Dunkirk DKVLT-050, DKVLT-299, DKVLT-075, DKVLT-100, DKVLT-150 Installation, Operation & Maintenance Manual

...

Models

DKVL T-050 DKVL T-075

WALL MOUNTED

DKVL T-100 DKVL T-150 DKVLT-200 DKVL T- 299

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

050/075/100/150/200

SIZE SHOWN

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com

P/N# 240008888, Rev. J [06/2013]

VERIFY CONTENTS RECEIVED

Description

Item

No. Illustration

Fully Assembled Boiler 1

Metal Wall Bracket 2

Lag Bolt, 3/8" x 3" Hex (4 ea) 3

*Safety Relief Valve 4

3/4" Tee 5

3/4" Nipple 6

299 SIZE

SHOWN

3/4" x 1/4" Elbow 7

Air Vent 8

**Temperature Pressure Gauge 9

Bushing 3/4" x 1/4" 10

3/4" Tee (Same as No. 11) 11

Nipple 1¼ x 5½ 12

Drain Valve, 3/4" 13

3/4" Tee 14

Nipple 1¼ x 5½ 15

Bushing 7/8" OD, Heyco (2 ea) 16

Used for electrical wire knockouts.

Stopper, Rubber 5/16" (2 ea) 17 Used for packaging holes on back of boiler.

Plastic Plug (2 ea) 18 Used for packaging holes on back of boiler.

Outdoor Sensor 19 Used for measuring outside temperature.

Critical Installation Instruction 20

11" x 17" Page for critical installation issues.

Document Package 21 Includes essential documents.

* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure

greater than 25 psig.

** Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system

pressure greater than 60 psig.

DIMENSIONS

FIGURE 1-1 Dimensions

(D)

Wall Hanging

Bracket

(D)

(E)

DIMENSIONS

Safety Relief Valve Connection (¾ NPT)

Vent Connector

Combustion Air

(A)

(B)

Models

Width (A) 20" (508mm)

Height (B) 30" (762mm)

Depth (C) 14" (356mm)

Bracket (D) 28" (711mm)

Height (E) 31" (787mm)

Water

Connections

Gas

Connection

Condensate Drain

Connection (L)

Weight

Location (G) 2" (51mm) 2" (51mm) Location (H)

Location (I) Location (J) 4-1/2" (114mm) 4-1/2" (114mm)

Table 1 : Physical Data

050/075/100 150/200 299

Size(F) 1-1/4" NPT

5" (127mm)

3" (76mm)

Size (K)

Shipping 111 lb (50 kg)

Unit 91 lb (41 kg)

1/2"

NPT

3/4" NPT

23" (584mm)

40" (1041mm)

16.0"

(406mm)

40" (1016mm)

42" (1092mm)

1-1/4" NPT

2" (51mm)

4-½"

(114mm)

3/4"

NPT

3/4" NPT

~182 lb (83 kg)

~157 lb (71 kg)

18.3"

(465mm)

~225 lb

(102 kg)

~195 lb (89 kg)

(G)

Supply Water (F)

Gas Connection (K)

Return Water (F)

(H)

(I)

(J)

(C)

Vent Connector 2" (51mm) 3" (76mm)

Condensate Drain Connection (L)

TABLE OF CONTENTS

1 - Introduction ............................................................................................................................... 5

2 - Important Safety Information .................................................................................................... 6

3 - Component Listing .....................................................................................................................7

4 - Locating Boiler .........................................................................................................................11

5 - Hydronic Piping ........................................................................................................................13

5.2 Special Conditions ................................................................................................................. 13

5.3 Safety Relief Valve and Air Vent............................................................................................ 13

5.4 Trim Piping ........................................................................................................................... 14

5.5 System Piping....................................................................................................................... 14

6 - Combustion Air And Vent Piping ...............................................................................................21

6.2 Removal of Existing Boiler From Common Vent System........................................................... 21

6.3 Venting Materials ................................................................................................................. 21

6.4 Vent Pipe Installation ............................................................................................................. 22

6.5 Vent Termination .................................................................................................................. 22

6.6 Venting Conﬁ gurations ........................................................................................................... 23

6.7 Side Venting Terminal Requirements..........................................................................................28

6.8 Multiple Boiler Venting Installation............................................................................................30

6.9 Condensate Piping ................................................................................................................. 31

7 - Gas Supply Piping ....................................................................................................................32

8 - Electrical Connections .............................................................................................................. 34

8.3 Line Voltage Connections ....................................................................................................... 34

8.4 External Connections ............................................................................................................. 34

9 - Start Up Procedure ...................................................................................................................36

9.6 Perform CSD-1 Compliance Test ......................................................................................................40

9.7 Complete Start Up Procedure .................................................................................................. 41

