Dunkirk XEB-4 Operating instructions

XEB Series
Gas-FiredHot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
DUNKIRK
85 Middle
BOILERS
Rd.
Dunkirk, NY 14048
www. dunkirk, corn
P/N 14683001 Rev. B [11/09]
Safety Symbols ........................................................................................................................................................
2
Installation
3
Instructions
.........................................................................................................................................
Boiler Ratings And Capacities ................................................................................................................................
3
Before You Start ......................................................................................................................................................
4
Locating The Boiler .................................................................................................................................................
5
Fresh Air For Combustion
6
Installation
.......................................................................................................................................
System Piping ..................................................................................................................................
10
Chimney & Vent Pipe Connection
.......................................................................................................................
12
Horizontal
.......................................................................................................................
15
Optional
Venting
Horizontal
Instructions
Venting
Instruction
...........................................................................................................
20
Gas supply Piping ................................................................................................................................................
21
Electrical Wiring ...................................................................................................................................................
22
Sequence
22
Wiring
of Operation
........................................................................................................................................
Diagrams ..................................................................................................................................................
Equipment
& Optional
Accessories ....................................................................................................................
23
24
Starting Your Boiler .............................................................................................................................................
26
Checking and Adjusting
27
Initial Operational
Maintaining
......................................................................................................................................
Boiler Test Check-Out
Procedure
........................................................................................
Your Boiler ......................................................................................................................................
Service Hints .........................................................................................................................................................
IMPORTANT:Read the followinginstructions COMPLETELYbefore installing!
29
31
32
Keepthis manual near boiler and retain for future reference.
The followingdefined 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,WILL result in death, serious injury or substantial
property damage.
Indicates an imminently hazardous situation which, ifnot
avoided,may result in death, serious injury or substantial
property damage.
Indicates an imminently hazardous situation which, if not
avoided,may result in injury or property damage.
Indicates information which should be followedto ensure
proper installation and operation.
C.S.A. Certified for
Natural gas or Propane
Tested for 50 Ibs. ASME
Working Pressure
These instructions must be affixedon or adjacent to the boiler.
This boiler cannot be used with all types of chimneys. Read these
instructions carefullybefore installing.
These Gas-Fired Hot Water Boilers are lowpressure, sectional cast
iron boilers Design Certified by C.S.A.(Canadian Standards Association) for use with Natural and Propane Gases. They are constructed
and hydrostaticallytested for a maximum working pressure of 50psi
in accordance with A.S.M.E.Boiler and Pressure VesselCode Section IV Standards for cast iron heating boilers.
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Improper installation, adjustment, alteration, service or
maintenance can cause injury or property damage. Refer
to this manual. For assistance or information consult a
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qualified installer, serviceagency or the gas supplier.
Figure 1 - Boiler Ratings and Capacities
ASME
R_LIEF
VALVE
\,®
.
VALVE
LeR Si_e
Fro_t
XEB-2
2
XEB-3
XEB-4
DESIGN CERTIFIED FOR
NATURAt
AND PROPANE
GAS
Right Side
42.5
36
31
11
4
3
3
75.0
63
55
14-1/4
4
3
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 2,000 feet, ratings should be reduced at the rate
of 4% for each f,O00 feet above sea level. Canada Only - Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10% de-rate.
+ Heating Capacity based on D.O.E. (Department of Energy) testprocedure.
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 allowanceof
1.15in accordance with the factors shownon the I=B=R Standard as
published by The Hydronics Institute.
Selectionof boiler sizeshould 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.
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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 Basepart number.
These Gas-Fired Hot Water Boilers are lowpressure, sectional cast
iron boilers Design Certified by CSA (Canadian Standards Association) for use with Natural and Propane Gases. They are constructed
and hydrostaticallytested for a maximum working pressure of 50psi
(pounds per square inch) in accordance with A.S.M.E.(American
Societyof Mechanical Engineers) Boilerand Pressure VesselCode
Section IV Standards for cast iron heating boilers.
Boilers For Use At High Altitude
This boiler is factory equipped for use at altitudes of 0-2,000feet
above sea level. For use at altitudes above 2,000feet above sea level,
the input ratings are reduced by a change in main burner orifice size.
sea level. Consult the National Fuel Gas Code (NFPA54/ANSI
Z223.l-latest revision), or the manufacturer for correct orifice sizing information. High altitude orifices are availablefrom the boiler
manufacturer.
Canada Only - For altitudes in the range of 2,000-4,500feet above
sea level,boilers may be field equipped for use at high altitudeby
using a certified fieldconversion kit. The change in main burner
orifice size results in the boiler'sinput rating being reduced by 10%.
The conversion shall be carried out by a manufacturer's authorized
representative,in accordance with the requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in
accordance with the requirements of the CSA-B149.1and CSAB149.2Installation Codes. The certifiedfield 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 filledin with
the correct conversion information.
U.S.A.Only - For altitudes above 2,000feet above sea level,input
ratings should be reduced at the rate of 4% for each 1,000feet above
Check to be sure you have the right sizeboiler before starting the
installation. Seerating and capacitytable on previous page.Also be
sure the new boiler is for the type of gas you are using. Check the
rating plate on the right side of the boiler.
Verifythat the boiler is supplied with the correct type of gas, fresh air
for combustion, and a suitable electricalsupply.Also,the boiler must
be connected to a suitablechimney 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. Takethe time to complete all of the
stepsfor SAFEand PROPER operation of the heating system.
If this boiler is installed in a building under construction, special
care must be taken to insure a clean combustion air supply during the construction process. Airborne particulates such as from
drywall dust and from fiberglassinsulation can clogthe burner ports
and cause incomplete combustion and sooting. Where required by
the authority having jurisdiction, the installation must conform to
American Societyof Mechanical Engineers SafetyCode for Controls
and SafetyDevicesfor AutomaticallyFired Boilers,No. CSD-1.
The installation must conform to the requirements of the authority
havingjurisdiction or, in the absence of such requirements, to the
National Fuel Gas Code, ANSIZ223.l-latest revision.
In Canada, the boiler shall be installed according to CSA-B149.1and
.2,Installation Code for Gas Burning Appliances and Equipment.
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als, gasoline and other flammable vapors and liquids
Keep boiler area clean and free from combustible materi-
If the boiler is part of a planned heating system, locate it where
shown on your plan. If boiler is to be part of an existing system,it
is usually best to put it where the old one was. Ifyou plan to change
location, you will need additional materials as wellas an adequate
base. The followingrules apply:
1. The boiler must be level. Metal shims may be used under base
legsfor final leveling.
2. Use a raised base if floor can becomewet or damp.
3.
The vent pipe connection should be as short as possible.
4.
Additional clearances for servicemay exceed clearancesfor fire
protection. Alwayscomplywith the minimum fire protection
clearances shown on the boiler. An 18inch clearance should
be maintained on any side where passageis required to access
for cleaning, servicing,inspection or replacement of any part
that may need attention. An 18inch clearance is recommended
on the control sidefor servicing. Figure 2 and Table2 shows
Figure 2 - Minimum
Construction
_1_
Clearances To Combustible
i8,,
Boiler
6 _'
_
,_
18"
_osite Side
6"
minimum clearances to combustible construction. Consult the
National
5.
6.
.
8,
Fuel Gas Code for further
information.
Equipment shall be installed in a location in which the facilities
for ventilation permit satisfactorycombustion of gas, proper
venting, and maintenance of ambient temperature at safelimits
under normal conditions of use. Equipment shall be located so
as not to interfere with proper circulation of air. When normal
infiltration does not provide the necessary air, outside air shall
be introduced (see"Fresh Air for Combustion").
Adviseowner to keep air passages free of obstructions. Ventilating and combustion air must enter boiler room without
restrictions.
