Dunkirk Q95M-200 User manual

Q95M-200 GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
_i!i!i
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk. NY 14048
www. dunkirk, com
An ECR Ir
An ISO 9001
P/N 240006103D. Rev. 1 1 [04/06.t

INSTALLATION MANUAL
P/N# 240006103D, Rev. 1.1 [04/06] • Printed in USA • Made In USA
O
LEFTSiDE
TOP
................s' ......
FRONT RIGHT SIDE BACK
AR VENi r;AKE
OPENING
"f ?_'PVC
OP IONAq
'CONDENSATE
DA[N
OP NING
1/2' PVC
I Introduction .......................................... 3
II Safety Symbols .................................... 4
III Rules for Safe Installation and Operation 4
IV Boiler Ratings and Capacities ............. 5
V Before Installing The Boiler .................. 6
VI Placing The Boiler ................................ 9
VII Near Boiler Piping ................................ 10
VIII Combustion Air and Vent Pipe ............. 11
IX Gas Supply Piping ............................... 13
X Electrical Wiring ................................... 15
XI Controls and Accessories .................... 16
XII Maintenance and Cleaning .................. 18
XIII Boiler Wire Diagram ............................ 21
XIV Piping and Wiring Appendix ................. 22
Keep this manual near boiler
and retain for future reference.
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This appliance is a gas-fired direct vent modulat-
ing cast aluminum hot water boiler. A revolutionary
cast aluminum monoblock heat exchanger means
better heat transfer and thermal storage than simi-
larly sized cast iron boilers, which results in higher
efficiency. The heating system water absorbs large
amounts of heat from the cast aluminum heat ex-
changer, cooling the flue gases and causing con-
densation. Sealed combustion, premix gas burner,
and low flame temperature means drastically re-
duced CO and NOx emissions, which contribute to
a cleaner and healthier environment.
This appliance, unlike normal residential atmo-
spheric and induced draft units, takes its combus-
tion air directly from the outdoors (sealed combus-
tion) and does not compete with building occupants
for fresh air. Sealed combustion (also known as
"direct vent") is the safest and best way to obtain
plenty of clean combustion air. The forced draft fan
draws in the outside combustion air to mix with gas,
which flows into the pre-mix burner and combusts.
The fan then forces the resulting flue gases from
the boiler unit and provides a positive removal of
the flue gases from the building through inexpen-
sive and readily available PVC and CPVC pipes.

The following defined symbols are used throughout this manual to notify the reader of potential hazards
of varying risk levels
dicates a potentially hazardous situation I
hich, if not avoided, could result in death I
serious injury: j/
Iw IAc u,,o.A
ndicates a potentially hazardous situation I
hich, if not avoided, may result in minor or I
oderate injury. It may also be used to alert I
gainst unsafe practices, j)
'-cMoPORTANT: Read the following instructlon_
mpletely before mstalhngll
wAR.I.GA i
This appliance has been equipped for resi-
dential installations. If used for commercial
applications, any and all additional code re-
quirements must be adhered to for installa-
tion. This may require additional controls,
including but not limited to an external wa-
ter cut off, a manual reset high temperature
limit, and wiring and/or piping modifications.
