Dunkirk XEB-3 Instruction manual

XEB Series
Gas-FiredHot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www. dunkirk, corn P/N14683001 Rev. B[11/09]

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 ........................................................................................................... 20
Gas supply Piping ................................................................................................................................................ 21
Electrical Wiring ................................................................................................................................................... 22
Sequence of Operation ........................................................................................................................................ 22
Wiring Diagrams .................................................................................................................................................. 23
Equipment &Optional Accessories .................................................................................................................... 24
Starting Your Boiler ............................................................................................................................................. 26
Checking and Adjusting ...................................................................................................................................... 27
Initial Operational Boiler Test Check-Out Procedure ........................................................................................ 29
Maintaining Your Boiler ...................................................................................................................................... 31
Service Hints ......................................................................................................................................................... 32
IMPORTANT:Readthe followinginstructions COM-
PLETELYbeforeinstalling! Keepthis manual near boiler and retain for future refer-
ence.
Thefollowingdefined symbols areused throughout this manual to notify the reader of potential hazards ofvarying risk levels.
Indicates an imminently hazardous situation which, if not
avoided,WILLresultin death, seriousinjury or substantial
property damage.
Indicates an imminently hazardous situation which, ifnot
avoided,mayresultin death, seriousinjury or substantial
property damage.
Indicates an imminently hazardous situation which, if not
avoided,may result in injury or property damage.
C.S.A. Certified for
Natural gas or Propane
Indicates informationwhich should be followedto ensure
proper installationand operation.
Tested for 50 Ibs. ASME
Working Pressure

Theseinstructions must be affixedon or adjacent to the boiler.
Thisboiler cannot be usedwith all types ofchimneys.Read these
instructions carefullybeforeinstalling.
TheseGas-Fired Hot Water Boilersare lowpressure, sectionalcast
iron boilers DesignCertifiedby C.S.A.(Canadian StandardsAssoci-
ation) foruse with Natural and Propane Gases. Theyareconstructed
and hydrostaticallytested for amaximum workingpressure of50psi
in accordance with A.S.M.E.Boiler and PressureVesselCode Sec-
tion IV Standardsfor castiron heatingboilers.
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Improper installation, adjustment, alteration, serviceor
maintenance can cause injury or property damage.Refer
to this manual. For assistanceor information consult a
qualifiedinstaller,serviceagencyor thegas supplier.
Figure 1 - Boiler Ratings and Capacities
ASME
R_LIEF
VALVE
VALVE
LeR Si_e Fro_t Right Side
\,® .
DESIGN CERTIFIED FOR
NATURAt AND PROPANE GAS
XEB-2 2 42.5 36 31 11 4 3
XEB-3 3 75.0 63 55 14-1/4 4 3
XEB-4 4 112.5 94 82 17-1/2 4 3
XEB-5 5 150.0 125 109 20-3/4 4 3
XEB-6 6 187.5 155 135 24 4 4
XEB-7 7 225.0 186 162 27-1/4 4 4
*MBH = f,O00 Btuh =British Thermal Unit Per Hou_ Boilers are equipped foraltitudes up to 2,000 feet on!_ U.S.A. Only -For altitudes above 2,000 feet, ratings should be reducedat the rate
of 4% for each f,O00 feet above sea level. Canada Only -Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10%de-rate.
+Heating Capacity based on D.O.E. (Department of Energy) testprocedure.
New YorkCity MEA Number 484-84-EVol. IV.
TheRatingsmarked "Net I=B=RRatings"indicate the amount ofre-
maining heat input that can be usedto heat the radiation or terminal
units. TheNet I=B=RRatingsshownare based on an allowanceof
1.15in accordancewith the factors shownon the I=B=RStandard as
publishedby TheHydronicsInstitute.
Selectionofboiler sizeshould be based upon "NetI=B=RRating"
being equalto or greater than thecalculatedheat lossofthe building.
Themanufacturer shouldbe consultedbeforeselectingaboiler for
installations having unusual piping and pickup requirements.

