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Dunkirk Q90 150 Installation Manual And Operating Instructions

  • Q90 150 Boiler
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  • Installation Manual And Operating Instructions
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Dunkirk Q90 150 Manual Online:

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Dunkirk Q90 150 User Manual
Dunkirk Q90 150 User Guide
Dunkirk Q90 150 Online Manual

Text of Dunkirk Q90 150 User Guide:

  • Dunkirk Q90 150, TROUBLESHOOTING CHART #6 CHART5 YES I I CHART 5 NO #3 CHART 5 I f RUNS FOR 25-50 SECONDS. THEN TURNS OFF. CHECK FIRING RATE OF UNIT. IS UNIT FIRING AT THE CORRECT RATE? _V YEs I CHECK BURNER FOR ANY DETERIORATION I_ _ IN THE FLAME PORTS. ARE BURNER PORTS IN GOOD CONDITION. YES l CHECK FLAME SIGNAL > 0.6uA? N_E_S CONSULT BOILER MFGR. FOR SPECIFIC INSTRUCTIONS REQUIRES SPECIFIC TOOLS BOILER SHUTS OFF BEFORE END OF CALL FOR HEAT. ARE HI LIMIT AQUASTAT CONTACTS CLOSED? YES SEE TROUBLESHOOTING PATH #2 ABOVE BOILER OFF ON HIGH LIMIT. IS ACTUAL BOILER WATER TEMP. GREATER THAN HI LIMIT SET POINT MI

  • CONCENTRICVENTROOFINSTALLATION VENT I MAINTAIN 12 IN (i8 IN FD_ CANADA> MINI_UN CLEARANCE SNO_ MAXINUM OF IN A_DVE NOOF NOTE, SbPPORT WUST BE FIELD INSTALLED TO SECC_RE TERMINAT[0N K!I /O STR/JCTURE 3" Diameter PVC Vent/Exhaust 1W' ,¢"_1d1_' 46% _ 3" Diameter PVC Intake/Combustion Air [ Figure 5 I Boiler must be placed on level surface. Boiler is NOT

  • Dunkirk Q90 150, sate from the boiler, an external float activated con- densate pump with integral sump (supplied by oth- ers) is required. The condensate pump can be piped to a remote tie in point to a sanitary sewer system. For this application, the boiler must be installed so that proper pitch of piping to the external condensate reservoir (sump) can be accomplished. Use wood frame or blocks (not factory supplied) to raise boiler as required for proper installation. 1. Consult local water treatment specialist for reco- mendations if your water pH levels are below of 7.0 or hardness is above 7 grains

  • Dunkirk Q90 150, faces and greatly reduce capacity and effi- ciency. f. Use of antifreeze in any boiler will reduce heating capacity by as much as 10-20% due to differing heat transfer and pumping char- acteristics. This must be taken into consid- eration when sizing the heating system, pump(s) and expansion tank. Consult anti- freeze manufacturer's literature for specific information on reduced capacity. g. Water content of the boiler is 2.6 gallons (10 liters). h. Antifreeze wilt raise the pH of the water in a heating system to between 8.0 and 10.0. This is due to the corrosion inhibit

  • Dunkirk Q90 150, IF BURNER APPEARS TO PULSATE DURING IGNITION: 1. Turn off boder power and shut off gas supply to the boiler. 2 Take the burner assembly apart by removing the com- bustion air blower and gas vatve/venturi assembly from the bo_ler and visually inspect the inside of the burner Look for any debris (PVC shavings, etc.) and, if anything is present, remove it. 3. Reassemble burner assembly, turn gas supply and boiler power back on, and retlght boiler. IF BURNER STILL PULSATES OR FAILS TO LIGHT: 1 Check for proper vent and intake pipe siz

  • Dunkirk Q90 150, SAFETY SEQUENCES DURING OPERATION DRAFT INDUCER TEMPERATURE SAFETY SWITCH IF DRAFT INDUCER TEMPERATURE REACHES i TEMPERATURE SAFETY SWITCH SETPOINT, / SAFETY SWITCH CONTACTS OPEN IMMEDIATELY, I [ CLOS NG GAS VALVE_ (L GHT GOES OUT). J [ ] POST PURGE AND SWITCHES OFF. FOR_HEAT. rWHENTEMPERATURESAFETYSWITCHCONTACTS EMAKE BEFORE END OF CALL FOR HEAT, CON- I [TROL GOES NTO NORMAL L GHT-OFF SEQUENCE.J LOSS OF FLAME SIGNAL IF AN ESTABLISHED FLAME SIGNAL IS LOST WHILE CONTROL EXPECTS THAT THE BURNER IS OPERAT- ING, CONTROL WILL IMMEDIATELY DE-ENERGIZE GAS VALVE.

