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ECR International Dunkirk HELIX VX, Installation, Operation & Maintenance Manual

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ECR International Dunkirk HELIX VX Installation, Operation & Maintenance Manual Download Page 61

61

13 - TROUBLE SHOOTING

Supply W

ater T

emperature 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?

See Thermisto

r Resistance Chart - 

Page 63 o

f this manual

 PN 240011342 Rev. E  [05/31/2018]

Summary of Contents for Dunkirk HELIX VX

Page 1: ...NSTALLATION OPERATION MAINTENANCE MANUAL Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240011342 REV E 05 31 2018 Models VX 050 VX...

Page 2: ...wire knockouts Stopper Rubber 5 16 2 ea 15 Used for packaging holes on back of boiler Plastic Plug 2 ea 16 Used for packaging holes on back of boiler Outdoor Sensor 17 Used for measuring outside temp...

Page 3: ...22 56 4mm 2 51mm Location H 2 3 59mm 3 76mm Condensate Drain Connection Location I 9 3 237mm 11 282mm Location J 1 4 35 6mm 4 6 116 8 Size 3 4 NPT 3 4 NPT Gas Connection Top of Boiler Size K 1 2 NPT...

Page 4: ...allation 31 6 9 Condensate Piping 31 7 Gas Supply Piping 32 8 Electrical Connections 34 8 4 External Connections 34 9 Start Up Procedure 36 9 6 Perform CSD 1 Compliance Test 40 9 7 Complete Start Up P...

Page 5: ...ign temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Connection provided for required field sourced low water cutoff LWCO Outdoor Temperature Reset Integral Multiple Boiler C...

Page 6: ...ARNING Fire explosion asphyxiation and electrical shock hazard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installat...

Page 7: ...mbustion See page 14 16 Condensate Trap Field Installed Condensate must be piped to appropriate drain See section 6 17 Jacket Panel Latch 18 Supply Water Outlet to Heating System Out Connections suppl...

Page 8: ...31 WALL MOUNT SUPPORT BRACKET 3 COMPONENT LISTING 050 075 100 150 200 SIZE SHOWN 32 GAS CONNECTION FIGURE 3 2 Jacket Removal Viewed from Bottom of Boiler Jacket Latch Lift latch to dis engage Bottom o...

Page 9: ...ATING SYSTEM OUT 12 LOW VOLTAGE TERMINAL STRIP 22 VENT TEMPERATURE SENSOR 1 GAS CONNECTION SHUT OFF VALVE 23 COMBUSTION ANALYSIS TEST PORT 20 HIGH VOLTAGE JUNCTION BOX 10 HEAT EXCHANGER 9 BOILER CONTR...

Page 10: ...OM HEATING SYSTEM IN 18 SUPPLY WATER TO HEATING SYSTEM OUT 12 LOW VOLTAGE TERMINAL STRIP 1 GAS CONNECTION SHUT OFF VALVE 20 HIGH VOLTAGE JUNCTION BOX 10 HEAT EXCHANGER 9 BOILER CONTROL MODULE Fuse and...

Page 11: ...freeze solution during boiler service or from safety relief valve discharge See section 5 Access to system water piping gas supply and electrical service See sections 5 7 and 8 Clearances to combustib...

Page 12: ...e figure 4 2 Boiler includes 4 3 8 x 3 lag screws and 4 washers for attaching wall mount bracket to wood studs Field source appropriate fasteners for other wall constructions masonry concrete Attach w...

Page 13: ...cycle 5 3 Safety Relief Valve NOTICE Boiler rated at 150 psig 1 03 MPa maximum allowable working pressure Boiler provided with 30 psig 206 kPa safety relief valve Field source safety relief valve for...

Page 14: ...al heating pumps Boiler control allows domestic hot water prioritization Function could be lost if central heating pump not directly connected to control system Multiple boiler system See figures 5 8A...

Page 15: ...No Valves 12 Max Air Vent Safety Relief Valve LWCO Pipe to condensate drain System Supply System Return MINIMUM ACCEPTABLE HEIGHT FOR LWCO PROBE Air Vent LWCO Safety Relief Valve Safety Relief Valve...

Page 16: ...ned System With Zone Valves figure 5 8A With Zone Pumps Not Shown Primary Secondary Pumping Without DHW Tank figure 5 8B With DHW Tank figure 5 8C NOTICE Illustrations are meant to show system piping...

Page 17: ...es FIGURE 5 6 Single Boiler Primary Secondary Two Pipe Zoned System With Zone Pumps DHW Pump CH System Pump DHW Pump Zone Pump 5 HYDRONIC PIPING Primary Loop Equivalent Length Calculation Pump Selecti...

