Dunkirk XEB-2 Installation, Operation & Maintenance Manual
Hide thumbs
Also See for XEB-2:
- Installation manual (37 pages) ,
- Installation instructions manual (33 pages) ,
- Installation, operation & maintenance manual (32 pages)
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Dunkirk XEB-2
Summary of Contents for Dunkirk XEB-2
- Page 1 XEB Series Gas-Fired Hot Water Induced Draft Boilers INSTALLATION, OPERATION & MAINTENANCE MANUAL DUNKIRK BOILERS 85 Middle Rd. Dunkirk, NY 14048 P/N 14683001 Rev. B [11/09] www.dunkirk.com An ISO 9001-2000 Certified Company...
-
Page 2: Table Of Contents
TABLE OF CONTENTS Safety Symbols................................2 Installation Instructions ............................3 Boiler Ratings And Capacities ..........................3 Before You Start ..............................4 Locating The Boiler ..............................5 Fresh Air For Combustion ............................6 Installation System Piping ..........................10 Chimney & Vent Pipe Connection ........................12 Horizontal Venting Instructions ........................15 Optional Horizontal Venting Instruction ...................... -
Page 3: Installation Instructions
Vent Diameter (Inches) Number of AGA/CGA Heating Net IBR Width Model Sections Input *MBH Capacity *MBH+ Rating *MBH To Chimney Horizontal Vent (Category I) (Category III) XEB-2 42.5 XEB-3 75.0 14-1/4 XEB-4 112.5 17-1/2 XEB-5 150.0 20-3/4 XEB-6 187.5 XEB-7 225.0 27-1/4 * MBH = 1,000 Btuh = British Thermal Unit Per Hour. -
Page 4: Before You Start
BOILEr rATINgS & CApACITIES sea level. Consult the National Fuel Gas Code (NFPA54/ANSI These boilers must stand on a noncombustible floor. If installed on Z223.1-latest revision), or the manufacturer for correct orifice siz- a combustible floor, please refer to the Repair Parts manual for the ing information. -
Page 5: Locating The Boiler
LOCATINg THE BOILEr If the boiler is part of a planned heating system, locate it where Figure 2 - minimum Clearances To Combustible shown on your plan. If boiler is to be part of an existing system, it Construction is usually best to put it where the old one was. If you plan to change 8”... -
Page 6: Fresh Air For Combustion
FrESH AIr FOr COmBuSTION Sizing Air/Ventilation Openings NOTICE Provision for combustion and ventilation air must be NOTICE in accordance with the National Fuel Gas Code, ANSI Z223.1- latest revision, or applicable provisions of the local Air openings must be sized to handle all appliances and building codes. - Page 7 FrESH AIr FOr COmBuSTION EXAmpLE 1: Boiler Located In unconfined Space An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of the total input rating of all appliances installed in that space.
- Page 8 FrESH AIr FOr COmBuSTION 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.
- Page 9 FrESH AIr FOr COmBuSTION Where communicating with the outdoors through horizontal ducts (see Figure 3D), each opening shall have a minimum free area of 1 area of sq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure. Figure 3d - Horizontal ducts Communicating to the Outdoors Table 4 FRESh AIR DUCT CAPACITIES (1 Square inch per 2,000 Btuh)
-
Page 10: Installation System Piping
INSTALLATION SySTEm pIpINg WARNING 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. •... - Page 11 INSTALLATION SySTEm pIpINg Figure 4 - relief Valve discharge piping rELIEF VALVE dISCHArgE pIpINg Check local codes Figure 6 - Forced Hot Water Typical piping With Zone for maximum Control Valve distance from floor or other al- lowable safe point of discharge Figure 5 - Forced hot Water Typical Piping...
- Page 12 INSTALLATION SySTEm pIpINg If you are installing an entire new heating system, first install all of Low design Water Temperature Systems (Below 140° F) your radiation units (panels, radiators or cabinets) and the Supply And Large Water Content Systems: and Return Mains - then make the connections at the boiler. In connecting the cold water supply to the water valve, make sure WARNING that a clean water supply is available.
-
Page 13: Chimney & Vent Pipe Connection
CHImNEy & VENT pIpE CONNECTION Where possible, it is recommended to common vent the water NOTICE heater and boiler. Consult the appropriate Vent Sizing Tables in either the National Fuel Gas Code, or the Canadian Installation For boilers for connection to gas vents or chimneys, vent Codes for specific requirements of multiple appliance venting. - Page 14 CHImNEy & VENT pIpE CONNECTION Figure 9 - Type B gas Vent Liner Chimney Thimble Vent System Cleanout Boiler CHECK yOur CHImNEy This is a very important part of your heating system. Chimney It must be clean, the right size, properly constructed and in GOOD CONDITION.
- Page 15 CHImNEy & VENT pIpE CONNECTION zontal pitch and determine there is no blockage or restriction, nected to the common venting system properly vents when tested leakage, corrosion and other deficiencies which could cause an as outlined above, return doors, windows, exhaust fans, fireplace unsafe condition.
-
Page 16: Horizontal Venting Instructions
HOrIZONTAL VENTINg INSTruCTIONS INDUCED DRAFT HIGH EFFICIENCY BOILERS Maximum Horizontal Vent Length For Stainless Steel Vent Pipe - 30’ ChOICE OF VENT PIPE MATERIAL Plus One 90º Elbow Plus Vent Terminal. U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe. Minimum Horizontal Vent Length - 2’... - Page 17 HOrIZONTAL VENTINg INSTruCTIONS These boilers may be vented horizontally as shown in Vent Termination Fitting: For all vent pipe materials, you may Figure 10. The vent pipe is pitched down from the boiler to use either: the vent termination. Do not connect other appliances to this A 90°...
