Dunkirk ARTESIAN 220 User manual

ARTESIAN 220 & 340
Instantaneous Indirect Water Heater
By Dunkirk Boilers
•INSTALLATION AND
OPERATING INSTRUCTIONS
•ENGINEERING MANUAL

Manufacturer's Warning
To reduce the possibility of injury due to scalding, a thermostatic mixing
valve should be installed on all installations. Failure to do so will result
in domestic water being delivered to the faucets at a temperature
equivalent to the boiler water.
All commercial installations requiring sustained water temperatures
beyond 120°F, must label all fixtures alerting water users of a potential
scalding hazard.
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CONTENTS pg
I. Product Description................................................................................................ 4
II. Specifications......................................................................................................... 4
III. Sizing A Water Heater For Installation................................................................ 7
Method A -Quick Residential............................................................................. 8
Method B -Detailed Residential........................................................................ g
Method C -Commercial....................................................................................13
IV. Before Starting Installation................................................................................19
V. Locating the Water heater..................................................................................19
VI. Piping ..................................................................................................................20
Zone Design
Boiler Side Piping .............................................................................................21
Domestic Piping ................................................................................................29
VII. Wiring..................................................................................................................33
VIII. Start-up and Check-out....................................................................................40
Appendix A.........................................................................................................40
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I. Product Description
The Indirect water heater is designed to generate domestic hot water in conjunction with a hot water
boiler using forced boiler water circulation. This indirect water heater consists of a plain steel tank in
which three smooth copper coils are located. The tank surrounded by 2" of Poly -urethane foam
insulation, which is surrounded by an enamel coated plain steel jacket.
The boiler water pumps through the tank and heats the domestic water in the coils.
Specifications
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Ill. Sizing The Hot Water Heater For Installation
IMPORTANT
The following procedures are used to size indirect water heaters based on the amount of
hot water required during a given hour. In doing so, it is assumed that this demand willbe
spread out over the course of the entire hour.
THESE SIZING PROCEDURES ARE PROVIDED AS A GUIDE TO ASSIST THE PROFESSIONAL
CONTRACTOR IN SIZING THE WATER HEATER. BECAUSE OF THE LARGE VARIETY OF
DEMAND SITUATIONS ENCOUNTERED IN THE FIELD, THE MANUFACTURER CANNOT
GUARANTEE THE SUITABILITY OF THESE PROCEDURES TO ALL INSTALLATIONS.
To properly apply the water heater to a particular system, the following 3 steps must be done:
1) Determine the domestic hot water requirements
2) Select the correct water heater/ boiler combination
3) Select a pump, zone piping size, and control system to provide proper water flow from
the boiler through the water heater tank.
This manual presents three methods of sizing this water heater:
Method A: Quick Residential
Method B: Detailed Residential
Method C: Commercial
Note:
The terms gross output and heating capacity are used interchangeably in this manual. Heating
Capacity is the gross output of boilers of less than 300,000 Btu/Hr input as defined by D.O.E. test
procedures. Gross Output is the term generally used with boilers of greater than or equal to
300,000 Btu/Hr. input.
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Method A: Quick Residential Sizing Method
Table 4 shows some typical structures under which many single residence applications can be
classified. This procedure will provide satisfactory results most of the time. Where greater accuracy
is desired, use Method B.
1) Find the description that best fits the job and select the Water heater called for. Also, note the
required boiler output under column (F).
2) The Water heater must be installed with a boiler having a gross output (DOE heating capacity)
greater than or equal to that shown in column (F) of Table 4. If the Water heater is to be used with
a boiler having a gross output less than that shown in table 4, use Method B.
If a boiler is to be installed with a water heater, first find a boiler, which will handle the space-
heating load alone. If this boiler has a DOE heating Capacity greater than that shown in column
(F) of table 4, do not add anything to the boiler selected for the Artesian.