Page 18: ...ndary Pumping FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With DHW Tank CH System Pump closely spaced tees in primary system loop Limit length to 5 1 6m 12 305mm Maximum separation Limit...

Page 19: ...ves See Multiple Boiler Guide 5 HYDRONIC PIPING PN 240011342 Rev E 05 31 2018 Up to 16 boilers DHW Pump See Multiple Boiler Guide CH System Pump 12 305mm Maximum Separation System Temperature Sensor S...

Page 20: ...5 HYDRONIC PIPING PN 240011342 Rev E 05 31 2018 Closely spaced tees in primary system loop 12 305mm Maximum Separation Up to 16 boilers CH System Pump System Temperature Sensor Size common piping per...

Page 21: ...Tank Closely spaced tees in primary system loop CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capacity of entire system Limit length to 5 1 6...

Page 22: ...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 Determine each appliance remaining connected to commo...

Page 23: ...6 ft 1 8 m 6 ft 1 8 m 6 ft 1 8 m Max 50 ft 15 2 m 100 ft 30 5 m 100 ft 30 5 m Table 5 Combustion Air and Vent Piping Length For Example Boiler can be installed on outside wall and vented with one 90...

Page 24: ...resh 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 Termi...

Page 25: ...f 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 Abando...

Page 26: ...t be field installed to prevent movement of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 or 3 51 or 76 mm Diameter intake combustion air Combustion Air 2 51mm Diameter...

Page 27: ...610mm above roof FIGURE 6 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 305mm above highest anticipated snow lev...

Page 28: ...r FIGURE 6 14 Side Wall Venting Terminal w T Terminal Combustion Air Vent w Accelerator 1 25 4mm Max Separation Vent w T Terminal 12 305mm Min Separation of Combustion Air and Vent shall be maintained...

Page 29: ...tructed Condensate Vent gas may condense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas 12 305mm Minimum Termination Forced Air Inlet 3 0 9m If located w...

Page 30: ...or recirculated 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...

Page 31: ...condensate drain 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 autho...

Page 32: ...CAUTION 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 phon...

Page 33: ...tection 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 Correct leaks immediat...

Page 34: ...l strip DHW PUMP L N G Primary Pump A Isolate pump from control module if pump FLA exceeds maximum allowable current draw See Figure 8 3 Table 9 B Connect pump to line voltage terminal strip primary p...

Page 35: ...ed 0 5 amps 120 VAC Boiler control does not provide 24 VAC power to central heating thermostat B Locate and install thermostat per manufacturer s instructions Maximum wire length is 330 ft 100m for 22...

Page 36: ...ntil boiler resets Do not open gas shutoff valve until all air is purged from system 9 2 Fill Condensate Trap with Water Remove spring tension clip from clear hose attached to barbed fitting at bottom...

Page 37: ...Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Required Low Water Cutoff Field Supplied Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminder Days 365...

Page 38: ...eating 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 Calculate inpu...

Page 39: ...Design Target A Natural Gas 9 0 9 5 9 5 200ppm 6 5 7 5 Propane 10 0 11 0 11 0 3 Switch to LOW fire in boiler System Test On user interface push Enter HIGH power starts flashing Scroll down to Low Powe...

Page 40: ...00 MBH White Plastic Offset Screw Is Located Under The Aluminum Cap 4 See Figure 9 4 for location of Offset Screw on modulating gas valve of various boiler models T40 male Torx bit is necessary for re...

Page 41: ...E Combustion Analyzer Port Shown 50 75 100 Model FIGURE 9 7 Control Module J7 Connector J7 CONNECTOR 9 7 Complete Start Up Procedure 1 Reset control parameters to operating settings if adjusted to all...

Page 42: ...gas shutoff valve to closed position Handle should be perpendicular to gas pipe Wait 5 minutes for any gas to clear Smell for gas including near floor If you smell gas STOP Follow instructions on this...

Page 43: ...operating properly and are free of blockages or obstructions system air vent check venturi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in p...

Page 44: ...ner if it cannot be cleaned or is showing deterioration Clean heat exchanger with low pressure water spray Use flexible handle nylon brush to loosen sediment and oxide on all accessible heating surfac...

Page 45: ...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 Maximum Minimum 050 50 10 47 41 95 0 075 75 15 69 60 95 0 100 100...

Page 46: ...in Release plug lock with finger remove and reconnect all 7 plugs Check wiring from User Interface to Low Voltage Terminal Strip including checking continuity of wires Does User Interface Display wor...

Page 47: ...High Temperature opens during normal operation Go to Page 53 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 48: ...ground wire is not grounded Go to Page 59 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replace Control Module Supply temperature sens...

