ECR International Dunkirk Q95M-200 User manual

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

2
TABLE OF CONTENTS
GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER
INSTALLATION MANUAL Printed in USA • Made In USA
Keep this manual near boiler
and retain for future reference.
IMPORTANT: This boiler is to be installed by a
qualied installer only.
I - Introduction.....................................................2
II - Safety Symbols and Warnings ......................3
III - Rules For Safe Installation and Operation ...3
IV - Boiler Ratings and Capacities......................4
v - before installing the boiler..............................5
VI - Placing the Boiler.......................................11
VII - Near Boiler Piping.....................................12
VIII - combustion air and vent pipe...................14
IX - Gas Supply Piping .....................................16
X - Electrical Wiring ..........................................18
XI - Controls and Accessories ..........................19
XII - Water Treatment & Freeze Protection .....22
XIII - Putting the Boiler in Operation.................25
XIV - Maintenance and Cleaning......................27
XV - Boiler Wiring Diagram...............................29
XVI - Piping and Wiring Appendix.....................30
I - INTRODUCTION
This appliance is a gas-red direct vent modulating cast
aluminum hot water boiler. A revolutionary cast aluminum
monoblock heat exchanger means better heat transfer
and thermal storage than similarly sized cast iron boilers,
which results in higher efciency. The heating system wa-
ter absorbs large amounts of heat from the cast aluminum
heat exchanger, cooling the ue gases and causing con-
densation. Sealed combustion, premix gas burner, and
low ame temperature means drastically reduced CO and
NOx emissions, which contribute to a cleaner and health-
ier environment.
This appliance, unlike normal residential atmospheric
and induced draft units, takes its combustion air directly
from the outdoors (sealed combustion) 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 ows into the pre-mix burner and
burns. The fan then forces the resulting ue gases from
the boiler unit and provides a positive removal of the ue
gases from the building through inexpensive and read-
ily available PVC and CPVC pipes. ULC S636 Material
must be used in Canada.

3
III - RULES FOR SAFE INSTALLATION AND OPERATION
IMPORTANT: Failure to follow these instruc-
tions could cause a malfunction of the boiler
and result in death, serious bodily injury, and/or
property damage. For assistance or additional
information, consult a qualied installer, service
agency, or the gas supplier.
II - SAFETY SYMBOLS AND WARNINGS
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 modications.
The manufacturer is not responsible for any
eld installation changes made to a boiler
installation which are not described or ac-
knowledged in this manual.
WARNING
!
Indicates an imminently hazardous situation
which, if not avoided, will result in death,
serious injury or substantial property dam-
age.
DANGER
!
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property dam-
age.
WARNING
!
Indicates a potentially hazardous situation
which, if not avoided, could result in minor or
moderate injury or property damage.
CAUTION
!
Indicates special instructions on installation,
operation or maintenance which are important
but not related to personal injury hazards.
NOTICE
The following dened symbols are used throughout this manual to notify the reader of potential
hazards of varying risk levels.
Check all applicable state and local building 1.
codes and utility company requirements before
installation. This installation must conform with
these requirements in their entirety. In the ab-
sence of these codes, use NFPA installation
codes and good industry practice.
Before servicing the boiler, allow it to cool. Al-
2.
ways shut off any electricity and gas supply con-
nected to the boiler prior to servicing.
Inspect gas line for leaks. 3.
Be certain gas input rate is correct. Overring 4.
may result in early failure of the boiler compo-
nents. This may cause dangerous operation.
Underring may result in too much air for the pre-
mix burner causing poor or loss of combustion.
Never vent the products of combustion from this 5.
boiler to an enclosed space. Always vent to the
outdoors. Never vent to another room or to in-
side a building.
Be sure there is adequate outdoor air supply to 6.
boiler for complete combustion.
Follow a regular service and maintenance sched- 7.
ule for efcient and safe operation.
Keep boiler area clean of debris and free of com- 8.
bustible and ammable materials.
Proper through-the-wall or through-the-roof com- 9.
bustion venting shall be in accordance with the
materials and methods described in this manual.
Installation must comply with local codes.