If the boiler required for space heating alone has a DOE heating capacity less than that called
for in column (F) of table 4, increase the size of the boiler selected to one with a DOE heating
capacity greater than or equal to that show in column (F).
3) See figures 5-7 for more information on designing a water heater zone system. It is recommended
that the zone be given priority.
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Method B Detailed Residential Sizing Method Directions
1) Record the total number of each type to fixture in column (c) of worksheet 1. A shower head is
installed over a bathtub, count both the bathtub and shower head although only one fixture will
be used at a time.
2) For each line, multiply the quantity entered in column (c) by the corresponding number in column
(b). Enter the result in column (d).
3) Total column (d). This is the PEAK HOUR DEMAND
4) Multiply the Peak Hour Demand by 1.20. This is the adjusted peak hour demand
5) Select the water heater based on:
a) If a new boiler is to be installed with the Artesian:
*Go to table 1 and select a water heater which has a 140°F first hour rating greater than or
equal to the adjusted peak hour demand calculated on work sheet 1.
*Refer to required boiler output in Table 1. Record the required boiler output (heating
capacity) for the selected water heater in your work sheet.
*Determine the boiler required to satisfy the space heating requirement alone by
multiplying the space heating load by 1.15. Record this, as the boiler heating capacity
required for space heating in your work sheet.
*Select the boiler with the larger of the above two heating capacities.
b) If the water heater is to be installed with an existing boiler:
*Go to table 1 and select a water heater which has a 140°F first hour rating greater than or
equal to the adjusted peak hour demand calculated above.
If the required boiler output for the selected water heater is greater than the heating
capacity of the existing boiler; the existing boiler is too small.
6) If a Whirlpool is on the job, see Appendix A.
7) Designing the water heater zone system. Refer to Table 1 for minimum boiler water flow, and
circulator sizing. For further information on zone systems refer to figures 4-9.
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Method B -Detailed Residential Sizing Sample Calculations
Example 1
A water heater is to be installed with a new boiler. The residence has the following fixtures: Bath
#1 Bath #2
3 GPM Shower Head Vanity
30 Gal. Bathtub
Vanity
Kitchen Laundry
Kitchen Sink Clothes Washer
Automatic Dishwasher
The heat loss of the house is 80,000 BTU/hr
Note:
Although a four section boiler would be capable of heating the house (Net Rating = 82,000 BTU/hr),
its DOE heating capacity is only 94,000 BTU/hr (Need 110,000 Btu/hr). For this reason, install a
five section boiler that has a heating capacity of 125,000 BTU/hr.
Solution:
The completed sizing sheet for this example is shown in figure 2. The adjusted peak hour demand
is 145 gallons per hour. From table 1, we see that a water heater 220 will fulfill this requirement
with the appropriate boiler. Refer to Table 1 for required boiler output.If the model 220 is used in
combination with a boiler capable of producing 110,000 Btu / hr. The output will give you 156 GPH
first hour ratings. The circulator on the boiler must be capable of producing 3.4 GPM.
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IMPORTANT
Do not attempt to use Method C to size a single-family
residence.
Method C: Commercial Sizing Method Directions
1) Table 5 and 6 show demands for various fixtures found in commercial buildings in
gallons per hour. To determine the hot water requirements of the building:
a) Using Worksheet 2, determine and record the total number of each type of fixture in
the building under Column (2)
b) Use Tables 5 and 6 to find the number of gallons of 140°F water used per hour per
fixture. Record this value for each fixture in Column (1).
c) Multiply each line in Column (1) by the number in Column (2). The result is the total
amount of water used for each type of fixture type per hour. Record this in Column
(3).
d) Total Column (3). The result is the total amount of water used by all fixtures per
hour. This is the possible maximum demand.
e) The demand factor is intended to take into consideration the fact that not all
fixtures will be in use at the same time. Use the appropriate demand factor from
Table 5. Multiply the total demand calculated in step (d) by this factor. The result is
the probable maximum demand.