- Page 18 HOrIZONTAL VENTINg INSTruCTIONS Figure 11 - Horizontal Venting Clearances Locate or guard the vent to prevent accidental contact with ing system shall terminate at least 4 feet below, 4 feet people or pets. horizontally from, or 1 foot above any door, window, or gravity air inlet into any building.
- Page 19 HOrIZONTAL VENTINg INSTruCTIONS For 3” vent pipe runs begin with the male end of the vent to which an even bead of high temperature silicone sealant pipe over the boilers induced draft blower outlet. For 4” should be applied. Then continue the 4” Saf-T-Vent pipe vent pipe runs begin with a 6”...
- Page 20 HOrIZONTAL VENTINg INSTruCTIONS Apply high temperature silicone in an even ¼” bead ap- all vent pipe seams and orient upward in all horizontal proximately ¼” from the end of the vent hood’s connecting applications. Adjustable vent lengths are available for 4” vent pipe.
-
Page 21: Optional Horizontal Venting Instruction
HOrIZONTAL VENTINg INSTruCTIONS If the horizontal vent must go through a crawl space or other required to prevent freezing of liquid condensate. Consult the unheated space, the cool temperatures will likely cause the flue vent pipe manufacturer’s instructions for specific guidelines. gases to continuously condense inside the vent pipe. -
Page 22: Gas Supply Piping
gAS SuppLy pIpINg Connecting The gas piping WARNING 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 Never use a match or open flame to test for leaks. right side. -
Page 23: Electrical Wiring
ELECTrICAL WIrINg All electrical work must conform to local codes as well as the Na- CAUTION tional Electrical Code, ANSI/NFPA-70, latest revision. In Canada, electrical wiring shall comply with the Canadian Electrical Code, Label all wires prior to disconnection when servicing CSA-C22.1. -
Page 24: Wiring Diagrams
ELECTRICAL WIRING DIAGRAMS FOR WIrINg dIAgrAmS INDUCED DRAFT HOT WATER BOILERS Figure #13 - Intermittent Ignition 120/60/1 LINE VOLTAGE WIRING POWER SUPPLY LOW VOLTAGE WIRING NEUT LOW VOLTAGE FIELD WIRING THERMOSTAT FUSED BLACK DISCONNECT BLACK WITH TRACER WHITE L8148A GREEN AQUASTAT BLUE DRAFT... -
Page 25: Equipment & Optional Accessories
EquIpmENT & OpTIONAL ACCESSOrIES relief Valve Air Eliminating Fitting (Air purger) You must have a relief valve on your boiler. Water expands as it is An Air Purger is used to remove excess air from the system. It is in- heated. - Page 26 EquIpmENT & OpTIONAL ACCESSOrIES Blower (draft Inducer) rollout Switch The blower provides a means for pulling air through the boiler and (Flame Rollout Safety Shutoff) exhausting the flue gasses into the vent system. The blower shuts off The rollout switch is a temperature-sensitive fuse link device. It is lo- when the burners are not firing.
-
Page 27: Starting Your Boiler
STArTINg yOur BOILEr How A Hot Water System Operates WARNING Your entire heating system (boiler, piping and radiation units) is Never run water into a hot empty boiler. filled with water. As the water in the boiler is heated, it is pumped from the top of the boiler through the supply main to the radia- tion units. -
Page 28: Checking And Adjusting
STArTINg yOur BOILEr Operating Instructions. WARNING Set the thermostat to lowest setting. Wait five (5) minutes to allow any gas in the combustion Turn off all electric power to the appliance. chamber to vent. If you then smell gas in the appliance This appliance is equipped with an ignition device which auto- area or near the floor, do not touch any electrical switch, matically lights the burner. - Page 29 CHECKINg ANd AdjuSTINg Adjust Limit Controls Figure 15 - pILOT FLAmE AdjuSTmENT Instructions for each control are included with the controls. recommended Boiler Water Temperatures Type of Heating Unit Limit Control Setting Flame Standing Radiators......... 180° F Sensor Baseboard and Convector Radiators..... 180° F These settings can be changed after you have had some idea how the system works.
-
Page 30: Initial Operational Boiler Test Check-Out Procedure
INITIAL OpErATIONAL BOILEr TEST CHECK-OuT prOCEdurE XEB Series Cast Iron gas-Fired Cast Iron Boilers ☑ Check off each step as completed. ☐ Verify base insulation is securely fastened to base panels. ☐ Verify air purged from hydronic heating system. ☐ Purge air from gas piping;... - Page 31 Boiler Manufacturer: Model #: _______________________________________________ Dunkirk Boilers Serial #: 85 Middle Road ________________________________________________ Dunkirk, NY 14048 t: _____________________ : ________ /________ /_________ Measured BTUH inpu Operational Test Date ☐ Installation Instructions in the XEB Installation, Operation and Maintenance Manual have been followed.
-
Page 32: Maintaining Your Boiler
mAINTAININg yOur BOILEr relief Valve Vent pipe This valve should open automatically if the system pressure exceeds The venting of this unit is very important and the piping should be the pressure rating (usually 30 psi) of the relief valve. Should it ever checked at least once a month. -
Page 33: Service Hints
SErVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service: WARNING WHAT TO DO IF YOU SMELL GAS Do Not try to light any appliance. Do not touch any electric switch, do not use the phone or any mobile electronics. These actions may create a spark and cause igni- tion. - Page 36 85 Middle Rd. Dunkirk, NY 14048...
Need help?
Do you have a question about the XEB-2 and is the answer not in the manual?
Questions and answers