Dunkirk XEB-2 Installation, Operation & Maintenance Manual Download | Manualshive

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Summary of Contents for XEB-2

Page 1: ...XEB Series Gas FiredHot Water Induced Draft Boilers INSTALLATION OPERATION MAINTENANCE MANUAL DUNKIRK BOILERS 85 Middle Rd Dunkirk NY 14048 www dunkirk corn P N 14683001 Rev B 11 09 ...

Page 2: ...followinginstructions COM PLETELY beforeinstalling Keepthis manual near boiler and retain for future refer ence Thefollowingdefined symbols are used throughout this manual to notify the reader of potential hazards ofvarying risk levels Indicates an imminently hazardous situation which if not avoided WILLresult in death serious injury or substantial property damage Indicates an imminently hazardous...

Page 3: ... VALVE VALVE LeR Si_e Fro_t Right Side DESIGN CERTIFIED FOR NATURAt AND PROPANE GAS XEB 2 2 42 5 36 31 11 4 3 XEB 3 3 75 0 63 55 14 1 4 4 3 XEB 4 4 112 5 94 82 17 1 2 4 3 XEB 5 5 150 0 125 109 20 3 4 4 3 XEB 6 6 187 5 155 135 24 4 4 XEB 7 7 225 0 186 162 27 1 4 4 4 MBH f O00 Btuh British Thermal Unit Per Hou_ Boilers are equipped for altitudes up to 2 000 feet on _ U S A Only For altitudes above 2...

Page 4: ...ailablefrom the boiler manufacturer Canada Only For altitudes in the range of 2 000 4 500feetabove sealevel boilers may be field equipped foruse at high altitudeby usinga certified fieldconversion kit Thechange in main burner orifice sizeresults in the boiler sinput rating being reduced by 10 Theconversionshall be carried out by a manufacturer s authorized representative in accordancewith the requ...

Page 5: ...tions of use Equipment shallbe located so as not to interfere with proper circulation of air When normal infiltration does not provide the necessaryair outside airshall be introduced see Fresh Air for Combustion 6 Adviseowner to keep airpassagesfree of obstructions Ven tilating and combustion air must enter boiler room without restrictions Thefloor supporting the boiler must be noncombustible If i...

Page 6: ...ireplaceor a kitchen or bathroom exhaustfan you should install an outside air intake These deviceswill rob the boiler and water heater of combustion air Sizing Air Ventilation Openings Air openings must be sizedto handle allappliances and air movers exhaust fans etc usingthe air supply For air openings into spaces containing other appliancesin addition to the boiler referto the National Fuel GasCo...

Page 7: ...and doors which meet the air leakage requirements of the International Energy Conservation Code Section 502 1 4 and 3 caulking or sealants are applied to areas such as joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and at other openings EXAMPLE 2 Boiler Located in Confined Spa...

Page 8: ... spaces crawl or attic that freely communicate with the outdoors 1 Where directly communicating with the outdoors see Figure 3B or where communicating to the outdoors through vertical ducts see Figure 3C each opening shall have a minimum free area of 1 sq in per 4000 Btu per hour of total input rating of all equip ment in the enclosure Figure 3B Directly Communicating to the Outdoors Figure 3C Ver...

Page 9: ...rmitted where the equipment has 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 com municate with the out doors and shall have a minimum free area off 1 1 sq inch per 3000 Btu p...

Page 10: ...imney as pos 3 sible Your boiler is shipped assembled You need only to install the circulator ball valves the relief valve with a drain line to carry any water to a drain and the drain valve Install relief valve on 3 4 pipe nipple in tapped boiler opening Pipe the discharge line following guidelines in the preceding Refer to example shown in Figure 4 The discharge line pipe size shall be equal or ...

Page 11: ...F VALVE DISCHARGE PIPING Check local code_ for maximum distance from floor or other al lowable safe point of discharge Figure 6 Forced Hot Water Typical Piping With Zone Control Valve ZONE VALVE o Figure 5 Forced Hot Water Typical Piping MAiN T_K ...

Page 12: ...e Low Design Water Temperature Systems Below 140 F And Large Water Content Systems Significant condensation may form in this boiler and or the venting system if the boiler is operated with return temperatures of less than 120 E Thiscondensation is corrosiveand can eventuallycause severedam ageto the boiler and venting system Theminimum design return water temperature to prevent this condensation i...