The manufacturer is not responsible for any
field installation changes made to a boiler
installation which are not described or ac-
knowledged in this manual. J
PORTANT: Failure to follow these mstruc-'-_
ns could cause a malfunction of the boiler I
d result in death, serious bodily injury, and/or I
operty damage For assistance or additional I
ormatlon, consult a quahfled installer, service I
ency, or the gas supplier ,j/
his boiler contains ceramic fiber materials. I
se care when handling these materials per I
Ithe instructions specified under "Modulating I
k...Burner' in Section xI of this manual, j)
1 Check all applicable state and local building
codes and utility company requirements before
installation This installation must conform with
these requirements m their enhrety In the absence
of these codes, use NFPA installation codes and
good industry practice
2 Before serwcmg the boiler, allow it to cool Al-
ways shut off any electricity and gas supply con-
nected to the boiler prior to serwcmg
3 Inspect gas line for leaks
4 Be certain gas input rate is correct Overflrmg
may result in early failure of the boiler components
This may cause dangerous operation Underflrlng
may result in too much air for the pre-mlx burner
causing poor or loss of combustion
5 Never vent the products of combustion from this
boiler to an enclosed space Always vent to the out-
doors Never vent to another room or to inside a
building
6 Be sure there is adequate outdoor air supply to
boiler for complete combustion
7 Followa regularserwce and maintenance sched-
ule for efficient and safe operation
8 Keep boiler area clean of debris and free of com-
bustible and flammable materials
9 Proper through-the-wall or through-the-roof
combustion venting shall be in accordance with the
materials and methods described in this manual
Installation must comply with local codes
10 This boiler and related hot water heating sys-
tems are not do4t-yourself items They must be m-
stalled and serwced by quahfled professionals Rat-

TABLE1:SEALEVELRATINGS- NATURALANDPROPANEGASES
HighFire
Low Fire 200 190 165 80 76 66 95% 2" CPVC & 3" PVC 284 Ibs.
I_)1 MBH =1,000 Btuh (British Thermal Units Per Hour)
12_Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
TABLE 2:95M-200 HiGH ALTITUDE DERATE CHART
High Fire 196 192 188 184 181 177 174 170
Low Fire 78.4 76.8 75.3 73.8 72.3 70.9 69.5 68.1
ings above are for sea level applications. The boiler
automatically derates input at a rate d2% for every
1000 feet above an elevation of 2000 feet (see Table
2). The boiler wilt also derate relative to the calorific
value of the gas being used. Use the formula speci-
fied in "Measure The Natural Gas Input Rate" in Sec-
tion VII of the Control Manual and Operating Instruc-
tions (P/N# 240006104) to determine the proper rate
due to derated gas. No alterations to the boiler are
required for altitudes above sea level.
These low pressure gas-fired hot water boilers are
design certified by CSA International, for use with
natural and propane gases. The boilers are con-
structed and hydrostatically tested for a maximum
working pressure of 50 PSIG (pounds per square
inch gauge) in accordance with ASME (American
Society of Mechanical Engineers) Boiler and Pres-
sure Vessel Code Section IV Standards for heating
boilers.
The Boilers are certified in accordance with ANSI
(American National Standards Institute) Z21.13
standards as gas-fired, direct vent, condensing,
hot water boilers.
Review the following before installing the boiler.
The Heating Capacity indicates the amount of heat
available after subtracting the losses up the stack.
Most of this heat is available to heat water. A small
portion is heat loss from the jacket and surfaces of
the boiler, and it is assumed that this heat stays in
the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied
to heat the radiation or terminal units (i.e., finned
tube baseboard, cast iron radiators, radiant floor,
etc.) The difference between the Heating Capacity
and the Net I=B=R Rating, called the piping and
pickup allowance, establishes a reserve for heating
the volume of water in the system and offsetting
heat losses from the piping. The Net I=B=R Rat-
ings shown are based on a piping and pickup factor
of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net I=B=R
Rating of the boiler selected should be greater than
or equal to the calculated peak heating load (heat
loss) for the building or area(s) served by the boiler
and associated hot water heating systems. The
manufacturer should be consulted before selecting
a boiler for installations having unusual piping and
pickup requirements.
This boiler product is a gas-fired, direct vent, con-
densing boiler and must be installed in accordance
with all applicable federal, state and local building
codes including, but not limited to the following:
United States - Installation shall conform with
National Fuel Gas Code (NFPA-54/ANSI Z223.1-
latest edition)
Canada - Installation shall be in accordance with
CSA-B149.1 and .2 installation codes.
Where required by the authority having jurisdiction,
the installation must conform to the ASME Safety
Code for Controls and Safety Devices forAutomati-
cally Fired Boilers, No.CSD-1.
