Cast iron gas fired boilers for forced hot water with hydrolevel control (40 pages)
Summary of Contents for Dunkirk HELIX VX-399
Page 1
Model VX - 399 GAS BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com P/N 240010940 Rev. A [10/2015]...
Page 2
VERIFY CONTENTS RECEIVED Description Illustration Item Fully Assembled Boiler *Safety Relief Valve ¾" Elbow ¾" 90° ¾" Close Nipple Temperature Pressure Gauge 2" Shank Aquastat Well 3/4" x 1½" Black Tee 1¼" x 1¼" x ¾" Tee Nipple 1¼" Close (2) Bushing ¾"...
Page 3
OVERALL DIMENSIONS FRONT LEFT SIDE RIGHTSIDE OF BOILER OF BOILER OF BOILER BACK OF BOILER Table 1 : Model 399 - Physical Data Location Inches Width 27 ⅛ Height - Unit only 1320 Depth 21 ⅛ Height unit w/ Piping 66 ¼...
1 - INTRODUCTION 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 liquefied petroleum gases (LP/propane). 1.2 The unit MUST NOT: •...
2 - IMPORTANT SAFETY INFORMATION 2.1 General 2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such Boiler installation shall be completed by qualified agency. requirements: See glossary for additional information. • United States WARNING •...
3 - COMPONENT LISTING FIGURE 3-1 Boiler Components (Viewed from Left side of Boiler) NOTE: See Section 5-3 Supply Water To Heating System For Safety Relief Limit Control Valve Piping Safety Relief Valve Instructions Controls Tree Combustion Air Inlet Temperature Pressure Gauge Vent Connector Return Water From Gas Supply...
Page 8
3 - COMPONENT LISTING 3.1 Component Listing - Refer to diagrams on following pages. Temperature Pressure Gauge (Field Installed) Combustion Air Inlet (4") See section 6. User Interface - Displays information regarding Vent Connector (4") See section 6. boiler condition. Allows adjustment of boiler operating parameters.
Page 9
3 - COMPONENT LISTING FIGURE 3-3 Boiler Components 399 MBH (View from Front of Boiler) As seen on front cover Supply Water To Heating System Combustion Air Inlet Limit Control Combustion Air Controls Tree Test Port Vent Connector Safety Relief Valve (Rear) Flue Gas Test Port Temperature Pressure...
4 - LOCATING BOILER 4.1 Boiler Location Considerations FIGURE 4-1 Clearance to Combustible Materials • 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.).
5 - HYDRONIC PIPING 5.1 General WARNING • Install piping in accordance with authority having • Poison hazard. Ethylene glycol is toxic. Do not jurisdiction. use ethylene glycol. NOTICE • Never use automotive or standard glycol Use two (2) wrenches when tightening boiler's antifreeze, even ethylene glycol made for fitting and pipes.
5 - HYDRONIC PIPING • Use pipe suitable for temperatures of 375°F (191°C) WARNING or greater. Burn and scald hazard. Safety relief valve could • Individual boiler discharge piping shall be independent discharge steam or hot water during operation. of other discharge piping. Install discharge piping per these instructions.
Page 13
5 - HYDRONIC PIPING Piping Legend 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. See Table 3 for primary pump sizing. Primary circuit pipe components must also be included to size pump.
Page 14
5 - HYDRONIC PIPING FIGURE 5-5 Single Boiler Primary/Secondary Two-Pipe Zoned System With Zone Valves Pump 12" Max. Separation CH/System Pump General Boiler Pump on Return Side FIGURE 5-6 Single Boiler Primary/Secondary Two-Pipe Zoned System With Zone Pumps Pump 12" Max. Separation Zone Pump General...
Page 15
5 - HYDRONIC PIPING FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping 12"(305mm) Max. separation 12"(305mm) Maximum separation Existing closely spaced tees in primary system loop CH/System Limit length Pump 5' (1.6m) General Boiler Pump on Return Side FIGURE 5-7B Single Boiler Using Primary/Secondary Pumping With DHW Tank Heating Load Heating Load 12"(305mm) Maximum separation...