f) If a commercial dishwasher or laundry is on the job, determine the maximum amount
of 140°F water, which could be used in an hour. This will depend upon the number
of machines, the amount of water used per machine and the way in which the
equipment is to be used. Consult the machine manufacturer and the building owner
for this information. Once the maximum hourly usage is known for this equipment,
enter it in the spaces provided under Column (3).
g) Add the hourly usage for dishwashers and washing machines to the Probable
Maximum Demand. This is the Adjusted Probable Maximum Demand. Select the
water heater
2)
a) If a new boiler is to be installed with the water heater, go to Table 1 and select a
water heater which has a 140°F first hour rating greater than or equal to the
Adjusted Probable Maximum Demand calculated in Method C step 1 g.
Determine the boiler size required to satisfy the space-heating requirement alone.
Note the gross output or Heating Capacity of this boiler. Compare the boiler's gross
output
required for the water heater and the gross output required for the space heating
(Gross output required for space heating = heating load x 1.15). Use the boiler
sized to the larger amount.
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b) If the water heater is to be installed with an existing boiler, go to table 1 and select a
water heater which has a 140°F first hour rating greater than or equal to the adjusted
probable maximum demand calculated in1g. Note the boiler's gross output required to
achieve the selected water heater's first hour ratings. If it is more than the gross output
of the existing boiler, the existing boiler is too small to provide the proper input to the
water heater.
3) Several water heaters may be used together to provide a greater first hour rating than the
largest available single Artesian, if needed. If this is done, keep the following in mind:
*The first hour ratings of several Artesians may be added together to give a first hour
rating for the total system.
*The gross boiler output required for each individual water heater must be totaled to
provide the gross boiler output required for the system.
*Use water heaters of equal size. Do not mix tanks of different sizes on the same
manifold.
*See the "Piping" and "Wiring" sections of this manual for proper installation of a
manifold system.
4) Note: Use of a storage tank can increase the system's performance by providing a buffer for
periods of high demand.
5) Keep in mind the following before settling on the choice made above:
Many building's peak demands result from the constant use of one type of fixture or
machine for a relatively short period of time (showers in a gymnasium, for example).
The procedure outlined above may not provide adequate hot water in these cases. The
best way to size water heaters for this type of application, is to determine the total flow
rate of all fixtures. Which are, or could be, in use at once and select a water heater from
Table 1, which will provide hot water at this flow rate for the period of time required.
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Method C -Commercial Sizing Sample Calculation Example2
This application is for a motel with 20 rooms. Each of these rooms has the following
fixtures: (1) Vanity, (1) Shower and (1) Bath
In addition, 5 rooms have an additional vanity. Also, there is a utility sink used by the staff
for cleaning and a laundry with two machines
Solution:
Use Table 5 and the fixture count to complete the example worksheet in figure 3 (on next
page). Note that we treated the vanities as "Private Lavatory Basins" and the utility tub as a
"Laundry Tub". From discussions with the washing machine manufacturer and the motel
owner, we find that 100 Gal/hr of 140°F water is used in the Laundry. This usage is recorded
on the "Laundry Line" at the bottom of Worksheet 2. The demand factor of 0.25 for a hotel is
from Table 6. The Probable Maximum Demand is 0.25 x 1978 = 494.5 GaVhr. To this, we add
the 100 GaVhr laundry usage for an Adjusted Probable maximum Demand of 594.5 Gal/hr.
From table 1, Select the most cost-effective combination of equal size Artesians that will
satisfy this requirement. In this case 2 model 340's, with 305 gph first hour rating at 140°F,
are selected. Combined first hour rating is 610 gph (2 x 305). The total gross boiler output
required is equal to the requirement for each model multiplied by the total number of water
heaters. In this case 2 x 220 = 440 MBH gross boiler output is required. Likewise, their total
boiler water flow through the water heater zone is equal to the requirement for each water
heater times the total number of water heaters. In this case (2 x 6.7) = 13.4 gal / min.