The installation must conform to the requirements
of the authority having jurisdiction or, in the ab-
sence of such requirements, to the National Fuel
Gas Code, ANSI Z223.1 -latest revision.

Installers - Followlocalregulationswith respect
to installationof Carbon MonoxideDetectors.
Follow maintenancerecommendationsin this
manual.
Check to be sure you have selectedthe
boilerwith thepropercapacitybeforecon-
tinuingtheinstallation.TheI=B=RRatingof
the boiler selectedshould be greaterthan
orequaltothecalculatedpeakheatingload
(heatloss)forthebuildingorarea(s)served
bytheboilerandassociatedhotwaterheat-
ingsystems.See "Table1: Sea Level Rat-
ings -Natural and Propane Gases" in Sec-
tion IV of this manual.
• Heat loss calculations should be based on
approved industry methods.
e | "_ 0 O" ;0 " 0 _0
1. Select a location which is level, central to the pip-
ing systems served and as close to the vent and air
intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e.
larger clearances) than required fire protection
clearances, must be used for the boiler installation.
Accessibility clearances may be achieved with the
use of removable walls or partitions.
3. The boiler is approved for installation in closets
and on combustible floors. This boiler shall NOT be
installed on carpeting.
4. The clearances shown in Table 3 below indicate
required clearances per CSA listing.
TABLE 3: BOILER CLEARANCES*
Before selecting a location for the boiler, the follow-
ing should be considered. Each boiler considered
for installation must be:
• Supplied with the correct type of gas (natural
gas or propane).
Connected to a suitable combustion air in-
take piping system to supply the correct
amounts of fresh (outdoor) air for combustion
(15' minimum length/60' maximum length).
Top 1" 8" 8"
Left Side 1" 24" 24"
Right Side 1"
Base 1"
Front 0 24" 24"
Back 6"
Intake/Vent Piping 0
Near Boiler Hot 1"
Water Piping
*All distances measured from the cabinet of the boiler.
Connected to a suitable venting system to
remove the hazardous products of gas com-
bustion (15' minimum length/60' maximum
length).
Connected to a suitable hot water heating
system,
Supplied with a suitable electrical supply for
all boiler motors and controls.
A minimum 1" clearance must be maintained be-
tween combustible construction and each of the
right, top and back surfaces of the boiler. Allow at
least 24" at the front and left side and 8"at the top
for servicing. No combustible clearances are re-
quired to venting or combustion air intake piping.
5. Equipment shall be installed in a location which fa-
cilitates the operation of venting and combustion air
intake piping systems as described in this manual.
Connected to a properly located thermostat or
operating control (not included with boiler).
Placed on level surface (must NOT be in-
stalled on carpeting).
6. Advise owner of boiler to keep venting and com-
bustion air intake passages free of obstructions.
Both the venting and combustion air intake piping
systems connected to the outdoors must permit
flow through the piping systems without restrictions
for the boiler to operate.
Condensate drain line must be pitched down
to floor drain or external condensate pump
with reservoir at ¼" per foot (wood frame or
blocks may be used to raise boiler).
7. The boiler shall be installed such that the auto-
matic gas ignition system components are protect-
ed from water (dripping, spraying, rain, etc.) during

operation and service (circulator replacement, con-
trol replacement, etc )
8 The boiler must be located where ambient room
temperatures (minimum possible temperatures
where boiler is installed assuming boiler is not in
operation and therefore contributes no heat to the
space) are always at or above 32°F to prevent
freezing of liquid condensate
Figure 1 - Roof Vent/Intake Terminations
Figure 2 - Sidewall Vent/Intake Terminations
L LESSTH_I] 12 CLEAR_I]CE
This boiler requires a dedicated direct vent system
In a direct vent system, all air for combustion is
taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere
Combustion air and vent pipe connections must
terminate together in the same atmospheric pres-
sure zone, either through the roof or sidewall (roof
termination preferred) See Figures 1 and 2 for re-
quired clearances
If the concentric vent termination is being used, re-
fer to Figure 3 for proper setup
Figure 3 - Concentric Vent Terminations
I rl. _lllijii
/_. 12 I IlNfI, IUM
cor 'BUSTION _,IR
i ~
EHT
pO.D=
D EP PI - r 1,3
ot°
I
12 FllNlr IUr,
rI_INT_EN l-" IN CLE-P-NCE
_BO E HIGHEST .NTICIP.TED
SrdC LE EL D = SPADE
t c 0,,o.