10 - Operating Instructions ........................................................................................................... 42

11 - General Maintenance And Cleaning ........................................................................................ 43

12 - Ratings And Capacities ........................................................................................................... 46

13 - Trouble Shooting ....................................................................................................................47

14 - Wiring Diagram ......................................................................................................................65

15 - Glossary .................................................................................................................................68

Appendix A - Control Module ......................................................................................................... 70

1.1 Introduction ......................................................................................................................... 70

1.2 Operation ............................................................................................................................. 70

1.3 Status Indication ................................................................................................................... 70

1.4 Sequence of Operation ........................................................................................................... 71

1.5 Theory of Operation .............................................................................................................. 73

1 - INTRODUCTION

1.1 Designated Use

• Hot water heating boiler.

• Indoor installation.

• Closet or alcove installation.

• Direct vent boiler.

• For use with natural gas or liqueﬁ ed petroleum gases (LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).

• Exceed 150 psig (1.03 MPa) maximum allowable working pressure.

• Exceed 195°F (90.5°C) system design temperature.

1.3 Operational Features

• Modulating: 20-100%.

• Integral Dual Limit.

• Integral Low Water Cutoff (with test button).

• Outdoor Temperature Reset.

• Integral Multiple Boiler Control.

Information and speciﬁ cations outlined in this manual in effect at the

time of printing of this manual. Manufacturer reserves the right to

discontinue, change speciﬁ cations or system design at any time without

notice and without incurring any obligation, whatsoever.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

2.2

Become familiar with symbols identifying

potential hazards.

2 - IMPORTANT SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualiﬁ ed agency. See glossary for additional information.

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

2.2

Become familiar with symbols identifying

potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, NFPA 70.

• Canada

• Natural Gas and Propane Installation Code, CAN/CSA B149.1.

• Canadian Electrical Code, Part I, Safety Standard for Electrical Installations, CSA C22.1

2.4 Where required by authority having jurisdiction, installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to:

Installation by licensed plumber or gas ﬁ tter.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

Low Voltage Terminal Strip

Heat Exchanger Pump

Gas Shutoff Valve

Fuel supply isolation during

servicing. See section 7

Combustion Air Blower

Delivers proper quantity of combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.

Gas (Control) Valve

Delivers proper quantity of fuel

to Combustion Air Blower. See section 7.

Supply Water Temperature Sensor and High Limit Switch

Low Water Cutoff

Senses inadequate quantity of

water. Turns off boiler before damage can occur.

Gas Connection

See section 7.

Boiler Control Module

3 - COMPONENT LISTING

3.1 Component Listing - Refer to diagrams on

following pages.

User Interface Displays information regarding boiler

condition. Allows adjustment of boiler operating parameters. NOTE: Does not replace thermostat used to control central heating space.

Combustion Air Inlet (2"/3") See section 6.

Return Water From Heating System (In)

Connection supplied at bottom of boiler. See section 5.

Low Voltage Terminal Strip Connection of all low

voltage wiring, including thermostat.

Igniter

Flame Sensor

Sight Glass Permits observation of burner ﬂ ame.

Burner (see page 40)

20.

Gas (Control) Valve

to Combustion Air Blower. See section 7.

21.

Supply Water Temperature Sensor and High Limit Switch

22.

Low Water Cutoff

water. Turns off boiler before damage can occur.

23.

Safety Relief Valve Factory supplied, Field installed.

See section 5.

24.

High Voltage Junction Box For connection of 120V

components. See section 88.

25.

Vent Connector See section 6.

26.

Gas Connection

27.

Wall Hanging Support Bracket (see page 12)

Integral to boiler. Allows wall mounting when used with supplied wall mounting bracket. See section 4.

28.

Air Vent

Delivers proper quantity of fuel

Senses inadequate quantity of

See section 7.

Heat Exchanger

10.

Condensate Collector

11.

Return Water Temperature Sensor

12.

Drain Valve (see page 14)

13.

Internal Primary Loop Ball Valve

14.

Supply Water Outlet to Heating System (Out)

Connections supplied for connecting from bottom of boiler. See section 5.

15.

Vent Temperature Sensor

16.

Condensate Drain Boiler produces a liquid

(condensate) as a by-product of combustion. Condensate must be piped to appropriate drain. See section 6.

17.

Heat Exchanger Pump

18.

Gas Shutoff Valve

servicing. See section 7

Fuel supply isolation during

29.

Boiler Control Module

30.

Lower Jacket Panel Gently pull upward then forward

to access.

31.

Transformer Supplies 24V power to low water cutoff.

32.

Flue Air Mixture Pressure Test Port - Not available

on all models.

33.

Combustion Analysis Test Port

34.

Internal Pump Relay - Not available on all models.

35.

