Dunkirk H2OI User Manual
H2O
INDIRECT-FIRED
WATER HEATERS
FOR SINGLE WATER HEATER
INSTALLATIONS
INSTALL ATION, OPER ATION &
MAINTENANCE MANUAL
30, 40, 50, 60, 80, 85, 115
Gallon
L = Low Boy Prole
C = Commercial Pipe
Connections
HO = High Output
XHO = Extra High Output
Conforms to UL STD 174
Certied to CAN/CSA STD C22.2 No. 110-94
Information and specications outlined in this manual in effect at the
time of printing of this manual. ECR International, Inc. reserves the
right to discontinue, change specications or system design at any time
without notice and without incurring any obligation, whatsoever.
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
An ISO 9001-2008 Certied Company
P/N# 615000054, Rev. C [12/2014]
MODELS
H2OI30 H2OI80HO
H2OI40 H2OI80HOC
H2OI40L H2OI85XHOC
H2OI50 H2OI115
H2OI60 H2OI115HO
H2OI60HO H2OI115HOC
H2OI60L H2OI115XHOC
H2OI80
Table of Contents
I. General Information ............................................................................................................... 3
II. Pre-installation Considerations ................................................................................................ 5
III. Piping .................................................................................................................................11
IV. Electrical .............................................................................................................................15
V. Operation ............................................................................................................................15
VI. Maintenance ........................................................................................................................20
VII. Troubleshooting ...................................................................................................................22
SAVE THESE INSTRUCTIONS
Hazard Denitions
The following dened terms are used throughout this manual to bring attention to the presence
of hazards or various risk levels or to important information concerning the life of the product.
!
DANGER
!
WARNING
Indicates a presence of hazards that WILL cause severe personal injury,
death or substantial property damage.
Indicates a presence of hazards that CAN cause severe personal injury,
death or substantial property damage.
!
CAUTION
NOTICE
Indicates a presence of hazards that will or can cause minor
personal injury, or property damage.
Indicates special instructions on installation, operation or
maintenance that are important but not related to personal injury
or property damage.
2
I. General Information
IMPORTANT INFORMATION – READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations required in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be
consulted before installations are made.
All wiring on water heaters shall be in accordance with the National Electrical Code and/or local regulations.
!
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss
of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation
and service must be performed only by an experienced, skilled installer or service agency.
This water heater contains very hot water under high pressure. Do not unscrew any pipe ttings or attempt to disconnect
any components of this water heater without positively assuring that the water is cool and has no pressure. Always wear
protective clothing and equipment when installing, starting up or servicing this water heater to prevent scalding injuries.
Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the water heater.
This water heater contains components that become very hot when the boiler is operating. Do not touch any components
unless they are cool.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all
those contained in component manufacturers’ manuals before installing, starting up, operating, maintaining, or servicing
the water heater.
!
CAUTION
To reduce the risk of excessive pressures and temperatures in this water heater, install temperature and pressure
protective equipment required by local codes but no less than a combination temperature relief valve certied by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials,
as meeting the requirements for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22latest edition. This valve must be marked with a maximum set pressure not to exceed the marked working pressure of
the water heater. Install the valve into an opening provide and marked for this purpose in the water heater, and orient it
or provide tubing so that any discharge from the valve will exit only within 6 inches above, or at any distance below, the
structural oor, and cannot contact any live electrical part. The discharge opening must not be blocked or reduced in size
under any circumstances.
These water heaters with single-wall stainless steel heat exchangers meet the Uniform Plumbing Code for installation in
potable water systems provided that:
• The boiler water, including additives, is practically non-toxic, having a toxicity rating of class 1 as listed in Clinical
Toxicology of Commercial Products, latest edition.
• The boiler water pressure is limited to maximum 30 psig by an approved safety or relief valve.
• The heat transfer medium is potable water or contains only substances that are recognized as safe by the U.S. Food
and Drug Administration. (FDA)
• The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the
potable water system.