4
IV - BOILER RATINGS AND CAPACITIES
TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES
Boiler Input Rate
(MBH)(1) Heating Capacity (MBH)(1)(2) Net I=B=R Rating (MBH)(1) AFUE(2) Flue Diameter Shipping Wt.
High Fire 200 190 165 95% 2” CPVC & 3” PVC 284 lbs.
Low Fire 80 76 66
(1) 1 MBH = 1,000 Btuh (British Thermal Units Per Hour)
(2) Heating Capacity and AFUE (Annual Fuel Utilization Efciency) are based on DOE (Department of Energy) test procedures.
TABLE 2: 95M-200 HIGH ALTITUDE DERATE CHART
Boiler Input
Rate (MBH) Altitude (In Feet)
3,000 (2) 4,000 (2) 5,000 (3) 6,000 7,000 8,000 9,000 10,000
High Fire 196 192 177 174.5 172 169 168 167
Low Fire 78.4 76.8 115 113.5 112 110 109 108
1) Boiler Input Rate is determined at minimum vent length. The rate will decrease as vent length increases.
2) Parameter 17 is set to 2,250 at elevations of 2,000 feet above and below.
3) Parameter 17 must be raised to 3,200 at altitudes or elevations of 2,000 feet and above.
These low pressure gas-red hot water boilers are de-
sign certied by CSA International, for use with natural
and propane gases. The boilers are constructed and hy-
drostatically 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 Pressure Vessel Code Section IV Standards
for heating boilers.
The Boilers are certied in accordance with ANSI (Ameri-
can National Standards Institute) Z21.13 standards as
gas-red, direct vent, condensing, hot water boilers.
The Heating Capacity indicates the amount of heat avail-
able 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 as-
sumed 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.,
nned tube baseboard, cast iron radiators, radiant oor,
etc.) The difference between the Heating Capacity and
the Net I=B=R Rating, called the piping and pickup allow-
ance, establishes a reserve for heating the volume of wa-
ter in the system and offsetting heat losses from the pip-
ing. The Net I=B=R Ratings 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 and related hot water heating sys- 10.
tems are not do-it-yourself items. They must be
installed and serviced by qualied profession-
als. Ratings above are for sea level applications.
The boiler automatically derates input at a rate
of 2% for every 1000 feet above an elevation
of 2000 feet (see Table 2). The boiler will also
derate relative to the caloric value of the gas
being used. Use the formula specied in “Mea-
sure The Natural Gas Input Rate” in Section VII
of the Control Manual and Operating Instructions
(P/N# 240006104) to determine the proper rate
due to derated gas. To ensure proper operation
at 5,000 feet of altitude and above, the minimum
RPM setting; parameter 17, must be raised to
3,200. Instructions on how to change the param-
eters are included in the Parameter Guide, part
number 240006105.

5
V - BEFORE INSTALLING THE BOILER
In the State of Massachusetts, boiler installation must
conform to state code 248 CMR which includes but is
not limited to:
This product must be installed by a licenced Plumber •
or Gastter.
When exible connectors are used, the maximum •
length shall not exceed 36 inches.
When lever type gas shut-offs are used, they shall be •
T-handle type.
For all side wall horizontally vented gas fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the commonwealth and where the
side wall exhaust vent termination is less than seven (7)
feet above nished grade in the area of the venting includ-
ing but not limited to, decks and porches, the following
requirements shall be satised:
Installation of carbon monoxide detectors:1. At
the time of installation of the side wall horizontal vent-
ed gas fueled equipment, the installing plumber or
gastter shall observe that a hard wired carbon mon-
oxide detector with an alarm and battery back-up is
installed on the oor level where the gas equipment
is to be installed. In addition, the installing plumber
or gastter shall observe that a battery operated or
hard wired carbon monoxide detector with an alarm
is installed on each additional level of the dwelling,
building or structure served by the side wall horizontal
vented gas fueled equipment. It shall be the respon-
sibility of the property owner to secure the services of
qualied licensed professionals for the installation of
hard wired carbon monoxide detectors.
In the event that the side wall horizontally vented A. gas fueled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide de-
tector with alarm and battery back-up may be in-
stalled on the next adjacent oor level.
In the event that the requirements of this subdivi-B.
sion can not be met at the time of completion of
installation, the owner shall have a period of thirty
(30) days to comply with the above requirements;
provided, however, that during said thirty (30) day
period, a battery operated carbon monoxide detec-
tor with an alarm shall be installed.
Approved carbon monoxide detectors:2. Each
carbon monoxide detector as required in accordance
with the above provisions shall comply with NFPA 720
and be ANSI/UL 2034 listed and IAS certied.
Signage3. : A metal or plastic identication plate shall
be permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade di-
rectly in line with the exhaust vent terminal for the hori-
zontally vented gas fueled heating appliance or equip-
ment. The sign shall read, in print size no less than
one-half (1/2) inch in size, “GAS VENT DIRECTLY
BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
Inspection4. : The state or local gas inspector of the
side wall horizontally vented gas fueled equipment
shall not approve the installation unless, upon inspec-
tion, the inspector observes carbon monoxide detec-
tors and signage installed in accordance with the pro-
visions of 248 CMR 5.08(2)(a)1 through 4.
INSTALLERS - Follow local regulations with respect
to installation of Carbon Monoxide Detectors. Fol-
low maintenance recommendations in this manual.
WARNING
!
Review the following before installing the boiler
This boiler product is a gas-red, direct vent, condensing
boiler and must be installed in accordance with all appli-
cable 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 in-
stallation must conform to the ASME Safety Code for Con-
trols and Safety Devices for Automatically Fired Boilers,
No.CSD-1.
The installation must conform to the requirements of the au-
thority having jurisdiction or, in the absence of such require-
ments, to the National Fuel Gas Code, ANSI Z223.1 - latest
revision.

