Dunkirk XEB-2 User manual

PRODUCT LITERATURE
MODELS
XEB-2
XEB-3
XEB-4
XEB-5
XEB-6
XEB-7
This boiler cannot be used with all types of
chimneys. Read these instructions carefully
before installing.
These Gas-Fired Hot Water Boilers are low pressure, sectional cast
iron boilers Design Certified by C. .A. (Canadian tandards
Association) for use with Natural and Propane Gases. They are
constructed and hydrostatically tested for a maximum working pressure
of 50 psi in accordance with A. .M.E. Boiler and Pressure Vessel
Code ection IV tandards for cast iron heating boilers.
INSTALLATION INSTRUCTIONS
These instructions must affixed on or adjacent to the boiler.
Gas-Fired
Hot Water
Induced Draft
BOILERS
DUNKIRK BOILERS
DUNKIRK, NEW YORK 14048 - AREA CODE 716 366 - 5500
MEMBER: The Hydronics Institute
XEB
SERIES
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause injury
or property damage. Refer to this manual. For assistance or information consult a qualified installer,
service agency or the gas supplier.

1
Boiler Ratings and Capacities
DESIGN CERTIFIED FOR
NATURAL AND PROPANE GAS
FIG. 1
*MBH = 1,000 Btuh = British Thermal Unit Per Hour
Boilers are equipped for altitudes up to 2,000 feet only.
U. .A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rat of 4% for each 1,000 feet above sea level.
Canada Only - Boilers may be used at high altitude by using a certified field conversion, kit, resulting in a 10% derate.
+ Heating Capacity based on D.O.E. (Department of Energy ) test procedure.
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New York City MEA Number 484-84-E Vol. IV.
The Ratings marked Net 1=B=R Ratings indicate
the amount of remaining heat input that can be
used to heat the radiation or terminal units. The
Net 1=B=R Ratings shown are based on an
allowance of 1.15 in accordance with the factors
shown on the 1=B=R tandard as published by
The Hydronics Institute.
election of boiler size should be based upon
Net 1=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.
These boilers must stand on a noncombustible
floor. If installed on a combustible floor, use
Combustible Floor Base.
These Gas-Fired Hot Water Boilers are low
pressure, sectional cast iron boilers Design
Certified by C A (Canadian tandards
Association) for use with Natural and Propane
Gases. They are constructed and hydrostatically
tested for a maximum working pressure of 50psi
(pounds per square inch) in accordance with
A. .M.E. (American ociety of Mechanical
Engineers) Boiler and Pressure Vessel Code
ection IV tandards for cast iron heating boilers.
BOILE S FO USE AT HIGH ALTITUDE
This boiler is factory equipped for use at altitudes
of 0-2,000 feet above sea level. For use at altitudes
above 2,000 feet above sea level, the input ratings
are reduced by a change in main burner orifice size.
U.S.A. Only - For altitudes above 2,000 feet above
sea level, input ratings should be reduced at the
rate of 4% for each 1,000 feet above sea level.
Consult the National Fuel Gas Code (NFPA54/AN I
Z223.1-latest edition), or the manufacturer for
correct orifice sizing information. High altitude
orifices are available from the boiler manufacturer.
Canada Only - For altitudes in the range of 2,000-
4,500 feet above sea level, boilers may be field
equipped for use at high altitude by using a certified
field conversion kit. The change in main burner orifice
size results in the boilers input 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 C A-
B149.1 and C A-8149.2 Installation Codes.The
certified field 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 filled in with the correct
conversion information.