The maximum boiler water supply temperature to the indirect heat exchanger must not exceed 240 deg. F (115 deg. C).
Improper water quality will reduce the life of the water heater. Hard water, sediment, high or low PH and high levels of
chlorides in the domestic water should be avoided. Be sure that PH levels fall between 6 and 8 and dissolved chlorides
are less than 100 ppm. A lter must be used where sediment is greater than 5 microns in size in the water supplied to
the unit. A water softening system is recommended for areas with hard water. In cases where water quality is unknown, a
qualied water treatment expert should be consulted.
NOTICE: Damage to tanks caused by improper water quality is not covered under the warranty.
3
!
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance.
If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in
the building. Immediately, call the gas supplier from a remote located phone. Follow the gas supplier’s instructions or if
the supplier is unavailable, contact the re department.
!
DANGER
This water heater is supplied with an adjustable thermostat to control the water temperature. Hot water temperatures
required for automatic dishwashers and laundry use can cause scald burns resulting in serious personal injury and/or
death. The temperature at which injury occurs varies with the person’s age and the time of exposure. The slower response
time of disabled persons increases the hazard to them. NEVER allow small children to use a hot water tap or to draw their
own bath water. NEVER leave a child or disabled person unattended in a bathtub or a shower.increases the hazard to
them. NEVER allow small children to use a hot water tap or to draw their own bath water. NEVER leave a child or disabled
person unattended in a bathtub or a shower.
II. IMPORTANT SAFETY INSTRUCTIONS
!
WARNING
– When using electrical appliances, basic safety precautions to reduce the risk of re,
electric shock, or injury to persons should be followed, including:
READ ALL INSTRUCTIONS BEFORE USING THIS INDIRECT WATER HEATER.
1.
Install or locate this water heater only in accordance with the provided installation instructions
2.
Use this water heater only for its intended use as described in this manual.
3.
As with any appliance, close supervision is necessary when used by children.
4.
Do not operate this water heater, if it is not working properly, or if it has been damaged or dropped.
5.
This water heater should be serviced only by qualied personnel. Contact nearest authorized service facility for
examination, repair, or adjustment.
4
II. Pre-installation Considerations
Inspect shipment carefully for signs of damage. All equipment is carefully inspected and packed. Manufacturer’s
responsibility ceases upon delivery of the water heater to the carrier in good condition. Any claims for damage or
shortage, must be led immediately against the carrier by the consignee. No claims for variances or shortages will be
allowed by the Manufacturer, unless they are presented within sixty days after receipt of the equipment.
Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements,
installation must conform to the National Plumbing Code and the National Electrical Code ANSI/NFPA No. 70, current
edition.
IMPORTANT CONSIDERATIONS BEFORE INSTALLATION
1.
Water Heater Sizing.
Choose the water heater model based on the expected water usage for the given site. The average residence
with one shower or more will require a Model 40 or larger. The Model 30 should only be considered for
residences with minimal water demand, or for commercial applications without showers. See Tables 2 and 3.
Consult ASHRAE sizing guides and other references.
Factors that increase water demand dramatically include high ow shower heads, hot tubs, and the use of more than one
shower at a time. Increase the tank size if these factors are present. Consult ASHRAE sizing guides and other references.
Dimensions, weights, ratings, and capacities are outlined in Table 1.
2.
Boiler Sizing.
The water heater will provide the rated performance only if it is used with a boiler with a heating capacity of at least as
much as the capacity ratings in Tables 2 and 3. If the boiler has less capacity, the water heating output will be reduced.
NOTICE
If the boiler takes longer to heat up from a cold start, hot water shortage may occur.
The maximum heat transfers through the coil (heat input) of the water heaters at 240 deg.
F boiler supply temperature and 210 deg. F potable water temperature are as follows:
• Models 30 – 115 single coil units and models 60-D, 80-D, and 115-D dual coil units
are less than 96,000 BTU/HR.
• Models 80-HO, 115-HO, 80-HO-C, and 115-HO-C high output units are less than
84,000 BTU/HR.
