Dunkirk XEB-2 Installation, Operation & Maintenance Manual
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Dunkirk XEB-2 Installation, Operation & Maintenance Manual

Dunkirk XEB-2 Installation, Operation & Maintenance Manual

Gas-fired hot water induced draft boiler
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See also: Instruction and Installation Manual , Installation, Operation & Maintenance Manual
XEB Series
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
H
C.S.A. Certified for
Tested for 50 psi. ASME
Working Pressure
Natural gas or Propane
DUNKIRK BOILERS
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com
P/N 14683001 Rev. C [06/2011]
An ISO 9001-2008 Certified Company

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Summary of Contents for Dunkirk XEB-2

  • Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL C.S.A. Certified for Tested for 50 psi. ASME Working Pressure Natural gas or Propane DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com P/N 14683001 Rev. C [06/2011] An ISO 9001-2008 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......................7 Chimney & Vent Pipe Connection ....................10 Horizontal Venting Instructions ....................13 Optional Horizontal Venting Instruction ..................18...

  • Page 3: Installation Instructions

    Vent Diameter (Inches) Number of Heating Net I=B=R 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 Boilers must stand on a noncombustible floor. If installed on Canada Only - For altitudes in the range of 2,000-4,500 a combustible floor, please refer to the Repair Parts manual feet (610 - 1350m) above sea level, boilers may be field for the appropriate Combustible Floor Base part number.

  • Page 5: Locating The Boiler

    LOCATINg ThE BOILEr If the boiler is part of a planned heating system, locate Figure 2 - minimum Clearances To Combustible it where shown on your plan. If boiler is to be part of an Construction existing system, it is usually best to put it where the old one was.

  • Page 6: Fresh Air For Combustion

    FrESh AIr FOr COmBuSTION • All Outdoor Air. Provide permanent opening(s) Provide combustion air and ventilation air in accordance communicating directly or by ducts with outdoors. with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections о...

  • Page 7: 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 8 INSTALLATION SySTEm pIpINg Figure 4 - Relief Valve Discharge Piping rELIEF VALVE dISChArgE pIpINg Check local codes Figure 6 - Forced Hot Water Typical Piping With for maximum distance from Zone Control Valve floor or other allowable safe point of discharge Figure 5 - Forced Hot Water Typical Piping...
  • Page 9 INSTALLATION SySTEm pIpINg If you are installing an entire new heating system, first Low Design Water Temperature Systems (Below install all of your radiation units (panels, radiators or 140° F) And Large Water Content Systems: cabinets) and the Supply and Return Mains - then make the connections at the boiler.

  • Page 10: Chimney & Vent Pipe Connection

    ChImNEy & VENT pIpE CONNECTION If the boiler is the only appliance connected to the Check Your Chimney vent, Type B vent pipe is recommended for the vent This is a very important part of your heating system. It connector. must be clean, the right size, properly constructed and in GOOD CONDITION.
  • Page 11 ChImNEy & VENT pIpE CONNECTION Figure 9 - Type B Gas Ven Liner Chimney Thimble Vent System Cleanout Boiler CHECK YOUR CHIMNEY For boilers for connection to gas vents or Chimney chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54, or “Venting systems and Air Supply for Appliances”, of the Natural Gas and...
  • Page 12 ChImNEy & VENT pIpE CONNECTION Insofar as is practical, close all building doors and After it has been determined that each appliance windows and all doors between the space in which the remaining connected to the common venting system appliances remaining connected to the common venting properly vents when tested as outlined above, return system are located and other spaces of the building.

  • Page 13: Horizontal Venting Instructions

    hOrIzONTAL VENTINg INSTruCTIONS INDUCED DRAFT HIGH EFFICIENCY BOILERS Horizontal (Category III) venting systems must be installed CHOICE OF VENT PIPE MATERIAL in accordance with these instructions. • U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe. Maximum Horizontal Vent Length For Stainless Steel Vent •...
  • Page 14 hOrIzONTAL VENTINg INSTruCTIONS These boilers may be vented horizontally as shown in Vent Termination Fitting: For all vent pipe materials, Figure 10. The vent pipe is pitched down from the you may use either: boiler to the vent termination. Do not connect other A 90°...
  • Page 15 hOrIzONTAL VENTINg INSTruCTIONS Figure 11 - Horizontal Venting Clearances Note: If there is a potential for excessive winds, special consideration should be given to locate the vent termination away from the windward side of the building. Vent Cap must be at least 7’...
  • Page 16 hOrIzONTAL VENTINg INSTruCTIONS Joining and Sealing the Vent Pipe: For Heat-Fab Saf-T-Vent stainless steel vent pipe The vent pipe needs to be both watertight and gastight. use a high temperature silicone sealant rated for Seal all joints and seams as follows: 550°F The outside of the male end and inside For Z-Flex Z-Vent stainless steel vent pipe use of the female end of the pipe must be cleaned...
  • Page 17 hOrIzONTAL VENTINg INSTruCTIONS For Flex-L StaR-34 stainless steel vent pipe use For ProTech Systems FasNSeal stainless steel a high temperature silicone sealant rated for vent pipe no cleaning fluid is required. For 3” 550°F. Before applying silicone, the outside of vent pipe runs on 2, 3, 4 and 5 section boilers, the male end and inside of the female end of the begin by locating the FasNSeal Ametek Adapter...