Page 16
5 - HYDRONIC PIPING FIGURE 5-8A Multiple Boiler Primary/Secondary Two Pipe Zoned System With Zone Valves - (See Multiple Boiler Guide) Pump CH/System Pump 12"/305mm Maximum Separation Size common piping System per maximum heat Temperature capacity of entire Sensor system Limit length to 5' (1.6m)
Page 17
5 - HYDRONIC PIPING FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping 12"/305mm 12"/305mm Maximum Separation Maximum Separation Existing closely spaced tees in primary system loop CH/System Size common piping Pump per maximum heat System capacity of entire Temperature system Sensor Limit length to 5' (1.6m)
Page 18
5 - HYDRONIC PIPING 5-8C Multiple Boilers Using Primary/Secondary Pumping with DHW Tank 12"/305mm Maximum Separation Existing closely spaced tees in primary system loop CH/System System Size common piping Pump Temperature per maximum heat Sensor capacity of entire system Limit length to 5' (1.6m) General...
6 - COMBUSTION AIR AND VENT PIPING 6.1 General • Any improper operation of common venting system should be corrected so installation conforms with National This boiler requires a dedicated direct vent system. Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas Install combustion air and vent piping in accordance and Propane Installation Code, CAN/CSA B149.1.
6 - COMBUSTION AIR AND VENT PIPING 6.4 Vent Pipe Installation plastic vent pipe from vent connector must be readily accessible for visual inspection. • Minimum and maximum combustion air and vent pipe lengths listed in Table 5. Pipe length counted from combustion air connector to termination.
Page 21
6 - COMBUSTION AIR AND VENT PIPING 6.6 Venting Configurations NOTICE Various venting configurations can be applied to this boiler. Use of vent covers may cause freezing. If using For guidance see Venting Configuration Table 7A and vent covers overall vent length must be considered. corresponding figures.
Page 22
6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 Two Pipe Roof Vent 12" (205mm) Min. horizontal 12" (205mm) Min. separation between combustion air intake and vent of same appliance. 12" (305mm) Min. 15" 12" (205mm) Min. or greater separation (381mm) ...
Page 23
6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-4 Side Wall Concentric Terminal FIGURE 6-5 Side Wall Concentric Terminal Multiple Appliances Roof 1"(2.54cm) 1" (25mm) Overhang Maximum 1" (25.4mm) Max. Max. 12" (305mm) Min. * See Note 36" (457mm) Min. Below Vent Maintain 12"...
Page 24
6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-7 Concentric Roof Terminal Vent Glue inner vent pipe to prevent Maintain 12"(305mm) US recirculation. (18"(457mm) Canada) clearance above highest Maintain 12" (305mm) US anticipated snow level 24" (18"(457mm) Canada) minimum Combustion Air (610mm) above roof clearance above highest...
Page 25
6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-10 Flue on Sidewall, Combustion Air on Roof FIGURE 6-12 Two Pipe Side Wall with 45° Vent Maintain 12"(305mm) US (18"(457mm) Canada) clearance above highest Combustion anticipated snow level 24" Vent (610mm) above roof 45°...
6 - COMBUSTION AIR AND VENT PIPING 6.7 Side Venting 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...
Page 27
6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-15 Keep vent termination 3’ minimum Vegetation, (0.9m) away from vegetation. Position Plants & termination where vent vapors will not Shrubs damage plants/shrubs or air conditioning equipment. Termination Vent termination US only - 4’ (1.2m), Meters, Canada - 6' (1.8m) horizontally from, Regulators,...