Heat Exchanger Surface Temperature Switch

36.

ASME Plate

19.

Combustion Air Blower

combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.

Delivers proper quantity of

SAFETY RELIEF VALVE

AIR VENT

WALL MOUNT

SUPPORT

BRACKET

3 - COMPONENT LISTING

FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)

SAFETY RELIEF VALVE

VENT CONNECTOR

COMBUSTION

AIR INLET

AIR VENT

NOTE:

See Section 5-3 For

Safety Relief Valve Piping Instructions

WALL MOUNT

SUPPORT

BRACKET

FIGURE 3-2 Lower Jacket (Viewed from front of boiler)

Disconnect connector

Lower Jacket

Connector to User

Interface

(1) User Interface

before removing lower

jacket

FIGURE 3-3 Upper and Lower Jacket Latch (Viewed

from front of boiler)

Upper and Lower

Jacket Latch

Lift Jacket up,

engage jacket with

chassis,

push down.

Service Switch

VALVE

AIR

BLOWER

(20) GAS (CONTROL)

VALVE

(22) LOW

WATER CUTOF

(23) SAFETY RELIEF VALVE

(28) AIR VENT

PUMP

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(26) GAS CONNECTION

PORT

JUNCTION BOX

(16) CONDENSATE

DRAIN

(

(13)

SURFACE TEMPERATURE

SWITCH

3 - COMPONENT LISTING

(36) ASME

PLATE

FIGURE 3-4 Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover

NOTE:

(28) AIR VENT

(23) SAFETY RELIEF VALVE

See Section 5

For Piping

Instructions

(21) SUPPLY WATER

TEMPERATURE SENSOR

& HIGH LIMIT SWITCH

(22) LOW

WATER CUTOFF

(13)

INTERNAL PRIMARY

LOOP BALL VALVE

(20) GAS (CONTROL)

(10) CONDENSATE

VALVE

(19) COMBUSTION

(18) GAS SHUTOFF

(35) HEAT EXCHANGER

SURFACE TEMPERATURE

(17) HEAT EXCHANGER

(33) COMBUSTION

AIR

BLOWER

VALVE

(SHOWN IN OPEN

POSITION)

SWITCH

PUMP

(15) VENT

TEMPERATURE

SENSOR

ANALYSIS TEST

PORT

COLLECTOR

(25) VENT CONNECTOR

(2) COMBUSTION

AIR INLET

(5) IGNITER

(6) FLAME

SENSOR

(7) SIGHT GLASS

(32) FLUE

AIR MIXTURE

PRESSURE

TEST PORT

(29) BOILER

CONTROL

MODULE

Fuse and

Holder

(36) ASME

PLATE

(9) HEAT

EXCHANGER

(31) TRANSFORMER

(11) RETURN WATER

TEMPERATURE SENSOR

(4) LOW VOLTAGE

TERMINAL STRIP

(24) HIGH VOLTAGE

JUNCTION BOX

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(16) CONDENSATE

DRAIN

(3) RETURN WATER

FROM HEATING

(26) GAS CONNECTION

SYSTEM (IN)

VALVE

CUTOFF

(23) SAFETY RELIEF VALVE

(28) AIR VENT

PUMP

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(4) LOW VOLTAGE

TERMINAL STRIP

(26) GAS CONNECTION

(24) HIGH VOLTAGE

JUNCTION BOX

(9) HEAT

(16) CONDENSATE

DRAIN

(13) INTERNAL PRIMARY

LOOP BALL VALVE

(35) HEAT

SENSOR

3 - COMPONENT LISTING

PLATE

FIGURE 3-5 Boiler Components 299 MBH (View from Front of Boiler)

(28) AIR VENT

(23) SAFETY RELIEF VALVE

(25) VENT CONNECTOR

NOTE:

See Section 5

For Piping

Instructions

(21) SUPPLY WATER

TEMPERATURE SENSOR &

HIGH LIMIT SWITCH

(22) LOW WATER

CUTOFF

(33) COMBUSTION

ANALYSIS TEST

PORT

(34) INTERNAL

PUMP RELAY

(29) BOILER CONTROL

(13) INTERNAL PRIMARY

MODULE

Fuse and Holder

LOOP BALL VALVE

(35) HEAT

EXCHANGER SURFACE

TEMPERATURE SWITCH

(17) HEAT EXCHANGER

PUMP

(2) COMBUSTION

AIR INLET

(7) SIGHT GLASS &

(31) TRANSFORMER

(15) VENT TEMPERATURE

(15) V

(19) BLOWER

VENTURI

(6) FLAME SENSOR

(5) IGNITER

(9) HEAT

EXCHANGER

(20) GAS (CONTROL)

VALVE

(36) ASME

PLATE

SENSOR

(10) CONDENSATE

COLLECTOR

(4) LOW VOLTAGE

TERMINAL STRIP

(24) HIGH VOLTAGE

JUNCTION BOX

(14) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(26) GAS CONNECTION

(18) GAS SHUTOFF

VALVE

(SHOWN IN OPEN

POSITION)

(11) RETURN

TEMPERATURE

SENSOR

(16) CONDENSATE

DRAIN

(3) RETURN WATER

FROM HEATING

SYSTEM (IN)

Model

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent

piping

Hot Water Piping

4 - LOCATING BOILER

4.1 Boiler Location Considerations

• Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate.

