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R
XEB Series
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2000 Certified Company
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www.dunkirk.com
P/N 14683001 Rev. B [11/09]
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H
TABLE OF CONTENTS
Safety Symbols........................................................................................................................................................2
Installation Instructions .........................................................................................................................................3
Boiler Ratings And Capacities ................................................................................................................................3
Before You Start ......................................................................................................................................................4
Locating The Boiler .................................................................................................................................................5
Fresh Air For Combustion .......................................................................................................................................6
Installation System Piping .................................................................................................................................. 10
Chimney & Vent Pipe Connection ....................................................................................................................... 12
Horizontal Venting Instructions ....................................................................................................................... 15
Optional Horizontal Venting Instruction ........................................................................................................... 20
Gas supply Piping ................................................................................................................................................ 21
Electrical Wiring ................................................................................................................................................... 22
Sequence of Operation ........................................................................................................................................ 22
Wiring Diagrams .................................................................................................................................................. 23
Equipment & Optional Accessories .................................................................................................................... 24
Starting Your Boiler ............................................................................................................................................. 26
Checking and Adjusting ...................................................................................................................................... 27
Initial Operational Boiler Test Check-Out Procedure ........................................................................................ 29
Maintaining Your Boiler ...................................................................................................................................... 31
Service Hints......................................................................................................................................................... 32
NOTICE
IMPORTANT: Read the following instructions COMPLETELY before installing!
Keep this manual near boiler and retain for future reference.
NOTICE
SAFETY SYMBOLS
e following dened symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.
DANGER
Indicates an imminently hazardous situation which, if not
!
avoided, WILL result in death, serious injury or substantial
property damage.
CAUTION
!
Indicates an imminently hazardous situation which, if not
avoided, may result in injury or property damage.
Indicates an imminently hazardous situation which, if not
!
avoided, may result in death, serious injury or substantial
property damage.
Indicates information which should be followed to ensure
proper installation and operation.
WARNING
NOTICE
Natural gas or Propane
C.S.A. Certied for
Tested for 50 lbs. ASME
Working Pressure
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H
INSTALLATION INSTRUCTIONS
ese instructions must be axed on or adjacent to the boiler.
is boiler cannot be used with all types of chimneys. Read these
instructions carefully before installing.
ese Gas-Fired Hot Water Boilers are low pressure, sectional cast
iron boilers Design Certied by C.S.A. (Canadian Standards Association) for use with Natural and Propane Gases. ey are constructed
and hydrostatically tested for a maximum working pressure of 50 psi
in accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.
BOILER RATINGS AND CAPACITIES
Figure 1 - Boiler Ratings and Capacities
WARNING
Improper installation, adjustment, alteration, service or
!
maintenance can cause injury or property damage. Refer
to this manual. For assistance or information consult a
qualied installer, service agency or the gas supplier.
DESIGN CERTIFIED FOR
NATURAL AND PROPANE GAS
Table 1 -RATINGS NATURAL AND PROPANE GASES
Model
XEB-2 2 42.5 36 31 11 4 3
XEB-3 3 75.0 63 55 14-1/4 4 3
XEB-4 4 112.5 94 82 17-1/2 4 3
XEB-5 5 150.0 125 109 20-3/4 4 3
XEB-6 6 187.5 155 135 24 4 4
XEB-7 7 225.0 186 162 27-1/4 4 4
* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only . U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate
of 4% for each 1,000 feet above sea level. Canada Only - Boilers may be used at high altitude by using a certied eld conversion kit, resulting in a 10% de-rate.
+ Heating Capacity based on D.O.E. (Department of Energy) test procedure.
Number of
Sections
AGA/CGA
Input *MBH
Heating
Capacity *MBH+
Net IBR
Rating *MBH
Width
A
Vent Diameter (Inches)
To Chimney
(Category I)
Horizontal Vent
(Category III)
New York City MEA Number 484-84-E Vol. IV.
e Ratings marked “Net I=B=R Ratings” indicate the amount of remaining heat input that can be used to heat the radiation or terminal
units. e Net I=B=R Ratings shown are based on an allowance of
1.15 in accordance with the factors shown on the I=B=R Standard as
published by e Hydronics Institute.
Selection of boiler size should be based upon “Net I=B=R Rating”
being equal to or greater than the calculated heat loss of the building.
e manufacturer should be consulted before selecting a boiler for
installations having unusual piping and pickup requirements.
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BOILER RATINGS & CAPACITIES
ese boilers must stand on a noncombustible oor. If installed on
a combustible oor, please refer to the Repair Parts manual for the
appropriate Combustible Floor Base part number.
ese Gas-Fired Hot Water Boilers are low pressure, sectional cast
iron boilers Design Certied by CSA (Canadian Standards Association) for use with Natural and Propane Gases. ey are constructed
and hydrostatically tested for a maximum working pressure of 50psi
(pounds per square inch) in accordance with A.S.M.E. (American
Society of Mechanical Engineers) Boiler and Pressure Vessel Code
Section IV Standards for cast iron heating boilers.
Boilers For Use At High Altitude
is boiler is factory equipped for use at altitudes of 0-2,000 feet
above sea level. For use at altitudes above 2,000 feet above sea level,
the input ratings are reduced by a change in main burner orice size.
U.S.A. Only - For altitudes above 2,000 feet above sea level, input
ratings should be reduced at the rate of 4% for each 1,000 feet above
BEFORE YOU START
sea level. Consult the National Fuel Gas Code (NFPA54/ANSI
Z223.1-latest revision), or the manufacturer for correct orice sizing information. High altitude orices are available from the boiler
manufacturer.
Canada Only - For altitudes in the range of 2,000-4,500 feet above
sea level, boilers may be eld equipped for use at high altitude by
using a certied eld conversion kit. e change in main burner
orice size results in the boiler’s input rating being reduced by 10%.
e conversion shall be carried out by a manufacturer’s authorized
representative, in accordance with the requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in
accordance with the requirements of the CSA-B149.1 and CSAB149.2 Installation Codes. e certied eld conversion kit includes
a conversion data plate, which must be attached to the boiler adjacent to the rating plate, indicating that the boiler has been converted
for high altitude use. e conversion data plate must be lled in with
the correct conversion information.
Check to be sure you have the right size boiler before starting the
installation. See rating and capacity table on previous page. Also be
sure the new boiler is for the type of gas you are using. Check the
rating plate on the right side of the boiler.
Verify that the boiler is supplied with the correct type of gas, fresh air
for combustion, and a suitable electrical supply. Also, the boiler must
be connected to a suitable chimney or horizontal venting system and
an adequate piping system. Finally, a thermostat, properly located, is
needed for control of the heating system. If you have any doubts as
to the various requirements, check with local authorities and obtain
professional help where needed. Take the time to complete all of the
steps for SAFE and PROPER operation of the heating system.
If this boiler is installed in a building under construction, special
care must be taken to insure a clean combustion air supply during the construction process. Airborne particulates such as from
drywall dust and from berglass insulation can clog the burner ports
and cause incomplete combustion and sooting. Where required by
the authority having jurisdiction, the installation must conform to
American Society of Mechanical Engineers Safety Code for Controls
and Safety Devices for Automatically Fired Boilers, No. CSD-1.
e installation must 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-latest revision.
In Canada, the boiler shall be installed according to CSA-B149.1 and
.2, Installation Code for Gas Burning Appliances and Equipment.
NOTICE
Installers - Follow local regulations with respect to installation of CO detectors. Follow maintenance recommendations in this instruction manual.
NOTICE
Keep boiler area clean and free from combustible materials, gasoline and other ammable vapors and liquids
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LOCATING THE BOILER
If the boiler is part of a planned heating system, locate it where
shown on your plan. If boiler is to be part of an existing system, it
is usually best to put it where the old one was. If you plan to change
location, you will need additional materials as well as an adequate
base. e following rules apply:
1.
e boiler must be level. Metal shims may be used under base
legs for nal leveling.
2.
Use a raised base if oor can become wet or damp.
e vent pipe connection should be as short as possible.
3.
Additional clearances for service may exceed clearances for re
4.
protection. Always comply with the minimum re protection
clearances shown on the boiler. An 18 inch clearance should
be maintained on any side where passage is required to access
for cleaning, servicing, inspection or replacement of any part
that may need attention. An 18 inch clearance is recommended
on the control side for servicing.
Figure 2
and Table 2 shows
minimum clearances to combustible construction. Consult the
National Fuel Gas Code for further information.
5.
Equipment shall be installed in a location in which the facilities
for ventilation permit satisfactory combustion of gas, proper
venting, and maintenance of ambient temperature at safe limits
under normal conditions of use. Equipment shall be located so
as not to interfere with proper circulation of air. When normal
inltration does not provide the necessary air, outside air shall
be introduced (see “Fresh Air for Combustion”).
6.
Advise owner to keep air passages free of obstructions. Ventilating and combustion air must enter boiler room without
restrictions.
7.
e oor supporting the boiler must be noncombustible. If it is
combustible, please refer to Repair Parts List for the appropriate
Combustible Floor Base part number. We use a 2” Cladlite pad
as a combustible oor base. ese are available from your local
supplier. Use 24” x 30” pad for 2-5 section boilers, and a minimum 30” x 30” pad for 6-7 sections boilers. e boiler must be
centered on the combustible oor base.
8.
e boiler shall be installed such that the automatic gas ignition
system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc..)