  • Dunkirk Q90 150, Operate the boiler and verify that all vent/air intake connections are gastight and watertight. Repair any leaks immediately. test for operation as outlined by the control manu- facturer. Burner should be operating and should go off when controls are tested. When safety controls are restored, burner should reignite. Verify that all connections are watertight, and that con- densate flows freely. Repair any leaks immediately. Verify that all connections are watertight. Repair any leaks immediately. 1. Turn off manual gas shut off valve. For a single thermo

  • Dunkirk Q90 150, These low pressure gas-fired hot water boilers are design certified by CSA International, for use with natural and propane gases. The boilers are constructed and hydrostatically tested for a maximum work- ing pressure of 50 psig (pounds per square inch gauge) in accordance with A.S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure 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. The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack. Mos

  • SYSTEM STATUS The indicator lights track the operating sequence If the system locks out, the lights indicate the point in the sequence of operation were lockout occurs If this table does not readily provide the reason for boiler malfunction or non-operation, refer to the following pages for more detailed troubleshooting procedures LIGHT STATUS INDICATES On IBC is energized through 24 v

  • Dunkirk Q90 150, CHART1 OPEN / l BLOWER STARTS YES _V l PURGE LIGHT ON? YES _v 15 SECOND PRE PURGE COMPLETE PURGE LIGHT IS OFF SIMULTANEOUSLY IGNITOR LIGHT iS ON AS IGNITOR CIRCUIT IS ENERGIZED. TROUBLESHOOTING CHART #3 J_ CHECK FOR VAC BETWEEN TERMINALS 1 AND 3 AT CONNECTOR CN4 ON IBC YES CHECK FOR 120 VAC AT BLOWER LEADS ON WIRING HARNESS YES REPAIR/REPLACE BLOWER IBC WAITS UP TO 5 MINUTES FOR NORMALLY OPEN AIR PRESSURE SWITCH CONTACTS TO CLOSE, INDICATING BLOWER SUCTION IS PRESENT 1_ REPLACEIBC REPAIR/REPLACE WIRI

  • The sequencecanbe followedviathe diagnosticindicatorlampson the IntegratedBoilerControlin Figure16(SectionXI).This isthenormalsequenceof operation.A moredetailedsequenceof opera- tioncontainingpotentialfaultscanbefoundinthe servicehintssection. (I) LampAisilluminated,indicatingthattheintegratedcontrolisreceiving 24voltsandisinstandbywaitingforthethermostattocallforheat.

  • Dunkirk Q90 150, • D2665 (PVC-DWV) Reduce the maximum vent length 5 feet per each additional elbow. • D2241 (SDR-21 and SDR-26 PVC) • D2661 (ABS-DWV) • F628 (schedule-40 ABS). Pipe cement and primer must conform to ASTM standards D2564 (PVC) or D2235 (ABS). In Canada construct all combustion air and vent pipes for this unit of CSA or U LC certified sched- ule-40 CPVC, schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in Canada. 3. Combustion air and vent piping connections on boiler are 2", but must increase to 3". Due to potential for flue gas temperatures over 155°F, the first 5 feet of

  • Dunkirk Q90 150, TROUBLESHOOTING CHART #5 CHART4 YES CHART4 YES POSSIBLY MIXTURE TOO LEAN! CHECK GAS LINES DOWNSTREAM OF GAS VALVE FOR BLOCKAGE. ARE GAS LINES CLEAR? IS GAS/VENTURI VALVE CORRECT SIZE? SEE REPAIR PARTS DIAGRAM. _V YES POSSIBLY MITURE TOO RICH! CHECK FLUE PASSAGES IN BOILER PER "MAINTENANCE AND CLEANING". ARE FLUE PASSAGES IN BOILER CLEAN? YES CHECK MIXERANDBURNERFOR BLOCKAGE PER MAINTENANCE AND CLEANINGINSTRUCTIONS. ARE AIR PASSAGESIN MIXER AND BURNER CLEAN? CHECK AIR ORIFICE AT BURNER INLET FOR CORRECT SIZE. SEE REPAIR PARTS DIAGRAM. IS ORIFICE CORRECT SIZE? CLEAN/REPLACE GAS LINES . BE SURE TO USE CORREC

  • Dunkirk Q90 150, 2. Before operating smell all around the appli- ance area for gas. Be sure to smell next to the floor because some gas is heavier than air and wilt settle to the floor. 5. Remove the front jacket panel. 6. Turn off the gas shut off valve. Valve handle should be perpendicular to the gas pipe. 7. Wait five minutes for any gas to clear. Then smell for gas, including near the floor. If you smell gas, STOP! Follow instructions at left un- der "What To Do If You Smefl Gas." If you do not smell gas, go to the next step. 8. Turn the gas shut off valve to the "On" posi- tion. The handle on the valve should be parallel to the gas pipe. 9. Replace

