Dunkirk DKVLT-050 Gebrauchsanweisung

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

P/N 240011326, Rev. B [04/15/2016]

Models

DK VLT-050

DK VLT- 075

DK VLT-100

DKVLT-150

DKVLT-200

DK VLT-299

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

050/075/100

SIZE SHOWN

VERIFY CONTENTS RECEIVED

* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure greater than 25

psig.

** Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system pressure

greater than 60 psig.

Fully Assembled Boiler

(50-100 size shown)

Metal Wall Bracket

w/ Lag Bolt, 3/8" x 3" Hex

(4 ea)

*Safety Relief Valve

w/ 3/4" Tee, 3/4" Nipple,

3/4" x 1/4" Elbow

and Air Vent

**Temperature

Pressure Gauge

w/ 3/4" x 1/4" Bushing,

3/4" Nipple, 1¼ x 5½ 4"

Tee,

Used for electrical wire

knockouts

Used for packaging holes on

back of boiler

Used for packaging holes on

back of boiler

Drain Valve, 3/4", 3/4"

Tee, 3/4" Tee

Bushing 7/8" OD, Heyco

(2 ea)

Stopper, Rubber 5/16" (2

ea) Plastic Plug (2 ea)

Used for measuring outside

temperature

11" x 17" Page for critical

installation issues. Includes essential documents.

Outdoor Sensor Critical Installation

Instruction Document Package

P/N 240011326, Rev. B [04/15/2016]

TABLE OF CONTENTS

1 - Important Safety Information.........................6

2 - Introduction....................................................7

3 - Component Listing ..........................................8

4 - Locating Boiler ..............................................12

5 - Hydronic Piping.............................................14

5.2 Special Conditions.......................................14

5.3 Safety Relief Valve And Air Vent....................15

5.4 Trim Piping.................................................16

5.5 System Piping ............................................16

6 - Combustion Air And Vent Piping....................23

6.2 Removal Of Existing Boiler From Common Vent

System.........................................................23

6.3 Materials ..................................................23

6.4 Pipe Installation..........................................24

6.5 Termination................................................24

6.6 Venting Congurations.................................25

6.7 Side Venting Terminal Requirements..............30

6.8 Multiple Boiler Venting Installation ................32

6.9 Condensate Piping ......................................33

7 - Gas Supply Piping .........................................34

8 - Electrical Connections ...................................36

8.3 Line Voltage Connections .............................36

8.4 External Connections...................................36

9 - Start Up Procedure........................................38

9.6 Perform CSD-1 Compliance Test .......................40

9.7 Complete Start Up Procedure ...........................41

10 - Operating Instructions ................................45

11 - General Maintenance And Cleaning .............46

12 - Ratings And Capacities................................49

13 - Trouble Shooting.........................................50

14 - Wiring Diagram ...........................................67

15 - Glossary ......................................................71

Appendix A - Control Module .............................. 73

1.1 Introduction ...............................................73

1.2 Operation ..................................................73

1.3 Status Indication ........................................73

1.4 Sequence of Operation ................................74

1.5 User Menu .................................................76

P/N 240011326, Rev. B [04/15/2016]

Table 1: Physical Data

Models

050/075/100 150/200 299

Width (A) 20" (508mm) 23" (584mm)

Height (B) 31" (787mm) 42" (1067mm)

Depth (C) 14-¾" (375mm) 16.0" (406mm) 18.4" (467mm)

Bracket (D) 27.7" (704mm) 38.7" (983mm)

Height (E) 32" (813mm) 43" (1092mm)

Water

Connections

Size (F) 1-1/4" NPT 1-1/4" NPT

Location (G) 2" (51mm) 2" (51mm) 3" (51mm)

Location (H) 5" (127mm) 3" (76mm) 2.6" (66mm)

Location (I) 3-½" (89mm) 4-½ (112mm) 4-¾" (114mm)

Gas

Connection

Location (J) 4-⁷/₈(124mm) 7-¾ " (197mm)

Size (K) 1/2" NPT 3/4" NPT

Condensate Drain Connection (L) 3/4" NPT 3/4" NPT

Weight

Shipping 111 lb (50 kg) ~182 lb (83 kg) ~225 lb (102 kg)

Unit 91 lb (41 kg) ~157 lb (71kg) ~195 lb (89 kg)

Vent Connector

2" (51mm) 3" (76mm)

PHYSICAL DATA

P/N 240011326, Rev. B [04/15/2016]

Dimensions

Condensate Drain Connection (L)

Return Water (F)

Gas Connection (K)

Vent Connector

Combustion Air

Safety Relief Valve

Connection (¾ NPT)

Front View Rear View

Wall Bracket

Top View 50-200

Bottom View

Dimensions

50-100 MBH

Bottom View

Connection

Identication 150-299 MBH

Supply Water (F)

PHYSICAL DATA

Condensate Drain Connection (L)

Return Water (F)

Gas Connection (K)

Bottom View

Connection

Identication 50-100 MBH

Supply Water (F)

Bottom View

Dimensions

150-200 MBH

Vent Connector

Combustion Air

Safety Relief Valve

Connection (¾ NPT)

Top View 299

Bottom View

Dimensions

299 MBH

P/N 240011326, Rev. B [04/15/2016]

1 - IMPORTANT INFORMATION

CAUTION

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.

DANGER

Indicates a hazardous situation which, if not

avoided, WILL result in death or serious injury.

This is the safety alert symbol. Symbol alerts you

to potential personal injury hazards. Obey all safety

messages following this symbol to avoid possible

injury or death.

Become familiar with symbols identifying potential hazards.

Boiler installation shall be completed by qualied agency. See

glossary for additional information.