Check to be sure you have the right size boiler before
starting the installation. ee rating and capacity table
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.
You must see that the boiler is supplied with the
correct type of gas, fresh air for combustion, and
a suitable electrical supply. Also, the boiler must
be connected to a suitable chimney 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. Take the time to complete all of the steps
for AFE and 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 fiberglass insulation
Before You Start
KEEP BOILE A EA CLEAN AND F EE F OM COMBUSTIBLE MATE IALS, GASOLINE
AND OTHE FLAMMABLE VAPO S AND LIQUIDS
Installers - Follow local regulations with
respect to installation of CO detectors. Follow
maintenance recommendations in this
instruction manual.
Techniciens - Veuillez vous conformer á la
réglementation en vigueur concernant Í
installation des détecteurs d oxyde de
carbone. uivre les consignes dentretien
figurant dans le manuel dinstruction cijoint.
can clog the burner ports and cause incomplete
combustion and sooting. Where required by the
authority having jurisdiction, the
installation must
conform to American ociety of Mechanical Engineers
afety Code for Controls and afety Devices for
Automatically Fired Boilers, No. C D-1*
The installation must conform to the requirements of
the authority having jurisdiction or, in the absence of
such requirements, to the National Fuel Gas Code,
AN I Z223.1-latest revision.
In Canada, the boiler shall be installed according to
C A-B149.1 and .2, Installation Code for Gas Burning
Appliances and Equipment.
2

If your 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. If you plan to change
location, you will need additional materials as well
as an adequate base. The following rules apply:
1. The boiler must be level. Metal shims may be
used under base legs for final leveling.
2. Use a raised base if floor can become wet or damp.
3. The vent pipe connection should be as short
as possible.
4. Additional clearances for service may exceed
clearances for fire protection. Always comply
with the minimum fire protection clearances
shown on the boiler. An 18 inch clearance should
be maintained on any side where passage is
required to access another side for cleaning,
servicing, inspection or replacement of any part
that may need attention. An 18 inch clearance is
recommended on the control side for servicing.
Figure 2 shows minimum clearances to
combustible construction. Rooms that are large
in comparison with the size of the boiler are
defined as rooms having a volume equal to or
greater than 16 times the volume of the boiler.
Where the actual ceiling height of a room is
greater that 8', the volume of a room shall be
figured on the basis of a ceiling height of 8'.
Determination of room size should be based
on the total volume of all gas fired equipment
installed in theroom. Consult section 6.3.1 of
the National Fuel Gas Code for further
information, including approved methodes for
reducing clearances in large room.
5. Equipment shall be installed in a location in
which the facilities for ventilation permit
satisfactory combustion of gas, proper venting,
and maintenance of ambient temperature at
safe limits 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 shell be introduced ( ee Page 4 -
Fresh Air for Combustion).
6. Advise owner to keep air passages free of
obstructions. Ventilating and combustion air
must enter boiler room without restrictions.
7.The floor supporting the boiler must be
noncombustible. If it is combustible, place the
3
Locating the Boiler
FIG. 2 - MINIMUM CLEA ANCE DIMENSIONS
THI UNIT MU T BE ET ON A CONCRETE OR OTHER
NONCOMBU TIBLE MATERIAL BA E OR FLOOR. IT MU T NOT
BE IN TALLED ON CARPETING.
boiler on Combustible Floor Base No 14614031
for 2-5 section boilers, or No. 14614032 for 6-7
section boilers. We use a 2" cloudlet pad as a
combustible floor base. These are available from
your localsupplier. Use 24 x 30 pad for 2-5
section boilers, and a minimum 30 x 30 pad for
6-7 sections boilers. The boiler must be centered
on the combustible floor base.
8. 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..)
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You must provide for enough fresh air to assure
proper combustion. The fire in the boiler uses
oxygen. It must have a continuous supply. The air
in a house contains only enough oxygen to supply
the burner for a short time. Outside air must enter
the house to replace that used by the burner. tudy
following examples 1 and 2 to determine your fresh
air requirements.
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 (unpartitioned
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.
Equipment located in buildings of unusually tight
construction shall be provided with air for
combustion, ventilation, and dilution of flue gases
using the methods described in example 2B or
shall be specially engineered. The authority having
jurisdiction must approve specially engineered
installations.
EXAMPLE 2: Boiler Located in Confined Space
A. 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
Fresh Air for Combustion
Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation, of
the National fuel Gas Code, ANSI Z223.1-latest revision, or applicable provisions of the local building codes.
NOTE
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.
WA NING
Be sure provide enough fresh air for combustion.
Enough air insures proper combustion and
assures that hazard will develop due to the
lack oxygen.
4
combined space shall be considered in making this
determination. Each opening shall have a
minimumfree 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.
B. All Air from Outdoors: The confined space
shall communicate with the outdoors in accordance
with methods 1 or 2. 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.
1.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.
a) Where directly communicating with the
outdoors or where communicating to the
outdoors through vertical ducts, 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.
( ee Figure 3A.)
b) Where communicating with the outdoors
throughhorizontal ducts, 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. ( ee Fig.3B.)

