Dunkirk XEB-7, XEB-5, XEB-6, XEB-4 User Manual

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XEB Series

Gas-FiredHot Water

Induced Draft Boilers

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

DUNKIRK BOILERS

85 Middle Rd.

Dunkirk, NY 14048

www. dunkirk, corn

P/N14683001 Rev.B[11/09]

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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

IMPORTANT:Readthe followinginstructions COM- PLETELYbeforeinstalling!

Keepthis manual near boiler and retainfor future refer- ence.

Thefollowingdefined symbolsareused throughout this manual to notify the reader ofpotential hazards ofvarying risk levels.

Indicates an imminently hazardous situation which, ifnot avoided,WILLresult in death, serious injury or substantial property damage.

Indicates an imminently hazardous situation which, ifnot avoided,may result in injury or property damage.

Indicates an imminently hazardous situation which, ifnot avoided,may result in death, serious injury or substantial property damage.

Indicates information which shouldbe followedto ensure proper installationand operation.

C.S.A. Certified for

Natural gas or Propane

Tested for 50 Ibs. ASME

Working Pressure

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Theseinstructions must be affixedon or adjacent to the boiler.

Thisboiler cannot be usedwith alltypes ofchimneys.Read these instructions carefullybefore installing.

TheseGas-Fired HotWater Boilersare lowpressure, sectionalcast iron boilers Design Certifiedby C.S.A.(Canadian StandardsAssoci- ation) foruse with Natural and Propane Gases.Theyare constructed

and hydrostaticallytested for amaximum workingpressure of 50psi in accordancewith A.S.M.E.Boilerand PressureVesselCode Sec-

tion IV Standardsfor castiron heating boilers.

Figure 1 - Boiler Ratings and Capacities

ASME

R_LIEF

VALVE

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Improper installation, adjustment, alteration, serviceor maintenance can cause injuryor property damage.Refer

to this manual. For assistanceor information consult a qualifiedinstaller,serviceagency or thegas supplier.

\,® .

VALVE

DESIGN CERTIFIED FOR

LeR Si_e Fro_t Right Side

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 = f,O00 Btuh = British Thermal Unit Per Hou_ Boilers areequipped foraltitudes up to 2,000 feet on!_ U.S.A. Only - For altitudes above 2,000 feet, ratings should be reducedat therate

of 4% for each f,O00feet above sealevel. Canada Only -Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10%de-rate. + Heating Capacity based on D.O.E. (Department of Energy) testprocedure.

NATURAt AND PROPANE GAS

New York City MEA Number 484-84-E Vol. IV.

TheRatingsmarked "Net I=B=RRatings"indicate the amount of re- maining heat input that can be usedto heat the radiation or terminal units. The Net I=B=RRatingsshown are based on an allowanceof

1.15in accordancewith thefactors shownon the I=B=RStandard as

publishedby TheHydronicsInstitute.

Selectionofboiler sizeshould be basedupon "NetI=B=RRating"

being equalto or greaterthan the calculated heat lossofthe building.

Themanufacturer shouldbe consulted before selecting a boiler for

installations havingunusual piping and pickup requirements.

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Theseboilers must stand on a noncombustible floor.If installed on a combustiblefloor,pleaserefer to the Repair Parts manual for the

appropriate CombustibleFloor Basepart number. TheseGas-Fired HotWater Boilersare lowpressure, sectionalcast

iron boilers Design Certifiedby CSA(Canadian StandardsAssocia- tion) foruse with Natural and Propane Gases.Theyare constructed

and hydrostaticallytested for amaximum workingpressure of 50psi (pounds per square inch) in accordance with A.S.M.E.(American Societyof Mechanical Engineers)Boilerand PressureVesselCode Section IV Standards forcast iron heating boilers.

Boilers For UseAt High Altitude

Thisboiler is factory equipped for useat altitudesof 0-2,000feet abovesealevel.For useat altitudes above2,000feet abovesea level,

the input ratings arereducedby a change in main burner orificesize.

U.S.A.Only- For altitudesabove2,000feet abovesea level,input ratingsshould be reduced atthe rateof 4% for each 1,000feet above

sealevel.Consult the NationalFuel GasCode (NFPA54/ANSI

Z223.l-latest revision), orthe manufacturer for correct orifice siz-

inginformation. Highaltitude orificesare availablefrom theboiler

manufacturer.

Canada Only - For altitudes in the rangeof2,000-4,500feetabove sealevel,boilers maybe fieldequipped foruse at high altitudeby usinga certified fieldconversion kit.Thechangein main burner

orifice size results in the boiler'sinput rating beingreduced by 10%.

Theconversionshall be carried out by a manufacturer'sauthorized representative,in accordancewith the requirements of the manufac-

turer, provincialor territorial authorities havingjurisdiction and in

accordancewith the requirements of the CSA-B149.1and CSA- B149.2Installation Codes. Thecertifiedfield conversionkit includes

aconversion data plate,which must beattached to the boileradja- centto the ratingplate, indicatingthat the boiler hasbeen converted

for high altitude use.The conversiondata platemust be filledin with the correct conversioninformation.

Checkto be sureyou havethe right sizeboiler beforestarting the installation. Seerating and capacitytable on previous page.Also be sure thenew boileris for thetype of gas youare using. Checkthe rating plateon the right side of the boiler.

Verifythat the boiler is suppliedwith the correct type ofgas,fresh air for combustion,and a suitableelectricalsupply.Also,the boilermust

be connectedto a suitablechimney or horizontal venting systemand an adequatepiping system. Finally,athermostat, properly located,is needed for controlof the heating system.Ifyou haveanydoubts as to the variousrequirements, checkwith localauthorities and obtain professionalhelp whereneeded. Takethe time to completeallof the

stepsfor SAFEand PROPERoperation ofthe heating system. Ifthis boiler is installed in a building under construction, special

caremust be taken to insure a clean combustion air supplydur- ing the construction process.Airborne particulates such asfrom

drywalldust and from fiberglassinsulation can clogthe burner ports and causeincompletecombustion and sooting. Where required by the authority having jurisdiction, theinstallation must conform to American SocietyofMechanicalEngineers SafetyCode for Controls and SafetyDevicesfor AutomaticallyFired Boilers,No. CSD-1.

Theinstallationmust conformto the requirements ofthe authority havingjurisdiction or,in the absence of suchrequirements, to the

NationalFuel GasCode, ANSIZ223.l-latest revision. In Canada,the boiler shallbe installed accordingto CSA-B149.1and

.2,Installation Code for GasBurning Appliancesand Equipment.

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als, gasoline and other flammable vapors and liquids Keep boiler area clean and free from combustible materi-

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Ifthe boiler is part of a planned heatingsystem, locateit where shown on your plan. If boiler isto be part of an existingsystem,it

is usuallybest to put it where the oldone was. Ifyou plan to change location,you willneed additionalmaterials aswellas an adequate base.Thefollowingrules apply:

1. Theboiler must be level.Metal shimsmay be used underbase legsfor finalleveling.

2. Use a raised baseif floor canbecomewet or damp.

3. The vent pipe connection should be asshort aspossible.

4. Additional clearancesfor servicemay exceedclearancesfor fire protection. Alwayscomplywith theminimum fireprotection

clearancesshownon the boiler.An 18inchclearance should bemaintained on anyside where passageisrequired to access

for cleaning,servicing,inspection or replacement ofany part that may need attention. An 18inch clearanceis recommended on the control sidefor servicing. Figure 2 and Table2 shows

minimum clearances to combustible construction. Consult the

National Fuel Gas Code for further information.

5. Equipment shallbe installedin alocation in whichthe facilities forventilation permit satisfactorycombustion ofgas,proper

venting,and maintenance of ambient temperature atsafelimits under normal conditions ofuse. Equipment shallbe located so asnot tointerfere with proper circulation ofair. When normal infiltration doesnot provide the necessaryair, outside airshall beintroduced (see"Fresh Air for Combustion").

6. Adviseowner tokeep airpassagesfree ofobstructions. Ven- tilating and combustion air must enter boiler room without

restrictions.

Thefloorsupporting the boilermust benoncombustible. If itis combustible,pleaserefer to RepairParts Listfor the appropriate Combustible Floor Basepart number. We usea 2" Cladlitepad

asa combustible floorbase. Theseare availablefrom your local supplier. Use24" x30"pad for 2-5 sectionboilers,and amini- mum 30"x 30"pad for 6-7sections boilers. Theboiler must be

centered on the combustible floor base.

