Dunkirk Q90-50 User manual

Aluminum Series 90+
Gas Fired Boiler Installation Guidelines,
Water Treatment and Antifreeze Protection
Z
P/N 240006888 Rev 1.0 [10/07]
IMPORTANT: These instructions are in addition to any existing
Antifreeze and Water Treatment information in the boiler instal-
lation manual, the boilers user's manual or any other existing
supplemental instruction or addendum. Antifreeze may be used
in most applications. Water alone may also be used in most
applications. Consult with your heating professional for recom-
mendations.
The information in this Supplemental Instruction is to be used
in place of that in the following manuals: 14683301 rev 3.4,
240004826D rev 1.3, 240006103D rev 1.1, 14683604 rev 3.4,
240004826K rev 1.3, 14683450 rev 3.5, 1305016 rev 2.1,
1305016 rev 2.1,240004826B rev 1.3, 240004826BF rev 1.3,
240006103B rev 1.1, 240006103BF rev 1.0, 1305011 rev 3.4,
240004826U rev 1.3, 240006103U rev 1.1.
Recommendations
* System leaks may not always be visible. An unseen system
leak will become obvious if boiler pressure decreases when
make up valve is closed.
* All system leaks must be repaired immediately. Constant in-
troduction of make up water will introduce dissolved oxygen,
resulting in accelerated boiler corrosion.
Water Chemistrv L.
* This boiler is designed for a closed loop hydronic heat sys-
tem ONLY! This boiler is not suitable for natural gravity type
installations, or any other open type system.
* System fluid pH must be maintained between 7.0 and 8.0.
* Maintain water hardness below 7 grains hardness.
* Filling with chlorinated fresh water should be acceptable
since drinking water chlorine levels are typically less than
5 ppm. Do not fill boiler with water containing chlorine in
excess of 100 ppm.

• Do not use inhibitors or other 2.
additives that are not specifically
approved for this product.
• Consult a local water treatment
specialist for recommendations
if any of the above are outside
the stated ranges. 3.
Cleanin tht_tb__vdronic S_stem:
IMPORTANT: Do not mix dif-
ferent manufacturers' prod-
ucts. Doing so will void the
warranty of the boiler.
Consideration should be given
to cleaning the heating system,
particularly in retrofit situations
where a new boiler with an alu-
minum heat exchanger is being
installed in an existing piping sys-
tem. Systems that have antifreeze
that is not approved by the boiler
manufacturer must be completely
flushed to ensure no unapproved
antifreeze remains
In older systems obviously discol-
ored, murky or dirty water; or a pH
reading outside the boiler manu-
facturer's stated acceptable range
are indications that the system
should be cleaned or treated.
1. Measure total capacity of the
system including the piping,
tanks, boiler, collector plates,
etc. The most accurate method
of measuring fluid capacity is
to fill the system and then com-
pletely drain it, volumetrically
measuring the fluid drained.
Thoroughly flush the system
with clean water to remove
any sediment or contaminants.
Sludge and iron oxide deposits
can cause rapid breakdown of
inhibitors.
Cleaning fluid - Flushing with
clean water is preferred. If
cleaning fluid is used, only
use cleaner specifically ap-
proved for use with alu-
minum boilers. Utilize the
cleaner in accordance with
manufacturer's instructions.
Freeze Protection
Aluminum Safe Antifreeze, Treat-
merits and Additive Guidelines:
Antifreeze, if needed, must be of a
type specifically designed for use
in closed hydronic heating systems
and be compatible with type 356
T6 aluminum at operating temper-
atures between 20°F (-6.7°C) and
250°F (121 °C). See the "Approved
Aluminum Antifreeze & Inhibitor
Suppliers" section of this manual
for a list of boiler manufacturer ap-
proved products.
• Always clean system prior to us-
ing antifreeze, refer to the Clean=
ing the Hydronic System section
of this manual for details.
•Only use the antifreeze manu-
facturers' products outlined in
this document.
• Use of antifreeze must be in accor-
dance with local plumbing codes.

•Antifreeze wilt raise the pH of
the hydronic solution in a heat-
ing system above the recom-
mended level due to the corro-
sion inhibitors in the antifreeze.
The solution must be treated to
maintain a pH within the boiler
manufacturer's recommended
level to avoid damage to the heat
exchanger. Follow antifreeze
manufacturer's instructions for
details on how to adjust the pH.
•If the system has leaked for
some reason, the water and an-
tifreeze chemistry will need to
be adjusted. To avoid damage
to the boiler, check the pH and
chemistry of the boiler solution
and consult the antifreeze man-
ufacturer for recommendations.
•It is recommended that a pH
reading is taken annually, and
adjusted as necessary. Follow
antifreeze /inhibitor manufac-
turer's instructions for details on
how to adjust the pH.
_NOTICE: Antifreeze solutions can
breakdown over time. Failure to
check antifreeze chemist_ including
inhibitors, periodically may result in
accelerated corrosion of boiler and
other system components. Consult
with the antifreeze manufacturer for
recommendations.
•Use of antifreeze in any boiler
will reduce heating capacity as
much as 10-20%. This must be
taken into consideration when
sizing the heating system, pumps
and expansion tank. Consult an-
tifreeze manufacturer's literature
for specific information on re-
duced capacity.
•Using the antifreeze manufac-
turer's instructions determine
the freezing temperature need-
ed and use the correct amount
of antifreeze. Never exceed 50%
antifreeze by volume.
•The boiler operating pressure
must remain below 15 psi for an-
tifreeze solutions that specify a
maximum of 250°F (121_C).
Aj2proved Aluminum Antifreeze & Inhibitor Suj2pliers:
Approved Product(s):
Intercool NFP-30,40,50 AA
Intercool RPH-15*
*This product may be used to adjust the
pH level of the hydronic system, but on
occasion may not resolve the pH issue.
In these cases it is recommended to
flush the system and refill with untreat-
ed water and new boiler manufacturer
approved antifreeze suitable for Alumi-
num heat exchangers.
Interstate Chemical
2797 Freedtand Road
P.O. Box 1600
Hermitage, PA 16148-0600
www.interstatechemical.com
Tel: [phone]
Fax: [phone]

(Continued) Aj2proved Aluminum Antifreeze & Inhibitor Sup.pliers:
Approved Product(s):
Noburst AL Antifreeze Noble Company PO Box 350
Grand Haven, MI 49417
www.noblecompany.com
Tel: [phone]
Fax: [phone]
Approved Product(s):
Rhogard Antifreeeze
Pro-Tek 922 Inhibitor*
Rhomar Water Management, Inc.
PO Box 229
Springfield, MO 65801
www.rhomarwater.com
Tel: [phone]
Fax: [phone]
*This product may be used to ad-
just the pH level of the hydronic
system, but on occasion may not
resolve the pH issue. In these
cases it is recommended to flush
the system and refill with untreat-
ed water and new boiler manu-
facturer approved antifreeze
suitable for Aluminum heat ex-
changers.
Approved Product(s):
Atphi-11
Nydronic Agencies Ltd.
(Fernox North America Distributor)
15363 117 Avenue
Edmonton, AB T5M 3X4
Canada
www.hydronicagencies.com
Tel: [phone]
Fax: [phone]
Fernox
www.fe rn ox. com
Tel: [phone]
Fax: [phone]
Fernox Technical Service
Tel: [phone]