WARNING

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

installation.

1. SAFETY INFORMATION

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 re

department.

WARNING

Do not tamper with or use this boiler for any

purpose other than its intended use. Failure

to follow these instructions could result in

death or serious injury. Use only manufacturer

recommended parts and accessories.

P/N 240011326, Rev. B [04/15/2016]

Check our website frequently for updates: www.ecrinternational.com

Information and specications outlined in this manual in effect at the

time of printing of this manual. ECR International reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

2 - INTRODUCTION

2.4 Designated Use

• Hot water heating boiler.

• Indoor installation.

• Closet or alcove installation.

• Direct vent boiler.

• For use with natural gas or liqueed petroleum gases

(LP/propane).

2.5 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals

present (example, swimming pool water).

• Exceed 150 psig (1.03 MPa) maximum allowable working

pressure.

• Exceed 195°F (90.5°C) system design temperature.

2.6 Operational Features

• Modulating: 20-100%.

• Integral Dual Limit.

• Integral Low Water Cutoff (with test button).

• Outdoor Temperature Reset.

• Integral Multiple Boiler Control.

• Heat exchanger over heat protection.

2 - INTRODUCTION

2.1 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 Installation Code, CAN/CSA

B149.1.

• Canadian Electrical Code, Part I, Safety Standard for

Electrical Installations, CSA C22.1

2.2 Where required by authority having jurisdiction,

installation shall conform to Standard for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be required.

2.3 Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of

Massachusetts code 248 CMR which includes but is not limited

to:

Installation by licensed plumber or gas tter.

P/N 240011326, Rev. B [04/15/2016]

3.1 Component Listing - Refer to diagrams on

following pages.

User Interface Displays information regarding boiler

condition. Allows adjustment of boiler operating

parameters. NOTE: Does not replace thermostat used to

control central heating space.

Combustion Air Inlet (2"/3") See section 6.

Return Water From Heating System (In) Connection

supplied at bottom of boiler. See section 5.

Low Voltage Terminal Strip Connection of all low voltage

wiring, including thermostat.

Igniter

Flame Sensor

Sight Glass permits observation of burner ame.

Burner (see page 43)

Heat Exchanger

10.

Condensate Collector

11.

Return Water Temperature Sensor

12.

Drain Valve (see page 16)

13.

Internal Primary Loop Ball Valve

14.

Supply Water Outlet to Heating System (Out)

Connections supplied for connecting from bottom of

boiler. See section 5.

15.

Vent Temperature Sensor

16.

Condensate Drain Boiler produces a liquid

(condensate) as a by-product of combustion. Condensate

must be piped to appropriate drain. See section 6.

17.

Heat Exchanger Pump

18.

Gas Shutoff Valve 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 for combustion.

20.

Gas (Control) Valve Delivers proper quantity of fuel to

Combustion Air Blower. See section 7.

21.

Supply Water Temperature Sensor and High Limit

Switch

22.

Low Water Cutoff Senses inadequate quantity of

water. Turns off boiler before damage can occur.

23.

Safety Relief Valve Factory supplied, Field installed. See

section 5.

24.

High Voltage Junction Box For connection of 120V

components. See section 8.

25.

Vent Connector See section 6.

26.

Gas Connection See section 7.

27.

Wall Hanging Support Bracket (see page 13) Integral

to boiler. Allows wall mounting when used with

supplied wall mounting bracket. See section 4.

28.

Air Vent

29.

Boiler Control Module

30.

Transformer Supplies 24V power to low water cutoff.

31.

Flue Air Mixture Pressure Test Port - Not available on all

models.

32.

Combustion Analysis Test Port

33.

Internal Pump Relay - Not available on all models.

34.

Heat Exchanger Surface Temperature Switch

35.

ASME Plate

3 - COMPONENT LISTING

P/N 240011326, Rev. B [04/15/2016]

FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)

Vent Connector

Combustion Air Inlet

Safety Relief Valve

Air Vent

Wall Mount Support Bracket

3 - COMPONENT LISTING

FIGURE 3-2 Jacket Removal -Viewed from Bottom of

Boiler (50-100 MBH shown)

Jacket Latch

Lift latch to dis-engage

Bottom of Boiler

FIGURE 3-3 Jacket Removal -Viewed from Left Side of

Boiler (50-100 MBH shown)

Dis-engage latch lift

jacket up and off

jacket support

Jacket Support (Lip)

Jacket Latch

Note

P/N 240011326, Rev. B [04/15/2016]

10 P/N 240011326, Rev. B [04/15/2016]

FIGURE 3-4 Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover

3 - COMPONENT LISTING

User Interface

Behind User Interface

See Section 5 For Piping Instructions

Note

Gas Shutoff Valve

(Shown In Open Position)

Vent Connector

Combustion Air Blower

Gas (Control) Valve

Low Water Cutoff

Air Vent

Combustion Air Inlet

Heat Exchanger Pump

Condensate Trap

Return Water From

Heating System (In)

Supply Water To Heating

System (Out)

Low Voltage Terminal Strip

Vent Temperature Sensor

Gas Connection

Combustion Analysis Test Port

High Voltage Junction Box

Heat Exchanger

Boiler Control Module

Fuse And Holder

Igniter

Flame Sensor

Sight Glass

Flue Air Mixture Pressure

Test Port

Condensate Drain

Transformer

Return Water Temperature

Sensor

Internal Primary Loop Ball Valve

Heat Exchanger Surface

Temperature Switch

ASME Plate

Supply Water Temperature

Sensor & High Limit Switch

Safety Relief Valve

Low Water Cutoff

Condensate Collector

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