Figure 2 - Minimum Clearances To Combustible
Construction
8”
Control Side
Rear
Boiler
18”
Front
6”
Opposite Side
6”
Table 2 - BOILER MINIMUM CLEARANCE TO COMBUSTIBLES
Unit Minimum Clearances
Top 6”
Rear 6”
Control Side 8”
Opposite Side 6”
Front (Alcove) 18”
Flue/Vent Connector 6”
Near Boiler Piping 1”
This unit must be set on a concrete or other noncombustible material base
or oor. IT MUST NOT BE INSTALLED ON CARPETING.
NOTICE
is unit must be set on a concrete or other noncombustible material base or oor. It must not be installed on
carpeting.
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FRESH AIR FOR COMBUSTION
NOTICE
Provision for combustion and ventilation air must be
in accordance with the National Fuel Gas Code, ANSI
Z223.1- latest revision, or applicable provisions of the local
building codes.
WARNING
Be sure to provide enough fresh air for combustion.
!
Enough air insures proper combustion and assures that no
hazard will develop due to the lack of oxygen.
You must provide for enough fresh air to assure proper combustion.
e re in the boiler uses oxygen. It must have a continuous supply.
e air in a house contains only enough oxygen to supply the burner
for a short time. Outside air must enter the house to replace that
used by the burner. Study following examples 1 and 2 to determine
your fresh air requirements.
NOTICE
If you use a replace or a kitchen or bathroom exhaust fan,
you should install an outside air intake. ese devices will
rob the boiler and water heater of combustion air.
Sizing Air/Ventilation Openings
NOTICE
Air openings must be sized to handle all appliances and
air movers (exhaust fans, etc.) using the air supply. For
air openings into spaces containing other appliances in
addition to the boiler refer to the National Fuel Gas Code,
ANSI Z223.1 for sizing.
If No Other Gas Appliances In The Same Space
Provide air openings into the boiler space as described in this section and the National Fuel Gas Code, ANSI Z223.1. Direct exhaust
installations require air for combustion and ventilation. Direct vent
installations may require air openings for ventilation (to prevent
overheating of boiler controls and boiler space).
When Other Gas Appliances Share the Same Space
For air openings into spaces containing other appliances in addition
to the boiler refer to the National Fuel Gas Code, ANSI Z223.1 for
sizing.
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FRESH AIR FOR COMBUSTION
EXAMPLE 1: Boiler Located In Unconned Space
An unconned space is dened as a space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (non-partitioned basement) in a conventional house, the air that leaks through the cracks around doors and
windows will usually be adequate to provide air for combustion. e doors should not t tightly. Do not caulk the cracks around the windows.
NOTICE
Equipment located in buildings of tight construction shall be provided with air for combustion, ventilation, and dilution of ue
gases using the methods described in example 2 (below) or shall be specially engineered. e authority having jurisdiction must
approve specially engineered installations. A building of tight construction is dened as: 1) walls exposed to the outdoor atmosphere have a continuous water vapor retarder with a rating of one perm or less with openings gasketed or sealed; and 2) openable
windows and doors which meet the air leakage requirements of the International Energy Conservation Code, Section 502.1.4; and
3) caulking or sealants are applied to areas such as joints around window and door frames, between sole plates and oors, between
wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, and at other openings.
EXAMPLE 2: Boiler Located in Conned Space
All Air from Inside the Building:1.
an additional room(s) of sucient volume so that the combined volume of all spaces meets the criteria for an unconned space. e
total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Each opening shall have a minimum free area of one square inch per 1,000 Btu per hour of the total input rating of all gas utilization equipment in
the conned space, but not less that 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the
bottom of the enclosure. e minimum dimension of air openings shall not be less than 3 inches (see
e conned space shall be provided with two permanent openings communicating directly with
Figure 3A
).
Figure 3A - Boiler Located in Conned Space
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FRESH AIR FOR COMBUSTION
All Air from Outdoors:2.
e conned space shall communicate with the outdoors in accordance with Methods A or B below. e
minimum dimension of air openings shall not be less than 3 in. Where ducts are used, they shall be of the same cross-sectional area as
the free area of the openings to which they connect.
Method A: Two permanent openings, one commencing within 12 inches of the top, and one commencing within 12 inches of the bot-
tom, of the enclosure shall be provided. e openings shall communicate directly, or by the ducts, with the outdoors or spaces (crawl or
attic) that freely communicate with the outdoors.
Where directly communicating with the outdoors (see 1.
(see
Figure 3C
Figure 3B
), each opening shall have a minimum free area of 1 sq. in. per 4000 Btu per hour of total input rating of all equip-
) or where communicating to the outdoors through vertical ducts
ment in the enclosure.
Figure 3B - Directly Communicating to the Outdoors
Figure 3C - Vertical Ducts Communicating to the Outdoors
FRESH AIR DUCT CAPACITIES (1 Square inch per 4,000 Btuh)
Fresh Air
Duct Size
3” x 12” 144,000 108,000 36,000
8” x 8” 256,000 192,000 64,000
8” x 12” 384,000 288,000 96,000
8 ½” x 16” 512,000 384,000 128,000
Louver Allowance
e free areas of openings means the area aer reduction for any installed louvers or grilles. Be
sure to consider this reduction when sizing the air openings.
see Figures - 3B and 3C
100% Free Area
1/4” Wire Mesh
Table 3
75% Free Area
Metal Louvers
8
25% Free Area
Wood Louvers
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FRESH AIR FOR COMBUSTION
Where communicating with the outdoors through horizontal ducts (see 2.
of 1 area of sq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure.
Figure 3D - Horizontal Ducts Communicating to the Outdoors
Figure 3D
), each opening shall have a minimum free area
Table 4
FRESH AIR DUCT CAPACITIES (1 Square inch per 2,000 Btuh)
see Figure 3D
Fresh Air
Duct Size
3” x 12” 72,000 54,000 18,000
8” x 8” 128,000 96,000 32,000
8” x 12” 192,000 144,000 48,000
8 ½” x 16” 256,000 192,000 64,000
100% Free Area
1/4” Wire Mesh
75% Free Area
Metal Louvers
25% Free Area
Wood Louvers
Louver Allowance
e free areas of openings means the area aer reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.
Method B: One permanent opening commencing within 12 inches of the top of the enclosure shall be permitted where the equipment has
clearance of at least 1 inch from the sides and back and 6 inches from the front of the appliance. e opening shall directly communicate
with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or to a crawl space or attic that freely communicate with the out doors, and shall have a minimum free area of:
1 sq. inch per 3000 Btu per hour of the total input of all equipment located in the enclosure (see chart below).1.
Not less than the sum of the areas of all vent connectors in the conned space.2.
Table 5
FRESH AIR DUCT CAPACITIES (1 Square inch per 3,000 Btuh)
Fresh Air
Duct Size
3” x 12” 108,000 81,000 27,000
8” x 8” 192,000 144,000 48,000
8” x 12” 288,000 216,000 72,000
8 ½” x 16” 384,000 288,000 96,000
100% Free Area
1/4” Wire Mesh
75% Free Area
Metal Louvers
25% Free Area
Wood Louvers
Louver Allowance
e free areas of openings means the area aer reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.
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INSTALLATION SYSTEM PIPING
WARNING
To avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation, a discharge
line shall be installed to relief valve outlet connection.
e discharge line shall:
connect to relief valve outlet and piped down to safe point of disposal.•
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 shuto 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;•
or greater.•
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.
Place boiler in the selected location (as near chimney as pos-
1.
sible). Your boiler is shipped assembled. You need only to
install the circulator, ball valves, the relief valve with a drain line
to carry any water to a drain, and the drain valve.
2.
Install relief valve on 3/4” pipe nipple in tapped boiler opening.
Pipe the discharge line following guidelines in the preceding
Warning. Refer to example shown in Figure 4. e discharge
line pipe size shall be equal or greater than that of the relief
valve outlet over the entire length of discharge line with no
intervening shuto valve between the safety relief valve and discharge to atmosphere. e discharge line shall terminate with
a plain end to atmosphere where any discharge will be clearly
visible and is at no risk of freezing. e discharge line shall be
independently supported to avoid applied stress on the relief
valve. e installation shall allow complete drainage of the
relief valve and the discharge line. e discharge line shall be as
short and straight as possible and constructed of a material suitable for exposure to temperatures of 375° F or greater.
Refer to local codes and appropriate ASME Boiler and Pressure
3.
Vessel Code for additional installation requirements.
4.
Install Drain Valve on lower le side of boiler as marked.
Install Temperature and Pressure Gauge into ¼” bushing
5.
threaded in tee furnished with supply piping See
and 6
).
6.
Connect Supply and Return Lines to boiler, as shown in
ures 5 and 6. e connections may require certain additional
ttings and parts.
Figures 5
Fig-
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Figure 4 - Relief Valve Discharge Piping
RELIEF VALVE
DISCHARGE
PIPING
Check local codes
for maximum
distance from
oor or other al-
lowable safe point
of discharge
INSTALLATION SYSTEM PIPING
Figure 6 - Forced Hot Water Typical Piping With Zone
Control Valve
Figure 5 -
Forced Hot Water Typical Piping
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INSTALLATION SYSTEM PIPING
If you are installing an entire new heating system, rst install all of
your radiation units (panels, radiators or cabinets) and the Supply
and Return Mains - then make the connections at the boiler.
In connecting the cold water supply to the water valve, make sure
that a clean water supply is available. When the water supply is from
a well or pump, a sand strainer should be installed at the pump.
A hot water boiler installed above radiation level must be equipped
with a low water cuto device. A periodic inspection is necessary, as
is ushing of oat type devices, per manufacturers specic instructions.
