Dunkirk HELIX VX-399 Instruction manual

P/N 240010940 Rev. A [10/2015]
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

2P/N 240010940, Rev. A [10/2015]
Description
Item No. Illustration
Fully Assembled Boiler 1
*Safety Relief Valve ¾" 2
Elbow ¾" 90° 3
¾" Close Nipple 4
Temperature Pressure Gauge 2"
Shank 5
Aquastat 6
Well 3/4" x 1½" 7
Black Tee 1¼" x 1¼" x ¾" Tee 8
Nipple 1¼" Close (2) 9
Bushing ¾" x ¼" 10
Bushing 1¼" x ¾" (2) 11
LWCO Harness 12 For connection of LWCO
Aquastat Harness 13 For connection of Aquastat
Critical Installation Instruction 14 11" x 17" Page for critical installation issues.
Document Package 15 Includes essential documents.
VERIFY CONTENTS RECEIVED
3
* 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.
1
4
2
5
6
7
8
10
9
9
11

3P/N 240010940, Rev. A [10/2015]
OVERALL DIMENSIONS
BACK
OF BOILER
TOP FRONT
OF BOILER
* Note - Alternate Condensate Drain Connection on Right Side of Boiler.
Table 1 : Model 399 - Physical Data
Location Inches mm
A Width 27 ⅛ 688
B Height - Unit only 52 1320
C Depth 21 ⅛537
D Height unit w/ Piping 66 ¼ 1683
E Height unit w/vent 56 ¼ 1439
G/H
Return Water
from System
1¼" NPT
Location (G) 3 ¼ 83
Location (H) 5 ⅛ 130
H/I
Supply Water
to System
1¼" NPT
Location (H) 5 ⅛ 130
Location (I) 4 ¼ 108
J/K
Gas
Connection
1" NPT
Location (J) 9 ½ 241
Location (K)
8 ⁹/₁₆ 217
*L/*M
Condensate
Drain
Connection
3/4"NPT
Location (L)
12¹/₁₆ 316
Location (M)
11⁷/₁₆ 281
Weight Shipping 290 lbs 132kg
Unit 265 lbs 121kg
Vent Connector 4 102
LEFT SIDE
OF BOILER
RIGHTSIDE
OF BOILER
FRONT
OF BOILER
*M
*L
E
D
B
AC
H
K
G
J
I
H

4P/N 240010940, Rev. A [10/2015]
1 - Introduction...............................................................................................................................5
2 - Important Safety Information....................................................................................................6
3 - Component Listing .....................................................................................................................7
4 - Locating Boiler .........................................................................................................................10
5 - Hydronic Piping........................................................................................................................ 11
5.2 Special Conditions................................................................................................................. 11
5.3 Safety Relief Valve and Air Vent .............................................................................................. 11
5.4 Trim Piping........................................................................................................................... 12
5.5 System Piping....................................................................................................................... 12
6 - Combustion Air And Vent Piping...............................................................................................19
6.2 Removal of Existing Boiler From Common Vent System................................................................19
6.3 Venting Materials ................................................................................................................. 19
6.4 Vent Pipe Installation............................................................................................................. 20
6.5 Vent Termination .................................................................................................................. 21
6.6 Venting Congurations........................................................................................................... 26
6.7 Side Venting Terminal Requirements of : .................................................................................. 29
6.8 Multiple Boiler 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 (Temperature Resistance Chart).................................................................61
14 - Wiring Diagram ...................................................................................................................... 62
15 - Glossary ................................................................................................................................. 64
APPENDIX A - CONTROL MODULE....................................................................................................66
1.1 Introduction ........................................................................................................................ 66
1.2 Operation ........................................................................................................................... 66
1.3 Status Indication ................................................................................................................. 66
1.4 Sequence of Operation ......................................................................................................... 67
1.5 User Menu .......................................................................................................................... 69
OPTIONAL USER INTERFACE RELOCATION.....................................................................................79
PRIMARY LOOP EQUIVALENT LENGTH CALCULATIONS & PUMP SELECTION...............................80-81
TABLE OF CONTENTS

5P/N 240010940, Rev. A [10/2015]
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Direct vent or single vent pipe boiler.
• For use with natural gas or liqueed petroleum gases
(LP/propane).
1.2 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.
1.3 Operational Features
• Modulating: 20-100%.
• Integral Dual Temperature Limit.
• CSD-1 Low Water Cutoff (LWCO) provided.
• Outdoor Temperature Reset Available.
• Heat exchanger over heat protection.
• Alternate mounting of User Interface Available
Information and specications outlined in this manual in effect at the
time of printing of this manual. ECR International, Inc. reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
Check our website frequently for updates: www.ecrinternational.com
1 - INTRODUCTION

6P/N 240010940, Rev. A [10/2015]
NOTICE
Used to address practices not related to personal
injury.
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.
2.2 Become familiar with symbols identifying
potential hazards.
2.1 General
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.
!
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 Installation Code, CAN/
CSA B149.1.
• Canadian Electrical Code, Part I, Safety Standard for
Electrical Installations, CSA C22.1
2.4 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.
2.5 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.
2 - IMPORTANT SAFETY INFORMATION

