Table of Contents
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Models
-
DXL
50
DXL-75
DXL-100
DXL-125
DXL-150
DXL-170
DXL-200
CAST IRON GAS FIRED BOILERS
FOR FORCED HOT WATER
INSTALLATION, OPERATION &
Tested For 100 psi.
ASME
Working Pressure
DXL SERIES II
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
2400009041
P/N
, Rev. C [04/30/2017]
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Table of Contents
Troubleshooting
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Summary of Contents for Dunkirk DXL-125
- Page 1 DXL SERIES II Models CAST IRON GAS FIRED BOILERS FOR FORCED HOT WATER DXL-75 DXL-100 DXL-125 INSTALLATION, OPERATION & DXL-150 MAINTENANCE MANUAL DXL-170 DXL-200 Tested For 100 psi. ASME Working Pressure Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
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Page 2: Dimensions
DIMENSIONS Figure 1 - Dimensions "A" 1¼" Supply 27" 5½" "B" "C" 3" 3½" "F" 1¼" Return "E" "D" 4¼" 14" 2½" 4¼" 4½" 240009041 , Rev. C [04/30/2017]... -
Page 3: Table Of Contents
TABLE OF CONTENTS Dimensions ............2 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Ratings & Data - Natural Gas & Propane Gas ..4 Locating the Boiler ..........5 Ventilation & Combustion Air ....... 6 IMPORTANT: Read the following instructions COMPLETELY before installing!! Supply and Return Piping ........ -
Page 4: Ratings & Data - Natural Gas & Propane Gas
RATINGS & DATA - NATURAL GAS & PROPANE GAS EXPLANATORY NOTES All boilers are design certified for installation on noncombustible floor. For installation on combustible floors use combustible floor kit. Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be reduced to 10 feet. -
Page 5: Locating The Boiler
LOCATING THE BOILER WARNING WARNING Improper installation, adjustment, alteration, service Fire hazard. Do not install boiler on combustible or maintenance could result in death or serious flooring or carpeting. Failure to follow these injury instructions could result in death or serious injury. Installation shall conform to requirements of authority FOR INSTALLATION ON NON-COMBUSTIBLE having jurisdiction or, in absence of such requirements,... -
Page 6: Ventilation & Combustion Air
VENTILATION & COMBUSTION AIR Provide combustion air and ventilation air in accordance • All Outdoor Air. Provide permanent opening(s) with the section “Air for Combustion and Ventilation,” of communicating directly or by ducts with outdoors. the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or о... -
Page 7: Supply And Return Piping
SUPPLY AND RETURN PIPING WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: • connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum distance from floor or allowable safe point of discharge. - Page 8 SUPPLY AND RETURN PIPING Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice. Figure 4 - Circulators Mounted on Supply System, Boiler Used In Configuration with Chiller System. See Special Conditions, Page 9 SEPARATOR Boiler, used in connection with a refrigeration system, the system or the condition of the installation.
- Page 9 SUPPLY AND RETURN PIPING Figure 5 - Bypass Piping Automatic Mixing Valve FROM SYSTEM TO SYSTEM WATER INLET EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION PRESSURE BALL VALVE AIR SEPARATOR CIRCULATOR REDUCER VALVE SHUT-OFF 3 WAY MIXING CHECK VALVE HOSE BIB VALVE VALVE Figure 6 - Bypass Piping - Fixed Low Temp Only Manual Mixing Valve...
- Page 10 SUPPLY AND RETURN PIPING Figure 7 - Single Zone System With DHW Priority Figure 8 - Multi Zone System With Circulators And DHW Priority 240009041 , Rev. C [04/30/2017]...
- Page 11 SUPPLY AND RETURN PIPING Figure 9 - Multi Zone System With Zone Valves And DHW Priority (With Circulator) Figure 10 - Multi Zone System With Zone Valves And DHW Priority (With Zone Valve) 240009041 , Rev. C [04/30/2017]...
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Page 12: Vent Installation
VENT INSTALLATION This boiler series is classified as a Category I. Vent WARNING installation shall be in accordance with "Venting of Boiler and venting installations shall be performed Equipment," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local by a qualified installer in accordance with the building codes. -
Page 13: Vent Damper Installation & Instructions
VENT DAMPER INSTALLATION & INSTRUCTIONS DAMPER INSTALLATION Follow Damper installation instructions provided with damper. See Figure 11. Verify only boiler is serviced by Vent Damper. Figure Clearance of not less than 6 inches (152mm) between Vent Damper and combustible material must be maintained. -
Page 14: Gas Service
GAS SERVICE General CAUTION • Use piping materials and joining methods acceptable WHAT TO DO IF YOU SMELL GAS to authority having jurisdiction. In absence of such requirements of National Fuel gas Code, ANSI Z223.1/ • Do not try to light any appliance. NFPA 54 •... -
Page 15: Electrical Section
ELECTRICAL SECTION WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. Electrical Wiring See wiring diagrams on the following two pages for details. -
Page 16: Wiring Diagram - Intermittent Ignition
WIRING DIAGRAM - INTERMITTENT IGNITION Figure 14 - Intermittent Electronic Ignition Control (240009076) WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. 240009041 , Rev. C [04/30/2017]... - Page 17 WIRING DIAGRAM - INTERMITTENT IGNITION Figure 15 - Intermittent Electronic Ignition Control (240009076) 240009041 , Rev. C [04/30/2017]...