6 - COMBUSTION AIR AND VENT PIPING 6.8 Multiple Boiler Venting Installation FIGURE 6-17 Condensate Piping • Multiple boiler application boiler shall be vented individually. • Follow guidelines as described in figures 6-1 through 6-7. • plastic vent pipe from vent connector must be readily accessible for visual inspection.
7 - GAS SUPPLY PIPING FIGURE 7-1 Gas Connection (at top of Boiler) CAUTION WHAT TO DO IF YOU SMELL GAS Gas Connection Top of Boiler • Do not try to light any appliance. 1"NPT • Do not touch any electrical switch; do not use any phone in your building.
Page 30
7 - GAS SUPPLY PIPING FIGURE 7-2 Manual Gas Shutoff Valve - Inside Boiler DANGER Jacket Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Gas Valve Failure to comply will result in death or serious injury.
8 - ELECTRICAL CONNECTIONS 8.1 General WARNING Electrically bond boiler to ground in accordance with Electrical shock hazard. Turn OFF electrical power requirements of authority having jurisdiction. Refer to: supply at service panel before making electrical • USA- National Electrical Code, ANSI/NFPA 70. connections.
Page 32
8 - ELECTRICAL CONNECTIONS • System Sensor (Multiple boiler applications only) NOTICE • Domestic Hot Water (DHW) Thermostat, if used. Use dry contact for wires to CH T-T terminal and A. Use temperature control with dry contacts rated DHW T-T terminal. E33 error code is displayed if at 0.5 amps @ 120 VAC.
9 - START UP PROCEDURE 9.1 Fill Boiler With Water And Purge Air NOTICE NOTICE IMPORTANT: Condensate trap must be manually filled with water at initial start up. To maintain boiler efficiency and prevent boiling inside the heat exchanger, flush entire heating FIGURE 9-1 Condensate Drain Assembly - Option may system until clean.
Page 34
9 - START UP PROCEDURE 9.3 Program Boiler Control FIGURE 9 -2 User Interface Description - Manual Lockout Reset - Enter/Exit user menu - Go to previous screen - Select a menu item - Confirm new parameter value - Scroll up to next menu item - Increase value - Scroll down to next menu item - Decrease value...
Page 35
9 - START UP PROCEDURE For Propane (LP): 9.4 Boiler Start-up and Operational Test Verify air is purged from hydronic piping 9160 x cu ft Input (MBH) System test pumps - verify each pump is seconds operational using vibration, noise and amp draw. For Metric formulas- See Glossary Verify gas piping •...
Page 36
9 - START UP PROCEDURE FIGURE 9-3 Throttle Screw Location - 399 MBH WARNING Fire, explosion, asphyxiation and electrical shock hazard. Read this instruction and understand all requirements, including requirements of authority having jurisdiction before making adjustments. Failure to follow these instructions could result in death or serious injury.
Page 37
9 - START UP PROCEDURE FIGURE 9-3 Offset Screw Location - 399 MBH LOW fire combustion - 399 MBH Flame signal Design μA Target Natural 8.8% 9.2% 9.0% <100ppm >4.5 Propane 9.8% 10.5% 10.0% See Figures 9-5 and 9-6 for location of Offset Screw on modulating gas valve of various boiler models.
9 - START UP PROCEDURE 9.7 Perform CSD-1 Compliance Test (see WARNING paragraph 2.4 page 6) Asphyxiation hazard. Carbon monoxide is odorless, Verify operation of boiler safety control operation with tasteless, clear colorless gas, which is highly toxic. regard to no flow conditions as follows: Verify cap is firmly placed on combustion analyzer Turn off boiler using boiler service switch.
9 - START UP PROCEDURE 9.8 Complete Start Up Procedure FIGURE 9-6 Control Module J7 Connector Reset control parameters to operating settings if adjusted to allow startup and operation test. Follow instructions TO TURN OFF GAS TO APPLIANCE (page 41) if boiler is not being placed into immediate operation.
10 - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WARNING WHAT TO DO IF YOU SMELL GAS If you do not follow these instructions • Do not try to light any appliance. exactly, a fire or explosion may result •...
