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DXL
CAST IRON
GAS FIRED BOILERS
FOR FORCED HOT WATER
With Hydrolevel 4200 Control
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Models
-
DXL
060K
DXL-095K
DXL-120K
DXL-150K
DXL-175K
DXL-205K
DXL-235K
Tested For 100 psi.
ASME
Working Pressure
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 325 5479
www.ecrinternational.com
PN 240013268 REV. D [08/15/2021]
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Summary of Contents for ECR International Dunkirk DXL-060K
- Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL Models 060K DXL-095K DXL-120K DXL-150K DXL-175K DXL-205K DXL-235K Tested For 100 psi. ASME Working Pressure Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com PN 240013268 REV. D [08/15/2021]...
- Page 2 Check our website frequently for updates: www.ecrinternational.com Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.
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Page 3: Table Of Contents
TABLE OF CONTENTS 1 - Physical Data ............................4 2 - Safety Symbols And Warnings ......................5 3 - Locating The Boiler ..........................7 3.1 Installation Requirements ........................7 3.2 Minimum Clearances To Combustible Construction 3.3 Recommended Clearances For Service ....................7 3.4 Boiler Location Considerations ...................... -
Page 4: Physical Data
1 - PHYSICAL DATA Model DXL-060K DXL-120K DXL-120K DXL-150K DXL-175K DXL-205K DXL-235K # Sections 13-³/8" 13-³/8" 16-1/4" 19" 21-7/8" 27-¹/2" 27-¹/2" A Width with Jacket 340 mm 340 mm 411 mm 483 mm 555 mm 700 mm 700 mm 6-³/4" 6-³/4"... -
Page 5: Safety Symbols And Warnings
2 - SAFETY SYMBOLS AND WARNINGS FOR YOUR SAFETY READ BEFORE OPERATING Become familiar with symbols identifying potential hazards. DANGER 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. - Page 6 2 - SAFETY SYMBOLS AND WARNINGS WARNING WARNING Combustion chamber insulation in this product This product contains Fibrous glass. Fibrous contains ceramic fiber material. Ceramic fibers glass is a synthetic fiber made from tiny particles can be converted to cristobalite in very high of glass.
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Page 7: Locating The Boiler
3 - LOCATING THE BOILER 3.2 Minimum Clearances to Combustible WARNING Construction Fire hazard! Do not install boiler on carpeting. Minimum clearances to combustible construction are: Failure to follow these instructions could result in 10 inches (254mm) death or serious injury. Front Alcove* CAUTION... -
Page 8: Boiler Location Considerations
3 - LOCATING THE BOILER 3.4 Boiler Location Considerations • System piping exposed to freezing conditions: Use inhibited propylene glycol solutions certified by fluid • Ambient room temperature always above 32°F (0°C) to manufacturer for use with closed water heating system. prevent the potential of freezing. -
Page 9: Connecting Supply And Return Piping
4 - CONNECTING SUPPLY AND RETURN PIPING • Supply and return may be piped to either side of boiler, WARNING as desired. Both supply and return shall be on same Burn and scald hazard. Boiler supplied with dust caps side of boiler. Do not "cross pipe" as boiler may not on supply and return tappings (4). -
Page 10: Safety Relief Valve Installation
4 - CONNECTING SUPPLY AND RETURN PIPING WARNING Figure 4-2 - Safety Relief Valve Burn and scald hazard. Safety relief valve could RELIEF VALVE discharge steam or hot water during operation. Alternate Location On Opposite Piped in Supply Line Install discharge piping per these instructions. Failure side of supply (Contractor supplied to follow these instructions could result in death or... -
Page 11: Flush And Rinse System
4 - CONNECTING SUPPLY AND RETURN PIPING WARNING 4.4 Water Treatment • Poison hazard. Ethylene glycol is toxic. Do not Manufacturer recommends a water analysis be done on water used to fill the system. Treatment may be required use ethylene glycol. based on the analysis results. -
Page 12: Supply And Return Requirements
4 - CONNECTING SUPPLY AND RETURN PIPING 4.5 Supply and Return Requirements Installation using circulators and zone valves are shown in Figures 4-4 through 4-9. For further piping Boiler used in connection with refrigeration system, information refer to AHRI Installation and Piping install so chilled medium is piped in parallel with boiler Guide. - Page 13 4 - CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND: BACK FLOW VALVE Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice. Figure 4-4 - Circulators Mounted on Supply System, Boiler Used In Configuration with Chiller System.
