Dunkirk 95M-200 Control Manual And Troubleshooting Manual
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Dunkirk 95M-200 Control Manual And Troubleshooting Manual

Dunkirk 95M-200 Control Manual And Troubleshooting Manual

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See also: User's Information Manual , Quick Manual
95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
Control Manual And

Troubleshooting Guide

P/N# 240006104, Rev. E [03/2013]

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Summary of Contents for Dunkirk 95M-200

  • Page 1: Troubleshooting Guide

    95M-200 GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER Control Manual And Troubleshooting Guide P/N# 240006104, Rev. E [03/2013]...

  • Page 2: Table Of Contents

    1- TABLE OF CONTENTS 1- Table Of Contents ...................... 2 2 - Important Safety Information ..................3 3 - Operating Information ....................4 4 - Modulating Control Features ..................6 5 - Boiler Startup ......................7 6 - Checkout Procedures And Adjustments ................ 9 7 - Detailed Sequence Of Operation ................

  • Page 3: Important Safety Information

    2 - IMPORTANT SAFETY INFORMATION General Installation shall conform to requirements of authority having jurisdiction or in absence of such Boiler installation shall be completed by qualifi ed agency. requirements: • United States WARNING • National Fuel Gas Code, ANSI Z223.1/NFPA 54. Fire, explosion, asphyxiation and electrical shock •...

  • Page 4: Operating Information

    3 - OPERATING INFORMATION Boiler is controlled by microprocessor electronic control that DHW heating: Target temperature is determined by senses: adding Parameter 1 to Parameter 33 (default 150°F and 30°F). Do not change Parameter 1 from factory • Outlet water temperature, default setting of 150°F unless application is specially •...

  • Page 5: Outdoor Reset Operation

    3 - OPERATING INFORMATION Control module provides freeze-up protection when boiler DHW heating. water temperature drops below 45° F: DHW Operation (option) • Below 45° F, boiler circulator operates constantly. Control allows connection of DHW aquastat to low voltage • Below 37° F, boiler operates at low fi re. terminal strip terminals DHW T1 and DHW T2.

  • Page 6: Modulating Control Features

    4 - MODULATING CONTROL FEATURES Boiler Control Design IMPORTANT: • Integrated modulating boiler control is designed for This boiler is equipped with a feature that saves energy central heating (CH) hot water boilers with modulating by reducing the boiler water temperature as the heating fan and gas-air control.

  • Page 7: Boiler Startup

    5 - BOILER STARTUP Control module turns on DHW circulator when indirect NOTICE water heater operating control closes. Control module Instructions in this manual are based on factory shuts off boiler circulator (stops space heating) during default parameter settings. calls for DHW heating. Startup Verify Operation –...
  • Page 8 5 - BOILER STARTUP • [1180] Post-purge. When room thermostat is satisfi ed Lower DHW aquastat to stop call for heat. (call for heat ended), burner turns off. Blower continues • [1150] Post-purge. When room thermostat is satisfi ed for 15-second post-purge, then turns off. If another (call for heat ended), burner turns off.

  • Page 9: Checkout Procedures And Adjustments

    6 - CHECKOUT PROCEDURES AND ADJUSTMENTS Verify Sequence Of Operation Test Other Field Installed Safety Controls (if used) Detailed sequence of operation containing faults can be found in Sections 7, “Detailed Sequence of Operation.” If boiler is equipped with any additional safety controls, test Refer to this section and Section 8, “Service Hints,”...
  • Page 10 6 - CHECKOUT PROCEDURES AND ADJUSTMENTS Drill ½” hole in plastic CPVC vent pipe or exhaust Boiler must be in high fi re mode for this operation. See tee, just large enough to allow access for combustion “User Interface Quick Reference” section 10, for more analyzer sample probe.
  • Page 11 6 - CHECKOUT PROCEDURES AND ADJUSTMENTS Pressure Guidelines Fan Speed Minimum RPM Maximum RPM Fuel Natural Gas Natural Gas Gas Line Inlet At least 4” WC At least 10” WC Pressure Differential Pres- 0.3” WC 2.0” WC sure Note: Differential pressure values listed for comparison only. These values will change with vent length and altitude of installation.

  • Page 12: Detailed Sequence Of Operation

    7 - DETAILED SEQUENCE OF OPERATION POWER ON. UNIT IN STANDBY THERMOSTAT CALLS FOR HEAT INTERNAL MICRO CONTROLLER TEST CIRCULATOR ENERGIZES CONTROL CHECKS N O AIR PRESSURE SWITCH CONTACTS CLOSED OPEN FALSE POSITIVE PROOF COMBUSTION AIR OF AIRFLOW BLOWER ENERGIZES CONTROL ENTERS CONTROL WAITS FOR LOCKOUT ERROR CODE...