When the boiler is used in connection with refrigeration systems
it shall be installed so that the chilled medium is piped in parallel
with the heating boiler with appropriate valves to prevent the chilled
medium from entering the heating boiler (
If the boiler is connected to heating coils located in air handling
units where they may be exposed to refrigerated air circulation, the
piping system shall be equipped with ow control valves or other
automatic means to prevent gravity circulation of the boiler water
during the cooling cycle.
Figure 7
).
Low Design Water Temperature Systems (Below 140° F)
And Large Water Content Systems:
WARNING
Signicant condensation may form in this boiler and/or
!
the venting system if the boiler is operated with return
temperatures of less than 120° F.
is condensation is corrosive and can eventually cause severe damage to the boiler and venting system. e minimum design return
water temperature to prevent this condensation in the boiler and
venting is 120°F. e minimum high limit setting is 140°F.
If the boiler is to be used in a heating system where design water
temperatures below 140°F are desired (e.g. radiant oor heating),
a 3-way or 4-way mixing valve or suitable alternative is required
to prevent low temperature return water from entering the boiler.
When using a mixing valve, follow the manufacturer’s installation
instructions.
If the boiler is to be connected to a system having a large water content (such as a former gravity system), it is suggested to use bypass
piping shown in
Figure 8
.
Figure 7 - Piping Arrangements For Boiler When Used In
Connection With Refrigeration System
Figure 8 - Bypass Piping
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CHIMNEY & VENT PIPE CONNECTION
NOTICE
For boilers for connection to gas vents or chimneys, vent
installations shall be in accordance with the National Fuel
Gas Code, ANSI Z223.1- latest revision and applicable
provisions of the local building codes.
Check Your Chimney
is is a very important part of your heating system. It must be
clean, the right size, properly constructed and in GOOD CONDITION. No boiler can function properly with a bad chimney.
1.
Use local codes for installation or National Fuel Gas Code
Z223.1-latest revision. In Canada, follow CSA B149.1 or .2
Installation Codes. It is very important to properly size the
venting system for induced dra appliances. Consult the Vent
Sizing Tables, in the National Fuel Gas Code ANSI Z223.1latest revision for correct sizing information. In Canada, consult
the Vent Sizing Tables, Amendment #1 to CSA-B149.1 and .2
Installation Codes.
2.
e boiler’s induced dra blower has a 3” outlet. A 3” X 4”
increaser tting is included in the parts bag. Locate the increaser tting on the outlet of the induced dra blower, and
secure gastight with a bead of the furnished silicone sealant. e
increaser tting is required on this boiler for Category I venting,
and 4” is the minimum permissible vent diameter. is does
not imply that the vent connector is intended to be 4” diameter pipe. e vent connector shall be sized according to the
appropriate venting tables in the National Fuel Gas Code or the
Canadian Installation Codes, and may be required to be larger
than 4” diameter.
NOTICE
e boiler installation for chimney venting is not complete
unless the 3” x 4” increaser tting is located and secured.
ese are high eciency boilers with a low stack or exhaust
3.
temperature.
4.
If venting into a masonry chimney without a liner, line the
chimney from top to bottom with either:
Listed Type B vent pipe A.
Listed exible vent linerB.
Poured ceramic liner. C.
5.
Outside chimneys should not be used unless they are (choose
one of the following):
Enclosed in a chaseA.
Lined with Type B vent pipeB.
Use a listed exible vent linerC.
Use a certied chimney lining systemD.
6.
e vent connector from the boiler to the chimney should run
as directly as possible with as few elbows as possible.
7.
Where possible, it is recommended to common vent the water
heater and boiler. Consult the appropriate Vent Sizing Tables in
either the National Fuel Gas Code, or the Canadian Installation
Codes for specic requirements of multiple appliance venting.
8.
If the boiler is the only appliance connected to the vent, Type B
vent pipe is recommended for the vent connector.
9.
Slope pipe up from boiler to chimney not less than 1/4” per
foot.
10.
End of vent pipe must be ush with the inside face of the chimney ue. Use a sealed-in thimble for the chimney connection.
11.
e sections of vent pipe should be fastened with sheet metal
screws to make the piping rigid. Use stovepipe wires to support
the pipe from above.
12.
Do not connect to replace ue.
Do not install a damper on this boiler.
13.
Minimum Vent Pipe Clearance
If the vent pipe must go through a crawl space, Type B vent pipe
should be used. Where vent pipe passes through a combustible wall
or partition, use a ventilated metal thimble. e thimble should be 4
inches larger in diameter than the vent pipe.
If boiler is installed with single wall vent, it must have a 6” clearance between its surface and any combustible material. A new Type
B gas vent or exible liner must be installed in accordance with the
instructions furnished with the vent. Maintain clearances as specied for the vent pipe.
Check the vent pipe to see if it is re-stopped where it goes through
the oor or ceiling. It should have an approved vent cap with clearances from the roof as shown in
than shown in
For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with the National Fuel Gas Code, ANSI
Z223.1-latest revision and applicable provisions of the local building
codes. In Canada, follow CSA B149.1 or .2 Installation Codes.
Vent connectors serving appliances vented by natural dra shall not
be connected into any portion of mechanical dra systems operating
under positive pressure.
Figure 9
Figure 9
, have the vent checked by local authorities.
. If clearances are less
Removing Existing Boiler From Common Venting System
When an existing boiler is removed from a common venting system,
the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps shall
be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliance
remaining connected to the common venting system are not in
operation.
1.
Seal any unused openings in the common venting system.
Visually inspect the venting system for proper size and hori-
2.
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Page 14
Liner
Chimney
Thimble
Vent System
Cleanout
Boiler
Boiler
Water Heater
Chimney
Figure 9 - Type B Gas Vent
CHIMNEY & VENT PIPE CONNECTION
CHECK YOUR CHIMNEY
is is a very important part of your heating system.
It must be clean, the right size, properly constructed
and in GOOD CONDITION. No boiler can function
properly with a bad chimney. Use local codes for installation or National Fuel Gas Code Z223.1-latest revision.
In Canada, follow CSA B149.1 or .2 Installation Codes.
It is very important to properly size the venting system
for induced dra appliances. Consult the Vent Sizing
Tables, in the National Fuel Gas Code ANSI Z223.1latest revision for correct sizing information. In Canada,
consult the Vent Sizing Tables, Amendment #1 to CSAB149.1 and .2 Installation Codes.
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CHIMNEY & VENT PIPE CONNECTION
zontal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deciencies which could cause an
unsafe condition.
3.
Insofar as is practical, close all building doors and windows and
all doors between the space in which the appliances remaining
connected to the common venting system are located and other
spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom exhausts,
so they will operate at maximum speed. Close replace dampers.
4.
Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust thermostat so appliance will operate
continuously.
5.
Test for spillage at the hood relief opening aer 5 minutes of
main burner operation.
6.
Aer it has been determined that each appliance remaining con-
nected to the common venting system properly vents when tested
as outlined above, return doors, windows, exhaust fans, replace
dampers and any other gas-burning appliance to their previous
conditions of use.
7.
Any improper operation of the common venting system should
be corrected so the installation conforms with the National
Fuel Gas Code, ANSI Z223.1-latest revision. When resizing any
portion of the common venting system, the common venting
system should be resized to approach the minimum size as
determined using the appropriate tables in the National Fuel
Gas Code, ANSI Z223.1-latest revision. In Canada, follow CSA
B149.1 or.2 Installation Codes.
NOTICE
NOTE: It is recommended that existing gas vents be
checked to be sure they meet local codes.
15
Page 16
HORIZONTAL VENTING INSTRUCTIONS
INDUCED DRAFT HIGH EFFICIENCY BOILERS
Maximum Horizontal Vent Length For Stainless Steel Vent Pipe - 30’
Plus One 90º Elbow Plus Vent Terminal.
Minimum Horizontal Vent Length - 2’ Plus One 90º Elbow Vent
Termination.
Additional elbows are equivalent to 6 feet of straight pipe for 4” diameter 90° elbow or 3 feet of straight pipe for 3” diameter 90° elbow.
2, 3, 4, 5, Section Boilers use 3” vent pipe; for 6, 7 Section Boilers use
4” vent pipe.
Figure 10 - Induced Draft High Eciency boilers
CHOICE OF VENT PIPE MATERIAL
U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe.
1.
U. L. Listed Heat-Fab Saf-T-Vent Stainless Steel Vent Pipe.
2.
U. L. Listed Flex-L Star-34 Stainless Steel Vent Pipe.
3.
U. L. Listed ProTech Systems FasNSeal Stainless Steel Vent Pipe.
4.
16
Page 17
HORIZONTAL VENTING INSTRUCTIONS
ese boilers may be vented horizontally as shown in
1.
Figure 10
. e vent pipe is pitched
down
from the boiler to
the vent termination. Do not connect other appliances to this
vent.
Vent Pipe Material:
2.
UL Listed Z-Flex Z-Vent stainless steel vent pipe from A.
boiler to vent termination,
-or-
UL Listed Heat-FabSaf-T-Vent stainless steel vent pipe B.
from boiler to vent termination,
-or-
UL Listed Flex-L StaR-34 stainless steel vent pipe from C.
boiler to vent termination,
6.
Vent Termination Fitting:
For all vent pipe materials, you may
use either:
A 90° elbow pointing down, tted with a minimum 1/4” A.
mesh screen to keep out rodents and birds. e elbow shall
be of the same material and size as vent pipe. e elbow
exit should be at least 6” away from exterior wall as shown
Figure 10
in
.
-or-
Tjernlund VH-1 Series side wall vent hood. For 2, 3, 4, 5 B.
section boilers use VH-1-3”, For 6, 7 section boilers use
VH-1-4”.
