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Dunkirk XEB-4 - User Manual

Dunkirk XEB-4
40 pages
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An ISO 9001-2008 Certified Company
XEB Series II
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION,OPERATION&
MAINTENANCEMANUAL
P/N 240009020 Rev. B [04/2012]
Manufacturedby:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
Models
XEB-2
XEB-3
XEB-4
XEB-5
XEB-6
XEB-7
Tested For 50 psi
ASME
Working Pressure
C.S.A. Certi ed
For Natural Gas Or Propane

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Summary

Safety Symbols & Warnings

Hazard Symbols and Descriptions

Explains DANGER, WARNING, CAUTION, and NOTICE symbols used in the manual.

Installation Safety Precautions

Critical warnings regarding fire, explosion, shock hazards, and keeping the area clear.

Boiler Ratings and Capacities

Natural and Propane Gas Ratings Table

Details input, heating capacity, AFUE, and vent diameter for models XEB-2 through XEB-7.

High Altitude Considerations

Explains input rating reductions and orifice sizing for high altitude installations.

Boiler Dimensions

Dimensional Drawings

Illustrates the left, front, and right side views of the boiler with key measurements.

Model Widths (A)

Table listing the width dimension for each XEB model.

Installation Procedure

General Installation Requirements

Outlines compliance with codes, boiler classification, and protection of components.

Location and Clearance Requirements

Details boiler placement, clearance to combustibles, and base requirements.

Ventilation and Combustion Air

Combustion Air Requirements

Explains methods for providing combustion air per National Fuel Gas Code and local codes.

Air Infiltration Table

Provides air infiltration rates for different input capacities and methods.

Installation System Piping

Safety Relief Valve Discharge Piping

Guidelines for installing the discharge line from the safety relief valve.

Boiler Piping Connections

Instructions for installing drain valve, temperature/pressure gauge, and supply/return lines.

Forced Hot Water Piping Diagrams

Typical Piping Diagram (Figure 3)

Illustrates typical piping for a forced hot water system without zone control.

Piping Diagram with Zone Control (Figure 4)

Shows typical piping for a forced hot water system with zone control valve.

Piping Arrangements and System Types

Piping for Refrigeration Systems

Describes how to pipe the boiler when used with refrigeration systems.

Low Design Water Temperature Systems

Addresses condensation issues and bypass piping for low temp/high content systems.

Vent Installation

Chimney Requirements and Checks

Details chimney condition, type, and checks required for safe venting.

Vent Pipe Material and Clearance

Specifies vent pipe types, clearances to combustibles, and installation rules.

Type B Gas Vent Installation

Type B Gas Vent Diagram

Illustrates the correct installation of Type B gas vent system.

Chimney Venting Compliance

States that chimney venting must comply with codes and regulations.

Removing Boiler from Common Venting

Procedures for Common Venting Removal

Steps to follow when removing a boiler from a common venting system.

Horizontal Venting Instructions

Vent Pipe Material Options

Lists approved U.L. listed stainless steel vent pipe materials for horizontal venting.

Horizontal Venting Diagram

Illustrates horizontal vent termination fittings and pitch requirements.

Horizontal Venting Details

Vent Pipe Sizing and Length

Specifies vent pipe sizes, maximum lengths, and elbow reduction factors.

Vent Termination and Wall Penetration

Details termination fittings, wall penetration, and thimble requirements for combustible walls.

Horizontal Venting Clearances

Vent Termination Clearances Diagram

Illustrates minimum clearances for vent termination from walkways, openings, and utilities.

Specific Termination Location Guidelines

Provides detailed rules for vent termination locations and protection from elements.

Joining and Sealing Vent Pipe

Sealing Procedure for Z-Flex Z-Vent

Step-by-step instructions for sealing Z-Flex Z-Vent pipe joints with silicone.

Sealing Procedure for Heat-Fab Saf-T-Vent

Step-by-step instructions for sealing Heat-Fab Saf-T-Vent pipe joints with silicone.

Sealing Vent Pipe and Supports

Sealing Procedure for Flex-L StaR-34

Instructions for sealing Flex-L StaR-34 vent pipe joints and using joiner bands.

Sealing Procedure for ProTech FasNSeal

Instructions for joining and sealing ProTech FasNSeal vent pipe with internal gasket and locking band.

