ECR International Dunkirk Helix DKVLT-050 Installation, Operation & Maintenance Manual Download

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•

Remove ¼-20 hex flange nuts securing condensate

collector to heat exchanger using 7/16" deep well

socket. See figures 11-3 & 11-4.

• Remove condensate collector assembly from heat

exchanger and flue pipe.

• Flush collector and condensate trap with water.

• Follow Burner Inspection Kit instructions to reassemble

boiler and resume operation.

11 - GENERAL MAINTENANCE AND CLEANING

P/N# 240008888, Rev. O [07/15/2015]

Summary of Contents for Dunkirk Helix DKVLT-050

Page 1: ...NTENANCE MANUAL P N 240008888 Rev O 07 15 2015 Models DKVLT 050 DKVLT 075 DKVLT 100 DKVLT 150 DKVLT 200 DKVLT 299 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ec...

Page 2: ...back of boiler Plastic Plug 2 ea 18 Used for packaging holes on back of boiler Outdoor Sensor 19 Used for measuring outside temperature Critical Installation Instruction 20 11 x 17 Page for critical...

Page 3: ...41mm Depth C 14 356mm 16 0 406mm 18 3 465mm Bracket D 28 711mm 40 1016mm Height E 31 787mm 42 1092mm Water Connections Size F 1 1 4 NPT 1 1 4 NPT Location G 2 51mm 2 51mm Location H 5 127mm 2 51mm Loc...

Page 4: ...Terminal Requirements 28 6 8 Multiple Boiler Venting Installation 30 6 9 Condensate Piping 31 7 Gas Supply Piping 32 8 Electrical Connections 34 8 3 Line Voltage Connections 34 8 4 External Connection...

Page 5: ...pressure Exceed 195 F 90 5 C system design temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Integral Low Water Cutoff with test button Outdoor Temperature Reset Integral Mult...

Page 6: ...N Indicates a hazardous situation which if not avoided could result in minor or moderate injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury DAN...

Page 7: ...lve Fuel supply isolation during servicing See section 7 19 Combustion Air Blower Delivers proper quantity of combustion air receives fuel from gas valve mixes air and fuel sending mixture to burner f...

Page 8: ...3 3 Upper and Lower Jacket Latch Viewed from front of boiler Lift Jacket up engage jacket with chassis push down FIGURE 3 2 Lower Jacket Viewed from front of boiler Disconnect connector before removin...

Page 9: ...TING SYSTEM IN 14 SUPPLY WATER TO HEATING SYSTEM OUT 4 LOW VOLTAGE TERMINAL STRIP 15 VENT TEMPERATURE SENSOR 26 GAS CONNECTION 33 COMBUSTION ANALYSIS TEST PORT 24 HIGH VOLTAGE JUNCTION BOX 9 HEAT EXCH...

Page 10: ...NSATE COLLECTOR 3 RETURN WATER FROM HEATING SYSTEM IN 14 SUPPLY WATER TO HEATING SYSTEM OUT 4 LOW VOLTAGE TERMINAL STRIP 33 COMBUSTION ANALYSIS TEST PORT 26 GAS CONNECTION 24 HIGH VOLTAGE JUNCTION BOX...

Page 11: ...C to prevent freezing of liquid condensate Approved for installation in closets Protect gas ignition system components from water dripping spraying rain etc during operation and service circulator rep...

Page 12: ...boiler vertically or slightly tilted backward to insure proper function of low water cutoff Failure to follow these instructions could result in death or serious injury When mounting boiler onto wall...

Page 13: ...irculation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Boiler rated at 150 psig...

Page 14: ...dance Additional considerations Boiler control is designed for single central heating pump Installer responsible for integration of multiple central heating pumps Boiler control allows domestic hot wa...

Page 15: ...drain Table 3 System Piping Configurations Single Boiler Two Pipe Zoned System With Zone Valves figure 5 5 With Zone Pumps figure 5 6 Primary Secondary Pumping Closed External Primary Loop figure 5 7A...