FIGURE 4-1 Clearance to Combustible Materials

• Approved for installation in closets.

• Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Wall mount only.

• Access to outdoors to meet minimum and maximum pipe lengths for combustion air and vent piping. See section 6.

• Disposal of condensate. See section 6.

• Drainage of water (or water - antifreeze solution) during boiler service or from safety relief valve discharge. See section 5.

• Access to system water piping, gas supply, and electrical service. See sections 5, 7 and 8.

• Clearances to combustible materials and service clearances. See Table 2 and ﬁ gure 4-1.

• Multiple Boilers can be wall mounted, placed side by side,

or back to back.

FLOOR

TABLE 2: BOILER CLEARANCES

Dimension

Model

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent

Hot Water Piping

(1)

Required distances measured from boiler jacket.

(2)

Service, proper operation clearance recommendation.

piping

Combustible

Materials

050/075/100/

150/200/299

0" (0 cm) 14" (36 cm)

0" (0 cm) 0" (0 cm)

0" (0 cm) 6" (16 cm)

0" (0 cm) 0" (0 cm)

0" (0 cm) 12" (32 cm)

0" (0 cm)

See local code 6" (16 cm)

(1)

FLOOR

Service

050/075/100/

150/200/299

6" (16 cm)

(1)(2)

4 - LOCATING BOILER

FIGURE 4-2 Wall Mount Bracket Engaged with Bracket on Boiler

Center brackets. Avoid

overhang on sides of

wall mount bracket.

4 Slots for attaching

Wall Mount Bracket

to Studs

4.2 Pre-pipe supply and return water connections

with factory ﬁ ttings before wall mounting.

4.3 Wall Mounting

Mount boiler on wall using wall mounting bracket included with unit.

• Structure must be capable of supporting boiler weight plus 60 lbs (28 kg). See Table 1, page 2.

• Wall mount bracket has 4 slots allowing mounting on two (2) wall studs spaced at 11½" to 16½" on center. See ﬁ gure 4-2.

• Boiler includes (4) 3/8" x 3" lag screws and (4) washers for attaching wall mount bracket to wood studs. Field source appropriate fasteners for other wall constructions (masonry, concrete).

• Attach wall mount bracket level on wall.

• Boiler must engage with wall mount bracket.

• Avoid overhang on sides of wall mount bracket. Verify boiler bracket is centered on wall bracket. See ﬁ gure 4-2.

WARNING

Fire, explosion hazard. Mount boiler vertically or slightly tilted backward to insure proper function of low water cutoff. Failure to follow these instructions could result in death or serious injury.

FIGURE 4-3 Low Water Cutoff Orientation

5° ~ 15°

Factory Default

10°

• When mounting boiler onto wall insert two plastic stoppers and two plastic plugs to packaging holes on back of boiler. See parts listed on page 2, number 17 and 18.

• Mount boiler vertically or slightly tilted backward to insure the low water cutoff functions properly. See ﬁ gure 4-3 for low water cutoff orientation.

CAUTION

Boiler weight exceeds 75 pounds (34 kg). Do not lift boiler onto wall without assistance.

NOTICE

Lift boiler using chassis. Using front jacket, vent piping, water or gas ﬁ ttings to lift boiler may cause damage to the boiler.

5 - HYDRONIC PIPING

5.1 General

• Install piping in accordance with authority having jurisdiction.

NOTICE

Use two (2) wrenches when tightening and ﬁ tting to pipe boiler's threaded ﬁ ttings. Boiler's internal piping can be damaged if subjected to excessive torque.

• Support system piping and safety relief valve discharge piping. Boiler's internal piping and wall mount bracket can be damaged if subjected to excessive weight.

• Size central heating pump (and domestic hot water pump, if used) for system requirements only. Internal heat exchanger pump compensates for pressure drop through boiler internal piping and heat exchanger.

• Thoroughly clean and ﬂ ush system before connecting to boiler.

• If oil is present in system water, use approved detergent to wash system.

• Flush system to remove any solid objects such as metal chips, ﬁ bers, or Teﬂ on tape, etc.

5.2 Special Conditions

• System piping exposed to freezing conditions: Use inhibited proplyene glycol solutions certiﬁ ed by ﬂ uid manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol.

