ECR International Dunkirk DXL-060K Instruction manual

DXL
CAST IRON
GAS FIRED BOILERS
FOR FORCED HOT WATER
With Hydrolevel 4200 Control
INSTALLATION, 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 Avenue, Utica, NY 13501
Tel. [phone]
www.ecrinternational.com
PN 240013268 REV. D [08/15/2021]

2
VERIFY CONTENTS RECEIVED
Fully Assembled Boiler Vent Damper Draft Hood Pump (Optional)
*Drain Valve *ASME Safety Relief Valve *Tridicator
*Black Iron Fittings
(see parts list for sizes
and use)
Includes Essential
Documents and Warranty
11x17 Wire Diagrams
Document Package *Junction Box *Circulator Harness
Check our website frequently for updates: www.ecrinternational.com
Information and specications outlined in this manual in eect at the
time of printing of this manual. ECR International reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
* Items found in parts box included with your boiler.
PN 240013268 Rev. D [08/15/2021]
For Parts lists see manual 240013269 included with your boiler literature package.

3
TABLE OF CONTENTS
1 - Physical Data ....................................................................................................................................... 4
2 - Safety Symbols And Warnings .............................................................................................................. 5
3 - Locating The Boiler .............................................................................................................................. 7
3.1 Installation Requirements .................................................................................................................. 7
3.2 Minimum Clearances To Combustible Construction 7
3.3 Recommended Clearances For Service................................................................................................. 7
3.4 Boiler Location Considerations ........................................................................................................... 8
4 - Connecting Supply And Return Piping .................................................................................................. 9
4.1 Connection Locations ........................................................................................................................ 9
4.2 Safety Relief Valve Installation 10
4.3 Flush And Rinse System ................................................................................................................. 11
4.4 Water Treatment ........................................................................................................................... 11
4.5 Supply And Return Requirements ..................................................................................................... 12
4.6 Special Conditions .......................................................................................................................... 12
5- Ventilation & Combustion Air .............................................................................................................. 19
5.1 Requirements................................................................................................................................. 19
6 - Vent System Modication ................................................................................................................... 20
6.1 Removal Of Existing Boiler From Venting System ................................................................................ 20
7 - Vent Installation ................................................................................................................................ 21
7.1 Check Your Chimney ....................................................................................................................... 21
7.2 Requirements................................................................................................................................. 21
7.3 Chimney Inspection ........................................................................................................................ 21
7.4 Vent Pipe....................................................................................................................................... 21
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 Installation.................................................................................................................. 25
11 - Wiring Diagrams ............................................................................................................................. 26
12 - Lighting Instructions ........................................................................................................................ 28
12.1 Lighting Procedure For Boiler With Intermittent Pilot System................................................................28
12.2 Operating Instructions For Intermittent Pilot System...........................................................................28
 .................................................................................................... 28
13 - Normal Sequence Of Operation ........................................................................................................ 29
13.1 General ....................................................................................................................................... 29
14 - General Maintenance And Care Instructions .................................................................................... 30
14.1 Seasonal Startup .......................................................................................................................... 30
14.2 Clean Flue Gas Passageways ......................................................................................................... 30
14.3 General Maintenance..................................................................................................................... 31
14.4 Adjusting Gas Input ...................................................................................................................... 32
15 - Ratings And Capacities ..................................................................................................................... 33
Appendix A - Control Function ................................................................................................................. 34
A-1. Intermittent Pilot........................................................................................................................... 35
Appendix B - Vent Damper Installation ................................................................................................... 37
B.1 Damper Installation ........................................................................................................................ 37
B.2 Vent Damper ................................................................................................................................. 37
B.3 Vent Damper Harness - Molex Plugs.................................................................................................. 38
B.4 Vent Damper Troubleshooting Guide.................................................................................................. 39
PN 240013268 Rev. D [08/15/2021]

