Models XEB-2 XEB-3 XEB-4 XEB-5 XEB-6 XEB-7 XEB Series II Gas-Fired Hot Water Induced Draft Boilers INSTALLATION, OPERATION & MAINTENANCE MANUAL C.S.A. Certified For Natural Gas Or Propane Tested For 50 psi ASME Working Pressure Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com An ISO 9001-2008 Certified Company P/N 240009020 Rev.
TABLE OF CONTENTS Boiler Ratings & Capacities...................... 3 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE Dimensions.............................................. 4 Safety Symbols & Warnings Installation Procedure.............................. 5 The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels. Ventilation & Combustion Air................... 6 Installation System Piping.......................
BOILER RATINGS & CAPACITIES Table 1 - RATINGS NATURAL AND PROPANE GASES Vent Diameter (Inches) Input *Mbh Heating Capacity *Mbh **Net AHRI Rating Water *Mbh XEB-2 42.5 36 31 XEB-3 75.0 63 55 XEB-4 112.5 94 XEB-5 150.0 125 XEB-6 187.5 155 XEB-7 225.0 186 Model AFUE To Chimney (Category I) Horizontal Vent (Category III) 84.4 4 3 83.4 4 3 82 83.0 4 3 109 82.7 4 3 135 82.3 4 4 162 82.0 4 4 * MBH = 1,000 Btuh = British Thermal Unit Per Hour.
DIMENSIONS Model XEB-2 XEB-3 XEB-4 XEB-5 XEB-6 XEB-7 Width (A) 11 14-1/4 17-1/2 20-3/4 24 27-1/4 4
INSTALLATION PROCEDURE ! WARNING NOTICE Follow local regulations with respect to installation of CO detectors. Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury. 1. Installation must conform to requirements of authority 2. 3. 6. 7. 8. 9. 8” 6” Rear Boiler Control Side 5. 6” Opposite Side 4.
VENTILATION & COMBUSTION AIR • All Outdoor Air. Provide permanent opening(s) communicating directly or by ducts with outdoors. Provide combustion air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes. оо Two Permanent Opening Method.
INSTALLATION SYSTEM PIPING ! WARNING Figure 2 - Safety Relief Valve Discharge Piping Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. RELIEF VALVE 1. Refer to local codes and appropriate ASME Boiler DISCHARGE PIPING and Pressure Vessel Code for additional installation requirements. Install safety relief valve using pipe fittings provided with boiler. See Figure 2 2.
INSTALLATION SYSTEM PIPING Figure 3 - Forced Hot Water Typical Piping Figure 4 - Forced Hot Water Typical Piping With Zone Control Valve MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR MINIMUM HEIGHT FOR LOW WATER CUTOFF PROBE LIMIT SENSOR 8
INSTALLATION SYSTEM PIPING Low Design Water Temperature Systems (Below 140°F) And Large Water Content Systems • Install radiation units (panels, radiators or cabinets) and supply and return mains first then make connections at boiler. • Verify clean water supply is available when connecting cold water supply to water valve. Install sand strainer at pump when water supply is from well or pump.
VENT INSTALLATION 11. Fasten sections of vent pipe with sheet metal screws to Check Your Chimney Chimney must be clean, right size, properly constructed and in GOOD CONDITION. make piping rigid. Use stovepipe wires to support pipe from above. 12. Do not connect to fireplace flue. 13. Do not install damper on this boiler. 1. Installation must conform to requirements of the authority having jurisdiction or, in absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
VENT INSTALLATION Figure 7 - Type B Gas Vent Vent pipe must be: At lease 2 ft. (610mm) higher than any part of the roof, but not less than 3 ft. (915mm) tall, and within a 10 ft. (3m) radius of the apex. Liner Chimney Thimble Vent System Cleanout Boiler CHECK YOUR CHIMNEY For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment”, of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building codes.
VENT INSTALLATION 5. Test for spillage at the draft hood relief opening after 5 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.
