Dunkirk DXL-50 User Manual

DXL SERIES II

CAST IRON GAS FIRED BOILERS

Models

DXL-50

DXL-75
DXL-100
DXL-125
DXL-150
DXL-1 70
DXL-200

FOR FORCED HOT WATER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

An ISO 9001-2008 Certified Company

Tested For 100 psi.

ASME

Working Pressure

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com

P/N 2400009041, Rev. B [09/2012]

4½"

¼¼

¼

C

A

4

Figure 1 - Dimensions

1- DIMENSIONS

"E"

"F"

"B"

"A"

"C"

3½""½

4¼"

4½"

1¼" Supply

14"

4¼"

27"

5½"

3"

1¼" Return

"D"

2½"

Table 1 - Dimensions

Boiler No.

50 ½" 11⅛"5½" 4" 30¾"

75 ½" 15 7½" 5" 30¾" 36¾" 6" 1¼"
100 ½" 15 7½" 6" 30¾" 37¼" 6½" 1¼"
125 ½" 18⅞"9½" 6" 30¾" 37¼" 6½" 1¼"
150 ½" 18⅞"9½" 7" 30¾" 37¾" 7" 1¼"
170 ½" 22¾"11½" 7" 30¾" 38¾" 7" 1¼"
200 ½" 22¾"11½" 8" 30¾" 38¾" 8" 1¼"

Natural Gas

Inlet*

ABCDEF

Dimensions

36¾"

Pump size Supply &

Return Tappings

6" 1¼"

2

2 - SAFETY SYMBOLS & WARNINGS

!

1- Dimensions .....................................................2

2 - Safety Symbols & Warnings .............................3

3 - Ratings & Data - Natural Gas & Propane Gas ...... 4

4 - Installation Procedure .....................................5

5 - Ventilation & Combustion Air ............................ 6

6 - Supply And Return Piping ................................7

7 - Vent Installation ........................................... 12

8 - Vent System Modifi cation ............................... 12

9 - Vent Damper Installation & Instructions ........... 13

10 - Connecting Gas Service ............................... 14

11 - Electrical Section ........................................ 15

12 - Wiring Diagram - Intermittent Ignition ........... 16

13 - Lighting Instructions ................................... 18

14 - Sequence Of Operation ................................ 19

15 - General Instructions .................................... 19

16 - Checking Gas Input Rate To Boiler ................. 21

17 - Setting The Control ..................................... 22

17 - System Start-Up ......................................... 23

17 - Limit Control Troubleshooting ...................... 24

18 - System Troubleshooting ............................... 25

Parts, Kits and Accessories.................................. 27

Warranty .......................................................... 33

Check Out Certifi cate ......................................... 35

Safety Symbols & Warnings

The following defi ned symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

WARNING

!

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.

WARNING

!

Keep boiler area clear and free from combustible
materials, gasoline and other fl ammable vapors
and liquids.

DO NOT obstruct air openings to the boiler room.
Modifi cation, substitution or elimination of factory

equipped, supplied or specifi ed components may
result in personal injury or loss of life.

TO THE OWNER - Installation and service of this
boiler must be performed by a qualifi ed installer.

TO THE INSTALLER - Leave all instructions with
boiler for future reference.

When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.

!

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 injury.

!

CAUTION

Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal
injury.

3

3 - RATINGS & DATA - NATURAL GAS & PROPANE GAS

Table 2 - Ratings and Capacities

(2)

Boiler

No.

(1)

Input

Mbh

(1)

Heating

Capacity

Mbh

Net AHRI

Rating

Water

Mbh AFUE

No.

of

Burners

Recommended

50 50 42 37 83.5 1 15 2.4 45,000

75 75 63 55 83.1 2 15 4.0 67,500
100 100 83 72 83.0 2 30 4.0 90,000
125 125 104 90 82.0 3 30 5.6 112,500
150 150 124 108 83.0 3 30 5.6 135,000
170 170

139

121 82.0 4 30 7.2 153,000

200 200 165 143 82.0 4 30 7.2 180,000

EXPLANATORY NOTES

-- All boilers are design certifi ed for installation on noncombustible fl oor.