7. (Figure 10)
Vent Pipe Termination Location
:
-or-
UL Listed ProTech FasNSeal stainless steel vent pipe from D.
boiler to vent termination.
Clearance to Combustible Materials:
3.
For stainless steel vent
pipe maintain 6” minimum air space clearance to combustible
materials.
4.
Vent Pipe Size:
2, 3, 4 and 5 section boilers use 3” vent pipe connected A.
directly to the outlet of the induced dra blower.
6 and 7 section boilers use 4” vent pipe, starting with a 3” B.
to 4” stainless steel vent pipe transition that is connected
directly to the outlet of the induced dra blower. Do not
use 3” vent pipe on 6 or 7 section boilers.
5.
Vent Pipe Length:
For stainless steel vent pipe, the maximum horizontal vent A.
length is 30 feet plus one 90
°
elbow plus termination tting.
Minimum horizontal vent length for all vent materials is 2 B.
feet plus one 90° elbow plus termination tting.
For additional elbows reduce the maximum vent length as C.
shown:
3” - 90° elbow - reduce vent length 3 feet per each 3” elbow•
4” - 90° elbow - reduce vent length 6 feet per each 4” elbow •
When venting through combustible walls, combustible A.
clearances must be considered. e VH-1 Side wall vent
hood provides both the outside vent termination and a
double wall pipe for passing through a combustible wall
up to 8” thick (VH-1-4”) or 9” thick (VH-1-3”). e hole
in the wall must be 6¼” square for 3” vent pipe and 7 1/2”
square for 4” vent pipe, in order to insert the VH-1 side
wall vent hood. e VH-1 may also be used in noncombustible walls.
If the 90° elbow is the termination tting of choice, then B.
the single wall pipe will be passing through the side wall.
For combustible walls, a UL listed thimble shall be used
where the single wall pipe passes through the wall. For
combustible walls using Z-Vent, Saf-T-Vent, or StaR-34
vent pipe, use the following:
3” vent pipe - use Simpson’s Duravent 3” thimble •
4” vent pipe - use Simpson’s Duravent 4” thimble. Maxi-•
mum wall thickness with this thimble is 7 inches.
For combustible walls using ProTech FasNSeal where the single wall
vent pipe must pass through the side wall, a UL Listed FasNSeal wall
thimble shall be used.
e thimble is adjustable for dierent wall thickness, with a maximum wall thickness of 7 inches. Seal the thimble along the outside
edge of the plate with caulk or silicone and fasten to the wall with
screws or nails.
Example:
6 section boiler has 3 elbows plus the termination tting.
is means 2 additional 4” elbows will be used, at 6 feet per elbow.
is is equivalent to 12 feet of pipe (2 x 6 =12), therefore maximum
vent length is now 18 feet (30 -12 =18).
For single wall pipe through non-combustible walls, the C.
hole through the wall need only be large enough to maintain the pitch of the vent pipe, and provide proper sealing. A thimble is not required for single wall pipe passing
through noncombustible walls.
e venting system shall terminate at least 3 feet above D.
any forced air inlet located within 10 feet. e vent-
17
Page 18
HORIZONTAL VENTING INSTRUCTIONS
Figure 11 - Horizontal Venting Clearances
ing system shall terminate at least 4 feet below, 4 feet
horizontally from, or 1 foot above any door, window,
or gravity air inlet into any building. e bottom of
the vent shall be located at least 12 inches above grade.
Termination of the vent shall be not less than 7 feet above
an adjacent public walkway. e vent terminal shall not be
installed closer than 3 feet from the inside corner of an L
shaped structure. Termination of the vent should be kept
at least 3 feet away from vegetation. e venting system
shall terminate at least 4 feet horizontally from, and in no
case above or below, unless a 4 foot horizontal distance is
maintained, from electric meters, gas meters, regulators,
and relief equipment.
e venting system shall terminate at least 4 feet below any E.
eve, sot, or roof overhang.
e venting system shall not terminate underneath any F.
deck, patio, or similar structure.
Put vent on a wall away from the prevailing winter wind. G.
(See Figure 11)
8.
Locate or guard the vent to prevent accidental contact with
people or pets.
Terminate the vent above normal snow-line. Avoid loca-H.
tions where snow may dri and block the vent. Ice or snow
may cause the boiler to shut down if the vent becomes
obstructed.
Under certain conditions, ue gas will condense, forming I.
moisture. In such cases, steps should be taken to prevent
building materials at the vent terminal from being damaged by exhaust of ue gas.
Joining and Sealing the Vent Pipe:
e vent pipe needs to be both watertight and gastight. Seal all
joints and seams as follows:
For Z-Flex Z-Vent stainless steel vent pipe use a high tem-A.
perature silicone sealant rated for 550°F. e outside of the
male end and inside of the female end of the pipe must be
c l e a n e d w i t h b r a k e c l e a n e r b e f o r e a p p l y i n g s i l i c o n e b e a d .
18
Page 19
HORIZONTAL VENTING INSTRUCTIONS
For 3” vent pipe runs begin with the male end of the vent
pipe over the boilers induced dra blower outlet. For 4”
vent pipe runs begin with a 6” length of 3” Z-Vent over the
boiler’s induced dra blower outlet, to which an even bead
of high temperature silicone sealant should be applied.
en connect the 3” Z-Vent to a Z-Vent 3” to 4” reducer.
en continue the 4” Z-Vent pipe run by connecting the
4” male end of the Z-Vent to the reducer. (A locking band
may be used around this joint for additional support.) en
following the sealing instructions, push the 4” male end of
the Z-Vent over the 4” increaser tting. When using the
Tjernlund VH-1 vent hood, the female end (ared end) of
the vent pipe will be connected to the termination hood.
e male end of the vent hood must be crimped before
pushing the Z-Vent over the vent hood’s connecting pipe.
Before the pipes are joined, apply a ¼” bead of silicone one
inch from the end of the male end. en push the pipes
together as far as they will go making sure any seams are
aligned and oriented upward. Now apply another bead of
silicone around this joint and smooth out. en use a ZFlex locking band around the center of the joint.
Apply the high temperature silicone approximately one 1.
inch from the end, around the male end of the pipe in
an even ¼” bead.
Pipes can now be pushed together as far as they will 2.
go. e seams on pipe should be aligned and oriented
upward in all horizontal appliances. Apply another bead
of silicone around this joint and smooth out.
Slide locking band over center of joint and tighten gear 3.
clamps. Make sure locking band is centered on joint.
Check all joints and seams for gas tightness.4.
Horizontal venting shall have a slope not less than ¼” 5.
(6.4mm) every 12 inches (305mm) downward away
from the boiler to prevent collection of condensate
throughout the assembly.
to which an even bead of high temperature silicone sealant
should be applied. en continue the 4” Saf-T-Vent pipe
run by connecting the 4” male end of the Saf-T-Vent to the
increaser. (A locking band may be used around this joint
for additional support.) e vent ow must be in the direction indicated on the vent pipe. When using the Tjernlund
VH-1 vent hood, the female end (ared end) of the vent
pipe will be connected to the termination hood. Apply high
temperature silicone in an even ¼” bead approximately ¼”
to ⅜” from the end of the vent hood’s connecting vent pipe.
Also, run a similar size bead of silicone sealant down the
seam weld of the vent pipe. en push the female end over
the vent hood’s connecting vent pipe.
Apply the high temperature silicone around the male 1.
end of the pipe (without the tabs) in an even ¼” bead.
Silicone bead should be approximately ¼” to ⅜” from
the end of the male end. Also, run a similar size bead of
silicone sealant down the seam weld at the end of each
joint.
Pipes can now be pushed together as far as they will 2.
go. e seams on the vent pipe should be aligned and
oriented upward in all horizontal appliances. With a
moistened nger or at tool, spread any sealant that
squeezes out around the circumference of the joint.
Attach the sections together with the locking rings and 3.
tabs (except at the blower outlet where no locking ring
exists.) Inspect the joint to ensure that ue gases will
not leak. If necessary apply additional sealant around
the joint.
Horizontal venting shall have a slope not less than ¼” 4.
(6.4mm) every 12 inches (305mm) downward away
from the boiler to prevent collection of condensate
throughout the assembly.
Allow the sealant to cure for 24 hours before operating 5.
the appliance.
Allow the sealant to cure for 24 hours before operating 6.
the appliance.
For Heat-Fab Saf-T-Vent stainless steel vent pipe use B.
a high temperature silicone sealant rated for 550°F
e outside of the male end and inside of the female
end of the pipe must be cleaned before applying the
silicone bead. For 3” vent pipe runs, the male end of
the vent pipe which goes over the outlet of the boiler’s
induced dra blower must be crimped. e vent pipe
should be crimped as minimal as possible to provide
a tight t over the outlet. Aer crimping is completed
f o l l o w t h e i n s t r u c t i o n s f o r a p p l y i n g s i l i c o n e s e a l a n t .
For 4” vent pipe runs, begin with a Saf-T-Vent 3” to 4” increaser tting over the boiler’s induced dra blower outlet,
For Flex-L StaR-34 stainless steel vent pipe use a high C.
temperature silicone sealant rated for 550°F. Before applying silicone, the outside of the male end and inside of the
female end of the pipe must be cleaned using a cleaner,
such as methyl ethyl ketone (MEK) or naptha. For 3”
vent pipe runs, begin with the male end of the vent pipe
over the boiler’s induced dra blower outlet. For 4” vent
pipe runs begin with a StaR-34 3” to 4” increaser tting
over the boiler’s induced dra blower outlet. For both
3” and 4” vent pipe runs, apply a bead of silicone sealant around the blower outlet and around the inside of
t h e m a l e e n d o f v e n t p i p e g o i n g o v e r t h e b l o w e r ’ s o u t l e t .