Top
6"
Rear
6"
Control Side
8"
Opposite Side
6"
Front (Alcove)
18"
Flue/Vent Connector
6"
Near Boiler Piping
1"
This unit must be set on a concrete
or other noncombustible
or floor. IT MUST NOT BE INSTALLED
ON CARPETING.
material
base
The floor supporting the boiler must be noncombustible. If it is
combustible, please refer to Repair Parts Listfor the appropriate
Combustible Floor Basepart number. We use a 2" Cladlite pad
as a combustible floor base. These are availablefrom your local
supplier. Use 24" x 30"pad for 2-5 section boilers, and a minimum 30"x 30" pad for 6-7 sections boilers. Theboiler must be
centered on the combustible floor base.
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..)
This unit must be set on a concrete or other noncombustible material base or floor. It must not be installed on
carpeting.
Sizing Air/Ventilation
Provision
forcombustion
andventilation
airmustbe
in accordance
withtheNational
FuelGasCode,
ANSI
Z223.1latestrevision,
orapplicable
provisions
ofthelocal
buildingcodes.
Besuretoprovide
enough
freshairforcombustion.
Enough
airinsures
propercombustion
andassures
thatno
hazard
willdevelop
duetothelackofoxygen.
Openings
Air openings must be sized to handle all appliances and
air movers (exhaust fans,etc.) using the air supply.For
air openings into spaces containing other appliancesin
addition to the boiler refer to the National Fuel Gas Code,
ANSIZ223.1 for sizing.
If No Other GasAppliances In The Same Space
Provide air openings into the boiler space as described in this sec-
Youmustprovide
forenough
freshairtoassure
propercombustion. tion and the National Fuel Gas Code, ANSI Z223.1.Direct exhaust
Thefireintheboileruses
oxygen.
It musthave
acontinuous
supply. installations require air for combustion and ventilation. Direct vent
Theairinahouse
contains
onlyenough
oxygen
tosupply
theburner installations may require air openings for ventilation (to prevent
forashorttime.Outside
airmustenterthehouse
toreplace
that
overheating of boiler controls and boiler space).
used
bytheburner.
Studyfollowing
examples
1and2todetermine
yourfreshairrequirements.
When Other GasAppliances Share the Same Space
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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.
For air openings into spaces containing other appliances in addition
to the boiler refer to the National Fuel Gas Code, ANSI Z223.1for
sizing.
EXAMPLE 1: Boiler Located
In Unconfined
Space
An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (non-partitioned basement) in a conventional house, the air that leaks through the cracks around doors and
windows will usually be adequate to provide air for combustion. The doors should not fit tightly. Do not caulk the cracks around the windows.
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Equipment located in buildings of tight construction shall be provided with air for combustion, ventilation, and dilution of flue
gases using the methods described in example 2 (below) or shall be specially engineered. The authority having jurisdiction must
approve specially engineered installations, a building of tight construction is defined as: 1) walls exposed to the outdoor atmosphere have a continuous water vapor retarder with a rating of one perm or less with openings gasketed or sealed; and 2) openable
windows and doors which meet the air leakage requirements of the International Energy Conservation Code, Section 502.1.4; and
3) caulking or sealants are applied to areas such as joints around window and door frames, between sole plates and floors, between
wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, and at other openings.
EXAMPLE 2: Boiler Located
1.
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 that 100 square inches. One opening shall be within 12 inches of the top and one within 12 inches of the
bottom of the enclosure. The minimum dimension of air openings shall not be less than 3 inches (see Figure 3A).
Figure 3A - Boiler Located in Confined Space
f
Chimney
Or
GasVent
Vent Pipe_
)
Openings
o
All Air from Outdoors: The confined space shall communicate with the outdoors in accordance with Methods A or B below. The
minimum dimension of air openings shall not be less than 3 in. Where ducts are used, they shall be of the same cross-sectional area as
the free area of the openings to which they connect.
Method A: Two permanent openings, one commencing within 12 inches of the top, and one commencing within 12 inches of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by the ducts, with the outdoors or spaces (crawl or
attic) that freely communicate with the outdoors.
1. Where directly communicating with the outdoors (see Figure 3B) or where communicating to the outdoors through vertical ducts
(see Figure 3C), each opening shall have a minimum free area of 1 sq. in. per 4000 Btu per hour of total input rating of all equipment in the enclosure.
Figure 3B - Directly
Communicating
to the Outdoors
Figure 3C - Vertical Ducts Communicating
Pipe
Air
3"x 12"
144,000
108,000
36,000
8"x 8"
256,000
192,000
64,000
8"x 12"
384,000
288,000
96,000
8 ½"x16"
512,000
384,000
128,000
Louver Allowance
The free areas of openings means the area after reduction for any installed louvers or grilles. Be
sure to consider this reduction when sizing the air openings.
to the Outdoors
2. Where
communicating
withtheoutdoors
throughhorizontal
ducts(seeFigure
3D), each opening shall have a minimum free area
of 1 area ofsq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure.
Figure 3D - Horizontal
Ducts Communicating
to the Outdoors
Louver Allowance
3"x 12"
72,000
54,000
18,000
8"x 8"
128,000
96,000
32,000
8"x 12"
192,000
144,000
48,000
8 ½"x16"
256,000
192,000
64,000
The free areas of openings means the area after reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.
Method B: One permanent opening commencing within 12 inches of the top of the enclosure shall be permitted where the equipment has
clearance of at least 1 inch from the sides and back and 6 inches from the front of the appliance. 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 communicate with the out doors, and shall have a minimum free area off
1. 1 sq. inch per 3000 Btu per hour of the total input of all equipment located in the enclosure (see chart below).
2. Not less than the sum of the areas of all vent connectors in the confined space.
Louver Allowance
3"x12"
108,000
81,000
27,000
8"x 8"
192,000
144,000
48,000
8"x12"
288,000
216,000
72,000
8 ½"x 16"
384,000
288,000
96,000
The free areas of openings means the area after reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.
To avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation, a discharge
line shall be installed to relief valve outlet connection.
The discharge line shall:
•connect to relief valve outlet and piped down to safe point of disposal.
•be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line;
•have no intervening shutoffvalve between safety relief valve and discharge to atmosphere (do not plug or
place any obstruction in discharge line.
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•terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;
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•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
1.
ASME Boiler and Pressure
Place boiler in the selected location (as near 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.
o
3.
o
5.
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 greater than that of the relief
valve outlet over the entire length of discharge line with no
intervening shutoffvalve between the safety relief valve and discharge to atmosphere. The discharge line shall terminate with
a plain end to atmosphere where any discharge will be clearly
visible and is at no risk of freezing. The discharge line shall be
independently supported to avoid applied stress on the relief
valve. The installation shall allow complete drainage of the
relief valve and the discharge line. The discharge line shall be as
short and straight as possible and constructed of a material suitable for exposure to temperatures of 375° F or greater.
6,
Vessel Code for additional
installation
requirements.
Referto local codes and appropriate ASMEBoilerand Pressure
Vessel Code for additional installation requirements.
Install Drain Valve on lower left side of boiler as marked.
Install Temperature and Pressure Gauge into 1A,,bushing
threaded in tee furnished with supply piping See Figures 5
and 6).
Connect Supply and Return Lines to boiler, as shown in Figures 5 and 6. The connections may require certain additional
fittings and parts.
Figure 4 - Relief Valve Discharge Piping
RELIEF
VALVE
DISCHARGE
PIPING
Check local code_
for maximum
distance from
Figure 6 - Forced Hot Water Typical Piping With Zone
Control Valve
floor or other allowable safe point
of discharge
ZONE VALVE o,
MAiN
Figure 5 - Forced Hot Water Typical Piping
T_K
If you are installing an entire new heating system,first install all of
your radiation units (panels, radiators or cabinets) and the Supply
and Return Mains - then make the connections at the boiler.
