Model Q95M-200 Q95M-200 GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured by: ECR International, Inc. An ISO 9001-2008 Certified Company 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com P/N# 240006103D, Rev.
1 - DIMENSIONS 18” (458mm) OPENING FOR SAFETY RELIEF VALVE DISCHARGE PIPE 30⅞” (785mm) 39⅜” (1.
2 - INTRODUCTION 1 - Dimensions...............................................................................................................2 2 - Introduction..............................................................................................................3 3 - Important Safety Information......................................................................................4 4 - Boiler Ratings & Capacities.........................................................................................
3 - IMPORTANT SAFETY INFORMATION 3.1 General Boiler installation shall be completed by qualified agency. See glossary for additional information. 3.2 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: • United States • National Fuel Gas Code, ANSI Z223.1/NFPA 54. ! WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury.
4 - BOILER RATINGS & CAPACITIES TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES Input (MBH)(1) Heating Capacity (MBH)(1)(2) Net AHRI Rating (MBH)(1) High Fire 200 182 158 Low Fire 80 73 63 (1) (2) AFUE(2) 92.5% Flue Diameter Shipping Wt. 2” CPVC & 3” PVC 284 lbs. 1 MBH = 1,000 BTUH (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
5 - BEFORE INSTALLING THE BOILER 5.1 Before Boiler Installation 5.2 Boiler Sizing • Verify you have selected boiler with proper capacity before continuing installation. AHRI Rating of selected boiler should be greater than or equal to calculated peak heating load (heat loss) for the building or area(s) served by boiler and associated hot water heating systems. See Sea Level Ratings - Natural and Propane Gases” Section 4. 1. Boiler is equipped for residential installations.
6 - LOCATING THE BOILER 6.1 Locating the Boiler 1. Place crated boiler as close to selected location as TABLE 3: BOILER CLEARANCES Dimension possible and un-crate boiler. Boiler may be moved into position with appliance dolly or 2 wheel hand truck. Insert dolly or hand truck under right hand side of boiler. It is possible to slide boiler for short distance on smooth floor or surface. 2. Select level location central to piping systems served and as close to vent and air intake terminals as possible. 3.
6 - LOCATING THE BOILER 6.2 Combustion Air and Vent Pipe Requirements 6.4 Removal of Existing Boiler From Common Vent System • This boiler requires dedicated direct vent system. • In direct vent system all air for combustion is taken directly from outside atmosphere, and all flue products are discharged to outside atmosphere. • Combustion air and vent pipe connections must terminate together in same atmospheric pressure zone, either through roof or sidewall (roof termination preferred).
7 - NEAR BOILER PIPING 7.1 Clean System First 7.2 Supply & Return Lines Before connecting boiler to heating system, clean and flush system thoroughly. Verify system is free of sediment, flux and any residual boiler water additives. See Appendix A for piping examples. • Packaged boiler set to receive 1¼” NPT return piping from rear of unit with option for left or right return connections. • Use two furnished dielectric unions at boiler supply and return connections between copper system piping and boiler.
7 - NEAR BOILER PIPING 7.3 Safety Relief Valve / Temperature Pressure Gauge ! WARNING Figure 2 - Safety Relief Valve Discharge Piping Safety Relief Valve Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. Installation of (supplied) safety relief valve shall conform to ANSI/ASME Boiler and Pressure Vessel Code, Section IV. • Install furnished safety relief valve using 3/4” pipe fittings provided with boiler.
7 - NEAR BOILER PIPING 7.5 Condensate Drain Piping 7.7 Chilled Water Piping Boiler is factory equipped with a condensate trap. Additional trap is not required and should NOT be used. • Use supplied 1/2” PVC tee, transition to ½” pipe and fittings for PVC condensate drain line. • The ½” diameter schedule 40 PVC or CPVC condensate drain and pipe fittings must conform to ANSI standards and ASTM D 1785 or D2846. • Schedule 40 PVC or CPVC cement and primer must conform to ASTM D2564 or F493.
8 - COMBUSTION AIR AND VENT PIPE 8.1 Connections And Termination Boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment” of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or “Venting Systems and Air Supply for Appliances”, of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.
8 - COMBUSTION AIR AND VENT PIPE ! WARNING 8.2 Vent/Air Intake Termination Location Consider following when determining appropriate location for termination of combustion air and vent piping. A. Position termination where vent vapors will not damage plants/shrubs, air conditioning equipment, or siding on the house. Allowable Vent and Air Intake Lengths B. Position termination so it will not be effected by wind 3” Pipe Min. Length 3” Pipe Max.