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Theseboilers must stand on a noncombustible floor.Ifinstalled on
a combustiblefloor,pleaserefer to the Repair Partsmanual forthe
appropriate Combustible Floor Basepart number.
TheseGas-Fired Hot Water Boilersare lowpressure, sectionalcast
iron boilers DesignCertifiedby CSA (Canadian StandardsAssocia-
tion) for use with Natural and Propane Gases.Theyareconstructed
and hydrostaticallytested for amaximum workingpressure of50psi
(pounds per square inch) in accordance with A.S.M.E.(American
SocietyofMechanical Engineers)Boilerand PressureVesselCode
Section IVStandards for cast iron heating boilers.
Boilers For UseAt High Altitude
Thisboiler isfactoryequipped for useat altitudesof 0-2,000feet
abovesealevel.For useat altitudes above2,000feet abovesea level,
the input ratings are reducedby achangein main burner orifice size.
U.S.A.Only - For altitudes above2,000feet abovesea level,input
ratings should be reduced at the rate of 4% for each 1,000feet above
sealevel.Consult the National Fuel GasCode (NFPA54/ANSI
Z223.l-latest revision), orthe manufacturer for correct orificesiz-
inginformation. High altitude orificesare availablefrom the boiler
manufacturer.
Canada Only - For altitudes in the range of2,000-4,500feetabove
sealevel,boilersmay be fieldequipped foruse at high altitudeby
usinga certified fieldconversion kit. Thechange in main burner
orifice sizeresults in the boiler'sinput rating being reduced by 10%.
Theconversionshall be carried out by amanufacturer's authorized
representative,in accordancewith the requirements ofthe manufac-
turer, provincialor territorial authorities having jurisdiction and in
accordancewith the requirements of the CSA-B149.1and CSA-
B149.2Installation Codes. Thecertifiedfieldconversionkit includes
aconversion data plate,which must beattached to the boiler adja-
centto the rating plate, indicating that theboiler hasbeen converted
for high altitude use.The conversiondata platemust be filledin with
the correct conversioninformation.
Checkto be sure you havethe right sizeboiler beforestarting the
installation. Seerating and capacitytable on previous page.Also be
sure thenew boileris for the type of gasyou areusing. Checkthe
rating plate on the right side of theboiler.
Verifythat the boileris suppliedwith the correct type of gas,fresh air
for combustion,and a suitable electricalsupply.Also,the boilermust
be connectedto a suitablechimney orhorizontal venting systemand
an adequatepiping system. Finally,athermostat, properly located,is
needed for control ofthe heating system.Ifyou have anydoubts as
to the variousrequirements, checkwith localauthorities and obtain
professionalhelp whereneeded. Takethe time to completeallof the
stepsfor SAFEand PROPERoperation ofthe heating system.
Ifthis boiler isinstalled in a buildingunder construction, special
caremust be taken to insurea clean combustion air supplydur-
ing the construction process. Airborne particulates such as from
drywalldust and from fiberglassinsulation can clogthe burner ports
and causeincompletecombustion and sooting. Where required by
the authority having jurisdiction, the installation must conform to
American Societyof MechanicalEngineers SafetyCode for Controls
and SafetyDevicesfor AutomaticallyFired Boilers,No.CSD-1.
Theinstallationmust conform to the requirements ofthe authority
havingjurisdiction or,in the absenceofsuch requirements, to the
NationalFuel GasCode, ANSIZ223.l-latest revision.
In Canada,the boiler shallbe installed accordingto CSA-B149.1and
.2,Installation Code for GasBurning Appliancesand Equipment.
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Keep boiler area clean and free from combustible materi-
als, gasoline and other flammable vapors and liquids

Ifthe boiler ispart of aplanned heatingsystem,locateit where
shown on your plan. Ifboiler isto be part ofan existingsystem,it
is usuallybestto put itwhere theold one was. Ifyou plan to change
location,you willneed additional materials as wellas an adequate
base.Thefollowingrules apply:
1. Theboilermust be level.Metalshimsmaybe used under base
legsfor finalleveling.
2. Usea raised baseif floor can becomewet or damp.
3. Theventpipe connection should be as short aspossible.
4. Additional clearancesfor servicemay exceedclearancesfor fire
protection. Alwayscomplywith the minimum fireprotection
clearancesshown on the boiler.An 18inchclearance should
bemaintained on anyside where passageisrequired to access
for cleaning, servicing,inspection or replacement of any part
that may need attention. An 18inch clearanceis recommended
on the control sidefor servicing. Figure 2and Table2shows
minimum clearances to combustible construction. Consult the
National Fuel Gas Code for further information.
5. Equipment shallbe installedin alocation in whichthe facilities
forventilation permit satisfactorycombustion ofgas,proper
venting,and maintenance of ambient temperature at safelimits
under normal conditions of use. Equipment shallbelocated so
asnot to interfere with proper circulation ofair. When normal
infiltration doesnot provide the necessaryair, outside airshall
beintroduced (see"FreshAir for Combustion").
6. Adviseowner to keep airpassagesfree ofobstructions. Ven-
tilating and combustion air must enter boiler room without
restrictions.
.Thefloorsupporting the boilermust benoncombustible. If itis
combustible,pleaserefer to RepairParts Listfor the appropriate
Combustible Floor Basepart number. We use a 2" Cladlitepad
asa combustible floorbase.Theseare availablefromyour local
supplier. Use24" x 30"pad for 2-5 sectionboilers,and a mini-
mum 30"x 30" pad for 6-7 sectionsboilers. Theboiler must be
centered on the combustible floorbase.
8, Theboilershall be installedsuchthat the automatic gasignition
systemcomponents are protected from water (dripping, spray-
ing,rain, etc.)during appliance operation and service(circula-
tor replacement, control replacement,etc..)
Figure 2 - Minimum Clearances To Combustible
Construction i8,,
_1_ 6 _' Boiler _ ,_
_ositeSide
6"
18"
Top 6"
Rear 6"
Control Side 8"
Opposite Side 6"
Front (Alcove) 18"
Flue/Vent Connector 6"
Near Boiler Piping 1"
This unit must be set on a concrete or other noncombustible material base
or floor. IT MUST NOT BE INSTALLED ON CARPETING.
Thisunit must be seton a concreteor other noncombus-
tiblematerial base or floor.It must not be installed on
carpeting.

Provisionforcombustionandventilationairmustbe
inaccordancewiththeNationalFuelGasCode,ANSI
Z223.1-latestrevision,orapplicableprovisionsofthelocal
buildingcodes.
Besuretoprovideenoughfreshairforcombustion.
Enoughairinsurespropercombustionandassuresthatno
hazardwilldevelopduetothelackofoxygen.
Youmustprovideforenoughfreshairtoassurepropercombustion.
Thefireintheboilerusesoxygen.Itmusthaveacontinuoussupply.
Theairinahousecontainsonlyenoughoxygentosupplytheburner
forashorttime.Outsideairmustenterthehousetoreplacethat
usedbytheburner.Studyfollowingexamples1and2todetermine
yourfreshairrequirements.
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Ifyou use afireplaceor akitchen or bathroom exhaustfan,
you should installan outside air intake. These deviceswill
rob theboiler and waterheater ofcombustion air.
Sizing Air/Ventilation Openings
Air openings must be sizedto handle allappliances and
air movers(exhaust fans,etc.) usingthe air supply.For
air openings into spaces containing other appliancesin
addition to theboiler referto the NationalFuel GasCode,
ANSIZ223.1for sizing.
If No Other GasAppliances InThe Same Space
Provide airopenings into the boiler space as describedin this sec-
tion and the NationalFuel GasCode,ANSI Z223.1.Direct exhaust
installationsrequire airfor combustion and ventilation. Direct vent
installations mayrequire air openings for ventilation (to prevent
overheatingof boilercontrols and boiler space).
When Other GasAppliances Share the Same Space
For air openings into spaces containing other appliances in addition
to theboiler refer to the NationalFuel GasCode,ANSI Z223.1for
sizing.

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 (non-partitioned 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 win-
dows.
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Equipment located in buildings of tight construction shall be provided with air for combustion, ventilation, and dilution of flue
gases using the methods described in example 2 (below) or shall be specially engineered. The authority having jurisdiction must
approve specially engineered installations, a building of tight construction is defined as: 1)walls exposed to the outdoor atmo-
sphere have a continuous water vapor retarder with a rating of one perm or less with openings gasketed or sealed; and 2) openable
windows and doors which meet the air leakage requirements of the International Energy Conservation Code, Section 502.1.4; and
3) caulking or sealants are applied to areas such as joints around window and door frames, between sole plates and floors, between
wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, and at other openings.
EXAMPLE 2: Boiler Located in Confined Space
1. 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 combined space shall be considered in making this determination. Eachopen-
ing shall have a minimum free 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 (see Figure 3A).
Figure 3A - Boiler Located in Confined Space
fChimney
Or
GasVent
Vent Pipe_
) Openings

oAll 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.
Method A: Two permanent openings, one commencing within 12 inches of the top, and one commencing within 12inches of the bot-
tom, 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.
1. Where directly communicating with the outdoors (see Figure 3B) or where communicating to the outdoors through vertical ducts
(see Figure 3C), each opening shall have a minimum free area of 1 sq. in. per 4000 Btu per hour of total input rating of all equip-
ment in the enclosure.
Figure 3B - Directly Communicating to the Outdoors Figure 3C - Vertical Ducts Communicating to the Outdoors
Air
Pipe
3"x 12" 144,000 108,000 36,000
8"x 8" 256,000 192,000 64,000
8"x 12" 384,000 288,000 96,000
8 ½"x16" 512,000 384,000 128,000
Louver Allowance
The free areas of openings means the area after reduction for any installed louvers or grilles. Be
sure to consider this reduction when sizing the air openings.

2. Wherecommunicatingwiththeoutdoorsthroughhorizontalducts(seeFigure 3D), each opening shall have a minimum free area
of 1area ofsq. in. per 2000 Btu per hour of total rating of all equipment in the enclosure.
Figure 3D - Horizontal Ducts Communicating to the Outdoors
3"x 12" 72,000 54,000 18,000
8"x 8" 128,000 96,000 32,000
8"x 12" 192,000 144,000 48,000
8 ½"x16" 256,000 192,000 64,000
Louver Allowance
The free areas of openings means the area after reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.
Method B:One permanent opening commencing within 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 from the front of the appliance. The opening shall directly communicate
with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or to a crawl space or attic that freely com-
municate with the out doors, and shall have a minimum free area off
1. 1sq. inch per 3000 Btu per hour of the total input of all equipment located in the enclosure (see chart below).
2. Not less than the sum of the areas of all vent connectors in the confined space.
3"x12" 108,000 81,000 27,000
8"x 8" 192,000 144,000 48,000
8"x12" 288,000 216,000 72,000
8 ½"x 16" 384,000 288,000 96,000
Louver Allowance
The free areas of openings means the area after reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.

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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.
•be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge line;
•have no intervening shutoffvalve between safety relief valve and discharge to atmosphere (do not plug or
place any obstruction in discharge line.
•terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;
•allow complete drainage of the valve and the discharge line;
•be independently supported and securely anchored to avoid applied stress on the relief valve;
•be as short and straight as possible;
•terminate with plain end (not threaded);
•be constructed of material suitable for exposure to temperatures of 375°F;
•or greater.
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.
1. Place boiler in the selected location (as near chimney as pos- 3.
sible). 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.
Install relief valve on 3/4" pipe nipple in tapped boiler opening.
Pipe the discharge line following guidelines in the preceding
Refer to example shown in Figure 4. The discharge
line pipe size shall be equal or greater than that of the relief
valve outlet over the entire length of discharge line with no
intervening shutoffvalve between the safety relief valve and dis-
charge to atmosphere. The discharge line shall terminate with
a plain end to atmosphere where any discharge will be clearly
visible and is at no risk of freezing. The discharge line shall be
independently supported to avoid applied stress on the relief
valve. The installation shall allow complete drainage of the
relief valve and the discharge line. The discharge line shall be as
short and straight as possible and constructed of a material suit-
able for exposure to temperatures of 375°F or greater.
o
o
5.
6,
Referto localcodes and appropriate ASMEBoilerand Pressure
VesselCode for additional installation requirements.
Install Drain Valveon lowerleft side of boiler as marked.
Install Temperature and Pressure Gauge into 1A,,bushing
threaded in tee furnished with supply piping See Figures 5
and 6).
Connect Supply and Return Lines to boiler, as shown in Fig-
ures 5 and 6. The connections may require certain additional
fittings and parts.

Figure 4- Relief Valve Discharge Piping
RELIEFVALVE
DISCHARGE
PIPING
Check local code_
for maximum
distance from
floor or other al-
lowable safe point
of discharge
Figure 6 - Forced Hot Water Typical Piping With Zone
Control Valve
ZONE VALVE o,
Figure 5-Forced Hot Water Typical Piping
MAiN
T_K

Ifyou are installing anentire new heating system,first install allof
your radiation units (panels,radiators or cabinets) and the Supply
and Return Mains-then make the connections atthe boiler.
In connecting the cold water supply to the water vane, 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 cutoffdevice. Aperiodic inspection is necessary, as
is flushing of float type devices, per manufacturers specific instruc-
tions.
When the 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 vanes to prevent the chilled
medium from entering the heating boiler (Figure 7).
If the 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 Water Temperature Systems (Below 140° F)
And Large Water Content Systems:
Significant condensation may form in this boiler and/or
the venting system ifthe boiler is operated with return
temperatures of less than 120° E
Thiscondensation is corrosiveand can eventuallycause severedam-
ageto the boiler and venting system. Theminimum design return
watertemperature to prevent this condensation in the boilerand
venting is 120°ETheminimum high limit setting is 140°E
Ifthe boileris to be used in aheating systemwheredesignwater
temperatures below140°Faredesired (e.g.radiant floor heating),
a3-wayor 4-waymixingvane or suitablealternative is required
to prevent lowtemperature return water from entering the boiler.
When using amixing vane, followthe manufacturer's installation
instructions.
If the boiler is to be connected to a system having a large water con-
tent (such as a former gravity system), it is suggested to use bypass
piping shown in Figure 8.
Figure 7 - Piping Arrangements For Boiler When Used In
Connection With Refrigeration System
VALVESA& B_OPENFORHEATmNG;CLOSEDFORCOOLING
VALVESC& D-CLOSEDFORHEATING;OPENFORCOOUNG
TOSYSTEM
Figure 8 -Bypass Piping
Front
ReturnFromSystem
Throttling
Thermometer
Aquastat Water To System
Feed
Fi_Rro_With
Air Purger
[ Adi_stthe twoth_ttli_g valvesto maintainat leas_i20_F i:ntheboilerreLum

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For boilers for connection to gas vents or chimneys, vent
installations shall be in accordance with the National Fuel
Gas Code, ANSI Z223.1-latest revision and applicable
provisions of the local building codes.
CheckYour Chimney
Thisis a very important part ofyour heating system.It must be
clean,the right size,properly constructed and in GOOD CONDI-
TION.No boilercan function properly with abad chimney.
1. Uselocalcodes forinstallation or National Fuel GasCode
Z223.l-latest revision.In Canada, followCSAB149.1or .2
Installation Codes.It isvery important to properly sizethe
venting systemfor induced draft appliances.Consult the Vent
SizingTables,in the National FuelGas Code ANSIZ223.l-
latest revision for correct sizinginformation. In Canada, consult
the Vent SizingTables,Amendment #1 to CSA-B149.1and .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 in-
creaser 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" diam-
eter 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 Y'x 4" increaser fitting is located and secured.
3.
.
Theseare high efficiencyboilerswith alowstackor exhaust
temperature.
Ifventing into amasonry chimneywithout aliner, line the
chimneyfrom top to bottom with either:
A. ListedType Bvent pipe
B. Listedflexiblevent liner
C. Poured ceramicliner.
5. Outside chimneysshould not beused unlessthey are (choose
one ofthe following):
A. Enclosedin a chase
B. Linedwith TypeBvent pipe
C. Usea listedflexiblevent liner
D. Usea certifiedchimney lining system
6. Thevent connector from the boilerto the chimney should run
asdirectlyas possiblewith asfewelbowsas possible.
7. Where possible,it is recommended to common ventthe water
heater andboiler. Consult the appropriate Vent SizingTablesin
either the National FuelGasCode, or the Canadian Installation
Codesfor specificrequirements of multiple applianceventing.
8. Ifthe boileris theonly appliance connected to the vent, TypeB
vent pipeis recommended for the vent connector.
9. Slopepipe up fromboiler to chimney not lessthan 1/4"per
foot.
10. End ofvent pipemust be flushwith the inside faceof the chim-
ney flue.Use asealed-in thimble for the chimney connection.
11. Thesectionsofvent pipe should be fastenedwith sheetmetal
screwsto make the piping rigid.Use stovepipewires to support
the pipe from above.
12. Donot connect to fireplaceflue.
13. Do not installa damper on this boiler.
Minimum Vent Pipe Clearance
If the vent pipe must go through a crawl space, Type Bvent 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.
If boiler is installed with single wall vent, it must have a 6" clear-
ance between its surface and any combustible material. A new Type
B gas vent or flexible liner must be installed in accordance with the
instructions furnished with the vent. Maintain clearances as speci-
fied for the vent pipe.
Check the vent pipe to see if it is fire-stopped where it goes through
the floor or ceiling. It should have an approved vent cap with clear-
ances from the roof as shown in Figure 9. If clearances are less
than shown in Figure 9, have the vent checked by local authorities.
For boilers for connection to gas vents or chimneys, vent installa-
tions shall be in accordance with the National Fuel Gas Code, ANSI
Z223. l-latest revision and applicable provisions of the local building
codes. In Canada, follow CSA B149.1 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.
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 vent-
ing 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 com-
mon venting system placed in operation, while the other appliance
remaining connected to the common venting system are not in
operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and hori-

Figure 9 - Type BGas Vent
Liner
Chimney
Vent System
Sheet Metal
Cleanout
CHECK YOUR 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. Use local codes for instal-
lation or National Fuel Gas Code Z223. l-latest revision.
In Canada, follow CSA B149.1 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 ANSI Z223. l-
latest revision for correct sizing information. In Canada,
consult the Vent Sizing Tables, Amendment # 1 to CSA-
B149.1 and.2 Installation Codes.
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3,
zontal pitch and determine there is no blockage or restriction,
leakage, corrosion and other deficiencies which could cause an
unsafe condition.
Insofar as ispractical, close allbuilding doors and windows and
alldoors betweenthe spacein which the appliancesremaining
connected to the common venting systemare located and other
spacesofthe building. Turn on clothes dryers and any appli-
ancenot connected to the common venting system.Turn on
anyexhaust fans, such as range hoods and bathroom exhausts,
so theywilloperate at maximum speed.Closefireplacedamp-
ers.
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.
G. After it has been determined that each appliance remaining con-
,
nected tothe commonventingsystemproperlyventswhentested
asoutlinedabove,returndoors,windows,exhaustfans,fireplace
dampers andanyothergas-burningapplianceto their previous
conditionsof use.
Any improper operation of the common venting systemshould
be corrected so the installationconforms with the National
FuelGasCode, ANSIZ223.l-latest revision.When resizing any
portion ofthe common venting system, the common venting
systemshould be resizedto approach the minimum sizeas
determined usingthe appropriate tablesin the National Fuel
GasCode,ANSI Z223.l-latest revision.In Canada, followCSA
B149.1or.2 Installation Codes.
NOTE:It isrecommended that existinggasvents be
checkedto be sure theymeet localcodes.

INDUCED DRAFT HIGH EFFICIENCY BOILERS
Maximum Horizontal VentLengthFor StainlessSteelVentPipe - 30'
Plus One 90° Elbow PlusVentTerminal.
Minimum Horizontal VentLength - 2' Plus One 90° ElbowVent
Termination.
Additional elbowsare equivalentto 6 feetof straightpipe for 4" di-
ameter 90° elbowor 3 feet ofstraight pipe for 3" diameter 90° elbow.
2,3,4, 5,Section Boilersuse3"vent pipe;for 6, 7 SectionBoilersuse
4"vent pipe.
CHOICE OF VENT PIPE MATERIAL
1. U.L.ListedZ-FlexZ-VentStainlessSteelVentPipe.
2. U.L.ListedHeat-Fab Saf-T-VentStainlessSteelVent Pipe.
3. U.L.ListedFlex-LStar-34StainlessSteelVentPipe.
4. U.L. ListedProTechSystemsFasNSealStainlessSteelVentPipe.
Figure 10 - Induced Draft High Efficiency boilers
Optional Termination Fitting
TJemlund S_deWall Vent Hood
VHolo3"for 2, 3, 4& 5Section Boilers
VH-I_4" for 6 &7 Section _i|ers
Termination Fitting
_° Elbow, pointing down, same matetiai and
pipe size as venting systems equtped with
screen (Min, I/4" Mesh) to keep birds outs
Fot a combustib|e wa|l, use a thimb|e_ Select as
fo|iows:
Vent Pipe: Z-Vent, SafoT_Vent, Star 34
_tmble: Simpson Duravent Thimb|e --
#3G_¢_,/T(3% # 4GV_t#T (4")
Vent Pt_: FasNSeal
Thimble: FasNSea| Wal| Thimble
#FSWT03-3'; FSWT04-4 _'
PRchDown Toward
Outside 1i4" Per Foot
Pitch Down Towa_
Outside 1/4" Per Foot
_vel

1,
,
3,
,
5,
Theseboilers may bevented horizontally as shown in
Figure 10.Thevent pipe is pitched down from the boilerto
thevent termination. Do not connect other appliances to this
vent.
Vent Pipe Material:
A. ULListedZ-FlexZ-Vent stainlesssteelvent pipe from
boilerto vent termination,
-or-
B. ULListedHeat-FabSaf-T-Ventstainless steelvent pipe
fromboiler to vent termination,
-or-
C. ULListedFlex-LStaR-34stainless steelvent pipe from
boilerto vent termination,
-or-
D. ULListedProTech FasNSealstainlesssteelventpipe from
boilerto vent termination.
Clearanceto Combustible Materials: Forstainless steelvent
pipe maintain 6" minimum airspace clearanceto combustible
materials.
Vent Pipe Size:
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 sectionboilers use 4"vent pipe, starting with a3"
to 4" stainless steelvent pipe transition that is connected
directlyto the outlet of the induced draft blower.Do not
use3" vent pipe on 6 or 7 sectionboilers.
Vent Pipe Length:
A. For stainlesssteelvent pipe,the maximum horizontal vent
length is 30feet plus one 90°elbowplus termination fitting.
6, Vent Termination Fitting:For allvent pipematerials,you may
useeither:
A. A 90° elbowpointing down, fitted with a minimum 114"
mesh screen to keep out rodents and birds. Theelbowshall
be ofthe same material and sizeasventpipe. The elbow
exit shouldbe at least 6" awayfrom exterior wallasshown
in Figure 10.
B.
-0r-
Tjernlund VH-1Seriessidewall venthood. For 2,3,4, 5
sectionboilers useVH-1-3",For 6, 7 sectionboilers use
VH-1-4".
7. Vent PipeTermination Location (Figure 10):
a. When venting through combustible walls,combustible
clearancesmust be considered. TheVH-1 Sidewallvent
hood provides both the outside vent termination and a
double wallpipe for passing through a combustiblewall
up to 8" thick (VH-1-4") or 9" thick (VH-1-3").Thehole
in thewallmust be 61_'' 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. TheVH-1may also be used in noncombus-
tible walls.
B. Ifthe 90° elbowisthe termination fittingof choice,then
the singlewall pipewillbe passingthrough the sidewall.
For combustiblewalls,a ULlisted thimble shall beused
where the singlewallpipe passesthrough the wall.For
combustiblewalls usingZ-Vent, Saf-T-Vent,or StaR-34
vent pipe, usethe following:
• 3" vent pipe - use Simpson's Duravent 3" thimble
•4" vent pipe - use Simpson's Duravent 4" thimble. Maxi-
mum wall thickness with this thimble is 7 inches.
B.
C.
Minimum horizontal vent length for all ventmaterials is 2
feetplus one 90° elbowplus termination fitting.
For additional elbowsreduce 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
For combustiblewallsusing ProTechFasNSealwhere the singlewall
vent pipemust pass through the side wall,a ULListedFasNSealwall
thimble shallbe used.
Thethimble isadjustablefor differentwall thickness,with amaxi-
mum wallthickness of7 inches. Sealthe thimble along theoutside
edgeof the platewith caulkor siliconeand fasten to thewallwith
screwsor nails.
Example: 6 section boiler has 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).
C. For singlewallpipe through non-combustible walls,the
hole through the wallneed onlybe large enough to main-
tain the pitch of thevent pipe, and provide proper seal-
ing.Athimble isnot required for singlewall pipe passing
through noncombustible walls.
D. Theventing systemshall terminate at least3 feet above

Figure 11 - Horizontal Venting Clearances
NOTE: _ THERE IS A POTENTIAL POR EXCES:S_VE WINDS, SPECIAL
CONSIDERATION _NOULD BE GIVEN TO LOCATE THE VENT TERMINATION
AWAY FROM THE WINDWARD Si:DE OR THE BUILD_NG,
LOCATE VENT CAP TO ALLOW
_2" (3_ CM) MIN ABOVE: ORADE
ing system shall terminate at least 4feet below, 4feet
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 3feet 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. (See Figure 11)
H,
Locate or guard the vent to prevent accidental contact with
people or pets.
Terminate the vent above normal snow-line. Avoid loca-
tions where snow may drift and block the vent. Ice or snow
may cause the boiler to shut down if the vent becomes
obstructed.
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 dam-
aged by exhaust of flue gas.
E, The venting system shall terminate at least 4 feet below any
eve, 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.
8_ Joining and Sealing the Vent Pipe:
The vent pipe needs to be both watertight and gastight. Seal all
joints and seams as follows:
A. For Z-Flex Z-Vent stainless steel vent pipe use a high tem-
perature silicone sealant rated for 550°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.

B,
For 3" vent pipe runs begin with the male endof the vent
pipeover the boilers induced draft blower outlet. For 4"
ventpipe runs beginwith a 6" length of 3"Z-Vent over the
boiler's induced draft bloweroutlet, to which an evenbead
of high temperature silicone sealant shouldbe applied.
Thenconnect the 3" Z-Vent to a Z-Vent 3"to 4" reducer.
Thencontinue the 4"Z-Vent pipe run by connecting the
4" maleend ofthe Z-Vent to the reducer. (Alocking band
maybe usedaround this joint for additional support.) Then
followingthe sealinginstructions, push the 4" male end of
the Z-Vent over the 4" increaserfitting. When using the
Tjernlund VH-1 vent hood, the femaleend (flaredend) of
thevent pipewillbe connected to the termination hood.
Themale endof the vent hood must be crimped before
pushing the Z-Vent over the vent hood's connecting pipe.
Beforethe pipes are joined, apply a ¼"bead of siliconeone
inch from the endof the maleend. Then push the pipes
together as far as theywillgo making sure any seamsare
alignedand oriented upward. Now apply another bead of
silicone around this joint and smooth out. Thenuse aZ-
Flexlockingband around the centerof the joint.
1. Apply the high temperature silicone approximatelyone
inchfrom the end, around the male end of the pipe in
an even ¼"bead.
,
,
,
5.
,
Pipescan now be pushed together asfar astheywill
go. Theseamson pipe should be alignedand oriented
upward in allhorizontal appliances. Applyanother bead
of siliconearound this joint and smooth out.
Slidelockingband over centerofjoint and tighten gear
clamps.Makesure locking band is centered on joint.
Checkalljoints and seamsfor gastightness.
Horizontal venting shall have a slopenot less than ¼"
(6.4mm) every12inches (305mm) downward away
from the boiler to prevent collectionof condensate
throughout the assembly.
Allowthe sealant to cure for 24hours before operating
the appliance.
For Heat-Fab Saf-T-Ventstainlesssteelvent pipe use
ahigh temperature silicone sealantrated for 550°F
Theoutside of the male end and inside ofthe female
end ofthe pipe must becleanedbefore applyingthe
siliconebead. For 3" vent pipe runs, the male endof
thevent pipewhich goesoverthe outlet of theboiler's
induced draft blower must be crimped. Thevent pipe
should be crimped asminimal aspossible to provide
atight fit overthe outlet. After crimping is completed
followthe instructions forapplying silicone sealant.
For 4"vent pipe runs, begin with a Saf-T-Vent3" to 4" in-
creaserfittingoverthe boiler'sinduced draft bloweroutlet,
C,
to whichan even bead ofhigh temperature siliconesealant
shouldbe applied. Thencontinue the 4" Saf-T-Ventpipe
run by connecting the 4" male endof the Saf-T-Ventto the
increaser.(Alockingband may be usedaround thisjoint
for additional support.) Thevent flowmust be in the direc-
tion indicated on the vent pipe. When using the Tjernlund
VH-1 vent hood, the femaleend (flaredend) ofthe vent
pipe willbeconnected to the termination hood. Applyhigh
temperature silicone in an even ¼" bead approximately¼"
to 3/8"from the end ofthe vent hood's connecting vent pipe.
Also,run a similar sizebead of silicone sealantdown the
seamweldofthe ventpipe. Thenpush the female end over
the vent hood'sconnecting vent pipe.
1. Apply the high temperature siliconearound the male
end ofthe pipe (without the tabs) in an even ¼"bead.
Siliconebead should be approximately ¼"to 3/8"from
the end of the maleend. Also,run a similarsizebead of
silicone sealantdown the seamweld atthe end ofeach
joint.
,Pipes can now be pushed together asfar as theywill
go. Theseamson the ventpipe should be alignedand
oriented upward in allhorizontal appliances.With a
moistened fingeror fiattool, spread any sealant that
squeezesout around the circumference ofthe joint.
,Attach the sections together with the locking rings and
tabs (exceptat the bloweroutlet where no locking ring
exists.) Inspect the joint to ensure that fluegaseswill
not leak.If necessaryapply additional sealant around
thejoint.
,Horizontal venting shallhave a slopenot lessthan ¼"
(6.4mm) every 12inches (305mm) downwardaway
from the boiler to prevent collectionof condensate
throughout the assembly.
5. Allowthe sealantto cure for 24 hours beforeoperating
the appliance.
For Flex-LStaR-34stainless steelventpipe use ahigh
temperature siliconesealant rated for 550°F.Beforeapply-
ing silicone,the outside of the male end and inside of the
femaleend ofthe pipe must be cleanedusing acleaner,
suchas methyl ethyl ketone (MEK)or naptha. For 3"
vent piperuns, beginwith the male endof thevent pipe
over the boiler's induced draft bloweroutlet. For 4" vent
pipe runs beginwith aStaR-343"to 4" increaser fitting
over the boiler's induced draft bloweroutlet. For both
3" and 4"vent pipe runs, applya bead ofsiliconeseal-
ant around the blower outlet and around the inside of
the male end ofvent pipegoing overthe blower's outlet.
When usingthe Tjernlund VH-1 vent hood,the
femaleend (flaredend) ofthe vent pipe
willbe connected to the termination hood.

D.
Applyhigh temperature siliconein an even ¼"bead ap-
proximately 1/4"from the end of thevent hood's connecting
ventpipe. Also,run a similar sizebead of siliconesealant
down theseam weldof thevent pipe. Thenpush the female
end over thevent hood's connecting ventpipe. Now fillin
the channel inlet with silicone sealant. Do not try to insert
thejoiner band, instead fastenthe vent pipe to the vent
hood's pipe with a steelgear clamp.
1. Apply the high temperature silicone around the male
endof the pipe in an even ¼" bead.Siliconebead
shouldbe approximately ¼" fromthe endof themale
end. Also,run a similarsizebead of siliconesealant
down the seamweld atthe end ofeach joint.
2. Theseamson the vent pipeshould be alignedand ori-
ented upward in allhorizontal vent pipe runs.
3. Insert the maleend ofone into the femaleend ofthe
other. Push the pipetogether sothe female end rests up
againstthe stop bead ofthemale end.
.Insert a StaR-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 over-
laps itself by about 1/2".
.Cutthe excessJoiner Band soit lays fiatin the beaded
channel.Fillthe inlet ofthe beaded channel with high
temperature silicone.Smooth out the siliconeover the
channel inlet and the siliconebetween the female end
and the stop bead ofthe maleend.
.Horizontal venting shall have a slopenot less than ¼"
(6.4mm) every12inches (305mm) downward away
from the boiler to prevent collectionof condensate
throughout the assembly.
7. Allowthe sealant to cure for 24hours before operating
the appliance.
For ProTech SystemsFasNSealstainlesssteelvent pipe
no cleaningfluid isrequired. For 3" ventpipe runs on 2,
3,4 and 5 section boilers,begin by locating the FasNSeal
AmetekAdapter over the boiler's induced draft blower.
Continue the vent piperun with 3" FasNSealvent pipe.
For 6 and 7 section boilers, begin by locatingthe FasNSeal
AmetekAdapter over the boiler'sinduced draft blower.
Thenconnect a FasNSeal3" to 4" increaserto the 3"
adapter outlet. Continue the vent pipe run with 4" FasNSeal
ventpipe. Other than the Ametek Adapterand increaser
fitting,DO NOT use 3"vent pipeon 6 or 7 sectionboilers.
FasNSealventpipe isjoined and sealedby the useof an
internal sealinggasketand alockingband on the female
end ofeach ventpipe. Allcomponents should be examined
for possibleshipping damage prior to installation. Align
allvent pipe seamsand orient upward in allhorizontal
applications.Adjustablevent lengths are availablefor4"
diameter vent piping. For 3" diameter vent piping, square
cutmale end atthe desired length. For2, 3,4 and 5 section
boilers usingthe VH-1-3" vent hood, connectthe FasNSeal
Ventto the VH-1-3"vent hood using FasNSealAdapter
#FSC-DUN-3.Thisadapter has no internal sealinggasket.
Toattach the adapter to the venthood, crimp the 3" vent
hood pipe,apply a 1/4"bead ofhigh temperature silicone
sealantaround the outside ofthe vent hood's crimped
connecting pipeand asimilar bead ofhigh temperature
siliconearound theinside ofthe FasNSealadapter. After
pressing the two pipes together and tightening the locking
band, finish creating acomplete sealby fillingthe FasNSeal
adapter'snotched holewith high temperature silicone.
For 6 and 7 section boilersusing the VH-1-4"vent hood,
an adapter isnot required. The4" FasNSealventpipe con-
nects directlyto the VH-1-4" vent hood, and isjoined and
sealedby the internal gasketand lockingband.
Tojoin and sealthe FasNSealvent pipe:
1. Insert maleend into female section.
2. Push the units together as far aspossible.
3. Firmlytighten locking band with anut driver.
4. DO NOT penetrate the FasNSealvent pipe with fasten-
ers.
.Horizontal venting shallhave a slopeof not less than
¼"(6.4mm) every 12inches (305mm) downward away
from the boilerto prevent the collectionofcondensate
throughout the assembly.
oSupport Spacing:
Donot restrict thermal expansion movement ofthe vent. The
vent pipe must expand and contract freelywith temperature
change.Eachrun ofvent piping shallbe supported as follows:
A. Z-Flex stainlesssteelventpiping requiresa loosefitting
metal strap or similar support at eachjoint at amaximum
of 4 feetbetween supports.
B. Heat-Fabstainless steelvent piping requiresa support for
every6 feet ofhorizontal piping run. Thesupport must be
securedusing at least#10fastenersto asolid material (solid
masonry or wood framing or blocking.)Do not fastento
drywall sheathing using hollowwall anchors. Each sup-
port willbe 11/2inch lower than the previous support when
spaced 6feet apart.
C. Flex-Lstainlesssteelvent piping requires a loose fitting
metal strap or similar support at eachjoint at amaximum
of 4 feetbetween supports.
D. ProTech stainlesssteel vent piping requires one loose fit-
ting FasNSealsupport strap for every6' ofhorizontal vent.