XEB Series Gas-FiredHot Water Induced Draft Boilers INSTALLATION, OPERATION & MAINTENANCE MANUAL DUNKIRK 85 Middle BOILERS Rd. Dunkirk, NY 14048 www. dunkirk, corn P/N 14683001 Rev.
Safety Symbols ........................................................................................................................................................ 2 Installation 3 Instructions ......................................................................................................................................... Boiler Ratings And Capacities ................................................................................................................................
These instructions must be affixedon or adjacent to the boiler. This boiler cannot be used with all types of chimneys. Read these instructions carefullybefore installing. These Gas-Fired Hot Water Boilers are lowpressure, sectional cast iron boilers Design Certified by C.S.A.(Canadian Standards Association) for use with Natural and Propane Gases. They are constructed and hydrostaticallytested for a maximum working pressure of 50psi in accordance with A.S.M.E.
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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. Ifyou plan to change location, you will need additional materials as wellas an adequate base. The followingrules apply: 1. The boiler must be level. Metal shims may be used under base legsfor final leveling. 2. Use a raised base if floor can becomewet or damp. 3. The vent pipe connection should be as short as possible. 4.
Sizing Air/Ventilation Provision forcombustion andventilation airmustbe in accordance withtheNational FuelGasCode, ANSI Z223.1latestrevision, orapplicable provisions ofthelocal buildingcodes. Besuretoprovide enough freshairforcombustion. Enough airinsures propercombustion andassures thatno hazard willdevelop duetothelackofoxygen. Openings Air openings must be sized to handle all appliances and air movers (exhaust fans,etc.) using the air supply.
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 windows.
o All Air from Outdoors: The confined space shall communicate with the outdoors in accordance with Methods A or B below. 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 12 inches of the bottom, of the enclosure shall be provided.
2. Where communicating withtheoutdoors throughhorizontal ducts(seeFigure 3D), each opening shall have a minimum free area of 1 area ofsq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure.
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.
Figure 4 - Relief Valve Discharge Piping RELIEF VALVE DISCHARGE PIPING Check local code_ for maximum distance from Figure 6 - Forced Hot Water Typical Piping With Zone Control Valve floor or other allowable safe point of discharge ZONE VALVE o, MAiN Figure 5 - Forced Hot Water Typical Piping T_K
If you are installing an entire new heating system,first install all of your radiation units (panels, radiators or cabinets) and the Supply and Return Mains - then make the connections at the boiler. Low Design Water Temperature And Large Water Content Systems: 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.
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_ iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_ 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. 7. Where possible,it is recommended to common vent the water heater and boiler.
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 installation 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.
nected to the common venting systemproperlyventswhen tested asoutlined above,return doors, windows,exhaustfans,fireplace dampers and any other gas-burningapplianceto their previous conditionsof use. zontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3, 4.
INDUCED DRAFT HIGH EFFICIENCY BOILERS Maximum Horizontal Vent Length For StainlessSteelVentPipe - 30' Plus One 90° Elbow PlusVent Terminal. CHOICE OF VENT PIPE MATERIAL Minimum Horizontal Vent Length - 2' Plus One 90° ElbowVent Termination. 2. U.L.Listed Heat-Fab Saf-T-Vent Stainless SteelVent Pipe. Additional elbowsare equivalent to 6 feet of straightpipe for 4" diameter 90° elbowor 3 feet of straight pipe for 3" diameter 90° elbow.
These boilers may be vented horizontally as shown in Figure 10. The vent pipe is pitched down from the boiler to the vent termination. Do not connect other appliances to this vent. 1, , Vent Pipe Material: A. UL ListedZ-FlexZ-Vent stainless steelvent pipe from boiler to vent termination, -orB. 6, Vent Termination Fitting: For all vent pipe materials, you may use either: A. A 90° elbow pointing down, fitted with a minimum 114" mesh screen to keep out rodents and birds.
