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Dunkirk Boilers XEB Series Gas FiredHot Water Induced Draft Boilers Instruction Manual

June 17, 2024
Dunkirk Boilers

Dunkirk Boilers XEB Series Gas FiredHot Water Induced Draft Boilers

Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers- product

NOTICE

  • IMPORTANT: Read the following instructions COMPLETELY before installing!

NOTICE

  • Keep this manual near the boiler and retain it for future reference.

SAFETY SYMBOLS

  • The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

DANGER

  • Indicates an imminently hazardous situation which, if not avoided, WILL result in death, serious injury, or substantial property damage.

WARNING

  • Indicates an imminently hazardous situation that, if not avoided, may result in death, serious injury, or substantial property damage.

CAUTION

  • Indicates an imminently hazardous situation that, if not avoided, may result in injury or property damage.

NOTICE

  • Indicates information that should be followed to ensure proper installation and operation.

INSTALLATION INSTRUCTIONS

  • These instructions must be affixed on or adjacent to the boiler.
  • This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing.
  • These Gas- Gas-fired hot Water Boilers are low-pressure, sectional cast iron boilers Design Certified by C.S.A. (Canadian Standards Association) for use with Natural and Propane Gases.
  • They are constructed and hydrostatically tested for a maximum working pressure of 50 psi under A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.

WARNING

  • Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual.
  • For assistance or information consult a qualified installer, service agency, or gas supplier.

BOILER RATINGS AND CAPACITIES

Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers- fig-1

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

  • The Ratings marked “Net I=B=R Ratings” indicate the amount of remaining heat input that can be used to heat the radiation or terminal units.
  • The Net I=B=R Ratings shown are based on an allowance of 1.15 under the factors shown on the I=B=R Standard as published by The Hydronics Institute.
  • Selection of boiler size should be based upon “Net I=B=R Rating being equal to or greater than the calculated heat loss of the building.
  • The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements.
  • These boilers must stand on a noncombustible floor. If installed on a combustible floor, please refer to the Repair Parts manual for the appropriate Combustible Floor Base part number.
  • These Gas-Fired Hot Water Boilers are low-pressure, sectional cast iron boilers Design Certified by CSA (Canadian Standards Association) for use with Natural and Propane Gases.
  • They are constructed and hydrostatically tested for a maximum working pressure of 50 psi (pounds per square inch) under A.S.M.E.
  • (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.

Boilers For Use At High Altitude

  • This boiler is factory-equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level, the input ratings are reduced by a change in the main burner orifice size.
  • U.S.A. Only – For altitudes above 2,000 feet above sea level, input ratings should be reduced at the rate of 4% for every 1,000 feet above sea level.
  • Consult the National Fuel Gas Code (NFPA54/ANSI Z223.1-latest revision), or the manufacturer for correct orifice sizing information. High-altitude orifices are available from the boiler manufacturer.
  • Canada Only – For altitudes in the range of 2,000-4,500 feet above sea level, boilers may be field-equipped for use at high altitudes by using a certified field conversion kit.
  • The change in the main burner orifice size results in the boiler’s input rating being reduced by 10%.
  • The conversion shall be carried out by a manufacturer’s authorized representative, under the requirements of the manufacturer, provincial or territorial authorities having jurisdiction, and under the requirements of the CSA-B149.1 and CSAB149.2 Installation Codes. The certified field conversion kit includes a conversion data plate, which must be attached to the boiler adjacent to the rating plate, indicating that the boiler has been converted for high-altitude use.
  • The conversion data plate must be filled in with the correct conversion information.

BEFORE YOU START

  • Check to be sure you have the right size boiler before starting the installation. See the rating and capacity table on the previous page. Also, be sure the new boiler is for the type of gas you are using.
  • Check the rating plate on the right side of the boiler.
  • Verify that the boiler is supplied with the correct type of gas, fresh air for combustion, and a suitable electrical supply.
  • Also, the boiler must be connected to a suitable chimney or horizontal venting system and an adequate piping system. Finally, a thermostat, properly located, is needed for control of the heating system.
  • If you have any doubts as to the various requirements, check with local authorities and obtain professional help where needed. Take the time to complete all of the steps for SAFE and PROPER operation of the heating system.
  • If this boiler is installed in a building under construction, special care must be taken to ensure a clean combustion air supply during the construction process.
  • Airborne particulates such as drywall dust and fiberglass insulation can clog the burner ports and cause incomplete combustion and sooting.
  • Where required by the authority having jurisdiction, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.
  • The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1-latest revision.
  • In Canada, the boiler shall be installed according to CSA-B149.1 and 2, Installation Code for Gas Burning Appliances and Equipment.

NOTICE

  • Installers – Follow local regulations for the installation of CO detectors.
  • Follow maintenance recommendations in this instruction manual.

NOTICE

  • Keep boiler area clean and free from combustible materials, gasoline, and other flammable vapors and liquids

LOCATING THE BOILER

  • If the boiler is part of a planned heating system, locate it where shown on your plan. If the boiler is to be part of an existing system, it is usually best to put it where the old one was.
  • If you plan to change location, you will need additional materials as well as an adequate base.

The following rules apply:

  1. The boiler must be level. Metal shims may be used under base legs for final leveling.

  2. Use a raised base if the floor can become wet.

  3. The vent pipe connection should be as short as possible.

  4. Additional clearances for service may exceed clearances for fire protection. Always comply with the minimum fire protection clearances shown on the boiler. An 18-inch clearance should be maintained on any side where passage is required to access for cleaning, servicing, inspection, or replacement of any part that may need attention. An 18-inch clearance is recommended on the control side for servicing. Figure 2 and Table 2 show minimum clearances to combustible construction. Consult the National Fuel Gas Code for further information.

  5. Equipment shall be installed in a location in which the facilities for ventilation permit satisfactory combustion of gas, proper venting, and maintenance of ambient temperature at safe limits under normal conditions of use. Equipment shall be located so as not to interfere with the proper circulation of air. When normal infiltration does not provide the necessary air, outside air shall be introduced (see “Fresh Air for Combustion”).

  6. Advise the owner to keep air passages free of obstructions. Ventilating and combustion air must enter the boiler room without restrictions.

  7. The floor supporting the boiler must be noncombustible. If it is combustible, please refer to the Repair Parts List for the appropriate
    Combustible Floor Base part number. We use a 2″ Cladlite pad as a combustible floor base. These are available from your local supplier. Use a 24″ x 30″ pad for 2-5 section boilers, and a mini- mum 30″ x 30″ pad for 6-7 sections boilers. The boiler must be centered on the combustible floor base.

  8. The boiler shall be installed such that the automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc…)Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-2

NOTICE

This unit must be set on a concrete or other noncombustible material base or floor. It must not be installed on carpeting.