  • Page 18: Optional Horizontal Venting Instruction

    hOrIzONTAL VENTINg INSTruCTIONS Support Spacing: If the horizontal vent must go through a crawl space Do not restrict thermal expansion movement of the or other unheated space, the cool temperatures will vent. The vent pipe must expand and contract freely likely cause the flue gases to continuously condense with temperature change.

  • Page 19: Gas Supply Piping

    gAS SuppLy pIpINg All pipe compound must be resistant to liquefied CAUTION petroleum gas. Install ground joint union in gas supply line between WHAT TO DO IF YOU SMELL GAS shut-off valve and boiler controls. Do not try to light any appliance. Install a sediment trap upstream of gas controls.

  • Page 20: Electrical Wiring

    gAS SuppLy pIpINg Table 8a - NATURAL GAS Pipe Capacity - BTU Per Hour Input Length Includes Fittings Pipe - Ft. ½" ¾" 1" 1¼" 92,000 190,000 350,000 625,000 63,000 130,000 245,000 445,000 50,000 105,000 195,000 365,000 Table 8b - PROPANE GAS Pipe Capacity - BTU Per Hour Input Length Includes Fittings...

  • Page 21: Sequence Of Operation

    SEquENCE OF OpErATION Sequence of Operation - Refer to Figure 13 Thermostat calls for heat, powering the 1K relay coil and closing contacts 1K1 and 1K2. Circulator pump is powered through terminals C1 and Induced draft blower and transformer primary are powered through terminals B1 and B2.

  • Page 22: Wiring Diagrams

    WIrINg dIAgrAmS Figure 13 - Intermittent Ignition NOTICE NOTICE If any of the original wire as supplied with The circulator harness is factory wired to the this appliance must be replaced, it must be aquastat. This harness needs to be connected to the circulator in the field.

  • Page 23: Equipment & Optional Accessories

    EquIpmENT & OpTIONAL ACCESSOrIES Relief Valve Air Eliminating Fitting (Air Purger) You must have a relief valve on your boiler. Water expands An Air Purger is used to remove excess air from the as it is heated. If there is no place for the water to system.
  • Page 24 EquIpmENT & OpTIONAL ACCESSOrIES Blower (Draft Inducer) Rollout Switch The blower provides a means for pulling air through the (Flame Rollout Safety Shutoff) boiler and exhausting the flue gasses into the vent system. The rollout switch is a temperature-sensitive fuse link The blower shuts off when the burners are not firing.

  • Page 25: Starting Your Boiler

    STArTINg yOur BOILEr How A Hot Water System Operates WARNING Your entire heating system (boiler, piping and radiation units) is filled with water. As the water in the boiler is BEFORE OPERATING smell all around the heated, it is pumped from the top of the boiler through appliance area for gas.

  • Page 26: Checking And Adjusting

    STArTINg yOur BOILEr Operating Instructions. WARNING STOP! Read Safety Information on previous page Wait five (5) minutes to clear out any gas. If Set the thermostat to lowest setting. you then smell gas STOP! Follow WHAT TO Turn off all electric power to the appliance. DO IF YOU SMELL GAS on previous page.
  • Page 27 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 Baseboard and Convector Radiators..... 180° F Sensor These settings can be changed after you have had some idea how the system works.

  • Page 28: 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; check gas piping for leaks. ...
  • Page 29 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 30: Maintaining Your Boiler

    mAINTAININg yOur BOILEr Relief Valve Water System This valve should open automatically if the system pressure If system is to remain out of service during freezing exceeds the pressure rating (usually 30 psi) of the relief weather, always drain it completely (water left in to freeze valve.

  • Page 31: 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 electrical switches; do not use any phones in your building. Immediately call your gas supplier from a neighbor’s phone.
  • Page 32 DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com...

This manual is also suitable for:

Xeb-5Xeb-6Xeb-3Xeb-7Xeb-4

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