Keep boiler area clean of debris and free of I
lammable and combustible materials, va- I
ors, and liquids. .i)
Failure to follow these warnings could result
in fire, property damage, personal injury, or
death.
• When vent pipe is exposed to tempera-
tures below freezing, such as when it pass-
es through an unheated space or when a
chimney is used as a chaseway, vent pipe
must be insulated with W'Armaflex or
equivalent. In extremely cold climate ar-
eas, use %'Armaflex or equivalent.
• Combustion air must be clean outdoor
air. Combustion air must not be taken
from inside the structure because that air
, is frequently contaminated by halogens,
H-'H H which include fluorides, chlorides, phos-
12"ORMORECLEARANCE LIr (Continued on next page)j

wAR"'"Ga,l -
(Continued from previous page)
phates, bromides and iodides. These ele-
ments are found in aerosols, detergents,
bleaches, cleaning solvents, salts, air
fresheners, paints, adhesives, and other
household products.
Locate combustion air inlet as far away as
possible from swimming pool and swim-
ming pool pump house. All combustion
air and vent pipes must be airtight and
watertight. Combustion air and vent pip-
ing must also terminate exactly as shown
in Figures 1 and 2. if a concentric vent
termination is being used, refer to Fig=
ures 3 through 5 for proper setup.
Vent connections serving appliances
vented by natural draft shall not be con-
nected into any portion of mechanical
draft systems operating under positive
pressure.
.Solvent cements are combustible. Keep
away from heat, sparks, or open flame.
Use only in well ventilated areas. Avoid
breathing in vapor or allowing contact
k,. with skin or eyes. ,J
Figure 4 - Concentric Vent w/Dimensions
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,-, F} 41H:-fH S',,,'(} IrJ:!b_,Cc_riLbu_t,ur_ Al_
Figure 5 - Concentric Vent Roof Installation
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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 the ½" PVC tee in
the parts bag to act as a vent as shown Attach ½"
PVC from this point to either a drain or an exter-
nal condensate pump (not furnished) If the drain
level is above the condensate trap, a condensate
pump must be used The condensate pump must
be designed for a flue gas condensate application
The condensate drain line must be pitched down to
the floor at a minimum of 1/4"per foot and must be
routed within the conditioned space to avoid freez-
ing of condensate and blockage of the drain line If
the unit will be started immediately upon comple-
tion of installation, prime trap by fllhng with water
until water is seen at the vent
f NOTES: _'_
1
2
3
pump tlf needed)
Condensate trap is integral to the boiler
Wood frarne or blocks may be used to raise the boiler to
maintain dram pitch or to be above external condensate
pump reservoir
There _s a 115 volt AC receptacle provided on the con-
trol panel to provide power for an external condensate
J

Boiler must be placed on level surface. Boiler is
NOT to be installed on carpeting.
f NOTES: _'
1. If boiler is not level condensate drain lines will not func-
tion properly. Adjustable feet are located on the boiler to
make up for minor surface irregularities or tilt,
2. Wood frame or blocks may be used to raise boiler to
maintain drain pitch or to be above external condensate
pump reservoir, j
in which the appliances remaining connected
to the common venting system are located and
other spaces of the building. Turn on clothes
dryer and any appliance not connected to the
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom ex-
haust, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close
fire dampers.
