DXL SERIES Dt l II i Hodels CAST IRON GAS FIRED BOILERS FOR FORCED HOT WATER DXL-50 DXL-75 DXL-100 DXL=:L25 DXL--150 DXL-170 DXL-200 iNSTALLATiON,OPERATION & MAINTENANCE MANUAL ;' T rpr " ' US H Tested For 100 psi. ASME Working Pressure Manufactured ECR by: International, inc. 220! Dwyer Avenue.
Supply n 21/2" 50 4" 303/4" 36¾" 6" 1¼" 75 =" ,., 3'_/'' u/4 "_/ .... _u/4 6 _ " 1¼ 30_/ ..... 01/4 _,/., 4,/. 1¼ 100 6" ............... i2 _.......................... '/;; •J 150 170 /2 ;; .................... i 8_/;;.... /8 1 7 ½ 18% _/,, /2 "3"_3/" /--_--/4 1 200 ½ 3 ,, 22¾ 9'";; 6" /2 1 9½ 44 // I/" /2 1 11½ /4 3 /., 3 i U/2 7 30¼ 37¾ 7 -7" t C, f'_3/" OU/4 903/" OO/4 -7" / ; 3 8 30¾ 3 / /4 1 41/" / /4 ; 1 ...............................
2 1= Dimensions 2 = Safety & Warnings & Data = Natural 4 = Installation Procedure 5 = Ventilation 6 = Supply SYMBOLS ..................................................... Symbols 3 = Ratings = SAFETY And Return 7 = Vent Installation 2 ............................. Gas & Propane Gas ...... 4 5 Air ............................ 6 Piping ................................ ........................................... ...............................
3 ' RATINGS &DATA Table 2 = NATURAL - Ratings GAS 8t PROPANE and GAS/ Capacities (2) (z) Heating Capacity Mbh Boiler No. (1) Input iVibh 5O 5O 42 75 75 63 EXPLANATORY Net AHRI Rating Water Mbh AFUE No. of Burners _3) Recommended Air Cushion Tank Input NOTES All boilers -- For installation -- Recommended chimney height 20 feet. In special cases where conditions reduced to 10 feet. Refer to the latest revision of NFGC part 11.
4. =INSTALLATION PROCEDURE Fire hazard. Do not install boiler on combustible flooring or carpeting. Failure to follow these instructions could result in death or serious injury. 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.
5 - VENTILATION 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. & COMBUSTION • All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors. Two Permanent Opening Method.
6 = SUPPLY AND RETURN PIPING ........................... Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: • Connect distance to relief valve outlet and piped down to safe point of disposal. from floor or allowable safe point of discharge. • Be of pipe size equal to or greater line.
6 = SUPPLY IHPORTANT: Circulators mounting on the system Figure AND RETURN in the following illustrations return side is also acceptable 4 - Circulators Hounted See Special Conditions, on Supply Page 9 System, PIPING ........................... are mounted practice. Boiler on the system Used In Configuration supply to Chiller side, but System.
6 = SUPPLY Figure 5 - Bypass Piping Automatic Mixing AND RETURN PIPING ........................... Valve TO SYSTEM FROM SYSTEM z WATER INLET EXPANSION TANK _\ "_ _ER iii JALTERNATE CIRCULATOR LOCATION (_ C,ROOLATOR _ P"ESSUREREoUOER VALVE _ BAL'VA'VE 01A'RSEPARATORE:: VA_vESRO_OFF t'q CHECKVALVE _ VA_vESWAYMIX'NG _ HOSEBIB Figure 6 - Bypass Piping - Fixed Low Temp Only Manual Mixing Valve FROM © TO SYSTEM V2 S_ CIRCULATOR 0 ....... WATER INLET EXPANSION TANK .
6 = SUPPLY Figure 7 - Single Zone System With DHW AND RETURN PIPING Priority CH CIRCULATOR )q WATER ........................... tip,.-.- INLET DHW CIRCULATOR BOILER PRiORiTY Figure 8 - Multi Zone System With ZONE Circulators And DHW Priority ZOO'4E 4 C_RC 4 ...... _ ZONE 3 CiRC 3 ...............................
6 ' SUPPLY Figure 9 - Hulti Zone System AND RETURN With Zone Valves And DHW PIPING ........................... Priority (With Circulator) ZONE -_ ';/"__ LL_]_i lill IIIIIIii I 4 lllil!Ill ._ II_!i.__.
7 - VENT INSTALLATION Boiler and venting installations shall be performed by a qualified expert and in accordance with the appropriate manual. Installing or venting boiler or other gas appliance with improper methods or materials may result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide with is odorless and invisible. Do not connect draft system 1. 2. boiler to any portion operating under positive 3.