FRESH AIR FOR COMBUSTION

NOTICE

  • Provision for combustion and ventilation air must be in accordance with the National Fuel Gas Code, ANSI Z223.1- latest revision, or applicable provisions of the local building codes.

WARNING

  • Be sure to provide enough fresh air for combustion.
  • Enough air ensures proper combustion and assures that no hazard will develop due to the lack of oxygen.
  • You must provide enough fresh air to ensure proper combustion.
  • The fire in the boiler uses oxygen. It must have a continuous supply.
  • The air in a house contains only enough oxygen to supply the burner for a short time. Outside air must enter the house to replace that used by the burner.
  • Study the following examples 1 and 2 to determine your fresh air requirements.

NOTICE

  • If you use a fireplace or a kitchen or bathroom exhaust fan, you should install an outside air intake.
  • These devices will rob the boiler and water heater of combustion air.

NOTICE

  • Air openings must be sized to handle all appliances and air movers (exhaust fans, etc.) using the air supply.
  • For air openings into spaces containing other appliances in addition to the boiler refer to the National Fuel Gas Code, ANSI Z223.1 for sizing.

If No Other Gas Appliances In The Same Space

  • Provide air openings into the boiler space as described in this section and the National Fuel Gas Code, ANSI Z223.1. Direct exhaust installations require air for combustion and ventilation.
  • Direct vent installations may require air openings for ventilation (to prevent overheating of boiler controls and boiler space).

When Other Gas Appliances Share the Same Space

  • For air openings into spaces containing other appliances in addition to the boiler refer to the National Fuel Gas Code, ANSI Z223.1 for sizing.

FRESH AIR FOR COMBUSTION

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.

NOTICE

  • 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 atmosphere have a continuous water vapor retarder with a rating of one perm or less with openings gasketed or sealed; and 2) openable windows and doors that 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 other openings.

EXAMPLE 2: Boiler Located in Confined Space

  • 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. Each opening shall have a minimum free area of one square inch per 1,000 Btu per hour of the total input rating of all gas utilization equipment in the confined space, but not less than 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).Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-3
  • All Air from Outdoors: The confined space shall communicate with the outdoors under 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.
  • The openings shall communicate directly, or by the ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.
  • Where directly communicating with the outdoors (see Figure 3B) or where communicating to the outdoors through vertical ducts (see Figure 3C), each opening shall have a minimum free area of 1 sq. in. per 4000 Btu per hour of total input rating of all equipment in the enclosure.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-4

Louver Allowance

  • The free areas of openings mean the area after reduction for any installed louvers or grilles.
  • Be sure to consider this reduction when sizing the air openings.
  • Where communicating with the outdoors through horizontal ducts (see Figure 3D), each opening shall have a minimum free area of 1 area of sq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-5

Louver Allowance

  • The free areas of openings mean the area after reduction for any installed louvers or grilles.
  • Be sure to consider this reduction when sizing the air openings.
  • Method B: One permanent opening commencing within 12 inches of the top of the enclosure shall be permitted where the equipment has a clearance of at least 1 inch 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 communicates with the outdoors, and shall have a minimum free area of:
  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 mean the area after reduction for any installed louvers or grilles.
  • Be sure to consider this reduction when sizing the air openings.
INSTALLATION SYSTEM PIPING

WARNING

  • To avoid burns, scalding, or water damage due to the discharge of steam and/or hot water during operation, a discharge line shall be installed to the relief valve outlet connection.

The discharge line shall:

  • connect to the relief valve outlet and piped down to the safe point of disposal.
  • be of pipe size equal to or greater than that of the relief valve outlet over the entire length of the discharge line;
  • have no intervening shutoff valve between the safety relief valve and discharge to the atmosphere (do not plug or place any obstruction in the discharge line.
  • terminate freely to an atmosphere where any discharge will be visible and at no risk of freezing;
  • allow complete drainage of the valve and the discharge line;
  • be independently supported and securely anchored to avoid applied stress on the relief valve;
  • be as short and straight as possible;
  • terminate with plain end (not threaded);
  • be constructed of material suitable for exposure to temperatures of 375° F;
  • or greater.
  • Refer to local codes and appropriate ASME Boiler and Pressure Vessel Codes for additional installation requirements.
  1. Place the boiler in the selected location (as near the chimney as possible). Your boiler is shipped assembled. You need only to install the circulator, ball valves, the relief valve with a drain line to carry any water to a drain, and the drain valve.
  2. Install relief valve on 3/4 pipe nipple in tapped boiler opening. Pipe the discharge line following the guidelines in the preceding
    • Warning. Refer to the example shown in Figure 4. The discharge line pipe size shall be equal to or greater than that of the relief valve outlet over the entire length of the discharge line with no intervening shutoff valve between the safety relief valve and discharge to the atmosphere. The discharge line shall terminate with a plain end to the atmosphere where any discharge will be 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 suitable for exposure to temperatures of 375° F or greater.
  3. Refer to local codes and appropriate ASME Boiler and Pressure Vessel Codes for additional installation requirements.
  4. Install a Drain Valve on the lower left side of the boiler as marked.
  5. Install Temperature and Pressure Gauge into ¼” bushing threaded in tee furnished with supply piping See Figures 5 and 6).
  6. Connect Supply and Return Lines to the boiler, as shown in Figures 5 and 6. The connections may require certain additional fittings and parts.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-8
  • If you are installing an entirely 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.
  • In connecting the cold water supply to the water valve, make sure that a clean water supply is available. When the water supply is from a well or pump, a sand strainer should be installed at the pump.
  • A hot water boiler installed above radiation level must be equipped with a low water cutoff device. A periodic inspection is necessary, as is the flushing of float-type devices, per manufacturers’ specific instructions.
  • When the boiler is used in connection with refrigeration systems it shall be installed so that the chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the heating boiler (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:

WARNING

  • Significant condensation may form in this boiler and/or the venting system if the boiler is operated with return temperatures of less than 120° F.
  • This condensation is corrosive and can eventually cause severe damage to the boiler and venting system. The minimum design return water temperature to prevent this condensation in the boiler and venting is 120°F.
  • The minimum high limit setting is 140°F
  • If the boiler is to be used in a heating system where design water temperatures below 140°F are desired (e.g. radiant floor heating), a 3-way or 4-way mixing valve or a suitable alternative is required to prevent low-temperature return water from entering the boiler.
  • When using a mixing valve, follow the manufacturer’s installation instructions.
  • If the boiler is to be connected to a system having a large water content (such as a former gravity system), it is suggested to use bypass piping shown in Figure 8.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-9

CHIMNEY & VENT PIPE CONNECTION

NOTICE

  • For boilers for connection to gas vents or chimneys, vent installations shall be under the National Fuel Gas Code, ANSI Z223.1 – latest revision and applicable provisions of the local building codes.

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.