Page 49: ...Valve and J13 connector on Control Module NO YES Disconnect J13 connector on gas valve Measure resistance across top and bottom pins 1 5 Is resistance between 1 0 and 1 2 k NO YES Disconnect harness f...

Page 50: ...ler ignite and stay running pressing the Reset button When the boiler tries to ignite is there a strong consistent spark evident throught the sight glass Disconnect the gas valve electrical harness an...

Page 51: ...ystem 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 Check continuity be...

Page 52: ...52 13 TROUBLE SHOOTING PN 240011342 Rev E 05 31 2018...

Page 53: ...y from J13 6 to Switch 3 continuity of the two purple wires Disconnect harness from High Temperature Supply Switch and Control Module J13 Check continuity of both purple wires Continuity available for...

Page 54: ...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 55: ...connector is connected Verify continuity between low voltage terminal strip LWCO connections and J16 1 and J16 4 Continuity Disconnect LWCO from low voltage terminal strip Check for continuity throug...

Page 56: ...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 57: ...water or antifreeze solution NO Is Primary Pump properly oriented YES NO Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 to 33 000 ohm...

Page 58: ...t 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 sy...

Page 59: ...K 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 than 10 ohms Is field grou...

Page 60: ...th 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 130 F C Resistance 130 to 1...

Page 61: ...esistance Chart Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Does temperature fall within ranges shown in chart See Thermistor Resistance Cha...

Page 62: ...l 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 Replace...

Page 63: ...10 50 22790 15 59 18290 20 68 14770 25 77 12000 30 86 9805 35 95 8055 40 104 6653 45 113 5524 50 122 4809 55 131 3863 60 140 3253 65 149 2752 70 158 2337 75 167 1994 80 176 1707 85 185 1467 90 194 126...

Page 64: ...64 14 1 Connection Diagram 050 075 100 MBH 14 WIRING DIAGRAM PN 240011342 Rev E 05 31 2018...

Page 65: ...65 14 2 Schematic Diagram of Ladder Form 050 075 100 MBH 14 WIRING DIAGRAM PN 240011342 Rev E 05 31 2018...

Page 66: ...66 14 3 Connection Diagram 150 200 MBH 14 WIRING DIAGRAM PN 240011342 Rev E 05 31 2018...

Page 67: ...67 14 4 Schematic Diagram of Ladder Form 150 200 MBH 14 WIRING DIAGRAM PN 240011342 Rev E 05 31 2018...

Page 68: ...eat or heat and light Complete combustion of fuel is possible only in presence of adequate supply of oxygen COMBUSTIBLE MATERIAL Materials made of or surfaced with wood compressed paper plant fibers o...

Page 69: ...d to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner in event source...

Page 70: ...ue 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 71: ...demand CH call is 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...

Page 72: ...g 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 73: ...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 74: ...point 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 I...

Page 75: ...difies 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 common problems...

Page 76: ...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 77: ...on 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 singl...

Page 78: ...stem Pump electrical terminal block See page 35 for diagram DHW pump terminal does not function This is typical of hydronic system design which utilizes zone valves for all CH zones and DHW indirect t...

Page 79: ...r 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...

Page 80: ...Curve below Calculated CH set point always limited between Reset Curve Boiler Minimum Maximum temperatures See points C D of Reset Curve below Figure A 2 Outdoor Reset Curve Calculated supply tempera...

Page 81: ...tting 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 r...

Page 82: ...automatically ends after 30 minutes boiler resumes normal operation The following modes are available Disabled Low power Burner starts After ignition period has finished the burner stays at low power...

Page 83: ...ie This harness will not be required when mounting user interface outside of boiler 7 Before installing user interface in new location route new two conductor wire through hole in back of user interfa...

Page 84: ...The figures below are based on industry average Consult valve fitting manufaturer for exact equivalent length or for fittings not shown below Chart 1 A B C Pipe Diameter Fitting Enter Number Of Fitti...

Page 85: ...ter Total 1 straight pipe length in feet Add up numbers in column C Total equivalent length of Primary Multiply Total of Column C in Chart 3 by 0 088 Pump Factor Chart 4 Total Equivalent Length of 3 4...

Page 86: ...re based on industry average Consult valve fitting manufaturer for exact equivalent length or for fittings not shown below Chart 1 A B C Pipe Diameter Fitting Enter Number of Fittings Multiply By Equi...

Page 87: ...lve 12 5 Lift check valve 75 0 Enter Total 1 straight pipe length in feet Add up numbers in column C Total equivalent length of Primary Multiply Total of Column C in Chart 3 by 0 15 Pump Factor Chart...

Page 88: ...OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decre...

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