Page 13: ...Vent SizingTablesin either the National FuelGasCode or the Canadian Installation Codesfor specificrequirements of multiple appliance venting 8 Ifthe boiler is the only appliance connected to the vent TypeB vent pipe is recommended for the vent connector 9 Slopepipe up from boiler to chimney not lessthan 1 4 per foot 10 End of vent pipe must be flushwith the inside faceof the chim ney flue Use a se...

Page 14: ...iiii iiiiii ii iii iiiii iiiiii iii iii iiii iiiiii i iiii i iiii iiiiii ii iii iiiii iiiiii ii iii iiiii iiiiii iii iii iiii iiiiii i iiii i iiii iiiiii ii iii iiiii iiiiii ii iii iiiii iiiiii iii iii iiii iiiiii iiiii i iiii iiiiii i iiii iiiii iiiiii ii iii iiiii iiiiii ii iiii iiii iiiiii iii iii iiii iiiiii i iiii iiiii iiiiii ii iii iiiii iiiiii ii iii iiiii iiiiii iii iii iiii iiiiii i iiii...

Page 15: ...operate continuously 5 Test for spillage at the hood relief opening after 5 minutes of main burner operation G After it has been determined that each appliance remaining con nected tothe commonventingsystemproperlyventswhentested asoutlinedabove returndoors windows exhaustfans fireplace dampers and any othergas burningapplianceto their previous conditionsof use Any improper operation of the common...

Page 16: ...essSteelVent Pipe 3 U L ListedFlex LStar 34StainlessSteelVent Pipe 4 U L ListedProTechSystemsFasNSeal StainlessSteelVent Pipe Figure 10 Induced Draft High Efficiency boilers Optional Termination Fitting T Jemlund S_deWall Vent Hood VHolo3 for 2 3 4 5 Section Boilers VH I_4 for 6 7 Section _i ers Termination Fitting _ Elbow pointing down same matetiai and pipe size as venting systems equtped with s...

Page 17: ... the outside vent termination and a double wallpipe for passing through a combustiblewall up to 8 thick VH 1 4 or 9 thick VH 1 3 Thehole in the wall must be 61_ square for 3 vent pipe and 7 1 2 square for 4 vent pipe in order to insert the VH 1 side wall vent hood TheVH 1may also be used in noncombus tible walls B Ifthe 90 elbow isthe termination fitting of choice then the singlewall pipe willbe p...

Page 18: ...s gas meters regulators and relief equipment See Figure 11 H Locate or guard the vent to prevent accidental contact with people or pets Terminate the vent above normal snow line Avoid loca tions where snow may drift and block the vent Ice or snow may cause the boiler to shut down if the vent becomes obstructed Under certain conditions flue gas will condense forming moisture In such cases steps sho...

Page 19: ... For 4 vent pipe runs begin with a Saf T Vent3 to 4 in creaser fitting overthe boiler sinduced draft bloweroutlet C to which an even bead of high temperature siliconesealant shouldbe applied Thencontinue the 4 Saf T Ventpipe run by connecting the 4 male end of the Saf T Ventto the increaser Alockingband may be used around this joint for additional support Thevent flowmust be in the direc tion indi...

Page 20: ...le end of each vent pipe Allcomponents should be examined for possibleshipping damage prior to installation Align allvent pipe seams and orient upward in allhorizontal applications Adjustablevent lengths are availablefor4 diameter vent piping For 3 diameter vent piping square cut male end at the desired length For2 3 4 and 5 section boilers usingthe VH 1 3 vent hood connect the FasNSeal Vent to th...

Page 21: ...ressure vent system 5 May be more cost effectivethan stainlesssteel venting particularly at longervent lengths TheFieldControls powervent kit includes either a SWG II 4HD or SWG II 5power venter a MG 1 4 barometric draft controller and the CK 43D controls kit Confirm that installing a power venter isan option allowedby local codes Followthe specificpower venter installation instructions issuedwith...

Page 22: ...ade by a licensed propane installer Never use a match or open flame to test for leaks 9 Two stage regulation should be used by the propane installer 10 Propane gas piping should be checked out by the propane installer Checking The Gas Piping Upon completion of piping check right away for gas leaks Open the manual shut offvalve Test for leaks by applying soap suds or a liquid detergent to each join...