  1. Use local codes for installation or National Fuel Gas Code Z223.1-latest revision. In Canada, follow CSA B149.1 or .2 Installation Codes. It is very important to properly size the venting system for induced draft appliances. Consult the Vent Sizing Tables, in the National Fuel Gas Code ANSI Z223.1 latest revision for correct sizing information. In Canada, consult the Vent Sizing Tables, Amendment #1 to CSA- B149.1 and .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 increaser fitting on the outlet of the induced draft blower, and secure the 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 a 4″ diameter 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″ in diameter.

    • NOTICE
    • The boiler installation for chimney venting is not complete unless the 3″ x 4″ increaser fitting is located and secured.

  3. These are high-efficiency boilers with a low stack or exhaust temperature.

  4. If venting into a masonry chimney without a liner, line the chimney from top to bottom with either:

    • A. Listed Type B vent pipe
    • B. Listed flexible vent liner
    • C. Poured ceramic liner.

  5. Outside chimneys should not be used unless they are (choose one of the following):

    • A. Enclosed in a chase
    • B. Lined with Type B vent pipe
    • C. Use a listed flexible vent liner
    • D. Use a certified chimney lining system

  6. The vent connector from the boiler to the chimney should run as directly as possible with as few elbows as possible.

  7. Where possible, it is recommended to commonly vent the water heater and boiler. Consult the appropriate Vent Sizing Tables in either the National Fuel Gas Code or the Canadian Installation Codes for specific requirements of multiple appliance venting.

  8. If the boiler is the only appliance connected to the vent, a Type B vent pipe is recommended for the vent connector.

  9. Slope pipe up from boiler to chimney not less than 1/4″ per foot.

  10. The end of the vent pipe must be flush with the inside face of the chimney flue. Use a sealed-in thimble for the chimney connection.

  11. The sections of the vent pipe should be fastened with sheet metal screws to make the piping rigid. Use stovepipe wires to support the pipe from above.

  12. Do not connect to the fireplace flue.

  13. Do not install a damper on this boiler.

Minimum Vent Pipe Clearance

  • If the vent pipe must go through a crawl space, a Type B vent 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 the boiler is installed with a single wall vent, it must have a 6″ clearance between its surface and any combustible material. A new Type B gas vent or flexible liner must be installed under the instructions furnished with the vent. Maintain clearances as specified 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 clearances 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 installations shall be under the National Fuel Gas Code, ANSI Z223. 1 latest revision and applicable provisions of the local building codes. In Canada, follow CSA B149.1 or .2 Installation Codes.
  • Vent connectors serving appliances vented by natural draft shall not be connected to 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 venting of the appliances remaining connected to it.
  • At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliance remaining connected to the common venting system are not in operation.
  1. Seal any unused openings in the common venting system.
  2. Visually inspect the venting system for proper size and height

CHIMNEY & VENT PIPE CONNECTION

Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers- fig-10

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 Z223.1-latest revision.
  • In Canada, follow CSA B149.1 or 2 Installation Codes.
  • It is very important to properly size the venting system for induced draft appliances.
  • Consult the Vent Sizing Tables, in the National Fuel Gas Code ANSI Z223.1 latest revision for correct sizing information.
  • In Canada, consult the Vent Sizing Tables, Amendment #1 to CSA-B149.1 and .2 Installation Codes zontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other deficiencies that could cause an unsafe condition.
  • Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.
  • Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Close fireplace dampers.
  • Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.
  • Test for spillage at the hood relief opening after 5 minutes of main burner operation.
  • After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
  • Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI 2223. 1-latest revision. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1-latest revision. In Canada, follow CSA B149.1 or 2 Installation Codes.

NOTICE

  • NOTE: It is recommended that existing gas vents be checked to be sure they meet local codes.

HORIZONTAL VENTING INSTRUCTIONS

INDUCED DRAFT HIGH-EFFICIENCY BOILERS

  • Maximum Horizontal Vent Length For Stainless Steel Vent Pipe – 30* Plus One 90° Elbow Plus Vent Terminal.
  • Minimum Horizontal Vent Length – 2′ Plus One 90° Elbow Vent Termination.
  • Additional elbows are equivalent to 6 feet of straight pipe for a 4″ diameter 90° elbow or 3 feet of straight pipe for a 3″ diameter 90° elbow.
  • 2, 3, 4, and 5, Section Boilers use 3″ vent pipe; for 6, 7 Section Boilers use 4″ vent pipe.

CHOICE OF VENT PIPE MATERIAL

  1. U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe.
  2. U. L. Listed Heat-Fab Saf-T-Vent Stainless Steel Vent Pipe.
  3. U. L. Listed Flex-L. Star-34 Stainless Steel Vent Pipe.
  4. U. L. Listed ProTech Systems FasNSeal Stainless Steel Vent Pipe.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-11
  5. 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.
  6. Vent Pipe Material:
  *  **A**. UL Listed Z-Flex Z-Vent stainless steel vent pipe from boiler to vent termination,
  * -Or-
  *  **B**. UL Listed Heat-FabSaf-T-Vent stainless steel vent pipe from boiler to vent termination,
  * -or-
  *  **C**. UL Listed Flex-L StaR-34 stainless steel vent pipe from boiler to vent termination,
  * -or-
  *  **D**. UL Listed ProTech FasNSeal stainless steel vent pipe from boiler to vent termination.
3. Clearance to Combustible Materials: For stainless steel vent pipe maintain 6″ minimum air space clearance to combustible materials.
4.  **Vent Pipe Size:**
  *  **A**. 2, 3, 4, and 5-section boilers use 3″ vent pipes connected directly to the outlet of the induced draft blower.
  *  **B**. 6 and 7-section boilers use a 4″ vent pipe, starting with a 3″* to 4″ stainless steel vent pipe transition that is connected directly to the outlet of the induced draft blower. Do not use a 3″ vent pipe on 6 or 7 section boilers.
5.  **Vent Pipe Length:**
  * A. For stainless steel vent pipe, the maximum horizontal vent length is 30 feet plus one 90° elbow plus termination fitting.
6.  **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).
7. Vent PipeTermination Location (Figure 10):

  • a. When venting through combustible walls, combustible clearances must be considered. The VH-1 Sidewallvent hood provides both the outside vent termination and a double wallpipe for passing through a combustible wall up to 8″ thick (VH-1 4″) or 9″ thick (VH-1-3″). The hole in the wall must be 61_” square for 3″vent pipe and 7 1/2″ square for 4″ vent pipe, to insert the VH-1 side wall vent hood. The VH-1 may also be used in noncombustible walls.

