manualshive.com logo in svg

HELIX VX-399, Installation, Operation & Maintanance Manual, Page: 48 / 82

Share
Download
HELIX VX-399 Installation, Operation & Maintanance Manual Download Page 48

48

 P/N 240010943, Rev. C [09/07/2016]

13 - TROUBLE SHOOTING

-

Lo-ck�ut 

Alarm

A 

O 

1 

lgnit 

error

In

st

al

l 

Enter 

the 

Installer 

Menu 

and 

place 

the 

boiler 

int

o 

test 

mode 

in 

high 

fire. 

Once 

the 

boiler 

sta

rt

s,

 go 

to 

the 

boiler 

status 

screen 

and 

monitor 

the 

flame 

signal. 

Is 

the 

flame 

signal 

greater 

than 

7.0uA 

w

he

n 

running 

on 

hi 

h 

fire? 

YES 

Has gas valve  been adjusted 

per 

instructions?

YES 

C

h

ec

k 

ven

t 

termination 

for 

proper 

consideration 

of 

wind 

ef

fe

ct

s 

Is 

this 

boiler 

to 

run 

with 

propane 

gas? 

Is 

this 

a 

new 

boiler 

on 

firs

t 

startup? 

YES 

Is 

the 

Gas 

Shutoff 

Va

lv

e 

closed? 

YES 

Open 

gas 

shutoff 

valves 

Reset 

the 

boiler 

by 

Check 

all 

wires 

including 

the 

ig

ni

te

r 

and 

flame 

sens

or

 leads. 

Check 

for

 proper 

and 

tight 

connections 

to 

control 

board. 

Are 

all 

wires 

connected? 

YES 

Ins

pec

t Vent 

System 

fo

r 

bl

oc

kag

es

. 

Is 

the 

vent 

sy

st

em

 

cl

ea

r?

 

YES 

Does 

the 

bo

iler

 

ignite 

and 

stay 

running? 

pressing 

the 

'Reset' 

button. 

When 

the 

boiler 

tries 

to 

ignite, 

is 

there 

a 

strong, 

consistent 

spark 

ev

id

en

t 

throught 

the 

sight 

glass? 

Disconnect 

the 

gas 

valve 

electrical 

harness 

and 

close 

the 

gas 

shutoff 

valve. 

YES 

YES 

Remove 

the 

flame 

14---

---

­

sens

or

 and 

igniter 

and 

inspect. 

Is 

there 

any 

indication 

of

 

da

m

ag

e 

or 

debris 

baked 

on? 

YES 

Replace/clean 

flame 

sensor 

or

 igniter 

With 

the 

ign

iti

on

 

lead 

connected 

to 

the 

igniter, 

ho

ld 

th

e 

tip 

ne

ar 

the 

ch

as

si

s 

ground 

and 

at

te

m

pt

 

ig

ni

tio

n.

 

Is 

a 

spark 

observed 

between 

the 

igniter 

and 

ground? 

--

-----i 

YES 

Replace 

Burner 

Remove 

the 

gas 

train 

in

cl

ud

in

g 

the 

flue 

transition. 

Remove 

the 

burner 

and 

inspect. 

Any 

sign 

of 

damage 

to 

burner 

su

rf

ace

? 

YES 

Co

nne

ct 

all 

wires 

and 

ch

ec

k 

for 

se

cu

re

 fit 

Inspect 

the 

flue 

way 

along 

the 

side

s 

of 

the 

baffle 

near 

the 

coil 

for

 

bl

oc

ka

ge

s.

 

Is 

there 

an

y 

apparent 

debris 

or 

obstruction 

of 

the 

flue 

w

ay?

 

YES 

Refer 

to 

the 

Gas 

Valve 

Troubleshooting 

Tree 

Ha

s the 

gas 

va

lv

e 

been 

adjusted 

per 

instructions?

Adjust gas v

alv

e 

throttle and offset  per

 instructions.

Summary of Contents for VX-399

Page 1: ...P N 240010940 Rev C 09 07 2016 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com GAS BOILER INSTALLATION OPERATION MAINTENANCE MANUAL Model VX 399 ...

Page 2: ...s Document Package 10 Includes essential documents VERIFY CONTENTS RECEIVED 3 Boiler provided with 50 psig 206 kpa safety relief valve Field source safety relief valve if system pressure greater than 40 psig Boiler provided with 75 psig temperature pressure gauge Field source temperature pressure gauge if system pressure greater than 60 psig 1 4 2 5 6 7 8 If optional equipment is ordered with this...