FIG. 3A - FRESH AIR DUCT CAPACITIES (Btuh)
FIG. 3B - FRESH AIR DUCT CAPACITIES (Btuh)
FIG. 4 - F ESH AI DUCT CAPACITIES (Btuh)
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2. One permanent opening commencing with 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 form the front of the appliance. The
opening shell directly communicate with the
outdoors or shall communicate through a vertical
or horizontal duct to the outdoors or spaces
(crawl or attic) that freely communicate with
the out doors, and shall have a minimum free
area of:
a) 1 sq. inch per 3000 Btu per hour of the total
input of all equipment located in the enclosure
( ee Fig. 4), and the front of the appliance
b) Not less than the sum of the areas of all
vent connectors in the confined space.
5

6
FIG. 5 - FORCED HOT WATER TYPICAL PIPING
Installation-System Piping
1. 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.
2. Install Relief Valve on 3/4pipe nipple in tapped
opening in the left end section. Connect a drain
line of the same pipe size (3/4 to carry any
water away to a drain. No shutoff of any
description shall be placed between the safety
relief valve and the boiler, or on discharge pipes
between such safety valves and the atmosphere.
Installation of the safety relief valve shall conform
to the requirements of the AN I/ A ME Boiler
and Pressure Vessel Code, ection IV.
3. Install Drain Valve on lower left side of boiler
as marked.
4. Connect upply and Return Lines to boiler.
The connections may require certain
additional fittings and parts, as shown on
diagram (Figs. 5 and 6).
If you are installing an entire new heating system,
first install all of your radiation units (panels,
radiators or cabinets) and the upply and Return
Mains - then make the connections at the boiler.
In connecting the cold water supply to the water
valve, 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.
A hot water boiler installed above radiation level
must be equipped with a low water cutoff device.
A periodic inspection is necessary, as is flushing
of float type devices, per manufacturers specific
instructions.
When 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 valves to prevent
the chilled medium from entering the heating
boiler (Fig. 7).
When this 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.
LOW DESIGN WATE TEMPE ATU E
SYSTEMS (BELOW 140° F)
If the boiler is to be used in a heating system
where design water temperatures below 140°
F are desired (e.g. radiant floor heating), a 3-
way or 4-way mixing valve or suitable alternative
is required to prevent low temperature return
water from entering the boiler. Follow the mixing
valve manufacturers installation instructions.The
minimum design return water temperature to
the boiler to prevent condensation in the boiler
and venting is 120° F The minimum high limit
setting is 140° F.

FIG. 6 - FORCED HOT WATER TYPICAL PIPING
WITH ZONE CONTROL VALVE
FIG. 7 - PIPING ARRANGEMENTS
FOR BOILER WHEN USED IN CONNECTION
WITH REFRIGERATION SYSTEM
7

