Dunkirk DXL-125 Installation, Operation And Maintenance Manual Download Page 1

Page: 1 / 32

P/N

2400009041

, Rev. C [04/30/2017]

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

DXL SERIES II

CAST IRON GAS FIRED BOILERS

FOR FORCED HOT WATER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Models

DXL

DXL-75

DXL-100

DXL-125

DXL-150

DXL-170

DXL-200

Tested For 100 psi.

ASME

Working Pressure

Summary of Contents for DXL-125

Page 1: ...201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com DXL SERIES II CAST IRON GAS FIRED BOILERS FOR FORCED HOT WATER INSTALLATION OPERATION MAINTENANCE MANUAL Models DXL 50 DXL 75 DXL 100 DXL 125 DXL 150 DXL 170 DXL 200 Tested For 100 psi ASME Working Pressure ...

Page 2: ...Gas Inlet Dimensions Pump size Supply Return Tappings A B C D E F 50 11 5 4 30 36 6 1 75 15 7 5 30 36 6 1 100 15 7 6 30 37 6 1 125 18 9 6 30 37 6 1 150 18 9 7 30 37 7 1 170 22 11 7 30 38 7 1 200 22 11 8 30 38 8 1 4 4 1 Return B C F 14 4 1 Supply 2 A E D 3 27 5 3 Figure 1 Dimensions ...

Page 3: ...ot Use appropriate personal protection equipment to include safety glasses and gloves when installing or servicing this boiler Failure to follow these instructions could result in minor or moderate injury DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious in...

Page 4: ...ler Jacket Cast Iron Boiler Battery Combination High Limit Low Water Cutoff Control Intermittent Electric Ignition Pilot System Vent Damper Relay Temperature Pressure Gauge Circulator With Return Piping To Boiler Main Gas Burners Gas Control Includes Automatic Gas Valve Gas Pressure Regulator Intermittent Pilot Safety Shutoff Pilot Flow Adjustment Pilot Filter A S M E Relief Valve Drain Valve Spil...

Page 5: ...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 9 FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY For installation on combustible flooring special base must be used See Replacement Parts Section Boiler can not be installed on carpeting Minim...

Page 6: ...t 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 vertical ducts Provide minimum free area of 1 in2 per 4 Mbh of total input rating of all appliances in enclosure Communicating through horizontal ducts Provide minimum free area of 1 in2 per 2 Mbh of total...

Page 7: ...an that of the relief valve outlet over the entire length of discharge line have no intervening shutoff valve between safety relief 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 ...

Page 8: ...ot water boilers and system must be filled with water and maintained to a minimum pressure of 12 psi 6 Bypass piping is an option which gives the ability to adjust the supply boiler water temperature to fit the system or the condition of the installation This method of piping however is not typically required for baseboard heating systems Typical installations where bypass piping is used are as fo...

Page 9: ... For further piping information refer to AHRI Installation and Piping Guide 8 Install discharge piping from safety relief valve See Warning Page 7 SUPPLY AND RETURN PIPING Figure 5 Bypass Piping Automatic Mixing Valve Figure 6 Bypass Piping Fixed Low Temp Only Manual Mixing Valve MANUAL MIXING vALVE MANUAL MIXING VALVE WARNING Burn and scald hazard Safety relief valve could discharge steam or hot ...

Page 10: ...10 SUPPLY AND RETURN PIPING Figure 7 Single Zone System With DHW Priority Figure 8 Multi Zone System With Circulators And DHW Priority P N 240009041 Rev C 04 30 2017 ...

Page 11: ...PLY 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 P N 240009041 Rev C 04 30 2017 ...

Page 12: ...g in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting syst...

Page 13: ...nce of not less than 6 inches 152mm 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 position when appliance main burners are operating 4 Vent Damper position indicator must be in visible location following installation 5 Thermostat s heat anticipator must be adjusted to match total c...

Page 14: ...PIPE IN CUBIC FEET OF GAS HOUR Gas Pressure 0 5 psig or less Pressure Drop 5 in w c Table 4 Pipe Sizes Length of Pipe Feet Nominal Iron Pipe Size 1 1 10 175 360 680 1400 20 120 250 465 950 30 97 200 375 770 40 82 170 320 660 60 66 138 260 530 80 57 118 220 460 100 50 103 195 400 For additional information refer to the National Fuel Gas Code Handbook Table 5 Gas Pressure Natural Gas Propane Min Sup...

Page 15: ... 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 setting as required to start and stop the burners 5 Instructions for the final adjustment of the thermostat are packaged with the thermostat adjusting heating anticipator calibration etc WA...

Page 16: ... 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 P N 240009041 Rev C 04 30 2017 ...

Page 17: ...17 WIRING DIAGRAM INTERMITTENT IGNITION Figure 15 Intermittent Electronic Ignition Control 240009076 P N 240009041 Rev C 04 30 2017 ...

Page 18: ...iance and to replace any part of control system and any gas control which has been under water NOTICE Before lighting any type of pilot burner standing or intermittent verify the hot water boiler and system are full of water to minimum pressure of 12 psi in the system also verify system is vented of air Set operating control of thermostat to below normal setting Refer to following appropriate ligh...

Page 19: ... if necessary Remove vent pipe at base of chimney or flue and using a mirror check vent for obstruction and verify vent is in good working order Boiler flue gas passageways may be inspected by a light and mirror Remove burner door See Figure 17 Place trouble lamp in flue collector through draft relief opening With mirror positioned above burners flue gas passageways can be checked for soot or scal...

Page 20: ...ure to replace cover screw after adjustment to prevent possible gas leakage See Figure 16 Page 19 Check burners and pilot 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 room must not be restricted or blocked Inspect f...

Page 21: ... inches water column from specified pressure Primary air adjustment is not necessary therefore air shutters are not furnished as standard equipment CHECK SAFETY CONTROL CIRCUIT Test ignition system safety shutoff device after placing boiler in operation 1 Pilot With main burner operating turn pilot gas adjusting screw clockwise until pilot gas is turned off Within 90 seconds main gas control close...

Page 22: ... Feature should be turned OFF to insure boiler supplies adequate temperature to heat the indirect tank Decimal Point Indicates heat call High Temperature Limit Setting 130 220 F Factory 190 F Economy Dial OFF or LO 1 2 3 4 5 HI Jumper B Dynamic Display Water Temperature and Real Time Verification of Setting Adjustments Differentials are automatic and will vary based on control settings and boiler ...

Page 23: ...add water until boiler has fully cooled Failure to follow these instructions could result in death or serious injury T STAT Illuminates whenever there is a call for heat from any thermostat zone device or indirect TARGET HI LIMIT Illuminates when boiler temperature has reached target temperature or high limit setting When economy feature is active the control utilizes thermal targeting technology ...

Page 24: ...t This metal clip must be in contact with the inside of the copper well in order for control to sense presence of water Check well does not have excessive build up of heat transfer grease that may interfere with clip contacting well 2 Remove well and examine for excessive residue build up Clean and re install WARNING Burn and scald hazard Do not add water until boiler has fully cooled Failure to f...

Page 25: ...ons Failure to do so could result in death or serious injury Energize module and listen for audible sparking noise When operating normally there should be a buzzing noise that turns on and off twice per second for duration of 1 7 seconds depending on model STEP 4 Verify pilot and main burner lightoff Initiate call for heat Turn thermostat above room temperature Ignition sequence may be delayed by ...

Page 26: ...ee Figure 19 Page 20 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 P N 240009041 Rev C 04 30 2017 ...

Page 27: ... 24 volts should be present i IF NOT source of the problem is not in damper check line voltage and 24 volt supply ii If 24 volts is present across brown and black continue to step iii iii Reconnect thermostat wires and turn up heat setting iv Check voltage across black and orange wires in Molex plug 24 volts AC should be present IF NOT source problem is not the damper If 24 volts is present contin...

Page 28: ...O POWER Between 4 1 1 Off on limit 120VAC 2 Bad transformer 3 Loose or broken connections 4 Blown fuse or circuit breaker 5 Disconnect switch off 6 Harness not plugged into receptacle 1 turn limit on 2 Replace transformer 3 Tighten repair or replace connection 4 Replace fuse or reset circuit breaker 5 Turn switch on 6 Plug harness in NO POWER Between 4 2 POWER Between 4 1 When calling for heat 1 T...

Page 29: ...on 2 Restore to damper pipe to round verify not binding 3 Correct the condition Damper Rotates Continuously 1 Defective damper motor assembly 1 Replace damper motor assembly Note For troubleshooting only Verify damper is in 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: ...30 P N 240009041 Rev C 04 30 2017 NOTES ...

Page 31: ...TU 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 Installer s Name Signature ...

Page 32: ...THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating 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 tankl...

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