HELIX VX-050 Page 54 Installation, Operation & Maintenance Manual Download

Page: 54 / 88

13 - TROUBLE SHOOTING

YES

Install LWCO wire t

o low

ltage terminal strip LWCO

connectio

ns.

Check

low v

oltage

ter

minal

strip

connections. V

ify J16

connector

connected. V

ify

continuit

y between

low

voltage

ter

minal strip L

WCO connections

d J16-1 an

d J

16-4.

Continuit

isconnect L

WCO f

rom

low

voltage

ter

minal

strip

. Check f

continuit

y through

LWCO

saf

circuit. Continuit

Check LWCO per manufacturer's instructions repair

or replace.

YES

Replace Wire Harness

YES

Replace Cont

l Mo

dule

Summary of Contents for VX-050

Page 1: ...PERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company P N 240010618 Rev B 08 2014 Models VX 050 VX 075 VX 100 VX 150 VX 200 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13...

Page 2: ...s 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 temperature Critic...

Page 3: ...22 56 4mm 2 51mm Location H 2 33 59mm 3 76mm Location I 9 32 237mm 11 279mm Gas Connection Location J 3 06 77 7mm 4 6 117mm Size K 1 2 NPT 3 4 NPT Condensate Drain Connection I 3 4 NPT 3 4 NPT Weight...

Page 4: ...tion 30 6 10 Condensate Piping 30 7 Gas Supply Piping 31 8 Electrical Connections 33 8 3 Line Voltage Connections 33 8 4 External Connections 33 9 Start Up Procedure 35 9 6 Perform CSD 1 Compliance Te...

Page 5: ...5 C system design 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 Mu...

Page 6: ...d Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation 2 3 Installation shall conform to requirements of authori...

Page 7: ...te as a by product of combustion 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 Syst...

Page 8: ...ETY RELIEF VALVE 27 WALL MOUNT SUPPORT BRACKET 3 COMPONENT LISTING 050 075 100 150 200 SIZE SHOWN GAS CONNECTION FIGURE 3 2 Jacket Removal Viewed from Bottom of Boiler Jacket Latch Lift latch to dis e...

Page 9: ...T 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 CONTROL MODULE Fuse...

Page 10: ...EM 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 Holder 5 FLAME...

Page 11: ...r or water antifreeze 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 Clearanc...

Page 12: ...16 on center See 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 co...

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

Page 14: ...ingle boiler system See figures 5 4 5 5 5 6 5 7A B for general guidance Additional considerations Boiler control is designed for single central heating pump Installer responsible for integration of mu...

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

Page 16: ...Single Boiler Primary Secondary Two Pipe Zoned System With Zone Valves FIGURE 5 6 Single Boiler Primary Secondary Two Pipe Zoned System With Zone Pumps DHW Pump CH System Pump DHW Pump Zone Pump 5 HY...

Page 17: ...iler Using Primary Secondary Pumping With Closed External Primary Loop FIGURE 5 7B Single Boiler Using Primary Secondary Pumping With Open External Primary Loop CH System Pump 12 305mm Maximum separat...

Page 18: ...m With Zone Valves See Multiple Boiler Guide 5 HYDRONIC PIPING Up to 16 boilers DHW Pump See Multiple Boiler Guide CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common pipi...

Page 19: ...l Primary Loop 5 HYDRONIC PIPING 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 S...

Page 20: ...mary Loop Existing closely spaced tees in primary system loop 12 305mm Maximum Separation CH System Pump 12 305mm Maximum Separation System Temperature Sensor Size common piping per maximum heat capac...

Page 21: ...Adjust thermostat 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 cig...

Page 22: ...nents must NOT be interchanged with other vent systems or unlisted pipe fittings Minimum Maximum Vent Lengths 2 Pipe 3 Pipe Model 050 075 100 075 100 150 200 Min 6 ft 1 8 m 6 ft 1 8 m 6 ft 1 8 m 6 ft...

Page 23: ...1 Concentric figure 6 7 Side Wall Single Pipe figure 6 8 Inside Air Single Pipe figure 6 9 Side Wall Roof Single Pipe figure 6 10 Side Wall Two Pipe figures 6 2 6 3 Concentric figures 6 4 6 5 6 6 Ins...

Page 24: ...ween combustion air intake and vent of different appliances 15 381mm Maximum horizontal length of vent Minimum vent intake between different appliances 12 305mm Maximum allowable total vertical vent l...

Page 25: ...ote Securing strap must 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 77 mm Diameter PVC intake combustion air Combu...

Page 26: ...ighest anticipated snow level 24 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 ab...

Page 27: ...w Line 6 COMBUSTION AIR AND VENT PIPING NOTICE Configurations of single pipe vent with flue on the sidewall requires a tee as the vent terminal See figures 6 10 and 6 11 Maintain 12 305mm US 18 457mm...

Page 28: ...may condense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas Termination must be 12 305mm from or below doors windows or gravity inlet 12 305mm Minimum Te...