When using the Tjernlund VH-1 vent hood,the
female end (ared end) of the vent pipe
w i l l b e c o n n e c t e d t o t h e t e r m i n a t i o n h o o d .
19
Page 20
HORIZONTAL VENTING INSTRUCTIONS
Apply high temperature silicone in an even ¼” bead approximately ¼” from the end of the vent hood’s connecting
vent pipe. Also, run a similar size bead of silicone sealant
down the seam weld of the vent pipe. en push the female
end over the vent hood’s connecting vent pipe. Now ll in
the channel inlet with silicone sealant. Do not try to insert
the joiner band, instead fasten the vent pipe to the vent
hood’s pipe with a steel gear clamp.
Apply the high temperature silicone around the male 1.
end of the pipe in an even ¼” bead. Silicone bead
should be approximately ¼” from the end of the male
end. Also, run a similar size bead of silicone sealant
down the seam weld at the end of each joint.
e seams on the vent pipe should be aligned and ori-2.
ented upward in all horizontal vent pipe runs.
Insert the male end of one into the female end of the 3.
other. Push the pipe together so the female end rests up
against the stop bead of the male end.
Insert a StaR-Joiner Band into the inlet of the beaded 4.
channel. Feed the Joiner Band in so it makes its way
around the pipe, back to the channel inlet and it overlaps itself by about ½”.
Cut the excess Joiner Band so it lays at in the beaded 5.
channel. Fill the inlet of the beaded channel with high
temperature silicone. Smooth out the silicone over the
channel inlet and the silicone between the female end
and the stop bead of the male end.
Horizontal venting shall have a slope not less than ¼” 6.
(6.4mm) every 12 inches (305mm) downward away
from the boiler to prevent collection of condensate
throughout the assembly.
9.
Allow the sealant to cure for 24 hours before operating 7.
the appliance.
For ProTech Systems FasNSeal stainless steel vent pipe D.
no cleaning uid is required. For 3” vent pipe runs on 2,
3, 4 and 5 section boilers, begin by locating the FasNSeal
Ametek Adapter over the boiler’s induced dra blower.
C o n t i n u e t h e v e n t p i p e r u n w i t h 3 ” F a s N S e a l v e n t p i p e .
For 6 and 7 section boilers, begin by locating the FasNSeal
Ametek Adapter over the boiler’s induced dra blower.
en connect a FasNSeal 3” to 4” increaser to the 3”
adapter outlet. Continue the vent pipe run with 4” FasNSeal
vent pipe. Other than the Ametek Adapter and increaser
tting, DO NOT use 3” vent pipe on 6 or 7 section boilers.
FasNSeal vent pipe is joined and sealed by the use of an
internal sealing gasket and a locking band on the female
end of each vent pipe. All components should be examined
for possible shipping damage prior to installation. Align
all vent pipe seams and orient upward in all horizontal
applications. Adjustable vent lengths are available for 4”
diameter vent piping. For 3” diameter vent piping, square
cut male end at the desired length. For 2, 3, 4 and 5 section
boilers using the VH-1-3” vent hood, connect the FasNSeal
Vent to the VH-1-3” vent hood using FasNSeal Adapter
# F S C - D U N - 3 . i s a d a p t e r h a s n o i n t e r n a l s e a l i n g g a s k e t .
To attach the adapter to the vent hood, crimp the 3” vent
hood pipe, apply a ¼” bead of high temperature silicone
sealant around the outside of the vent hood’s crimped
connecting pipe and a similar bead of high temperature
silicone around the inside of the FasNSeal adapter. Aer
pressing the two pipes together and tightening the locking
band, nish creating a complete seal by lling the FasNSeal
adapter’s notched hole with high temperature silicone.
For 6 and 7 section boilers using the VH-1 - 4” vent hood,
an adapter is not required. e 4” FasNSeal vent pipe connects directly to the VH-1- 4” vent hood, and is joined and
sealed by the internal gasket and locking band.
To join and seal the FasNSeal vent pipe:
Insert male end into female section.1.
Push the units together as far as possible.2.
Firmly tighten locking band with a nut driver.3.
DO NOT penetrate the FasNSeal vent pipe with fasten-4.
ers.
Horizontal venting shall have a slope of not less than 5.
¼” (6.4mm) every 12 inches (305mm) downward away
from the boiler to prevent the collection of condensate
throughout the assembly.
Support Spacing:
Do not restrict thermal expansion movement of the vent. e
vent pipe must expand and contract freely with temperature
change. Each run of vent piping shall be supported as follows:
Z-Flex stainless steel vent piping requires a loose tting A.
metal strap or similar support at each joint at a maximum
of 4 feet between supports.
Heat-Fab stainless steel vent piping requires a support for B.
every 6 feet of horizontal piping run. e support must be
secured using at least #10 fasteners to a solid material (solid
masonry or wood framing or blocking.) Do not fasten to
drywall sheathing using hollow wall anchors. Each support will be 1½ inch lower than the previous support when
spaced 6 feet apart.
Flex-L stainless steel vent piping requires a loose tting C.
metal strap or similar support at each joint at a maximum
of 4 feet between supports.
ProTech stainless steel vent piping requires one loose t-D.
ting FasNSeal support strap for every 6’ of horizontal vent.
20
Page 21
HORIZONTAL VENTING INSTRUCTIONS
If the horizontal vent must go through a crawl space or other
10.
unheated space, the cool temperatures will likely cause the ue
gases to continuously condense inside the vent pipe. Do not
insulate the vent pipe. It must be visible for monthly inspection. Insure that the vent pipe is properly pitched away from
the boiler, with no low spots, so that condensate in the vent will
drain away from the boiler. An insulated enclosure or chase,
with access for inspection and servicing of the vent, may be
OPTIONAL HORIZONTAL VENTING INSTRUCTION
required to prevent freezing of liquid condensate. Consult the
vent pipe manufacturer’s instructions for specic guidelines.
11.
At the beginning of each heating season and monthly during
the heating season, check all vent pipes and the vent terminal
to make sure there are no obstructions. Periodically clean the
screen in the vent terminal.
Horizontal venting with a power venter is an alternate method of
sidewall venting. is boiler is CSA listed for sidewall venting with
standard single wall galvanized or Type B vent pipe when using the
following power venter kits, which were specically sized for these
boilers:
Table 6
Number Of
Boiler Sections
2, 3, 4, 5 SWG-4D
6, 7 SWG-5D
Field Controls
Power Venter
Some possible reasons for using a power venter for sidewall venting:
1.
May be preferred by local codes.
Need a vent piping run beyond 30’ (but not more than 50’).
2.
e boiler installation site experiences gusting or high winds. A
3.
power venter can help prevent the boiler from short cycling due
to gusting or high winds by providing vent exhaust pressures
greater than the boiler’s induced dra blower alone.
4.
When installers or homeowners prefer a negative pressure vent
system instead of a positive pressure vent system.
5.
May be more cost eective than stainless steel
venting, particularly at longer vent lengths.
e Field Controls power vent kit includes either a SWG-II4HD or SWG-II-5 power venter, a MG-1 4” barometric dra
controller, and the CK-43D controls kit.
Conrm that installing a power venter is an option allowed by local
codes. Follow the specic power venter installation instructions
issued with the power venter kits. Although the power venter is
equipped with its own fan, the fan on the boiler remains in place and
is unaltered when a power venter is used.
When sidewall venting, ue gases must be vented to a point in relation to the prevailing wind so that they may freely disperse without
being blown back at the building causing discoloration, or into the
building through doors or windows causing odors. Also, under certain conditions ue gases will condense, forming moisture. In such
cases, steps should be taken to prevent building materials at the vent
terminal from being damaged by the exhausted ue gas.
When installing single wall galvanized vent pipe for power venting
follow the specic power venter installation instructions for layout,
location of the barometric dra control and termination connections.
When joining and sealing the single wall galvanized or Type B vent
piping, use RTV silicone sealant with a minimum temperature rating
of 400°F. For 3” vent pipe runs, begin with the female end of the vent
pipe over the boiler’s induced dra blower outlet. For 4” vent pipe
runs begin with the galvanized 3” to 4” increaser tting (included in
the boiler’s parts bag) over the induced dra blower outlet. en follow by placing the female end of the 4” vent pipe over the increaser
tting.
When joining pieces of single wall galvanized vent pipe, a substantial bead of silicone should be used at the joint to insure a leakproof
connection.
21
Page 22
GAS SUPPLY PIPING
Sediment
Trap
Manifold
Floor Line
Automatic
Gas Valve
Ground
Joint
Union
Connecting The Gas Piping
Refer to
basic ttings you will need. e gas line enters the boiler from the
right side. Flexible gas connectors must never breach any boiler
openings.
Figure 12
for the general layout at the boiler. It shows the
Figure 12 - GAS PIPING AT BOILER
!
WARNING
Never use a match or open ame to test for leaks.
Two-stage regulation should be used by the propane installer.
9.
Propane gas piping should be checked out by the propane
10.
installer.
Checking The Gas Piping
Upon completion of piping, check right away for gas leaks. Open
the manual shut-o valve. Test for leaks by applying soap suds (or
a liquid detergent) to each joint. Bubbles forming indicate a leak.
CORRECT EVEN THE SMALLEST LEAK AT ONCE.