7P/N 240010940, Rev. A [10/2015]
FIGURE 3-1 Boiler Components (Viewed from Left side of Boiler) NOTE:
See Section 5-3
For Safety Relief
Valve Piping
Instructions
3 - COMPONENT LISTING
FIGURE 3-2 Jacket Removal (Viewed from Left Side of Boiler)
Disengage jacket latches on
both sides of boiler.
Lift jacket up and off
support at bottom of jacket
and remove.
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 Tree
Left Side
Jacket Handle

8P/N 240010940, Rev. A [10/2015]
3 - COMPONENT LISTING
3.1 Component Listing - Refer to diagrams on
following pages.
Temperature Pressure Gauge (Field Installed)
User Interface - Displays information regarding
boiler condition. Allows adjustment of boiler
operating parameters. NOTE: Does not replace
thermostat used to control central heating space.
Supply Water Temperature Sensor
Combustion Air Blower Delivers proper quantity
of combustion air, receives fuel from gas valve,
mixes air and fuel sending mixture to burner for
combustion
Sight Glass - Permits observation of burner ame.
Heat Exchanger Strap and Buckle (2)
Transformer
DHW Pump, Primary Pump, CH Pump and
Blower Relays
Heat Exchanger
ASME Plate
Flue Collector
Return Water Temperature Sensor
Leveling Feet (4)
Safety Relief Valve Factory supplied, Field
installed. See section 5.
Burner not shown (see page 3)
Spare Fuse not shown (see page 3)
Flue Gas Test Port
Combustion Air Test Port
39
38
37
35
34
33
32
31
30
29
28
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,
(1¼" 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 120V
components. See section 8.
10 Amp Breaker
Low Voltage Terminal Strip Connection of all low
voltage wiring, including thermostat.
Wire Knockouts
Boiler Control Module with Spare Fuse
Heat Exchanger Surface Temperature Switch
(Not Shown
Vent Temperature Sensor
Condensate Drain Right or Left Option
Condensate must be piped to appropriate drain. See
section 6.
Drain Valve
Condensate Trap - Right or Left Option Boiler
produces a liquid (condensate) as a by-product of
combustion. (See page 33)
Control Tee (Field installed)
Low Water Cutoff (LWCO)
Supply Water Outlet to Heating System - Out,
(1¼" NPT) See section 5.
Manual Reset temperature Limit Control (Field
Installed)
Optional Air Filter
1
13
23
22
21
20
19
18
17
15
7
6
5
4
3
2
16
14
11
10
9
8
12

9P/N 240010940, Rev. A [10/2015]
3 - COMPONENT LISTING
Gas Shutoff
5
FIGURE 3-3 Boiler Components 399 MBH (View from Front of Boiler) As seen on front cover
User Interface
Low Water Cutoff
Gas Supply
Limit Control
Temperature Pressure
Gauge
Supply Water To
Heating System
Combustion Air Inlet
Vent Connector
Return Water From
Heating System
Gas (Control) Valve
(Behind Air Filter)
High Voltage Junction
Box
Low Voltage Terminal
Strip
Boiler Control Module
Fuse and Holder
W/ Spare Fuse
Transformer
DHW Pump, Primary
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
7
8
9
10
21
11
12
13
15
16
17
18
22
24
25
20
27
28
29
30
31
32
33
34
35
36
Controls Tree
19
37
Safety Relief Valve
(Rear)
Spare Fuse
39
Flue Gas Test Port
40
Combustion Air
Test Port
41
Optional Air Filter
23
Condensate Drain
Connection
16
Condensate Trap 18
26

10 P/N 240010940, Rev. A [10/2015]
FIGURE 4-1 Clearance to Combustible Materials
4.1 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent freezing of liquid condensate.
• Approved for installation in closets.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap,
control replacement, etc.).
• Locate boiler on level, solid base as near outside vent
wall as possible and centrally located with respect to
heat distribution system as practical.
• Determine alternate User Interface mounting location
if desired. See page 81 - Optional User Interface
Relocation.
• Access to outdoors to meet minimum and maximum
pipe lengths for combustion air 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 gure 4-1.
• Multiple Boilers can be placed side by side, or back to
back.
WARNING
Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
• FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS
ONLY - For installation on combustible ooring special
base shall be used. Boiler shall not be installed on
carpeting.
TABLE 2: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Model 399 399
Top (A) 0" (0 cm) 18" (36 cm)
Left Side (B) 0" (0 cm) 6" (0 cm)
Right Side (C) 0" (0 cm) 6" (0 cm)
Front (D) 0" (0 cm) 24" (16 cm)
Back (E) 0" (0 cm) 0" (0 cm)
Combustion Air/Vent
piping
0" (0 cm) 6" (16 cm)
Hot Water Piping See local code 6" (16 cm)
(1) Required distances measured from boiler jacket.
(2) Service clearance recommendation.
C
B
FLOOR
4 - LOCATING BOILER
FRONT OF BOILER
A
FLOOR
LEFT SIDE
OF BOILER
A
ED