Dunkirk Q95M-200 Installation Manual

DUNKIRK BOILERS85 Middle Rd.Dunkirk, NY 14048www.dunkirk.com P/N 240006103D, Rev.C [04/2009]RAn ISO 9001-2000 Certified CompanyQ95M-200GAS-FIRED DIREC

V  BEFORE INSTALLING THE BOILER! WARNINGe boiler must be located on a surface that can support the weight of the installed boiler.e boiler should

VII  NEAR BOILER PIPINGPressure Relief Valve / Temperature Pressure Gaugee boiler is furnished with a relief valve in the boiler parts bag. Pro-vide

VII  NEAR BOILER PIPINGExcess water should go through the overow and out through 2. the condensate drain line. Verify proper operation of the drain

VIII  COMBUSTION AIR AND VENT PIPEshould be taken to prevent building materials at the vent from being damaged by exhaust of ue gas.e venting syste

VIII  COMBUSTION AIR AND VENT PIPEWhile cement is still wet, insert pipe into socket with a ¼ turn 8. twist. Be sure pipe is fully inserted into tti

Figure 9 - Gas Piping1/2” GAS CONNECTION*NOTE: 3/4” GAS SUPPLYTO BOILER JACKETREQUIRED TO FEEDTHE BOILER.e boiler is equipped with a ½” NPT connectio

Route all wires and conduits to the openings in the right jacket 5. panel.Line Voltage Monitoris boiler is factory equipped with a line voltage monit

XI  CONTROLS AND ACCESSORIESis section provides a brief description of the key controls and accessories found in this boiler. See the Repair

XI  CONTROLS AND ACCESSORIEScondition. e LWCO senses water through a probe at the top of the boiler that sends a signal through the water to ground.

Air Proving Blocked Vent Safety Assemblye air proving blocked vent safety assembly incorporates two pressure switches that are designed to discontinu

Table of ContentsGASFIRED DIRECT VENT MODULATING HOT WATER BOILERInstallation Manual Printed in USA • Made In USAHI - Introduction ...

XII  WATER TREATMENT & FREEZE PROTECTIONleak will become obvious if boiler pressure decreases when make up valve is closed.All system leaks must

XII  WATER TREATMENT & FREEZE PROTECTIONRecommended Aluminum Antifreeze& Inhibitor SuppliersRecommended ProductsInterstate Chemical2797 Free

Filling boiler with water and purging airFor each of the following systems, refer to the appropriate piping diagrams in the Installation ManualSystems

Control Valve “OFF”Control Valve “ON”XIII  PUTTING THE BOILER IN OPERATIONTO TURN OFF GAS TO APPLIANCESet the thermostat to the lowest setting.1. Tur

and Freeze Protection section of manual 240006104.Check that boiler area is free from combustible materials, gaso-2. line, and other ammable vapors a

ened sediment using a shop vacuum with a snorkel attach-ment.Inspect burner for any foreign matter in the ame ports or •inside the burner. Any foreig

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XV  BOILER WIRING DIAGRAMCOMPONENT CODING (CODE DES COMPOSANTES)NOTE:WIRING (CÂBLAGE)LINE VOLTAGE BY FACTORY / LIGNE DE VOLTAGE PAR L'USINELOW V

XVI  PIPING AND WIRING APPENDIXCH C1L1T-STATL2CH C2DHW C2DHW C1DHW T2A2A1DHW T1CH T2CH T1OUTDOORAIR SENSORBOILER CONTROL PANELDHW CIRCL1120 V

BOILERDHW CIRCULATORCH CIRCULATORPRIORITY ZONECIRCULATOREXPANSIONTANKWATER INLETFLOW CONTROLV AV L ESHUT-OFFV A L V EPRESSUREREDUCER VALVECHECK VALVEB

III  RULES FOR SAFE INSTALLATION AND OPERATIONII  SAFETY SYMBOLS AND WARNINGS! WARNINGis appliance has been equipped for residential instal-lation

ZONE 3ZONE 2ZONE 1 (PRIORITY ZONE)BOILERWATER INLETCH & DHWSYSTEMCIRCULATOR*USE FULL PORT ZONE VALVE. FOR OPTIMUM TANK PERFORMANCE, CONSIDER USIN

XVI  PIPING AND WIRING APPENDIX23DO NOT USE1REDBLACKBLACKREDand 4 whenvalvesusing zonewithout anend switch.Note: Installwire jumperbetweenterminals 3