Theboilershall be installedsuch that the automatic gasignition systemcomponents are protected from water (dripping, spray- ing,rain, etc.) during applianceoperation and service(circula- tor replacement, control replacement,etc..)

Figure 2 - Minimum Clearances To Combustible

Construction i8,,

_1_ 6 _'

Boiler _ ,_

18"

_ositeSide

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 floor. IT MUST NOT BE INSTALLED ON CARPETING.

Thisunit must be set on a concreteor other noncombus- tiblematerial base or floor.It must not be installed on

carpeting.

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Provisionforcombustionandventilationairmustbe inaccordancewiththeNationalFuelGasCode,ANSI Z223.1-latestrevision,orapplicableprovisionsofthelocal

buildingcodes.

Besuretoprovideenoughfreshairforcombustion. Enoughairinsurespropercombustionandassuresthatno

hazardwilldevelopduetothelackofoxygen.

Youmustprovideforenoughfreshairtoassurepropercombustion. Thefireintheboilerusesoxygen.Itmusthaveacontinuoussupply.

Theairinahousecontainsonlyenoughoxygentosupplytheburner forashorttime.Outsideairmustenterthehousetoreplacethat usedbytheburner.Studyfollowingexamples1and2todetermine

yourfreshairrequirements.

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Ifyou use afireplaceor a kitchen or bathroom exhaustfan, you should installan outside air intake. These deviceswill

rob theboiler and water heater of combustion air.

Sizing Air/Ventilation Openings

Airopenings must be sized to handle allappliances and air movers(exhaust fans,etc.) usingthe air supply.For

air openingsinto spaces containing other appliancesin addition to the boiler referto the NationalFuel GasCode,

ANSIZ223.1for sizing.

If NoOther GasAppliances InThe Same Space

Provide air openings intothe boiler spaceas describedin this sec-

tion and the National FuelGasCode,ANSI Z223.1.Direct exhaust

installationsrequire airfor combustion and ventilation. Directvent installationsmay require air openings for ventilation(to prevent

overheatingof boiler controls and boiler space).

When Other GasAppliances Sharethe Same Space

For airopenings into spaces containing other appliancesin addition

to the boiler referto the NationalFuel GasCode,ANSI Z223.1for

sizing.

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EXAMPLE 1: Boiler Located In Unconfined Space An unconfined space is defined 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. The doors should not fit tightly. Do not caulk the cracks around the win-

dows.

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Equipment located in buildings of tight construction shall be provided with air for combustion, ventilation, and dilution of flue gases using the methods described in example 2 (below) or shall be specially engineered. The authority having jurisdiction must approve specially engineered installations, a building of tight construction is defined as: 1)walls exposed to the outdoor atmo- sphere 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 floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, and at other openings.

EXAMPLE 2: Boiler Located in Confined Space

1. All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination. Eachopen-

ing 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 confined 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. The minimum dimension of air openings shall not be less than 3 inches (see Figure 3A).

Figure 3A - Boiler Located in Confined Space

Chimney

GasVent

Vent Pipe_

) Openings

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All Air from Outdoors: The confined space shall communicate with the outdoors in accordance with Methods A or Bbelow. The 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 12inches of the bot-

tom, of the enclosure shall be provided. The openings shall communicate directly, or by the ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

1. Where directly communicating with the outdoors (see Figure 3B) or where communicating to the outdoors through vertical ducts (see Figure 3C), each opening shall have aminimum free area of 1 sq. in. per 4000 Btu per hour of total input rating of all equip-

ment in the enclosure.

Figure 3B - Directly Communicating to the Outdoors Figure 3C - Vertical Ducts Communicating to the Outdoors

Air

Pipe

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"x16" 512,000 384,000 128,000

Louver Allowance

The free areas of openings means the area after reduction for any installed louvers or grilles. Be sure to consider this reduction when sizing the air openings.

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2. Wherecommunicatingwiththeoutdoorsthroughhorizontalducts(seeFigure 3D), each opening shall have a minimum free area

of 1area ofsq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure.

Figure 3D - Horizontal Ducts Communicating to the Outdoors

Louver Allowance

The free areas of openings means the area after reduction for any installed louvers or grilles. Be sure to consider this reduction when

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"x16" 256,000 192,000 64,000

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 1inch from the sides and back and 6 inches from the front of the appliance. The 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 com- municate with the out doors, and shall have a minimum free area off

1. 1 sq. inch per 3000 Btu per hour of the total input of all equipment located in the enclosure (see chart below).

2. Not less than the sum of the areas of all vent connectors in the confined space.

Louver Allowance

The free areas of openings means the area after reduction for any

3"x12" 108,000 81,000 27,000

8"x 8" 192,000 144,000 48,000

8"x12" 288,000 216,000 72,000

8 ½"x 16" 384,000 288,000 96,000

installed louvers or grilles. Be sure to consider this reduction when sizing the air openings.

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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.

The 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 shutoffvalve between safety relief valve and discharge to atmosphere (do not plug or

place any obstruction in discharge line.

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•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;

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•be independently supported and securely anchored to avoid applied stress on the relief valve;

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

1. Place boiler in the selected location (as near chimney as pos- 3.

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.

Install relief valve on 3/4" pipe nipple in tapped boiler opening. Pipe the discharge line following guidelines in the preceding

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 shutoffvalve between the safety relief valve and dis-

charge to atmosphere. Thedischarge line shall terminate with a plain end to atmosphere where any discharge will be clearly visible and is at no risk of freezing. The discharge line shall be independently supported to avoid applied stress on the relief valve. The installation shall allow complete drainage of the

relief valve and the discharge line. The discharge line shall be as short and straight as possible and constructed of a material suit- able for exposure to temperatures of 375° F or greater.

•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.

Referto localcodes and appropriate ASMEBoilerand Pressure

VesselCode for additional installation requirements.

Install Drain Valveon lowerleftside ofboiler as marked.

Install Temperature and Pressure Gauge into 1A,,bushing

threaded in tee furnished with supply piping See Figures 5

Refer to example shown in Figure 4. The discharge

and 6).

Connect Supply and Return Lines to boiler, as shown in Fig- ures 5 and 6. The connections may require certain additional

fittings and parts.

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Figure 4 - Relief Valve Discharge Piping

RELIEFVALVE

DISCHARGE

PIPING

Check local code_

for maximum distance from

floor or other al-

lowable safe point

of discharge

Figure 6 - Forced Hot Water Typical Piping With Zone Control Valve

ZONE VALVE o,

Figure 5 - Forced Hot Water Typical Piping

MAiN

T_K

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Ifyou areinstalling an entire new heating system,first install allof yourradiation units (panels,radiators or cabinets)andthe Supply

and Return Mains - then make the connections atthe boiler.

In connecting the cold water supply to the water vane, 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 cutoffdevice. A periodic inspection is necessary, as

is flushing of float type devices, per manufacturers specific instruc- tions.

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 vanes to prevent the chilled medium from entering the heating boiler (Figure 7).

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 flow control valves or other automatic means to prevent gravity circulation of the boiler water

during the cooling cycle.

Low Design Water Temperature Systems (Below 140° F)

And Large Water Content Systems:

Significant condensation may form in this boiler and/or the venting system if the boiler is operated with return temperatures of less than 120° E

Thiscondensation is corrosiveand can eventuallycauseseveredam- ageto the boilerand venting system.The minimum designreturn

watertemperature toprevent this condensation in the boilerand venting is 120°ETheminimum high limit setting is 140°E

Ifthe boileris to be usedin aheating systemwheredesign water

temperatures below 140°Faredesired (e.g.radiant floor heating),

a3-wayor 4-waymixingvane or suitablealternative is required

to prevent lowtemperature return waterfrom entering the boiler. When using amixing vane, followthe manufacturer's installation

instructions.

If the boiler is to be connected to a system having a large water con-

tent (such as aformer 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

VALVESA& B_OPENFORHEATmNG;CLOSEDFORCOOLING VALVESC& D- CLOSEDFORHEATING;OPENFORCOOUNG

TOSYSTEM

Figure 8 - Bypass Piping

ReturnFromSystem

Thermometer

Aquastat Water To System

Front

Throttling

Feed

Fi_Rro_With Air Purger

[ Adi_stthe twoth_ttli_g valvesto maintainat leas_i20_F i:ntheboilerreLum

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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.

CheckYour Chimney

Thisis avery important part ofyour heating system.It must be clean,the right size,properly constructed and in GOOD CONDI-

TION.No boiler can function properly with abad chimney.