(3)

Air Cushion

Tank

Water

Content

(Gals.)

High

Altitude

Input

-- For installation on combustible fl oors use combustible fl oor kit.

-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be
reduced to 10 feet. Refer to the latest revision of NFGC part 11.

-- Electric 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. Reduce input rate 4% for every 1000 ft (304m) above sea level.

(2) Net AHRI 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 non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and
radiation.

STANDARD EQUIPMENT: Boiler 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,
Spill Switch, Rollout Switch, Combination Gas Control, Automatic Vent Damper. Not Shown Are: Wiring Harness,
Thermocouple, Non-linting Safety Pilot.

4

4 - INSTALLATION PROCEDURE

!

WARNING

Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury

.

1.

Installation must conform to requirements of authority
having jurisdiction or, in absence of such requirements,
to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

2.

Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
and Safety Devices for Automatically fi red Boilers,
ANSI/ASME CSD-1.

3.

Boiler series is classifi ed as Category I. Vent
installation shall be in accordance with "Venting of
Equipment ," of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of local
building codes.

4.

Boiler has met safe lighting and other performance
criteria with gas manifold and control assembly on
boiler per latest revision of ANSI Z21.13/CGA 4.9.

5.

Boiler shall be installed such that gas ignition system
components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service, (circulator replacement, condensate trap,
control replacement, etc.).

6.

Locate boiler 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.

!

WARNING

Fire hazard. Do not install boiler on combustible
fl ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.

9.

FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible

fl ooring special base must be used. (See Replacement

Parts Section.) Boiler can not be installed on
carpeting. Minimum clearances to combustible

construction are:

TOP ....................................18 IN. (457mm)

FRONT .........................................ALCOVE *

FLUE CONNECTOR ................. 6 IN. (152mm)

REAR ................................... 4 IN. (102mm)

CONTROL SIDE ..................... 9 IN. (229mm)

OTHER SIDE ........................... 3 IN. (76mm)

HOT WATER PIPING ................ Per Local Code

NOTE: Greater clearances for access should supersede fire

protection clearances.
* Defi nition of Alcove is three sided space with no wall in
front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.

Figure 2 - Clearance to Combustibles

Minimum Clearances to Combustible

Construction (as seen from above)

4"

3"

BOILER

Front

9"

18"

5

5 - VENTILATION & COMBUSTION AIR

Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or
applicable provisions of local building codes.

Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.

National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.

• Engineered Installations. Must be approved by
authority having jurisdictions.

• Mechanical Air Supply. Provide minimum of 0.35
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.

• All Indoor Air. Calculate minimum volume for all
appliances in space. Use a different method if
minimum volume not available.

о Standard Method. Cannot be used if known air

infi ltration rate is less than 0.40 air changes per
hour. See Table 3 for space with boiler only. Use
equation for multiple appliances.

3

Volume ≥ 50 ft

x Total Input [Mbh]

о Known Air Infi ltration Rate. See Table 3 for

space with boiler only. Use equation for multiple
appliances. Do not use an air infi ltration rate
(ACH) greater than 0.60.

Volume ≥ 21 ft3/ACH x Total Input [Mbh]

о 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.

о 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 vertical ducts. Provide
minimum free area of 1 in

2

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 input rating of all appliances in
enclosure.

о One Permanent Opening Method. Provide opening

commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides
and back and 6 inches on front of boiler (does not
supersede clearance to combustible materials).

о Combination Indoor and Outdoor Air. Refer to

National Fuel Gas Code for additional requirements
for louvers, grilles, screens and air ducts.

• Combination Indoor and Outdoor Air. Refer to
National Fuel Gas Code for application information.