4
1 - PHYSICAL DATA
Model DXL-060K
DXL-120K DXL-120K DXL-150K DXL-175K DXL-205K DXL-235K
# Sections 3456789
A Width with Jacket 13-³/"13-³/"16-/"19"21-/ 27-¹/ 27-¹/
340 mm 340 mm 411 mm 483 mm 555 mm 700 mm 700 mm
BVent Location (Half Width) 6-
³/ "6- ³/ "8-¹/" 9-¹/ 10-¹5/"13- ³/ "13-
³/ "
171 mm 171 mm 206 mm 241 mm 278 mm 349 mm 349 mm
CHeight 32-¹/" 32-¹/" 32-¹/" 32-¹/" 32-¹/" 32-¹/" 32-¹/"
816 mm 816 mm 816 mm 816 mm 816 mm 816 mm 816 mm
DDamper Height 6" 6" 6-¹/ 6-¹/ 7" 7" 7"
153 mm 153 mm 165 mm 165 mm 178 mm 178 mm 178 mm
EDepth w/o Draft Hood Installed 22" 22" 22" 22" 22" 22" 22"
559 mm 559 mm 559 mm 559 mm 559 mm 559 mm 559 mm
FDepth W/ Draft Hood Installed 26" 26" 26" 26" 26" 26" 26"
660 mm 660 mm 660 mm 660 mm 660 mm 660 mm 660 mm
G Flue 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/ " NPT 1- ¹/ " NPT 1- ¹/ " NPT 1- ¹/ " NPT 1- ¹/ " NPT 1- ¹/ " NPT 1- ¹/ " NPT
Natural Gas Inlet 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 1/2" NPT 3/4" NPT 3/4" NPT
Relief Valve NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT
Drain Valve NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT
Heating Water Content, Gal (Liters) 1.9 (7.2) 2.3 (8.8) 2.8 (10.5) 3.2 (12.2) 3.7 (13.9) 4.1 (15.6) 4.6 (17.3)
Air Cushion Tank, Gal (Liters) Estimate.*
(Actual Based on System Size)
15 (27)* 30 (114)* 30 (114)* 30 (114)* 30 (114)* 30 (114)* 30 (114)*
Boiler Weight, less pkg - Lbs (KG) 170 (77) 210 (96) 250 (114) 280 (128) 320 (145) 350 (159) 390 (177)
Shipping Weight, lbs (KG) 215 (98) 250 (114) 295 (134) 335 (152) 385 (175) 420 (191) 465 (211)
PN 240013268 Rev. D [08/15/2021]
Figure 1 - Dimensions
Front View Right Side View
"A" "B"
"C"
"D"
"G"
2"
(50.8 mm)
"F"
"
(549.3 mm)
7"
(117.8mm)
12¹/"
(317.5 mm)
23" (584mm)
7¹/" (181mm)
16³/" (416mm)
"E"
GAS SUPPLY

5
2 - SAFETY SYMBOLS AND WARNINGS
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
!!
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury.
!
This is the safety alert symbol. Symbol alerts
you to potential personal injury hazards. Obey all
safety messages following this symbol to avoid
possible injury or death.
Become familiar with symbols identifying potential hazards.

2.1. Safety Information
WARNING
Do not tamper with or use this boiler for any
purpose other than its intended use. Failure to follow
these instructions could result in death or serious
injury. Use only manufacturer recommended parts
and accessories.
!
CAUTION
Laceration, burn hazard. Metal edges and parts
may have sharp edges and/or may be hot. Use
appropriate personal protection equipment to
include safety glasses and gloves when installing
or servicing this boiler. Failure to follow these
instructions could result in minor or moderate injury.
!!
NOTICE
Used to address practices not related to personal
injury.
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.
!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald and
cause permanent injury.

persons are more likely to be permanently injured by
hot water. Never leave them unattended in bathtub or
shower. Never allow small children to use a hot water
tap or draw their own bath.