1. Uselocal codes forinstallation or National Fuel GasCode Z223.l-latest revision.In Canada, followCSAB149.1or .2 Installation Codes.It isvery important to properly sizethe venting systemfor induced draft appliances.Consult the Vent

SizingTables,in the National FuelGas Code ANSIZ223.l- latest revision for correct sizinginformation. In Canada, consult the Vent SizingTables,Amendment #1 toCSA-B149.1and .2

Installation Codes.

2. The boiler's induced draft blower has a 3" outlet. A 3" X 4" increaser fitting is included in the parts bag. Locate the in-

creaser fitting on the outlet of the induced draft blower, and secure gastight with a bead of the furnished silicone sealant. The increaser fitting is required on this boiler for Category I venting, and 4" is the minimum permissible vent diameter. This does

not imply that the vent connector is intended to be 4" diam- eter pipe. The 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.

The boiler installation for chimney venting is not complete unless the Y'x 4" increaser fitting islocated and secured.

Theseare highefficiencyboilers withalow stackor exhaust temperature.

Ifventing into amasonry chimneywithout aliner, linethe chimneyfrom top to bottom with either:

A. ListedType Bvent pipe B. Listedflexiblevent liner

C. Poured ceramicliner.

5. Outside chimneysshould not be used unlessthey are (choose one ofthe following):

A. Enclosedin a chase B. Lined with TypeBvent pipe

C. Usea listedflexiblevent liner D. Usea certified chimney lining system

6. The vent connector from the boiler tothe chimney should run asdirectlyas possiblewith asfewelbowsas possible.

7. Where possible,it is recommended to common vent the water heater andboiler. Consult the appropriate Vent SizingTablesin

either the National FuelGasCode, or the Canadian Installation Codesfor specificrequirements ofmultiple appliance venting.

8. If the boiler isthe onlyappliance connected to the vent, Type B vent pipe is recommended forthe vent connector.

9. Slopepipe up from boiler to chimney not lessthan 1/4"per foot.

10. End ofvent pipe must be flushwith theinside faceof the chim- ney flue.Use asealed-in thimble for the chimney connection.

11. The sections ofvent pipe should be fastenedwith sheetmetal

screwsto make the piping rigid. Use stovepipewires to support

the pipe from above.

12. Do not connect to fireplaceflue.

13. Do not installa damper on this boiler.

Minimum Vent Pipe Clearance If the vent pipe must go through a crawl space, Type Bvent pipe

should be used. Where vent pipe passes through a combustible wall

or partition, use a ventilated metal thimble. The 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" clear-

ance between its surface and any combustible material. A new Type B gas vent or flexible liner must be installed in accordance with the instructions furnished with the vent. Maintain clearances as speci-

fied for the vent pipe.

Check the vent pipe to see if it is fire-stopped where it goes through

the floor or ceiling. It should have an approved vent cap with clear-

ances from the roof as shown in Figure 9. If clearances are less

than shown in Figure 9, have the vent checked by local authorities.

For boilers for connection to gas vents or chimneys, vent installa-

tions shall be in accordance with the National Fuel Gas Code, ANSI Z223. l-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 draft shall not be connected into any portion of mechanical draft systems operating

under positive pressure.

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 vent-

ing 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 com-

mon 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.

2. Visually inspect the venting system for proper size and hori-

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Figure 9 - Type B Gas Vent

Liner

Chimney

Sheet Metal

Vent System

Cleanout

CHECK YOUR CHIMNEY

This 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 instal-

lation or National Fuel Gas Code Z223. l-latest revision. In Canada, follow CSA B149.1 or .2 Installation Codes. It is very important to properly size the venting system

for induced draft appliances. Consult the Vent Sizing Tables, in the National Fuel Gas Code ANSI Z223. l-

latest revision for correct sizing information. In Canada, consult the Vent SizingTables, Amendment # 1to CSA-

B149.1 and.2 Installation Codes.

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Page 15

zontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an

unsafe condition.

Insofar asispractical, closeallbuilding doors and windows and alldoors between the spacein which the appliancesremaining connected to the common venting systemare locatedand other

spacesof the building. Turn on clothesdryers and any appli- ancenot connected to the common venting system.Turn on anyexhaust fans,such as range hoods and bathroom exhausts, so theywill operate at maximum speed. Closefireplacedamp-

ers.

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 after 5minutes of main burner operation.

G. After it has been determined that each appliance remaining con-

nected tothe commonventingsystemproperlyventswhentested

asoutlinedabove,returndoors,windows,exhaustfans,fireplace

dampers andany other gas-burningapplianceto their previous

conditionsof use.

Anyimproper operation of the common venting systemshould be corrected so the installationconforms with the National

FuelGas Code, ANSIZ223.l-latest revision.When resizing any

portion ofthe common ventingsystem,the common venting

systemshould be resizedto approach the minimum sizeas

determined usingthe appropriate tables in the National Fuel

GasCode,ANSIZ223.l-latest revision.In Canada, followCSA B149.1or.2 Installation Codes.

NOTE:It is recommended that existinggasvents be

checkedto be sure theymeet localcodes.

Page 16

INDUCED DRAFT HIGH EFFICIENCY BOILERS

Maximum Horizontal Vent Length ForStainlessSteelVentPipe - 30' PlusOne 90° ElbowPlusVent Terminal.

Minimum Horizontal VentLength- 2' PlusOne 90° ElbowVent Termination.

Additional elbowsare equivalent to 6 feetof straightpipe for 4" di- ameter 90° elbowor 3 feetof straight pipefor 3"diameter 90°elbow.

2,3,4, 5,Section Boilersuse 3"vent pipe;for 6, 7 SectionBoilersuse 4"vent pipe.

Figure 10 - Induced Draft High Efficiency boilers

Optional Termination Fitting

T Jemlund S_deWall Vent Hood

VHolo3"for 2, 3, 4& 5 Section Boilers

VH-I_4" for 6 & 7 Section _i|ers

CHOICE OF VENT PIPE MATERIAL

1. U.L. ListedZ-FlexZ-VentStainlessSteelVentPipe.

2. U.L.ListedHeat-Fab Saf-T-VentStainless SteelVent Pipe.

3. U.L. ListedFlex-LStar-34StainlessSteelVentPipe.

4. U.L. ListedProTechSystemsFasNSealStainlessSteelVent Pipe.

Termination Fitting

_° Elbow, pointing down, same matetiai and

pipe size as venting systems equtped with screen (Min, I/4" Mesh) to keep birds outs

Fot a combustib|e wa|l, use a thimb|e_ Select as

fo|iows:

Vent Pipe: Z-Vent, SafoT_Vent,Star 34

_tmble: Simpson Duravent Thimb|e --

# 3G_¢_,/T(3% # 4GV_t#T (4")

Vent Pt_: FasNSeal

Thimble: FasNSea| Wal| Thimble

#FSWT03-3'; FSWT04-4 _'

PRchDown Toward

Outside 1i4" Per Foot

Pitch Down Towa_

Outside 1/4" Per Foot

_vel

Page 17

Theseboilers maybe vented horizontally as shown in Figure 10.Thevent pipe is pitched down from the boiler to

thevent termination. Do not connect other appliances tothis vent.

Vent Pipe Material: A. ULListedZ-FlexZ-Vent stainlesssteelvent pipe from

boilerto vent termination,

-or-

B. ULListedHeat-FabSaf-T-Vent stainless steelvent pipe

fromboiler to vent termination,

-or-

C. UL ListedFlex-LStaR-34stainless steelvent pipe from

boilerto vent termination,

Vent Termination Fitting: For allvent pipe materials,you may

useeither:

A. A 90° elbowpointing down, fittedwith aminimum 114"

mesh screen to keepout rodents and birds. Theelbow shall be ofthe same material and size as ventpipe. The elbow

exit should be at least 6" awayfrom exterior wall asshown in Figure 10.

-0r-

Tjernlund VH-1Seriessidewall vent hood. For 2,3,4, 5 sectionboilers use VH-1-3",For 6, 7section boilers use

VH-1-4".

7. Vent PipeTermination Location (Figure 10):

-or-

D. ULListedProTech FasNSealstainlesssteelvent pipe from

boilerto vent termination.

Clearanceto CombustibleMaterials: Forstainless steelvent pipemaintain 6" minimum airspaceclearanceto combustible

materials.

Vent Pipe Size: A. 2, 3, 4 and 5 section boilers use 3" vent pipe connected

directly to the outlet of the induced draft blower.

