Dunkirk DXL-100, DXL-125, DXL-150, DXL-170, DXL-50 Installation Guide

NATURAL DRAFT CAST IRON SERIES II

GAS FIRED BOILERS FOR FORCED HOT WATER

NATURAL GAS TO LP CONVERSION

MGB/OMGB/MCB/DXL SIZES THROUGH 200 MBTU

Kit #'s 550002663, 550002664, 550002665

Conversion kit shall be installed by qualified service
agency in accordance with manufacturer's instructions

and all applicable codes and requirements of authority

having jurisdiction. If information in these instructions

is not followed exactly, a fire, explosion or production
of carbon monoxide may result causing personal injury
or loss of life. Qualified service agency is responsible

for proper installation of this kit. Installation is not

proper and complete until operation of converted
appliance is checked as specified in manufacturer's

instructions supplied with the kit.

PART# PART#

(QTY) (QTY)

Pilot Orifice - Spark
Orifice # 47 (4) # 49 (4)

Label, "Nat to LP"

Conversion Plate

Liquid Sealing 140010 (i)
Compound

Spring Kit 1272030 (i)
Instructions 240009725 (i)

PB00208 (1)

# 50(2)

240004822 (1)

Tools Required

• Flat Head Screwdriver

• 1/4" Nut Driver
° 7/16" Open Ended Wrench

° 3/16" Allen Wrench
° 18" Manometer (or dial manometer)

Converting Boiler From Natural Gas To Propane (LP):

1. Follow instruction TO TURN OFFGAS TO APPLIANCE.
Verify electrical power is OFF.

2, Remove front panel.

3. Remove burner access door.
4, Remove main gas burner tubes. See Figure 1.

5. Remove main burner orifices. See Figure 1.

6. Install LP gas main burner orifices. Discard excess LP
orifices.

7, Use 7/16" wrench, disconnect pilot tube from pilot. See

Figure 2.

8. Remove pilot orifice.

9. Install LP gas pilot orifice.

10. Apply liquid sealing compound (provided) to threads of
pilot assembly fitting.

11. Reattach pilot tube to pilot and securely tighten. See

Figure 2.

12, Replace main gas burner tubes.

Figure 1 - Burners Assembly

OR FtCES

Figure 2 - Pilot Assembly

Pilot Orifice----....._,. <_:_:

Pilot Tube

DOOR

P/N 240009725, Rev. C [10/2012]

13. Remove cover screw from gas valve pressure regulator.
See Figure 3.

14. Remove adjustment screw by turning counterclockwise

_'_i. See Figure 4.

15. Remove stainless steel natural gas spring.

16. Insert Red LP gas spring.

17. Install new adjustment screw. Assure screw top is flush
with regulator top.

18. Turn pressure regulator adjustment screw clockwise

eleven (11) complete turns. (This is starting point

for manifold pressure,)

19. Install manometer to pressure tap on outlet side of gas
valve. See Figure 3.

NOTE: Gas inlet pressure should be between minimum

of 11" w.c. and maximum of 14" w.c.

20. Turn electric and gas supply ON.

Figure 3 - Gas Valve

PRESSURE REGULATOR
ADJUSTMENT BENEATH

INLET
PRESSURE QUTLET PRESSURE

COVER SCREW

--TAP

Fire Hazard. Do not use matches, candles, open

flames, or other methods providing ignition source.

Failure to comply will result in death or serious
injury.

21. Check for gas leaks around all gas connections using
commercially available soap solution specifically made

for leak detection.

22. While boiler is running adjust manifold pressure to ii"
water column by turning pressure regulator adjustment

screw. Check for CO2and CO levels to assure proper
operation.

23. Turn electric and gas supply OFF.

24. Remove manometer. Replace pressure tap cover screw

securely.

25. Install Black LP gas regulator adjustment cover screw
with o-ring. See Figure 4.

26. Mount conversion label on gas valve (found in spring

kit).

27. Turn electric and gas supply ON.

28. Cycle boiler to ensure proper operation and lighting.

29. Replace front panel.

NOTE: Complete following steps to provide proper

identification for customer service or technical support
issues.

30. Copy serial number from old rating plate to new one.

31. Mount new rating plate adjacent to old one.

Figure 4 - Gas Valve Adjustment Screw

Assembly

...............CAP SCREW

.................O-RUNG

.............ADJUSTMENT SCREW

C::_ .............SPRING

.... : < ........

)

BoilerSizeii , Orificeii

50,100,150,200 47

125,170 49

75 50

Parts for steps 16, 17, 25, and 26 are located in
Honeywell LP gas conversion kit HW#393691 (ECR #

1272030) for VR8204r and VR8304 gas valves.

Manufacturer

ECR

Honeywell

PartNumber

PB00208

390686-36