Page 3: ...21 537 D Height unit w Optional Kit L 4006 66 1683 E Height unit w vent 56 1439 G H Return Water from System 1 NPT Location G 3 83 Location H 5 130 H I Supply Water to System 1 NPT Location H 5 130 Location I 4 108 J K Gas Connection 1 NPT Location J 9 241 Location K 8 217 L M Condensate Drain Connection 3 4 NPT Location L 12 316 Location M 11 281 Weight Shipping 290 lbs 132kg Unit 265 lbs 121kg V...

Page 4: ... Venting Installation 28 6 9 Condensate Piping 28 7 Gas Supply Piping 29 8 Electrical Connections 31 8 3 Line Voltage Connections 31 8 4 External Connections 31 9 Start Up Procedure 33 9 7 Perform CSD 1 Compliance Test 38 9 8 Complete Start Up Procedure 39 10 Operating Instructions 40 11 General Maintenance And Cleaning 41 12 Ratings And Capacities 43 13 Trouble Shooting 41 13 Trouble Shooting Tem...

Page 5: ...lating 20 100 Integral Dual Temperature Limit CSD 1 Compliant listing based on manufacturer s interpretation of CSD 1 requirements Consult authority having jurisdiction prior to installation X X Manual reset low water cutoff X X Manual reset high temperature limit Outdoor Temperature Reset Available Heat exchanger over heat protection Alternate mounting of User Interface Available Information and ...

Page 6: ...rical shock hazard 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 authority having jurisdiction or in absence of such requirements United States National Fuel Gas Code ANSI Z223 1 NFPA 54 National Electrical Code NFPA 70 Canada Natural Gas and Propane Inst...

Page 7: ...e of Boiler Disengage jacket latches on both sides of boiler Lift jacket up and off support at bottom of jacket and remove Optional Left Side Jacket Latch Bottom Jacket Support Safety Relief Valve Limit Control Temperature Pressure Gauge Gas Supply Combustion Air Inlet Vent Connector User Interface 25 Supply Water To Heating System 21 37 1 2 22 19 24 3 Return Water From Heating System 4 Controls T...

Page 8: ... 27 26 24 25 36 40 41 Combustion Air Inlet 4 See section 6 Vent Connector 4 See section 6 Gas Supply 1 NPT Return Water From Heating System In 1 NPT See section 5 Gas Shutoff Valve Fuel supply isolation during servicing See section 7 Gas Control Valve Delivers proper quantity of fuel to Combustion Air Blower Not shown See section 7 Igniter Flame Sensor High Voltage Junction Box For connection of 1...

Page 9: ...are Fuse Transformer DHW Pump General Boiler Pump CH Pump and Blower Relays ASME Plate Heat Exchanger Strap and Buckle 2 Igniter Flame Sensor Combustion Air Blower Sight Glass Supply Temperature Sensor Heat Exchanger Flue Collector Vent Temperature Sensor Condensate Drain Connection Condensate Trap Drain Valve Return Water Temperature Sensor Leveling Feet 4 Wire Knockouts 10 AMP Breaker 1 2 3 4 6 ...

Page 10: ...and vent piping See section 6 Disposal of condensate See section 6 Drainage of water 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 Clearances to combustible materials and service clearances See Table 2 and figure 4 1 Multiple Boilers can be placed side by ...

Page 11: ...sig 1 03 MPa maximum allowable working pressure Boiler provided with 50 psig 345 kPa safety relief valve Field source safety relief valve for system pressures greater than 25 psig Temperature Pressure Gauge satisfactory for 60 psig operation Field source temperature pressure gauge for system pressures greater than 60 psig Install safety relief valve See figure 5 1 Install safety relief valve with ...

Page 12: ...atic fill valves require back flow prevention device Single boiler system See Figure 5 5 through 5 7 for general guidance 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 water prioritization Function could be lost if central heating pump not directly conne...

Page 13: ...ary Pumping Without DHW Tank figure 5 8B With DHW Tank figure 5 8C NOTICE Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdiction NOTICE Arrange piping to prevent water dripping onto boiler Primary Loop Equivalent Length Calculation Pump Selections may be found on pages 79 thru 80 of this manual T...