HORIZONTAL VENTING INSTRUCTIONS INDUCED DRAFT HIGH EFFICIENCY BOILERS Horizontal (Category III) venting systems must be installed in accordance with these instructions. Maximum Horizontal Vent Length For Stainless Steel Vent Pipe - 30’ Plus One 90º Elbow Plus Vent Terminal. Minimum Horizontal Vent Length - 2’ Plus One 90º Elbow Vent Termination. Additional elbows are equivalent to 6 feet of straight pipe for 4” diameter 90° elbow or 3 feet of straight pipe for 3” diameter 90° elbow.
HORIZONTAL VENTING INSTRUCTIONS 1. Boilers may be vented horizontally as shown in 6. Vent Termination Fitting: For all vent pipe materials, Figure 8, Page 13. Vent pipe is pitched down from boiler to vent termination. Do not connect other appliances to this vent. you may use either: A. A 90° elbow pointing down, fitted with a minimum 1/4” mesh screen to keep out rodents and birds. The elbow shall be of the same material and size as vent pipe.
HORIZONTAL VENTING INSTRUCTIONS Figure 9 - Horizontal Venting Clearances D. The venting system shall terminate at least 3 feet (0.9m) above any forced air inlet located within 10 feet (3m). The venting system shall terminate at least 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (300 mm) above any door, window, or gravity air inlet into any building. The bottom of the vent shall be located at least 12 inches (300mm) above grade. Termination of the vent shall be not less than 7 feet (2.
HORIZONTAL VENTING INSTRUCTIONS B. For Heat-Fab Saf-T-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 before applying the silicone bead. 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. The vent pipe should be crimped as minimal as possible to provide a tight fit over the outlet.
HORIZONTAL VENTING INSTRUCTIONS D. For ProTech Systems FasNSeal stainless 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” FasNSeal vent pipe. For 6 and 7 section boilers, begin by locating the FasNSeal Ametek Adapter over the boiler’s induced draft blower. Then connect a FasNSeal 3” to 4” increaser to the 3” adapter outlet.
HORIZONTAL VENTING INSTRUCTIONS 9. Support Spacing: 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.
GAS SUPPLY PIPING ! CAUTION Connecting Gas Piping Gas line enters boiler from right side. Flexible gas connectors must never breach any boiler openings. • Use piping materials and joining methods acceptable to authority having jurisdiction. In absence of such requirements National Fuel gas Code, ANSI Z223.1/ NFPA 54 WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building.
GAS SUPPLY PIPING Table 6 - PROPANE GAS Table 5 - NATURAL GAS Length of Pipe - Ft. Pipe Capacity - BTU Per Hour Input Length of Pipe - Ft.
ELECTRICAL WIRING ! WARNING LWCO kit 550002998 includes wiring instructions and diagrams. If using other LWCO, refer to specific manufacturer instructions supplied by appropriate manufacturer. Connect 115 volt power supply to terminals L1 (HOT) and L2 inside J box. Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod. Electrical shock hazard.
SEQUENCE OF OPERATION Sequence of Operation -See Figure 12, Page 23 1. Thermostat calls for heat, control relay contacts. 2. Circulator pump is powered through terminals C1 and C2. Control holds off burner and attempts to satisfy thermostat with residual boiler heat. 3. Induced draft blower and transformer primary are powered. 4.
WIRING DIAGRAMS Figure 12 - Control Module Damper is not an option.
STARTING YOUR BOILER NOTICE Do not add water into hot empty boiler. Filling System With Water • Close air vents on all radiation units. Open valves to these units. • Verify boiler and expansion tank drain valves are closed. Air bleed screw on tank drain fitting should be closed. • Open valve in line from boiler to expansion tank. • Open water inlet to your boiler and leave open. • Start with lowest radiation unit. Open air vent on this unit.