• Boiler installed above radiation level (or as required by authority having jurisdiction). Integral low water cutoff provided in boiler. See pages 9 & 10.

• Boiler used in connection with refrigeration system. Install piping in parallel with boiler, with appropriate valves to prevent chilled medium from entering boiler.

• System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation. Install ﬂ ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

5.3 Safety Relief Valve and Air Vent

WARNING

• Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol.

• Never use automotive or standard glycol antifreeze, even ethylene glycol made for hydronic systems.

• Ethylene glycol can attack gaskets and seals used in hydronic systems.

• Use only inhibited proplyene glycol solutions certiﬁ ed by ﬂ uid manufacturer as acceptable for use with closed water heating system.

• Thoroughly clean and ﬂ ush any system that used glycol before installing new Boiler.

• Provide user with Material Safety Data Sheet (MSDS) on ﬂ uid used.

NOTICE

Do not expose boiler and condensate piping to freezing temperatures.

FIGURE 5-1 Safety Relief Valve & Air Vent (Viewed

from front of boiler)

Safety Relief

Valve

Air Vent

3/4"F x 3/4"M

NPT Tee

3/4 NPT

NOTICE

Boiler rated at 150 psig (1.03 MPa) maximum allowable working pressure. Boiler provided with 30 psig (206 kPa) safety relief valve. Field source safety relief valve for system pressures greater than 25 psig. Temperature Pressure Gauge and Air Vent satisfactory for 75 psig operation. Field source temperature pressure gauge for system pressures greater than 60 psig.

• Install safety relief valve and air vent using pipe ﬁ ttings provided with boiler. See ﬁ gure 5-1

• Install safety relief valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety relief valve.

3/4" x 1/4" NPT

90° Elbow

3/4" NPT

Nipple

Position Air Vent and Safety Relief Valve

to provide space for discharge piping.

5 - HYDRONIC PIPING

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

FIGURE 5-2 Safety Relief Valve Discharge Piping

Safety Relief Valve

• Install discharge piping from safety relief valve. See ﬁ gure 5-2.

• Use ¾" or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

5.4 Trim Piping

• Temperature - Pressure Gauge. Install temperature pressure gauge using nipple, tee and bushing provided with boiler. See ﬁ gure 5-3.

Check Local Codes

For Maximum

Distance To Floor

FIGURE 5-3 Temperature Pressure Gauge and Drain Valve Installations

Gas Supply

Temperature Pressure

Gauge shown at

System Supply

Connection

Drain Valve shown

at System Return

Connection to Boiler

5.5 System Piping

• Drain Valve. Install drain valve using nipple, tee and bushing provided with boiler. See ﬁ gure 5-3.

• See Table 3 for basic system piping conﬁ gurations.

• Systems with automatic ﬁ ll valves require back ﬂ ow prevention device.

• Single boiler system. See ﬁ gures 5-4, 5-5, 5-6, 5-7A, & B for general guidance. Additional considerations:

• Boiler control is designed for single central heating pump. Installer responsible for integration of multiple central heating pumps.

• Boiler control allows domestic hot water prioritization. Function could be lost if central heating pump not directly connected to control system.

• Multiple boiler system. guidance. Additional considerations:

• Control system requires equivalent water temperatures entering each boiler to properly sequence and adjust system supply temperature.

• Install multi boiler sensor kit. See "Parts, Kits & Optional Accessories" manual for part number.

• Heating system with existing primary loop, close internal primary loop ball valve.

• Heating system without existing primary loop, leave internal primary loop ball valve open to use internal primary loop.

See ﬁ gure 5-8A, B & C

for general

5 - HYDRONIC PIPING

NOTICE

Illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction.

FIGURE 5-4 System Piping

Safety Relief Valve

MOUNTED

Piping Legend

WALL

ONLY

Pipe to

condensate

drain

Multiple Boilers

Single Boiler

System

Supply

System

Return

Table 3 - System Piping Conﬁ gurations

Two Pipe Zoned System

Primary/Secondary Pumping

Two Pipe Zoned System

Primary/Secondary Pumping

With Zone Valves ﬁ gure 5-5

With Zone Pumps ﬁ gure 5-6

Closed External Primary Loop

Open External Primary Loop ﬁ gure 5-7B

With Zone Valves ﬁ gure 5-8A

With Zone Pumps Not Shown

Closed External Primary Loop ﬁ gure 5-8B

Open External Primary Loop

ﬁ gure 5-7A

ﬁ gure 5-8C

5 - HYDRONIC PIPING

FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves

DHW Pump

CH/System

Pump

Heat exchanger

ball valve open

(as shipped)

FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps

DHW Pump

Zone

Pump

3/8"/10mm Open

End

Wrench

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm Open

End Wrench

5 - HYDRONIC PIPING

FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping With Closed External Primary Loop

HeatingLoad HeatingLoad

12"(305mm) Maximum

separation

12"(305mm)

CH/System

Pump

Maximum

separation

Existing closely spaced tees

in primary system loop

Limit length

HeatingLoad

5' (1.6m)

Heating system

with existing

primary loop.