description, or if state laws or local codes require
certain water temperatures at hot water taps, you
must take special precautions:
• Use lowest possible temperature setting.
• Install some type of tempering device, such as
an automatic mixing valve, at hot water tap or
water heater. Automatic mixing valve must be
selected and installed according to manufacturer's
recommendations and instructions.
• Water passing out of drain valves may be
extremely hot. To avoid injury:
• Make sure all connections are tight.
• 
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note: Warning for Infants, Children, and Elderly:
Great care must be taken when exposing the
aforementioned groups to warm or hot water as they
can be badly burned in exposure times less than half
of the time for an adult.
PN 240013268 Rev. D [08/15/2021]

6
WARNING
Keep boiler area clear and free from combustible

liquids.
DO NOT obstruct air openings to the boiler room.


result in personal injury or loss of life.
Installation and service of this boiler shall be performed

When this product is installed in the Commonwealth
of Massachusetts the installation shall be performed
by a Licensed Plumber or Licensed Gas Fitter.
!
WARNING
Combustion chamber insulation in this product

can be converted to cristobalite in very high
temperature applications. The International Agency
for Research on Cancer (IARC) has concluded,
Crystalline silica inhaled in the form of quartz
or cristobalite from occupational sources is
carcinogenic to humans (Group1). Avoid breathing
dust and contact with skin and eyes. Use NIOSH

respirator is based on the OSHA requirements
for cristobalite at the time this document was
written. Other types of respirators may be needed
depending on the job site conditions. Current
NIOSH recommendations can be found on the
NIOSH website https://www.cdc.gov/niosh/topics/
silica/. NIOSH approved respirators, manufacturers,
and phone numbers are also listed on this website.

and eye protection. Apply enough water to the
combustion chamber lining to prevent dust. Wash
potentially contaminated clothes separately from
other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid. Eye: Irrigate immediately.
Breathing: Fresh air.
!
2 - SAFETY SYMBOLS AND WARNINGS
2.2 For Your Safety 2.2 For Your Safety
Manufacturer recommends a carbon monoxide detectorManufacturer recommends a carbon monoxide detector


jurisdictions may, by law, require.jurisdictions may, by law, require.
WARNING
Fire, Explosion, Asphyxiation, Electrical shock
hazard! Flooding will result in damages such as
electrical problems, corrosion, inoperative parts,
mold and other unforeseen issues which can
occur over time. Any equipment determined by

excess of water or other liquid, shall be replaced.
Failure to follow these directions will result in a
Hazardous Situation.
!
!
WARNING
This product contains Fibrous glass. Fibrous


possible human carcinogen. When disturbed as a

airborne and, if inhaled, may be hazardous to
your health. It can harm the eyes, skin, and the

been listed by the State of California as a possible
cause of cancer through inhalation. Adhere
to the following precautions and procedures.
Avoid breathing dust and contact with skin and

N95). Other types of respirators may be needed
depending on the job site conditions. Current NIOSH
recommendations can be found on the NIOSH
website https://www.cdc.gov/niosh/ Approved
respirators, manufacturers, and phone numbers
are also listed on this website. Wear appropriate
personal protective clothing to prevent skin contact,
as well as gloves and eye protection. Wash skin
daily at end of each work shift, and prior to eating,
drinking, smoking, etc. Workers whose clothing
may have been contaminated should change into
uncontaminated clothing before leaving the work
premises. Wash potentially contaminated clothes
separately from other clothing. Rinse clothes washer
thoroughly. Follow all Local, State and Federal
guidelines for disposal.
NIOSH stated First Aid. Eye: Irrigate immediately.
Breathing: Fresh air.
!
PN 240013268 Rev. D [08/15/2021]