8
Chimney and ent Pipe Connection
CHECK YOU 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 Z223.1-latest issue. In Canada,
follow C A 13149.1 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 AN I Z223.1-latest revision for
correct sizing information In Canada, consult
the Vent izing Tables, Amendment #1 to C A-
13149.1 and .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 3" x 4" increaser
fitting is located and secured.
3. These are high efficiency boilers with a low stack
or exhaust temperature.
4. If venting into a masonry chimney without a liner,
line the chimney from top to bottom with either:
a. listed Type B vent pipe
b. listed flexible vent liner
c. poured ceramic liner.
For boilers for connection to gas vents or chimneys, vent installations shell be in accordance
with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1-latest issue
and applicable provisions of the local building codes.
5. Outside chimneys should not be used unless
they are either:
a. enclosed in a chase, or
b. Iined with Type B vent pipe, or listed flexible
vent liner, or other certified chimney lining system.
6. The vent connector from the boiler to the
chimney should run as directly as possible with
as few elbows as possible.
7. Where possible, it is recommended to common
vent the water heater and boiler. Consult the
appropriate Vent izing Tables in either the
National Fuel Gas Code, or the Canadian
Installation Codes for specific requirements
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. lope pipe up from boiler to chimney not less
than 1/4 per foot.
10. End of vent pipe must be flush with the inside
face of the chimney flue. Use a sealed-in
thimble for the chimney connection.
11. The sections of vent pipe should be fastened
with sheet metal screws to make the piping
rigid. Use stovepipe wires 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 CLEA ANCE
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.

FIG. 8 - TYPE B GAS VENT
9
For boilers for connection to gas vents or
chimneys, vent installations shall be in
accordance with Part 7, Venting Equipment,
of the national Fuel Gas Code, ANSI Z223.1-
latest issue and applicable provisions of the
local building codes. In Canada, follow CSA
13149.1 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.
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
orflexible 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 firestopped
where it goes through the floor or ceiling. It
should have an approved vent cap with
clearances from the roof as shown in Fig. 8. If
clearances are less than shown in Fig. 8, have
the vent checked by local authorities.

10
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. eal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an
unsafe condition.
3. Insofar as is practical, close all building doors
and windows and all doors between the space
in which the appliances remaining connected to
the common venting system are located and
other spaces of 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. Do not operate a summer exhaust fan,
Close fireplace dampers.
4. Place in operation the appliance being inspected.
Follow the 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. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-burning
appliance to their previous conditions of use.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code,
AN I Z223.1-latest issue. 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 Part 11 in the National
Fuel Gas Code, AN I Z223.1-latest issue. In
Canada, follow C A B149.1 or.2 Installation
Codes.
NOTE
It is recommended that existing gas vents be
checked to be sure they meet local codes.

FIG. 9 - HORIZONTAL VENTING
INDUCED DRAFT HIGH EFFICIENCY BOILERS


3$57180%(5'(6&5,37,21
VLGH:DOO9HQW+RRG7MHUQOXQG9+
VLGH:DOO9HQW+RRG7MHUQOXQG9+
7KLPEOH LPSVRQ
7KLPEOH LPSVRQ


HO IZONTAL VENTING ACCESSO IES PA T NUMBE S
Maximum Horizontal Vent Length For tainless
teel 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 90º elbow or 3 feet of
straight pipe for 3 diameter 90º elbow
2, 3, 4, 5, ection Boilers use 3 vent pipe.
6, 7 ection Boilers use 4 vent pipe.
CHOICE OF VENT PIPE MATE IAL
a) U.L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe.
b) U.L. Listed Heat-Fab Sat-T-Vent Stainless SteelVent Pipe.
c) U.L. Listed Flex-L Star-34 Stainless Steel VentPipe.
d) U.L. Listed ProTech Syste s FasNSeal Stainless Steel
Vent Pipe.
11