  • B. If the 90° elbow is the termination fitting of choice,then the single wall pipe will be passing through the sidewall.
    For combustible walls, a ULlisted thimble shall be used where the single wall pipe passes through the wall. For combustible walls using Z-Vent, Saf-T-Vent, or StaR-34 vent pipe, use the following:

  • vent pipe – use Simpson’s Duravent 3″ thimble

  • vent pipe – use Simpson’s Duravent 4″ thimble. The maximum wall thickness with this thimble is 7 inches.

  • For combustible blewalls using ProTechFasNSealwhere the single-wall vent pipe must pass through the side wall, a UL ListedFasNSealwall thimble shall be used.

  • The thimble is adjustable for differential thickness, with a maximum wall thickness of 7 inches. Seal the thimble along the outside edge of the plate with caulk or silicone and fasten to the wall with screws or nails.

  • C. For single wall pipe through non-combustible walls, the hole through the wall need only be large enough to maintain the pitch of the vent pipe and provide proper sealing. A thimble is not required for a single wall pipe passing through noncombustible walls.

  • D. The venting system shall terminate at least 3 feet above any forced air inlet located within 10 feet The venting 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)Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-16

  • E. 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 a vent on a wall away from the prevailing winter wind.

  • Locate or guard the vent to prevent accidental contact with people or pets.

  • H. Terminate the vent above the normal snowline. Avoid locations where snow may drift and block the vent. Ice or snow may cause the boiler to shut down if the vent becomes obstructed.

  • I. 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 damaged by the 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-Hex Z-Vent stainless steel vent pipe use a high-temperature silicone sealant rated at 550°F. The outside of the male end and inside of the female end of the pipe must be For 3″ vent pipe runs begin with the male end of the vent pipe over the boiler-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.) Then following the sealing instructions, push the 4″ male end of the Z-Vent over the 4″ increaser fitting. When using the Tjernlund VH-1 vent hood, the female end (flared end) of the vent pipe will be connected to the termination hood.
  • The male end of the vent hood must be crimped before pushing the Z-Vent over the vent hood’s connecting pipe.
  • Before the pipes are joined, apply a ¼” bead of a silicone one inch from the end of the male end.
  • Then push the pipes together as far as they will go making sure any seams are aligned and oriented upward. Now apply another bead of silicone around this joint and smooth it out.
  • Then use a Z-Flex locking band around the center of the joint.
  1.  Apply the high-temperature silicone approximately one inch from the end, around the male end of the pipe in an even ¼” bead.
  2. Pipes can now be pushed together as far as they will go. The seams on the pipe should be aligned and oriented upward in all horizontal appliances. Apply another bead of silicone around this joint and smooth it out.
  3. Slide the locking band over the center of the joint and tighten the gear clamps. Make sure the locking band is centered on the joint.
  4. Check all joints and seams for gas tightness.
  5. Horizontal venting shall have a slope not less than ¼” (6.4mm) every 12 inches (305mm) downward away from the boiler to prevent collection of condensate throughout the assembly.
  6. Allow the sealant to cure for 24 hours before operating the appliance.
  • B. For Heat-Fab Saf-T-Vent stainless steel vent pipe use a high-temperature silicone sealant rated for 550°F
  • The outside of the male end and inside of the female end of the pipe must be cleaned before applying the silicone bead.
  • For 3″ vent pipe runs, the male end of the vent pipe which goes over the outlet of the boiler’s induced draft blower must be crimped.
  • The vent pipe should be crimped as minimally as possible to provide a tight fit over the outlet. After crimping is completed follow the instructions for applying silicone sealant.
  • For 4″ vent pipe runs, begin with a Saf-T-Vent 3″ to 4″ in-creaser fitting over the boiler’s induced draft blower outlet, to which an even bead of high-temperature silicone sealant should be applied.
  • Then continue the 4″ Saf-T-Vent pipe run by connecting the 4″ male end of the Saf-T- Vent to the increaser. (A locking band may be used around this joint for additional support.) The vent flow must be in the direction indicated on the vent pipe. When using the Tjernlund VH-1 vent hood, the female end (flared end) of the vent pipe will be connected to the termination hood.
  • Apply high-temperature silicone in an even ¼” bead approximately ¼” to ⅜” from the end of the vent hood’s connecting vent pipe.
  • Also, run a similar-sized bead of silicone sealant down the seam weld of the vent pipe. Then push the female end over the vent hood’s connecting vent pipe.
  1. Apply the high-temperature silicone around the male end of the pipe (without the tabs) in an even ¼” bead.
    • The silicone bead should be approximately ¼” to ⅜” from the end of the male end. Also, run a similar-sized bead of silicone sealant down the seam weld at the end of each joint.
  2. Pipes can now be pushed together as far as they will go. The seams on the vent pipe should be aligned and oriented upward in all horizontal appliances. With a moistened finger or flat tool, spread any sealant that squeezes out around the circumference of the joint.
  3. Attach the sections with the locking rings and tabs (except at the blower outlet where no locking ring exists.) Inspect the joint to ensure that flue gases will not leak. If necessary apply additional sealant around the joint.
  4. Horizontal venting shall have a slope not less than ¼” (6.4mm) every 12 inches (305mm) downward away from the boiler to prevent collection of condensate throughout the assembly.
  5.  Allow the sealant to cure for 24 hours before operating the appliance.
  • C. For Flex-L StaR-34 stainless steel vent pipe use a high-temperature silicone sealant rated for 550°F. Before applying silicone, the outside of the male end and inside of the female end of the pipe must be cleaned using a cleaner, such as methyl ethyl ketone (MEK) or naphtha. For 3″ vent pipe runs, begin with the male end of the vent pipe over the boiler’s induced draft blower outlet. For 4″ vent pipe runs begin with a StaR-34 3″ to 4″ increaser fitting over the boiler’s induced draft blower outlet. For both 3″ and 4″ vent pipe runs, apply a bead of silicone sealant around the blower outlet and the inside of the male end of the vent pipe going over the blower’s outlet.
  • When using the Tjernlund VH-1 vent hood, the female end (flared end) of the vent pipe will be connected to the termination hood.
  • Apply high-temperature silicone in an even ¼” bead ap- approximately ¼” from the end of the vent hood’s connecting vent pipe. Also, run a similar-sized bead of silicone sealant down the seam weld of the vent pipe. Then push the female end over the vent hood’s connecting vent pipe. Now fill in the channel inlet with silicone sealant. Do not try to insert the joiner band, instead fasten the vent pipe to the vent hood’s pipe with a steel gear clamp.
  1. Apply the high-temperature silicone around the male end of the pipe in an even ¼” bead. Silicone bead should be approximately ¼” from the end of the male end. Also, run a similar-sized bead of silicone sealant down the seam weld at the end of each joint.
  2. The seams on the vent pipe should be aligned and oriented upward in all horizontal vent pipe runs.
  3. Insert the male end of one into the female end of the other. Push the pipe together so the female end rests up against the stop bead of the male end.
  4. 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 overlaps itself by about ½”.
  5. Cut the excess Joiner Band so it lays flat in the beaded channel. Fill the inlet of the beaded channel with high-temperature silicone. Smooth out the silicone over the channel inlet and the silicone between the female end and the stop bead of the male end.
  6. Horizontal venting shall have a slope not less than ¼” (6.4mm) every 12 inches (305mm) downward away from the boiler to prevent collection of condensate throughout the assembly.
  7. Allow the sealant to cure for 24 hours before operating the appliance.
    • D. For ProTech Systems Fas~Seal stainless steel vent pipe no cleaning fluid is required. For 3″ vent pipe runs on 2, 3, 4, and 5-section boilers, begin by locating the FasNSeal Ametek Adapter over the boiler’s induced draft blower.
    • Continue the vent pipe run with a 3″ FasNSeal vent pipe.
    • For 6 and 7 section boilers, begin by locating the FasNSeal Ametek Adapter over the boiler’s induced draft blower.
    • Then connect a FasNSeal 3″ to 4″ increaser to the 3″ adapter outlet. Continue the vent pipe run with a 4″ FasNSeal vent pipe. Other than the Ametek Adapter and increase fitting, DO NOT use a 3″ vent pipe on 6 or 7-section boilers.
    • FasNSeal vent pipe is joined and sealed by the use of an internal sealing gasket and a locking band on the female end of each vent pipe. All components should be examined for possible shipping damage before installation. Align all vent pipe seams and orient upward in all horizontal applications. Adjustable vent lengths are available for 4″ diameter vent piping. For 3″ diameter vent piping, square cut male end at the desired length. For 2, 3, 4, and 5-section boilers using the VH-1-3″ vent hood, connect the FasNSeal Vent to the VH-1-3″ vent hood using FasNSeal Adapter #FSC-DUN-3. This adapter has no internal sealing gasket.
    • To attach the adapter to the vent hood, crimp the 3″ vent hood pipe, apply a ¼” bead of high-temperature silicone sealant around the outside of the vent hood’s crimped connecting pipe and a similar bead of high-temperature silicone around the inside of the FasNSeal adapter. After pressing the two pipes together and tightening the locking band, finish creating a complete seal by filling the FasNSeal adapter’s notched hole with high-temperature silicone.
    • For 6 and 7 section boilers using the VH-1 – 4″ vent hood, an adapter is not required. The 4″ FasNSeal vent pipe connects directly to the VH-1 – 4″ vent hood and is joined and sealed by the internal gasket and locking band.