STARTING YOUR BOILER ! WARNING Operating Instructions. 1. STOP! Read Safety Information on previous page. 2. Set the thermostat to lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the burner. Do not attempt to light pilot by hand. 5. Remove burner access panel. If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
CHECKING AND ADJUSTING Gas Valve Safety Shutdown Test Figure 14 - Automatic Gas Valve ! WARNING Electrical shock hazard. Follow instructions to turn off electric power. Failure to do so could result in death or serious injury. Ignition system safety shutoff device must be tested after placing boiler in operation. With main burners firing, disconnect ignition cable from intermittent pilot control box. Gas valve should shut off main burners.
CHECKING AND ADJUSTING Figure 16 Adjust Thermostat Heat Anticipator Instruction for final adjustment of thermostat are packaged with thermostat. 1. Set Heat anticipator at .2. 2. Check thermostat operation. When set above temperature indicated on thermometer, boiler burners should ignite. Verify thermostat turns off boiler when room temperature reaches selected setting and starts boiler operating when room temperature falls few degrees.
MAINTAINING YOUR BOILER Burners Beginning of heating season visually check pilot end main burner flames. See Figures 14, 15 & 16 Pages 26 & 27. 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. Safety Relief Valve Test safety relief valve for proper operation. Refer to valve manufacturer’s instructions packaged with relief valve. • Remove top and front jacket panels.
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service: ! CAUTION WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the fire department. IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
EQUIPMENT & OPTIONAL ACCESSORIES ! WARNING AIR ELIMINATING FITTING (AIR PURGER) Air purger is used to remove excess air from system. It is installed in supply line. It will eliminate air from water before it reaches radiators and bleed off this air. and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.
EQUIPMENT & OPTIONAL ACCESSORIES PRESSURE SWITCH Air pressure switch works on negative pressure. When blower comes on air pressure switch operates intermittent pilot and gas valve. Air pressure switch is factory set and will only work when blower operates properly. It will not allow boiler to come on if blower does not generate enough pressure or if 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.
APPENDIX A - CONTROL MODULE A.1 Installation Environment Considerations A.3 Adjusting Settings ! WARNING To discourage unauthorized changing of settings, procedure to enter adjustment mode is required. To enter adjustment mode, press UP, DOWN, and I buttons (see Figure 1) simultaneously for three seconds.
APPENDIX A - CONTROL MODULE A.5 Operation 2. Control determines burner operation is required, module proceeds to start burner (see state codes list) and heats water in boiler until setpoint temperature is achieved or thermostat is satisfied. . 3. Burner is de-activated, ignition module completes heating cycle, returns to idle and waits for temperature to drop again. 4. Circulator is turned on throughout “Call for Heat.
APPENDIX A - CONTROL MODULE A.6 Boiler High Limit Temperature Controller A.7 Troubleshooting • When water temperature reaches setpoint, controller ends heating cycle. • Following service procedures are provided as general guide. • When water temperature drops below setpoint minus differential, controller restarts heat cycle to re-heat boiler water. • On lockout and retry models, meter readings between gas control and ignition module must be taken within trial for ignition period.
APPENDIX A - CONTROL MODULE Table 8 - Troubleshooting Error Codes Error Code Number Definition Consequence 2 Pressure switch failed to open (stuck closed). Wait for recovery 4 Flame current too low. Check for flame. Non critical alarm 6 Flame sensed out of normal sequence (before opening or after closing gas valve). Soft lockout 18 Gas valve relays welded. Five consecutive soft lockouts. Hard lockout 23 Flame sensed during prepurge ( before gas valve signaled opened).
APPENDIX A - CONTROL MODULE STEP 3: Check spark ignition circuit. • Recheck ignition sequence as follows. ! WARNING — — — — Reconnect main valve wire. Adjust thermostat above room temperature. Verify ignition sequence at burner. If spark does not stop after pilot lights, replace module. — If main burner does not light or if main burner lights and system locks out, check module, ground wire and gas control as described in troubleshooting table. See Table 9, Page 35. Electrical shock hazard.
NOTES
NOTES 38
Date Service Performed Company Name & Tech Initials Company Address & Phone # SERVICE RECORD 39
DUNKIRK BOILERS 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.