11 - GENERAL MAINTENANCE AND CLEANING 11.1 Beginning of Each Heating Season DANGER • Check boiler area is free from combustible materials, Before servicing, turn off electrical power to boiler gasoline, and other flammable vapors and liquids. at service switch. Close manual gas valve to turn •...
Page 42
11 - GENERAL MAINTENANCE AND CLEANING 11.2 Annual Shut Down Procedure Figure 11-2 Condensate Trap (Left Side Shown) • Follow instructions “To Turn Off Gas To Appliance” unless boiler is also used to supply domestic hot water. See section 10. •...
12 - RATINGS AND CAPACITIES Table 13 - Sea Level Ratings SEA LEVEL RATINGS NATURAL AND PROPANE GASES Heating Net AHRI Thermal Boiler Input Rate (MBH) Size Capacity Rating, Water Efficiency (MBH) (MBH) (1)(2) (1)(3) Maximum Minimum 96.0 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and Thermal Efficiency is based on DOE (Department of Energy) test procedures.
Page 44
13 - TROUBLE SHOOTING If boiler does not function. Remove Jacket. Is User Interface lit? Check for 120 vac in boiler high Does display show "Standby - No voltage terminal box. Demand? Is 120 vac present? Locate fuse holder on front of Check power supply to There is no call for control and pull to check fuse.
Page 45
13 - TROUBLE SHOOTING Go to Page For Screen Display Explanation Troubleshooting Control has blocking error for more than 20 Go to Page 47 hours in a row. Thirty five unsuccessful ignition attempts in a Go to Page 48 Open gas valve power circuit. May involve high temperature switch, gas valve, or gas Go to Page 47 valve relay in control module.
Page 46
13 - TROUBLE SHOOTING Go to Page For Screen Display Explanation Troubleshooting Low water cutoff sees no water. Go to Page 53 Flue temperature sensor sees temperature Go to Page 54 B l o c k i n g E r r o r E 39 higher than 200°F.
15 - GLOSSARY • ANSI - American National Standards Institute, Inc. • GAS PIPE SIZES - Size pipe per NFPA-54. oversees creation and maintenance of voluntary • HIGH-VOLTAGE - Circuit involving potential of not consensus standards, including ANSI Z21.13/CSA 4.9: more than 600 volts and having circuit characteristics in Gas-Fired Low Pressure Steam and Hot Water Boilers.
Page 65
15 - GLOSSARY • SAFETY RELIEF VALVE - 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 in event source of ignition fails.
APPENDIX A - CONTROL MODULE 1.1 Introduction Operation with LCD character display module Boiler is equipped with programmable electronic control and user interface module. 1.2 Operation • Display: 4 x 20 character LCD screen to show boiler status. • Function Keys Description - Manual Lockout Reset - Enter/Exit user menu...
APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation Boiler operates in standby mode until demand for Central Heat (CH) Heat or Domestic Hot Water (DHW) is Demand? detected. CH or DHW pump is turned on based on type of heating demand.
Page 68
APPENDIX A - CONTROL MODULE 1.4 Sequence of Operation Operational State User Interface Display Explanation After 2 seconds If flame detected before Gas Valve opens during ignition boiler will lockout. Lockout Flame Error A21 Detected? Please refer to troubleshooting guide. Note: Lockout A01 after allowed...
APPENDIX A - CONTROL MODULE 1.5 User Menu Explanation User Interface Display Boiler operates in standby mode until demand for Central Heat (CH) or Domestic Hot Water (DHW) is detected. User Menu (Press Menu button on user interface to access User Menu) User Menu structure includes: •...
Page 70
APPENDIX A - CONTROL MODULE Explanation User Interface Display Adjust CH set point to hydronic system design while in Operating in CH Mode = 0 (CH with Thermostat) or 3 (Permanent Demand). In CH Mode = 1 (CH with Thermostat and Outdoor Reset) or 2 (CH with Full Outdoor Reset).