To join and seal the FasNSeal vent pipe:

  1. Insert the male end into a female section.
  2. Push the units together as far as possible.
  3. Firmly tighten the locking band with a nut driver.
  4. DO NOT penetrate the FasNSeal vent pipe with fasten- ers.
  5. Horizontal venting shall have a slope of not less than ¼” (6.4mm) every 12 inches (305mm) downward away from the boiler to prevent the collection of condensate throughout the assembly.

Support Spacing:

  • Do not restrict the thermal expansion movement of the vent. The vent pipe must expand and contract freely with temperature change. Each run of vent piping shall be supported as follows:
  • A. Z-Flex stainless steel vent piping requires a loose-fitting metal strap or similar support at each joint at a maximum of 4 feet between supports.
  • B. Heat-Fab stainless steel vent piping requires support for every 6 feet of horizontal piping run. The support must be secured using at least #10 fasteners to a solid material (solid masonry or wood framing or blocking.) Do not fasten to drywall sheathing using hollow wall anchors. Each support will be 1½ inches lower than the previous support when spaced 6 feet apart.
  • C. Flex-L stainless steel vent piping requires a loose-fitting metal strap or similar support at each joint at a maximum of 4 feet between supports.
  • D. ProTech stainless steel vent piping requires one loose-fitting FasNSeal support strap for every 6′ of the horizontal vent.
  • 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. Ensure that the vent pipe is properly pitched away from the boiler, with no low spots, so that condensate in the vent will drain away from the boiler. An insulated enclosure or chase, with access for inspection and servicing of the vent, may be required to prevent freezing of liquid condensate. Consult the vent pipe manufacturer’s instructions for specific guidelines.
  • 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.

OPTIONAL HORIZONTAL VENTING INSTRUCTION

  • Horizontal venting with a power venter is an alternate method of sidewall venting.
  • This boiler is CSA-listed for sidewall venting with standard single-wall galvanized or Type B vent pipe when using the following power venter kits, which were specifically sized for these boilers:

Some possible reasons for using a power venter for sidewall venting:

  1. May be preferred by local codes.
  2. Need a vent piping run beyond 30′ (but not more than 50).
  3. The boiler installation site experiences gusting or high winds. A power venter can help prevent the boiler from short cycling due to gusting or high winds by providing vent exhaust pressures greater than the boiler’s induced draft blower alone.
  4. When installers or homeowners prefer a negative pressure vent system instead of a positive pressure vent system.
  5. May be more cost-effective than stainless steel venting, particularly at longer vent lengths.
  • The Field Controls power vent kit includes either a SWG-II- 4HD or SWG-11-5 power venter, an MG-1 4″ barometric draft controller, and the CK-43D control kit. Confirm that installing a power venter is an option allowed by the local codes. Follow the specific power venter installation instructions issued with the power venter kits. Although the power venter is equipped with its fan, the fan on the boiler remains in place and is unaltered when a power venter is used.
  • When sidewall venting, flue gases must be vented to a point concerning the prevailing wind so that they may freely disperse without being blown back at the building causing discoloration, or into the building through doors or windows causing odors.
  • Also, under certain conditions flue gases will condense, forming moisture. In such cases, steps should be taken to prevent building materials at the vent terminal from being damaged by the exhaust flue gas.
  • When installing single wall galvanized vent pipe for power venting follow the specific power venter installation instructions for layout, location of the barometric draft control, and termination connec- tions.
  • When joining and sealing the single wall galvanized or Type B vent piping, use RTV silicone sealant with a minimum temperature rating of 400°F. For 3″ vent pipe runs, begin with the female end of the vent pipe over the boiler’s induced draft blower outlet. For 4″ vent pipe runs begin with the galvanized 3″ to 4″ increaser fitting (included in the boiler’s parts bag) over the induced draft blower outlet. Then follow by placing the female end of the 4″ vent pipe over the increase fitting.
  • When joining pieces of single-wall galvanized vent pipe, a substantial bead of silicone should be used at the joint to ensure a leakproof connection.

GAS SUPPLY PIPING

Connecting The Gas Piping

Refer to Figure 12 for the general layout of 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.