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IV. BEFORE STARTING INSTALLATION Table 7: Water Chemistry Requirements
1) Make sure that the planned installation is Water used in the water heater must have
in accordance with all local codes. characteristics falling within the following limits:
2) Be certain the domestic water supply to the tank Characteristic Min. Max.
has physical and chemical characteristics that
fall within the limits shown in Table 7. Where pH 6.0 8.0
questions exist as to the composition of the Dissolved Chlorine (PPM) 0.0 100.0
water on the job, a qualified water treatment No measurable amounts of chlorine containing
expert should be consulted. compounds, such as cuprous chloride, are permitted.
IMPORTANT
Water with characteristics outside the limits shown in Table 7 may severely shorten the life of the heat
exchanger due to corrosion. Damage to the heat exchanger is not covered under warranty. Do not use the
water heater if the water is excessively hard. Lime and other deposits will occur and reduce the unit's
effectiveness.
3) Read and understand all installation requirements in this manual.
4) When adding a water heater to an existing system, the additional water content of the tank must be
considered. Verify that the expansion tank sizing is correct.
IV Locating The Artesian
WARNING
Failure to properly support a water heater tank installation could result in property damage or personal injury.
1) Table 2 shows the weights of all water heaters filled with water. The location chosen for the water heater
must be capable of supporting both the weight of the water heater(s) and the weight of the boiler(s).
2) Locate the water heater in an area where a leak in the tank, or the adjacent piping, or an open temperature
and pressure relief valve will not damage the surrounding `structure. If the area around the desired tank
location is highly susceptible to water damage, install the water heater in a pan with a drain.
3) The water heater may be located some distance from the boiler provided the piping system is designed to
provide the minimum boiler water flow called for in Table 1. Also, the further the water heater is from the
boiler, the longer the response time of the boiler will be to a call for heat from the water heater zone. If long
runs exist between the boiler and the water heater, it is advisable to insulate the piping.
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V. Piping
IMPORTANT
All First Hour Ratings shown in this manual are based on the, minimum boiler water, flow rates shown in
Table 1. Read this section for information on sizing piping and circulators for the water heater zone. Zone
Design
In designing the water heater zone piping system, the following points should be considered: 1) Circulator or
Zone Valve Zoning? -Circulator zones are usually a better choice. Zone valves have a relatively high
pressure, drop with respect to flow rate required through the water heater tank (see Table 1).
If zone valves are selected, use a zone valve with a minimal delay in opening, such as a motorized type.
a) Priority Zoning -Priority zoning is used to divert all boiler output to the water heater when its zone calls for
heat regardless of any simultaneous calls for heat from space heating zones
b) Priority zoning can be done using a 3-way zone valve, or by using a relay to de-energize the heating
zones when the water heater calls for heat. (See the piping and wiring sections for more information on these
zone systems).
Boiler Side Piping
Figures 4-9 show typical boiler side piping for several common situations. Regardless of which system is
used, it is imperative that the minimum boiler water flow rates called for in Table 1 are developed through
the tank. This requires properly sized piping and a properly sized pump. The systems shown in figures 4-
9 are described below:
Standard Circulator Zone
This system is just like the circulator zone system on a straight heat job except that one of the zones goes
to the water heater tank instead of radiation. As on any circulator zone system, appropriate controls should
be installed in each zone to prevent unwanted circulation through zones, which are not calling for heat.
Figure 4 illustrates typical circulator zone piping.
Zone Valve System
As with the circulator zone system, this system is just like a standard heating only zone valve system
except that one of the zones is connected to the tank. The circulator must be large enough to move the
boiler water through the tank at the minimum boiler water flow rate called for in Table 1, regardless of the
flow rate required through the heating zones. Figure 5 illustrates a typical zone valve system.
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