- Page 14 4 - CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND: BACK FLOW VALVE Figure 4-5 - Bypass Piping With Automatic Mixing Valve PURGE VALVE BACK FLOW VALVE ASME RELIEF VALVE DRAIN VALVE PN 240013268 Rev. D [08/15/2021]...
- Page 15 4 - CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND: BACK FLOW VALVE Figure 4-6 - Bypass Piping - Fixed Low Temp Only With Zone Valve ASME RELIEF VALVE * Manually adjust until proper system temperature is reached. PN 240013268 Rev. D [08/15/2021]...
- Page 16 4 - CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND: BACK FLOW VALVE Figure 4-7 - Bypass Piping (4-Way Valve Option With Circulator On Supply side) FLOW CONTROL VALVE ASME RELIEF VALVE DRAIN VALVE PN 240013268 Rev. D [08/15/2021]...
- Page 17 4 - CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND: BACK FLOW VALVE Figure 4-8 - Single Zone System With DHW Priority Back Flow Valve ASME RELIEF VALVE Purge DRAIN Valve VALVE PN 240013268 Rev. D [08/15/2021]...
- Page 18 4 - CONNECTING SUPPLY AND RETURN PIPING PIPING LEGEND: BACK FLOW VALVE Figure 4-9 - Multi Zone System With Zone Valves And DHW Priority (With Zone Valve) * Hot Water Supply Tempered Tank Sensor Optional Indirect DHW Tank Cold T & P Relief Water Valve to DHW Pump...
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Page 19: 5- Ventilation & Combustion Air
5- VENTILATION & COMBUSTION AIR 5.1 Requirements B. Known Air Infiltration Rate. See Table 5-1 for space with boiler only. Use equation for multiple WARNING appliances. Do not use an air infiltration rate Asphyxiation Hazard! Provide enough air openings (ACH) greater than 0.60. to boiler/combustion area to dilute flue gases Volume ≥... -
Page 20: Vent System Modification
6 - VENT SYSTEM MODIFICATION 6.1 Removal Of Existing Boiler From Venting System Typical Masonry Chimney Requirements Figure 6-1 - When an existing boiler is removed from a common venting system, the system is likely too large for proper venting of appliances still connected to it. -
Page 21: Vent Installation
7 - VENT INSTALLATION 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 by a qualified expert and in accordance with the Z223.1/NFPA 54, or "Venting Systems and Air Supply for Appliances,"... -
Page 22: Vent Damper Installation & Instructions
8 - VENT DAMPER INSTALLATION & INSTRUCTIONS 8.1 Vent Damper Fasten sections of vent pipe with sheet metal screws to make piping rigid. Support horizontal potions of vent Connecting The Vent Damper And Vent Connector system to prevent sagging. Use stovepipe wires every 5’ to Refer to page 4 for size and location of vent (flue opening). - Page 23 8 - VENT DAMPER INSTALLATION & INSTRUCTIONS Figure 8-2 - Vent Damper Placement Figure 8-3 - Vent Damper Position Indicator PN 240013268 Rev. D [08/15/2021]...
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Page 24: Connecting Gas Service
9 - CONNECTING GAS SERVICE Table 9-1 Natural Gas Propane DANGER Min. Supply Pressure 5" w.c. 11" w.c. Fire Hazard. Do not use matches, candles, open Max. Supply Pressure 13.5" w.c. 13.5" w.c. flames, or other methods providing ignition source. Failure to comply will result in death or serious 10"... -
Page 25: Electrical
10 - ELECTRICAL There are two (2) options when using Zone 2 for an WARNING indirect tank or heating zone using the IC control to Electrical shock hazard. Turn OFF electrical power power the Zone 2 pump: supply at service panel before making electrical a. -
Page 26: Wiring Diagrams
11 - WIRING DIAGRAMS WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. Figure 11-1 - 4200 Fuel Smart Hydrostat IC Control PN 240013268 Rev. D [08/15/2021]... - Page 27 11 - WIRING DIAGRAM Figure 11-2 - 4200 Fuel Smart Hydrostat IC Control - ladder PN 240013268 Rev. D [08/15/2021]...