  • Dunkirk Q90 150, SERVICE HINTS The differential air pressure switch is a safety device which will prevent the boiler from firing if there is an air intake, boiler heat exchanger or vent blockage. 1. Turn off service switch, or lower ther- mostat setting. 2. Remove vinyl caps from Tee. 3. Install testing lines as shown to inclined manometer or differential pressure gauge with the ability to read 0.01" to at least 6.0" w.c. 4. Turn on service switch and set ther- mostat to call for heat. 5. If manometer readings do not corre- spond to the

  • Dunkirk Q90 150, SERVICE HINTS ,_ WARNING ,_k f- IMPORTANT 1. In a reset from lockout condition, all electri- cal meter readings at the gas control valve (24 VAC) must be taken within the trial for ignition period. 2. If any component does not function properly, make sure it is correctly installed and wired be- fore replacing it. 3. Static electricity discharge can damage the Inte- grated Boiler Control (IBC). Touch metal surface to discharge static electricity before touching IBC. 4. The IBC cannot be repaired. If it malfunctions it must be replaced.

  • Dunkirk Q90 150, POWER ON STAND BY 4, THERMOSTAT CALLS FOR HEAT 4, C_RCULATOR ENERGIZES THRU 2KI CONTACTS IBC SELF CHECK OF INTERNAL CIRCUITRY 1-2 SEC IF MAIN BURNER DOES NOT PROVE FLAME IN 3 TRIALS, CONTROL LOCKOUT. VALVE/FLAME LIGHT BLINKS, MANUAL RESET IS REQUIRED OR CONTROL WILL AUTOMATICALLY RESET AFTER 1 HOUR. THIS PROBLEM IS A RESULT OF NOT ESTABLISHING FLAME SIGNAL. t CONTROL WILL ATTEMPT 2 ADDITTIONAL IGNITION SEQUENCES STARTING WITH PREPURGE CLOSED DRAFTINDUCER ENERGIZESTHRU 1KICONTACTS IBC WAITS FOR UP TO 5 MINUTES FOR AIR PRESSURE SWITCH CONTACTS TO CLOSE INDICATING FAN SUCTION PRESENT CONTROL LOCKOUT PURGE LIGHT BLINKS. MANUAL RESET IS R

  • Dunkirk Q90 150, TROUBLESHOOTING CHART #2 CHART I CHECK THAT CIRCUIT BREAKER IS ON OR FUSES ARE OK AT THE ELECTRICAL PANEL , GK CHECK THAT SERVICE SWITCH IS ON CHECK CASTING TEMPERATURE SAFETY SWITCH. PUSH RESET BUTTON ON SWITCH CONTACTS OPEN (BUTTON UP) OR CLOSED (BUTTON DOWN)? OPEN _ CLOSED CHECK WIRING TO IBC. 120 VAC BETWEEN NO TERMINAL 1 AND 3 AT WIRING HARNESS PLUG CN7? YES 120 VAC BETWEEN TERMINALS 1 AND 3 AT NOCONNECTOR CN3 ON IBC? V YES 120 VAC AT TRANSFORMERTERMINALS?PRIMARY NO _- yYES 24 VAC AT TRANSFORMERTERMINALS?SECONDARY NO V YES 24 VAC AT WIRING HARNESS PLUG CN2? NO _YES ] REPLACE IBC I CHECK FOR 120 VAC BETWEEN TERMINALS t NO1 AND 3 AT CONNECTOR CN5 ON IBC? YES CHECK FOR 120 VAC

  • Dunkirk Q90 150, 1. Follow the instructions in "To Turn Off Gas To Ap- pfiance" in Section XII. i. Use a flexible handle nylon brush to loosen sediment and aluminum oxide on all exposed heating surfaces of boiler (see "Repair Parts Manual"for diagram). Be sure that brush does not get stuck in heat exhanger! 2. If heating system is to remain out d service dur- ing freezing weather, and does not contain antifreeze, drain system completely. If boiler will be exposed to freezing temperatures, drain conde

  • Dunkirk Q90 150, INSTALLATION MANUALAND OPERATING INSTRUCTIONS P/N# 240004826D, Rev. 1.3 [01/06] • Printed in USA • Made In USA I. Introduction ........................................................ 2 II. Safety Symbols ................................................ 2 III. Rules For Safe Installation and Operation ......... 3 IV. Boiler Ratings and Capacities ......................... 4 V. Before Installing The Boiler .............................. 5 VI. Placing The Boiler ........................................... 9 V

  • SIDEWALL VENTIINTAKE TERMINATIONS I LESS THAN 12 CLE;,R;,riCE J 12" OR MORE CLEARANCE If the concentnc vent termination is being used, re- fer to Figure 3 for proper setup CONCENTRIC VENT TERMINATIONS 12_ P IlNll 1UP 1 I COt 1EUSTIOH AIR _1 PCOF 3 E_=H-IIG t 12 I11PJRIIJ[ _ J ENT r1-ff4T_in IC irl CLE-_-NCE :BC E H;GHEST .NTIC_P-TED SI_ ' LE ELOF = SP-DE eep boiler

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