  • Page 13: Service Hints

    8 - SERVICE HINTS Troubleshooting Tools WARNING Tools needed for troubleshooting your boiler: Fire, Explosion, Shock Hazard. Revision, modifi cation, substitution or elimination of factory • Voltmeter that can check 120 VAC, 24 VAC, and 12 equipped, supplied or specifi ed components could result in death or serious injury.

  • Page 14: Troubleshooting

    9 - TROUBLESHOOTING DANGER Checking the Differential Air Pressure Electric shock hazard! Following procedures may expose you to dangerous line voltage. Use caution to avoid touching live electrical contacts. All service must be performed by a trained, experienced service technician. Failure to follow these instructions WILL result in death or serious injury WARNING Fire, Explosion.
  • Page 15 9 - TROUBLESHOOTING DANGER Electric shock hazard! Disconnect power before servicing. All service must be performed by a trained, experienced service technician. Never jumper (bypass) any device except for momentary testing as outlined on the following pages of this manual. Failure to follow these instructions WILL result in death or serious injury Control Module Fuses Check control module fuses before replacing control module...
  • Page 16 9 - TROUBLESHOOTING Boiler Not Firing And: Check For: Step Corrective Actions: NO - Check external line switch and fuse or breaker. Determine if red light on line voltage monitor is fl ashing 120 vac at terminals L1 and L2 of indication fault.
  • Page 17 9 - TROUBLESHOOTING SOFT LOCKOUT (Display fl ashes “9” and then “b” in fi rst position; last two digits on steady (code)) Code Reason For Soft Lockout Corrective Actions (pressing RESET should restart boiler immediately): 0.14” Pressure switch contacts Check pressure switch for proper operation. Replace pressure switch if moisture has open entered switch.
  • Page 18 9 - TROUBLESHOOTING Check boiler wiring against wiring diagram. Blower turning when it should be Replace line voltage and low voltage wiring harnesses if necessary. off. Replace control module if wire replacement doesn’t resolve. Flow rate too low. Check system for: Verify boiler and system are full of water.
  • Page 19 9 - TROUBLESHOOTING HARD LOCKOUT (Display fl ashes fi rst digit “E” and last two digits (code)) Code Reason For Hard Lockout Corrective Actions (pressing RESET should restart boiler immediately): Burner may be operating too hot due to incorrect combustion. Inspect fl ame during operation following procedure in this manual.
  • Page 20 9 - TROUBLESHOOTING HARD LOCKOUT (Display fl ashes fi rst digit “E” and last two digits (code)) Code Reason For Hard Lockout Corrective Actions (pressing RESET should restart boiler immediately): WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component. Internal control failure.

  • Page 21: User Interface Quick Reference

    10 - USER INTERFACE QUICK REFERENCE STANDBY MODE - KEY FUNCTIONS AND DISPLAY When boiler is powered on, the display will always show a single character (which represents the boiler’s current operating sequence) followed by the measured outlet water temperature during self-test. When entering Standby Mode, user then displays Sequence and Measured or Target Outlet Stby...
  • Page 22 10 - USER INTERFACE QUICK REFERENCE STANDBY MODE - BOILER SEQUENCE DISPLAY After display shows Stby for a brief period, fi rst character shows boiler status, followed by boiler outlet water temp. If the burner is being held off due to a soft lockout, the display alternates between showing “9” followed by boiler outlet water temp. and “b” followed by the two-digit codes below.
  • Page 23 10 - USER INTERFACE QUICK REFERENCE PARAMETER MODE Press [MODE] button 1 time from Standby Mode. Display shows Para until a key is then displays Parameter and Current Status. Para 1 180 pressed Press and Hold Key(s) in BLACK Duration Result Display Step to next parameter (continue tapping...
  • Page 24 10 - USER INTERFACE QUICK REFERENCE INFORMATION MODE Press [MODE] button 2 times from Standby Mode. Display shows Info until a key is Info Then displays Parameter, Flashing Dot, and Current Status. 1.190 pressed Press and Hold Key(s) in BLACK (1) Duration Result Display Step to next...
  • Page 25 10 - USER INTERFACE QUICK REFERENCE HARD LOCKOUT MODE Boiler in hard lockout (requires manual RESET) Display fl ashes fi rst digit E and last two digits (lockout code) (see below) Code Reason for hard lockout Code Reason for hard lockout Flame detected on start-up Supply water temperature higher than 200°F Ignition failed after 5 retries...
  • Page 26 NOTES...
  • Page 27 NOTES...

  • Page 28: Installation And Checkout Certifi Cate

    11 - INSTALLATION AND CHECKOUT CERTIFICATE Boiler Model: Boiler Serial Number: Date of Installation: Measured BTUH Input: Boiler Location: Altitude of Location: Honeywell AM Kit Installed? (Yes/No): Service Dates: System Type (Give Brief Description): Installation Instructions Have Been Followed Checkout Procedure/Adjustments Performed Maintenance/Service Issues Reviewed With Owner or Maintenance Person Installation Manual Affi...

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