9= VENT DAMPER DAMPER INSTALLATION & INSTRUCTIONS DAMPER INSTRUCTIONS INSTALLATION NOTE: Referto Figure 10 forsteps i-6. Figure Figure 11 - Damper Motor 12 - Vent Damper Placement Wiring Damper Motor \ Vent Damper Vent Outlet "iOF 1. 1. Place vent damper on or as close to vent outlet of boiler as possible. See Figure 12, 2. Remove vent damper motor cover. 3. Feed damper wire harness connector through bracket hole on damper motor frame. 2.
:10-CONNECTING TO DO IF YOU SHELL GAS • Do not try to light any appliance. • Do not touch any electrical any phone in your building. switch; do not use • Immediately call your gas supplier from neighbor's phone. Follow gas supplier's instructions. • If you cannot department. SERVICE General CAUTION WHAT GAS reach your gas supplier, a call the fire • Use piping materials and joining methods acceptable to authority having jurisdiction.
1 =ELECTRICAL Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. Electrical Wiring See wiring details, diagrams on the following two pages for Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to National Electrical Code, ANSI/NFPA 70. Thermostat Installation 1.
o_rt WIRING DIAGRAM BY_ALUER _____c t _SVALV_ (R_O_@ENDED)1 _h7 I 1 PJMP o "-_ I ! R£D _ 0 _N | Ii_ II INSTALLED L .................... ] Z _Nm_ M(>DULE _ o "<-2 | 0 Z m 0 0 0 _C(_OUT F_ UNK _ O_ @ ÷ @ @ 0 m Z W_ _LY_L MLOT O_ I--I _LE Z WIRING UNE VOLT_ THEF_ .....
"rl c Vl WIRING SCHEMATIC ! "'l 3 m,i i_ E Z G} _o X o z o o o _ o M _ -.! .--! m Z _ CIRCULATOR PUMP _GN_T_RI C2 Cl B2 B_ 00¸0¸ CON_OL MODULE 32® Z -.! TT WATE_j TEMPERATURE _I%OR L, .............
%3' LIGHTING If you do not follow these instructions exactly, a fireor explosion may result causing property damage, personal injury or loss of life. • This appliance is equipped with an ignition device which automatically lights burner. Do NOT try to light this burner by hand. • Before operating smell all around appliance INSTRUCTIONS OPERATING INSTRUCTIONS PILOT SYSTEM FOR INTERHITTENT I. STOP! Read the safetyinformationto the left. 2. Set thethermostatto lowestsetting. 3.
14' SEQUENCE Thermostat actuates on call for heat, completing circuit to control. Completed circuit to control will first activate circulator and damper which will close end switch inside damper. Completes circuit to ignition system, ignition takes place. In event boiler water temperature exceeds high limit setting on boiler mounted high limit control, power is interrupted between control system and ignition system. Power remains off until boiler water temperature drops below high limit setting.
Makevisualcheckof mainburnerandpilotflamesat start of heatingseasonandagainin mid-season. Mainburner flameshouldhavewelldefinedinnerbluemantelwith lighterblueoutermantel.Checkburnerthroatsandburner orificesfor lint or dustobstruction.SeeFigures17 and 19. Figure 20 - Combustion Chamber GAS VALVE BURNERS, ORIFICES Figure 19 - Gas Burner Pilot flame should envelop 3/8to 1/2inch of tip of pilot thermocouple, ignition/sensing electrode or mercury sensor. See Figure 19.
16 -CHECKING GAS INPUT Adjust gas input to boiler by removing protective cap on RATE TO BOILER Figure pressure regulator, and turning screw_clockwise _ to increase input and counterclockwise _ ]b to decrease input.
Wiring An Indirect Water Heater When installing with indirect water heater, signal from indirect must be separated from heating zone signals and wired appropriately. If you choose not to separate indirect signal from heating zones, Economy Feature should be turned off to insure boiler supplies adequate temperature to heat the indirect tank. Setting The Control Settings can be checked using the TEST/SETTINGS Button. See page 23 for details.
System Start=up At initial start-up, with Economy feature active, control establishes 145°F target temperature. To test the high limit shut-off function, Economy Dial must be turned to OFF. Once tested, restore the Economy setting. If heating demand is high, target will increase over time to satisfy heat load. to reduce potential for condensing, control will allow boiler to heat to 120°F prior to energizing the circulator.
Fahrenheit/Celsius Change To change from Celsius to Fahrenheit: Control has the ability to operate in degrees Fahrenheit (default setting) or Celsius, 1. Set low limit to 44°C, 2. Set high limit to 44°C, 3. Display will delay 2 seconds and then display a "c", To change from Fahrenheit to Celsius: 4. Push the LWCO test button to change settings to "F", 1. Set low limit to 112°F 5. Re-set limit dials to correct settings, 2. Set high limit to 112°F 3.
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DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site"www,ecrinternational,com