Check Gas Supply
e gas pipe to your boiler must be the correct size for the length
of the run and for the total BTU per hour input of all gas utilization
equipment connected to it.
Be sure your gas line complies with local codes and gas company
requirements.
See Gas Table 8
for the proper size.
Table 7
PRESSURE
NATURAL PROPANE
GAS
MIN. SUPPLY 5" w.c. 11" w.c.
MAX. SUPPLY 14" w.c. 14" w.c.
MANIFOLD 3.5" w.c. 10" w.c.
e following rules apply:
1.
Use only those piping materials and joining methods listed
as acceptable by the authority having jurisdiction, or in the
absence of such requirements, by the National Fuel Gas Code,
ANSI Z223.1- latest revision. In Canada, follow the CSA B149.1
and .2 Installation Codes for Gas Burning Appliances and
Equipment.
2.
All pipe compound must be resistant to liqueed petroleum gas.
Install ground joint union in gas supply line between shut-o
3.
valve and boiler controls.
4.
Install a sediment trap upstream of gas controls.
Use two pipe wrenches when making the connection to the gas
5.
valve to keep it from turning.
6.
Install manual shut-o valve in vertical pipe about 5 feet above
oor.
7.
Tighten all joints securely.
Propane gas connections should only be made by a licensed
8.
propane installer.
Table 8a - NATURAL GAS
Length of
Pipe - Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
½" ¾" 1" 1¼"
20 92,000 190,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000
Table 8b - PROPANE GAS
Pipe Capacity - BTU Per Hour Input
Length of
Pipe - Ft.
Copper Tubing* Iron Pipe
Includes Fittings
⅝" ¾" ½" ¾"
20 131,000 216,000 189,000 393,000
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000
*Outside diameter:
e length of pipe or tubing should be measured from the gas meter or propane
second stage regulator.
e boiler and its individual shuto valve must be disconnected
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of ½ Psig (3.5 kPa).
e boiler must be isolated from the gas supply piping system by
closing its individual manual shuto valve during any pressure testing of the gas supply piping system at test pressures equal to or less
than ½ Psig (3.5 kPa).
22
Page 23
ELECTRICAL WIRING
All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision. In Canada,
electrical wiring shall comply with the Canadian Electrical Code,
CSA-C22.1.
WARNING
!
Turn o electric power at fuse box before making any line
voltage connections. Follow local electrical codes.
Electric Power Supply
Run a separate 120 volt circuit from a separate over current protective device in the electrical service entrance panel. is should be a
15 ampere circuit. Locate a shut-o switch at the boiler. It must be
turned o during any maintenance. Connect 120 volt power supply
to aquastat terminals L1 (HOT) and L2.
e boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or,
in the absence of such requirements, with the National Electrical
Code, ANSI/NFPA No. 70 - latest revision. Run a 14 gauge or heavier
copper wire from the boiler to a grounded connection in the service
panel or a properly driven and electrically grounded ground rod.
CAUTION
Label all wires prior to disconnection when servicing
!
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation aer servicing.
Install Your Thermostat
e thermostat location has an important eect on the operation of
your boiler system. BE SURE TO FOLLOW THE INSTRUCTIONS
INCLUDED WITH YOUR THERMOSTAT. Locate the thermostat about ve feet (5’) above the oor on an inside wall. It may be
mounted directly on the wall or on a vertically mounted outlet box.
It should be sensing average room temperature.
THERMOSTAT LOCATIONS TO AVOID
DEAD SPOTS HOT SPOTS COLD SPOTS
Behind doors
Corners &
alcoves
Concealed pipes
Fireplace
TV sets Stairwells - dras
Radios Doors - dras
Lamps
Direct sunlight
Kitchens
Concealed pipes
or ducts
Unheated room on
other side of wall
SEQUENCE OF OPERATION
Sequence of Operation - Refer to Figure 13
ermostat calls for heat, powering the 1K relay coil and closing
1.
contacts 1K1 and 1K2.
2.
Circulator pump is powered through terminals C1 and C2.
Induced dra blower and transformer primary are powered
3.
through terminals B1 and B2.
4.
When blower gets up to speed and blower suction pressure
reaches pressure switch set point, pressure switch contacts close
sending 24 volts to intermittent pilot control from transformer
secondary.
5.
Pilot gas valve opens and spark initiates to light pilot burner.
When pilot ame is proven, spark drops out.
6.
Main gas valve opens and pilot burner ignites main burners.
7.
Set heat anticipator at .2 amps. e 24 volt thermostat connects
to aquastat terminals T and T.
If boiler water temperature reaches high limit set point, high
8.
limit contacts B-R open, cutting power to blower and intermittent pilot control. Burners extinguish and blower stops. Circulator pump continues to run as long as the thermostat continues
to call for heat. When boiler water temperature drops past the
high limit set point and through the dierential, high limit
contacts B-R close, repeating steps 3-7.
9.
If venting system becomes blocked, blower suction pressure will
drop below the pressure switch set point, opening the pressure
switch contacts and cutting power to the intermittent pilot control. Burners will extinguish, but blower will remain powered
as long as the thermostat continues to call for heat. If venting
system clears, steps 4-7 will repeat.
10.
ermostat is satised, ending call for heat. Relay coil 1K is deenergized, opening 1K1 and 1K2 contacts. Burners extinguish.
Blower and circulator pump stop.
23
Page 24
ELECTRICAL WIRING DIAGRAMS FOR
INDUCED DRAFT HOT WATER BOILERS
B1
CIRCULATOR
B
C1
B
C2
W
HOT
FUSED
DISCONNECT
R
B
3
L1
L2
T
NEUT
POWER SUPPLY
120/60/1
24V
LOW VOLTAGE FIELD WIRING
BK
GND.
BK
PV/MV
SWITCH
PRESSURE
ROLLOUT
SWITCH
W
R
G
PV
MV
W
G
R
BK
TO PILOT
VR8204A / VR8304M
GAS VALVE
BT
BL
AT 140C TRANSFORMER
BT
B2
MV/PV
INTERMITTENT PILOT CONTROL
MV
(24V)
PV
GND.
L8148A
T
DRAFT
BLUE
(GND.)
(24V)
SPARK
BL
R RED
LOW VOLTAGE WIRING
LINE VOLTAGE WIRING
BLACK WITH TRACER
GREEN
WHITE
BLACK
BT
W
G
B
G
G
B
W
W
B
INDUCER
AQUASTAT
THERMOSTAT
BURNER
1K
(24V)
(24V)
(GND)
INTERMITTENT
PILOT CONTROL
PRESSURE
SWITCH
1K1
HIGH LIMIT
B1
R
B
3
1K2
T
AT 140C TRANSFORMER
24 V SECONDARY
SWITCH
ROLLOUT
24 V SECONDARY
120V PRIMARY
24 V THERMOSTAT
C1
T
CIRCULATOR
DRAFT INDUCER
FUSED
DISCONNECT
L1
HOT
120/60/1 POWER SUPPLY
120 V PRIMARY
TO GAS
VALVE
B2
C2
L2
NEUT
G
B
W
B
W
G
B
W
B
BT
WIRING DIAGRAMS
Figure #13 - Intermittent Ignition
NOTICE
If any of the original wire as supplied with this appliance
must be replaced, it must be replaced with type 105° C
thermoplastic wire or its equivalent.
NOTICE
NOTE: e circulator harness is factory wired to the
aquastat. is harness needs to be connected to the circulator in the eld.
24
Page 25
EQUIPMENT & OPTIONAL ACCESSORIES
Relief Valve
You must have a relief valve on your boiler. Water expands as it is
heated. If there is no place for the water to expand into, water pressure will build up inside the boiler and system. Should this happen,
the Relief Valve will automatically open at a pre-determined pressure. is will relieve the strain on the boiler and system. Run a pipe
from the relief valve outlet (pipe must be same size as outlet and the
open end must not be threaded) to an open drain, tub or sink, or
other suitable drainage point not subject to freezing. Failure to do so
may cause water damage or injury should relief valve release.
Expansion Tank
In a properly assembled system, the expanding water ows into an
Expansion Tank. is tank should be of the correct size.
e tank is partially lled with air. As the water expands it compresses the air in the tank to form an air pressure cushion. is “springlike” cushion serves to maintain correct operating water pressure
regardless of water temperature. is assures a “full measure” of water, even in the highest radiation unit of the system. It also prevents
blowing o of the relief valve.
e air in the tank in the beginning (with system lled with cold water) is sucient for proper operation. e tank also serves as a trap
for excess air in the system. e air would cause gurgling in the pipes
and inecient circulation in the radiators if le in the system.
It is possible for a tank to become “waterlogged” (lled with water).
It can also become overlled with air. is can happen aer lling
the system with new water. Fittings provided on the tank and in the
line to the tank are for bleeding o excess water or air.
When installing this tank, it is important:
1) at the tank be higher than the boiler top.
2) at the pipe to the tank continuously rises up to the tank (so that
air can “bubble” up to it).
Diaphragm Type Expansion Tank
e Diaphragm Type Expansion Tank (EX-TROL) takes the place
of the conventional expansion tank. Carefully read the instructions
packed with your EX-TROL Tank Assembly. e EX-TROL Tank
comes to you with a 10-12 pounds per square inch air charge. is is
the same as the pressure produced in the system by the automatic ll
valve. When the system is rst lled, the EX-TROL Tank will contain
little or no water.
As the water is heated its pressure increases. It expands into the EXTROL Tank, compressing the air in the tank. is compressed air
cushion permits the water in the system to expand as the temperature changes.