Page 29: ...rn leaves snow 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 Walkwa...

Page 30: ...provided with boiler and field sourced piping to condensate drain at bottom of boiler See figure 6 17 Slope condensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensa...

Page 31: ...See figure 7 1 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler 7 3 Leak Check Gas Piping CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance...

Page 32: ...as detector 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 so...

Page 33: ...allowable current draw See Figure 8 3 and Table 9 B Connect pump to line voltage terminal strip DHW PUMP L N G C PUMP L N G Primary Pump A Isolate pump from control module if pump FLA exceeds maximum...

Page 34: ...e wire C Connect wires interchangeable 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 Bo...

Page 35: ...Reset button until 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 fi...

Page 36: ...104 195 F 40 91 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Required Field Supplied Pump Mode 0 0 4 Service Reminder Status On ON OFF Service R...

Page 37: ...ws adequately and is disposed properly 8 Check control module operation 9 Check field sourced limits low water cutoffs etc per manufacturer s instructions 9 5 Check Combustion Natural Gas 1 Measure in...

Page 38: ...opane systems do not have flow meters 1 Check CO2 Propane should be between 10 and 11 0 If CO2 is low increase gas flow following figure 9 3 If CO2 is high decrease gas flow following figure 9 3 FIGUR...

Page 39: ...boiler will automatically refire then Lockout A 06 requiring manual reset of control module Press Reset button on User Interface OR C Shut off burner E39 Flue Temperature Sensor This is a soft lockou...

Page 40: ...E page 41 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all instructions manuals wiring diagrams warranty registration car...

Page 41: ...e upper jacket panel Turn 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 F...

Page 42: ...r manufacturer s instruction Check following components are operating properly and are free of blockages or obstructions system air vent check venturi air inlet for blockage and clean as required veri...

Page 43: ...vacuuming Replace burner 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 acce...

Page 44: ...g jurisdiction for installations above 4500 feet 1350 m above sea level 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...

Page 45: ...properly pushed 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 Interf...

Page 46: ...Control Module High Temperature opens during normal operation Go to Page 52 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas...

Page 47: ...61 Hz Go to Page 57 Boiler power supply ground wire is not grounded Go to Page 58 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replac...

Page 48: ...ed to both Gas 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 Disco...

Page 49: ...49 13 TROUBLE SHOOTING...

Page 50: ...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 Chec...

Page 51: ...51 13 TROUBLE SHOOTING...

Page 52: ...tch 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 continuity of both purple wires Continuit...

Page 53: ...TURN OFF GAS TO 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 operat...

Page 54: ...ions Verify J16 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 co...

Page 55: ...blem if any purging 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 fl...

Page 56: ...Liquid might be 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 95...

Page 57: ...supply rated at 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...

Page 58: ...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 than 10 ohm...

Page 59: ...r 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 130 F C Resi...

Page 60: ...rature 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 Thermistor...

Page 61: ...Replace 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...

Page 62: ...100 5 41 28590 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...

Page 63: ...63 14 1 Connection Diagram 050 075 100 MBH 14 WIRING DIAGRAM...

Page 64: ...64 14 2 Schematic Diagram of Ladder Form 050 075 100 MBH 14 WIRING DIAGRAM...

Page 65: ...65 14 3 Connection Diagram 150 200 MBH 14 WIRING DIAGRAM...

Page 66: ...66 14 4 Schematic Diagram of Ladder Form 150 200 MBH 14 WIRING DIAGRAM...

Page 67: ...production of heat 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...

Page 68: ...E Valve designed 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 i...

Page 69: ...em Increase value 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 Ope...

Page 70: ...ype of heating 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 spee...

Page 71: ...g rate according 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 Prior...

Page 72: ...as part of multiple 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 se...

Page 73: ...to OD Reset Setpoint 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 Settin...

Page 74: ...ings 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 common p...

Page 75: ...ition If at end 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 afte...

Page 76: ...ler Configuration 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 ope...

Page 77: ...s pump to CH System 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...

Page 78: ...and Warm Weather 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 tem...

Page 79: ...ts A B of Reset 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...

Page 80: ...100 Default Setting 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 Ther...

Page 81: ...demand being present 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...

Page 82: ...dle with wire tie 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...

Page 83: ...83 PRIMARY LOOP EQUIVALENT LENGTH CALCULATION PUMP SELECTION 50 75 100 MBH...

Page 84: ...84 PRIMARY LOOP EQUIVALENT LENGTH CALCULATION PUMP SELECTION 50 75 100 MBH...

Page 85: ...85 PRIMARY LOOP EQUIVALENT LENGTH CALCULATION PUMP SELECTION 150 200 MBH...

Page 86: ...86 PRIMARY LOOP EQUIVALENT LENGTH CALCULATION PUMP SELECTION 150 200 MBH...

Page 87: ...87 NOTES...

Page 88: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com...

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