• Models 85-XHO and 115-XHO, the extra high output series, are less than 175,000
BTU/HR.
Potable water temperature is limited to below 210 deg. F and nominal water containing
capacity is below 120 gallons for all indirect models.
Accordingly, per Part HLW-101.2, Section IV of the ASME Boiler and Pressure Vessel Code,
all indirect water heater products are exempt from compliance with the code.
Check with local codes for applicability
5
STANDARD AND HO UNITS
HOC UNITS
6
XHOC EXTRA HIGH OUTPUT UNITS
XHOC HIGH OUTPUT INDIRECTS
MODEL 115-XHOC - HEIGHT = 74" - 115 GAL.
MODEL 85-XHOC - HEIGHT = 64" - 86 GAL.
COLD AND HOT DOMESTIC - 1 ½" NPT CONNECTIONS
COIL SUPPLY AND RETURN - 1 ½" NPT CONNECTIONS
TABLE 1- Dimensions and Capacities
Model
Storage
Volume
Coil
Heating
Surface
Dimensions
(Inches)
Gals. Sq. Ft. Ht. Dia.
Piping Connections
N.P.T
Domestic
Water
In/Out
Boiler
Water
In/Out
Max. Tank
Working
Pressure
Max. Coil
Working
Pressure
shipping
(psi) (psi) Lbs.
Approx.
H2OI30 30 7.3 34.0 23.5 3/4 1 150 90 85
H2OI40 40 7.7 44.0 23.5 3/4 1 150 90 100
H2OI40L 42 7.4 36.0 28.0 3/4 1 150 90 100
H2OI50 50 8.2 54.0 23.5 3/4 1 150 90 110
H20I60 60 8.6 62.0 23.5 3/4 1 150 90 125
H2OI60L 60 7.7 46.0 28.0 3/4 1 150 90 120
H2OI80 80 8.2 56.0 28.0 1 1 150 90 140
H2OI115 115 9.1 74.0 28.0 1 1 150 90 175
High Output Units
H2OI60HO 60 15.1 62.0 23.5 1 1 150 90 145
H2OI80HO 80 14.8 56.0 28.0 1 1 150 90 155
H2OI8H0C 80 14.8 56.0 28.0 1½ 1¼ 150 90 155
H2OI115HO 115 15.6 74.0 28.0 1 1 150 90 190
H2OI115HOC 115 15.6 74.0 28.0 1½ 1¼ 150 90 190
Extra High Output Units 85-XHO and 115-XHO
H20I85XHOC 87 28.7 64.0 28.0 1½ 1½ 150 90 215
H20I115XHOC 115 28.7 74.0 28.0 1½ 1½ 150 90 240
Wt.
7
Table 2 - 200 deg F Boiler Supply Ratings
Max. First
Hour Rating
Continuous
Rating
Boiler Output
Needed
Model
Gal/Hr. @ Gal/Hr @
140 F 115 F 140 F 115 F
H20I30 202 269 175 242 131,250 14.0 5.3
H2OI40 221 292 185 256 138,670 14.0 5.7
H2OI40L 212 251 176 215 132,000 14.0 5.3
H2OI50 223 291 178 246 133,280 14.0 6.0
H20I60 262 342 208 288 155,700 14.0 6.2
H20I60L 239 310 185 256 138,570 14.0 5.7
H2OI80 271 248 199 276 149,390 14.0 6.0
H2OI115 324 409 221 306 165,750 14.0 6.6
(BTU/Hr) Gal/Min (Ft. Water)
Boiler Water
Flow Through
Coil
Pressure
Drop
Through Coil
High Output Units 60-HO, 80-HO, and 15-HO
H2OI60HO 406 541 352 478 263,600 14.0 10.1
H2OI80HO 418 551 346 479 259,340 14.0 9.9
H2OI80HOC 442 584 370 512 277,070 21.0 10.5
H2OI15HO 467 607 364 504 273,100 14.0 15.8
H2OI115HOC 479 623 376 520 281,800 21.0 16.7
Extra High Output Units 85-XHO and 115-XHO
H2OI85XHOC 738 992 660 914 495,000 28.0 13.0
H2OI115XHOC 763 1017 660 914 495,000 28.0 13.0
Table 3 - 180 deg F Boiler Supply Ratings
Max. First
Hour Rating
Model
Gal/Hr. @ Gal/Hr @
140 F 115 F 140 F 115 F
H20I30 176 233 149 206 111,560 14.0 5.3
H2OI40 193 254 157 218 117,870 14.0 5.7
H2OI40L 186 251 150 215 223,300 14.0 5.3
H2OI50 196 254 151 209 113,290 14.0 6.0
H20I60 231 298 177 244 132,340 14.0 6.2
H20I60L 211 272 157 218 117,785 14.0 5.7
H2OI80 241 306 169 234 126,980 14.0 6.0
H2OI115 291 363 188 260 140,890 14.0 6.6