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 compounds must be resistant to liquefied petroleum gas.
  3. Install ground joint union in the gas supply line between the shut-off valve and boiler controls.
  4. Install a sediment trap upstream of gas controls.
  5. Use two pipe wrenches when making the connection to the gas valve to keep it from turning.
  6. Install a manual shut-off valve in the vertical pipe about 5 feet above the floor.
  7. Tighten all joints securely.
  8. Propane gas connections should only be made by a licensed propane installer.
    • WARNING 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-off valve.
  • Test for leaks by applying soap suds (or a liquid detergent) to each joint. Bubbles forming indicate a leak.
  • CORRECT EVEN THE SMALLEST LEAK AT ONCE.

Check Gas Supply

  • 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.
  • The length of the pipe or tubing should be measured from the gas meter or propane second-stage regulator:
  • The boiler and its shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures above ½ Psig (3.5 kPa).
  • The boiler must be isolated from the gas supply piping system by closing its manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ Psig (3.5 kPa).

ELECTRICAL WIRING

  • All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision.
  • In Canada, electrical wiring shall comply with the Canadian Electrical Code, CSA-C22.1.

WARNING

  • Turn off the electric power at the fuse box before making any line voltage connections.
  • Follow local electrical codes.

Electric Power Supply

  • Run a separate 120-volt circuit from a separate over-current protective device in the electrical service entrance panel.
  • This should be a 15 ampere circuit. Locate a shut-off switch at the boiler. It must be turned off during any maintenance. Connect 120-volt power supply to aquastat terminals L1 (HOT) and L2.
  • The boiler, when installed, must be electrically grounded under the requirements of the authority having jurisdiction or; in the absence of such requirements, with the National Electrical Code, ANSI/NFPA No. 70 – latest revision.
  • Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service panel or a properly driven and electrically grounded ground rod.

CAUTION

  • Label all wires before disconnection when servicing controls.
  • Wiring errors can cause improper and dangerous operations. 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 thermostat about five feet (5) above the floor on an inside wall.
  • It may be mounted directly on the wall or a vertically mounted outlet box.
  • It should be sensing average room temperature.
  • Set the heat anticipator at .2 amps. The 24-volt thermostat connects to aquastat terminals T and T.

SEQUENCE OF OPERATION

Sequence of Operation – Refer to Figure 13

  1. The thermostat calls for heat, powering the 1K relay coil and closing contacts 1K1 and 1K2.
  2. The circulator pump is powered through terminals C1 and C2.
  3. The induced draft blower and transformer primary are powered through terminals B1 and B2.
  4. When the blower gets up to speed and the blower suction pressure reaches the pressure switch set point, the pressure switch contacts close sending 24 volts to intermittent pilot control from the transformer secondary.
  5. The pilot gas valve opens and the spark initiates to light the pilot burner.
  6. When a pilot flame is proven, the spark drops out.
  7. The main gas valve opens and the pilot burner ignites the main burner.
  8. If boiler water temperature reaches a high limit set point, high limit contacts B-R open, cutting power to a blower and intermittent pilot control. The burners extinguish and the blower stops. The circulatory pump continues to run as long as the thermostat continues to call for heat. When the boiler water temperature drops past the high limit set point and through the differential, high limit contacts B-R close, repeating steps 3-7.
  9. If the venting system becomes blocked, the blower suction pressure will drop below the pressure switch set point, opening the pressure switch contacts and cutting power to the intermittent pilot control. Burners will extinguish, but the blower will remain powered as long as the thermostat continues to call for heat. If the venting system clears, steps 4-7 will repeat.
  10. The thermostat is satisfied, ending the call for heat. Relay coil 1K is de-energized, opening 1K1 and 1K2 contacts. Burners extinguish. The blower and circulator pump stop.

WIRING DIAGRAMS

Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers- fig-21

  • If any of the original wires supplied with this appliance must be replaced, it must be replaced with type 105° C thermoplastic wire or its equivalent.
  • NOTE: The circulator harness is factory-wired to the aquastat. This harness needs to be connected to the circulator in the field.

EQUIPMENT & OPTIONAL ACCESSORIES

Relief Valve

  • You must have a relief valve on your boiler. Water expands as it is heated. If there is no place for the water to expand into, water pressure will build up inside the boiler and system. Should this happen,
  • The relief Valve will automatically open at a pre-determined pressure. This will relieve the strain on the boiler and system.
  • Run a pipe from the relief valve outlet (the pipe must be the same size as the outlet and the open end must not be threaded) to an open drain, tub sink, or other suitable drainage point not subject to freezing.
  • Failure to do so may cause water damage or injury should the relief valve release.

Expansion Tank

  • In a properly assembled system, the expanding water flows into an Expansion Tank. This tank should be of the correct size.
  • The tank is partially filled with air. As the water expands it compresses the air in the tank to form an air pressure cushion.
  • This “springlike” cushion serves to maintain correct operating water pressure regardless of water temperature.
  • This assures a “full measure” of water, even in the highest radiation unit of the system. It also prevents the blowing off of the relief valve.
  • The air in the tank in the beginning (with the system filled with cold water) is sufficient for proper operation.
  • The tank also serves as a trap for excess air in the system.
  • The air would cause gurgling in the pipes and inefficient circulation in the radiators if left in the system.
  • A tank can become “waterlogged” (filled with water).
  • It can also become overfilled with air. This can happen after filling the system with new water.
  • Fittings provided on the tank and in the line to the tank are for bleeding off excess water or air.

When installing this tank, it is important to:

  1. That the tank be higher than the boiler top.
  2. That the pipe to the tank continuously rises to the tank (so that air can “bubble” up to it).

Diaphragm Type Expansion Tank

  • The Diaphragm Type Expansion Tank (EX-TROL) takes the place of the conventional expansion tank. Carefully read the instructions packed with your EX-TROL Tank Assembly.
  • The EX-TROL Tank comes to you with a 10-12 pounds per square inch air charge. This is the same as the pressure produced in the system by the automatic fill valve. When the system is first filled, the EX-TROL Tank will contain little or no water.
  • As the water is heated its pressure increases. It expands into the EXTROL Tank, compressing the air in the tank. This compressed air cushion permits the water in the system to expand as the temperature changes.

Air Eliminating Fitting (Air Purger)

  • An Air Purger is used to remove excess air from the system. It is installed in the supply line. It will help to eliminate air from the water before it reaches the radiators and bleed off this air.
  • Main Air Vent For Down Flow Systems Or Diaphragm Type

Expansion Tank

  • Before a system is filled with water, there is air in the pipes and radiation units. Some of it will be trapped as the system is filled.
  • It is possible to eliminate most of this air through the air vents on the radiation units. A Main Air Vent will speed up and simplify this.
  • It should be installed on the highest point in the main when all radiation is below the top of the boiler.

Automatic Fill Valve

  • For safe, efficient operation, a hot water system must be filled with water. Adding new water, when needed can be done manually (by use of a hand valve in the water supply line).
  • This requires regular attention to the system’s needs. An Automatic Fill Valve accomplishes this without attention.
  • It is installed in the Supply Line on hot water boilers only. The Valve operates through water pressure differentials.
  • It does not require an electrical connection.

