Dunkirk DCCF/DCBF High Efficiency Floor-Standing Modulating Condensing Boiler Owner's manual

Dunkirk
Brand
Dunkirk
Model
DCCF/DCBF High Efficiency Floor-Standing Modulating Condensing Boiler
Type
Owner's manual
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com
DCBF-125,DCBF-165
DCCF-150, DCCF-205
CONDENSING GAS
FIRED BOILER
CONTENTS :
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
(240012879)
APPLICATION GUIDE
(240012875)
COMMISSIONING
GUIDE
(240011376)
REQUIRED
INSPECTION SPECIAL
(240011561)
BACK COVER
CONDENSING GAS FIRED
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Models
DCBF-125, DCCF-150
DCBF-165, DCCF-205
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com
PN 240012879 REV. A [01/31/2020]
2
Fully Assembled Boiler 30 PSI Safety Relief Valve
Temperature Pressure
Gauge (2" Shank)
3/4 NPT Ball Gas

Includes Essential
Documents and Warranty
11x17 Wire Diagrams
DHW Optional Pipe
Heat Only Boiler
Copper Flush Bushing
1/2” x 1/4” NPT
Copper Tee
1-1/24” x 1-1/4 “x 1/2”
Docu
ment Package
VERIFY CONTENTS RECEIVED
Threaded End
Non-Threaded End
Copper Tee
NOTICE
Using proper brazing or soldering technique, insert


is not UP the TP gauge cannot engage the threads

240012879 REV A, [01/31/2020]
3
Verify contents received ................................................ 2
Table of contents
...........................................................3
1 - Important Information
.............................................4
2A - Physical Data
.........................................................5
2B - Component Listing
.................................................8
3 - Introduction
........................................................... 12
4 - Locating Boiler
.......................................................13
5 - Combustion Air And Vent Piping
.............................15

15

15

16

17

17

18

18

20

 21
 
26
6 - Hydronic Piping
...................................................... 27

27

27

28

28

28










7 - Gas Supply Piping
..................................................33






8 - Electrical Connections
............................................35

...............................................................35















9 - Start Up Procedure
.................................................39

 
 


















2
 
2 


 





10 - Operating instructions
.........................................48













 
11 - General Maintenance and Cleaning.......................49



50

 50
51
51

52

52

52

52


    
    







12 - Ratings And Capacities
......................................... 54





55

55
13 - Trouble Shooting
.................................................. 56

 56
          

58
14 - Glossary
...............................................................59
Appendix A - Wiring Diagrams
............................... 61-64

................................................... 67
TABLE OF CONTENTS
240012879 REV A, [01/31/2020]
4
CAUTION


!!
WARNING


!
DANGER


!







1. Safety Information
WARNING





!
CAUTION






!!
NOTICE
Used to address practices not related to personal

WARNING




!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!













• 
• 


must be selected and installed according


• 

• 
• 
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note:




1 - IMPORTANT INFORMATION
240012879 REV A, [01/31/2020]
5
Dimensions
SYSTEM


2A - PHYSICAL DATA
DIMENSIONS
125 & 150 165 & 205
 
 
Depth 
Condensate Trap Connection 
NPT
  



Connection


Connection




Connection
 





Connection




Connection
  
Boiler Filling Connection External to Boiler
Primary Water Content  


Central Heating (Sealed System) 125 / 150
165/ 205



psi 



176°F 


  


Domestic Hot Water (Sealed System)
150 205
  
  
    
  
  