6 and 7 sectionboilers use4" ventpipe, starting with a3" to 4"stainless steelvent pipe transition that is connected

directlyto the outlet of the induced draft blower.Do not use3" ventpipe on 6or 7 sectionboilers.

Vent Pipe Length: A. For stainlesssteelvent pipe,the maximum horizontal vent

length is 30feet plus one 90°elbowplus termination fitting.

Minimum horizontal vent length forall ventmaterials is 2 feetplus one 90° elbowplus termination fitting.

For additional elbowsreduce the maximum vent length as 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

clearancesmust be considered. TheVH-1 Sidewallvent

hood provides both the outside vent termination and a double wallpipe for passing through a combustiblewall

up to 8"thick (VH-1-4")or 9" thick (VH-1-3").Thehole in thewall must be 61_'' square for 3"vent pipe and 7 1/2" square for 4" vent pipe, in order to insert theVH-1 side

wallvent hood. TheVH-1may alsobeused in noncombus- tible walls.

Ifthe 90° elbow isthe termination fittingof choice,then

the singlewallpipe will be passingthrough the sidewall.

For combustiblewalls, a ULlisted thimble shall be used

where the singlewallpipe passes through the wall.For

combustiblewalls usingZ-Vent, Saf-T-Vent,or StaR-34

vent pipe, usethe following:

• 3" vent pipe - use Simpson's Duravent 3" thimble

•4" vent pipe -use Simpson's Duravent4" thimble. Maxi- mum wallthickness with this thimble is 7inches.

For combustiblewallsusing ProTechFasNSealwhere the singlewall

vent pipe must pass through the sidewall,a ULListedFasNSealwall thimble shallbe used.

Thethimble isadjustable for differentwall thickness,with amaxi-

mum wallthickness of 7 inches.Sealthe thimble along the outside

edgeof the platewith caulkor siliconeand fasten to the wallwith screwsor nails.

Example: 6 section boiler has 3 elbows plus the termination fitting. This means 2 additional 4" elbows will be used, at 6 feet per elbow.

This is equivalent to 12 feet of pipe (2 x 6 =12), therefore maximum

vent length is now 18 feet (30 -12 =18).

C. For singlewallpipe through non-combustible walls, the

hole through the wallneed onlybe large enough to main- tain the pitch of thevent pipe, and provide proper seal-

ing.A thimble isnot required for singlewall pipe passing

through noncombustible walls.

D. Theventing systemshall terminate at least 3feet above

Page 18

Figure 11 - Horizontal Venting Clearances

NOTE: _ THERE IS A POTENTIAL POR EXCES:S_VE WINDS, SPECIAL CONSIDERATION _NOULD BE GIVEN TO LOCATE THE VENT TERMINATION AWAY FROM THE WINDWARD Si:DE OR THE BUILD_NG,

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. The 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. The 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. The 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. (See Figure 11)

The venting system shall terminate at least 4 feet below any eve, soffit, or roof overhang.

F. The venting system shall not terminate underneath any

deck, patio, or similar structure.

G. Put vent on awall away from the prevailing winter wind.

LOCATE VENT CAP TO ALLOW

_2" (3_ CM) MIN ABOVE: ORADE

Locate or guard the vent to prevent accidental contact with

people or pets.

Terminate the vent above normal snow-line. Avoid loca-

tions where snow may drift and block the vent. Ice or snow may cause the boiler to shut down if the vent becomes

obstructed.

Under certain conditions, flue gas will condense, forming

moisture. In such cases, steps should be taken to prevent building materials at the vent terminal from being dam-

aged by exhaust of flue gas.

Joining and Sealing the Vent Pipe:

The vent pipe needs to be both watertight and gastight. Seal all

joints and seams as follows: A. For Z-Flex Z-Vent stainless steel vent pipe use a high tem-

perature silicone sealant rated for 550°F. The outside of the male end and inside of the female end of the pipe must be

cleaned with brake cleaner before applying silicone bead.

Page 19

For 3"vent pipe runs beginwith the male endof the vent pipeover the boilersinduced draft bloweroutlet. For 4"

ventpipe runs begin with a 6" lengthof 3"Z-Vent over the boiler's induced draft blower outlet, to which an evenbead

ofhigh temperature silicone sealantshouldbe applied. Thenconnect the 3" Z-Ventto a Z-Vent 3"to 4"reducer.

Thencontinue the 4"Z-Vent piperun byconnecting the 4" male end of the Z-Ventto the reducer. (A locking band maybe used around this joint for additional support.) Then followingthe sealinginstructions, push the4" male end of the Z-Vent overthe 4" increaserfitting. When using the

Tjernlund VH-1 vent hood, the femaleend (flaredend) of thevent pipe willbe connected to the termination hood. Themale endof thevent hood must be crimped before pushing the Z-Vent over thevent hood's connecting pipe. Beforethe pipes are joined, applya ¼" bead of siliconeone inch from the endof the male end. Then pushthe pipes

together asfar asthey willgo makingsure any seamsare alignedand oriented upward. Now apply another beadof silicone around this joint and smooth out. Then use a Z- Flexlockingband around the center of the joint.

1. Apply the high temperature silicone approximatelyone inchfrom the end, around the male end ofthe pipe in

an even ¼" bead.

Pipescan now be pushed together asfar as they will

go. Theseams onpipe should be alignedand oriented

upward in allhorizontal appliances. Applyanother bead

of siliconearound this joint and smooth out.

Slidelockingband overcenter of joint and tighten gear clamps.Makesure locking band is centered onjoint.

Checkalljoints and seams for gastightness.

Horizontal ventingshall haveaslope notless than ¼" (6.4mm) every12inches (305mm)downward away

from the boilerto preventcollectionof condensate throughout the assembly.

Allowthe sealant to cure for 24hours before operating the appliance.

For Heat-Fab Saf-T-Ventstainlesssteelvent pipe use ahigh temperature siliconesealantrated for 550°F

Theoutside ofthe male end and inside ofthe female end ofthe pipe must becleanedbefore applyingthe

siliconebead. For 3"vent pipe runs, the male endof thevent pipe which goes overthe outlet of theboiler's

induced draftblower must be crimped. Thevent pipe should be crimpedas minimal aspossible to provide atight fit overthe outlet. After crimping is completed followthe instructions forapplying siliconesealant.

For 4"vent pipe runs, begin with a Saf-T-Vent3"to 4" in- creaserfittingoverthe boiler'sinduced draft bloweroutlet,

to which an even bead of high temperature siliconesealant

shouldbe applied. Thencontinue the 4" Saf-T-Ventpipe run by connecting the 4" male end of the Saf-T-Ventto the

increaser.(Alockingband maybe usedaround thisjoint for additional support.) Thevent flowmust be in the direc- tion indicatedon the ventpipe. When usingthe Tjernlund VH-1 vent hood, the femaleend (flared end) ofthe vent

pipe willbeconnected to the termination hood. Applyhigh temperature silicone in an even ¼"bead approximately¼" to 3/8"from the end of the venthood's connecting vent pipe.

Also,run asimilar sizebead ofsilicone sealantdown the

seamweldofthe vent pipe. Then push the femaleend over the vent hood'sconnecting vent pipe.

1. Apply thehigh temperature siliconearound the male end ofthe pipe (without the tabs) in an even ¼"bead.

Siliconebead should be approximately¼"to 3/8"from the end ofthe male end. Also,run a similarsizebead of silicone sealantdown the seam weld at the end of each

joint.

Pipes cannow be pushed together asfar as theywill go. Theseams onthe vent pipe should be alignedand oriented upward in allhorizontal appliances.With a moistened fingeror fiat tool, spreadany sealant that squeezesout around the circumference of the joint.

Attach the sectionstogether with the locking rings and tabs (exceptat the bloweroutlet where no locking ring exists.) Inspectthe joint to ensurethat fluegaseswill

not leak.If necessaryapplyadditional sealantaround thejoint.

Horizontal venting shallhave a slopenot lessthan ¼" (6.4mm) every 12inches (305mm) downwardaway from the boilerto prevent collectionof condensate

throughout the assembly.