12
Horizontal enting Instructions
1. These boilers may be vented horizontally as
shown in Fig. 9. The vent pipe is pitched down
from the boiler to the vent termination. Do not
connect other appliances to this vent.
2. Vent Pipe Material:
a) UL Listed Z-Flex Z-Vent stainless steel vent
pipe from boiler to vent termination,
-or-
b) UL Listed Heat-Fab af-T-Vent stainless steel
vent pipe from boiler to vent termination,
-or-
c) UL Listed Flex-L taR-34 stainless steel vent
pipe from boiler to vent termination,
-or-
d) UL Listed ProTech FasN eal stainless steel
vent pipe from boiler to vent termination.
3. Clearance to Combustible Materials:
For stainless steel vent pipe maintain 6" minimum
air space clearance to combustible materials.
4. Vent Pipe ize:
a) 2, 3, 4 and 5 section boilers use 3" vent pipe
connected directly to the outlet of the induced
draft blower.
b) 6 and 7 section boilers use 4" vent pipe,
starting with a 3" to 4" stainless steel vent
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.
5. Vent Pipe Length:
a) For stainless steel vent pipe, the maximum
horizontal vent length is 30 feet plus one 90°
elbow plus termination fitting.
b) Minimum horizontal vent length for all vent
materials is 2 feet plus one 90° elbow plus
termination fitting.
c) For additional elbows reduce the maximum
vent length as shown:
3" - 90° elbow - reduce vent length 3 feet per each 3"
elbow,
4" - 90° elbow - reduce vent length 6 feet per
each 4" elbow.
Example: 6 section boiler requires 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).
6. Vent Termination Fitting:
For all vent pipe materials, 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. The
elbow exit should be at least 6" away from
exterior wall as shown in Figure 9.
-or-
b) Tjernlund VH-1 eries side wall vent hood.
For 2, 3, 4, 5 section boilers use VH-1-3", For
6, 7 section boilers use VH-1-4".
7. Vent Pipe Termination Location:
a) When venting through combustible walls,
combustible clearances must be considered.
The VH-1 Side wall vent hood provides both
the outside vent termination and a double
wall pipe 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 6% 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-1 may also be used in
noncombustible walls.
b) If the 90' elbow is the termination fitting of
choice, then the single wall pipe will be passing
through the side wall. For combustible walls,
a UL listed thimble shall be used where the
single wall pipe passes through the wall. For
combustible walls using Z-Vent, at-T-Vent,
or taR-34 vent pipe, use the following:
3" vent pipe - use impsons Duravent
#905295 3" thimble or equivalent
4" vent pipe - use impsons Duravent
#915295 4" thimble or equivalent Maximum
wall thickness with this thimble is 7 inches.
For combustible walls using ProTech
FasN eal where the single wall vent pipe must
pass through the side wall, a UL Listed
FasN eal wall thimble shall be used as
follows:
3" FasN eal vent pipe - use 3" FasN eal Wall
Thimble #F WT03 4" FasN eal vent pipe - use
4" FasN eal Wall Thimble #F WT04
The thimble is adjustable for different wall
thickness, with a maximum wall thickness of
7 inches. eal the thimble along the outside
edge of the plate with caulk or silicone and
fasten to the wall with screws or nails.

c) For single wall pipe through non-combustible
walls, the hole through the wall need 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) The venting system shall terminate at least 3
feet above any forced air inlet located within
10 feet. The venting 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 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 maintained, from electric
meters, gas meters, regulators, and relief
equipment.
e) The venting system shall terminate at least 4
feet below any eave, 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. Locate or guard the vent to prevent
accidental contact with people or pets.
h) Terminate the vent above normal snowline.
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.
i) Under certain conditions, flue gas will condense,
forming moisture. In such cases, steps should
be taken to prevent building materials at the
vent terminal from being damaged by exhaust
of flue gas.
8. Joining and ealing the Vent Pipe:
The vent pipe needs to be both watertight and
gastight. eal all joints and seams as follows:
A. For Z-Flex Z-Vent stainless steel vent pipe
use a high temperature red silicone sealant rated
for 500°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 (#02 VEPxx0306) 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 (#02 VERxx0403).
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 following
the sealing instructions, push the 4" male end of
the Z-Vent over the 4" increaser fitting. 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. Before the pipes are joined,
apply a 1/4" bead of silicone one inch from the
end of themale 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 Z-Flex locking band
around the center of the joint.
Z-Flex Z-Vent ize Locking Band Part #
3" #02 V LBX03
4" #02 V LBX04
1) Apply the high temperature silicone
approximately one inch from the end, around
the male end of the pipe in an even 1/4" bead.
2) Pipes can now be pushed together as far
as they will go. The seams on pipe should
be aligned and oriented upward in all
horizontal appliances. Apply another bead
of silicone around this joint and smooth
out.3) lide locking band over center of joint
and tighten gear clamps. Make sure locking
band is centered on joint.
4) Check all joints and seams for gas tightness.
5) Horizontal venting shall have a slope not
less than 1/4" (6.4mm) every 12 inches
(305mm) downward away from the boiler
to prevent collection of condensate
throughout the assembly.
6) Allow the sealant to cure for 24 hours before
operating the appliance.
13