8 - COMBUSTION AIR AND VENT PIPE Figure 5 - Side Wall Vent / Intake terminations - Less Than 12” Clearance Above Grade 3” MIN SEPARATION 14
8 - COMBUSTION AIR AND VENT PIPE Figure 6 -Roof Vent / Intake Terminations 3” MINIMUM SEPARATION Figure 7 - Concentric Vent Terminations 1" (26mm) Maximum 1" (26mm) Maximum Roof Overhang 12" (300mm) Minimum * See Note Below 36"(915mm) Minimum Vent Combustion Air Vent Combustion Air Maintain 12"(300mm) clearance above highest anticipated snow level or grade *Must be less than 4" (102mm) or greater than 24"(610mm) Horizontal distance between end bells of each air intake to prevent flue gas recirc
8 - COMBUSTION AIR AND VENT PIPE Figure 8 - Concentric Vent w/ Dimensions 8.3 Installation When transitioning from CPVC to PVC use Weld-On CPVC 724 or other cement approved for CPVC to PVC. In Canada ULC S636 approved cement must be used. A 1. Recommend all pipes be cut, prepared, and pre- assembled before permanently cementing any joint. 2. Rigid supports cause excess noise in vent piping. 3. Attach combustion air intake piping to supplied 2” 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
9 - GAS SUPPLY PIPING ! CAUTION • • • • 9.2 Connecting Gas Piping WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions. If you cannot reach your gas supplier, call the fire department. 9.1 Check Gas Supply TABLE 6: GAS SUPPLY PRESSURE Natural Gas 4” min. w.c. 10” max. w.c. LP Gas 10” min. w.c. 14” max. w.c.
9 - GAS SUPPLY PIPING ! DANGER Figure 10 - Gas Piping Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Failure to comply will result in death or serious injury. 9.3 Leak Check Gas Piping After making gas connections, open manual shutoff valve(s) and check all gas connections for leaks before placing boiler in operation.
10 - ELECTRICAL WIRING ! WARNING Figure 11 - Line Voltage Monitor Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. 10.1 Codes Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. In absence of such requirements, Refer to: • USA - National Electrical Code, ANSI/NFPA 70. • Canada - Canadian Electrical Code, Part I, CSA C22.
10 - ELECTRICAL WIRING 10.6 Thermostat 1. Connect room thermostat or end switch (isolated AVOID THE FOLLOWING contact only) between terminals T1 and T2. 2. Install thermostat on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sun rays, or fireplaces. 3. Thermostat anticipator (if applicable) A. Set for 0.1 amps if connected directly to boiler. B.
11 - CONTROLS AND ACCESSORIES Refer to Repair Parts Manual for illustrations, and Control Manual and Troubleshooting Guide for detailed sequence of operation and troubleshooting guide. • Gas controls perform all functions required to safely regulate gas flow to main burner of boiler. • Gas valve is directly connected to gas/air mixer. 11.1 Aluminum Heat Exchanger • Monoblock design cast aluminum heat exchanger eliminates need for mating sections eliminates leaks between sections.
11 - CONTROLS AND ACCESSORIES • High limit control is mounted in ½” NPT control well and ¾” X ½” bushing on top of front boiler section at hot water outlet. • High limit control is tied in with boiler control and is factory set at 180°F (82°C) water temperature. • High limit setpoint is field adjustable and may be set anywhere between 100°F (38°C) and 180°F (82°C), with maximum high limit setpoint not exceeding 180°F (82°C).
12 - BOILER STARTUP Water Treatment And Freeze Protection - See Appendix B 2. Systems With Conventional Closed Type Expansion Tanks A. Close all zone service valves on supply and return piping and close expansion tank service valve. Drain expansion tank. Open feed valve and fill boiler with water. Hold relief valve open until water runs air free for five seconds to rapidly bleed air from boiler, then let relief valve snap shut. B. Open zone service valve on supply pipe for first zone.
13 - OPERATING INSTRUCTIONS ! CAUTION 13.1 Lighting Instructions For Your Safety Read Before Operating!! WHAT TO DO IF YOU SMELL GAS ! WARNING • Do not try to light any appliance. If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. • This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to light this burner by hand. • Before operating smell all around appliance area for gas.
14 - MAINTENANCE AND CLEANING Acidic nature of flue gases condensing on aluminum boiler sections cause formation of aluminum oxide. This oxide formation is normal, and represents negligible mass of aluminum consumed by oxidation during life of boiler. If left unchecked, this buildup may eventually cause blockage of flue gas passages in boiler sections, reducing efficiency, and ultimately shutting boiler down due to lack of combustion air flow, or drainage of condensate. 14.2 Daily During Heating Season 1.
14 - MAINTENANCE AND CLEANING ! WARNING G. Aluminum oxide deposits are water soluble and may be rinsed away by inserting hose into burner opening of casting and slowly run water through flue side of boiler and out condensate drain. Debris rinsed away by this method will exit through condensate drain. Be wary of drain lines getting clogged and causing water to back up in the bottom of casting. H.
