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Figure 14-3 - Gas Burner Flame

Figure 14-2 - Gas Burner Pilot Assembly

Figure 14-1 - Burner Tray

BURNERS

ORIFICES

GAS VALVE

• 

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 

blue mantel with lighter blue outer mantel. 

◊ Check burner throats and burner orifices for lint or 

dust obstruction. Figures 14-1 and 14-3.

• 

Pilot flame should envelop ⅜ to ½ inch of tip of 

ignition/sensing electrode.  See Figure 14-2.

• 

To adjust pilot flame: remove pilot adjustment 

cover screw and turn inner adjustment screw 

counterclockwise 

 to increase or clockwise 

 

to decrease pilot flame. Replace cover screw after 

adjustment to prevent possible gas leakage. See 

Figure 12-1, Page 28.

• Check burners and pilot for signs of corrosion, rust or 

scale buildup. 

• Area around boiler shall be 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 shall not be restricted or blocked.

• 

Inspect factory supplied and field sourced low water 

cutoffs annually, or as recommended by low water 

cutoff manufacturer.  Flush float type low water cutoffs 

per manufacturer's instructions.

• Contact a 

Qualified Service Agency

 to make 

annual  inspection  of  boiler  and  heating  system.                                 

This should include:

1. 

 Check casting and vent for signs of corrosion from 

condensate.

2. 

 Examine pilot lint screen and clean if needed.

3. 

 Check venting for any signs of corrosion, rust, 

damage or deterioration. Contact a 

Qualified 

Service Agency

 immediately if you observe any of 

these conditions.

4. 

 Clean oxidation on the igniter/flame sensor with an 

abrasive cloth.

14.3 General Maintenance

14 - GENERAL  MAINTENANCE AND CARE INSTRUCTIONS

INNER BLUE 

MANTEL

LIGHT BLUE 

OUTER MANTEL

3/8"  to  1/2  "                                 

(9.5 to 12.7mm)

PILOT LINT 

SCREEN

Proper Flame 

Adjustment 

Shown

 PN 240013268 Rev. D  [08/15/2021]

Summary of Contents for Dunkirk DXL-060K

Page 1: ...ATION 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 Avenu...

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...

Page 3: ...1 8 Vent Damper Installation Instructions 22 8 1 Vent Damper 22 9 Connecting Gas Service 24 9 1 General 24 9 2 Leak Check Gas Piping 24 10 Electrical 25 10 1 Electrical Wiring 25 10 2 Thermostat Insta...

Page 4: ...ue Diameter 4 5 6 6 7 7 7 102 mm 127 mm 152 mm 152 mm 178 mm 178 mm 178 mm Supply Return Tappings 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT 1 1 4 NPT Natural Gas Inlet 1 2 NPT 1 2 NP...

Page 5: ...and all requirements before beginning installation FOR YOUR SAFETY READ BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can...

Page 6: ...w your detector s located on each floor of your home Follow your detector s instructions for operation and verification Some instructions for operation and verification Some jurisdictions may by law r...

Page 7: ...nd height 7 Verify floor will support weight of boiler water and equipment 8 Boiler may be installed on combustible floor Do not install boiler on carpeting 9 Do not install where gasoline or other fl...

Page 8: ...Acids Solvents etc Paint Varnish Turpentine etc Cleaning Solvents Hydrochloric acid muriatic acid Cements adhesives and glues Photo processing plants Garages with workshops Furniture refinishing areas...

Page 9: ...d off unused supply tapping IN UPRIGHT POSITION ONLY Drain valve may be located off of unused return tapping using a contractor supplied tee piped right or left side as desired See Figure 4 3 Unused s...

Page 10: ...rge B be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line C have no intervening shutoff valve between safety relief valve and discharge to...

Page 11: ...e size less than 50 micron If the water quality is outside these ranges consult a local water treatment specialist for recommendations If the water is treated do not use petroleum based products or pr...

Page 12: ...onnected to heating coils located in air handling unit exposed to refrigerated air circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water durin...

Page 13: ...e mounted on system supply side mounting on system return side is also acceptable practice BACK FLOW VALVE PIPING LEGEND Figure 4 4 Circulators Mounted on Supply System Boiler Used In Configuration wi...

Page 14: ...ure 4 5 Bypass Piping With Automatic Mixing Valve BACK FLOW VALVE PIPING LEGEND 4 CONNECTING SUPPLY AND RETURN PIPING PURGE VALVE DRAIN VALVE ASME RELIEF VALVE BACK FLOW VALVE PN 240013268 Rev D 08 15...

Page 15: ...PLY AND RETURN PIPING Figure 4 6 Bypass Piping Fixed Low Temp Only With Zone Valve BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE Manually adjust until proper system temperature is reached PN 2400132...