5. Allowthe sealantto cure for 24 hours beforeoperating the appliance.

For Flex-LStaR-34stainless steelvent pipe use ahigh

temperature siliconesealant rated for 550°F.Beforeapply-

ing silicone,the outside of themale end and inside ofthe

femaleend of the pipe must be cleaned using acleaner,

suchas methyl ethyl ketone (MEK)or naptha. For 3"

vent pipe runs, beginwith the male endof the vent pipe over the boiler'sinduced draftbloweroutlet. For 4"vent

pipe runs begin with aStaR-34 3"to 4"increaser fitting over the boiler'sinduced draftbloweroutlet. For both

3" and 4"vent pipe runs,apply a bead ofsilicone seal- ant around the blower outlet and around the inside of

the male end ofvent pipe going overthe blower's outlet. When usingthe Tjernlund VH-1 vent hood,the

femaleend (flaredend) ofthe vent pipe willbe connected to the termination hood.

Page 20

Applyhigh temperature siliconein an even ¼"bead ap- proximately 1/4"from the end ofthe vent hood's connecting

ventpipe. Also,run a similar sizebead of siliconesealant down the seam weldof the vent pipe. Then push the female end over thevent hood's connecting vent pipe. Now fillin the channel inlet with siliconesealant.Do not try to insert

thejoiner band, instead fastenthe vent pipe tothe vent hood's pipe with a steelgear clamp.

1. Apply the high temperature silicone around the male endof the pipe in an even ¼" bead. Siliconebead

shouldbe approximately ¼" fromthe end of the male end. Also,run a similarsize bead of siliconesealant

down the seamweld at the end of each joint.

2. The seams on the vent pipe should be alignedand ori- ented upwardin allhorizontal vent pipe runs.

3. Insert the maleend ofone into thefemaleend of the

other. Push the pipe together sothe female end rests up

againstthe stop bead of themale end.

Insert a StaR-Joiner Band into the inlet of the beaded channel. Feed the Joiner Band in so it makes its way

around the pipe, back to the channel inlet and it over-

laps itself by about 1/2".

Cutthe excessJoiner Band soit lays fiatin the beaded channel.Fillthe inlet ofthe beaded channel withhigh

temperature silicone.Smooth outthe siliconeover the

channel inlet and the siliconebetween the female end and thestop bead of the male end.

Horizontal ventingshall haveaslope notless than ¼" (6.4mm) every12inches (305mm)downward away

from the boilerto preventcollectionof condensate throughout the assembly.

7. Allowthe sealant to cure for 24hours before operating

the appliance.

For ProTechSystemsFasNSealstainlesssteel vent pipe no cleaningfluid isrequired. For 3" vent pipe runs on 2, 3,4 and 5 section boilers,begin bylocating the FasNSeal AmetekAdapter overthe boiler's induced draft blower. Continue the vent piperun with 3" FasNSealvent pipe.

For 6and 7 section boilers, begin by locatingthe FasNSeal AmetekAdapter over the boiler'sinduced draft blower.

Thenconnect a FasNSeal3"to 4" increaserto the 3" adapter outlet.Continue thevent piperun with 4"FasNSeal

ventpipe. Other than the Ametek Adapter and increaser fitting,DO NOT use 3"vent pipe on 6or 7 sectionboilers.

FasNSealventpipe isjoined and sealedby the useof an internal sealinggasketand alocking band on the female end ofeachvent pipe.Allcomponents should be examined

for possibleshippingdamage prior to installation. Align

allvent pipe seamsand orient upward in allhorizontal applications.Adjustablevent lengths areavailablefor4"

diameter vent piping.For 3" diameter vent piping, square

cutmale end at the desired length. For2, 3,4 and 5 section boilers usingthe VH-1-3" vent hood, connect the FasNSeal Ventto the VH-1-3"vent hood using FasNSealAdapter

#FSC-DUN-3.Thisadapter has no internal sealinggasket.

Toattach the adapter to the vent hood, crimp the 3"vent hood pipe,apply a 1/4"bead ofhigh temperature silicone

sealantaround the outside of the venthood's crimped

connecting pipeand asimilar bead of high temperature

siliconearound theinside ofthe FasNSealadapter. After pressing thetwo pipestogether and tightening the locking

band, finish creatinga complete sealby fillingthe FasNSeal

adapter'snotched holewith hightemperature silicone.

For 6 and 7 sectionboilers using the VH-1- 4"vent hood,

an adapter isnot required. The 4" FasNSealventpipe con- nects directlyto the VH-1-4" venthood, and is joined and

sealedby the internal gasketand lockingband.

Tojoin and seal the FasNSealvent pipe:

1. Insert maleend into female section.

2. Push the units together as faras possible.

3. Firmly tighten locking band with anut driver.

4. DO NOT penetrate theFasNSealvent pipe with fasten-

ers.

Horizontal venting shallhave a slopeof not less than

¼"(6.4mm) every12inches (305mm)downward away

from the boilerto prevent the collectionof condensate throughout the assembly.

Support Spacing:

Donot restrict thermal expansion movement of the vent. The

vent pipe must expand and contract freely with temperature

change.Eachrun ofventpiping shallbe supported asfollows:

A. Z-Flexstainlesssteel ventpiping requires a loosefitting

metal strap or similar support at eachjoint at a maximum of 4 feetbetween supports.

B. Heat-Fab stainlesssteelvent piping requiresa support for

every6 feet ofhorizontal piping run. Thesupport must be

securedusing at least#10fastenersto asolid material (solid masonry or wood framing or blocking.)Do not fastento

drywall sheathingusing hollowwall anchors. Each sup- port willbe 11/2inch lowerthan the previous support when

spaced6feet apart.

C. Flex-Lstainlesssteelvent piping requires aloose fitting

metal strap or similar support at eachjoint at a maximum of 4 feetbetween supports.

D. ProTech stainlesssteelvent piping requires one loose fit-

ting FasNSealsupport strap for every6' ofhorizontal vent.

Page 21

10. If the horizontal vent must go through a crawl space or other unheated space, the cool temperatures will likely cause the flue

gases to continuously condense inside the vent pipe. Do not

insulate the vent pipe. It must be visible for monthly inspec- tion. Insure that the vent pipe is properly pitched away from the boiler, with no low spots, sothat 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

required to prevent freezing of liquid condensate. Consult the

vent pipe manufacturer's instructions for specific 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 ventingwith apower venter is an alternatemethod of sidewallventing. Thisboiler is CSAlisted for sidewallventing with standard singlewallgalvanized or TypeBvent pipe when usingthe followingpower venterkits, which werespecificallysizedfor these

boilers:

2,3, 4,5 SWG-4D

6,7 SWG-SD

Somepossiblereasons for using apower venterfor sidewallventing:

1. May be preferred by localcodes.

2. Need avent pipingrun beyond 30' (butnot more than 50').

3. The boiler installation site experiencesgusting or high winds.A

power venter canhelp prevent the boiler from short cyclingdue to gusting or high winds byproviding ventexhaust pressures

greater than the boiler'sinduced draft blower alone.

4. When installersor homeowners prefera negativepressure vent systeminstead of a positive pressure vent system.

5. May bemore costeffectivethan stainlesssteel venting,particularly at longer vent lengths.

TheFieldControls powervent kit includeseither a SWG-II- 4HD or SWG-II-5power venter,a MG-1 4" barometric draft

controller,and the CK-43Dcontrols kit.

Confirm that installingapower venter isan option allowedby local

codes.Followthe specificpowerventer installation instructions issuedwith the power venter kits. Although the powerventer is

equippedwith itsownfan, the fanon the boiler remains in place and isunaltered whena power venter isused.

When sidewallventing, fluegasesmust be vented to apoint in rela- tion tothe prevailingwind so that they may freelydisperse without

being blown backat the building causingdiscoloration, orinto the building through doors or windows causingodors. Also,under cer- tain conditions fluegaseswill condense, forming moisture. In such

cases,steps should be taken to preventbuilding materialsat the vent

terminal frombeing damaged by the exhaustedfluegas. When installing singlewall galvanizedvent pipe forpower venting

followthe specificpower venter installation instructions for layout, location ofthe barometric draft control and termination connec-

tions. When joining and sealingthe singlewall galvanizedor Type Bvent

piping, use RTVsilicone sealantwith aminimum temperature rating of 400°EFor 3"vent pipe runs, begin with the female end of the vent

pipe overthe boiler'sinduced draft bloweroutlet. For4" ventpipe

runs begin with the galvanized3" to 4" increaser fitting (included in the boiler'sparts bag)over the induced draft bloweroutlet. Thenfol- low by placingthefemale end of the 4"vent pipe overthe increaser

fitting. When joining piecesofsinglewall galvanizedvent pipe,a substan-

tial bead ofsiliconeshould be used atthe joint to insure aleakproof

connection.

Page 22

Connecting The Gas Piping Refer to Figure 12 for the general layout at the boiler. It shows the

basic fittings you will need. The gas line enters the boiler from the right side. Flexible gas connectors must never breach any boiler openings.