 
240012879 REV A, [01/31/2020]
6
2A- PHYSICAL DATA
MODELS - 125 & 150
MODELS - 125 & 150
240012879 REV A, [01/31/2020]
Top View
125 & 150
Front View
125 & 150
Right Side View
125 & 150
Left Side View
125 & 150
10.44 in.10.44 in.
[266 mm][266 mm]
6.87 in.6.87 in.
[175 mm][175 mm]
18.56 in. [472 mm]18.56 in. [472 mm]
20.50 in. [521 mm]20.50 in. [521 mm]
24.70 in. [628 mm]24.70 in. [628 mm]
2.22 in.2.22 in.
[56.4 mm][56.4 mm]
9.13 in.9.13 in.
[232 mm][232 mm]
7.92 in.7.92 in.
[201 mm][201 mm]
6.63 in.6.63 in.
[168 mm][168 mm]
4.35 in.4.35 in.
[111 mm][111 mm]
6.12 in.6.12 in.
[156 mm][156 mm]
6.12 in.6.12 in.
[155 mm][155 mm]
7.31 in.7.31 in.
[186 mm][186 mm]
3.42 in.3.42 in.
[87 mm][87 mm]
1.80 in.1.80 in.
[46 mm][46 mm]
43.65 in.43.65 in.
[1.1 m][1.1 m]
40.23 in.40.23 in.
[1.0 m][1.0 m]
37.20 in.37.20 in.
[.95 m][.95 m]
2.99 in.2.99 in.
[76 mm][76 mm]
3.15 in.3.15 in.
[80 mm][80 mm]
10 in.10 in.
[255 mm][255 mm]
6.56 in.6.56 in.
[167 mm][167 mm]
4.35 in.4.35 in.
[110 mm][110 mm]
6.63 in.6.63 in.
[168 mm][168 mm]
6.47 in.6.47 in.
[165 mm][165 mm]
42.03 in.42.03 in.
[1.0 m][1.0 m]
17.46 in.17.46 in.
[443 mm][443 mm]
7
2A - PHYSICAL DATA
240012879 REV A, [01/31/2020]
Front View
165 & 205 Models
MODELS - 165 & 205
Right Side View
165 & 205
Left Side View
165 & 205 Models
5.35 in.5.35 in.
[136 mm][136 mm]
13.33in.13.33in.
[339 mm][339 mm]
5.35 in.5.35 in.
[136 mm][136 mm]
8.38 8.38
[213 mm][213 mm]
6.47 in.6.47 in.
[165 mm][165 mm]
42.69 in.42.69 in.
[1.08m][1.08m]
40.23 in.40.23 in.
[1.0 m][1.0 m]
37.20 in.37.20 in.
[.95 m][.95 m]
4.17 in.4.17 in.
[106 mm][106 mm]
2.46 in.2.46 in.
[62 mm][62 mm]
2.82 in.2.82 in.
[71 mm][71 mm]
3.32 in.3.32 in.
[84 mm][84 mm]
9.39 in.9.39 in.
[239 mm][239 mm]
6.26 in.6.26 in.
[159 mm][159 mm]
3.07 in.3.07 in.
[78 mm][78 mm]
41.87in.41.87in.
[1.06 m][1.06 m]
7.39 in.7.39 in.
[187 mm][187 mm]
6.26 in.6.26 in.
[159 mm][159 mm]
10 in.10 in.
[255 mm][255 mm]
23.55 in.23.55 in.
[598 mm][598 mm]
9.079.07
[230 mm][230 mm]
1.67in.1.67in.
[43mm][43mm]
8.46 in.8.46 in.
[215 mm][215 mm]
12.02 in.12.02 in.
[205 mm][205 mm]
Top View
165 & 205
7.18 in.7.18 in.
[182 mm][182 mm]
16.71 in.16.71 in.
[424 mm][424 mm]
18.56 in. [472 mm]18.56 in. [472 mm]
20.43 in. [519 mm]20.43 in. [519 mm]
24.75 in. [624 mm]24.75 in. [624 mm]
25.80 in. [655 mm]25.80 in. [655 mm]
8
2B - COMPONENT LISTING



Dunkirk
DCBF-125
1 Coaxial Connector
2 
3 
4 
5 Flame Detection Electrode
6 
7

8 Fan
9

10 Boiler Drain Tap
11 
12 
13

Connection
14 
15 Condensate Connection
16 
17 
18 
19 
20


21 Ignition Electrode
22 
23 
9
2
4
1
3
6
5
7
8
10
13
22
20
19
21
11
12
14
15
16
17
18
23
240012879 REV A, [01/31/2020]
DUNKIRK - DCBF 125
9
2B - COMPONENT LISTING


Dunkirk
DCCF-150
1 Coaxial Connector
2 
3 
4 
5 Flame Detection Electrode
6 
7 
8 Fan
9 
10 
11


12 Boiler Drain Tap
13 
14 
15 
16 
17 
18 Condensate Connection
19 
20 
21 
22 
23 
24 
25


26 Ignition Electrode
27 
28


9
16
27
2
25
24
19
4
1
26
3
6
5
7
8
28
10
11
12
14
13
15
17
18
20
21
22
23
240012879 REV A, [01/31/2020]
DUNKIRK DCCF-150
10


Dunkirk
DCCF-205
1 Coaxial Connector
2 
3 
4 
5 Flame Detection Electrode
6 
7 Fan
8 
9 
10 
11


12 
13 
14 
15 
16 
17 Condensate Connection
18 
19 
20 
21 
22 
23


24 
25 Ignition Electrode
26

9
15
2
24
23
18
4
1
25
3
6
5
7
8
26
10
11
13
12
14
16
17
19
20
21
22
2B - COMPONENT LISTING
240012879 REV A, [01/31/2020]
11


Dunkirk
DCBF-165
1 Coaxial Connector
2 
3 
4 
5 Flame Detection Electrode
6 
7
Fan
8 
9