4. Place in operation the appliance being inspect-
ed. Follow the lighting instructions. Adjust ther-
mostat so appliances will operate continuously.
When an existing boiler is removed from a com-
mon venting system, the common venting system
is likely to be too large for proper venting of the
appliances remaining connected to it. At the time
of removal of an existing boiler, the following steps
shall be followed with each appliance remaining
connected to the common venting system placed
in operation, while the other appliances remaining
connected to the common venting system are not
in operation.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restrictions, leakage, corrosion
and other deficiencies which could cause an un-
safe condition.
3. When it is practical, close all building doors
and windows and all doors between the space
5. Test for spillage at the draft hood relief open-
ing after 5 minutes of main burner operation. Use
the flame of a match or candle, or the smoke
from a cigarette, cigar or pipe.
6. After it has been determined that each ap-
pliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans and any other gas-burning appliance to
their previous condition of use.
7. Any improper operation of the common vent-
ing system should be corrected so the instal-
lation conforms with the National Fuel Code,
NFPA-54/ANSI -Z223.1-tatest revision, or sec-
tion 5 of CSA-B149 for Canadian standards.
When resizing any portion of the common vent-
ing system, the common venting system should
be resized to approach the minimum size as de-
termined using the appropriate tables in part 11
in the National Fuel Gas Code, NFPA-54/ANSI-
Z223.1 -latest revision, or section 5 of CSA-B 149
for Canadian standards.
The boiler should be placed to provide the most
direct connections to the combustion air, vent and
system piping as possible.
Place crated boiler as close to selected location
as possible and uncrate boiler. The uncrated boiler
may be moved into position with an appliance dol-
ly or 2-wheel hand truck. The dolly or hand truck
should be inserted under the right hand side of the
boiler. It is possible to slide the boiler for a short
distance on a smooth floor or surface.
NmaOTE: Refer to "Locating The Boiler" in Section V of this'_
nual for required clearances for servicing and mainte- J
ce. J

--'JsMPORTANT: For piping examples using the Gas-Fired Direct Vent Modulating Hot Water Boiler,
ee the Piping Appendix in Section XIV of this manual.
Copper supply and return piping must NOT be
installed directly into aluminum boiler section
castings due to galvanic corrosion between
dissimilar metals. Iron or steel bushings or
pipe nipples should be used between copper
system piping and boiler to make final con-
nection to boiler. Also, the use of dielectric
unions is acceptable. The packaged boiler is
furnished with iron piping where necessary
k.for the supply and return connections. J
When the installation of the boiler is for a new
heating system, first install all of the radiation units
(panels, radiators, baseboard, or tubing) and the
supply and return mains. After all heating system
piping and components have been installed, make
final connection of the system piping to the boiler.
A hot water boiler installed above radiation level
must be equipped with a low water cut off device.
A periodic inspection is necessary, as is flushing
of float type devices, per low water cut off manu-
facturers specific instructions. This boiler is factory
equipped with a manual reset probe-type low water
cut off.
0
I Non-potable water only piped directly t
_,boiler.
Determine required system fill pressure, system
design temperature, and system water content.
Boiler contains 2.6 gallons (US). Size expansion
tank accordingly. Consult expansion tank manufac-
turer for proper sizing information. Connect prop-
erly sized expansion tank (not furnished) as shown
in Figure 6 for diaphragm type expansion tank. For
diaphragm type expansion tanks, adjust the tank
air pressure to match the system fill pressure. In-
stall air vent (furnished) as shown for diaphragm
type expansion tank system only. Install make-up
water connections as shown and per local codes.
If a pressure reducing valve is used, adjust to
match the system fill pressure. In connecting the
cold make-up water supply to the boiler, make sure
that clean water supply is available. When the wa-
ter supply is from a well or pump, a sand strainer
should be installed at the pump.
Figure 6 - Diaphragm Type
Expansion Tank Piping ..... o.........