Low Design Water Temperature
And Large Water Content Systems:
In connecting the cold water supply to the water vane, make sure
that a clean water supply is available. When the water supply is from
a well or pump, a sand strainer should be installed at the pump.
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
A hot water boiler installed above radiation level must be equipped
with a low water cutoffdevice. A periodic inspection is necessary, as
is flushing of float type devices, per manufacturers specific 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 vanes to prevent the chilled
medium from entering the heating boiler (Figure 7).
If the boiler is connected to heating coils located in air handling
units where they may be exposed to refrigerated air circulation, the
piping system shall be equipped with flow control valves or other
automatic means to prevent gravity circulation of the boiler water
during the cooling cycle.
Systems (Below 140 ° F)
This condensation is corrosiveand can eventuallycause severedamage to the boiler and venting system. The minimum design return
water temperature to prevent this condensation in the boiler and
venting is 120°EThe minimum high limit setting is 140°E
If the boiler is to be used in a heating system where design water
temperatures below 140°Fare desired (e.g. radiant floor heating),
a 3-way or 4-way mixing vane or suitablealternative is required
to prevent lowtemperature return water from entering the boiler.
When using a mixing vane, followthe manufacturer's installation
instructions.
If the boiler is to be connected to a system having a large water content (such as a former gravity system), it is suggested to use bypass
piping shown in Figure 8.
Figure 7 - Piping Arrangements For Boiler When Used In
Connection With Refrigeration System
Figure 8 - Bypass Piping
Return From System
VALVESA & B_OPENFORHEATmNG;
CLOSEDFORCOOLING
VALVESC & D - CLOSEDFORHEATING;OPENFORCOOUNG
Throttling
TOSYSTEM
Thermometer
Aquastat
Water
Feed
To System
Fi_Rro_With
Air Purger
Front
[ Adi_stthe
at leas_i20_F
two th_ttli_g
i:nthe boiler
valves
reLum
to maintain
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For boilers for connection to gas vents or chimneys, vent
installations shall be in accordance with the National Fuel
Gas Code, ANSI Z223.1-latest revision and applicable
provisions of the local building codes.
7. Where possible,it is recommended to common vent the water
heater and boiler. Consult the appropriate Vent SizingTables in
either the National Fuel Gas Code, or the Canadian Installation
Codesfor specificrequirements of multiple appliance venting.
8.
If the boiler is the only appliance connected to the vent, Type B
vent pipe is recommended for the vent connector.
9.
Slopepipe up from boiler to chimney not less than 1/4" per
foot.
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.l-latest revision. In Canada, followCSAB149.1or .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 ANSIZ223.llatest revision for correct sizing information. In Canada, consult
the Vent SizingTables,Amendment #1 to CSA-B149.1and .2
Installation Codes.
2.
The boiler's induced draft blower has a 3" outlet. A 3" X 4"
increaser fitting is included in the parts bag. Locate the increaser fitting on the outlet of the induced draft blower, and
secure gastight with a bead of the furnished silicone sealant. The
increaser fitting is required on this boiler for Category I venting,
and 4" is the minimum permissible vent diameter. This does
not imply that the vent connector is intended to be 4" 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" diameter.
The boiler installation for chimney venting is not complete
unless the Y'x 4" increaser fitting is located and secured.
These are high efficiencyboilers with a low stack or exhaust
temperature.
3.
.
If venting into a masonry chimney without a liner, line the
chimney from top to bottom with either:
A. ListedType Bvent pipe
B. Listedflexiblevent liner
C. Poured ceramicliner.
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 flexiblevent 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 elbowsas possible.
10. End of vent pipe must be flush with the inside faceof the chimney flue.Use a sealed-in thimble for the chimney connection.
11. The sections of vent pipe should be fastenedwith sheet metal
screwsto make the piping rigid. Use stovepipewires to support
the pipe from above.
12. Do not connect to 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, 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 boiler is installed with single wall vent, it must have a 6" clearance between its surface and any combustible material. A new Type
B gas vent or flexible liner must be installed in accordance with 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 in accordance with the National Fuel Gas Code, ANSI
Z223. l-latest revision and applicable provisions of the local building
codes. In Canada, follow CSA B149.1 or .2 Installation Codes.
Vent connectors serving appliances vented by natural draft shall not
be connected into any portion of mechanical draft systems operating
under positive pressure.
Removing
Existing Boiler From Common Venting
System
When an existing boiler is removed from a common venting system,
the common venting system is likely to be too large for proper 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 hori-
Figure 9 - Type B Gas Vent
Liner
Chimney
Sheet Metal
Vent System
Cleanout
CHECK YOUR CHIMNEY
This is a very important part of your heating system.
It must be clean, the right size, properly constructed
and in GOOD CONDITION. No boiler can function
properly with a bad chimney. Use local codes for installation or National Fuel Gas Code Z223. l-latest revision.
In Canada, follow CSA B149.1 or .2 Installation Codes.
It is very important to properly size the venting system
for induced draft appliances. Consult the Vent Sizing
Tables, in the National Fuel Gas Code ANSI Z223. llatest revision for correct sizing information. In Canada,
consult the Vent Sizing Tables, Amendment # 1 to CSAB 149.1 and.2 Installation Codes.
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nected to the common venting systemproperlyventswhen tested
asoutlined above,return doors, windows,exhaustfans,fireplace
dampers and any other gas-burningapplianceto their previous
conditionsof use.
zontal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deficiencies which could cause an
unsafe condition.
3,
4.
Insofar as is practical, close allbuilding doors and windows and
alldoors between the space in which the appliancesremaining
connected to the common venting system are located and other
spacesof the building. Turn on clothes dryers and any appliance not connected to the common venting system.Turn on
any exhaust fans, such as range hoods and bathroom exhausts,
so they will operate at maximum speed. Close fireplace dampers.
Place in operation the appliance being inspected. Follow the
,
Any improper operation of the common venting system should
be corrected so the installation conforms with the National
Fuel Gas Code, ANSIZ223.l-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.l-latest revision. In Canada, followCSA
B149.1or.2 Installation Codes.
lighting instructions. Adjust thermostat so appliance will 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-
NOTE:
recommended
that
existing
checkedIttoisbe
sure they meet
local
codes.gasvents be
INDUCED
DRAFT HIGH EFFICIENCY
BOILERS
Maximum Horizontal Vent Length For StainlessSteelVentPipe - 30'
Plus One 90° Elbow PlusVent Terminal.
CHOICE OF VENT PIPE MATERIAL
Minimum Horizontal Vent Length - 2' Plus One 90° ElbowVent
Termination.
2. U.L.Listed Heat-Fab Saf-T-Vent Stainless SteelVent Pipe.
Additional elbowsare equivalent to 6 feet of straightpipe for 4" diameter 90° elbowor 3 feet of straight pipe for 3" diameter 90° elbow.
2, 3, 4, 5, Section Boilers use 3"vent pipe;for 6, 7 SectionBoilers use
4"vent pipe.
1. U.L. ListedZ-FlexZ-Vent StainlessSteelVent Pipe.
3. U.L. ListedFlex-LStar-34StainlessSteelVent Pipe.
4.
U.L. ListedProTechSystemsFasNSealStainlessSteelVent Pipe.
Figure 10 - Induced Draft High Efficiency boilers
Termination Fitting
Elbow, pointing down, same matetiai and
pipe size as venting systems equtped with
screen (Min, I/4" Mesh) to keep birds outs
Fot a combustib|e wa|l, use a thimb|e_ Select as
fo|iows:
_°
Optional
T Jemlund
Termination Fitting
S_de Wall Vent Hood
Vent Pipe: Z-Vent, SafoT_Vent, Star 34
_tmble:
Simpson Duravent Thimb|e -# 3G_¢_,/T(3% # 4GV_t#T (4")
Vent Pt_: FasNSeal
Thimble: FasNSea| Wal| Thimble
#FSWT03-3'; FSWT04-4 _'
VHolo3"for 2, 3, 4& 5 Section Boilers
VH-I_4" for 6 & 7 Section _i|ers
PRchDown Toward
Outside 1i4" Per Foot
Pitch Down Towa_
Outside 1/4" Per Foot
_vel
These boilers may be vented horizontally as shown in
Figure 10. The vent pipe is pitched down from the boiler to
the vent termination. Do not connect other appliances to this
vent.