10 Boiler Drain Tap
11 
12 
13 
14 Condensate Connection
15 
16 Inlet Element
17 
19

20

21 Ignition Electrode
22 
2B - COMPONENT LISTING
240012879 REV A, [01/31/2020]
12
Check our website frequently for updates: www.ecrinternational.com

time of printing of this manual. ECR International reserves the right to

notice and without incurring any obligation, whatsoever.
3.5 Designated Use
• DCCF

• DCBF-125 and DCBF
• 
• 

• 
• 

3.6 The unit MUST NOT:
• 

• 

• 


• 


• 
3.7 Operational Features
• DCBF-125 

• DCCF-150

• -165
• DCCF-205

• 
DCCF-150 

-205



• 
• 
• 
• Boiler operating at maximum operating temperature,



3 - Introduction
3.1 

UNITED STATES
• 
.
• 
3.2 



3.3 Requirements for Commonwealth of
Massachusetts:




3.4 Manufacturer recommends use of Carbon
Monoxide monitor may be requirement of local
jurisdiction.
3 - INTRODUCTION
240012879 REV A, [01/31/2020]
13
4.1 Boiler Location Considerations
• 

• 


• 



• 


• 
• 


• 

• 

• 




• 

• 
• 


WARNING



!
4 - LOCATING BOILER
4.2 Floor Location
• Place crated boiler as close to selected location as





• 

• 


• 




• 
This boiler shall NOT be
installed on carpeting.
• 



• 




• 

WARNING



!
WARNING

installation could result in death or serious


!
240012879 REV A, [01/31/2020]
14


Minimum ClearanceMinimum Clearance
17 ¾ in. [450 mm ] 17 ¾ in. [450 mm ]
From Front of Boiler From Front of Boiler
13.58 in /
345.00 mm
1212 inin
[305 mm][305 mm]
17  in
[450 mm]
8 ⅝in [220 mm]
40  in
[1.02 m]
125 & 150
13  in
[345 mm]
4.3 Clearances
1 1   inin
[45 mm] [45 mm]



Boiler
Service Clearances
4 - LOCATING BOILER
1  in
[45 mm
]
17in


Closet Installation

1  in
[45 mm]
1in
[45 mm]
1in
[45 mm]
[450 mm]

0 in
[0 mm]
0 in
[0 mm]

0 in
[0 mm]
0 in
[0 mm]
Combustible Clearances
TABLE 1: BOILER CLEARANCES
Dimension
Combustible
Materials
(1)
Manufacturer
Recommended for
Service
(1)(2)
Top
 

 

 
Front





Bottom



 
(1)
Required distances measured from boiler jacket.
(2)
Service, proper operation clearance recommendation.
* Allowance for piping and venting not included.
165 & 205
23 ½ in
[597 mm]
240012879 REV A, [01/31/2020]
15
WARNING

installation could result in death or serious


!
• 
• 


• 


• 


• 

• 
• 


• 

• 

• 





• 
 
WARNING










!
5 - COMBUSTION AIR AND VENT PIPING
NOTICE


• 

• 

• 


• 


• 

• 



5.2 Removal of Existing Boiler From Common Vent
System








• 
• 



• 







• 


• 


• Determine each appliance remaining connected to common




• 




should be re-sized to approach minimum size as determined



5.1 General
• 

» 
240012879 REV A, [01/31/2020]
16

1.
Coaxial piping 

2.
Twin Pipe –
Figure 5-1 - Venting Support
5 - COMBUSTION AIR AND VENT PIPING



240012879 REV A, [01/31/2020]
17
5.4 Approved Venting Materials
5.5 Vent Termination
• 




• 



• 



• 




• 
1.

2.

WARNING





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


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• 

• 
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• 
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3.
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

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4.
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

Ap
proved Polypropylene Manufacturers
* Natalini
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*Centrotherm
 


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Vent Material Options
125 & 150 165 & 205
1  1 
2
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2
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
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



5


5


 

240012879 REV A, [01/31/2020]
18


Coaxial Elbows - Equivalent length












• 

• 



• 


• 


• 


• 

• 
Figure 5-2 - Coaxial Screw Placement
5.7 Coaxial Vent Screw Placement - See Figure 5-2




WARNING





!


FIGURE 5-3 - Coaxial Venting Horizontal or Vertical
CAN BE USED ON ALL SIZES
5 - COMBUSTION AIR AND VENT PIPING
5.6 Coaxial Venting Instructions

Coaxial Pipe Vent Lengths
(Includes First Elbow And Termination)
Boiler Size 125/150 165/205
ALL
Vent Size







Natalini 



 
Centrotherm 
240012879 REV A, [01/31/2020]
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Dunkirk DCCF/DCBF High Efficiency Floor-Standing Modulating Condensing Boiler Owner's manual

Dunkirk
Brand
Dunkirk
Model
DCCF/DCBF High Efficiency Floor-Standing Modulating Condensing Boiler
Type
Owner's manual
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