XVI  PIPING AND WIRING APPENDIXZONE 3ZONE 2ZONE 1 (PRIORITY ZONE)BOILERWATER INLETZONE 4*USE FULL PORT ZONE VALVE. DHWCIRCULATORCHCIRCULATORCIRCULAT

XVI  PIPING AND WIRING APPENDIX23DO NOT USE1REDBLACKBLACKREDand 4 whenvalvesusing zonewithout anend switch.Note: Installwire jumperbetweenterminals 3

ZONE 3ZONE 2ZONE 1 (PRIORITY ZONE)BOILERZONE 4DHW CIRCULATORWATER INLETCIRC 2CIRC 3CIRC 4CIRCULATORSHUT-OFFVALVEPRESSUREREDUCER VALVECHECK VALVEBALL V

COMMONZONE MODULETO EXTRA24 VAC@ 1VAPRIORITY ONHotline indirect water heaterZR-ZCCONTROL WITHPRIORITY120V ACL2 NL1 (HOT)ISOLATEDCH C1L1SWITCHX X

XVI  PIPING AND WIRING APPENDIXBOILERPRIMARYPUMP(CH & DHW)ZONE 1 (PRIORITY ZONE)ZONE 2ZONE 3ALTERNATE PUMPLOCATION12" MAX APART(TO PREVENT F

XVI  PIPING AND WIRING APPENDIX120V ACL2 NL1 (HOT)BOILER CIRC (WILL RUN FOR ALL CHAND DHW CALLS FOR HEAT)ELECTRONIC FUSEVACCIRCUIT ONL2120NO4NC

XVI  PIPING AND WIRING APPENDIXZONE 3ZONE 2ZONE 1 (PRIORITY ZONE)SYSTEMCIRCULATOR(TO PREVENT FORCEDFLOW IN SECONDARY)12" MAX APARTBOILERBOILERCI

23DO NOT USE1REDBLACKBLACKREDand 4 whenvalvesusing zonewithout anend switch.Note: Installwire jumperbetweenterminals 3120 VACT-STATENDSWITCHMOTOR*BOIL

IV  BOILER RATINGS AND CAPACITIESTABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASESBoiler Input Rate (MBH)(1)Heating Capacity (MBH)(1)(2)Net I=B=

XVI  PIPING AND WIRING APPENDIXZONE 3ZONE 2ZONE 1 (PRIORITY ZONE)(TO PREVENT FORCEDFLOW IN SECONDARY)12" MAX APARTPRIMARYPUMPBOILERALTERNATEPRIM

23DO NOT USE1REDBLACKBLACKREDand 4 whenvalvesusing zonewithout anend switch.Note: Installwire jumperbetweenterminals 3120 VACT-STATENDSWITCHMOTOR*BOIL

XVI  PIPING AND WIRING APPENDIXBOILERWATER INLETALTERNATECIRCULATORLOCATIONTO SYSTEMFROM SYSTEMCIRCULATORSHUT-OFFVALV EPRESSUREREDUCER VALVECHECK VAL

XVI  PIPING AND WIRING APPENDIXBOILERALTERNATECIRCULATORLOCATIONTO SYSTEMFROM SYSTEMCIRCULATORWATER INLETSHUT-OFFVA LV EPRESSUREREDUCER VALVECHECK VA

XVI  PIPING AND WIRING APPENDIXTRANSFORMER24VAC 40 VABlackWhiteYellowYellowDHW C1DHW C2CH C2CH C1A2DWH T1DHW T2A1BOILER CONTROL PANELCH T1CH T2L1L21

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NOTES

Date Service Performed Company Name & Tech Initials Company Address & Phone #

V  BEFORE INSTALLING THE BOILERless than seven (7) feet above nished grade in the area of the vent-ing including but not limited to, decks and porch

V  BEFORE INSTALLING THE BOILERe clearances shown in 4. Table 3 indicate required clearances per CSA listing. A minimum 1” clearance must be mainta

V  BEFORE INSTALLING THE BOILERIf the concentric vent termination is being used, refer to Figure 3 for proper setup.NOTE: IF THERE IS A POTENTIAL FOR

V  BEFORE INSTALLING THE BOILEROVERHANG12" MINIMUM90°VENT12" SEPARATIONBETWEEN BOTTOM OFCOMBUSTION AIR INTAKEAND BOTTOM OF VENTMAINTAIN 12&

V  BEFORE INSTALLING THE BOILERFoundation RequirementsBoiler must be placed on level surface. Boiler is NOT to be installed on carpeting. NOTICEIf bo