7
1. Installation shall conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, and/or Natural Gas and Propane
Installation Code, CAN/CSA B149. Where required
by the authority having jurisdiction, the installation
must conform to the Standard for Controls and Safety
Devices for Automatically red Boilers, ANSI/ASME
CSD-1.
2. 
installation shall be in accordance with "Venting of
Equipment", of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or "Venting Systems and Air Supply
for Appliances," of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
3. Boiler has met safe lighting and other performance
criteria with the gas manifold and control assembly on
the boiler per the latest revision of ANSI Z21.13/CSA
4.9.
4. Install boiler 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.).
5. Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
6. Horizontal vent run to chimney shall be as short as
practicable. Refer to NFPA 54 to determine maximum
permissible horizontal run for chimney type and height.
7. 
equipment.
8. Do not
install boiler on carpeting.
9. 
or vapors will be stored or used. See Table 3-1 page 8,
Contaminants.
10. Chimney shall be lined in a manner acceptable to the
authority having jurisdiction.
11. 

front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.
3 - LOCATING THE BOILER
Minimum Clearances to Combustible Construction
(as seen from above)
3.1 Installation Requirements
3.2 Minimum Clearances to Combustible
Construction
1. Minimum clearances to combustible construction are:
CAUTION
Boiler weight exceeds 200 pounds (90.7 kg). Do not
lift boiler without assistance.
!!
WARNING
Fire hazard! Do not install boiler on carpeting.
Failure to follow these instructions could result in
death or serious injury.
!
2"
6"
BOILER
18"
2"
Front
TOP ............................. 10 IN. (254 mm)
FRONT ......................... ALCOVE *
FLUE CONNECTOR ......... 6 IN. (152 mm)
REAR (DRAFT HOOD) ..... 6 IN. (152 mm)
both SIDEs.......................... 2 IN. (51 mm)
HOT WATER PIPING ....... Per Local Code
Top 10 inches (254mm)
Front Alcove*
Flue Connector 6 inches (152mm)
Rear 6 inches (152mm)
Both Sides 2 inches (51 mm)
Hot Water Piping Per Local Code
3.3 Recommended Clearances for Service
1. Allow 24 inches (610 mm) at front and one side for
servicing and cleaning.
2. When installed in utillity room, door should be wide
enough to allow largest boiler part to enter, or to
permit replacement of another applicance such as a
water heater.
NOTE: Greater clearances for access and servicing should
supersede fire protection clearances.
PN 240013268 Rev. D [08/15/2021]

8
3.4 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent the potential of freezing.
• Drainage of water (or water/ antifreeze solution) during
boiler service or from safety relief valve discharge.
• Access to system water piping, gas supply, and
electrical service.
• 
capable of supporting the weight of the boiler, water,
and equipment.
• 
wet.
• Water, gas, and electrical may connect to either side of
boiler as desired.
• Horizontal run to chimney shall be as short as possible.
3 - LOCATING THE BOILER
Items to Avoid Products Which May Contain These
Items Areas Where These Items May Be Found
Chlorine, Fluorine, and Compounds

Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Swimming pool or spa chemicals
De-icing salts or chemicals
Carbon Tetrachloride
Swimming pools and pool storage areas


Airborne Particulates
Drywall dust
Road or gravel dust
Dryer lint
Cat litter


Acids, Solvents, etc.
Paint, Varnish, Turpentine, etc.
Cleaning Solvents
Hydrochloric acid/muriatic acid
Cements, adhesives and glues
Photo processing plants
Garages with workshops

establishments
Laundry Chemicals
Laundry detergents, bleaches, fabric
softeners, etc.
Antistatic fabric softeners (dryer sheets)
Dry cleaning/laundry areas and
establishments
Other
Permanent wave solutions
Refrigerants (Freon, etc) (only where
the refrigerant may be leaking from the
appliance)
Beauty shops
Refrigeration repair shops
Notes:


passages possibly resulting in unsafe operation. In this case, unit servicing shall include


the room be generously ventilated (well in excess of combustible air requirements), and
homeowner seal laundry supply containers, and minimize room vapors.
. Piping allowing fresh air in should also be considered. See Section 5-1.
Table 3-1: CONTAMINANTS
• System piping exposed to freezing conditions: Use

manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
Maximum recommended mixture 50% glycol.
PN 240013268 Rev. D [08/15/2021]