Internal primary

3/8"/10mm

Open End Wrench

loop ball valves

closed

FIGURE 5-7B Single Boiler Using Primary/Secondary Pumping With Open External Primary Loop

HeatingLoad HeatingLoad

12"(305mm) Maximum

12"(305mm)

CH/System

Pump

Maximum

separation

Existing closely spaced tees

in primary system loop

Limit length

HeatingLoad

5' (1.6m)

Internal primary loop

ball valves open.

Heating system without existing

3/8"/10mm

Open End Wrench

primary loop.

5 - HYDRONIC PIPING

FIGURE 5-8A Multiple Boiler Two Pipe Zoned System With Zone Valves - (See Multiple Boiler Guide)

DHW Pump

CH/System

Pump

12"/305mm Maximum Separation

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

All internal

primary loop

ball valves

closed

Up to 16

boilers

(See Multiple Boiler Guide)

3/8"/10mm Open End

Wrench

5 - HYDRONIC PIPING

FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping with Closed External Primary Loop

HeatingLoad HeatingLoad

12"/305mm Maximum Separation

CH/System

Pump

System

Temperature

Sensor

Existing closely spaced tees

in primary system loop

HeatingLoad

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

Up to 16

boilers

All internal

primary loop

ball valves

closed

3/8"/10mm Open End

Wrench

5 - HYDRONIC PIPING

5-8C Multiple Boilers Using Primary/Secondary Pumping with Open External Primary Loop

12"/305mm Maximum Separation

CH/System

Pump

System

Temperature

Sensor

Existing closely spaced tees

in primary system loop

Size common piping

per maximum heat

capacity of entire

system

Up to 16

boilers

Limit

length to

5' (1.6m)

Heat exchanger

ball valve open

(as shipped)

3/8"/10mm Open End

Wrench

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

This boiler requires a dedicated direct vent system. Install combustion air and vent piping in accordance with these instructions, authority having jurisdiction,

and:

• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.

• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1

Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

Install vent system in accordance with these instructions.

6.2 Removal of Existing Boiler From Common Vent System

When existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.

After removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation:

• Seal any unused openings in common venting system.

• Visually inspect venting system for proper size and horizontal pitch. Determine there is no blockage or restrictions, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

• When practical, close all building doors, windows, and all doors between space in which appliances remaining connected to common venting system are located and other spaces of building. Turn on clothes dryer and any appliance not connected to common venting system. Turn on exhaust fans, such as range hoods and bathroom exhaust so they will operate at maximum speed. Do not operate summer exhaust fan. Close ﬁ replace dampers.

• Any improper operation of common venting system should be corrected so installation conforms with National Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1. When re-sizing any portion of common venting system, common venting system should be re-sized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

6.3 Venting Materials

• See Table 4

Table 4 - Combustion air and vent pipe ﬁ ttings

must conform with the following:

Item Material Standards

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC schedule 40

Vent Pipe

and Fittings

Pipe

Cement/

Primer

• IPEX is approved vent manufacturer in Canada listed to ULC-S636.

• IPEX System 636 Cements and Primers are approved in Canada listed to ULC-S636.

SDR-21 & SDR-26 PVC ANSI/ASTM D2241

ABS-DWV ANSI/ASTM D2661

Schedule 40ABS ANSI/ASTM F628

PP (Polypropylene)

Pipe and Components

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

ANSI/ASTM D1784/

F441

UL 1738

ULC S636-08

• Turn on appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances will operate continuously.

• Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use ﬂ ame of match or candle, smoke from cigarette, cigar or pipe.

• Determine each appliance remaining connected to common venting system properly vents when tested as outlined above. Then return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition of use.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® ,

(Polyphenolsulfone) in venting systems shall be prohibited.

WARNING

Use of cellular core PVC for venting ﬂ ue gas could result in death, or serious injury.

6 - COMBUSTION AIR AND VENT PIPING

6.4 Vent Pipe Installation

• Minimum and maximum combustion air and vent pipe lengths listed in Table 5. Pipe length counted from combustion air connector to termination.

• Install ﬁ eld-sourced 2" to 3" transition, if used, in vertical section at combustion air inlet and vent connector.

• 90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no equivalent length. See Table 6.

• Use ﬂ exible Polyproplyene piping (PP) in a vertical position only. Check PP pipe manufacturer for details. Each foot of PP ﬂ exible pipe is equivalent to 2⅝ feet of smooth pipe of same diameter.