Drain Valve

  • This manual valve provides a means of draining all water from the boiler and system. It is often installed in the ¾” Tapping at the bottom 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° F.
  • This depends on the type and amount of radiation involved and weather conditions.

Circulating Pump

  • Every Forced Hot-Water System requires a Circulating Pump. A separate pump or zone valve is required for each Zone if you have two or more Zone Systems.
  • This pump must have the capacity to provide the circulation required by your system.
  • The pump does not come pre-installed on the boiler. It must be connected to the circulator harness in the field according to the pump manufacturer’s instructions and the wiring diagrams in this manual.

EQUIPMENT & OPTIONAL ACCESSORIES

  • Blower (Draft Inducer)
    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 pilot and gas valve.
  • 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 Setpoint:

  • 0.4″ wc. for 2-5 section boilers.
  • 0.5″ w.c. for 6-7 section boilers.

Rollout Switch

(Flame Rollout Safety Shutoff)

  • The rollout switch is a temperature-sensitive fuse link device. It is located on the boiler base just outside the firebox.
  • In the event of heat exchanger flue way blockage causing the flame to roll out of the firebox, 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 replacement. Check heat exchanger flueways for blockage when restoring the system to operating condition.
  • Do not operate the system without a rollout switch.

STARTING YOUR BOILER

How A 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 a 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 automatically as needed. Check the temperature-pressure gauge. Note the position of the hand indicating pressure.
  • This should be between 10 and 15 lbs. Any lowering of this movable hand below 10 Ibs. will indicate loss of water due to leakage. The automatic fill valve should compensate for this. Instructions are packaged with the valve.

WARNING

Never run water into a hot empty boiler.

WARNING

  • This appliance is equipped with an ignition device that automatically lights the burner. Do not attempt to light the burner by hand.
  • If you do not follow these instructions exactly, fire or explosion may result in property damage, personal injury, or loss of life.
    BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

IF YOU SMELL GAS:

  1. Do not attempt to operate any appliance, do not touch any electrical switch, do not use the phone.
  2. Leave the building immediately and call your gas supplier.
  3. If your gas supplier cannot be reached, call the fire department.
    • When turning or depressing the gas control knob, use only your hand to push down or turn the knob. Never use tools.
  • If the knob will not operate by hand, the control must be replaced by a qualified service technician. Force or at- attempted repair may result in a fire or explosion.
  • If any part of this appliance has been underwater, do not operate. Immediately call a qualified service technician to inspect the appliance and to replace any part of the gas control system that has been under water.

STARTING YOUR BOILER

Operating Instructions.

  1. Set the thermostat to the lowest setting.
  2. Turn off all electric power to the appliance.
  3. This appliance is equipped with an ignition device that automatically lights the burner. Do not attempt to light the burner by hand.
  4. Remove the burner access panel.
  5. Depress the gas control knob slightly and turn it clockwise to the “OFF” position.
    • NOTICE
    • NOTE: The knob cannot be turned to “OFF” unless the knob is depressed slightly. Do not force.
    • WARNING
    • Wait five (5) minutes to allow any gas in the combustion chamber to vent. If you then smell gas in the appliance area or near the floor, do not touch any electrical switch, and do not use the phone.
    • Leave the building immediately and call your gas supplier. If your gas supplier cannot be reached, call the fire department. Failure to do so may result in a fire or explosion. If you don’t smell gas, go to the next step.
  6. Turn the gas control knob counterclockwise to “ON.”
  7. Turn on all electric power to the appliance.
  8. Set the thermostat to the desired setting.
  9. After visually inspecting the flame, replace the lower front panel.

WARNING
If the appliance will not operate after several tries, turn the gas control knob to “OFF” and call your service technician or gas supplier.

To Turn Off Appliance:

  1. Set the thermostat to the lowest setting.
  2. Turn off all electric power to the appliance if servicing is to be performed.
  3. Depress the gas control knob slightly and turn it clockwise to the “OFF” position. Do not force.

CHECKING AND ADJUSTING

Gas Valve Safety Shutdown Test

  • With the main burners firing, disconnect the ignition cable from the intermittent pilot control box.
  • The gas valve should shut off the main burners.
  • TURN OFF the ELECTRIC POWER to the boiler before reconnecting the ignition cable, to prevent electric shock.

Adjust Pilot Burner

  1. Remove the screw cover over the pilot adjusting screw.
  2. Insert a small screwdriver and adjust the flame as needed (Figure #16. Turn the screw counterclockwise to increase the flame, and clockwise to decrease (Figure #17).
  3. Replace the screw cover over the pilot adjusting screw.

Main Burner(S)

  • The main burners do not require primary air adjustment and are not equipped with primary air shutters. Main burner flames should form sharp blue inner cones in a softer blue outer mantel, with no yellow:
  • Puffs of air from blowing on the flame or stamping on the floor will cause the flames to turn orange momentarily. This is not unusual. Remain still when observing the main burner flames.
  • Refer to Figure #17. If the flame appearance is not correct, check the main burner orifices and the burner throat and flame ports for dust and lint obstruction.
  • It may be necessary to remove the rollout shield to observe the main burner flames. Replace the rollout shield after observation.

CHECKING AND ADJUSTING

Adjust Limit Controls

  • Instructions for each control are included with the controls.

Recommended Boiler Water Temperatures

  • Type of Heating Unit Limit Control Setting
  • Standing Radiators ………………………………….. 180° F
  • Baseboard and Convector Radiators …………. 180° F
  • These settings can be changed after you have had some idea how the system works.
  • Example: If your system does not give quite enough heat in very cold weather, you can raise the limit setting to 190°F
  • These settings can be changed after you have had some idea how the system works. If your system does not give quite enough heat in very cold weather, you can raise the limit set to 190°

Adjust the Thermostat Heat Anticipator

  • INSTRUCTIONS FOR THE FINAL ADJUSTMENT OF THE THERMOSTAT ARE PACKAGED WITH THE THERMOSTAT.
  • Set the Heat anticipator at .2.
  • Check thermostat operation. When set above the temperature indicated on the thermometer, boiler burners should ignite. Make certain the thermostat turns off the boiler when room temperature reaches the selected setting and starts the boiler operating when room temperature falls a few degrees. After setting limit control to the desired setting, check to see if it shuts off the gas supply to the burners.
  • 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.
  • 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 the ignition of the main burners.
  • Finally, set the thermostat for the desired temperature. Special conditions in your home and the location of the thermostat will govern this setting
  • Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13-latest revision.

