Dunkirk Q90-100, Q90-50, Q90-75 Installation Guide

Z

Aluminum Series 90+

Gas Fired Boiler Installation Guidelines,

Water Treatment and Antifreeze Protection

P/N 240006888 Rev 1.0 [10/07]

IMPORTANT: These instructions are in addition to any existing

Antifreeze and Water Treatment information in the boiler instal-

lation manual, the boilers user's manual or any other existing

supplemental instruction or addendum. Antifreeze may be used

in most applications. Water alone may also be used in most

applications. Consult with your heating professional for recom-

mendations.

The information in this Supplemental Instruction is to be used

in place of that in the following manuals: 14683301 rev 3.4,

240004826D rev 1.3, 240006103D rev 1.1, 14683604 rev 3.4,
240004826K rev 1.3, 14683450 rev 3.5, 1305016 rev 2.1,

1305016 rev 2.1,240004826B rev 1.3, 240004826BF rev 1.3,

240006103B rev 1.1, 240006103BF rev 1.0, 1305011 rev 3.4,
240004826U rev 1.3, 240006103U rev 1.1.

Recommendations

* System leaks may not always be visible. An unseen system

leak will become obvious if boiler pressure decreases when
make up valve is closed.

* All system leaks must be repaired immediately. Constant in-

troduction of make up water will introduce dissolved oxygen,

resulting in accelerated boiler corrosion.

Water Chemistrv L.

* This boiler is designed for a closed loop hydronic heat sys-

tem ONLY! This boiler is not suitable for natural gravity type

installations, or any other open type system.

* System fluid pH must be maintained between 7.0 and 8.0.
* Maintain water hardness below 7 grains hardness.

* Filling with chlorinated fresh water should be acceptable

since drinking water chlorine levels are typically less than
5 ppm. Do not fill boiler with water containing chlorine in

excess of 100 ppm.

• Do not use inhibitors or other 2.
additives that are not specifically

approved for this product.

• Consult a local water treatment

specialist for recommendations

if any of the above are outside

the stated ranges. 3.

Cleanin tht_tb__vdronic S_stem:

IMPORTANT: Do not mix dif-
ferent manufacturers' prod-

ucts. Doing so will void the
warranty of the boiler.

Consideration should be given

to cleaning the heating system,
particularly in retrofit situations

where a new boiler with an alu-

minum heat exchanger is being
installed in an existing piping sys-

tem. Systems that have antifreeze
that is not approved by the boiler

manufacturer must be completely
flushed to ensure no unapproved

antifreeze remains

In older systems obviously discol-

ored, murky or dirty water; or a pH
reading outside the boiler manu-

facturer's stated acceptable range

are indications that the system
should be cleaned or treated.

1. Measure total capacity of the
system including the piping,

tanks, boiler, collector plates,
etc. The most accurate method

of measuring fluid capacity is
to fill the system and then com-

pletely drain it, volumetrically
measuring the fluid drained.

Freeze Protection

Aluminum Safe Antifreeze, Treat-

Antifreeze, if needed, must be of a

• Always clean system prior to us-

• Only use the antifreeze manu-

• Use of antifreeze must be in accor-

Thoroughly flush the system

with clean water to remove

any sediment or contaminants.
Sludge and iron oxide deposits

can cause rapid breakdown of
inhibitors.

Cleaning fluid - Flushing with

clean water is preferred. If
cleaning fluid is used, only

use cleaner specifically ap-
proved for use with alu-

minum boilers. Utilize the
cleaner in accordance with

manufacturer's instructions.

merits and Additive Guidelines:

type specifically designed for use
in closed hydronic heating systems

and be compatible with type 356
T6 aluminum at operating temper-

atures between 20°F (-6.7°C) and
250°F (121 °C). See the "Approved

Aluminum Antifreeze & Inhibitor

Suppliers" section of this manual

for a list of boiler manufacturer ap-

proved products.

ing antifreeze, refer to the Clean=
ing the Hydronic System section

of this manual for details.

facturers' products outlined in
this document.

dance with local plumbing codes.

• Antifreeze wilt raise the pH of
the hydronic solution in a heat-

ing system above the recom-
mended level due to the corro-

sion inhibitors in the antifreeze.
The solution must be treated to

maintain a pH within the boiler
manufacturer's recommended

level to avoid damage to the heat
exchanger. Follow antifreeze

manufacturer's instructions for
details on how to adjust the pH.

• If the system has leaked for
some reason, the water and an-

tifreeze chemistry will need to
be adjusted. To avoid damage

to the boiler, check the pH and
chemistry of the boiler solution

and consult the antifreeze man-
ufacturer for recommendations.

• It is recommended that a pH
reading is taken annually, and

adjusted as necessary. Follow
antifreeze / inhibitor manufac-

turer's instructions for details on
how to adjust the pH.

_NOTICE: Antifreeze solutions can

breakdown over time. Failure to
check antifreeze chemist_ including

inhibitors, periodically may result in
accelerated corrosion of boiler and

other system components. Consult
with the antifreeze manufacturer for

recommendations.

• Use of antifreeze in any boiler
will reduce heating capacity as

much as 10-20%. This must be
taken into consideration when

sizing the heating system, pumps
and expansion tank. Consult an-

tifreeze manufacturer's literature

for specific information on re-

duced capacity.

• Using the antifreeze manufac-

turer's instructions determine
the freezing temperature need-

ed and use the correct amount
of antifreeze. Never exceed 50%

antifreeze by volume.

• The boiler operating pressure

must remain below 15 psi for an-
tifreeze solutions that specify a

maximum of 250°F (121_C).

Aj2proved Aluminum Antifreeze & Inhibitor Suj2pliers:

Approved Product(s):

Intercool NFP-30,40,50 AA
Intercool RPH-15*

Interstate Chemical

2797 Freedtand Road
P.O. Box 1600

Hermitage, PA 16148-0600

* This product may be used to adjust the

pH level of the hydronic system, but on

occasion may not resolve the pH issue.
In these cases it is recommended to

flush the system and refill with untreat-
ed water and new boiler manufacturer

approved antifreeze suitable for Alumi-
num heat exchangers.

www.interstatechemical.com

Tel: [phone]

Fax: [phone]

(Continued) Aj2proved Aluminum Antifreeze & Inhibitor Sup.pliers:

Approved Product(s):

Noburst AL Antifreeze

Approved Product(s):

Rhogard Antifreeeze
Pro-Tek 922 Inhibitor*

Rhomar Water Management, Inc.

PO Box 229

Springfield, MO 65801
www.rhomarwater.com

Tel: [phone]

Fax: [phone]

Approved Product(s):

Atphi-11

Nydronic Agencies Ltd.

(Fernox North America Distributor)
15363 117 Avenue

Edmonton, AB T5M 3X4
Canada

www.hydronicagencies.com
Tel: [phone]

Fax: [phone]

Noble Company

PO Box 350
Grand Haven, MI 49417
www.noblecompany.com

Tel: [phone]

Fax: [phone]

* This product may be used to ad-

just the pH level of the hydronic

system, but on occasion may not
resolve the pH issue. In these

cases it is recommended to flush
the system and refill with untreat-

ed water and new boiler manu-
facturer approved antifreeze

suitable for Aluminum heat ex-
changers.

Fernox

www.fe rn ox. com
Tel: [phone]

Fax: [phone]

Fernox Technical Service

Tel: [phone]