Page 14: ...stem With Zone Pumps DHW Pump CH System Pump DHW Pump Zone Pumps 5 HYDRONIC PIPING Primary Loop Equivalent Length Calculation Pump Selections may be found on pages 79 thru 80 of this manual General Boiler Pump on Return Side General Boiler Pump on Return Side Limit length to 5 1 6m 12 305mm Maximum separation 2 1 Limit length to 5 1 6m 12 305mm Maximum separation 2 1 2 1 1 2 ...

Page 15: ...Primary Secondary Pumping With DHW Tank CH System Pump 5 HYDRONIC PIPING Primary Loop Equivalent Length Calculation Pump Selections may be found on pages 79 thru 80 of this manual General Boiler Pump on Return Side General Boiler Pump on Return Side 2 2 2 2 2 2 1 2 Limit length to 5 1 6m 12 305mm Maximum separation 2 1 Limit length to 5 1 6m 12 305mm Maximum separation 2 1 1 2 ...

Page 16: ...h Zone Valves See Multiple Boiler Guide 5 HYDRONIC PIPING Limit length to 5 1 6m 12 305mm Maximum separation 2 1 Up to 16 boilers DHW Pump See Multiple Boiler Guide CH System Pump System Temperature Sensor Size common piping per maximum heat capacity of entire system General Boiler Pumps on Return Side 1 2 ...

Page 17: ...ers Using Primary Secondary Pumping 5 HYDRONIC PIPING Limit length to 5 1 6m 12 305mm Maximum separation 2 1 Up to 16 boilers CH System Pump System Temperature Sensor Size common piping per maximum heat capacity of entire system General Boiler Pumps on Return Side See Multiple Boiler Guide 1 2 2 2 2 ...

Page 18: ...ilers Using Primary Secondary Pumping with DHW Tank CH System Pump System Temperature Sensor Size Common Piping Per Maximum Heat Capacity Of Entire System 5 HYDRONIC PIPING General Boiler Pumps on Return Side Limit length to 5 1 6m 12 305mm Maximum separation 2 1 Up to 16 boilers 1 2 2 2 2 ...

Page 19: ...g inspected Follow lighting instructions 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 cigar or pipe Determine each appliance remaining connected to common venting system properly vents when tested as outlined above Then return doors windows exhaust ...

Page 20: ...air tight and water tight Certified vent system components must NOT be interchanged with other vent systems or unlisted pipe fittings Canadian 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 visual inspection 6 5 Vent Termination Terminate combusti...

Page 21: ...e Pipe Figure 6 9 Side Wall Roof Single Pipe Figure 6 10 Side Wall Two Pipe Figure 6 2 6 3 Concentric Figure 6 4 6 5 6 6 Inside Air Single Pipe Figure 6 11 Table 7A Allowed Venting Locations Type Location Terminal Type Corresponding Figure Venting Flue Gas Side Wall S Terminal with 90 elbow Figure 6 2 6 3 S Terminal with 45 elbow Figure 6 12 Concentric Figure 6 4 6 5 6 6 Concentric with accelerato...

Page 22: ...m Max vertical separation between combustion air intake and vent 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 Abandoned unused masonry chimney may be used as chaseway for combustion air and vent Both combustion air and vent pipe must exit above top o...

Page 23: ...prevent movement of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 4 102mm Diameter PVC intake combustion air Combustion Air 4 102mm Diameter 36 Length 0 9m Note Overall length may be modified by cutting or extending both combustion air and vent pipes 12 305mm is minimum allowable length and 60 1 2m is maximum allowable length for this dimension SDR 26 PVC D2241 only ma...

Page 24: ...learance above highest 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 above highest anticipated snow level Avoid locations where snow may drift and block vent and combustion air Ice or snow may cause boiler to shut down if vent or combustion air becomes ob...

Page 25: ... shown in Fig 6 14 Use of T Teminal 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 4mm Max Separation Vent w T Terminal 12 305mm Min Separation of Combustion Air and Vent shall be maintained No Maximum separation is required when using T Terminal for v...

Page 26: ... Terminal Requirements of USA National Fuel Gas Code ANSI 223 1 NFPA 54 Canada Natural Gas and Propane Installation Code CAN CSA B149 1 Venting terminal from doors and windows See figure 6 12 Venting terminal from forced air inlet of other appliances See figure 6 13 Venting terminal from snow level See figure 6 14 Venting terminal from vegetation See figure 6 15 Venting terminal from public walkwa...