Figure 12 - GAS PIPING AT BOILER

Never use a match or open flame to test for leaks.

9. Two-stage regulation should be used by the propane installer.

10. Propane gas piping should be checked out by the propane

installer.

Checking The Gas Piping

Upon completion of piping, check right away for gas leaks. Open the manual shut-offvalve. Test for leaks by applying soap suds (or

a liquid detergent) to each joint. Bubbles forming indicate a leak.

CORRECTEVENTHE SMALLEST LEAK AT ONCE.

Manifold

Automatic Ground GasValve, Joint

Check Gas Supply

The 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. See Gas Table 8 for the proper size.

Be sure your gas line complies with local codes and gas company

requirements.

Tmp

Floor Line

.iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

20 92,000 190,000 350,000 625,000 40 63,000 130,000 245,000 445,000

MIN. SUPPLY 5" w.c. 11" w.c.

MAX. SUPPLY 14" w.c. 14" w.c.

MANIFOLD 3.5" w.c. 10" w.c.

The 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 liquefied petroleum gas.

3. Install ground joint union in gas supply line between shut-off

vane and boiler controls.

4. Install a sediment trap upstream of gas controls.

5. Use two pipe wrenches when making the connection to the gas

vane to keep it from turning.

6. Install manual shut-offvaNe in vertical pipe about 5 feet above floor.

7. Tighten alljoints securely.

8. Propane gas connections should only bemade bya licensed propane installer.

60 50,000 105,000 195,000 365,000

216,000 189,000 393,000

145,000 129,000 267,000 121,000 103,000 217,000

The length of pipe or tubing should be measured j?om the gas meter or propane

second stage regulatoc

The boiler and its individual shutoffvaNe must be disconnected

from the gas supply piping system during any pressure testing of that

system at test pressures in excess of 1/2Psig (3.5 kPa). The boiler must be isolated from the gas supply piping system by

closing its individual manual shutoff vane during any pressure test-

ing of the gas supply piping system at test pressures equal to or less than 1/2Psig (3.5 kPa).

Page 23

All electrical work must conform to local codes as well as the Na- tional Electrical Code, ANSI/NFPA-70, latest revision. In Canada,

electrical wiring shall comply with the Canadian Electrical Code, CSA-C22.1.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiTurn offelectricpower atfuseboxbefore makinganyline iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiivoltageconnections. Followlocalelectricalcodes.

Electric Power Supply

Run a separate 120volt circuit from a separate over current protec- tive device in the electrical service entrance panel. This should be a

15 ampere circuit. Locate a shut-off switch at the boiler. It must be turned offduring any maintenance. Connect 120 volt power supply to aquastat terminals L1 (HOT) and L2.

The boiler, when installed, must be electrically grounded in accor- dance 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 14gauge or heavier copper wire from the boiler to a grounded connection in the service

panel or a properly driven and electrically grounded ground rod.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

Label allwires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous

operation. Verify proper operation after servicing.

Install Your Thermostat

The thermostat location has an important effect on the operation of

your boiler system. BE SURE TO FOLLOW THE INSTRUCTIONS

INCLUDED WITH YOUR THERMOSTAT. Locate the thermo- stat about five feet (5') above the floor 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.

Behinddoors

Corners&

alcoves

Concealed pipes

Fireplace

TV sets

Radios

Lamps

Direct sunlight

Kitchens

Concealed pipes

or ducts

Stairwells-drafts

Doors- drafts

Unheated room on

other side of wall

Sequence of Operation - Refer to Figure 13

1. Thermostat calls for heat, powering the 1Krelay coil and closing contacts 1K1and 1K2.

2. Circulator pump ispowered through terminals C1and C2.

3. Induced draft blower and transformer primary arepowered

through terminals B1and B2.

4. When blowergets up to speed andblower suction pressure reaches pressure switchset point, pressure switchcontacts close

sending 24 voltsto intermittent pilot control from transformer secondary.

5. Pilot gasvalve opens and spark initiates to light pilot burner.

6. When pilotflame isproven, sparkdrops out.

7. Main gasvalveopens and pilot burner ignites main burners.

Setheat anticipator at .2amps. The 24 voltthermostat connects

to aquastat terminals T and T.

8. If boiler water temperature reaches high limit setpoint, high

limit contacts B-Ropen, cutting powerto blower and intermit- tent pilot control. Burnersextinguishand blower stops.Circula- tor pump continues to run aslong asthe thermostat continues to call for heat. When boilerwater temperature drops pastthe

high limit set point and through the differential,high limit

contacts B-Rclose,repeating steps3-7.

9. If venting systembecomesblocked, blower suction pressurewill drop belowthe pressure switchset point, opening the pressure

switch contacts and cutting power to the intermittent pilot con-

trol. Burners willextinguish, butblower willremain powered

aslong asthe thermostat continuesto callfor heat. Ifventing systemclears,steps 4-7will repeat.

10. Thermostat is satisfied,ending callfor heat. Relaycoil 1Kisde-

energized,opening 1K1and 1K2contacts. Burners extinguish. Blowerand circulator pump stop.

Page 24

Figure #13 -Intermittent Ignition

120/60/1

POWER SUPPLY

NEUT 24V HOT_ I THERMOSTAT

,Olw7:DISCONNEC 1

;1)/L. q <T_

\_>' _'/ \/

-!_ L8148A

AQUASTAT G

LINE VOLTAGE WIRING LOW VOLTAGE WIRING

LOW VOLTAGE FIELD WIRING

B BLACK BT BLACK WITH TRACER

W WHITE G GREEN

R RED BL BLUE

INDUCER DRAFT

AT 140C TRANSFORMER

CIRCULATOR

HOT

FUSED

fll_ +DISCONNECT

i ,

1K1

?_ HIGHLIMIT

B_ B

INTERMITTENT PILOT CONTROL

> -_s-2_ l

>5> >_ z_Z_ I

I I

_(_ TBKTBKTBT_Bk--TOPILOT /// / / / _" BURNER

PRESSURE ROLLOUT/// 'Ln_in

SWITCH SWITCH // W _.- GAS VALVE

/VR8204A/VRS,04M

170/60/1P?WERSUPPLY

120 V PRIMARY

[ 24ZVrSEC%NDARY _IK

.) \. _/ -

24 V THERMOSTAT O

1K2

¥_L31

PRESSURE ROLLOUT

SWITCH SWITCH

B _ w

'\S

DRAFT INDUCER 120V PRIMARY

\)_/,),..J

24 V SECONDARY

CIRCULATOR

AT 140C TRANSFORMER

INTERMITTENT

PILOT CONTROL

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

NEUT

(LL"i

\l j'

1/c2

\j'

TO GAS

VALVE

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii!Ifanyoftheoriginalwireassuppliedwiththisappliance

must be replaced,it must be replacedwith type 105° C

thermoplastic wireor its equivalent.

NOTE:Thecirculatorharness isfactorywired to the aquastat.Thisharness needs to beconnected to the circu-

latorin thefield.

Page 25

Relief Valve

Youmust havea reliefvalve on your boiler.Water expands asit is heated. Ifthere is no placefor thewater to expand into,waterpres-

surewill build up insidethe boiler and system. Should this happen, the ReliefValvewillautomaticallyopen ata pre-determined pres- sure. Thiswillrelievethe strain on the boilerand system.Run apipe from thereliefvalveoutlet (pipemust be samesizeasoutlet and the open end must not be threaded) to anopen drain, tub or sink,or

other suitabledrainagepoint not subject tofreezing. Failure to do so maycausewater damageor injuryshould reliefvalverelease.

Expansion Tank

In aproperly assembledsystem, the expanding water flowsinto an ExpansionTank.This tank should be ofthe correct size.

Thetank ispartially filledwith air.Asthe water expandsit compress- esthe air in the tankto form an airpressure cushion. This"spring- like"cushion servesto maintain correct operating water pressure regardlessof watertemperature. Thisassuresa "fullmeasure"ofwa-

ter, evenin the highest radiation unit ofthe system.It alsoprevents blowingoffof the reliefvalve.

Theair in the tank inthe beginning (with systemfilledwith cold wa- ter) issufficientfor proper operation. Thetank also servesasa trap for excessair in the system. The air would causegurgling in the pipes

and inefficientcirculation in the radiators ifleft in the system. It ispossible fora tank to become "waterlogged"(filledwith water).