APPENDIX A - BOILER PIPING AND WIRING Electrical Wiring Diagram 27
APPENDIX A - BOILER PIPING AND WIRING Boiler Control Wiring Diagram: Single Zone System With Domestic Hot Water Priority BOILER CONTROL PANEL T-STAT CH T1 L1 CH T2 L2 DHW T1 CH C1 DHW T2 CH C2 A1 DHW C1 A2 DHW C2 L1 120 VAC L2 CH CIRC OUTDOOR AIR SENSOR DHW CIRC Note: CH & DHW Circulator connections on boiler only support pump with 1 amp rating or less.
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 1: Single Zone System With Domestic Hot Water Priority NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS Wiring Diagram 1 : Single Zone System With Domestic Hot Water Priority Hotline indirect water heater aquastat or thermostat Boiler Control Panel T-STAT AR822-II TORQUE TERMINAL SCREWS 6 TO 7 INCH LBS AR822-TT T 24V W C NO 5 6 CH T2 L2 6 DHW T1 CH C1 DHW T2 CH C2 A1 DHW C1 A2 DHW C2 DHW CIRC L2 120 VAC 4 NO OUTDOOR AIR SENSOR
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 2 : Multizone Piping With Zone Valves And Domestic Hot Water Priority (With Zone Valve) NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS 30
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 2: Multizone Wiring With Zone Valves And Domestic Hot Water Priority (With Zone Valve) SWITCH LEGEND INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT TANK CONTROL ON OFF T-STAT T-STAT ARGO AZ-4CUP CONTROL L Yellow T T T T T T X N X 24VAC 40 VA STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON ZONE VALVE/PUMP PRIORITY ZR-ZC ZC ON L DPM-2 LINE IN OPTION SWITCH N N L PRIMARY PUMP N L PRIORITY PUMP N FROM BOILER L
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 3 : Multizone System With Zone Valves And Domestic Hot Water Priority (With Circulator) NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS 32
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 3: Multizone System With Zone Valves And Domestic Hot Water Priority (With Circulator) SWITCH LEGEND INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT TANK CONTROL ON OFF T-STAT T-STAT ARGO AZ-4CP CONTROL L Yellow T T T T T X N 24VAC 40 VA ON ZONE VALVE/PUMP PRIORITY ZR-ZC ZC ON L DPM-2 LINE IN OPTION SWITCH N N L PRIMARY PUMP N L PRIORITY PUMP N FROM BOILER L ZR ZC ZONE 2 PRI ZONE BLACK 1 DWH CIRCULATOR Boiler Control Pa
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 4: Multizone System With Circulators And Domestic Hot Water Priority NOTE: NOT RECOMMENDED FOR ANTIFREEZE APPLICATIONS 34
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 4: Multizone System With Circulators And Domestic Hot Water Priority Hotline indirect water heater aquastat or thermostat NOTE: IN PLACE OF 115 VOLT ISOLATION RELAY, OPTIONAL CONTROL ARGO AR822II T-STAT T-STAT T-STAT TERMINAL 5 & 6 N.O.
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 5 : Primary/Secondary Piping With Circulators And Domestic Hot Water MAX = 4 X DIAMETER CLOSELY - SPACED TEES BOILER PUMP *SEE NOTE NOTE: RECOMMENDED FOR ANTIFREEZE APPLICATIONS 36
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 5 : Primary/Secondary Wiring With Circulators And Domestic Hot Water INDIRECT HOT WATER HEATER AQUASTAT OR THERMOSTAT NOTE: IN PLACE OF 115 VOLT ISOLATION RELAY, OPTIONAL CONTROL ARGO AR822II TERMINAL 5 & 6 N.O. TO DHW T1 & DHW T2 T-STAT TORQUE TERMINAL SCREWS 6 TO 7 INCH LBS AR822-TT TT ELECTRONIC FUSE T R NO 5 6 T-STAT NC 6 THERMOSTATS DATA PORT PRIORITY ZONE 1.2K TW 2.
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 6 : Primary/Secondary Multizone System Piping With Zone Valves And Domestic Hot Water (With Zone Valve) ZONE 1 (PRIORITY ZONE)* * USE FULL PORT ZONE VALVE. FOR OPTIMUM TANK PERFORMANCE, CONSIDER USING ZONE CIRCULATOR.