1,
,
Vent Pipe Material:
A. UL ListedZ-FlexZ-Vent stainless steelvent pipe from
boiler to vent termination,
-orB.
6,
Vent Termination Fitting: For all vent pipe materials, you may
use either:
A. A 90° elbow pointing down, fitted with a minimum 114"
mesh screen to keep out rodents and birds. The elbow shall
be of the same material and size as vent pipe. The elbow
exit should be at least 6" awayfrom exterior wall as shown
in Figure 10.
-0rB.
UL ListedHeat-FabSaf-T-Vent stainless steelvent pipe
from boiler to vent termination,
Tjernlund VH- 1Series sidewall vent hood. For 2, 3, 4, 5
section boilers use VH- 1-3", For 6, 7 section boilers use
VH-1-4".
-or-
C. UL ListedFlex-LStaR-34stainless steelvent pipe from
boiler to vent termination,
-or-
7. Vent Pipe Termination Location (Figure 10):
a.
D. UL ListedProTech FasNSealstainless steel vent pipe from
boiler to vent termination.
Clearance to Combustible Materials: For stainless steelvent
pipe maintain 6" minimum air space clearance to combustible
materials.
3,
,
Vent Pipe Size:
A.
B.
5,
2, 3, 4 and 5 section boilers use 3" vent pipe connected
directly to the outlet of the induced draft blower.
6 and 7 section boilers use 4" vent pipe, starting with a 3"
to 4" stainless steelvent pipe transition that is connected
directly to the outlet of the induced draft blower. Do not
use 3" vent pipe on 6 or 7 section boilers.
Vent Pipe Length:
A. For stainless steel vent pipe, the maximum horizontal vent
length is 30feet plus one 90°elbowplus termination fitting.
B.
C.
Minimum horizontal vent length for all vent materials is 2
feet plus one 90° elbowplus termination fitting.
For additional elbowsreduce the maximum vent length as
shown:
•3" - 90° elbow - reduce vent length 3 feet per each 3" elbow
B.
When venting through combustible walls, combustible
clearancesmust be considered. TheVH- 1 Sidewallvent
hood provides both the outside vent termination and a
double wallpipe for passing through a 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, in order to insert the VH- 1 side
wall vent hood. The VH- 1may also be used in noncombustible walls.
If the 90° elbow is the termination fitting of choice,then
the singlewall pipe will be passing through the sidewall.
For combustible walls, a ULlisted thimble shall be used
where the single wallpipe passes through the wall. For
combustible walls using Z-Vent, Saf-T-Vent,or StaR-34
vent pipe, use the following:
• 3" vent pipe - use Simpson's Duravent 3" thimble
•4" vent pipe - use Simpson's Duravent 4" thimble. Maximum wall thickness with this thimble is 7 inches.
For combustible wallsusing ProTech FasNSealwhere the singlewall
vent pipe must pass through the side wall, a UL ListedFasNSealwall
thimble shall be used.
The thimble is adjustable for differentwall thickness, with a maximum wallthickness of 7 inches. Sealthe thimble along the outside
edge of the plate with caulk or siliconeand fasten to the wall with
screwsor nails.
•4" - 90° elbow - reduce vent length 6 feet per each 4" elbow
Example: 6 section boiler has 3 elbows plus the termination fitting.
This means 2 additional 4" elbows will be used, at 6 feet per elbow.
This is equivalent to 12 feet of pipe (2 x 6 =12), therefore maximum
vent length is now 18 feet (30 -12 =18).
C. For single wallpipe through non-combustible walls, the
hole through the wallneed only be large enough to maintain the pitch of the vent pipe, and provide proper sealing. A thimble is not required for single wall pipe passing
through noncombustible walls.
D. Theventing system shall terminate at least 3 feet above
Figure 11 - Horizontal
Venting Clearances
NOTE:
_
THERE
CONSIDERATION
AWAY
FROM
IS
A
POTENTIAL
_NOULD
THE
WINDWARD
BE
POR
GIVEN
Si:DE
TO
OR
EXCES:S_VE
LOCATE
THE
WINDS,
THE
VENT
SPECIAL
TERMINATION
BUILD_NG,
LOCATE
_2"
(3_
VENT
CM)
CAP
TO ALLOW
MIN
ABOVE:
ORADE
Locate or guard the vent to prevent accidental contact with
people or pets.
ing system shall terminate at least 4 feet below, 4 feet
horizontally from, or 1 foot above any door, window,
or gravity air inlet into any building. 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
H,
Terminate the vent above normal snow-line. 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.
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
Under certain conditions, flue gas will condense, forming
moisture. In such cases, steps should be taken to prevent
maintained, from electric meters, gas meters, regulators,
and relief equipment. (See Figure 11)
building materials at the vent terminal from being damaged by exhaust of flue gas.
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 vent on a wall away from the prevailing winter wind.
8_
Joining and Sealing the Vent Pipe:
The vent pipe needs to be both watertight and gastight. Seal all
joints and seams as follows:
A.
For Z-Flex Z-Vent stainless steel vent pipe use a high 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 with brake cleaner before applying silicone bead.
For 3" vent pipe runs begin with the male end of the vent
pipe over the boilers induced draft blower outlet. For 4"
vent pipe runs begin with a 6" length of 3"Z-Vent over the
boiler's induced draft blower outlet, to which an even bead
of high temperature silicone sealant should be applied.
Then connect the 3" Z-Vent to a Z-Vent 3"to 4" reducer.
Then continue the 4"Z-Vent pipe run by connecting the
4" male end of the Z-Vent to the reducer. (A locking band
may be used around this joint for additional support.) Then
followingthe sealinginstructions, push the 4" male end of
the Z-Vent over the 4" increaserfitting. 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.
Beforethe pipes are joined, apply a ¼" bead of siliconeone
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 out. Then use a ZFlex lockingband around the center of the joint.
to which an even bead of high temperature siliconesealant
should be applied. Then continue the 4" Saf-T-Ventpipe
run by connecting the 4" male end of the Saf-T-Ventto the
increaser. (A locking band may be used around this joint
for additional support.) Thevent flowmust 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. Applyhigh
temperature silicone in an even ¼" bead approximately ¼"
to 3/8"from the end of the vent hood's connecting vent pipe.
Also, run a similar size bead of silicone sealant down the
seam weld of the vent pipe. Then push the female end over
the vent hood's connecting vent pipe.
1. Apply the high temperature siliconearound the male
end of the pipe (without the tabs) in an even ¼" bead.
Silicone bead should be approximately ¼" to 3/8"from
the end of the male end. Also,run a similar size bead of
silicone sealant down the seam weld at the end of each
joint.
,
1. Apply the high temperature silicone approximately one
inch from the end, around the male end of the pipe in
an even ¼" bead.
,
,
,
Pipes can now be pushed together asfar as they will
go. The seams on pipe should be aligned and oriented
upward in allhorizontal appliances. Applyanother bead
of siliconearound this joint and smooth out.
,
Slidelockingband over center of joint and tighten gear
clamps. Make sure locking band is centered on joint.
,
Check alljoints and seams for gas tightness.
5. Horizontal venting shall have a slope not less than ¼"
(6.4mm) every 12inches (305mm) downward away
from the boiler to prevent collection of condensate
throughout the assembly.