Page 16: ...ystem With Zone Pumps Heat exchanger ball valve open as shipped Heat exchanger ball valve open as shipped DHW Pump CH System Pump DHW Pump Zone Pump 5 HYDRONIC PIPING 3 8 10mm Open End Wrench may be r...

Page 17: ...ternal primary loop ball valves closed FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With Open External Primary Loop CH System Pump 12 305mm Maximum separation Existing closely spaced tees...

Page 18: ...88 Rev O 07 15 2015 Up to 16 boilers DHW Pump See Multiple Boiler Guide CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire syst...

Page 19: ...Load Heating Load Existing closely spaced tees in primary system loop 12 305mm Maximum Separation Up to 16 boilers CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common pipi...

Page 20: ...305mm Maximum Separation CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system Heat exchanger ball valve open as shipped L...

Page 21: ...at so appliances will operate continuously Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use flame of match or candle smoke from cigarette cigar or pipe Deter...

Page 22: ...installations only All venting material primer and glue must be listed to ULC S636 Canadian installations only First 3 ft 0 9 m of plastic vent pipe from vent connector must be readily accessible for...

Page 23: ...Air Roof Single Pipe Figure 6 10 Side Wall Two Pipe Figures 6 2 6 3 Concentric Figures 6 4 6 5 6 6 Inside Air Single Pipe Figure 6 11 Table 7A Combustion Air Venting Locations Type Location Terminal...

Page 24: ...of different appliances 15 381mm Max horizontal length of vent Min vent intake between different appliances 12 305mm Max allowable total vertical vent length with outside exposure is 10 ft 3 05m Aband...

Page 25: ...ment of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 or 3 51 or 76mm Diameter PVC intake combustion air Combustion Air 2 51mm Diameter 41 Length 1 1m 3 76mm Diameter 47...

Page 26: ...8 Flue on Roof Air Intake on Side Wall FIGURE 6 9 Flue on Roof Combustion Air Grade Snow Ice Terminate vent system bottom minimum 12 300 mm above highest anticipated snow level Avoid locations where...

Page 27: ...inal for vent as shown in Fig 6 14 does not have a max separation requirement between flue gas and fresh air FIGURE 6 14 Side Wall Venting Terminal w T Terminal Combustion Air Vent w Accelerator 1 25...

Page 28: ...s or gravity inlet If boiler uses inside air min 4 1219 mm 12 305mm Min Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termination Less than 10 3m Min 3 0 9m Min FIGUR...

Page 29: ...ecirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkways Locate vent term...

Page 30: ...ultiple boiler application boiler can vent individually or use common vent pipes If boilers vent individually follow guidelines as described in figures 6 1 through 6 7 If boilers vent through common v...

Page 31: ...pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by authority having juri...

Page 32: ...manual main shutoff valve outside of jacket See figure 7 2 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler Table 10 Gas Supply Pressure CAUTION WHAT TO DO IF...

Page 33: ...ector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods that can provide ignition source C...

Page 34: ...oltage terminal strip CH PUMP L N G Domestic Hot Water Pump if used A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figure 8 3 and Table 11 B Connect pump to...

Page 35: ...to DHW T T terminals Wires are interchangeable Central Heating Thermostat A Use thermostat or boiler system control with dry contacts related 0 5 amps 120 VAC Boiler control does not provide 24 VAC p...

Page 36: ...s if available Close manual gas shut off valve Let system run for 30 minutes When boiler goes into lockout reset boiler by pressing Reset button until boiler resets Do not open gas shutoff valve until...

Page 37: ...5 F 40 91 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Enabled Enable Disabled Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminde...

Page 38: ...vate some heating zones to dissipate heat Set boiler on high fire Use 1 or 2 cu ft dial on gas meter Measure time required for two or more complete revolutions Measure time for one or more minutes Cal...

Page 39: ...ower starts flashing Scroll down to Low Power Push Enter Low Power stops flashing and becomes solid Boiler is now locked in LOW fire Adjust Offset Screw slowly and in small steps no more than 1 8 of a...