9
WARNING
Burn and scald hazard. Boiler supplied with dust caps
on supply and return tappings (4). Shall remove all

water. Failure to follow these instructions could result
in death or serious injury.
!
4.1 Connection Locations
• Boiler has one supply and one return tapping on each
side (4 total). Boiler supplied with dust caps only.

with water.
• Supply and return may be piped to either side of boiler,
as desired. Both supply and return shall be on same
side of boiler. Do not "cross pipe" as boiler may not
deliver adequate heat with cross piping.
• ASME relief valve may be located o unused
supply tapping IN UPRIGHT POSITION ONLY.
• 
tapping using a contractor supplied tee, piped right or
left side as desired. See Figure 4-3
• Unused supply and return tappings may be capped, as
desired. Relief valve and drain valve may be located on
near boiler piping using contractor supplied tees with
no valves.
4 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4-1 Piping Options
PIPING OPTIONS
THIS BOILER HAS TWO SUPPLY (OUTLET) AND TWO RETURN (INLET) TAPPINGS.
PIPE SUPPLY AND RETURN ON THE SAME SIDE (FIG. 1 & 2)
DO NOT CROSS PIPE! (FIG 3 & FIG 4)
FIG 1.
FIG. 2
FIG 3.
FIG 4.
FRONT
FRONT
FRONT
FRONT
RETURN
RETURN
SUPPLY
SUPPLY
. A . B
. C . D
PIPING OPTIONS
THIS BOILER HAS TWO SUPPLY (OUTLET) AND TWO RETURN (INLET)
TAPPINGS.
PIPE SUPPLY AND RETURN ON THE SAME SIDE (SEE FIG. A AND B)
DO NOT CROSS PIPE - (SEE FIG. C AND D)
PN 240013268 Rev. D [08/15/2021]

10
4 - CONNECTING SUPPLY AND RETURN PIPING
Figure 4-2 - Safety Relief Valve
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions. Failure
to follow these instructions could result in death or
serious injury.
!
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:
4 . 2 S a f e t y R e l i e f V a l v e I n s t a l l a t i o n
See Figure 4-2
Check local codes for maximum
distance from oor or allowable
safe point of discharge.
RELIEF VALVE
On Opposite
side of supply
DISCHARGE
LINE
WARNING
Burn and scald hazard. Safety relief valve shall be
installed with spindle in upright position only,
following ASME BPV code. Failure to follow these
instructions could result in death or serious injury.
!
A. connect to relief valve outlet and piped down
to safe point of disposal. Check local codes for

point of discharge.
B. be of pipe size equal to or greater than that of
the relief valve outlet over the entire length of
discharge line;
C. 
relief valve and discharge to atmosphere (do not
plug or place any obstruction in discharge line.
D. terminate freely to atmosphere where any
discharge will be clearly visible and at no risk of
freezing;
E. allow complete drainage of the valve and the
discharge line;
F. be independently supported and securely anchored
to avoid applied stress on the relief valve;
G. be as short and straight as possible;
H. terminate with plain end (not threaded);
I. be constructed of material suitable for exposure to
temperatures of 375° F (191°C); or greater.
J. Terminate freely to atmosphere where discharge is
clearly visible and no risk of freezing.
Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements.
Alternate Location
Piped in Supply Line
(Contractor supplied

Do Not Install
Pressure
Relief Valve
Horizontally
Figure 4-3 Optional Locations for Drain Valve
Left Side Drain
Valve Location With
Standard
Manufacturer
Supplied Hardware
Optional Right side
Drain Valve Location
with Contractor
Supplied Tee
PN 240013268 Rev. D [08/15/2021]