/vEN]
i SU :'i>LY iIi1{
EX'AN I)r, TANK Db/IE \'AL_'E
{ATE VALVE O_ FJLL
8ALL YAL_E ',
COL}
REDUCEC PRESSURE
BACKFLO,k PREVE TER
FX ANSI)N TANK
ST OPTION F(;R FEED _yATE{,
2NO OPTION FOR FEE} W#TE:_
Figure 7 - Relief Valve Discharge Piping
,PRESSURE RELIEF DEVCE
/
/
/
/
/
/
/
The boiler is furnished with a relief valve in the
boiler parts bag. Provide ¾" piping from the sup-
plied relief valve to a local floor drain, but leave
an air gap between piping and drain. No shutoff of
any description shall be placed between safety re-
lief valve and the boiler, or on the discharge pipes

betweensuch safety valve and the atmosphere.
Installationof the safetyreliefvalveshallconform
toANSI/ASMEBoilerand PressureVesselCode,
SectionIV.Themanufacturerisnotresponsiblefor
anywaterdamage.
The packaged boiler unit is set up to receive 1¼"
NPT return piping from the rear of the unit with an
option for left or right return connections. 1¼" NPT
supply piping exits the boiter jacket at the top of the
unit.
/_OTE: Circulator pump and isolation valves are furnished_
[within a carton inside the boiler cabinet and can be installed I
_,a! the installer preferred location. ,,,j/
The condensate trap is integral to the boiler.
Provide ½" pipe and fittings for PVC condensate
drain line. Condensate drain line to be pitched
down to floor drain at a minimum of ¼" per foot.
The ½" diameter schedule 40 PVC condensate
drain piping and pipe fittings must conform to ANSI
standards and ASTM D1785. Schedule 40 PVC ce-
ment and primer must conform to ASTM D2564.
In Canada, use CSA or ULC certified schedule 40
PVC drain pipe and cement.
A condensate pump with a reservoir (not furnished)
may be used to remove condensate to a drain line
(sanitary line) above boiler if a floor drain is not
available or is inaccessible.
lrMaPORTANT: On initial start up the condensate_
p must be manually filled with water. 1/'
The following are the steps required to initially fill
the condensate trap for start up, these steps are
only required at the initial start up or if maintenance
requires draining of the condensate trap:
1. Pour about 1 cup of cold tap water into the
vent drain line.
2. Excess water should go through the overflow
and out through the condensate drain line. Ver-
ify proper operation of the drain line (or external
condensate pump if used).
3. Reinstall the vent drain line.
The boiler, when used in connection with a refrig-
eration system, must be installed so the chiller me-
dium is piped in parallel with the boiler with appro-
priate valves to prevent the chilled medium from
entering the boiler.
The boiler piping system of a hot water boiler con-
nected to heating coils located in air handling units
where they may be exposed to refrigerated air cir-
culation must be equipped with flow control valves
or other automatic means to prevent gravity circu-
lation of the boiler water during cooling cycle.
For boilers connected to gas vents or chimneys,
vent installations shall be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1-1atest revision, CSA-B149.1
and B149.2, and applicable provisions of the local
building codes.
Provisions for combustion and ventilation air must
be in accordance with Section 5.3, Air For Com-
bustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1-tatest revision, CSA-B149.1
and B149.2, or applicable provisions of the local
building code.
These boilers require a dedicated direct vent sys-
tem. All air for combustion is taken directly from
outdoors through the combustion air intake pipe.
All flue products are discharged to the outdoors
through the vent pipe. Insulate lengths of combus-
tion pipe in unconditioned areas.
1. See Figures 1 through 5 for combustion air
and vent pipe roof and sidewall termination (roof
termination is preferred). Combustion air and
vent pipes must terminate together in same at-
mospheric pressure zone as shown. Construc-
tion through which vent and air intake pipes may
be installed is a maximum 24" and a minimum
¼" thickness.