,
B,
Allowthe sealant to cure for 24hours before operating
the appliance.
For Heat-Fab Saf-T-Vent stainless steelvent 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 applyingthe
siliconebead. 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. Thevent pipe
should be crimped as minimal aspossible to provide
a tight fit over the outlet. After crimping is completed
followthe instructions for applying silicone sealant.
For 4"vent pipe runs, begin with a Saf-T-Vent3" to 4" increaser fitting over the boiler'sinduced draft blower outlet,
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 fiat tool, spread any sealant that
squeezes out around the circumference of the joint.
Attach the sections together with the locking rings and
tabs (except at the blower outlet where no locking ring
exists.) Inspect the joint to ensure that flue gaseswill
not leak.If necessary apply additional sealant around
the joint.
Horizontal venting shall have a slopenot lessthan ¼"
(6.4mm) every 12inches (305mm) downward away
from the boiler to prevent collection of condensate
throughout the assembly.
5. Allowthe sealant to cure for 24 hours before operating
the appliance.
C,
For Flex-LStaR-34stainless steelvent pipe use a high
temperature siliconesealant rated for 550°F.Beforeapplying silicone,the outside of the male end and inside of the
female end of the pipe must be cleaned using a cleaner,
such as methyl ethyl ketone (MEK)or naptha. For 3"
vent pipe runs, begin with the male end of the vent pipe
over the boiler's induced 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 around the inside of
the male end of 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.
Applyhigh temperature siliconein an even ¼" bead approximately 1/4"from the end of the vent hood's connecting
vent pipe. Also,run a similar sizebead of siliconesealant
down the seam weld of the vent pipe. Then push the female
end over the vent hood's connecting vent pipe. Now fillin
the channel inlet with silicone sealant. Do not try to insert
the joiner band, instead fasten the vent pipe to the vent
hood's pipe with a steelgear clamp.
all vent pipe seams and orient upward in allhorizontal
applications. Adjustablevent lengths are availablefor 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 FasNSealAdapter
#FSC-DUN-3. This adapter has no internal sealinggasket.
Toattach the adapter to the vent hood, crimp the 3" vent
hood pipe, apply a 1/4"bead of high temperature silicone
sealant around the outside of the vent hood's crimped
connecting pipe and a similar bead of high temperature
siliconearound the inside of the FasNSealadapter. After
pressing the two pipes together and tightening the locking
band, finish creating a complete sealby fillingthe FasNSeal
adapter'snotched holewith high temperature silicone.
For 6 and 7 section boilers using the VH- 1 - 4"vent hood,
an adapter is not required. The 4" FasNSealvent pipe connects directly to the VH- 1-4" vent hood, and is joined and
sealed by the internal gasket and locking band.
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 size bead of siliconesealant
down the seam weld at the end of each joint.
2. The seams on the vent pipe should be aligned and oriented upward in allhorizontal 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.
.
Tojoin and seal the FasNSealvent pipe:
1. Insert male end into female section.
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 1/2".
.
.
3. Firmly tighten locking band with a nut driver.
Cut the excessJoiner Band so it lays fiatin the beaded
channel. Fill the inlet of the beaded channel with high
temperature silicone.Smooth out the siliconeover the
channel inlet and the siliconebetween the female end
and the stop bead of the male end.
Horizontal venting shall have a slope not less than ¼"
(6.4mm) every 12inches (305mm) downward away
from the boiler to prevent collection of condensate
throughout the assembly.
7. Allowthe sealant to cure for 24hours before operating
the appliance.
D.
2. Push the units together as far as possible.
For ProTech Systems FasNSealstainless 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 3" FasNSealvent pipe.
For 6 and 7 section boilers, begin by locatingthe FasNSeal
Ametek Adapter over the boiler'sinduced draft blower.
Then connect a FasNSeal3" to 4" increaserto the 3"
adapter outlet. Continue the vent pipe run with 4" FasNSeal
vent pipe. Other than the Ametek Adapter and increaser
fitting, DO NOT use 3"vent pipe on 6 or 7 section boilers.
FasNSealvent pipe is joined and sealed by the use of an
internal sealing gasket and a locking band on the female
end of each vent pipe. All components should be examined
for possible shipping damage prior to installation. Align
4. DO NOT penetrate the FasNSealvent pipe with fasteners.
.
o
Horizontal venting shall have a slopeof not less than
¼" (6.4mm) every 12inches (305mm) downward away
from the boiler to prevent the collection of condensate
throughout the assembly.
Support Spacing:
Do not restrict thermal expansion movement of the vent. 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 loosefitting
metal strap or similar support at eachjoint at a maximum
of 4 feet between supports.
B. Heat-Fab stainless steelvent piping requires a support for
every6 feet of horizontal piping run. The support must be
secured using at least #10fasteners 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 11/2inch lower than the previous support when
spaced 6feet apart.
C. Flex-Lstainless steelvent piping requires a loose fitting
metal strap or similar support at eachjoint at a maximum
of 4 feet between supports.
D. ProTech stainless steel vent piping requires one loose fitting FasNSealsupport strap for every6' of horizontal vent.
10. If the horizontal vent must go through a crawl space or other
unheated space, the cool temperatures will likely cause the flue
gases to continuously condense inside the vent pipe. Do not
insulate the vent pipe. It must be visible for monthly inspection. Insure that the vent pipe is properly pitched away from
the boiler, with no low spots, so that condensate in the vent will
drain away from the boiler. An insulated enclosure or chase,
with access for inspection and servicing of the vent, may be
Horizontal venting with a power venter is an alternate method of
sidewallventing. Thisboiler is CSAlisted for sidewallventing with
standard single wallgalvanized or TypeB vent pipe when using the
followingpower venter kits, which were specificallysized for these
boilers:
2, 3, 4, 5
SWG-4D
6, 7
SWG-SD
Some possible reasons for using a power venter for sidewallventing:
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 experiencesgusting or high winds. A
power venter can help prevent the boiler from short cyclingdue
to gusting or high winds by providing vent exhaust pressures
greater than the boiler's induced draft blower alone.
4.
When installersor homeowners prefer a negative pressure vent
system instead of a positive pressure vent system.
5.
May be more cost effectivethan stainless steel
venting, particularly at longer vent lengths.
The Field Controls power vent kit includes either a SWG-II4HD or SWG-II-5power venter, a MG-1 4" barometric draft
controller, and the CK-43D controls kit.
Confirm that installing a power venter is an option allowedby local
required to prevent freezing of liquid condensate. Consult the
vent pipe manufacturer's instructions for specific guidelines.
11. At the beginning of each heating season and monthly during
the heating season, check all vent pipes and the vent terminal
to make sure there are no obstructions. Periodically clean the
screen in the vent terminal.
codes. Followthe specificpower venter installation instructions
issued with the power venter kits. Although the power venter is
equipped with its own fan, the fan on the boiler remains in place and
is unaltered when a power venter is used.
When sidewallventing, flue gasesmust be vented to a point in relation to the prevailingwind so that they may freelydisperse 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 exhausted flue gas.
When installing single wall galvanizedvent pipe for power venting
followthe specificpower venter installation instructions for layout,
location of the barometric draft control and termination connections.
When joining and sealingthe singlewall galvanizedor Type B vent
piping, use RTVsilicone sealant with a minimum temperature rating
of 400°EFor 3" vent pipe runs, begin with the female end of the vent
pipe over the boiler'sinduced draft blower outlet. For 4" vent pipe
runs begin with the galvanized3" to 4" increaser fitting (included in
the boiler'sparts bag) over the induced draft blower outlet. Then follow by placing the female end of the 4" vent pipe over the increaser
fitting.
When joining pieces of single wall galvanizedvent pipe, a substantial bead of siliconeshould be used at the joint to insure a leakproof
connection.
