Dunkirk DXL-100 Installation, Operation & Maintenance Manual Download Page 4 | Manualshive

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Dunkirk DXL-100 Installation, Operation & Maintenance Manual Download Page 4

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Summary of Contents for DXL-100

Page 1: ... II CAST IRON GAS FIRED BOILERS FOR FORCED HOT WATER iNSTALLATiON OPERATION MAINTENANCE MANUAL T rpr US H Tested For 100 psi ASME Working Pressure Manufactured by ECR International inc 220 Dwyer Avenue Utica NY 13501 web site www ecnnternatlonal corn P N 2400009041 Rev B 09 2012 ...

Page 2: ...n 50 4 303 4 36 6 1 75 3 _ _ _ u 4 _u 4 6 1 100 6 i2 _ i 8_ 9 6 30_ _ 4 J 2 8 2 4 01 4 i U 2 4 1 7 1 3 3 1 150 18 9 7 30 37 7 1 170 _ 3 _3 44 I 7 C f _3 903 7 41 2 _ 4 2 t OU 4 OO 4 4 1 3 1 3 3 1 200 22 11 8 30 8 1 ...

Page 3: ...installing 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 Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids DO NOT obstruct air openings to the boiler room Modification substitution or eliminat...

Page 4: ...I Water Ratings shown based on piping and pickup allowance of 1 15 Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc For forced hot water systems where boiler and all piping within area to be heated boiler may be selected on basis of its heating capacity 3 Tank sized for no...

Page 5: ...iler on level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical 7 Allow 24 inches 610mm at front and right side for servicing and cleaning 8 When installed in utility room door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater Fire hazard Do not install boil...

Page 6: ...nput Mbh o Refer to National Fuel Gas Code for opening requirements between connection indoor spaces All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors Two Permanent Opening Method Provide opening commencing within 12 inches of top and second opening commencing within 12 inches of bottom enclosure Direct communication with outdoors or communicating through...

Page 7: ...valve and discharge to atmosphere do not plug or place any obstruction in discharge line Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing Allow complete drainage of the valve and the discharge line Be independently supported and securely anchored to avoid applied stress on the relief valve Be as short and straight as possible Terminate with plai...

Page 8: ...s required by authority having jurisdiction must be provided with a low water cut off device 4 When a boiler is connected to a heating system that utilizes multiple zoned circulators each circulator must be supplied with a flow control valve to prevent gravity circulation 5 Hot water boilers and system must be filled with water and maintained to a minimum pressure of 12 psi Bypass piping is an opt...

Page 9: ...Temp Only Manual Mixing Valve TO SYSTEM S_ CIRCULATOR 0 WATER INLET EXPANSION TANK V2 FROM SYSTEM i5 _ ER _ _JALTERNATE CIRCULATOR LOCATION Installation using circulators and zone valves are shown in Figure 7 8 9 and 10 Pages 10 and 11 For further piping information refer to AHRI Installation and Piping Guide Burn and scald hazard Safety relief valve could discharge steam or hot water during opera...

Page 10: ...ystem With DHW Priority CH CIRCULATOR BOILER WATER INLET q DHW CIRCULATOR tip PRiORiTY ZONE Figure 8 Multi Zone System With Circulators And DHW Priority ZOO 4 E 4 C_RC 4 _ ZONE 3 CiRC 3 ZONE 2 C RC 2 DHW CIRCULATOR ZONE _ PRK RI Y ZONE EXPANSION TANK ...

Page 11: ...ONE 4 _ LL_ _i _ i __ _w_j _ _ _ lill IIIIIIii I lllil Ill II II ZONE 3 ZONE 2 DHW CIRCULATOR ZONE 1 PRIORITY ZONE Figure 10 Multi Zone System With Zone Valves And DHW Priority With Zone Valve ZONE 4 BOILER EXPANSION TANK CH DHW SYSTEM ZONE 3 ZONE 2 USE FULL PORT ZONE VAWE FOR OPTIMUM TANK PERFORMANCE CONSIDER USING ZONE CfRCULA OR ZONE 1 PR ORITY ZONE ...

Page 12: ...oper venting of the appliances sill connected to it If this situation occurs the following test procedure must be followed REMOVAL OF BOILER FROM VENTING SYSTEM At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common ventin...