6
Boiler Sizing
Check to be sure you have selected the boiler •
with the proper capacity before continuing the
installation. The I=B=R Rating of the boiler se-
lected 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 as-
sociated hot water heating systems. See “Ta-
ble 1: Sea Level Ratings - Natural and Propane
Gases” in Section IV of this manual.
Heat loss calculations should be based on approved •
industry methods.
Considerations for Boiler Location
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 intake •
piping system to supply the correct amounts
of fresh (outdoor) air for combustion (15’ mini-
mum equivalent length/100’ maximum equiva-
lent length).
Connected to a suitable venting system to re-•
move the hazardous products of gas combustion
(15’ minimum equivalent length/100’ maximum
equivalent length).
Connected to a suitable hot water heating system.•
V - BEFORE INSTALLING THE BOILER
Product-approved vent/air intake:5. A product-ap-
proved vent terminal must be used and, if applicable, a
product-approved air intake must be used. Installation
shall be in strict compliance with the manufacturer’s in-
structions.
Installation instructions:6. A copy of all installation
instructions for all Product Approved side wall hori-
zontally vented gas fueled equipment, all venting in-
structions, all parts lists for venting instructions, and/
or all venting design instructions shall remain with the
appliance or equipment at the completion of the in-
stallation.
Supplied with a suitable electrical supply for all •
boiler motors and controls.
Connected to a properly located thermostat or
•
operating control (not included with boiler).
Placed on level surface (must NOT be installed •
on carpeting).
Condensate drain line must be pitched down
•
to oor drain or external condensate pump
with reservoir at ¼” per foot (wood frame or
blocks may be used to raise boiler).
Locating the Boiler
Select a location which is level, central to the piping 1.
systems served and as close to the vent and air intake
terminals as possible.
Accessibility clearances, if more stringent (i.e. larger 2.
clearances) than required re protection clearances,
must be used for the boiler installation. Accessibility
clearances may be achieved with the use of remov-
able walls or partitions.
The boiler is approved for installation in closets and on 3.
combustible oors. This boiler shall NOT be installed
on carpeting.
The clearances shown in 4. Table 3 indicate required
clearances per CSA listing. A minimum 1” clearance
must be maintained between combustible construc-
tion 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 clear-
ances are required to venting or combustion air intake
piping.
TABLE 3: BOILER CLEARANCES*
Dimension Combustible
Construction Accessibility/ Cleaning Service
Top 1” 8” 8”
Left Side 1” 24” 24”
Right Side 1” - -
Base 1” - -
Front 024” 24”
Back 6” - -
Intake/Vent Piping 0- -
Near Boiler Hot
Water Piping 1” - -
* All distances measured from the cabinet of the boiler.

7
V - BEFORE INSTALLING THE BOILER
COMBUSTION AIR
EXHAUST
3” MAX.
8” MAX.
12” MIN ABOVE
HIGHESTANTICIPATED
SNOW LEVEL
Figure 1 - Roof Vent/Intake Terminations
OVERHANG
12" MINIMUM
90°
VENT
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
MAX.
SEPARATION
18"
MAXIMUM
15"
MAXIMUM
LESS THAN 12" CLEARANCEABOVE GRADE
12" OR MORE CLEARANCE ABOVE GRADE
90°
BRACKET
VENT
18"
MAXIMUM
12" MINIMUM
OVERHANG
3"
MAXIMUM
SEPARATION
3”
Figure 2 - Sidewall Vent/Intake Terminations
VENT
1” MAX.
COMBUSTION AIR
Figure 3 - Concentric Vent Terminations
Equipment shall be installed in a location which fa- 5.
cilitates the operation of venting and combustion air
intake piping systems as described in this manual.
Advise owner of boiler to keep venting and combus-
6.
tion air intake passages free of obstructions. Both
the venting and combustion air intake piping systems
connected to the outdoors must permit ow through
the piping systems without restrictions for the boiler
to operate.
The boiler shall be installed such that the automatic 7.
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during operation
and service (circulator replacement, control replace-
ment, etc.).
The boiler must be located where ambient room tem- 8.
peratures (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.
Combustion Air and Vent Pipe Requirements
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 ue products are dis-
charged to outside atmosphere.
Combustion air and vent pipe connections must terminate
together in the same atmospheric pressure zone, either
through the roof or sidewall (roof termination preferred).
See Figures 1 and 2 for required clearances. If neces-
sary, use of screening no smaller than 1/2” hardware cloth
is acceptable.
If the concentric vent termination is being used, refer to
Figure 3 for proper setup.