Connecting
The Gas Piping
Refer to Figure 12 for the general layout at the boiler. It shows the
basic fittings you will need. The gas line enters the boiler from the
right side. Flexible gas connectors must never breach any boiler
openings.
Never use a match or open flame to test for leaks.
9.
Two-stage regulation should be used by the propane installer.
10. Propane gas piping should be checked out by the propane
installer.
Figure 12 - GAS PIPING AT BOILER
Checking The Gas Piping
Upon completion of piping, check right away for gas leaks. Open
the manual shut-offvalve. Test for leaks by applying soap suds (or
a liquid detergent) to each joint. Bubbles forming indicate a leak.
CORRECT EVEN THE SMALLEST LEAK AT ONCE.
Manifold
Check Gas Supply
Automatic Ground
Gas Valve,
Joint
The gas pipe to your boiler must be the correct size for the length
of the run and for the total BTU per hour input of all gas utilization
equipment connected to it. See Gas Table 8 for the proper size.
Be sure your gas line complies with local codes and gas company
requirements.
Tmp
Floor Line
.iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
MIN. SUPPLY
5" w.c.
11" w.c.
MAX. SUPPLY
14" w.c.
14" w.c.
MANIFOLD
3.5" w.c.
10" w.c.
20
92,000
190,000
350,000
625,000
40
63,000
130,000
245,000
445,000
60
50,000
105,000
195,000
365,000
216,000
189,000
393,000
145,000
129,000
267,000
121,000
103,000
217,000
The following rules apply:
1.
Use only those piping materials and joining methods listed
as acceptable by the authority having jurisdiction, or in the
absence of such requirements, by the National Fuel Gas Code,
ANSI Z223.1- latest revision. In Canada, follow the CSA B149.1
and .2 Installation Codes for Gas Burning Appliances and
Equipment.
2.
All pipe compound must be resistant to liquefied petroleum gas.
3.
Install ground joint union in gas supply line between shut-off
vane and boiler controls.
second stage regulatoc
4.
Install a sediment trap upstream of gas controls.
5.
Use two pipe wrenches when making the connection to the gas
vane to keep it from turning.
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of 1/2Psig (3.5 kPa).
The length of pipe or tubing should be measured j?om the gas meter or propane
The boiler and its individual shutoffvaNe must be disconnected
6.
Install manual shut-offvaNe in vertical pipe about 5 feet above
floor.
The boiler must be isolated from the gas supply piping system by
closing its individual manual shutoff vane during any pressure testing of the gas supply piping system at test pressures equal to or less
7.
Tighten all joints securely.
than 1/2Psig (3.5 kPa).
8.
Propane gas connections should only be made by a licensed
propane installer.
All electrical work must conform to local codes as well as the National Electrical Code, ANSI/NFPA-70, latest revision. In Canada,
electrical wiring shall comply with the Canadian Electrical Code,
CSA-C22.1.
Label all wires prior to disconnection when servicing
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controls.
Wiring
errors can cause improper
and dangerous
operation. Verify proper operation after servicing.
Install Your Thermostat
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voltageconnections. Followlocalelectricalcodes.
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 offduring any maintenance. Connect 120 volt power supply
to aquastat terminals L1 (HOT) and L2.
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 on a vertically mounted outlet box.
It should be sensing average room temperature.
The boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or,
in the absence of such requirements, with the National Electrical
Code, ANSI/NFPA No. 70 - latest revision. Run a 14 gauge or heavier
copper wire from the boiler to a grounded connection in the service
Concealed pipes
Behinddoors
panel or a properly driven and electrically grounded ground rod.
Corners &
alcoves
Fireplace
Concealed pipes
or ducts
TV sets
Stairwells- drafts
Radios
Doors- drafts
Lamps
Direct sunlight
Unheated room on
other side of wall
Kitchens
Set heat anticipator at .2 amps. The 24 volt thermostat connects
to aquastat terminals T and T.
Sequence of Operation
- Refer to Figure 13
1.
Thermostat calls for heat, powering the 1K relay coil and closing
contacts 1K1 and 1K2.
2.
Circulator pump is powered through terminals C1 and C2.
3.
Induced draft blower and transformer primary are powered
through terminals B1 and B2.
4.
When blower gets up to speed and blower suction pressure
reaches pressure switchset point, pressure switch contacts close
sending 24 volts to intermittent pilot control from transformer
secondary.
5.
Pilot gasvalve opens and spark initiates to light pilot burner.
6.
When pilot flame is proven, spark drops out.
7.
Main gas valve opens and pilot burner ignites main burners.
8.
If boiler water temperature reaches high limit set point, high
limit contacts B-R open, cutting power to blower and intermittent pilot control. Burners extinguish and blower stops. Circulator pump continues to run as long as the thermostat continues
to call for heat. When boiler water temperature drops past the
high limit set point and through the differential, high limit
contacts B-R close,repeating steps 3-7.
9.
If venting systembecomes blocked, blower suction pressure will
drop below the pressure switch set point, opening the pressure
switch contacts and cutting power to the intermittent pilot control. Burners will extinguish, but blower will remain powered
as long as the thermostat continues to callfor heat. If venting
system clears, steps 4-7 will repeat.
10. Thermostat is satisfied, ending callfor heat. Relaycoil 1Kis deenergized,opening 1K1and 1K2contacts. Burners extinguish.
Blowerand circulator pump stop.
Figure #13 -Intermittent
Ignition
120/60/1
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Ifanyoftheoriginalwireassuppliedwiththisappliance NOTE: The circulator harness is factory wired to the
must be replaced,it
must
be replaced with type 105° C
thermoplastic
wire or
its equivalent.
aquastat. This harness needs to be connected to the circulator in the field.
Relief Valve
Air Eliminating Fitting (Air Purger)
Youmust have a reliefvalve on your boiler. Water expands as it is
heated. If there is no place for the water to expand into, water pressure will build up inside the boiler and system. Should this happen,
the ReliefValvewill automaticallyopen at a pre-determined pressure. This will relievethe strain on the boiler and system.Run a pipe
from the reliefvalve outlet (pipe must be same size as outlet and the
open end must not be threaded) to an open drain, tub or sink, or
other suitable drainage point not subject to freezing. Failure to do so
may causewater damageor injury should reliefvalve release.
An Air Purger is used to remove excessair from the system. It is installedin the supply line. It will help to eliminate air from the water
before it reaches the radiators and bleed offthis air.
Expansion Tank
In a properly assembled system, the expanding water flowsinto an
Expansion Tank.This tank should be of the correct size.
The tank is partially filledwith 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
regardlessof water temperature. This assures a "full measure" ofwater, even in the highest radiation unit of the system. It also prevents
blowing offof the reliefvalve.
The air in the tank in the beginning (with system filledwith cold water) is sufficientfor proper operation. Thetank also serves as a trap
for excessair in the system. The air would causegurgling in the pipes
and inefficientcirculation in the radiators if left in the system.
It is possible for a tank to become "waterlogged"(filledwith water).
It can also become overfilledwith 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 excesswater or air.
When installingthis tank, it is important:
1)That the tank be higher than the boiler top.
2) That the pipe to the tank continuously rises up 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-TROLTank Assembly.The EX-TROLTank
comes to you with a 10-12pounds per square inch air charge.This is
the same as the pressure produced in the systemby the automatic fill
valve.When the system is firstfilled, the EX-TROLTank will contain
little or no water.
Asthe water is heated its pressure increases.It expands into the EXTROLTank,compressing the air in the tank. This compressed air
cushion permits the water in the system to expand as the temperature changes.
Main Air Vent For Down Flow Systems Or Diaphragm Type
Expansion Tank
Beforea system is filledwith 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 eliminatemost of this air through the air vents on the
radiation units. A Main Air Vent will speed and simplifythis. It
should be installed on the highest point in the main when allradiation is below top of boiler.