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 6 : Primary/Secondary Multizone System Wiring With Zone Valves And Domestic Hot Water (With Zone Valve) INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT SWITCH LEGEND ON OFF TANK CONTROL T-STAT T-STAT ARGO AZ-4CP CONTROL T Yellow T T T T T T T Yellow X STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON 24VAC 40 VA TRANSFORMER X ON ZONE VALVE/PUMP PRIORITY ZR-ZC ZC ON Black DPM-2 OPTION SWITCH White L PRIORITY PUMP N
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 7 : Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator) ZONE VALVE MAX = 4 X DIAMETER CLOSELY - SPACED TEES *SEE NOTE NOTE: RECOMMENDED FOR ANTIFREEZE APPLICATIONS 40
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 7 : Primary/Secondary Piping With Zone Valves And Domestic Hot Water (With Circulator) INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT SWITCH LEGEND ON OFF TANK CONTROL T-STAT ARGO AZ-4CP CONTROL T Yellow T T T T T-STAT T T T Yellow X STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON 24VAC 40 VA TRANSFORMER X ON ZONE VALVE/PUMP PRIORITY ZR-ZC ZC ON Black DPM-2 OPTION SWITCH White PRIMARY PUMP N L PRIORITY PUMP N L
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 8 : Bypass Piping (Automatic Mixing Valve) FROM SYSTEM TO SYSTEM WATER INLET EXPANSION TANK BOILER CIRCULATOR PRESSURE REDUCER VALVE Piping Diagram 9SHUT-OFF : Bypass Piping (Fixed LowVALVE Temp Only) CHECK VALVE ALTERNATE CIRCULATOR LOCATION BALL VALVE AIR SEPARATOR 3 WAY MIXING VALVE HOSE BIB FROM SYSTEM TO SYSTEM V1 V2 SYSTEM CIRCULATOR WATER INLET EXPANSION TANK CIRCULATOR SHUT-OFF VALVE BOILER ALTERNATE CIRCULATOR LOCATION PRES
APPENDIX A - BOILER PIPING AND WIRING Piping Diagram 10 : Bypass Piping (4-Way Valve Option With Circulator On Supply) TO SYSTEM FROM SYSTEM WATER INLET EXPANSION TANK BOILER PRESSURE Piping Diagram 11 : Multiple Boiler Piping CIRCULATOR BALL VALVE REDUCER VALVE SHUT-OFF VALVE CHECK VALVE TO SYSTEM ALTERNATE CIRCULATOR LOCATION AIR SEPARATOR 4-WAY MIXING VALVE HOSE BIB 12” MAX 12” MAX FLOW CONTROL VALVE FROM SYSTEM WATER INLET EXPANSION TANK ALTERNATE CIRCULATOR LOCATION BOILER 1 CIRC
APPENDIX A - BOILER PIPING AND WIRING Wiring Diagram 9: Multiple Boiler Wiring (AMB-4) AMB-4 WATER SENSOR OUTSIDE SENSOR IF USING EXTERNAL DAY/NIGHT FEATURE CONNECT HERE (DRY CONTACT) IF USING REQ/ACK CONNECT HERE (TT/THERMOSTAT DRY CONTACT) TO PRIORITY IF USING (DRY CONTACT) CH T1 L1 CH T2 L2 DWH T1 CH C1 DHW T2 CH C2 A1 DHW C1 A2 DHW C2 Yellow BOILER 1 CIRC BOILER CONTROL PANEL 24VAC 40 VA TRANSFORMER Yellow BOILER 2 Black BOILER 1 White TO AUXILIARY DEVICE 120 V TO BOILER T-T (TERMINALS 1&2)
APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION ! WARNING Install boiler so gas ignition system components are protected from water (dripping, spraying, rain, etc) during appliance operation and service (circulator replacement, etc). • DIELECTRIC ISOLATION Two (2) 1-1/4” X 1-1/4” Female to female dielectric isolation unions are shipped loose in boiler parts bag. Install Dielectric Isolation unions at boiler supply line and return line.
APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas-Fired Water Boilers Clean System First BEFORE connecting boiler to heating system, clean and flush system thoroughly. Verify system is free of sediment, flux and any residual boiler water additives. Eliminate System Leaks Systems having not recommended antifreeze must be completely flushed to ensure no old antifreeze remains.
APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas-Fired Water Boilers General Guidelines When Using Antifreeze • Use only antifreeze products recommended for use with aluminum boilers, as listed in this addendum. See Table 1, page 48. • Continuous addition of make-up water will dilute power of antifreeze and change buffers ability to maintain pH. • Flush old antifreeze from system.
APPENDIX B - WATER QUALITY, WATER TREATMENT AND FREEZE PROTECTION System and Operating Precautions Applies to ALL Aluminum High Efficiency Gas-Fired Water Boilers Table 1 Antifreeze Products Compatible Aluminum Antifreeze & Inhibitor Suppliers Noburst AL Antifreeze Noble Company P. O. Box 350 Grand Haven, MI 49417 www.noblecompany.com Tel: 800-878-5788 Fax: 231-799-8850 Rhogard Antifreeze & Pro-Tek 922 Inhibitor* Rhomar Water Management, Inc. P. O. Box 229 Springfield, MO 65801 www.rhomarwater.
NOTES 49
NOTES 50
Date Service Performed Company Name & Tech Initials Company Address & Phone # SERVICE RECORD 51
IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