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Page 18: Lighting Instructions
LIGHTING INSTRUCTIONS OPERATING INSTRUCTIONS FOR INTERMITTENT WARNING PILOT SYSTEM If you do not follow these instructions exactly, STOP! Read the safety information to the left. a fire or explosion may result causing property Set the thermostat to lowest setting. damage, personal injury or loss of life. Turn off all electric power to the appliance. -
Page 19: Sequence Of Operation
SEQUENCE OF OPERATION Thermostat actuates on call for heat, completing Figure 17 - Blocked Vent Safety Switch, Roll-out circuit to control. Completed circuit to control will Safety Switch first activate circulator and damper which will close end switch inside damper. Completes circuit to Integral Draft ignition system, ignition takes place. - Page 20 GENERAL INSTRUCTIONS • Make visual inspection of main burner and pilot flames Figure 18 - Gas Burner Flame at start of heating season and again in mid-season. Main burner flame should have well defined inner blue mantel with lighter blue outer mantel. Check burner throats and burner orifices for lint or dust obstruction.
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Page 21: Checking Gas Input Rate To Boiler
CHECKING GAS INPUT RATE TO BOILER • Adjust gas input to boiler by removing protective cap on Figure 21 - High Limit Control Location pressure regulator and turning screw clockwise High Limit and increase input and counterclockwise to decrease Operating Control input. -
Page 22: Control Settings
CONTROL SETTINGS Indirect Water Heater SETTING When installing with indirect water heater, signal from Disables economy function. Will allow boiler to fire indirect must be separated from heating zone signals and until hi-limit temp is reached and re-fire with a 10° wired appropriately. -
Page 23: System Start-Up
SYSTEM START-UP System Start-up TARGET/HI LIMIT At initial start-up, with Economy feature active, control Illuminates when boiler temperature has reached target establishes 145°F target temperature. To test the high temperature or high limit setting. When economy feature limit shut-off function, Economy Dial must be turned to is active, the control utilizes thermal targeting technology OFF. -
Page 24: Limit Control Troubleshooting
LIMIT CONTROL TROUBLESHOOTING Fahrenheit/Celsius Change WARNING Control has the ability to operate in degrees Fahrenheit Burn and scald hazard. Do not add water until boiler (default setting) or Celsius. has fully cooled. Failure to follow these instructions To change from Fahrenheit to Celsius: could result in death or serious injury. -
Page 25: Intermittent Pilot Troubleshooting
INTERMITTENT PILOT TROUBLESHOOTING A. Intermittent Pilot STEP 4: Verify pilot and main burner lightoff. Ignition System Checks • Initiate call for heat. Turn thermostat above room temperature. Ignition sequence may be delayed by STEP 1: Check ignition cable. thermal purge up to 2 minutes. •... - Page 26 INTERMITTENT PILOT TROUBLESHOOTING Figure 20 - Troubleshooting Pilot Flame • Recheck ignition sequence as follows. — Reconnect main valve wire. — Adjust thermostat above room temperature. — Verify ignition sequence at burner. — If spark does not stop after pilot lights, replace module.
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Page 27: Appendix A-1 - Vent Damper Harness
APPENDIX A-1 - VENT DAMPER HARNESS A.1 Vent Damper Harness - Molex Plugs A. Remove damper harness from control. Jump Molex connector on control board between two center WARNING holes using ~18ga. thermostat wire. Do Not negate the action of any existing safety If boiler ignites, replaces damper harness orperational controls. -
Page 28: Appendix A-2 - Vent Damper Troubleshooting
APPENDIX A-2 - VENT DAMPER TROUBLESHOOTING A.2 Vent Damper Troubleshooting Guide WARNING Do Not negate the action of any existing safety orperational controls. Avoidance of these instructions could result in death or serious injury. When servicing controls, all wires must be Note labeled prior to disconnection. - Page 29 APPENDIX A-2 - VENT DAMPER TROUBLESHOOTING For troubleshooting only. Verify damper is in Note open position. Use service switch to keep damper in open position. Place jumper between 2 & 3. If appliance fires, remove jumper and plug receptacle back into damper controller plug.
- Page 30 NOTES 240009041 , Rev. C [04/30/2017]...
- Page 31 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/ maintenance person Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone...
- Page 32 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. DUNKIRK BOILERS DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com...
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