• Slope vent pipes minimum 1/4" per foot (21 mm/m) back toward boiler. Support horizontal sections to prevent sags capable of accumulating condensate.

• Support piping in accordance with pipe manufacturer's instruction and authority having jurisdiction. In absence of manufacturer's instruction use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located at intervals of 4 ft (1.2m) or less. Allow for expansion/contraction of pipe.

• Canadian installations only. All venting material, primer and glue must be listed to ULC S636.

• Canadian installations only. First 3 ft (0.9 m) of plastic vent pipe from vent connector must be readily accessible for visual inspection.

6.5 Vent Termination

• Terminate combustion air and vent pipes with ﬁ ttings or concentric vent kit.

A. See "Parts, Kits and Optional Accessories" manual

for concentric vent kit part numbers.

B. Use horizontal pipe for vent and 90° elbow for

combustion air termination when using ﬁ ttings.

• Terminate combustion air and vent pipes in same atmospheric pressure zone through exterior sidewall or roof.

• Locate combustion air termination as far as possible from swimming pool, swimming pool pump house, and other sources of airborne chlorine.

• Locate combustion air and vent terminals as required by authority having jurisdiction.

• Combustion air and vent piping must be air tight and water tight.

• Certiﬁ ed vent system components must NOT be interchanged with other vent systems or unlisted pipe/ ﬁ ttings.

Vent extending through exterior wall shall not terminate adjacent to wall or below building extensions such as eaves, balconies, parapets or decks. Failure to comply could result in death or serious injury.

Table 5 - Combustion Air and Vent Piping Length

Minimum/Maximum Vent Lengths

2” Pipe 3” Pipe 4” Pipe

Model 050 075/100 075/100 150/200 299 299

Min.

Max.

For Example: Boiler can be installed on outside wall and vented with one 90° elbow and 1 ft (0.30 m) of vent pipe.

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 ft.

(1.8 m)

50ft.

(15.2 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

Table 6 -Equivalent Length of Venting Components

Equivalent Length of Venting Components

Component Feet Meters

90° Elbow 5 1.6

45° Elbow 3 1/2 1.1

2" x 4" Adapter 0 0

3" x 4" Adapter 0 0

Concentric Vent Kit 5 1.6

Polypropylene Flexible Pipe per Foot 2 5/8 0.8

6 ft.

(1.8 m)

100 ft.

(30.5 m)

WARNING

6 ft.

(1.8 m)

25 ft.

(7.7 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 - COMBUSTION AIR AND VENT PIPING

6.6 Venting Conﬁ gurations

Various venting conﬁ gurations can be applied to this boiler. For guidance see Venting Conﬁ guration Table 7 and

corresponding ﬁ gures.

Table 7 - Venting Conﬁ gurations

Flue Gas Location

Roof

Combustion Air

Location

Roof

Side Wall Single Pipe ﬁ gure 6-8

Inside Air Single Pipe ﬁ gure 6-9

Roof Single Pipe ﬁ gure 6-10

NOTICE

Use of vent covers may cause freezing. If using vent covers overall vent length must be considered. Failure to heed this information may compromise operation of this boiler.

Flue Gas Terminals

Two Pipe ﬁ gure 6-1

Concentric ﬁ gure 6-7

Corresponding Figures

Side Wall

Two Pipe ﬁ gures 6-2, 6-3

Side Wall

Concentric ﬁ gures 6-4, 6-5, 6-6

Inside Air Single Pipe ﬁ gure 6-11

FIGURE 6-1 Two Pipe Roof Vent

3" (80mm)

Minimum

12" (305mm)

Minimum

8" (203mm)

Minimum

Vent Combustion

Air

12" (305mm) US,

18" (458mm) Canada

Minimum Above

Anticipated Snow Line

6 - COMBUSTION AIR AND VENT PIPING

 3" (80mm) Minimum horizontal

separation between combustion air

15" (381mm)

Maximum

Roof Line

Roof

Terminations

intake and vent of same appliance.

 8" (203mm) Minimum vertical

separation between combustion air intake and vent of different appliances.

 15" (381mm) Maximum horizontal

length of vent.

 Minimum vent/intake between

different appliances 12" (305mm).

 Maximum allowable total vertical

vent length with outside exposure is 10 ft.(3.05m).

 Abandoned unused masonry

chimney may be used as chaseway for combustion air and vent. Both combustion air and vent pipe must exit above top of chimney with clearances as shown in ﬁ gure 6-1.

FIGURE 6-2 Two Pipe Side Wall Vent

12" (305mm)

Minimum From

Overhang

See Snow & Ice

Page 22

FIGURE 6-3 Two Pipe Side Wall Vent (Multiple Appliances.