B. For Heat-Fab Saf-T-Vent stainless steel
vent pipe use a high temperature red silicone
sealant rated for 500°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. After crimping is completed
follow the instructions for applying silicone
sealant. For 4" vent pipe runs, begin with a
af-T-Vent 3" to 4" increaser fitting
(#7374GC) over the boilers induced draft
blower outlet, to which an even bead of high
temperature silicone sealant should be
applied. Then continue the 4" af-T-Vent pipe
run by connecting the 4" male end of the af-
T-Vent to the increaser. (A locking band may
be used around this joint for additional
support.) The vent flow must bein 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. Apply high
temperature silicone in an even 1/4" bead
approximately 1/4" 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 silicone around
the male end of the pipe (without the tabs)
in an even W bead. ilicone bead should be
approximately 1/4" 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.
2) 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 flat tool, spread any sealant that squeezes
out around the circumference of the joint.
3) Attach the sections together with the
locking rings and tabs (except at the blower
outlet where no locking ring exists.)
14
Inspect the joint to ensure that flue gases
will not leak. If necessary apply additional
sealant around the joint.
4) Horizontal venting shall have a slope not
less than 1/4" (6.4mm) every 12 inches
(305mm) downward away from the boiler
to prevent collection of condensate
throughout the assembly.
5) Allow the sealant to cure for 24 hours
before operating the appliance.
C. For Flex-L Sta -34 stainless steel vent
pipe use a high temperature red silicone
sealant rated for 500°F. Before applying
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 taR-34 3"
to 4" increaser fitting (# R10304) 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. Apply high
temperature silicone in an even %4" bead
approximately 1/4"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.
Now fill in 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 steel gear clamp.
1) Apply the high temperature silicone around
the male end of the pipe in an even 1/4"
bead. ilicone bead should be approximately
1/4" 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.
2) The seams on the vent pipe should be
aligned and oriented upward in all horizontal
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.
4) Insert a taR-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".
5) Cut the excess Joiner Band so it lays flat in
the beaded channel. Fill the inlet of the beaded
channel with high temperature silicone. mooth
out the silicone over the channel inlet and the
silicone between the female end and the stop
bead of the male end.
6) Horizontal venting shall have a slope not less
than 1/4" (6.4mm) every 12 inches (305mm)
downward away from the boiler to prevent
collection of condensate throughout the assembly.
7) Allow the sealant to cure for 24 hours before
operating the appliance.
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 FasN eal Ametek
Adapter (part #F AMETEK) over the boilers
induced draft blower. Continue the vent pipe run
with 3" FasN eal vent pipe. For 6 and 7 section
boilers begin by locating the FasN eal Ametek
Adapter (part #F AMETEK) over the boilers
induced draft blower. Then connect a
FasN eal 3" to 4" increaser (part #F 341) to
the 3" adapter outlet. Continue the vent pipe
run with 4" FasN eal vent pipe. Other than
the Ametek Adapter and increaser fitting, DO
NOT use 3" vent pipe on 6 or 7 section boilers.
FasN eal vent 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 all vent pipe seams and orient upward in
all horizontal applications. Adjustable vent
lengths are available for 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 FasN eal Vent to the VH-1-3" vent
hood using FasN eal Adapter #F C-DUN-3.
This adapter has no internal sealing gasket.
To attach the adapter to the vent hood, crimp
the 3" vent hood pipe, apply a 1/4" bead of high
temperature red silicone sealant around the
outside of the vent hoods crimped connecting
pipe and a similar bead of high temperature
silicone around the inside of the FasN eal
adapter. After pressing the two pipes together
and tightening the locking band, finish creating a
complete seal by filling the FasN eal adapters
notched hole with high temperature silicone.
For 6 and 7 section boilers using the VH-1 -4" vent
hood, an adapter is not required. The 4" FasN eal
vent pipe connects directly to the VH-1-4" vent
hood, and is joined and sealed by the internal gasket
and locking band.
To join and seal the FasNSeal vent pipe:
1) Insert male end into female section.
2) Push the units together as far as possible.
3) Firmly tighten locking band with a nut driver.
4) DO NOT penetrate the FasN eal vent pipe
with fasteners.
5) Horizontal venting shall have a slope of not less than
1/4 (6.4mm).every 12 inches (305mm) downward
away from the boiler to prevent the collection of
condensate throughout the assembly.
9. upport pacing:
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 loose fitting metal strap or similar support
at each joint at a maximum of 4 feet
between supports.
b) Heat-Fab stainless steel vent piping requires
a support for every 6 feet of horizontal piping
run. The support must be secured using at
least #10 fasteners to a solid material (solid
masonry or woodframing or blocking.) Do
not fasten to drywall sheathing using hollow
wall anchors. Each support will be 1 1/2 inch
lower than the previous support when
spaced 6 feet apart.
c) Flex-L stainless steel vent piping requires
a loose fitting metal strap or similar support
at each joint at a maximum of 4 feet
between supports.
15

