Dunkirk 95M-200 gas condensing boiler approaching 15 years. Should I replace it?

Nitroman58

As I stated above, my boiler is coming up on its 15 year. Thus far, I had to replace the heat exchanger around 2007 which was under warranty for the part, but not the labor. Last January, the igniter required replacement, and then again in December (last month) the igniter required replacement.
The igniter is certainly not a big expense, but has left us with manually starting the boiler multiple times for the E-02 code (ignition failure). It took close to 3 weeks to get a new igniter since my problem occurred just before the Christmas holiday. I would like to get through this winter, but I am starting to look into getting a new boiler.
My heating contractor came by last week to give me an estimate on a new boiler. He is recommending the Energy Kinetics Resolute RT because of its reliability. Unfortunately, the price for this is pretty steep. I want to think this over carefully.
My current system has 4 zones, plus another for the hot water tank. My contractor is proposing a 40 gallon water to replace the 80 gallon tank we currently have. The 80 gallon tank was probably overkill when it was put in, but we had two teenagers living here at that time. We have natural gas as a fuel source.
I have read that the high efficiency boilers tend to last 15 to 20 years, and when they break down the parts get expensive. Am I approaching the end of life on this Dunkirk unit, or should I try to ride the Dunkirk out a bit longer?

Jamie Hall

It's a judgement call, and there is no "one right answer". From the standpoint of reliability, though, you may be getting to the point where indeed it is less expensive to replace it rather than keep repairing it.

JUGHNE

So in 15 years, the labor on heat exchanger and 2 ignitors.

The exchanger is unusual but the rest sounds like small change.

Not at all familiar with that brand/model but, some maint books recommend replacing the ignitor every 1-2 years.

IIWM, I would just have an ignitor on hand and carry on.

Nitroman58

Thanks. It was so hard to get the part (the ignitor). Having a spare is a good idea.
Is there a good source for finding a spare ignitor?
They were saying something about possibly another part involving a screen getting clogged. Do you know what that would be?

EdTheHeaterMan

What model Dunkirk do you have. Once we know the model number we may be able to locate the ignitor. As far as the screen??? is that part of the Dunkirk boiler or is it an accessory that is used to install the boiler

Nitroman58

EdTheHeaterMan said:

What model Dunkirk do you have. Once we know the model number we may be able to locate the ignitor. As far as the screen??? is that part of the Dunkirk boiler or is it an accessory that is used to install the boiler

As the tidal states, it is the 95M-200. The part number for the igniter is #550001325.

EBEBRATT-Ed

Condensing boilers......the max life is "supposed" to be 15-20 years. Failures are one thing the parts are expensive and with new technology coming out if your old boiler is no longer available the MFGs tend to obsolete the parts at around 10-15 years.

If it was mine (and I am old school and don't like to give up on boilers) I would get the parts list and make a list of the most common parts to fail. Then see what is available and at what cost.

That could help your decision.

You will generally get a better install in the summer when the installers are not in panic mode.

EKs are expensive but come highly recommended by most everyone on this forum

Roger

Thank you for your post, @Nitroman58 . Good points from everyone, including working on a boiler replacement during warmer weather if that is an option. If your boiler is running well and safe, that is certainly a good option. If you'd like, call Energy Kinetics at (908) 735-2066 (or PM me), and we can connect with your territory manager to coordinate with your installing contractor and answer any specific questions you may have. For reference, the Resolute uses nearly all industry standard parts, and we stock parts for all of our boiler models dating back almost 44 years to 1979.
Best,
Roger

cas1717

Hi Nitroman58,

Did you replace? What boiler did you choose ?

I’m in similar situation: ub95m-200 with heat exchanger replaced in 2021.

Boiler is 15 years old .

I m researching a replacement with as little piping rework as possible.

ZackR

I was in a similar situation a couple years ago with a different aluminum HX dunkirk. I ended up just replacing the HX and doing what @EBEBRATT-Ed suggested and priced out the rest of the parts and purchased spares to have on hand. If you already have the HX done(that's the expensive part), the other more costly parts are the blower and boiler control and those are way less than getting a new boiler installed.

It does seem odd that you've been going trough so many ignitors, as it seems like you have a spark ignitor and not a hot surface ignitor like I have, which are much more fragile.

ZackR

Also, as far as I know, Dunkirk recommends for the all the aluminum HX boilers to be flushed out in the combustion parts every year to get rid of all the gunk(aluminum oxide?) that builds up in there. That also gives you a change to inspect the burner.

cas1717

Anybody on this thread from Connecticut ?

I have ub95m-200 installed in 2010 with HX replaced in 2021. The expansion tank was replaced twice. The hydronic loop was flushed with fresh water few times during annual maintenance .

The HX got replaced on warranty (no labor) because the exhaust outlet got corroded away .

I've tried a few local companies for annual maintenance. They brush the igniter, do a combustion check and that's it.
They say this HX cannot be taken apart to get access to combustion chamber to be cleaned (which is true)
and throw theirs hands up when I show them the boiler manual with the flushing instructions for the HX.

My friend in Germany has similar boiler and the flush is done as part of annual maintenance with a special solution which is circulated inside the combustion chamber then with water. I could not find anything similar in Connecticut/New York. The acid from the aluminum oxide was the reason for the failure of the first HX.

Does anybody know of a contractor covering South Connecticut area who knows to flush the combustion chamber ?