Page 27: ...s 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 Walkways Locate vent termination minimum 7 2 1m above any public walkway with consideration to condensate Meters Regulators deck porch Vent termination US only 4 1 2m Canada 6 1 8m horizontally from no case above o...

Page 28: ...vided with boiler and field sourced piping to condensate drain at bottom of left or right side of boiler See figure 6 17 Slope 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 authority having jurisdiction or for environmentally friendly condensate dispo...

Page 29: ...liquefied petroleum gas 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler 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 phone Follow gas supplier s instructions If you cannot reach your gas supplier call the fir...

Page 30: ...d 7 4 Locate leakage using gas 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 source Correct leaks immediately and retest FIGURE 7 3 Gas Shutoff Valve OPEN Parallel To Pipe DANGER Fire Hazard Do not use matches candles open flames or other methods prov...

Page 31: ... pump FLA exceeds 10 amp maximum allowable current draw See Figure 8 3 B Connect pump to line voltage terminal strip primary pump L N G 8 3 External Connections figure 8 4 User Interface Terminals A Factory wired to USER INTERFACE terminals Argus Link Multiple boiler applications only Outdoor Sensor if used A Provided with boiler B Locate outdoor sensor to protect against wind and direct sunlight ...

Page 32: ... Maximum wire length is 330 ft 100m for 22 ga wire C Connect wires to CH T T terminals Wires are interchangeable Low Water Cutoff LWCO Factory installed NOTICE Boiler transformer does not have adequate VA to power accessories other than factory supplied LWCO FIGURE 8 4 External Connections Do not apply external voltage to external terminals NOTICE Use dry contact for wires to CH T T terminal and D...

Page 33: ...set 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 fitting at bottom of flue collector See figure 9 1 Disconnect hose from barbed fitting Fill trap through fitting with approximately 2 cup 473 ml water Place hose barbed fitting back through bottom of chass...

Page 34: ...0 91 C DHW Setpoint 180 F 82 C 104 195 F 40 91 C Temperature Units F F C Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff External N A Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminder Days 365 Days 1 999 Days CH Settings CH Mode 1 0 1 2 3 Warm Weather Shutdown 70 F 21 C 35 100 F 2 38 C Reset Curve Design Temperature Boiler 180 F 82 C 60 195 F 40 91 C Res...

Page 35: ... a gas meter is installed in the system Turn off gas to all other appliances Activate 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 Calculate input For Natural Gas Input MBH 3600 x cu ft seconds Example Natural Gas Gas flow from Meter 2 cu ft Measured ti...

Page 36: ...erface push Enter HIGH power 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 turn each time See Figure 9 3 and 9 6 Perform combustion test on LOW fire using calibrated combustion analyzer Adjust CO2 to within specifications by turning Offset Screw cloc...

Page 37: ...F Push Enter button OFF stops flashing C Push Menu button twice to escape Installer Manual Boiler returns to CH mode or DHW mode depending on type of call for heat available 7 Check ignition quality 4 times with front jacket off Close internal manual gas valve for 5 seconds and then re open it Boiler will go through post purge prepurge ignition sequence Reset boiler if boiler goes into lockout 8 C...

Page 38: ...afety Relay Error Requires manual reset of control module Press reset button on User interface See 9 3 Program Boiler Control OR B Shut off burner E40 Return Water Temp This is a soft lockout When water temperature drops below limit 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 Temperat...

Page 39: ...TO APPLIANCE 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 card and other supporting information Review with user and or affix in conspicuous location adjacent to boiler FIGURE 9 7 Control Module J7 Connector 9 START UP PROCEDURE J7 CONNECTOR SPARE FU...

Page 40: ...ner by hand Remove front 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 Follow instructions on this page What To Do If You Smell Gas If you do not smell gas go to next step Turn gas shutoff valve to the open position Handle should be parallel to gas pipe R...

Page 41: ...r motors according to pump and or motor manufacturer s instruction Check following components are operating properly and are free of blockages or obstructions A system air vent B check venturi air inlet for blockage and clean as required C verify pressure test port cap and combustion test port are in place D return temperature sensor clip must be securely seated on pipe Check boiler for any sign o...

Page 42: ...islodge any debris in burner ports Inspect burner for foreign matter in flame ports or inside burner Remove foreign matter by blowing with compressed air or vacuuming Replace burner if it cannot be cleaned or is showing deterioration D Clean heat exchanger with low pressure water spray Use flexible handle nylon brush to loosen sediment and oxide on all accessible heating surfaces of heat exchanger...