Page 71
APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu Installer Menu structure includes: • User 'Menu' can be accessed by pressing 'Menu' key on user interface. • Installer 'Menu' can be accessed by first pressing and holding the 'Enter' key continue to hold and at the same time press and hold the 'Menu’...
Page 72
APPENDIX A - CONTROL MODULE Explanation User Interface Display Installer Menu Control module logs successful and failed ignition attempts. Information accessed in ‘Ignition Attempts’ Screen as shown. Ignition attempts are stored in non-volatile memory and are retained in event of power failure. Figure A-1 Typical Ignition Cycle Following control features are implemented to ensure safe and reliable operation of Combustion System:...
Page 73
APPENDIX A - CONTROL MODULE Explanation User Interface Display Boiler stores information regarding total CH and DHW run time in hours. Data stored in non-volatile memory and retained in event of power failure. Boiler logs last 16 blocking errors and 16 lockout errors in non-volatile memory.
Page 74
APPENDIX A - CONTROL MODULE Explanation User Interface Display Two pump modes are available: Pump Mode = 0 ‘CH or CH&DHW’ • In this mode either CH or DHW pump terminal is energized depending on type of demand (CH or DHW). •...
Page 75
APPENDIX A - CONTROL MODULE Explanation User Interface Display 4. Central Heating (CH) modes available: • CH Mode = 0 ‘CH with Thermostat’ • Boiler will attempt to satisfy CH demand while CH thermostat input is closed. • Boiler will modulate its firing rate to maintain CH set point and match system heat load.
Page 76
APPENDIX A - CONTROL MODULE Explanation User Interface Display If outdoor temperature is greater than Warm Weather Shutdown Temperature, demand for CH blocked and pumps stopped. Allowed Range: 35°F to 100°F (2°C to 38°C) Default Setting: 70°F (21°C) Boiler capable of operating in Outdoor Reset Mode when included Outdoor Sensor is connected and proper CH Mode selected.
Page 77
APPENDIX A - CONTROL MODULE Explanation User Interface Display Outdoor reset boost function increases CH set point by increment (‘Temp’) if CH demand continues beyond pre-set time limit (‘Time’). CH set point will continue to increase until set point reaches 195°F / 91°C Allowable Temperature Increment: 0..36 °F (0..20 °C) Default Temperature increment:...
Page 78
APPENDIX A - CONTROL MODULE Explanation User Interface Display Maximum time boiler operates in DHW mode limited by DHW Maximum Priority Time Setting. Priority timer starts when both CH and DHW demand is present. Boiler will switch from DHW back to CH operation after Maximum Priority Time has elapsed.
OPTIONAL USER INTERFACE RELOCATION User interface can be easily relocated outside of the boiler. Figure - A User Interface Terminal Block Follow instructions TO TURN OFF GAS TO APPLIANCE found on page 42. Verify all electrical power to boiler is turned off.
399 MBH - PRIMARY LOOP EQUIVALENT LENGTH CALCULATION & PUMP SELECTION For 399MBH Boiler (This boiler must be piped with a primary loop) These charts are valid for piping diagrams on pages 17 & 18 Instructions: Pipe diameter determines pump size. Smaller the diameter of pipe, larger the pump. 399 Mbh boiler can be piped in 1¼"...
Page 81
399 MBH - PRIMARY LOOP EQUIVALENT LENGTH CALCULATION & PUMP SELECTION Chart 3 Equivalent Length Enter Number of Pipe Diameter Fitting Multiply By Fittings A x B 90° Elbow 45° Elbow 1½" Tee-branch (Any pipe/fitting larger than 1½", Tee-through count as 1½") Swing check valve 12.5 Lift check valve...
Need help?
Do you have a question about the HELIX VX-399 and is the answer not in the manual?
Questions and answers