d) ProTech stainless steel vent piping requires
one loose fitting FasN eal support strap
(#F H) for every 6' 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 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.
Optional Horizontal Venting Instruction
Horizontal venting with a power venter is an
alternate method of sidewall venting. This boilers
C A listed for sidewall venting with standard
single wall galvanized or Type B vent pipe when
using the following power venter kits, which were
specifically sized for these boilers:
Number of Field Controls
Boiler ections Kit Power
Venter
2, 3, 4, 5 WG-4D
6, 7 WG-5D
ome possible reasons for using a power venter
for sidewall venting:
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 experiences
gusting or high winds. A power venter can
help prevent the boiler from short cycling
due to gusting or high winds by providing
vent exhaust pressures greater than the
boilers induced draft blower alone.
4. When installers or homeowners prefer a
negative pressure vent system instead of
a positive pressure vent system.
5. May be more cost effective than stainless
steel venting, particularly at longer vent
lengths.
The Field Controls power vent kit includes either
a WG-II-4HD or WG-II-5 power venter, a
MG-1 4" barometric draft controller, and the
CK-43D controls kit.
Confirm that installing a power venter is an option
allowed by local codes. Follow the specific power
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 sidewall venting, flue gases
must be vented to a point in relation to the
prevailing wind so that they may freely disperse
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 galvanized vent pipe
for power venting follow the specific power
venter installation instructions for layout, location
of the barometric draft control and termination
connections. When joining and sealing the single
wall galvanized or Type B vent piping, use RTV
silicone sealant with a minimum temperature
rating of 400°F. For 3" vent pipe runs, begin with
the female end of the vent pipe over the boilers
induced draft blower outlet. For 4" vent pipe runs
begin with the galvanized 3" to 4" increaser fitting
(included in the boilers parts 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 galvanized vent pipe, a substantial bead of
silicone should be used at the joint to insure a
leakproof connection.
16

Gas Supply Piping
CHECK GAS SUPPLY
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. ee Fig. 10 for
the proper size. Be sure your gas line complies with local
codes and gas company requirements.
The boiler and its individual shutoff valve must be
disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in
excess of 1/2 psig (3.5 kPa).
The boiler must be isolated from the gas supply piping
system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 psig (3.5 kPa).
CONNECTING THE GAS PIPING
Refer to Fig, 11 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.
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, AN I ZX223.1-latest revision. In
Canada, follow the C A 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 valve and boiler controls.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection
to the gas valve to keep it from turning.
6. Install manual shut-off valve in vertical pipe about 5
feet above floor.
7. Tighten all joints securely.
8. Propane gas connections should only be made by a
licensed propane installer.
9. Two-stage regulation should be used by the propane
installer.
10. Propane gas piping should be checked out by the
propane installer.
CHECKING THE GAS PIPING
Upon completion of piping, check right away for gas
leaks. Open the manual shut-off valve. Test for leaks
by applying soap suds (or a liquid detergent) to each
joint. Bubbles forming indicate a leak. CORRECT
EVEN THE MALLE T LEAK AT ONCE.
3LSH)W    
    
    
    
3LSH)W
   
    
    
    
&RSSHU7XELQJ URQ3LSH
1$785$/*$6
3523$1(*$6
/HQJWKRI
3LSH&DSDFLW\%783HU+RXU QSXW
QFOXGHV)LWWLQJV
QFOXGHV)LWWLQJV
3LSH&DSDFLW\%783HU+RXU QSXW
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FIG. 10 - GAS PIPE SIZES
*Outside diameter
The length of pipe or tubing should be measured from the
gas meter or propane second stage regulator.
FIG. 11 - GAS PIPING AT BOILE
WARNING
Never use a match or open flam to test for leaks.
17

Electrical Wiring
All electrical work must conform to local codes as
well as the National Electrical Code, AN I/NFPA-70,
latest revision. In Canada, electrical wiring shall comply
with the Canadian Electrical Code, C A-C22.1.
ELECT IC POWE SUPPLY
Run a separate 120 volt circuit from a separate
overcurrent 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
off during any maintenance. Connect 120 volt power
supply to aquastat terminals L1 (HOT) and L2.
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,
AN I/NFPA No. 70-latest revision. Run a 14 gauge
or heavier copper wire from the boiler to a grounded
connection in the service panel or a properly driven
and electrically grounded ground rod.
INSTALL YOU THE MOSTAT
The thermostat location has an important effect on the
operation of your boiler system. BE SURE TO FOLLOW THE
I STRUCTIO S I CLUDED WITH YOUR THERMOSTAT
Locate the thermostat about five feet 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, so avoid the following:
DEAD SPOTS:
Behind doors
Corners and alcoves
HOT SPOTS:
Concealed pipes
Fireplace
TV sets
Radios
Lamps
Direct sunlight
Kitchens
COLD SPOTS:
Concealed pipes or ducts
Stairwells - drafts
Doors - drafts
Unheated room on other side of wall
Set heat anticipator at .2 amps. 24 volt thermostat connects
to aquastat terminals T and T
Sequence of Operation
1. Thermostat calls for heat, powering the 1K relay
coil and closing contacts 1 K1 and 1 K2.
2. Circulator pump is powered through terminals
C1 and C2. 3. Induced draft blower and AT140C
transformer primary are powered through
terminals B1 and B2.
4. When blower gets up to speed and blower
suction pressure reaches pressure switch
setpoint, pressure switch contacts close sending
24 volts to 8600 intermittent pilot control from
AT140C transformer secondary.
5. Pilot gas valve 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
setpoint, high limit contacts B-R open, cutting power
to blower and 8600 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 setpoint
and through the differential, high limit contacts
B-R close, repeating steps 3-7.
9. If venting system becomes blocked, blower
suction pressure will drop below the pressure
switch setpoint, opening the pressure switch
contacts and cutting power to the 8600
intermittent pilot control. Burners will extinguish,
but blower will remain powered as long as the
thermostat continues to call for heat. If venting
system clears, steps 4-7 will repeat.
10. Thermostat is satisfied, ending call for heat.
Relay coil 1 K is de-energized, opening 1K1
and 1K2 contacts. Burners extinguish. Blower
and circulator pump stop.
WA NING
Turn off electric power at fuse box before ma ing any
line voltage connections. Follow local electrical codes.
18

INTE MITTENT IGNITION
IF ANY OF THE O IGINAL WI E AS SUPPLIED WITH THIS APPLIANCE MUST BE EPLACED,
IT MUST BE EPLACED WITH TYPE 105° C THE MOPLASTIC WI E O ITS EQUIVALENT.
NOTE: The circulator harness is factory wired to the aquastat. This harness needs to be
connected to the circulator in the field.
FIG. 12 - WIRING DIAGRAMS FOR HOT WATER BOILERS
19