It can alsobecome overfilledwith air.Thiscan happen afterfilling the systemwith newwater.Fittings provided on the tank and inthe line to the tank are for bleeding offexcesswater or air.

When installingthis tank, itis important:

1)Thatthe tank be higher than the boiler top.

2)That the pipe to the tank continuouslyrises up to the tank (so that air can "bubble"up toit).

Diaphragm Type Expansion Tank TheDiaphragm Type Expansion Tank (EX-TROL)takes the place

ofthe conventionalexpansion tank. Carefullyread the instructions packedwith your EX-TROLTank Assembly.The EX-TROLTank

comesto youwith a 10-12pounds per squareinch air charge.Thisis the sameasthe pressure produced inthe systemby the automatic fill valve.When the systemis firstfilled,the EX-TROLTankwillcontain

littleor no water. Asthe water is heated itspressure increases.It expands into the EX-

TROLTank,compressing the air in the tank. Thiscompressed air cushion permits the waterin the systemto expand asthe tempera- ture changes.

Air Eliminating Fitting (Air Purger)

AnAir Purger is usedto remove excessairfrom the system. It is in-

stalledin the supplyline.It willhelp to eliminateairfrom the water

before it reachesthe radiators andbleed offthis air.

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

Beforeasystem isfilledwith water,there is air in the pipesand radiation units. Someof itwill be trapped as the systemis filled.It ispossible to eliminatemost of this airthrough the airvents on the radiation units.A Main AirVent will speed and simplifythis. It

shouldbe installed on the highest point inthe main when allradia-

tion isbelowtop ofboiler.

Automatic Fill Valve

For safe,efficientoperation, a hotwater systemmust befilledwith

water.Adding new water,when needed canbe done manually(by

useof a hand valvein thewater supplyline). Thisrequires regular at- tention to thesystem'sneeds. AnAutomaticFillValveaccomplishes this without attention. It isinstalled in the Supply Lineon hot water boilers only.TheValveoperates through water pressure differentials.

It does not require an electricalconnection.

Drain Valve

This manual valve provides a means of draining all water from the boiler and system. It isoften installed in the _" Tapping at the bot-

tom of the left boiler section. Or it can be installed in a tee where the

return line enters the boiler.

Water Temperature Control

The 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° E This depends on the type and amount of radiation involved

and weather conditions.

Circulating Pump

EveryForcedHot-Water Systemrequires a Circulating Pump. A

separatepump or zonevalveis requiredfor eachZone, ifyou have

atwo or more Zone System.Thispump must havethe capacityto provide the circulation required byyour system.

Thepump does notcome pre-installed on theboiler. It must be con- nected to the circulator harness in the fieldaccording to the pump

manufacturer's instructions andthe wiring diagrams inthis manual.

Page 26

Blower (Draft Inducer)

Rollout Switch

The blower provides a means for pulling air through the boiler and exhausting the flue gasses into the vent system. The blower shuts off when the burners are not firing. This keeps heat in the house rather than having it go up the chimney.

Pressure Switch

The air pressure switch works on a negative pressure. When the blower comes on the air pressure switch operates the intermittent pi- lot and gasvalve. The 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.

(Flame Rollout Safety Shutoff)

The rollout switch is a temperature-sensitive fuse link device. It is lo-

cated on the boiler base just outside the fire box. In the event of heat

exchanger flueway blockage causing flame to roll out of the fire box, the fuse will blow, shutting down the flow of gas to the main burners.

The fuse does not change in appearance when blown.

If the rollout switch blows, it must be replaced with an exact replace- ment. Check heat exchanger flueways for blockage when restoring

system to operating condition. Do not operate system without a

rollout switch.

Page 27

HowA Hot Water System Operates

Your entire heating system (boiler, piping and radiation units) is filled 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 radia- tion units. The cooler water in them flows back through the return main to the boiler. This 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. The 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 flow 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

filling 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 refill the system au- tomatically as needed. Check the temperature-pressure gauge. Note the position of the hand indicating pressure. This should be between

10 and 15lbs. Any lowering of this movable hand below 10lbs. will

indicate loss of water due to leakage. The automatic fillvalve should compensate for this. Instructions are packaged with the valve.

Never run water into a hot empty boiler.

: Thisappliance isequipped with an ignition devicewhich

automaticallylights the burner. Do notattempt to light the

iiiiiiiiiiiiiiiiiiiiiiiiburnerbyhand

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

Ifyou do not follow these instructions exactly, fire or ex- plosion may resultwith property damage,personal injury,

or lossof life.

BEFOREOPERATINGsmellall around the appliancearea forgas. Besure to smellnext to the floorbecausesomegas

isheavier than air and will settle on the floor.

IF YOU SMELL GAS:

1. Do not attempt to operate any appliance,do not

...... your hand to push down or turn the knob. Never use tools.

touch any electrical switch, do not use the phone.

2. Leave the building immediatelyand call your gas

supplier.

3. Ifyour gas supplier cannotbe reached,call the fire

department.

When turning or depressing the gas control knob, use only

If the knob will not operate by hand, the control must be

replacedby a qualifiedservice technician. Force or at- tempted repairmay result in a fire or explosion.

operate. Immediately call aqualified service technician to inspect the applianceand to replaceany part ofthe gas

Ifany part of this appliance has beenunder water,do not control systemwhich has been under water.

Page 28

Operating Instructions.

1. Setthe thermostat to lowestsetting.

2. Turn off allelectric power to the appliance.

3. Thisappliance is equipped with an ignition devicewhich auto- maticallylights the burner. Donot attempt to light the burner by hand.

4. Removeburner accesspanel.

Depressgas control knob slightlyand turn clockwisef_ to "OFF"position.

Figure 14 - Gas Control Knob

INLETii_

Waitfive (5) minutes to allowanygasin the combustion chamber to vent.Ifyou then smellgas in the appliance areaor near the floor,do not touch any electrical switch, do not usethe phone. Leavethe buildingimmediately

and callyour gas supplier. If your gas supplier cannot be reached,callthe firedepartment. Failureto do somay resultin afireor explosion.Ifyou don't smellgas,go to next step.

Turn gascontrol knob counterclockwise_'_ to "ON."

Turn on all electricpower to the appliance.

Setthermostat to desired setting.

After visuallyinspecting the flame,replace the lowerfront panel.

Ifthe appliancewill not operate after severaltries, turn the gascontrol knob to"OFF"and callyour servicetechnician

or gassupplier.

GAS CONTROL KNOB

SHOWN IN "ON" POSITION

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

NOTE:Knob cannot be turned to "OFF"unless knob is depressed slightly.Donot force.

Gas Valve Safety Shutdown Test

With main burners firing, disconnect the ignition cable from the intermittent pilot control box. The gas valve should shut offthe main

burners. TURN OFF ELECTRIC POWER to boiler before recon- necting ignition cable, to prevent electric shock.

Adjust Pilot Burner

Removescrewcover over pilotadjusting screw.

Insert small screwdriver and adjustflameas needed (Figure #16. Turn screwcounterclockwise_"_ to increaseflame,

clockwiseto decrease (Figure #17).

3. Replacescrew coverover pilot adjusting screw.

To Turn Off Appliance:

1. Setthe thermostat to lowest setting.

2. Turn offall electricpower to the appliance if servicingisto be performed.

3. Depress gascontrol knob slightlyand turn clockwise/_ to

"OFF"position. Donot force.

Main Burner(S)

Themain burners do not require primary air adjustment and are not equippedwith primary air shutters. Main burner flamesshould form

sharp blueinner conesin a softer blue outer mantel,with no yellow. Puffsof air from blowingon the flameor stamping on the floorwill causethe flamesto turn orangemomentarily. Thisisnot unusual.Re-

main stillwhen observingthe main burner flames.Referto Figure #17. If the flameappearance isnot correct,check main burner ori- ficesand the burner throat and flameports for dust and lint obstruc-

tion. It maybe necessaryto removethe rollout shield to observe the main burner flames.Replacerollout shieldafter observation.

Page 29

Adjust Limit Controls

Instructions for each control are included with the controls.

Figure 15 - PILOT FLAME ADJUSTMENT

Recommended Boiler Water Temperatures

Type of Heating Unit Limit Control Setting

Standing Radiators ......................................... 180° F

Baseboard and Convector Radiators ............. 180° F

These settings can be changed after you have had some idea how the system works. Exam l,_.If your system does not give quite enough heat in very coldweather, you can raise the limit setting to 190°E

Adjust Thermostat Heat Anticipator

INSTRUCTIONS FOR THE FINAL ADJUSTMENT

OF THE THERMOSTAT ARE PACKAGED WITH

THE THERMOSTAT.

