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Dunkirk PWXL - User Manual

Dunkirk PWXL
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P/N 240007958 REV B [03/2011]
An ISO 9001-2008 Certified Company
PWXL
Cast Iron Gas Fired
Hot Water Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
DUNKIRK BOILERS
2210 Dwyer Avenue, Utica NY 13504-4729
Phone: (315) 797-1310 • Fax: (866) 432-7329
e-mail: info@ecrinternational.com
web site: www.ecrinternational.com
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Summary

Safety Symbols

Boiler Ratings and Capacities

Boilers For Use At High Altitude

Explains adjustments and considerations for operating the boiler at high altitudes.

Before You Start

Locating the Boiler

Combustion and Ventilation Air

System Piping

For Use With Cooling Units

Instructions for connecting the boiler to refrigeration systems.

Low Design Water Temperature Systems (Below 140°)

Guidance for systems requiring lower water temperatures to prevent condensation.

Temperature;Pressure Gauge Installation

Instructions for installing the temperature and pressure gauge.

Chimney and Vent Pipe Operation

Connecting The Vent Damper And Vent Connector

Details how to connect the vent damper and vent connector to the chimney.

Chimney and Vent Pipe Connection

Minimum Vent Pipe Clearance

Specifies minimum safe clearance distances for vent pipes from combustibles.

Removing Existing Boiler From Common Venting System

Procedures for safely removing a boiler from a shared venting system.

Vent Damper Operation

Explains how to install and operate the automatic vent damper.

Vent Damper Operation

Manual Operation Of The Vent Damper

Details manual control options for the vent damper.

Gas Supply Piping

Gas Supply Piping Leak Check

Electrical Wiring

Thermostat Locations to Avoid

Lists locations that are unsuitable for thermostat installation.

Electric Power Supply

Specifies requirements for the boiler's electrical power source.

Install Your Thermostat

Instructions for proper thermostat installation location and wiring.

Connect Circulator Pump Wiring

Details how to wire the circulator pump to the boiler system.

Equipment and Optional Accessories

Relief Valve

Explains the function and installation of the safety relief valve.

Expansion Tank

Details the purpose and installation of the expansion tank.

Diaphragm Type Expansion Tank

Describes the diaphragm type expansion tank and its installation.

Air Eliminating Fitting (Air Purger)

Explains the function of the air purger in removing system air.

Main Air Vent For Down Flow Systems Or Diaphragm Type Expansion Tank

Instructions for installing a main air vent in down flow systems.

Automatic Fill Valve

Describes the automatic fill valve for maintaining system water levels.

Drain Valve

Explains the purpose and location of the drain valve.

Circulating Pump

Details the requirement and function of the circulating pump.

Vent Damper

Describes the automatic motorized stack damper for efficiency.

Rollout Switch (Flame Rollout Safety Shutoff)

Explains the function of the rollout switch as a safety shutoff.

Equipment and Optional Accessories

Blocked Vent Safety Shutoff

Details the blocked vent safety shutoff switch and its function.

Starting the Boiler

How A Hot-Water System Operates

Explains the basic operational principle of the hot water heating system.

Filling System With Water

Guides the process of filling the heating system with water.

Starting the Boiler Valve Operations

Intermittent Ignition Boiler VR8204 A;VR8304 M Gas Valve Operating Instructions

Operating instructions for intermittent ignition gas valves.

Continuous Pilot Boiler VR8200 A;VR8300 A Gas Valve Lighting Instructions

Lighting instructions for continuous pilot gas valves.

To Turn Off Gas To Appliance

Steps for safely shutting off the gas supply to the appliance.

Initial Operational Boiler Test Check-Out Procedure

Natural Gas Procedure

Procedure for measuring gas input for natural gas.

LP Gas Procedure

Procedure for measuring gas input for propane gas.

Initial Operational Boiler Test Check-Out Certificate & Signed Receipt

Operating Your Boiler

Automatic Gas Valve Function

Explains the function of the automatic gas valve.

Safety Pilot Function

Describes the safety pilot's role in preventing burner operation.

Ignition System Safety Shutdown Test

Procedure for testing the ignition system safety shutdown.

Relight Procedure

Instructions for relighting the boiler after shutdown.

Thermostat Operation

Guidance on setting and using the thermostat.

Checking and Adjusting

Pilot Burner Adjustment

Instructions for adjusting the pilot burner flame.

Main Burner Check

Guidance on checking the main burner flame appearance.

Limit Controls Adjustment

Instructions for adjusting temperature limit controls.

Maintaining Your Boiler

Boiler Flue Passages Maintenance

Recommendations for cleaning flue passages.

Vent System Inspection

Importance of checking the vent system seasonally.

Water System Preparation

Instructions for draining the system to prevent freezing.

Cleaning Boiler and Burners

Detailed steps for cleaning the boiler and its burners.

Sequence of Operation

PWXL with Electronic Ignition Operation

Details the sequence of operation for electronic ignition models.

Low Water Condition Response

Explains the system response and indicator for low water conditions.

Troubleshooting

Initial Service Checks

Essential checks to perform before starting troubleshooting.

Troubleshooting Tools

Lists necessary tools for troubleshooting.

Service Hints

No Heat or Insufficient Heat Troubleshooting

Troubleshooting steps for no or insufficient heating.

Noisy Burner Troubleshooting

Advice for addressing noisy burner operation.

Leaking Relief Valve

Steps to take if the relief valve is leaking.

Dunkirk PWXL Specifications

General IconGeneral
BrandDunkirk
ModelPWXL
CategoryBoiler
LanguageEnglish

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