National Gas and Propane Installation Code Requires
providing air supply in accordance with:

• Section 8.2 and 8.3 when combination of appliances
has a total input of up to and including 400 Mbh (120
kW).

• Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW).

• Refer to Natural Gas and Propane Installation Code
for specifi c air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.

Table 3 - Ventilation & Combustion Air

Input Mbh

Standard

Method

50 2500 10500 5250 3500 2625 2100 1750

75 3750 15750 7875 5250 3938 3150 2625

100 5000 21000 10500 7000 5250 4200 3500

125 6250 26250 13125 8750 6563 5250 4375

150 7500 31500 15750 10500 7875 6300 5250

170 8500 35700 17850 11900 8925 7140 5950

200 10000 42000 21000 14000 10500 8400 7000

Known Air Infi ltration Rate Method ACH (Air Changes Per Hour)

0.1 0.2 0.3 0.4 0.5 0.6

6

6 - SUPPLY AND RETURN PIPING

!

WARNING

Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

• Connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from fl oor or allowable safe point of discharge.

• Be of pipe size equal to or greater than 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 supported and securely anchored to avoid applied stress on the relief valve.

• Be as short and straight as possible.

• Terminate with plain end (not threaded).

• Be constructed of material suitable for exposure to temperatures of 375°F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.

Figure 3 - Safety Relief Valve

RELIEF VALVE

DISCHARGE

LINE

Check local

codes for

maximum

distance

from fl oor

or allowable

safe point of

discharge.

7

6 - SUPPLY AND RETURN PIPING

IMPORTANT: Circulators in the following illustrations are mounted on the system supply side, but
mounting on the system return side is also acceptable practice.

Figure 4 - Circulators Mounted on Supply System, Boiler Used In Confi guration to Chiller System.

See Special Conditions, Page 9

1.

Boiler, used in connection with a refrigeration system,
must be installed so chilled medium is piped in parallel
with boiler with appropriate valves to prevent chilled
medium from entering boiler. See Figure 4 .

2.

Boiler piping system of hot water boiler connected to
heating coils located in air handling units where they
may be exposed to refrigerated air circulation must be
equipped with fl ow control valves or other automatic
means to prevent gravity circulation of boiler water
during cooling cycle.

3.

Hot water boilers installed above radiation level or
as 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 fl ow control valve to prevent gravity
circulation.

5.

Hot water boilers and system must be fi lled 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 fi t 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 follows:

A. This method is used to protect boilers from con-

densation forming due to low temperature return
water. Generally noticed in large converted grav­ity systems or other large water volume systems.

Figure 5 & 6, Page 9.

B. These methods are used to protect systems using

radiant panels and the material they are encased in
from high temperature supply water from the boiler

and protect the boiler from condensation.

NOTE#1: When using bypass piping, adjust

valves V1 & V2 until desired system temperature
is obtained.

NOTE#2: Bypass loop must be same size piping

as the supply and return piping.

8

6 - SUPPLY AND RETURN PIPING

Figure 5 - Bypass Piping Automatic Mixing Valve

TO SYSTEM

WATER INLET

EXPANSION

TANK

FROM SYSTEM

CIRCULATOR

SHUT-OFF
VALVE

PRESSURE
REDUCER VALVE

CHECK VALVE

BOILER

BALL VALVE

3 WAY MIXING
VALVE

ALTERNATE

CIRCULATOR

LOCATION

AIR SEPARATOR

HOSE BIB

Figure 6 - Bypass Piping - Fixed Low Temp Only Manual Mixing Valve

TO SYSTEM

WATER INLET

SYSTEM

CIRCULATOR

EXPANSION

TANK

V2V1

BOILER

FROM SYSTEM

ALTERNATE

CIRCULATOR

LOCATION

7. 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.

!

WARNING

Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.

8. Install discharge piping from safety relief valve. See

Warning, Page 7.

9