Automatic
Fill Valve
For safe,efficientoperation, a hot water system must be filledwith
water. Adding new water,when needed can be done manually (by
use of a hand valvein the water supply line). This requires regular attention to the system'sneeds. An Automatic Fill Valve accomplishes
this without attention. It is installed in the Supply Lineon hot water
boilers only.The Valveoperates 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 _" 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° E This depends on the type and amount of radiation involved
and weather conditions.
Circulating Pump
Every Forced Hot-Water Systemrequires a Circulating Pump. A
separate pump or zone valve is required for each Zone, ifyou have
a two or more Zone System. Thispump must have the capacityto
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.
Blower (Draft Inducer)
Rollout Switch
The blower provides a means for pulling air through the boiler and
exhausting the flue gasses into the vent system. The blower shuts off
when the burners are not firing. This keeps heat in the house rather
than having it go up the chimney.
(Flame Rollout Safety Shutoff)
Pressure Switch
The air pressure switch works on a negative pressure. When the
blower comes on the air pressure switch operates the intermittent pilot and gas valve. The air pressure switch is factory set and will only
work when the blower operates properly. It will not allow the boiler
to come on if the blower does not generate enough pressure or if the
venting system is blocked.
Factory
Pressure
Switch Set point:
-0.4" wc. for 2-5 section boilers.
-0.5" w.c. for 6-7 section boilers.
The rollout switch is a temperature-sensitive
fuse link device. It is lo-
cated on the boiler base just outside the fire box. In the event of heat
exchanger flueway blockage causing flame to roll out of the fire box,
the fuse will blow, shutting down the flow of gas to the main burners.
The fuse does not change in appearance when blown.
If the rollout switch blows, it must be replaced with an exact replacement. Check heat exchanger flueways for blockage when restoring
system to operating condition. Do not operate system without a
rollout switch.
HowA Hot
Water System
Operates
Your entire heating system (boiler, piping and radiation units) is
filled with water. As the water in the boiler is heated, it is pumped
from the top of the boiler through the supply main to the radiation units. The cooler water in them flows back through the return
main to the boiler. This provides positive and rapid response to the
thermostat.
Filling System With Water
Close the Air Vents on all radiation units. Open the Valves to these
units. Make sure the boiler and Expansion Tank Drain Cocks are
Never run water into a hot empty boiler.
:
This appliance is equipped with an ignition devicewhich
automaticallylights the burner. Do not attempt to light the
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burner
by
hand
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Ifyou do not follow these instructions exactly, fire or explosion may result with property damage, personal injury,
or lossof life.
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
BEFOREOPERATINGsmell all around the appliance area
for gas. Besure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
IF YOU SMELL GAS:
1.
m
touch any electrical switch, do not use the phone.
filling of your system.
2.
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 lbs. will
indicate loss of water due to leakage. The automatic fill valve should
compensate for this. Instructions are packaged with the valve.
Do not attempt to operate any appliance, do not
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 attempted repair may result in a fire or explosion.
operate. Immediately call a qualified service technician
to
inspect
applianceand
to replace
any part
of the
gas
If any
part the
of this
appliance has
been under
water,
do not
control systemwhich has been under water.
Operating Instructions.
1. Set the thermostat to lowestsetting.
2.
Turn off allelectric power to the appliance.
3.
This appliance is equipped with an ignition devicewhich automaticallylights the burner. Do not attempt to light the burner
by hand.
4.
5.
Removeburner accesspanel.
Depress gas control knob slightlyand turn clockwisef_
"OFF" position.
Waitfive (5) minutes to allowany gas in the combustion
chamber to vent. If you then smell gas in the appliance
area or near the floor, do not touch any electrical switch,
do not use the phone. Leavethe building immediately
and callyour 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
next step.
to
7.
Turn gas control knob counterclockwise _'_
Turn on all electricpower to the appliance.
8.
Set thermostat to desired setting.
9.
After visuallyinspecting the flame,replace the lower front
panel.
6.
Figure 14 - Gas Control Knob
o
If the appliancewill not operate after severaltries, turn the
gas control knob to "OFF" and call your servicetechnician
or gas supplier.
INLET
ii_
GAS CONTROL KNOB
SHOWN IN "ON" POSITION
To Turn Off Appliance:
/
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NOTE: Knob cannot be turned to "OFF"unless knob is
depressed slightly.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 shut offthe main
burners. TURN OFF ELECTRIC POWER to boiler before reconnecting ignition cable, to prevent electric shock.
Adjust Pilot Burner
.
to "ON."
Removescrew cover over pilot adjusting screw.
2.
Insert small screwdriver and adjust flame as needed (Figure
#16. Turn screwcounterclockwise _"_ to increase flame,
clockwiseto decrease (Figure #17).
3.
Replacescrew coverover pilot adjusting screw.
1.
Set the thermostat to lowest setting.
2.
Turn offall electricpower to the appliance if servicing is to be
performed.
3.
Depress gas control knob slightlyand turn clockwise/_
"OFF" position. Do not force.
to
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.
Puffsof air from blowing on the flame or stamping on the floor will
causethe flames to turn orange momentarily. Thisis not unusual.Remain stillwhen observing the main burner flames.Referto Figure
#17. If the flame appearance is not correct, check 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.Replacerollout shield after observation.
Adjust Limit Controls
Instructions for each control are included with the controls.
Recommended
Figure 15 - PILOT FLAME ADJUSTMENT
Boiler Water Temperatures
Type of Heating Unit
3i8 '!tO 112"
t
Limit Control Setting
Flame
on
Sensor
Standing Radiators ......................................... 180° F
Baseboard and Convector Radiators ............. 180° F
These settings can be changed after you have had some idea how the
system works. Exam l,_.If your system does not give quite enough heat in
very cold weather, you can raise the limit setting to 190°E
Adjust Thermostat Heat Anticipator
INSTRUCTIONS
FOR THE FINAL ADJUSTMENT
OF THE THERMOSTAT
ARE PACKAGED
WITH
THE THERMOSTAT.
4.
Set Heat anticipator at .2.
5.
Check thermostat operation. When set above temperature 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 desired setting, check to see if it shuts off the gas supply to the burners.
6.
PRESSURE
(UNDER
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
REGULATOR
WIRING
TERMINALS (2)
ADJUSTMENT
CAP SCREW)
OUTLET
PRESSURE
TAP
INLET
PRESSURE.
TAP _'-,
GROUND
(2)
Turn your thermostat up to call for heat and let your boiler run
until the temperature of the water reaches the limit setting. The
gas valve should shut off and the circulator keep running until
the thermostat is satisfied, or the water cools enough to restart
the burners through the limit control.
7.
Figure 16 -AUTOMATIC GAS VALVE
OUTLET _
INLET
PILOT
OUTLET
GAS
CONTROL
KNOB
PILOTADJUSTMENT
(UNDER CAP SCREW)
Figure 17 - Main Burner Flame
operating. The burners should extinguish and the blower should
keep running. When the tubing is reconnected to the pressure
switch, the ignition sequence should begin, resulting in ignition
of the main burners.
LIGHT
8° Finally, set the thermostat for the desired temperature. Special
conditions in your home and the location of the thermostat will
govern this setting.
Safe lighting and other performance criteria were met with the gas
manifold and control assembly provided on the boiler when the
boiler underwent tests specifiedin ANSI Z21.13-latestrevision.
The main burner flame should form a
sharp blue inner mantel with no yellow.
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.
BLUE
XEB Series Cast Iron Gas-Fired Cast Iron Boilers
[]
Check off each step as completed.
[]
Verify base insulation is securely fastened to base panels.
[]
Verify air purged from hydronic heating system.
[]
Purge air from gas piping; check gas piping for leaks.
[]
Verify proper orifices have been installed.
