) *USE FULL PORT ZONE VALVE. ZONE 4 ZONE 3 ZONE 2 CH CIRCULATOR PUMP ZONE 1 (PRIORITY ZONE) CIRCULATOR PUMP 12"...
  • Page 41 Xvi - pipinG and wirinG appendiX wiring diagram 7 : primary/secondary piping with zone valves and domestic hot water (with circulator) 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...
  • Page 42 Xvi - pipinG and wirinG appendiX piping diagram 8 : bypass piping (automatic mixing valve) 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...
  • Page 43 Xvi - pipinG and wirinG appendiX piping diagram 10 : bypass piping (4-way valve option with circulator on supply) 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...
  • Page 44 Xvi - pipinG and wirinG appendiX wiring diagram 9: 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...

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