High Output Units 60-HO, 80-HO, and 15-HO
H2OI60HO 353 468 299 414 224,200 14.0 10.1
H2OI80HO 366 479 294 407 220,440 14.0 9.9
H2OI80HOC 386 507 314 435 235,510 21.0 10.5
H2OI15HO 413 532 310 429 232,135 14.0 15.8
H2OI115HOC 423 545 320 442 239,530 21.0 16.7
Extra High Output Units 85-XHO and 115-XHO
H2OI85XHOC 649 868 571 790 428,000 28.0 13.0
H2OI115XHOC 674 893 571 790 428,000 28.0 13.0
Continuous
Rating
Boiler Output
Needed
Boiler Water
Flow Through
Coil
Pressure
Drop
Through Coil
(BTU/Hr) Gal/Min (Ft. Water)
NOTE: All ratings are based on 50 deg. F cold water inlet.
8
3.
Circulator Sizing.
Refer to Tables 2 and 3 for the minimum ow through the water heater coil and the pressure drop at minimum ow.
Calculate the pressure drop across all piping and ttings connected to the water heater zone. Be sure to include all zone
valves, check valves, and shut-off valves. It is recommended that the water heater zone be piped with 1” pipe around the
entire loop on typical residential sites.
A. System Zone Control
The water heater must be installed as a separate zone from the space heating system. The water heating zone’s piping
and circulator must be sized for the minimum ow rate with all the zones in use and a maximum ow with only the water
heater in use. Best performance is normally achieved using zone control with circulators.
The three most common systems are:
1.
Zone Circulators- Space heating zones use a circulator for each zone. The water heater is controlled with an
additional circulator.
2.
Hybrid System- Space heating zones use zone valves for each zone. The water heater is controlled with an
additional circulator.
3.
Zone Valves – Space heating zones use zone valves for each zone. The water heater is controlled with an
additional zone valve. Select a valve with a low pressure drop, and assure minimum ow with adequate pipe
sizing.
B. Priority or Non-Priority for Hot Water
1.
Option 1 – Priority. The demand for space heating is interrupted until the hot water demand is satised. This
option provides the maximum delivery of hot water.
Priority is recommended when:
A. The boiler output is less than 100,000 Btu per hour, or
B. The boiler output required to satisfy the hot water demand is more than 50% of the boiler output needed to
satisfy the space heating demand, or
C. When an interruption in space heating can be tolerated during long domestic hot water draws.
In most cases the delay in space heating will not be noticed because of the rapid recovery of the water
heater. It must be recognized however that certain water heater malfunctions, such as a failed thermostat or
circulator, could delay space heating indenitely.
2.
Option 2 – Non-Priority. The boiler output is divided between space heating and water heating. Heating of
domestic hot water can be reduced during simultaneous space and water heating demands. The amount of
reduction depends on the boiler output, the number of space heating zones calling, and the amount of boiler
water ow split between the space heating and zones and the water heater zone.
9
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