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.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-25Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-26

INITIAL OPERATIONAL BOILER TEST CHECK-OUT PROCEDURE

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 is purged from the hydronic heating system.
  • Purge air from gas piping; check gas piping for leaks.
  • Verify proper orifices have been installed.
  • Follow lighting instructions in the series XEB installation, operation, and maintenance manual furnished with the boiler.
  • Visually check the main burner flame and verify it has a well-defined inner blue mantel with a lighter blue outer mantel.
  • Inspect the vent system to verify it is functional, unobstructed, and not leaking.
  • Test the temperature limit control: With the burner operating, adjust the indicator on limit control below the actual boiler water temperature. Verify burners are turned off. Verify the circulator continues to operate.
  • Adjust the indicator on limit control above the actual boiler water temperature and verify burners reignite.
  • Test any additional field-installed controls. If the 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 off when controls are tested. When controls are reset, burners should reignite.
  • Test safety control circuit: with the 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 verifying the safety control circuit, turn off the electric power and reconnect the ignition cable. Once the ignition cable is securely reset to the intermittent pilot control box, turn the electric power on.
  • For multiple heating system zones, balance flow through each zone so that it is about equal per zone.
  • Verify several operating cycles of proper operation.

Measure gas input:

  • Natural Gas Procedure
  • Operate the boiler for 10 minutes.
  • Turn off all other gas appliances piped with the boiler.
  • At the gas meter, measure the cubic feet of gas used in 10 seconds (CF10).
  • Calculate input: BTUh = CF10 x 360,000
  • Verify the BTUh is approximate to the input rating on the boiler rating plate.

LP Gas Procedure

  • LP gas input rate is determined by measuring gases produced during combustion. Refer to the Boiler Manual for combustion guidelines and corresponding BTU input.
  • Verify the BTUh is approximate to the input rating on the boiler rating plate.
  • Record the BTUh input on the OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
  • Set operating control (thermostat(s)) to the desired design requirement.
  • Forward boiler manuals, instructions, wiring diagrams, piping diagrams, and supporting information shipped with this boiler to the owner and/or maintenance personnel.
  • Complete and sign the INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.

INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT

  • Boiler Manufacturer: —————
  • Dunkirk Boilers——————-
  • 85 Middle Road——————-
  • Dunkirk, NY 14048————
  • Boiler Identification:—————
  • Model #:———————-
  • Serial #:—————————-
  • Measured BTUH input:———————
  • Operational Test Date:————————-
  • Installation Instructions in the XEB Installation, Operation, and Maintenance Manual have been followed.
  • Initial Operational Boiler Test Check-Out Procedure has been performed.
  • Information on this form is certified to be correct.
  • All boiler instructions, wiring diagrams, piping diagrams, and supporting information shipped with this boiler are forwarded to owner/maintenance personnel.
  • Installation Location:———————–
  • Customer Name:——————
  • Address:——————
  • City:——————-

Installer information

  • Company/Contractor:——————–
  • Address: —————————–
  • City:——————————-
  • Telephone #:——————————-
  • Installer’s Signature——————————-
  • Installer’s Printed Name:—————————-
  • State:—————————-
  • Zip:——————————-
  • State:————————————-
  • Zip:———————————-
  • Date:————————————-

MAINTAINING YOUR BOILER

Relief Valve

  • This valve should open automatically if the system pressure exceeds the pressure rating (usually 30 psi) of the relief valve. Should it ever fail to open under this condition, shut down your system. Drain the system until system pressure is reduced below the relief valve pressure rating. If valve discharge occurs, or if the valve fails to open as described above, contact an authorized contractor or qualified service technician to replace the relief valve and inspect the heating system to determine the cause, as this may indicate an equipment malfunction.
  • This valve should be tested every month during periods of boiler operation and at the beginning and end of any extended non-service period. Before testing, make certain the discharge pipe is properly connected to the valve outlet and arranged to contain and safely dispose of boiler discharge. Test at normal system operating pressure. Hold the trip lever fully open for at least five seconds to flush free any sediment that may lodge on the valve seat. Then permit the valve to snap shut.

Expansion Tank

  • As previously noted, this tank may become waterlogged or may receive an excess of air. Frequent automatic opening of the relief valve indicates water logging. A high boiler temperature accompanied by unusually low radiation unit temperature (and “knocking”) indicates excess air in the tank. To correct either condition, close the valve between the boiler and the tank. Drain the tank until it is empty. Check all the tank plugs and fittings. Tighten as necessary. Open the valve between the boiler and tank. Water will rise to the normal height in the tank if you have an automatic fill valve (otherwise, manually refill the system).

Boiler Flue Passages

  • Under normal operating conditions, with the burners properly adjusted, it should not be necessary to clean the boiler flue gas passages. However, to ensure trouble-free operation, we recommend that you have the flue passages, burner adjustment, and operation of the controls checked once each year by a competent Service Technician.

Before The Start Of Each Season

  • (or whenever the system has been shut down for some time) recheck the whole system for leaks… and recheck the boiler and vent pipe for leaks. Replace or patch any faulty boiler seals.

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 a 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, and remove burners, pilot, and vent pipe. Remove the top and front jacket panels. Split the silicone seal between the flue collector and the clean-out plates with a razor knife. Remove the flue collector. Remove clean-out plates by tapping upwards on the bottom of the plate with a hammer. Remove loose silicone sealant from sections, and 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 the 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. All joints must be airtight. Be sure to check the tightness of pilot connections and the condition of burner flames after reassembly (see Figures 15, and 17). Be sure vent pipe connections to the chimney are secure and no obstructions are present.

Blower

  • The blower motor features a permanently lubricated ball-bearing construction. Lubrication is not required.

Circulator Pump Isolation Valves

  • The isolation valves in the circulator pump flanges should be operated manually once or twice per year to prevent the valves from becoming stuck in the open position.
  • Rotate the valves from the open position to the closed position and back to the open position.

SERVICE HINTS

  • You may avoid inconvenience and service calls by checking these points before you call for service:

WARNING

WHAT TO DO IF YOU SMELL GAS

  • Do Not try to light any appliance.
  • Do not touch any electric switch, and do not use the phone or any mobile electronics.
  • These actions may create a spark and cause ignition.
  • Leave the building immediately, then call your gas supplier.
  • If you cannot reach the gas supplier, call the fire department.Dunkirk-Boilers-XEB-Series-Gas-Fired-Hot-Water-Induced-Draft-Boilers-fig-27
  • DUNKIRK BOILERS
  • 85 Middle Rd.
  • Dunkirk, NY 14048
  • www.dunkirk.com

Documents / Resources

| Dunkirk Boilers XEB Series Gas FiredHot Water Induced Draft Boilers [pdf] Instruction Manual
XEB Series Gas FiredHot Water Induced Draft Boilers, XEB Series, Gas FiredHot Water Induced Draft Boilers, Water Induced Draft Boilers, Induced Draft Boilers, Draft Boilers, Boilers
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