Vent Pipe Support and Optional Venting

Vent Pipe Support Spacing

Guidelines for supporting different types of stainless steel vent piping.

Optional Horizontal Venting with Power Venter

Discusses using power venter kits as an alternative sidewall venting method.

Gas Supply Piping

Connecting Gas Piping

Instructions for connecting the gas line to the boiler, including materials and methods.

Gas Supply and Pressure Requirements

Details pipe sizing, pressure checks, and safety precautions for gas supply.

Gas Supply Pipe Sizing Tables

Natural Gas Pipe Capacity

Table showing pipe capacity in BTU/hr for natural gas based on pipe size and length.

Propane Gas Pipe Capacity

Table showing pipe capacity in BTU/hr for propane based on tubing/pipe size and length.

Electrical Wiring

Electric Power Supply Requirements

Specifies requirements for the 115-volt power supply circuit and connections.

Thermostat Installation Guidelines

Provides guidance on where and how to install the thermostat for optimal performance.

Sequence of Operation

Boiler Operation Steps

Describes the step-by-step process of how the boiler starts, runs, and shuts down.

Wiring Diagrams

Control Module Wiring

Illustrates the electrical connections to the boiler's control module.

Starting Your Boiler

Filling the System with Water

Step-by-step instructions for filling the boiler and heating system with water.

System Water Pressure Check

How to check and maintain the correct operating water pressure in the system.

Boiler Operation and Lighting

Operating Instructions and Safety

Critical safety information and operating procedures for starting the boiler.

Lighting Procedure for Intermittent Pilot

Detailed steps for lighting the boiler with an intermittent pilot system.

Checking and Adjusting

Gas Valve Safety Shutdown Test

Procedure to test the ignition system safety shutoff device.

Pilot and Main Burner Adjustment

Instructions for adjusting the pilot and main burner flames for proper operation.

Burner Flame Appearance

Main Burner Flame Description

Describes the correct appearance of the main burner flame (sharp blue inner mantel).

Thermostat Heat Anticipator Adjustment

Guidance on setting the thermostat heat anticipator and checking operation.

Maintaining Your Boiler

Boiler Cleaning and Burner Maintenance

Procedures for cleaning flue passages, burners, and checking connections.

System Components Maintenance

Covers maintenance for expansion tank, vent pipe, circulator pump, and low water cutoff.

Service Hints and Troubleshooting

Troubleshooting System Not Heating

Lists common causes and solutions for system not heating or insufficient heat.

Troubleshooting Burner Noise and Leaks

Addresses causes and solutions for noisy burners and relief valve leaks.

Equipment and Optional Accessories

Safety Relief Valve and Expansion Tank

Explains the function and installation of the safety relief valve and expansion tank.

Air Purger, Fill Valve, and Controls

Describes optional accessories like air purgers, automatic fill valves, and water temperature control.

Boiler Safety Controls

Pressure Switch Function

Explains how the pressure switch operates and its set points.

Rollout Switch (Flame Rollout Safety Shutoff)

Describes the function and replacement of the rollout safety switch.

Appendix A: Control Module

Installation Environment Considerations

Safety and environmental precautions for installing the control module.

Electrical Connections for Control Module

Details how to connect wiring harnesses and thermostat to the control module.

Control Module Settings Adjustment

Procedure to enter adjustment mode and change setpoint and differential.

Control Module Operation States

Boiler Operation State Codes

Explains the different operational states of the boiler control module and their definitions.

Control Module Troubleshooting

High Limit Temperature Controller Function

Explains how the high limit controller ends the heating cycle and its lockout state.

General Troubleshooting and Error Codes

Provides general troubleshooting steps and refers to error code tables.

Troubleshooting Error Codes

Troubleshooting Error Code Table

Lists error codes, their definitions, and consequences for the control module.

Ignition System Checks

Steps to check the ignition cable, grounding, and connections for the pilot system.

Spark Ignition and Pilot Flame

Spark Ignition Circuit Check

Instructions for checking the spark ignition circuit and listening for sparking noise.

Pilot Flame Appearance and Causes

Explains correct pilot flame appearance and common causes for flame problems.

Dunkirk XEB-4 Specifications

General IconGeneral
BrandDunkirk
ModelXEB-4
CategoryBoiler
LanguageEnglish

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