Air Eliminating Fitting (Air Purger)
An Air Purger is used to remove excess air from the system. It is installed in the supply line. It will help to eliminate air from the water
before it reaches the radiators and bleed o this air.
Main Air Vent For Down Flow Systems Or Diaphragm Type
Expansion Tank
Before a system is lled with water, there is air in the pipes and
radiation units. Some of it will be trapped as the system is lled. It
is possible to eliminate most of this air through the air vents on the
radiation units. A Main Air Vent will speed and simplify this. It
should be installed on the highest point in the main when all radiation is below top of boiler.
Automatic Fill Valve
For safe, ecient operation, a hot water system must be lled with
water. Adding new water, when needed can be done manually (by
use of a hand valve in the water supply line). is requires regular attention to the system’s needs. An Automatic Fill Valve accomplishes
this without attention. It is installed in the Supply Line on hot water
boilers only. e Valve operates through water pressure dierentials.
It does not require an electrical connection.
Drain Valve
is manual valve provides a means of draining all water from the
boiler and system. It is oen installed in the ¾” Tapping at the bottom of the le boiler section. Or it can be installed in a tee where the
return line enters the boiler.
Water Temperature Control
e water temperature limit control in the relay is adjustable and
may be set as necessary. It may be set as low as 140° F, or as high as
240° F. is depends on the type and amount of radiation involved
and weather conditions.
Circulating Pump
Every Forced Hot-Water System requires a Circulating Pump. A
separate pump or zone valve is required for each Zone, if you have
a two or more Zone System. is pump must have the capacity to
provide the circulation required by your system.
e pump does not come pre-installed on the boiler. It must be connected to the circulator harness in the eld according to the pump
manufacturer’s instructions and the wiring diagrams in this manual.
25
Page 26
EQUIPMENT & OPTIONAL ACCESSORIES
Blower (Draft Inducer)
e blower provides a means for pulling air through the boiler and
exhausting the ue gasses into the vent system. e blower shuts o
when the burners are not ring. is keeps heat in the house rather
than having it go up the chimney.
Pressure Switch
e air pressure switch works on a negative pressure. When the
blower comes on the air pressure switch operates the intermittent pilot and gas valve. e air pressure switch is factory set and will only
work when the blower operates properly. It will not allow the boiler
to come on if the blower does not generate enough pressure or if the
venting system is blocked.
Factory Pressure Switch Set point:
-0.4” wc. for 2-5 section boilers.
-0.5” w.c. for 6-7 section boilers.
Rollout Switch
(Flame Rollout Safety Shuto)
e rollout switch is a temperature-sensitive fuse link device. It is located on the boiler base just outside the re box. In the event of heat
exchanger ueway blockage causing ame to roll out of the re box,
the fuse will blow, shutting down the ow of gas to the main burners.
e fuse does not change in appearance when blown.
If the rollout switch blows, it must be replaced with an exact replacement. Check heat exchanger ueways for blockage when restoring
system to operating condition. Do not operate system without a
rollout switch.
26
Page 27
STARTING YOUR BOILER
How A Hot Water System Operates
Your entire heating system (boiler, piping and radiation units) is
lled with water. As the water in the boiler is heated, it is pumped
from the top of the boiler through the supply main to the radiation units. e cooler water in them ows back through the return
main to the boiler. is provides positive and rapid response to the
thermostat.
Filling System With Water
Close the Air Vents on all radiation units. Open the Valves to these
units. Make sure the boiler and Expansion Tank Drain Cocks are
closed. e Air Bleed Screw on the tank Drain Fitting should be
closed. Open the valve in the line from the boiler to the expansion
tank. Open the water inlet to your boiler and leave it open. Start with
the lowest radiation unit. Open the air vent on this unit. When all
the air has escaped and water starts to ow from the vent, close it.
Go to the next radiation unit, and repeat this process. Repeat until
you have covered every radiation unit in the system (ending up at
the highest unit in the system). If your units have automatic vents,
this manual venting is unnecessary but it will speed up the proper
lling of your system.
If your system is a closed expansion tank system, you may have an
Automatic Fill Valve. You may leave it open to rell the system automatically as needed. Check the temperature-pressure gauge. Note
the position of the hand indicating pressure. is should be between
10 and 15 lbs. Any lowering of this movable hand below 10 lbs. will
indicate loss of water due to leakage. e automatic ll valve should
compensate for this. Instructions are packaged with the valve.
!
WARNING
Never run water into a hot empty boiler.
WARNING
is appliance is equipped with an ignition device which
automatically lights the burner. Do not attempt to light the
burner by hand.
If you do not follow these instructions exactly, re or explosion may result with property damage, personal injury,
or loss of life.
BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the oor because some gas
is heavier than air and will settle on the oor.
IF YOU SMELL GAS:
1.
!
Do not attempt to operate any appliance, do not
touch any electrical switch, do not use the phone.
2.
Leave the building immediately and call your gas
supplier.
3.
If your gas supplier cannot be reached, call the re
department.
When turning or depressing the gas control knob, use only
your hand to push down or turn the knob. Never use tools.
If the knob will not operate by hand, the control must be
replaced by a qualied service technician. Force or attempted repair may result in a re or explosion.
If any part of this appliance has been under water, do not
operate. Immediately call a qualied service technician
to inspect the appliance and to replace any part of the gas
control system which has been under water.
27
Page 28
OFF
ON
INLET
GAS CONTROL KNOB
SHOWN IN "ON" POSITION
STARTING YOUR BOILER
Operating Instructions.
Set the thermostat to lowest setting.
1.
Turn o all electric power to the appliance.
2.
is appliance is equipped with an ignition device which auto-
3.
matically lights the burner. Do not attempt to light the burner
by hand.
4.
Remove burner access panel.
Depress gas control knob slightly and turn clockwise
5.
“OFF” position.
Figure 14 - Gas Control Knob
to
WARNING
Wait ve (5) minutes to allow any gas in the combustion
chamber to vent. If you then smell gas in the appliance
area or near the oor, do not touch any electrical switch,
!
do not use the phone. Leave the building immediately
and call your gas supplier. If your gas supplier cannot be
reached, call the re department. Failure to do so may
result in a re or explosion. If you don’t smell gas, go to
next step.
6.
Turn gas control knob counterclockwise
7.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
8.
Aer visually inspecting the ame, replace the lower front
9.
to “ON.”
panel.
WARNING
If the appliance will not operate aer several tries, turn the
!
gas control knob to “OFF” and call your service technician
or gas supplier.
NOTICE
NOTE: Knob cannot be turned to “OFF” unless knob is
depressed slightly. Do not force.
CHECKING AND ADJUSTING
Gas Valve Safety Shutdown Test
With main burners ring, disconnect the ignition cable from the
intermittent pilot control box. e gas valve should shut o the main
burners. TURN OFF ELECTRIC POWER to boiler before reconnecting ignition cable, to prevent electric shock.
Adjust Pilot Burner
Remove screw cover over pilot adjusting screw.
1.
Insert small screwdriver and adjust ame as needed (
2. Figure
. Turn screw counterclockwise to increase ame,
#16
clockwise to decrease (
3.
Replace screw cover over pilot adjusting screw.
Figure #17
).
To Turn O Appliance:
Set the thermostat to lowest setting.
1.
Turn o all electric power to the appliance if servicing is to be
2.
performed.
3.
Depress gas control knob slightly and turn clockwise
to
“OFF” position. Do not force.
Main Burner(S)
e main burners do not require primary air adjustment and are not
equipped with primary air shutters. Main burner ames should form
sharp blue inner cones in a soer blue outer mantel, with no yellow.
Pus of air from blowing on the ame or stamping on the oor will
cause the ames to turn orange momentarily. is is not unusual. Re-
main still when observing the main burner ames. Refer to
#17
. If the ame appearance is not correct, check main burner orices and the burner throat and ame ports for dust and lint obstruction. It may be necessary to remove the rollout shield to observe the
main burner ames. Replace rollout shield aer observation.
Figure
28
Page 29
CHECKING AND ADJUSTING
Adjust Limit Controls
Instructions for each control are included with the controls.
Recommended Boiler Water Temperatures
Type of Heating Unit Limit Control Setting
Standing Radiators......................................... 180° F
Baseboard and Convector Radiators............. 180° F
ese settings can be changed aer you have had some idea how the
system works. Example: If your system does not give quite enough heat in
very cold weather, you can raise the limit setting to 190°F.
Adjust Thermostat Heat Anticipator
INSTRUCTIONS FOR THE FINAL ADJUSTMENT
OF THE THERMOSTAT ARE PACKAGED WITH
THE THERMOSTAT.
Set Heat anticipator at .2.
4.
Check thermostat operation. When set above temperature indi-
5.
cated on the thermometer, boiler burners should ignite. Make
certain the thermostat turns o the boiler when room temperature reaches the selected setting and starts the boiler operating
when room temperature falls a few degrees. Aer setting limit
control to desired setting, check to see if it shuts o the gas supply to the burners.
6.
Turn your thermostat up to call for heat and let your boiler run
until the temperature of the water reaches the limit setting. e
gas valve should shut o and the circulator keep running until
the thermostat is satised, or the water cools enough to restart
the burners through the limit control.
7.
To check the operation of the contacts in the pressure switch,
disconnect the rubber tubing (located between the blower and
the pressure switch) from the pressure switch, while the boiler is
operating. e burners should extinguish and the blower should
keep running. When the tubing is reconnected to the pressure
switch, the ignition sequence should begin, resulting in ignition
of the main burners.
8.
Finally, set the thermostat for the desired temperature. Special
conditions in your home and the location of the thermostat will
govern this setting.