4. Set Heat anticipator at .2.

5. Check thermostat operation. When set above temperature indi-

cated on the thermometer, boiler burners should ignite. Make certain the thermostat turns off the boiler when room tempera-

ture reaches the selected setting and starts the boiler operating when room temperature falls a few degrees. After setting limit control to desired setting, check to see if it shuts off the gas sup- ply 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. The gas valve should shut off and the circulator keep running until the thermostat is satisfied, 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. The 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.

3i8'!tO112"

Figure 16 -AUTOMATIC GAS VALVE

PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW)

INLET

PRESSURE.

TAP _'-,

INLET

GAS CONTROL KNOB

PILOTADJUSTMENT

(UNDER CAP SCREW)

Figure 17 - Main Burner Flame

Flame

Sensor

WIRING TERMINALS (2)

LIGHT BLUE

OUTLET

PRESSURE

TAP

GROUND

(2)

OUTLET _

PILOT OUTLET

8° Finally,set thethermostat for the desired temperature. Special

conditions in your home and the location of the thermostat will govern this setting.

Safelighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boilerunderwent tests specifiedinANSI Z21.13-latestrevision.

Burners

A visual check of the pilot and main burner flames should be made at least once each year, preferably at the beginning of the heating season.

See Figures 15, and 17.

Themain burner flameshould form a sharp blueinner mantel with no yellow.

Page 30

XEB Series Cast Iron Gas-Fired Cast Iron Boilers

[]

Check off 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 orifices have been installed.

Follow lighting instructions in series XEBinstallation, operation and maintenance manual furnished with boiler.

Visually check the main burner flame and verify ithas a well defined 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 off. Verify the circulator continues to operate. Adjust the indicator on limit control above actual boiler water temperature and verify burners reignite.

Test any additional field-installed controls. If boiler has a low water cut-off or additional high limit, test for

operation as outlined by the controls manufacturer. Burners should be operating and should go offwhen 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 off the gas to the main burner. After verify

ing safety control circuit, turn off 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 flowthrough each zone so that it is about equal per zone. Verify several operating cycles of proper operation. Measure gas input:

NaturalGasProcedure £P GasProcedure [] Operate boiler for 10minutes.

[] Turn offallother gasappliancespiped with the produced duringcombustion. Referto BoilerManual

boiler, for combustion guidelinesand correspondingBTU

[] Atthe gasmeter,measure the cubic feetof gas input.

usedin 10seconds (CF10). [] Verifythe BTUhis approximateto the input rating on

[] Calculateinput: BTUh= CF10x 360,000 the boiler ratingplate. [] Verifythe BTUhis approximateto the input

rating onthe 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.

[] LPgasinput rate isdetermined bymeasuring gases

[]

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.

Page 31

Boiler Manufacturer: Dunkirk Boilers

Boiler Identification: Model #:

85 Middle Road

Serial #:

Dunkirk, NY 14048

MeasuredBTUH input: Operational Test Date:

[] []

InstallationInstructions in the XEBInstallation,Operation andMaintenanceManual havebeen followed. Initial OperationalBoilerTestCheck-Out Procedure hasbeen performed.

Information on this form is certifiedto be correct. Allboiler instructions,wiringdiagrams, pipingdiagrams, and supporting informationshipped with this boiler

forwardedto owner/maintenance personnel.

Installation Location:

Customer Name: Address:

/ /

City: State: Installer Information

Company/Contractor: Address:

City: State: Telephone #:

Installer's Signature Date: Installer's Printed Name:

Zip:

Page 32

Relief Valve

Thisvalveshould open automaticallyif the systempressure exceeds the pressurerating (usually 30psi) ofthe reliefvaNe.Should it ever failto open under this condition, shut downyour system.Drain the systemuntil systempressure isreduced belowthe reliefvaNe pressurerating. IfvaNe dischargeoccurs, or if vaNefails to open asdescribed above,contact an authorized contractor or qualified

servicetechnician to replacethe reliefvaNeand inspect the heating systemto determine the cause,as this may indicate an equipment

malfunction. Thisvalveshould be tested everymonth during periods ofboiler

operation, and atthe beginning and end of any extendednon-service period. Prior totesting, make certain discharge pipeis properly

connected to vane outlet and arranged soas to contain and safely dispose of boilerdischarge.Test at normal systemoperating pres- sure. Hold the trip leverfullyopen for atleastfivesecondsin order to flushfreeanysediment that may lodgeon thevane seat. Then permit the valve to snap shut.

Expansion Tank Aspreviously noted, thistank may becomewaterlogged,or may re-

ceivean excessof air.Frequent automaticopening of the reliefvalve indicateswaterlogging.A high boiler temperature accompaniedby

unusuallylow radiation unit temperature (and"knocking") indicates excessairin tank.Tocorrect either condition, closethe valvebe-

tween theboiler and the tank. Drain the tank until it is empty.Check allthe tank plugs and fittings.Tighten asnecessary.Open the vane betweenthe boiler and tank. Waterwillrise to the normal heightin

the tank if youhave an automaticfillvane (otherwise,manually refill the system).

Boiler Flue Passages

Under normal operating conditions,with the burners properly adjusted,it should not be necessary to cleantheboiler fluegas pas-

sages.However,to assuretrouble-free operation, we recommend that you havethe fluepassages,burner adjustment, and operation ofthe controlscheckedonce eachyear byacompetent ServiceTechnician.

Before The Start Of Each Season

(or wheneversystemhasbeen shutdown forsome time) recheckthe wholesystemfor leaks.., andrecheck the boiler andvent pipe for leaks.Replaceor patch anyboiler sealsthat are faulty.

Vent Pipe

The 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 left 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 flue collector and the

clean out plates with a razor knife. Remove flue collector. Remove clean out plates by tapping upwards on the bottom of the plate with a

hammer. Remove loose silicone sealant from sections, flue collector,

and clean out plates.

Clean passageways between sections with a flexible 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 flame ports in burners are open and clear. Shake out or blow out all loose dirt in burners. Reassemble all parts. Seal flue

collector and clean out plates to sections with silicone sealant (400° F

RTV silicone sealant or equivalent). Reseal seams between adjacent

sections where necessary. Alljoints must be airtight. Be sure to check tightness of pilot connections and condition of burner flames after

reassembly (see Figures 1S, and 17). Be sure vent pipe connec- tions to chimney are secure and no obstructions are present.

Blower

Theblowermotor features apermanently lubricatedball bearing

construction. Lubricationisnot required.

Circulator Pump Isolation Valves

The isolation vanes in the circulator pump flanges should be oper-

ated manually once or twice per year to prevent the vanes from be-

coming stuck in the open position. Rotate the vanes from the open position to the closed position and back to the open position.

Page 33

WHATTODOIFYOUSMELLGAS DoNottrytolightanyappliance.

Do not touch any electricswitch,do not usethe phone or any mobileelectronics.Theseactions may create a spark and cause igni- tion. Leavethe building immediately,then callyour gas supplier.

Ifyou cannot reach the gas supplier,callthe firedepartment.

Thermostat is not set correctly Reset thermostat

Checkflame.Ifit isyellow,the burner is not getting enough air. Or, ifflameis blue

Burner is not operating properly

and noisyand seems to liftoffthe burner, the burner isgettingtoo much air.Contact

your servicetechnician.

Noelectric power to boiler

Checkover-current protection. Checkto be sure electric power supplycircuit is "ON".

Controls out of adjustment Resetaccordingto instructions.

Open radiator ventsto excessair.Check flowcontrolvalve(if used). It maybe in

Radiatorsnot heating closedposition. Circulating pump not running Checkovercurrent protection. Check relayoperation.

Poor electricalcontact Checkall control terminals and wirejoints.

Chimney flueisblocked

Rollout switch blown

Pressureswitch willnot closeand pilot sparkwill not operate to start pilot. Have

your servicetechnician checkand correct,if necessary.

Haveyour servicetechnician check heat exchangerfor blockage.Replacerollout switchwith exactreplacement.

Gasinput amount isincorrect

Contact your service technician.

Dirt on seat

Water logged expansion tank

Open valvemanually.Allowwater to run and clearvalveseat. Drain tank, see instructions.

Page 34

Page 35

Page 36

Dmi'_i__

85 Middle Rd.

Dunkirk, NY 14048

Dunkirk XEB-7, XEB-5, XEB-6, XEB-4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual