Dunkirk PWXL Installation, Operation & Maintenance Manual Download Page 1

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P/N

240007958 REV B [03/2011]

An ISO 9001-2008 Certified Company

PWXL

Cast Iron Gas Fired

Hot Water Boilers

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

DUNKIRK BOILERS

2210 Dwyer Avenue, Utica NY 13504-4729

Phone: (315) 797-1310 • Fax: (866) 432-7329

e-mail: [email protected]

web site: www.ecrinternational.com

Summary of Contents for PWXL

Page 1: ...ed Company PWXL Cast Iron Gas Fired Hot Water Boilers INSTALLATION OPERATION MAINTENANCE MANUAL DUNKIRK BOILERS 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ec...

Page 2: ...e Operation 11 Vent Damper Operation 12 Gas Supply Piping 14 Electrical Wiring 16 Equipment and Optional Accessories 20 Starting the Boiler 21 Initial Operational Boiler Test Check Out Procedure 23 In...

Page 3: ...n monoxide which is odorless and invisible CAUTION Indicates a hazardous situation which if not avoided may result in injury NOTICE Indicates information which should be followed to ensure proper inst...

Page 4: ...by a change in main orifice size For altitudes above 2 000 feet above sea level input ratings should be reduced at the rate of 4 for each 1 000 feet above sea level Consult the latest edition of the N...

Page 5: ...care must be taken to insure a clean combustion air supply during the construction process Airborne particulates such as from drywall dust and from fiberglass insulation can clog the burner ports flu...

Page 6: ...crated boiler at selected location remove crate 2 by pulling crate sides from top and bottom boards This boiler must be set on non combustible floor or 3 optional non combustible Base Plate placed ove...

Page 7: ...not use an air infiltration rate ACH greater than 0 60 Volume 21 ft3 ACH x Total Input Mbh Refer to National Fuel Gas Code for opening C requirements between connected indoor spaces All Outdoor Air Pr...

Page 8: ...o avoid D reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Run pipe as short and straight as possible to E location protecting user from scald...

Page 9: ...or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Low Design Water Temperature Systems Below 140 If the boiler is to be used in a heating system wher...

Page 10: ...ly Pipe Sealant On Shaft of Gauge Thread the gauge into the supply water tee as shown in 3 Figure 8 To Prevent damage do not overtighten Figure 8 Thread Gauge Into Supply Water Tee NOTICE IMPORTANT DO...

Page 11: ...the 10 chimney height HT for single appliance venting see Figure 11 The sections of vent pipe should be fastened with sheet metal screws to make the piping rigid Horizontal portions of the vent syste...

Page 12: ...damper on pipe curve Do not run wires near high temperature surfaces Use standoff brackets if necessary For safe efficient operation the vent damper and all flue product carrying areas of the applian...

Page 13: ...l control the burner firing as before while the damper will remain open DO NOT turn damper open manually or motor damage will result Set switch to AUTOMATIC OPERATION to close vent damper during burne...

Page 14: ...compound pipe dope suitable for liquefied petroleum gas Provide sediment trap upstream of gas valve See Figure 15 GAS SUPPLY PIPING CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any applianc...

Page 15: ...e using gas detector non corrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods providing ignition...

Page 16: ...r on a vertically mounted outlet box It should be sensing aver age room temperature THERMOSTAT LOCATIONS TO AVOID DEAD SPOTS HOT SPOTS COLD SPOTS Behind doors Concealed pipes Concealed pipes or ducts...

Page 17: ...NOTES VENT DAMPER SHIPPED LOOSE IN CRATE VENT DAMPER HARNESS MUST BE CONNECTED TO VENT WHEN MOUNTED VENT DAMPER HARNESS Figure 16 1 Field Wiring Connections Circulator Pump Wiring Thermostat TW TR Re...

Page 18: ...2 Wiring Diagram Electronic Ignition NOTICE If any of the original wire as supplied with this appliance must be replaced It must be replaced with type 105 C thermoplastic wire or it s equivalent ELECT...

Page 19: ...16 3 Wiring Diagram Standing Pilot NOTICE If any of the original wire as supplied with this appliance must be replaced It must be replaced with type 105 C thermoplastic wire or it s equivalent ELECTRI...

Page 20: ...re changes The diaphragm type tank can be mounted on the air purger fitting or at any convenient place in the supply or return line Air Eliminating Fitting Air Purger An air purger is used to remove e...

Page 21: ...any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only yo...

Page 22: ...Turn off all electric power to the appliance 3 Remove lower front panel 4 Rotate the gas control knob clockwise 5 to OFF See Figure 18 Wait five 5 minutes to clear out any gas Then smell 6 for gas inc...

Page 23: ...rating and should go off when controls are tested When controls are reset burners should reignite o Test ignition system safety shutoff device after placing boiler in operation See page 25 o For multi...

Page 24: ...er maintenance personnel Installation Location Customer Name __________________________________________________________________________ Address ________________________________________________________...

Page 25: ...e inter mittent pilot control box The gas valve should shut off the main burners TURN OFF ELECTRIC POWER to boiler before reconnecting ignition cable to prevent electric shock Relight The electric and...

Page 26: ...ntact an authorized contractor or qualified service technician to replace the relief valve and inspect the heating system to determine the cause as this may indicate an equipment malfunction This valv...

Page 27: ...hermostat call for heat HIGH LIMIT YELLOW Water temperature at high limit ACTIVE GREEN Active power to unit is on There are four adjustable settings on the control These can be adjusted using a small...

Page 28: ...mit setting For example if the High Temperature Limit is set at 1900 F with the High Temperature Differential at 200 F then the Low Temperature Limit needs to be set at 1700 F or lower If the settings...

Page 29: ...er current protection Check to be sure electric power supply circuit is ON Controls out of adjustment Reset according to instructions Radiators not heating Open radiator vents to excess air Check flow...

Page 30: ...NOTES...

Page 31: ...Date Service Performed Company Name Tech Initials Company Address Phone...

Page 32: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13504 4729 web site www ecrinternational com...

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