8
V - BEFORE INSTALLING THE BOILER
NOTE: IF THERE ISA POTENTIAL FOR EXCESSIVE WINDS, SPECIAL
CONSIDERATION SHOULD BE GIVEN TO LOCATE THE VENT TERMINATION
AWAY FROM THE WINDWARD SIDE OF THE BUILDING.
VENT TERMINATION MUST BE AT LEAST
12” (31 CM) HORIZONTALLY FROM
ANY ELECTRIC METERS, GAS METERS
OR RELIEF EQUIPMENT.
LOCATE VENT TERMINATION TOALLOW
12” (31 CM) MINIMUMABOVE GRADE
VENT TERMINATION MUST BE AT LEAST
3 FEET (92 CM)ABOVE ANYFORCED
AIR INLET LOCATED WITHIN 10 FT (305 CM)
MOUNT VENT TERMINATION AT LEAST
3 FT (92 CM) FROM INSIDE CORNERS
VENT TERMINATION MUST BE INSTALLED WITH
A CLEARANCE OF AT LEAST 12 INCHES (31 CM)
FROM ANY AIR OPENING INTO A BUILDING.
12”
MAX
Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not terminate over
public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the
operation of regulators, relief vales, or other equipment. Where local experience indicates that condensate is a problem with
Category I and III appliances, this provision shall also apply.
When utilizing two or more boilers, each termination must have at least 12 inches of clearance from any adjacent termination.
See diagrams below.

9
Keep boiler area clean of debris and
free of ammable and combustible
materials, vapors, and liquids.
CAUTION
!
Failure to follow these warnings could result in
re, property damage, personal injury, or death.
Whenventpipeisexposedtotemperatures• below freezing, such as when it passes
through an unheated space or when a
chimney is used as a chaseway, vent pipe
must be insulated with ½”Armaex or
equivalent. In extremely cold climate ar-
eas, use ¾”Armaex 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,
which include uorides, chlorides, phos-
phates, bromides and iodides. These ele-
ments are found in aerosols, detergents,
bleaches, cleaning solvents, salts, air
fresheners, paints, adhesives, and other
household products.
WARNING
!
NOTES:
Condensate trap is integral to the boiler.
Wood frame or concrete blocks may be used to
raise the boiler to maintain drain pitch or to be
above external condensate pump reservoir.
There is a 115 volt AC receptacle provided on the
control panel to provide power for an external
condensate pump (if needed).
Failure to follow these warnings could result in
re, property damage, personal injury, or death.
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 water-
tight. Combustion air and vent piping must
also terminate exactly as shown in Figures
1 and 2. If a concentric vent termination is
being used, refer to Figures 3 through 5 for
proper setup.
Vent connections serving appliances vent-• ed by natural draft shall not be connected
into any portion of mechanical draft sys-
tems operating under positive pressure.
Solvent cements are combustible. Keep
•
away from heat, sparks, or open ame.
Use only in well ventilated areas. Avoid
breathing in vapor or allowing contact
with skin or eyes.
WARNING
!
V - BEFORE INSTALLING THE BOILER
3” Diameter PVC Intake/CombustionAir
Concentric Vent w/Dimensions
3” Diameter PVC Vent/Exhaust
Figure 4 - Concentric Vent w/ Dimensions

10
NOTES:
If boiler is not level condensate drain lines will 1. not function properly. Adjustable feet are lo-
cated on the boiler to make up for minor sur-
face irregularities or tilt.
Wood frame or blocks may be used to raise 2. boiler to maintain drain pitch or to be above
external condensate pump reservoir.
Removal of Existing Boiler From Common Vent
System
When an existing boiler is removed from a common vent-
ing 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 boil-
er, the following steps shall be followed with each appli-
ance remaining connected to the common venting system
placed in operation, while the other appliances remaining
connected to the common venting system are not in op-
eration.
Seal any unused openings in the common venting 1.
system.
Visually inspect the venting system for proper size and 2.
horizontal pitch and determine there is no blockage or
restrictions, leakage, corrosion and other deciencies
which could cause an unsafe condition.
When it is practical, close all building doors and windows 3.
and all doors between the space 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 exhaust, so they will operate
at maximum speed. Do not operate a summer exhaust
fan. Close replace dampers.
Foundation Requirements
Boiler must be placed on level surface. Boiler is
NOT to be installed on carpeting.
V - BEFORE INSTALLING THE BOILER
Figure 5 - Concentric Vent Roof Installation
Condensate Drain Requirements
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 ue gas condensate application.
The condensate drain line must be pitched down to
the oor at a minimum of ¼” 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 completion
of installation, prime trap by lling with water until
water is seen at the vent.
FOUND