Page 13: ...ss connector 5 Plug damper connector into socket on damper motor frame 6 Replace damper motor cover and wire damper See Figure 11 1 Verify only boiler is serviced by vent damper See Figure 12 2 Clearance of not less than 6 inches between vent damper and combustible material must be maintained Additional clearance should be allowed for service of vent damper 3 Vent damper must be in the open positi...

Page 14: ...ure components to prevent or dampen excessive vibrations and prevent strain on gas connection Boiler will not support piping weight Use thread joint compound pipe dope suitable for liquefied petroleum gas Install field sourced manual main shutoff valve ground joint union and sediment trap upstream of gas valve See Figure 13 Table 5 Gas Pressure 13 5 w c 3 5 w c 13 5 w c 10 5 w c Fire Hazard Do not...

Page 15: ...l Electrical Code ANSI NFPA 70 Thermostat Installation 1 Thermostat should be installed on an inside wall about four feet above the floor 2 NEVER install a thermostat on an outside wall 3 Do not install a thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures televisions a fireplace or a chimney 4 Check thermostat operation by raising and lowering thermostat se...

Page 16: ...I INSTALLED L _LE _LY_L W_ _C _OUT F_ UNK J k_ _A6E RE_ _UPPU_D T_T RELD SSHA_ US_ C_R U_LTAGE _ _I_Y _RNBC AND LOCAL_COES _SVALV_ _h7 _N _Nm_ M DULE MLOT WIRING UNE VOLT_ THEF_ LOW_T_ THEFACTO_f _d_E _NST_ o_rt _____c o _ _ 0 _ o 2 0 0 0 0 0 O_ Z Z m m Z I I Z 0 Z ...

Page 17: ...WATE_j TEMPERATURE _I OR WIRING SCHEMATIC CIRCULATOR PUMP _GN_T_RI B2 00 0 CON_OL MODULE 32 C2 Cl B_ TT L rl c Vl l 3 m i i_ E Z G _ X o o z o _ o o _ m o Z M _ Z O Z ...

Page 18: ...ACAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switches do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions Ifyou cannot reach your gas supplier call the fire department OPERATING INSTRUCTIONS FOR INTERHITTENT PILOT SYSTEM I STOP Read the safetyinformation tothe l...

Page 19: ...air vents if used to expel any air accumulated in the system Check entire piping system and if any leaks appear have them repaired Circulators need to be checked and maintained Refer to circulatormanufacturer s instructions Inspect venting system at the start of each heating season Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints Repair if necessary Remov...

Page 20: ...se _ to decrease pilot flame Be sure to replace cover screw after adjustment to prevent possible gas leakage See Figure 14 Page 16 Burners and pilot should be checked for signs of corrosion rust or scale buildup Area around boiler must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler roo...

Page 21: ...inus 0 3 inches water column from specified pressure Primary air adjustment is not necessary therefore air shutters are not furnished as standard equipment Air shutters can be furnished on request where required by local codes or conditions Figure 21 Burner Access Door High Limit Control Location High Limit and Operating Control _ _ocated Inside Boiler CHECK SAFETY CONTROL CIRCUIT Test ignition sy...

Page 22: ...urn dial to 2 or 1 Conversely if boiler provides adequate heat added fuel savings can be achieved by selecting a higher setting example 4 or 5 If heating and indirect water heater signals were not separated when wiring control Economy Feature should be turned OFF to insure boiler supplies adequate temperature to heat the indirect tank SETTING Disables economy function Will allow boiler to fire OFF...

Page 23: ...and When boiler water temperature reaches the target or high limit temperature LED illuminates and burner shuts down Boil water continues to circulate and heat the house as long as thermostat call continues The LED will stay lit until boiler temperature drops to predetermined differential The LED illuminates regularly during normal operation OBURNER Illuminates whenever the burner is running B1 is...

Page 24: ... low temperature maintenance feature Boiler will Not Maintain Low Limit Temperature Temperature Display Differs from Boiler Temperature Pressure Gauge Temperature Reading TSTAT Light Green LED is Not On Low Water Light RED LED is On Check for overlapping high temperature setting If high limit setting is below low limit setting control will default to high limit setting Temperature variances can re...

Page 25: ...i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i_i _i_i_ i_i_i_ i_i...

Page 26: ...NOTES ...

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Page 28: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

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