Page 40: ...nd adjustment of Offset Screw 2 Set boiler to High Power using System Test to confirm combustion in High Fire Step 2 3 Combustion setting is now complete A Exit System Test mode by pushing Enter High...

Page 41: ...system 4 Establish call for heat Jump CHW T T terminals on low voltage terminal block Turn on boiler using boiler service switch 5 Boiler will fire Based on natural convection within boiler boiler wi...

Page 42: ...ctions TO TURN OFF GAS TO APPLIANCE page 43 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all instructions manuals wiring...

Page 43: ...h automatically lights the burner Do not try to light burner by hand Remove upper jacket panel Turn gas shutoff valve clockwise to closed position Handle should be perpendicular to gas pipe Wait 5 min...

Page 44: ...turi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in place return temperature sensor clip must be securely seated on pipe Check boiler for an...

Page 45: ...ve and or gasket material from removed burner Clean burner using air hose directed into top of burner opening to dislodge any debris in burner ports Inspect burner for foreign matter in flame ports or...

Page 46: ...socket See figures 11 3 11 4 Remove condensate collector assembly from heat exchanger and flue pipe Flush collector and condensate trap with water Follow Burner Inspection Kit instructions to reassemb...

Page 47: ...stallations above 4500 feet 1350 m above sea level TABLE 12 1 SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net AHRI Rating Water MBH 1 3 AFUE 2 Max...

Page 48: ...48 13 TROUBLE SHOOTING P N 240008888 Rev O 07 15 2015...

Page 49: ...High Temperature opens during normal operation Go to Page 54 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas valve opens Rep...

Page 50: ...e 59 Boiler power supply ground wire is not grounded Go to Page 60 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replace Control Module...

Page 51: ...Gas Valve and J13 connector on Control Module NO YES Disconnect J13 connector on Control Module Measure resistance across third blue wire and fourth brown wire terminals Is resistance between 1 0 and...

Page 52: ...52 13 TROUBLE SHOOTING P N 240008888 Rev O 07 15 2015...

Page 53: ...ystem piping Flush system if water is dirty Is boiler supply pipe above heat exchanger hot Wait for boiler to cool down YES NO Replace Broken Switch Unplug molex connector on supply temperature sensor...

Page 54: ...54 13 TROUBLE SHOOTING P N 240008888 Rev O 07 15 2015...

Page 55: ...J13 Continuity from J13 5 to Switch 1 Continuity from J13 6 to Switch 3 continuity of the two purple wires Disconnect harness from High Temperature Supply Switch and Control Module J13 Check continuit...

Page 56: ...APPLIANCE Replace Gas Valve Turn off manual gas shutoff valve Follow instructions TO TURN OFF GAS TO APPLIANCE Replace Gas Valve Follow Operating Instructions to initiate boiler operation Enter Insta...

Page 57: ...Repair System Piping remove any remaining air in system Connect harness to Transformer Disconnect harness from Low Water Cutoff Is 24 vac at terminals 1 2 Between blue and yellow wires YES NO P N 2400...

Page 58: ...ging all air out of the system Replace Flue Gas Sensor Replace Control Module Use thermal couple to measure flue gas temperature through sampling port Is the measured temperature and flue temperature...

Page 59: ...solution NO Is Heat Exchanger Pump properly oriented Pump arrow pointing down YES NO Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 t...

Page 60: ...60 Hz 2 Replace Control Module YES YES NO NO Replace circuit breaker 13 TROUBLE SHOOTING Fix the connection These error messages are displayed when the control board detects fault in blower motor sys...

Page 61: ...130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Supply Water Sensor Resistance Chart Disconnect field wiring Is continuity between field wiring neutral and ground less...

Page 62: ...rature Sensor resistance with digital meter Estimate Sensor temperature Do temperature and resistance fall within ranges shown in chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to...

Page 63: ...Water Temperature Sensor Resistance Chart Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Does temperature fall within ranges shown in chart P...