Page 16: ...ING SUPPLY AND RETURN PIPING Figure 4 7 Bypass Piping 4 Way Valve Option With Circulator On Supply side BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE DRAIN VALVE FLOW CONTROL VALVE PN 240013268 Rev...

Page 17: ...4 CONNECTING SUPPLY AND RETURN PIPING Figure 4 8 Single Zone System With DHW Priority BACK FLOW VALVE PIPING LEGEND ASME RELIEF VALVE Back Flow Valve DRAIN VALVE Purge Valve PN 240013268 Rev D 08 15 2...

Page 18: ...1 DHW Pump 12 po 305 mm Distance recommand e Ne d passez pas 12 po 305 mm Note Note Manufacturer requires all domestic hot water DHW installations use an anti scald valve Local codes may require addi...

Page 19: ...Infiltration Rate See Table 5 1 for space with boiler only Use equation for multiple appliances Do not use an air infiltration rate ACH greater than 0 60 Volume 21 ft3 ACH x Total Input Refer to Nati...

Page 20: ...operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes o...

Page 21: ...onform to requirements of the authority having jurisdiction or in absence of such requirements to The National Fuel Gas Code ANSI Z223 1 NFPA 54 7 4 Vent Pipe Connect draft hood to boiler using 2 scre...

Page 22: ...ccessible for servicing See Figure 8 2 page 22 4 Damper must be in the open position when appliance main burners are operating 5 Boiler is equipped with factory wired harness that plugs into vent damp...

Page 23: ...23 Figure 8 2 Vent Damper Placement Figure 8 3 Vent Damper Position Indicator 8 VENT DAMPER INSTALLATION INSTRUCTIONS PN 240013268 Rev D 08 15 2021...

Page 24: ...INSTALL MANUAL VALVE WITHIN 6 FT 183 cm OF BOILER AND 5 FT 152 cm ABOVE THE FLOOR WHERE REQUIRED BY LOCAL CODES 3 8 cm Minimum Sediment Trap To Gas Control Inlet DANGER Fire Hazard Do not use matches...

Page 25: ...drafts hot or cold pipes sunlight lighting fixtures televisions fireplace or chimney 5 Check thermostat operation by raising and lowering thermostat setting as required to start and stop burners 6 Ins...

Page 26: ...gure 11 1 4200 Fuel Smart Hydrostat IC Control WARNING Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life PN 24...

Page 27: ...27 11 WIRING DIAGRAM Figure 11 2 4200 Fuel Smart Hydrostat IC Control ladder PN 240013268 Rev D 08 15 2021...

Page 28: ...urn clockwise to OFF DO NOT FORCE 5 Call qualified service technician WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or...

Page 29: ...in death or serious injury A Power remains off until boiler water temperature drops below high limit setting B Circulator continues to operate under this condition until thermostat is satisfied 3 In e...

Page 30: ...lamp in flue collector through draft relief opening or flue inspection cover With mirror positioned above burners flue gas passageways can be checked for soot or scale Follow this procedure to clean f...

Page 31: ...r and free of combustible materials gasoline and other flammable vapors and liquids Free flow of combustion and ventilating air to boiler and boiler room shall not be restricted or blocked Inspect fac...

Page 32: ...re than plus or minus 0 3 inches water column from specified pressure listed on boiler rating plate 7 Primary air adjustment is not necessary therefore air shutters are not furnished CHECK SAFETY CONT...

Page 33: ...ric service to be 120 Volts 15 Amps 60 Hz The MEA number for the this boiler is 19 79 E 1 Input rating for sea level to 2 000 ft 610m above sea level United States over 2000 ft 610m above sea level Re...

Page 34: ...he ECONOMY dial WARNING Burn and scald hazard Do not add water until boiler has fully cooled Failure to follow these instructions could result in death or serious injury Control LED legend 1 2 3 4 6 E...

Page 35: ...it leakage to ground Replace pilot burner igniter sensor and provide shield if necessary If flame rod or bracket is bent out of position restore to correct position APPENDIX A CONTROL FUNCTION DANGER...

Page 36: ...connect ignition cable STEP 4 Verify pilot and main burner light off 1 Initiate call for heat Turn thermostat above room temperature Ignition sequence may be delayed by thermal purge up to 2 minutes 2...

Page 37: ...d position 4 Return thermostat to desired position 5 Place vent damper in open position to permit burner operation by using HOLD DAMPER OPEN switch located on damper controller 6 Thermostat controls b...

Page 38: ...jumper wire across orange and yellow wires in Molex plug see Figure 4 This will create bypass of the damper boiler should then ignite If boiler ignites Go to section B 4 Vent Damper Troubleshooting G...

Page 39: ...or heat 1 Thermostat not calling for heat 2 Burned out heat anticipator 3 Loose or broken connections 4 Off On operating limit pressure control or low water cut off 5 Off On blocked vent switch or fla...

Page 40: ...tion 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 l...

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