Page 23: ...n inside wall It may be mounted directly on the wall or on a vertically mounted outlet box It should be sensing average room temperature Behinddoors Corners alcoves Concealed pipes Fireplace TV sets Radios Lamps Direct sunlight Kitchens Concealed pipes or ducts Stairwells drafts Doors drafts Unheated room on other side of wall Setheat anticipator at 2amps The24 voltthermostat connects to aquastat ...

Page 24: ...T i II 1K2 _ HIGHLIMIT B_ B l 170 60 1 P WERSUPPLY 120 V PRIMARY 24ZVrSEC NDARY _IK _ 24 V THERMOSTAT O B _ w CIRCULATOR _L31 PRESSURE ROLLOUT SWITCH SWITCH G w S DRAFT INDUCER 120V PRIMARY _ J AT 140C TRANSFORMER 24 V SECONDARY iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii Ifanyoftheoriginalwireassuppliedwiththisappliance must be replaced it must be replacedwith type 105 C ...

Page 25: ... When the systemis firstfilled the EX TROLTankwillcontain little or no water Asthe water is heated its pressure increases It expands into the EX TROLTank compressingthe air in the tank Thiscompressed air cushion permits the water in the systemto expand as the tempera ture changes Air Eliminating Fitting Air Purger An Air Purger is used to remove excessairfrom the system It is in stalledin the supp...

Page 26: ...e blower does not generate enough pressure or if the venting system is blocked Rollout Switch Flame Rollout Safety Shutoff The rollout switch is a temperature sensitive fuse link device It is lo cated on the boiler base just outside the fire box In the event of heat exchanger flueway blockage causing flame to roll out of the fire box the fuse will blow shutting down the flow of gas to the main bur...

Page 27: ...ically as needed Check the temperature pressure gauge Note the position of the hand indicating pressure This should be between 10 and 15lbs Any lowering of this movable hand below 10lbs will indicate loss of water due to leakage The automatic fill valve should compensate for this Instructions are packaged with the valve Thisappliance isequipped with an ignition devicewhich automaticallylights the ...

Page 28: ...rvicetechnician or gas supplier To Turn Off Appliance 1 Setthe thermostat to lowest setting 2 Turn offall electricpower to the appliance if servicingisto be performed 3 Depress gas control knob slightlyand turn clockwise _ to OFF position Do not force Gas Valve Safety Shutdown Test With main burners firing disconnect the ignition cable from the intermittent pilot control box The gas valve should s...

Page 29: ... shut off and the circulator keep running until the thermostat is satisfied or the water cools enough to restart the burners through the limit control 7 To check the operation of the contacts in the pressure switch disconnect the rubber tubing located between the blower and the pressure switch from the pressure switch while the boiler is operating The burners should extinguish and the blower shoul...

Page 30: ...ating disconnect the ignition cable from the intermittent pilot control box Verify that the main gas control closes shutting off the gas to the main burner After verify ing safety control circuit turn off electric power and reconnect ignition cable Once ignition cable securely reset to intermittent pilot control box turn electric power on For multiple heating system zones balance flow through each...

Page 31: ...nitial Operational BoilerTestCheck Out Procedure has been performed Information on this form is certifiedtobe correct Allboiler instructions wiringdiagrams pipingdiagrams and supporting information shipped withthis boiler forwardedto owner maintenance personnel Installation Location Customer Name Address City State Installer Information Company Contractor Address City State Telephone Installer s S...

Page 32: ...ServiceTechnician Before The Start Of Each Season or whenever systemhas been shut down for some time recheck the whole systemfor leaks and recheck the boiler and vent pipe for leaks Replaceor patch any boiler sealsthat are faulty Vent Pipe The venting of this unit is very important and the piping should be checked at least once a month If the vent piping shows any sign of leaking replace it immedi...

Page 33: ...supplycircuit is No electric power to boiler ON Controls out of adjustment Resetaccording to instructions Open radiator vents to excessair Check flowcontrol valve if used It may be in Radiators not heating closedposition Circulating pump not running Checkovercurrent protection Check relayoperation Poor electricalcontact Checkall control terminals and wirejoints Pressureswitch willnot closeand pilo...

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