Safe lighting and other performance criteria were met with the gas
manifold and control assembly provided on the boiler when the
boiler underwent tests specied in ANSI Z21.13-latest revision.
Figure 15 - PILOT FLAME ADJUSTMENT
Flame
on
Sensor
Figure 16 -AUTOMATIC GAS VALVE
Figure 17 - Main Burner Flame
e main burner ame should form a
sharp blue inner mantel with no yellow.
Burners
A visual check of the pilot and main burner ames should be made at
least once each year, preferably at the beginning of the heating season.
See
Figures 15, and 17
.
29
Page 30
INITIAL OPERATIONAL BOILER TEST CHECKOUT PROCEDURE
XEB Series Cast Iron Gas-Fired Cast Iron Boilers
☑ Check o each step as completed.
☐ Verify base insulation is securely fastened to base panels.
☐ Verify air purged from hydronic heating system.
☐ Purge air from gas piping; check gas piping for leaks.
☐ Verify proper orices have been installed.
☐ Follow lighting instructions in series XEB installation, operation and maintenance manual furnished with
boiler.
☐ Visually check the main burner ame and verify it has a well dened inner blue mantel with a lighter blue
outer mantel.
☐ Inspect vent system to verify it is functional, unobstructed, and not leaking.
☐ Test the temperature limit control: With burner operating, adjust indicator on limit control below actual boiler
water temperature. Verify burners turn o. Verify the circulator continues to operate. Adjust the indicator on
limit control above actual boiler water temperature and verify burners reignite.
☐ Test any additional eld-installed controls. If boiler has a low water cut-o or additional high limit, test for
operation as outlined by the controls manufacturer. Burners should be operating and should go o when
controls are tested. When controls are reset, burners should reignite.
☐ Test safety control circuit: with main burner operating, disconnect the ignition cable from the intermittent
pilot control box. Verify that the main gas control closes, shutting o the gas to the main burner. Aer verify
ing safety control circuit, turn o electric power and reconnect ignition cable. Once ignition cable securely
reset to intermittent pilot control box, turn electric power on.
☐ For multiple heating system zones, balance ow through each zone so that it is about equal per zone.
☐ Verify several operating cycles of proper operation.
☐ Measure gas input:
Natural Gas Procedure
☐ Operate boiler for 10 minutes.
☐ Turn o all other gas appliances piped with the
boiler.
☐ At the gas meter, measure the cubic feet of gas
used in 10 seconds (CF10).
☐ Calculate input: BTUh = CF10 x 360,000
☐ Verify the BTUh is approximate to the input
rating on the boiler rating plate.
LP Gas Procedure
☐ LP gas input rate is determined by measuring gases
produced during combustion. Refer to Boiler Manual
for combustion guidelines and corresponding BTU
input.
☐ Verify the BTUh is approximate to the input rating on
the boiler rating plate.
☐ Record the BTUh input on the OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
☐ Set operating control (thermostat(s)) to the desired design requirement.
☐ Forward boiler manuals, instructions, wiring diagrams, piping diagrams, and supporting information shipped
with this boiler to owner and/or maintenance personnel.
☐ Complete and sign the INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
30
Page 31
INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT
Boiler Manufacturer:
Dunkirk Boilers
85 Middle Road
Boiler Identication:
Model #: _______________________________________________
Serial #:
________________________________________________
Dunkirk, NY 14048
Measured BTUH input: _____________________ Operational Test Date: ________ /________ /_________
☐ Installation Instructions in the XEB Installation, Operation and Maintenance Manual have been followed.
☐ Initial Operational Boiler Test Check-Out Procedure has been performed.
☐ Information on this form is certied to be correct.
☐ All boiler instructions, wiring diagrams, piping diagrams, and supporting information shipped with this boiler
forwarded to owner/maintenance personnel.
Installation Location:
Customer Name: __________________________________________________________________________
Address: _________________________________________________________________________________
City: ________________________________________________ State: ________ Zip: ___________________
Installer Information
Company/Contractor: ______________________________________________________________________
Address: _________________________________________________________________________________
City: ________________________________________________ State: ________ Zip: ___________________
Telephone #: _____________________________________________________________________________
Installer’s Signature ___________________________________ Date: ________ /________ /_________
Installer’s Printed Name: ___________________________________________
31
Page 32
MAINTAINING YOUR BOILER
Relief Valve
is valve should open automatically if the system pressure exceeds
the pressure rating (usually 30 psi) of the relief valve. Should it ever
fail to open under this condition, shut down your system. Drain
the system until system pressure is reduced below the relief valve
pressure rating. If valve discharge occurs, or if valve fails to open
as described above, contact an authorized contractor or qualied
service technician to replace the relief valve and inspect the heating
system to determine the cause, as this may indicate an equipment
malfunction.
is valve should be tested every month during periods of boiler
operation, and at the beginning and end of any extended non-service
period. Prior to testing, make certain discharge pipe is properly
connected to valve outlet and arranged so as to contain and safely
dispose of boiler discharge. Test at normal system operating pressure. Hold the trip lever fully open for at least ve seconds in order
to ush free any sediment that may lodge on the valve seat. en
permit the valve to snap shut.
Expansion Tank
As previously noted, this tank may become waterlogged, or may receive an excess of air. Frequent automatic opening of the relief valve
indicates water logging. A high boiler temperature accompanied by
unusually low radiation unit temperature (and “knocking”) indicates
excess air in tank. To correct either condition, close the valve between the boiler and the tank. Drain the tank until it is empty. Check
all the tank plugs and ttings. Tighten as necessary. Open the valve
between the boiler and tank. Water will rise to the normal height in
the tank if you have an automatic ll valve (otherwise, manually rell
the system).
Vent Pipe
e venting of this unit is very important and the piping should be
checked at least once a month. If the vent piping shows any sign of
leaking, replace it immediately.
Water System
If system is to remain out of service during freezing weather, always
drain it completely (water le in to freeze will crack the pipes and/or
boiler).
Cleaning Your Boiler And Burners
Flue passages between sections should be examined yearly and
cleaned if necessary.
To clean, remove burners, pilot and vent pipe. Remove top and front
jacket panels. Split the silicone seal on the ue collector and the
clean out plates with a razor knife. Remove ue collector. Remove
clean out plates by tapping upwards on the bottom of the plate with a
hammer. Remove loose silicone sealant from sections, ue collector,
and clean out plates.
Clean passageways between sections with a exible handle wire
brush and a straightened out wire coat hanger. Remove dirt from the
bottom of the boiler and from between sections by vacuuming.
Make sure all ame ports in burners are open and clear. Shake out
or blow out all loose dirt in burners. Reassemble all parts. Seal ue
collector and clean out plates to sections with silicone sealant (400° F
RTV silicone sealant or equivalent). Reseal seams between adjacent
sections where necessary. All joints must be airtight. Be sure to check
tightness of pilot connections and condition of burner ames aer
reassembly (see
tions to chimney are secure and no obstructions are present.
Figures 15, and 17
). Be sure vent pipe connec-
Boiler Flue Passages
Under normal operating conditions, with the burners properly
adjusted, it should not be necessary to clean the boiler ue gas passages. However, to assure trouble-free operation, we recommend that
you have the ue passages, burner adjustment, and operation of the
controls checked once each year by a competent Service Technician.
Before The Start Of Each Season
(or whenever system has been shut down for some time) recheck the
whole system for leaks . . . and recheck the boiler and vent pipe for
leaks. Replace or patch any boiler seals that are faulty.
Blower
e blower motor features a permanently lubricated ball bearing
construction. Lubrication is not required.
Circulator Pump Isolation Valves
e isolation valves in the circulator pump anges should be operated manually once or twice per year to prevent the valves from becoming stuck in the open position. Rotate the valves from the open
position to the closed position and back to the open position.
32
Page 33
SERVICE HINTS
You may avoid inconvenience and service calls by checking these points before you call for service:
WARNING
WHAT TO DO IF YOU SMELL GAS
Do Not try to light any appliance.
!
Do not touch any electric switch, do not use the phone or any mobile electronics. ese actions may create a spark and cause ignition.
Leave the building immediately, then call your gas supplier.
If you cannot reach the gas supplier, call the re department.
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
POSSIBLE CAUSE WHAT TO DO
ermostat is not set correctly Reset thermostat
Check ame. If it is yellow, the burner is not getting enough air. Or, if ame is blue
Burner is not operating properly
and noisy and seems to li o the burner, the burner is getting too much air. Contact
your service technician.
No electric power to boiler
Controls out of adjustment Reset according to instructions.
Radiators not heating
Circulating pump not running Check overcurrent protection. Check relay operation.
Poor electrical contact Check all control terminals and wire joints.
Chimney ue is blocked
Rollout switch blown
Check over-current protection. Check to be sure electric power supply circuit is
“ O N ”.
Open radiator vents to excess air. Check ow control valve (if used). It may be in
closed position.
Pressure switch will not close and pilot spark will not operate to start pilot. Have
your service technician check and correct, if necessary.
Have your service technician check heat exchanger for blockage. Replace rollout
switch with exact replacement.
IF BURNER IS NOISY . . .
POSSIBLE CAUSE WHAT TO DO
Gas input amount is incorrect Contact your service technician.
RELIEF VALVE LEAKING . . .
POSSIBLE CAUSE WHAT TO DO
Dirt on seat Open valve manually. Allow water to run and clear valve seat.
Water logged expansion tank Drain tank, see instructions.
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU
ARE UNABLE TO CORRECT.
33
Page 34
34
Page 35
35
Page 36
85 Middle Rd.
Dunkirk, NY 14048
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