Figure 11 - Horizontal Venting Clearances NOTE: _ THERE CONSIDERATION AWAY FROM IS A POTENTIAL _NOULD THE WINDWARD BE POR GIVEN Si:DE TO OR EXCES:S_VE LOCATE THE WINDS, THE VENT SPECIAL TERMINATION BUILD_NG, LOCATE _2" (3_ VENT CM) CAP TO ALLOW MIN ABOVE: ORADE Locate or guard the vent to prevent accidental contact with people or pets. 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.
For 3" vent pipe runs begin with the male end of the vent pipe over the boilers induced draft blower outlet. For 4" vent pipe runs begin with a 6" length of 3"Z-Vent over the boiler's induced draft blower outlet, to which an even bead of high temperature silicone sealant should be applied. Then connect the 3" Z-Vent to a Z-Vent 3"to 4" reducer. Then 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.
Applyhigh temperature siliconein an even ¼" bead approximately 1/4"from the end of the vent hood's connecting vent pipe. Also,run a similar sizebead of siliconesealant down the seam weld of the vent pipe. Then push the female end over the vent hood's connecting vent pipe. Now fillin 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 steelgear clamp. all vent pipe seams and orient upward in allhorizontal applications.
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 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.
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. 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.
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. Label all wires prior to disconnection when servicing iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii controls.
Figure #13 -Intermittent Ignition 120/60/1 POWER SUPPLY LINE VOLTAGE WIRING LOW VOLTAGE WIRING NEUT HOT_ 24V THERMOSTAT I LOW VOLTAGE FIELD WIRING ,Ol w7: DISCONNEC 1 ;1)/L.
Relief Valve Air Eliminating Fitting (Air Purger) Youmust have a reliefvalve 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 ReliefValvewill automaticallyopen at a pre-determined pressure. This will relievethe strain on the boiler and system.
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. (Flame Rollout Safety Shutoff) Pressure Switch The air pressure switch works on a negative pressure. When the blower comes on the air pressure switch operates the intermittent pilot and gas valve.
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 radiation 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.
Operating Instructions. 1. Set the thermostat to lowestsetting. 2. Turn off allelectric power to the appliance. 3. This appliance is equipped with an ignition devicewhich automaticallylights the burner. Do not attempt to light the burner by hand. 4. 5. Removeburner accesspanel. Depress gas control knob slightlyand turn clockwisef_ "OFF" position. Waitfive (5) minutes to allowany gas in the combustion chamber to vent.
Adjust Limit Controls Instructions for each control are included with the controls. Recommended Figure 15 - PILOT FLAME ADJUSTMENT Boiler Water Temperatures Type of Heating Unit 3i8 '!tO 112" t Limit Control Setting Flame on Sensor 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,_.
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 XEB installation, operation and maintenance manual furnished with boiler.
Boiler Manufacturer: Boiler Identification: Dunkirk Boilers Model #: 85 Middle Road Serial #: Dunkirk, NY 14048 Measured BTUH input: [] [] [] [] Operational Test Date: / / Installation Instructions in the XEBInstallation,Operation and MaintenanceManual have been followed. Initial Operational BoilerTestCheck-Out Procedure has been performed. Information on this form is certifiedto be correct.
Relief Valve Vent Pipe This valveshould open automaticallyif the system pressure exceeds the pressure rating (usually 30psi) of the reliefvaNe. Should it ever fail to open under this condition, shut down your system. Drain the system until system pressure is reduced below the reliefvaNe pressure rating.
WHATTODOIFYOUSMELL GAS DoNottrytolightanyappliance. Do not touch any electricswitch, do not use the phone or any mobile electronics. These actions may create a spark and cause ignition. Leavethe building immediately,then callyour gas supplier. If you cannot reach the gas supplier, call the fire department. Thermostat is not set correctly Reset thermostat Burner is not operating properly Check flame. If it is yellow,the burner is not getting enough air.
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