Page 43: ...1000 ft 300m beyond 4500 ft Canada Contact Provincial authority having jurisdiction for installations above 4500 feet 1350 m above sea level SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 GROSS OUTPUT MBH 1 2 Net AHRI Rating Water MBH 1 3 Thermal Efficiency Maximum Minimum 399 399 80 383 333 96 0 1 1000 Btu hr British Thermal Units Per Hour 2 Gross Output and Thermal Effi...

Page 44: ...rness plugs are 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 Interface Display work Remove User Interface from base Using Digital Voltmeter check for 25 to 30 Vdc Is voltage present Does display show Standby No Demand There is no call for heat or hot ...

Page 45: ...ternal error Replace Control Module High Temperature opens during normal operation Go to Page 51 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas valve opens Replace Gas Valve Control module internal error Replace Control Module Lost flame signal 3 times during one heat call Go to Page 52 Control Module internal error Replac...

Page 46: ...n range of 59 to 61 Hz Go to Page 56 Boiler power supply ground wire is not grounded Go to Page 57 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replace Control Module Supply temperature sensor is open No continuity Go to Page 57 Return water temperature sensor is open No continuity Go to Page 58 Flue temperature sensor is open No co...

Page 47: ...Is wire harness connected 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 kΩ NO YES Disconnect harness from Gas Valve Does each wire have continuity between Gas Valve and Control Module NO YES Is supply pipe heat exchanger hot NO YES Boiler has been dry fired Syste...

Page 48: ...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 and close the gas shutoff valve YES YES Remove the flame 14 sensor and igniter and inspect Is there any indication of damage or debris baked on YES Replace clean flame sensor or igniter With the ignitio...

Page 49: ...er flow in system 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 Check continuity between two pins on sensor two pins connected to two pink wires Is continuity available YES NO Check for loose connections on two pink wires on J13 connector supply senso...

Page 50: ...50 P N 240010943 Rev C 09 07 2016 13 TROUBLE SHOOTING ...

Page 51: ...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 continuity of both purple wires Continuity available for both purple wires 13 TROUBLE SHOOTING See Thermistor Resistance Chart Page 61 of this manual ...

Page 52: ... instructions TO 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 operation Enter Installer Menu Boiler Status Flame Signal Is flame signal greater than 3 7µA Boiler may be running at any firing rate YES NO Replace Control Module Replace Flame Sensor and ...

Page 53: ...ify 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 through LWCO safety circuit Continuity Check LWCO per manufacturer s instructions repair or replace NO YES Replace Wire Harness NO YES Replace Control Module Verify system is filled with water NO YES Fill system with water Press Rese...

Page 54: ...t for boiler to cool Fix flow rate problem if any purging all air out of the system Replace Flue Gas Sensor Replace Control Module Use thermcouple to measure flue gas temperature through sampling port Is the measured temperature and flue temperature reading on User Interface significantly different YES NO 3 B l o c k i n g E r r o r F l u e G a s E r r o r E 39 ...

Page 55: ...d on metal pins 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 950 to 33 000 ohms Install Primary Pump in proper orientation YES NO Replace Control Module Verify order of pins on J2 Pin order should be empty black or red white green Measure volts on...

Page 56: ...stabilized power 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 blower motor system Check wire connector to blower Check connector J9 on control board Is any connection loose YES NO Replace blower motor Does this correct the problem YES NO Boiler i...

Page 57: ...Module J5 _ P _ _ _ Blocking Error E 5 1 Supply Sens Open Insert Harness Replace Supply Water Sensor Disconnect J5 from Control Module Using digital meter measure check continuity of white wires between Control and Sensor Continuity Using digital meter measure resistance between Supply Water Sensor terminals J5 11 and J5 3 Measure resistance of Sensor with digital meter Estimate Sensor temperature...

Page 58: ...emperature 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 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Return Temperature Sensor Resistance Chart YES NO Insert Harness YES NO YES NO Measure Return Tem...

Page 59: ...upply 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 See Thermistor Resistance Chart Page 61 of this manual ...

Page 60: ...urn Water Sensor 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 Shorted Replace Vent Temperature Sensor 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 t...

Page 61: ...esistance 0 32 36100 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 1467 90 194 1265 95 203 1095 100 212 952 Thermistor Resistance Chart ...

Page 62: ...62 P N 240010943 Rev C 09 07 2016 14 3 Connection Diagram 399 MBH 14 WIRING DIAGRAM ...

Page 63: ...63 P N 240010943 Rev C 09 07 2016 14 4 Schematic Diagram of Ladder Form 399 MBH 14 WIRING DIAGRAM ...

Page 64: ...E Liquid separated from flue gas due to reduction in temperature DIRECT VENT BOILER Boiler constructed and installed so all combustion air is derived directly from outdoors and all vent gases are discharged to outdoors DRAFT Pressure difference causes gases or air to flow through a chimney vent flue or appliance FLA Full load amps FLUE GASES Products of combustion plus excess air in appliance flue...

Page 65: ...ut off gas supply to controlled burner in event source of ignition fails SEDIMENT TRAP Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve VENT Passageway used to convey flue gases from appliance vent connector to outdoors VENTING SYSTEM Continuous open passageway from of appliance vent connector to outdoors for purpose of removing flue or vent gase...

Page 66: ... to next menu item 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 Open D DHW Pump On Service Reminder Indicator Boiler in Standby Mode Boiler Supply Water Temperature Indicator Boiler Running in Central Heat mode Combustion Air Blower Speed Indicator Bo...

Page 67: ...ating demand CH call is illustrated General boiler pump is activated for any heat call 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 setting for 15 seconds Sparking initiated sequence Heat Demand DHW CH Pump on Supply Temperature Setpoint 15 Second Prepurge Ignition...

Page 68: ...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 amount of time boiler can run in DHW mode to meet CH demand Max DHW Priority Time setting determines maximum time allowed for DHW heating mode Please refer to section Appendix A section 1 5 for more ...

Page 69: ...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 set point displayed If boiler running in CH mode CH set point displayed Note While running in Outdoor Reset mode this value may change in proportion with the outdoor temperature If the boiler is running...

Page 70: ...lay will change 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 Settings submenu in Installer Menu Setting Range 104 F to 195 F 40 C to 91 C Default Value 180 F 82 C DHW set point determines supply water temperature set point while operating in DHW mode ...

Page 71: ...er 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 Fan Speed Allows adjustment of minimum and maximum ignition speeds if the specific installation requires it Boiler Status Combustion air Blower provides airflow through Combustion and Vent systems Fan speed status screen i...

Page 72: ...ill occur Re ignition 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 after which lockout occurs Intermittent Operation Boiler can be firing continuously for 24 hours Burner switched off and restart sequence follows Flame out too late If flame detected after...

Page 73: ...de history Boiler 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 operating in single boiler mode Boiler incorporates integrated Low Water Cutoff device LWCO that disables boiler when low water condition exists LWCO device located at high point of interna...

Page 74: ...r DHW Connect this 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 DHW indirect tank Note Pump Mode selection depends on electrical and hydronic system design Please refer to sections 5 and 8 for recommended hydronic piping and electrical configurat...

Page 75: ...door temperature 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 temperature using outdoor reset curve See figure A 2 CH Mode 3 CH with Permanent Demand CH demand is permanently on Boiler will permanently attempt to satisfy CH demand CH thermostat inp...

Page 76: ...eratures See points 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 supply temperature follows thick black line in graph below based on outdoor temperature Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor dete...

Page 77: ...llowable Range 1 100 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 Thermostat Boiler reacts to DHW demand when DHW thermostat input closes Boiler modulates to meet DHW demand similar to CH Mode except DHW set point is used DHW set point set in Settings su...

Page 78: ...started without CH or DHW 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 are available Disabled Low power Burner starts After ignition period has finished the burner stays at low power Ignition power Burner starts Stays at ignition power High powe...

Page 79: ...for pump selection 3 Pump size may be decreased by decreasing equivalent length of pipe Use larger diameter pipe as primary loop to decrease equivalent length Use charts 2 or 3 Note The Figure 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 Fittings Multiply By Equi...

Page 80: ...0 Elbow 3 8 45 Elbow 2 0 Tee branch 7 5 Tee through 2 5 Swing check valve 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 4 Pump Factor Chart 3 1 Pipe Eq Ft System T Pump 25 20 25 Grundfos UPS 40 60 Taco 1634 25 30 Grundfos UPS 26 150 Taco 2400 50 30 50 Grundfos UPS 26 99 ...

Page 81: ...81 P N 240010943 Rev C 09 07 2016 Company Address Phone Company Name Tech Initials Service Performed Date ...

Page 82: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

Reviews:

No comments