[]
Follow lighting instructions in series XEB installation, operation and maintenance manual furnished with
boiler.
[]
Visually check the main burner flame and verify it has a well defined inner blue mantel with a lighter blue
outer mantel.
[]
Inspect vent system to verify it is functional, unobstructed, and not leaking.
[]
Test the temperature limit control: With burner operating, adjust indicator on limit control below actual boiler
water temperature. Verify burners turn off. Verify the circulator continues to operate. Adjust the indicator on
limit control above actual boiler water temperature and verify burners reignite.
[]
Test any additional field-installed controls. If boiler has a low water cut-off or additional high limit, test for
operation as outlined by the controls manufacturer. Burners should be operating and should go offwhen
controls are tested. When controls are reset, burners should reignite.
[]
Test safety control circuit: with main burner operating, disconnect the ignition cable from the intermittent
pilot control box. Verify that the main gas control closes, shutting off the gas to the main burner. After verify
ing safety control circuit, turn off electric power and reconnect ignition cable. Once ignition cable securely
reset to intermittent pilot control box, turn electric power on.
[]
For multiple heating system zones, balance flow through each zone so that it is about equal per zone.
[]
Verify several operating cycles of proper operation.
[]
Measure gas input:
NaturalGas Procedure
[] Operate boiler for 10minutes.
£P Gas Procedure
[]
LP gas input rate is determined by measuring gases
produced during combustion. Referto Boiler Manual
for combustion guidelinesand corresponding BTU
input.
[]
Verifythe BTUhis approximateto the input rating on
the boiler rating plate.
[] Turn off allother gas appliancespiped with the
boiler,
[] Atthe gas meter, measure the cubic feet of gas
used in 10seconds (CF10).
[] Calculate input: BTUh = CF10x 360,000
[]
Verifythe BTUh is approximateto the input
rating on the boiler rating plate.
[]
Record the BTUh input on the OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
[]
Set operating control (thermostat(s)) to the desired design requirement.
[]
Forward boiler manuals, instructions, wiring diagrams, piping diagrams, and supporting information shipped
with this boiler to owner and/or maintenance personnel.
[]
Complete and sign the INITIAL OPERATIONAL BOILER TEST CERTIFICATE & SIGNED RECEIPT form.
Boiler Manufacturer:
Boiler Identification:
Dunkirk Boilers
Model #:
85 Middle Road
Serial #:
Dunkirk, NY 14048
Measured BTUH input:
[]
[]
[]
[]
Operational Test Date:
/
/
Installation Instructions in the XEBInstallation,Operation and MaintenanceManual have been followed.
Initial Operational BoilerTestCheck-Out Procedure has been performed.
Information on this form is certifiedto be correct.
Allboiler instructions, wiring diagrams, piping diagrams, and supporting information shipped with this boiler
forwarded to owner/maintenance personnel.
Installation Location:
Customer Name:
Address:
City:
Installer Information
State:
Zip:
State:
Zip:
Company/Contractor:
Address:
City:
Telephone #:
Installer's Signature
Installer's Printed Name:
Date:
Relief Valve
Vent Pipe
This valveshould open automaticallyif the system pressure exceeds
the pressure rating (usually 30psi) of the reliefvaNe. Should it ever
fail to open under this condition, shut down your system. Drain
the system until system pressure is reduced below the reliefvaNe
pressure rating. If vaNe discharge occurs, or if vaNefails to open
as described above,contact an authorized contractor or qualified
service technician to replace the reliefvaNeand inspect the heating
system to determine the cause, as this may indicate an equipment
malfunction.
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.
This valveshould be tested everymonth during periods of boiler
operation, and at the beginning and end of any extended non-service
period. Prior to testing, make certain discharge pipe is properly
connected to vane outlet and arranged so as to contain and safely
dispose of boiler discharge. Test at normal system operating pressure. Hold the trip lever fully open for at least five seconds in order
to flush free any sediment that may lodgeon the vane seat. Then
permit the valve to snap shut.
Water
System
If system is to remain out of service during freezing weather, always
drain it completely (water left in to freeze will crack the pipes and/or
boiler).
Cleaning Your Boiler And Burners
Flue passages between sections should be examined yearly and
cleaned if necessary.
To clean, remove burners, pilot and vent pipe. Remove top and front
jacket panels. Split the silicone seal on the flue collector and the
clean out plates with a razor knife. Remove flue collector. Remove
clean out plates by tapping upwards on the bottom of the plate with a
hammer. Remove loose silicone sealant from sections, flue collector,
Expansion Tank
and clean out plates.
Aspreviously noted, this tank may becomewaterlogged, or may receivean excessof air.Frequent automatic opening of the reliefvalve
indicates water logging.A high boiler temperature accompanied by
unusually low radiation unit temperature (and "knocking") indicates
excessair in tank. Tocorrect either condition, closethe valvebetween the boiler and the tank. Drain the tank until it is empty.Check
allthe tank plugs and fittings. Tighten as necessary.Open the vane
between the boiler and tank. Water will rise to the normal height in
the tank if you have an automatic fill vane (otherwise, manually refill
the system).
Clean passageways between sections with a flexible handle wire
brush and a straightened out wire coat hanger. Remove dirt from the
bottom of the boiler and from between sections by vacuuming.
Make sure all flame ports in burners are open and clear. Shake out
or blow out all loose dirt in burners. Reassemble all parts. Seal flue
collector and clean out plates to sections with silicone sealant (400° F
RTV silicone sealant or equivalent). Reseal seams between adjacent
sections where necessary. All joints must be airtight. Be sure to check
tightness of pilot connections and condition of burner flames after
reassembly (see Figures 1S, and 17). Be sure vent pipe connections to chimney are secure and no obstructions are present.
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 assure trouble-free operation, we recommend that
you have the flue passages,burner adjustment, and operation of the
controls checked once eachyear by a competent Service Technician.
Before The Start Of Each Season
(or whenever system has been shut down for some time) recheck the
whole system for leaks.., and recheck the boiler and vent pipe for
leaks.Replaceor patch any boiler sealsthat are faulty.
Blower
The blower motor features a permanently lubricated ball bearing
construction. Lubrication is not required.
Circulator
Pump Isolation Valves
The isolation vanes in the circulator pump flanges should be operated manually once or twice per year to prevent the vanes from becoming stuck in the open position. Rotate the vanes from the open
position to the closed position and back to the open position.
WHATTODOIFYOUSMELL
GAS
DoNottrytolightanyappliance.
Do not touch any electricswitch, do not use the phone or any mobile electronics. These actions may create a spark and cause ignition.
Leavethe building immediately,then callyour gas supplier.
If you cannot reach the gas supplier, call the fire department.
Thermostat is not set correctly
Reset thermostat
Burner is not operating properly
Check flame. If it is yellow,the burner is not getting enough air. Or, ifflame is blue
and noisy and seems to liftoff the burner, the burner is getting too much air.Contact
your service technician.
No electric power to boiler
Check over-current protection. Check to be sure electric power supply circuit is
"ON".
Controls out of adjustment
Resetaccording to instructions.
Radiators not heating
Open radiator vents to excessair.Check flowcontrol valve (if used). It may be in
closed position.
Circulating pump not running
Check overcurrent protection. Check relay operation.
Poor electrical contact
Check all control terminals and wire joints.
Chimney flue is blocked
Pressure switch will not close and pilot spark will not operate to start pilot. Have
your service technician checkand correct, if necessary.
Rollout switch blown
Haveyour servicetechnician check heat exchangerfor blockage.Replacerollout
switchwith exact replacement.
Gas input amount is incorrect
Contact your service technician.
Dirt on seat
Open valvemanually. Allowwater to run and clear valve seat.
Water logged expansion tank
Drain tank, see instructions.
Dmi'_i__
85 Middle Rd.
Dunkirk, NY 14048