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Page 28: Lighting Instructions
12 - LIGHTING INSTRUCTIONS 12.2 Operating Instructions For Intermittent WARNING Pilot System If you do not follow these instructions STOP! Read and follow all safety information. exactly, a fire or explosion may result causing property damage, personal injury or loss of Set the thermostat to lowest setting. -
Page 29: Normal Sequence Of Operation
13 - NORMAL SEQUENCE OF OPERATION WARNING A. Power remains off until boiler water temperature drops below high limit setting. Burn Hazard. View port on burner door may be hot. B. Circulator continues to operate under this condition Wear personal protection when servicing this boiler. until thermostat is satisfied. -
Page 30: General Maintenance And Care Instructions
14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS 14.2 Clean Flue Gas Passageways WARNING Follow this procedure to clean flue gas passageways: Label all wires prior to disconnection when servicing controls. Wiring errors could cause improper and Remove burner tray from heat exchanger by disconnecting the gas supply, by removing two (2) dangerous operation. -
Page 31: General Maintenance
14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS 14.3 General Maintenance Figure 14-1 - Burner Tray BURNERS • Visually inspect main burner and pilot flames at start of heating season and again in mid-season. ◊ Main burner flame should have well defined inner GAS VALVE blue mantel with lighter blue outer mantel. -
Page 32: Adjusting Gas Input
14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS 14.4 Adjusting Gas Input Adjust gas input to boiler by removing protective cap on pressure regulator and turning screw clockwise increase input and counterclockwise to decrease input. See Figure 12-1 page 28. Manifold pressures are taken at outlet side of gas valve. -
Page 33: Ratings And Capacities
15 - RATINGS AND CAPACITIES EXPLANATORY NOTES All boilers are design certified for installation on noncombustible floor. Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be reduced to 10 feet. Refer to the latest revision of National Fuel Gas Code ANSI Z223.13/NFPA 54 part 11. Electric service to be 120 Volts, 15 Amps, 60 Hz. -
Page 34: Appendix A - Control Function
APPENDIX A - CONTROL FUNCTION ECONOMY TARGET When the Economy feature is WARNING active, the Fuel Smart HydroStat continually sets Burn and scald hazard. Do not add water until boiler target temperatures below the high limit setting has fully cooled. Failure to follow these instructions to maximize fuel efficiency. -
Page 35: A-1. Intermittent Pilot
APPENDIX A - CONTROL FUNCTION Ignition - LED Legend A-1. Intermittent Pilot Ignition System Checks STEP 1: Check ignition cable. a. Verify ignition cable does not make contact with metal surfaces. b. Verify only factory supplied Ignition cable (or approved replacement) is used. c. - Page 36 APPENDIX A - CONTROL FUNCTION STEP 3: Check spark ignition circuit. Recheck ignition sequence as follows: a. Adjust thermostat above room temperature. WARNING b. Verify ignition sequence at burner. Electrical shock hazard. Ignition circuit generates over 10,000 volts. Turn OFF electrical power supply at service panel before making electrical Figure A-1 - Troubleshooting Pilot Flame connections.
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Page 37: Appendix B - Vent Damper Installation
APPENDIX B - VENT DAMPER INSTALLATION WARNING Figure 1a - Horizontal Installations Flow Asphyxiation, burn hazard. Improper operation of vent damper may result in serious injury or death due to fire or to asphyxiation from poisonous gases Vent Damper o Chimney To Boiler such as carbon monoxide which is odorless and Install vent damper with actuator to sides of... -
Page 38: Vent Damper Harness - Molex Plugs
APPENDIX B - VENT DAMPER INSTALLATION B.3 Vent Damper Harness - Molex Plugs Figure 4 WARNING Follow all instructions regarding safety operational controls in this manual. Failure to follow these instructions could result in death or serious injury. When servicing controls, all wires must be Note labeled prior to disconnection. -
Page 39: Vent Damper Troubleshooting Guide
APPENDIX B - VENT DAMPER INSTALLATION B.4 Vent Damper Troubleshooting Guide Normal Sequence of Operation WARNING 24 VAC Power ON Damper Position Power Follow all instructions regarding safety operational 4 & 1 All times Open or Closed controls in this manual. Failure to follow these instructions could result in death or serious injury. - Page 40 • 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. 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 325 5479 ©2021 ECR International, Inc. www.ecrinternational.com...
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