Page 64: ...Control Module Disconnect wire harness from Vent Temperature Sensor Measure Sensor resistance Does resistance match estimated flue temperature NO YES _ P _ _ _ Blocking Error E 6 5 Flue Sens Shorted...

Page 65: ...65 14 WIRING DIAGRAM 14 1 Connection Diagram 050 075 100 MBH EXTERNAL PUMP RELAY LIMIT OF 1 AMP PER PUMP SEE SECTION 8 P N 240008888 Rev O 07 15 2015...

Page 66: ...66 14 2 Schematic Diagram of Ladder Form 050 075 100 MBH 14 WIRING DIAGRAM P N 240008888 Rev O 07 15 2015...

Page 67: ...67 14 WIRING DIAGRAM 14 3 Connection Diagram 150 200 299 MBH P N 240008888 Rev O 07 15 2015...

Page 68: ...ATA PWM HALL GND DC N GROUND FLAME SENSOR IGNITION LWCO CH THERMOSTAT USER INTERFACE DISPLAY ARGUS LINK MULTI BOILER OPTIONAL ARGUS LINK POWER ON OFF SUPPLY SENSOR RETURN SENSOR DHW THERMOSTAT FLUE SE...

Page 69: ...Rapid oxidation of fuel gases accompanied by production of heat or heat and light Complete combustion of fuel is possible only in presence of adequate supply of Oxygen COMBUSTIBLE MATERIAL Materials m...

Page 70: ...s with all requirements of authority having jurisdiction SAFETY RELIEF VALVE Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY...

Page 71: ...e Scroll down to next menu item Decrease value Boiler Status Indicator F Flame Detected P Central Heating System pump On B Combustion Air Blower On S Safety Relay Check G Gas Valve Open D DHW Pump On...

Page 72: ...s illustrated Control Module compares supply temperature to set point Boiler proceeds to ignition if supply temperature is less than set point Combustion Air Blower speed modulates to pre purge settin...

Page 73: ...to heating demand When Boiler detects demand met will enter post purge mode then standby mode If simultaneous demand for Central Heat and DHW boiler will enter DHW Priority Mode Priority mode limits...

Page 74: ...iple boiler installation submenu used to view runtime parameters See Multiple Boiler Manual This line is not shown if boiler is not in cascade system Boiler Status Supply Temperature set point display...

Page 75: ...oint and cannot be changed Controller calculates set point based on outdoor temperature Note For explanation of available CH heating modes refer to CH Mode section located in CH Settings submenu in In...

Page 76: ...ettings Modifies Domestic hot Water control settings such as DHW priority time Cascade Settings Refer to Multiple Boiler Manual System Test Tool aids setup of boiler installation or diagnosis of commo...

Page 77: ...of safety period no flame detected control will go to post purge removing unburned gas Re ignition attempt started following same cycle Number of re ignition attempts limited to 3 after which lockout...

Page 78: ...n Address Selection screen used to set boiler position in multiple boiler cascade installation Refer to Multiple Boiler Installation Manual Default setting of 0 indicates boiler is operating in single...

Page 79: ...the CH System Pump electrical terminal block See page 56 for diagram The DHW pump terminal does not function This is typical of a hydronic system design which utilizes zone valves for all CH zones and...

Page 80: ...Shutdown temperature Boiler will permanently attempt to satisfy CH demand when CH demand is available CH thermostat input is ignored CH set point calculated as function of outdoor temperature using o...

Page 81: ...re follows thick black line in graph below based on outdoor temperature Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor detected CH set point equal to Boiler...

Page 82: ...ting 100 DHW Settings Two DHW modes are available DHW Mode 0 No DHW DHW Mode is disabled The DHW thermostat input is ignored and the DHW pump is not used DHW Mode 2 DHW Store with Thermostat Boiler re...

Page 83: ...esent System Test has priority over any system demand while test mode activated System Test mode automatically ends after 30 minutes boiler resumes normal operation The following modes are available D...

Page 84: ...is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An...

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