See snow & ice

page 23

3" (80mm)

Minimum

Separation

12" (305mm) Separation

Between Bottom Of

Combustion Air Intake And

Bottom Of Vent

Vent

Combustion Air

12" (305mm)

Minimum

Separation

Side Wall

Terminations

 3" (80mm) Minimum horizontal

separation between combustion air intake and vent terminations.

 8" (203mm) Minimum vertical

separation between combustion air intake and vent terminations.

 12" (305mm) Separation between

bottom of combustion air intake and bottom of vent.

 Multiple terminations as shown

in 6-1, 6-2, and 6-3 must be a minimum of 12” (305mm) horizontally between vent of one termination and air intake of next appliance.

 Maximum allowable total outside

exposure vent length equals 10 ft. (3.05m).

 Maintain a pitch of 1/2" per ft.

(42mm/m) outside exposure back to boiler to ensure proper condensate drainage for horizontal runs.

Combustion Air

Vent

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-4 Side Wall Concentric Terminal FIGURE 6-5 Side Wall Concentric Terminal Multiple

Appliances

1"(2.54cm)

1" (25.4mm)

Maximum

Vent

Combustion

Air

FIGURE 6-6 Concentric Terminal Connection

*2 or 3" (51 or 77 mm) Diameter

PVC intake/combustion air

Roof

1" (25mm)

Maximum

* See Note

Below

Combustion

Air

Overhang

12" (305mm) Minimum

36"(0.9m) Minimum

Vent

Maintain 12"(30cm) US

(18"(46cm) Canada)

highest anticipated

Clearance Above

snow level or grade

Highest Anticipated

Snow Level Or Grade

Maintain 12"

clearance above

*Must be less than 4" (102mm) or greater than 24" (610mm) Horizontal distance between end bells of each air intake to prevent ﬂ ue gas recirculation.

Note: Securing strap must be ﬁ eld installed to prevent movement of termination kit in side wall

Combustion Air

OD 3½" (

89mm)

- *2" (

51mm)

kit

OD 4½" (114mm) - 3" (77mm) kit

** Note Overall length may be modiﬁ ed by cutting or extending both combustion air and vent pipes. 12" (305mm) is minimum allowable length and 60" (1.2m) is maximum allowable length for this dimension.

SDR-26 PVC (D2241) only may be used for extending pipes. Do not use Schedule 40 PVC or use couplings to extend pipes. Dimension will change if intake/vent pipes are lengthened or shortened.

**See

Note

*2" (

51mm)

Diameter = 41" Length (1.1m)

3" (77mm) Diameter = 47" Length (1.2m)

1"(25.4mm) Maximum

Vent

Combustion Air

* Note: 2" (51mm) For use with models 050/075/100. 3" (77mm) For use with models 075/100/150/200/299

4" (101mm) For use with model 299

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-7 Concentric Roof Terminal

Vent

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

Combustion Air

Roof boot/ﬂ ashing (ﬁ eld supplied)

Note: Support must be ﬁ eld installed to secure termination kit to structure

Vent

FIGURE 6-8 Flue on Roof, Air Intake on Side Wall

Vent

anticipated snow level 24"

(610mm) above roof

Support (ﬁ eld supplied)

Combustion Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

Concentric

Vent Roof

Terminations

 Glue inner vent pipe to prevent

recirculation.

 Maintain 12" (305mm) US

(18"(457mm) Canada) minimum clearance above highest anticipated snow level. Maximum of 24"(610mm) above roof.

 Support must be ﬁ eld installed to

secure termination kit to structure.

 Elbow, roof boot/ﬂ ashing ﬁ eld supplied.  Allowed Wall/Roof thickness 1/2"-30"

(12.7mm - 762mm).

 Vertical concentric vent system can be

installed in unused masonry chimney.

 Contact Technical Support 800-

325-5479 for questions regarding installation or use.

Terminate vent system bottom, minimum 12" (300 mm) above highest anticipated snow level.

Combustion Air

12" (305mm) Anticipated Snow Line

Ground Level

FIGURE 6-9 Flue on Roof, Combustion Air

Vent

Combustion

Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

clearance above highest

anticipated snow level 24"

(610mm) above roof

24" (610mm) * Minimum Length

Grade, Snow

& Ice

Doors &

Windows

* See Tables

4 & 5

Avoid locations where snow may drift and block vent and combustion air. Ice or snow may cause boiler to shut down if vent or combustion air becomes obstructed.

Combustion air and vent termination must be 12" (305mm) from or below doors, windows or gravity inlet.

Combustion air and Vent Piping Length Page 22 .

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Dunkirk DKVLT-050, DKVLT-299, DKVLT-075, DKVLT-100, DKVLT-150 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual