Dunkirk 4ES1.50C, 3ES1.00C, 4ES1.75C, 4ES1.85C, 3ES1.00 Installation & Operation Manual

O|L-F|REDCAST |RONSTF.AM

BO|

Installation

• Operation

• RepairParts

Theseinstructionsmustbeaffixedonoradjacenttotheboiler.DUNKIRKBOILERS

DUNKIRK,NEWYORK14048- 716366-5500

MEMBER: The llydronies Institute

I/2" NPT

TANKLESS

HEATER

, o i

F , t , t i

, t , * ,

LEFT SIDE

3/4 _ NPT

_LOW UMIT

CONTROL ON
COIL PLATE

I/2" NPT

PRESSURETROL

PRESSURE GAUGE

COMBINATION

\

1-1/2" NPT
RETURN

i

FRONT

T

27"

WATER

IJNE

_l

2-I/2" NPT

SUPPLY

iq°p

i-i/2" NPT

i SKIM TAPPING

i

'L

,-V2 ° NPTi

RETURN

REAR

5/4" ASNE

POP SAFETY

VALVE

35

EMPIRE OIL-FIRED STEAM BOILER RATINGS

BOILER MODEL NO.

With Without

Tankless Tankless

Coil Cotl

3ESt O0C 3ES100 3
3ES1.25C 3ES1,25 3
3ES1.35C 3ES1.35 3
4ES1,50C 4ES1,50 4
4ES1.75C 4ES1 75 4
4ES1.85C 4ES1.85 4

* MBH = 1,000 BTUpet hour

No.

9ec.

Input

*MBH

140
175

189

2!0

245
259

Nesting

Capacity

*MBH

118
145
156
177

204
215

Net

I=B-R

Rating

"MBH

89
109
117
133

153

161

Not I-S-R

Rating

Sq. Ft,

Radiation

371
454

488
554

638
671

*Tonldelm

Cell

Ratings

GPM*

2.75
3,10

3.25

3.50

3.85
4,00

Typl©al

Chimney

Size and

Height

8" x 8' x 15'
8" x 8' x 15'
8" x 8' x 15'
8' x 8' x 15'

8" x 8" x 15'
8" x 8' x 20'

CIMF31SIONS- INCHES

A B C

16% 7 9
16½ 7 9

16% 7 9
20% 8 11
20% 8 11
20% 8 11

BTUH = British Thermal Unit Per Hour
GPH _ Gallons per Hour Oil at 140,000 BTU per Gallon

** Heating Capacity is based on a 13% CO2 with a -,02' w.c, draft over fire, and a #1 smoke or less. The testing on the boilers

was done in accordance with lhe DOE. (Department of Energy) test procedure

NewYorkCityMEANumber134-98-E
Selectionofboilersizeshouldbe basedupon"Net1=8=RRatingbeing

equaltoorgreaterthanthesq.ft.of radiationalreadyinstalledinthe
building.

TheNetI=B=R Ratingsshownarebasedonanallowanceof1.333in
accordancewiththefactorsshownonthe 1=B=RStandardas publishedby
TheHydronicsInstitute.

Theseboilersmusthavea non-combustiblebaseifinstalledon acombustible
floor.Two-inchcladlitepadmaybeused.Theseboilersarelowpressure

sectionalcastironboilersconstructedandhydrostaticallytestedfora maximum
workingpressureof 15psiin accordancewithA.SME. (AmericanSocietyof
MechanicalEngineers)SectionIVStandardsfor castironheatingboilers.They
arecapacityratedinaccordancewiththecodeofthe1=B=R(Hydronics

Institute).

RulesforSafeInstallationandOperation

1. Readthe Owner'sManualforSafeOperationcarefully.Failuretofollow
therulesforsafeoperationandtheinstructionscancausea malfunctionof
the boilerand result in death,_rious bodily injury, and/or property

damage.

2. Checkyourlocalcodesandutilityrequirementsbeforeinstallation.The
installationmustbeinaccordancewiththeirdirectives,orfollowNFPA31

- InstallationofOilBurningEquipment,latestrevision.

3. Beforeservicing,allowboilertocool.Nwaysshutoffanyelectricityand
oiltoboilerwhenworkingonit.Thiswillpreventanyelectricalshocksor

burns.

4. Inspectoillineandconnectionsforleaks.

5. Be certainoil burnernozzleis size required.Overfiringwill resultin
earlyfailureofthe boilersections.Thiswill causedangerousoperation.

6. Nevervent this boiler into an enclosedspace.Alwaysvent to the
outside.Neverventto anotherroomor insidea building.

7. Besurethereisadequateairsupplyforcompletecombustion.

8. Followa regutarserviceandmaintenancescheduleforefficientand
safeoperation.

9. Keepboilerareacleanandfreeofcombustiblematerial,gasolineand
otherflammablevaporsandliquids.

This boiler has been designed for residentialinstallations. If used for commercial

applications,alljurisdictionalrequirementsmustbe met.This mayrequirewiringandlor
pipingmodifications.Themanufactureris notresponsibleforany changesto the original

design.

BeforeYouStart

Check to be sure you have the dght size boiler beforestartingthe
installation.See ratingand capacitytableon precedingpage.Checkthe

ratingplateontheboiler.
You mustsee that theboileris suppliedwiththe properoil,freshair for

combustion,and a suitableelectricalsupply.Also, the boiler must be
connectedto a suitableventingsystemand an adequatepipingsystem.

Finally,a thermostat,properlylocated,is neededforcontrolofthe heating
system.If youhaveanydoubtsas to thevariousrequirements,checkwith
local authorities and obtain professionalhelp where needed. THE

OPERATING INSTRUCTIONSand THE FINAL CHECKS AND
ADJUSTMENTSare vitalto the properandsafe operationof the heating

system.Takethetimeto besuretheyarealldone.

Thefollowingstepsareallnecessaryforproperinstallationandsafe
operationof yourboiler.

1. LOCATINGTHEBOILER

2. OILSUPPLYANDPIPING

3. FRESHAIR FORCOMBUSTION

4. PIPINGCONNECTIONS

5. CHIMNEY& VENTPIPECONNECTIONS

6. ELECTRICALWIRING

7. THERMOSTATLOCATION

8. CHECKING&ADJUSTING

9. MAINTENANCE

Locatingthe Boiler

If yourboileris partof a plannedheatingsystem,locateit as nearlyas

possiblewhereshownon yourplan.If boileris to be partof an existing
system,it is usuallybestto put it wherethe old onewas.If youplanto

changelocation,youwill needadditionalmaterialsaswellasan adequate
base.Thefollowingrulesapply:

1. The boilermustbelevelandlocatednearpiping.

2. Usea raisedbaseiff]oorcanbecomewetordamp.

3. Theventpipeconnectionshouldbeas shortaspossible.

4. Maintainclearancesforfiresafetyaswellasservicing.SeeFigure2for
minimumclearances.18"clearancemustbemaintainedatasidewhere

passageisrequiredforaccessto anothersidefor cleaning,servicing,
inspection,or replacementofanypartsthatnormallymayrequiresuch

attention.Boilersmustbe installedat least6"fromcombustiblematerial
onallsidesandabove.Allowat least24"frontclearancefor servicing.

Allowat least18"leftsideclearanceforservicingboilersequippedwith

atanklesscoil.

5. FRESHAIRfor combustionmustbeavailableatthefrontoftheboiler.
FRESHAIRfor ventilationmustbeavailabletothefrontANDrearof

theboiler.Airpassagesmustbefreeofobstructionsatalltimes.

Ventilatingandcombustionairmustenterboilerroomwithout
restrictions.

6. The floor suppo_ng the boiler must be non-combustible.If it is
combustible,placetheboileron 2" cladlitepad.Thepadmustbeunder

theentireboilertoprotectthefloor.

7. Besureinstallationisinaccordancewiththerequirementsofthelocal
authoritieshavingjurisdiction.Compliancewiththeseregulationsis
required.In theabsenceof localcodes,followNFPA31- Insbtlationof

OilBurningEquipment.

Q 6" MIN. 18" WITH COIL

• _

_" 6" MIN. "

I_// . I BOILER

I-----2, .,..------IFRO.T

6" MIN.

SeRVraceL_NeLL,.------e_.ec_rRic

F_LPtFE ] I I[ s_,rrc_

GENERAL PRINCIPAL REQUiREMEnTS FOR A TYPICAL INSTALLATION

m_

Fresh Air for Combustion

WARNING

NOTE

Be sure to provide enough fresh airfor combustion. Enough air ensures
proper combustion and assures that no hazard will develop due to

the lackof oxygen.

If you use a fireplaceor a kitchenor bathroomexhaustfan,you

shouldinstallan outsideairintake.Thesedeviceswill robthe boiler
andwaterheaterof combustionair.

You must providefor enough fresh air to assurepropercombustion.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 mustenter the house to replace that used by the burner. Study
foIIowingexampIes 1 and 2to determineyour fresh air requirements.
EXAMPLE 1:Boiler Located in Unconfined Space

If your boiler is in an open area (unpartitioned basement) ina 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 caulkthecracks aroundthe windows.

An unconfinedspace isdefined as aspace whose volume isnot lessthan 50
cubic feet per 1,000Btu per hour of the total inputrating of all appliances

installedin that space.
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 sufficientvolume so that the combined volume of all spaces
meets the criteria for an unconfined space. The total input of all

combustion equipment installed in the combined space shall be
considered in making this determination. Each opening shall have a

minimumfree area of one square inch per 1,000Btu per hourof thetotal
inputratingofall combustionequipment inthe confinedspace, but not less

than 100 squareinches. One opening shall be within 12 inches ofthe top

andonewithin 12 inchesof the bottom of theenclosure.See Figure 4.
Example: Your boiler is rated at 100,000 Btu per hour. The water heater

is rated at 30,000 Btu per hour. The total is 130,000 Btu per hour. You
need two grilles, each with 130 square inchesof FREE opening. Metal

grilles have about 60% FREE area. To find the Iouveredarea needed,

multiply the FREE area required by 1.7 (130 x 1.7 = 221.0 sq. in.
Iouvered area). In thisexample twogrilles, each having an 8"x 30" (240
sq.in,) Iouvered area would be used. Fig. 4 shows the grille locations.

B. All Air from Outdoors: The confined space shall be provided with two

permanent openings, one commencing within 12 inches of the top and
one commencing within 12 inches of the bottom of the enclosure. The
openings shall communicate directly, or by ducts, with the outdoors or
spaces (crawlor attic)thatfreely communicatewith the outdoors.

1.When directly communicatingwith the outdoors, each opening shallhave
a minimum free area of one squareinchper 4,000 Btu per hour of total

inputratingof all equipment in theenclosure.

2. When communicatingwith the outdoors through ve_cal ducts, each
opening shall have a minimumfree areaof one square inch per 4,000
Btu perhour of total input ratingof all equipmentin theenclosure.

3.Whencommunicatingwiththeoutdoorsthroughhorizontalducts,each
openingshall havea minimumfreearea of onesquareinchper

2,000 Btu per hour of totalinput ratingof all equipmentin the
enclosure.

4. Whenductsareused,theyshallbeof thesamecross-sectionalarea
asthe freeareaof theopeningstowhichtheyconnect.Theminimum

dimensionofrectangularairductsshal{benotlessthanthreeinches.

VENTILATING -'_--i
GRII.LE I

i I ' 1

i ,11 II ',

AIR GRILLE _

Fresh Air Duct Capacities for Ducts Supplying Fresh Air to
boiler in tightly constructed houses. British Thermal Units per

hour Input (Btuh)*.

Fresh Air
Duct Size

31/2"x 12"
8* x 8"

8" x 12"
8" x 16"

1/4"Mesh

Screen Btuh

144,000
256,000

384,000
512,0O0

Wood

Louvers Stuh

36,000

64,000
96,000

128,000

Metal

Louvers Btuh

108,000
!92,000
288,000
384,000

*Based on opening covered by IA" mesh screen, wood louvers, or mela{ louvers

FRESH

Boilers With Tankless Heater Coil

Boilersmaybefactorypackagedwithatanklessheatercoil.Theuseof this

coileliminatesthe needforahot waterstoragetank.Instantaneousheatingof
waterinthecoil willprovidea flowof hotwaterfor domesticuse- ifproper
watersupplylinecontrolsareused.

IMPORTANT

Donot usea tanklesscoilif yourwateris excessivelyhardwithlimeor
otherdepositswhichwillaccumulateinsidethecoil.

Forsummerrunningwithcoilyou needtofill boilerwithwaterandaddthe
L6006limitcontrolto the coil.Thiswill maintainwatertemperaturein the

boilerand bringtheburneronwhennecessary.

TANKLESSCOlL PIPING

PipingisshowninFigure7B.A temperingvalve(mixingvalve)is

recommended.

LowLimit(whenused)- 140° F

Thesesettingscanbechangedafteryouhavesomeideahowthe system
responds.If moredomestichotwateris required,the lowlimitsettingcan

alsoberaised.

_NT_pERE_ _OT WATER

¢OL_ WATE_ _N_ET

WLV_

Installation-SystemPiping

Thenearboilerpiping,thatisthe pipingaroundtheboiler,mustbeconsidered
aspartofthe boilerforproperwaterlevelcontrol,andto producedrysteam.

Correctnearboilerpipingis crucialtothe properoperationoftheboilerand
theheatingsystem.Followtheserecommendationscarefully.

1.Placeboilerintheselectedlocation,as nearchimneyaspossible.

2. Installthepopsafetyvalve,usingthefurnished3/a" 90" ell,intothe3/4"
pipenippleonthebackof theboiler.Makea dischargepipe,using3/4"pipe
(notfurnished)to carrythe wateror steamto a nearbydrain.Do not
connectthe dischargepipe directlyto a drain but leavean airgap.No
shutoffofany descriptionshallbeplacedbetweenthe popsafetyvalveand
theboiler,or ondischargepipes

betweensuchsafetyvalvesandthe atmosphere.Installationof thepop
safetyvalveshallconformtotherequirementsoftheANSI/ASMEBoiler

and Pressure Vessel Code, Section IV The manufactureris not
responsibleforanywaterdamage.

3.Thisboileris equippedwithtwo 21/2"supplyconnectionson topand
two 1V2"returnconnections,oneeachon frontand backsidesof the
boiler.Unusedconnectionsmust

4.Recommendednearboilerpipingfor gravityreturnsys-temsisshown
in Figure8. Thisconfigurationusesonesupplyandonereturntapping.
Pipingoff bothboilertap-pingsis recommendedon units5 sectionand
larger.

Note:Usebothsupplytappingsonboilers5 sectionandlarger.

PtPES_E

5.Forinstailerschoosingto usebothsupplytappings,Figure8Ashowsthe
correctwayto pipethissystem.Figure8Bshowsthewrongwaytopipe

a headerwithtworisers.

, Headersmustbe fittedwithheaderoffsetsor swingjoints, or be

equippedwith expansionjoints, so that thermalexpansionand
contractionofthe headerwillnat damagetheboiler.Headersshall
netbewelded.

, Systemtakeoffsfromtheheadermustbebetweentheequalizerand

therisertothe headernearesttheequalizer.Systemtakeoffsmust
neverbebetweentworisers.

6.Systemtakeoffsfromtheheadermustneverbe bull-headed.Ifthesteam
maingoesintwodirections,theremustbetwotakeoffsfromtheheader,
oneforeachmain.

7. All boilersingravityreturnsystemsmustbeequippedwitha Hartford
LoopasshowninFigures8and8A.

8. Whenpipingtheverticalrisersfromtheboilertotheheader,thebottom
ofthe headermustbea minimumof 24inchesabovethewaterlevel

lineantherightsideoftheboiler(i.e.51inchesabovethefloor).

9. Steamriser(s)andheadershallbe272"pipesize.

10. Equalizerlineshailbeminimum1 1/2"pipesize.

11. The boilerhasa 1V2"tappinginrearsecflanfarskimming.

_EA_{ MAINS

HART_ORO

CLOSE

N|PPLE

MAIN VENT

D_Y RETURN

M_[N

THIS, PIPING

COMMON

tS INCORRECT

MISTAKES

TO SHOW

©

L

12. The near boilerpipingshall includea 1 1/2"ballvalveinthereturn
pipingasshowninFigure8Afarbottomblowdawnanddraining.

13. Forgravityreturnsystems,thebottomof theloweststeamcarrying
pipe,beita dryreturn,ortheendofthesteammain,mustbeatleast
28"abovethenormalwaterlevellineanthedghtsideoftheboiler.

Thisisknownas"DimensionA."

14. Forpumpedreturnsystems,followthecondensatepumporbailerfeed
pumpmanufacturer'sinstructionsforproperinstallationandhookup.

15. Inconnectingthecoldwarer supplytothewaterinletvalve,makesure

thata deanwatersupplyisavailable.Whenthewatersupplyis froma
wellor pump,asandstrainershouldbeinstalledatthepump.

FORUSEWITHCOOLINGUNITS

A.

This boiler, when used in connection with chilledwater systems,must

be installed so that the chilled water is piped in parallel with the heating
boiler. Appropriate valves must be used to prevent the chilled water

from enteringthe heating boiler(Fig. g).

B.Whenthis boileris connectedto heatingcoilslocatedin air handlingunit.,

wherethey may be exposedto refrigeratedaircirculation,the piping
systemshall be equippedwith flow controlvalves or other automatic

meansto preventgravitycirculationof theboilerwaterduringthecoolinc
cycle.

'_rd,.vE8 A & m

VALVESC & Q

_R _OUNG

ChimneyandChimneyConnection

CHECKYOURCHIMNEY

Followlocalcodes.Inthe absenceof localcodes,followANSI/NFPA31
Installationof OilBurningEquipment,latestedition.

Thisisaveryimportantpartof yourheatingsystem.Noboiler,however
efficientitsdesign,canperformsatisfactorilyifthechimneythatservesitis

inadequate.Checkyourchimneytomakecertainthatit isthe rightsize,
properlyconstructedandinsoundcondition.

Itischeapertorebuildapoorchimneythanto payexcessivefuelbills.If

yoursisanoldmasonrychimney,a newsteellineror anew

prefabricatedchimneymaybethebestsolution.Thefollowingchartshows
recommendedminimumchimneysizesbasedonTable3andFigure6 of

theI:B:R TestingandRatingStandardfor HeatingBoilers,Sixth

Edition,June1989.

MUST BE REQUIRED MIN*
IMUM HEIGHT, MUST BE

AT LEAST 3 FT. HIGHER
THAN HIGHEST PART OF

PASSAGE THROUGH
ROOF. MUST BE AT

LEAST 2 FT. HIGHER
THAN ANY NEIGHBORING
OBJECT. MUST HAVE AN
UNOBSTRUCTED TOP

OPENING,

MUST BE AT LEAST

4 INCHES THICK -

AND BE LINED.

_l_ CHFM_ I

.60- i 30 15

13Iol 80 15
i,81o2,00 20

FIECOMMENDED MtNiMUM _IMNEY SIZES

=!:

_ER_ LNER;

_!NNqY' i_DE I_

8"×8 ' 6' 6:5_x 6_'
8' x 8" 7' , 6_f;_"× 6_!4"

[:<]re#_@:(Y)88_ee 2,#_ if,,8J3_es_ _i, ad_3 feetIocblm_qeYhe_gP4_
[_!et la Fiqure 1@t

Foradditionalchimneydesignandsizinginformation,consulttheASHRAE
1996HVACSystemsandApplicationsHand-book,Chapter30,Chimney,
GasVentandFireplaceSystems;ortheNationalStandardforChimneys,
Fireplaces,VentsandSolidFuelBurningAppliances,ANSI/NFPA211.

CHIMNEYCONNECTORANDDRAFTREGULATOR

Yourboilerrequires7"diameterchimneyconnectorpipeon 3 section,8"
diameterchimneyconnectorpipeon 4 section.Youmustalsouse a dralt
regulatorpackedwithboiler.Properlyinstalled,theregulatorwillcontrolthe
draftautomatically.Itis bettertoinstallitina horizontalsectionofthe pipe;but
itmaybeinanangledorverticalsection.Justmakecertainthatthe"top"isat
top- andthattheshortpipesectionwhichholdstheVaneishorizontal.Install

itascloseaspracticableto theboiler.
Toinstallthechimneyconnector,startatthe boilerandpreferablytakeoff

fromthefluecollectorcollarwithanelbow- theninstallthedraftregulator
next,makingit horizontal.Whentheregulatoris inplace,startatthechimney
andworkbacktotheregulator.JointhetwosectionswithaDrawband.The
horizontalpipemustslopeuptowardthechimneyatleast1/4inchperfoot.It
mustnotleakandmustbefirmlysupported.Joinsectionswithatleasttwo
sheet-metalscrews.Supporteverysecondsectionwithastovepipewire.

MINIMUMVENTPIPECLEARANCE

ALTERNATE POSITIONS

TOP

1

MUSTSLOPEUP
AT LEAST 1/

PER FOOT OF
HORIZONTALRUN
DRAWBAND

LAST PIECE
INSTALLED

I

I L

_,TIGHT. SMOOTH,

CORRECTLY SIZED.

I

I

t

I

&LEDIN

THIMBLE

TIGHT

DOOR

DRAFT REGULATOR
VANE

Woodandothercombustiblematerialsmustnotbecloserthan18"fromany BALANCEDWEIGHT
surfaceoftheventpipe.

EquipmentandOptionalAccessories-WhatTheyDo

POPSAFETYVALVE

Youmusthavea popsafetyvalveonyourboiler.Steamexpandsasit isheated.

Ifthereisno placeforthesteamtoexpandinto,pressurewillbuildupinsidethe
boilerandsystem.Shouldthishappen,the popsafetyvalvewillautomatically
openata pre-determinedpressure.Thiswill relievethestrainontheboilerand
system.Runapipefromthesafetyvalveoutlet(pipemustbesamesizeasoutlet
andtheopenendmustnotbethreaded)toan opendrain,tuborsink,or other
suitabledrainagepointnotsubjecttofreezing.Failuretodosomaycausewater
damageorinjuryshouldreliefvalverelease.Do notcapoffthedrainlinefrom
thisvalve!Eachpopsafetyvalveisprovidedwitha liftingdevicefortestingand
shouldbetestedmonthlyduringtheheatingseason.Refertosafetyvalve
manufacturer'sinstructionspackagedwithsafetyvalve.

STEAMPRESSUREGAUGE

Everysystemshouldhaveapressuregaugeinstalledintheboiler.Thisgauge
enablesyoutomonitorthe pressureinthesystem.Ifthesafetydevicesfailtoshut

offyourboileratthepropersettings,notifyyourservicetechnicianimmediately

WATERLEVELGAUGE

Thewaterlevelin theboilercanbeseenthroughtheglasstubeinthewater
levelgaugeatsideof boiler.Correctcoldboilerwaterlevelisstampedonside

jacketpanel.Whenmakingsteam,thewaterlevelwilldroponetothreeinches.

Thewaterlevelshouldbecheckedregularly.

STEAMPRESSURECONTROL

Thesteampressurelimitcontrol(pressuretrol)shutsofftheoiltotheburnerifthe
steampressureintheboilerreachesthecut-offsetpoint(i.e.thesumofthecut-in

andthedifferentialsetpoints).Burnerretireswhenthesteampressuredropsto
thecut-insetpoint.Systempressurerequirementsarebasedonthesizeand

conditionofthepipes,andtheload.

Forgoodsystemoperation,thecut-insettingofthe pressuretrolshouldnever
be less than twicethe systempressuredrop. In a typicalsinglefamily
residencewith a cleanonepipeheatingsystemandcastiron radiation,this
meansthatthecut-inwillusuallybesetattheminimumsetting,i.e._/2psi.

Steamradiationis usuallysizedbasedon squarefeet of equivalentdirect

radiation(EDR).Thisis basedon a steampressureintheradiatorofjust less
than1 psi.Therefore,in our examplesystemfromabove,wewouldsetthe
differentialadjustmentat1psi,i.e.thesteampressurerequiredinthe radiators.
Thiswillgiveusa cut-offsetpointd 1_12psi.
Theaboveisan exampleofa typicalonepipesystem.Forlargersystemsor
othertypesofsystemssuchas two pipesystems,orsystemswithconvectors
or fan coil units,the pressuretrolsettingswill needto be determinedon a
system-by-systembasis.

The cut-insetpointisdeterminedbythesystempressuredroptothe furthest

radiatoror terminalunit.Doublethesystempressuredropasa safetyfactor,

resultinginthe rulethatthe cut-insettingshouldneverbe lessthantwicethe
systempressuredrop.
Thedifferentialset#ointis thesteampressurerequiredattheterminalheating

units.

Nowyourboilerwill operateinthe correctpressurerange.It will maintain
enoughsteampressureto sendthe steamouttothe furthestradiator,andnot

go overtheoptimumsteampressurethatisrequiredat theradiators.

67D-t LOWWATERCUT-OFF

Thefloat-typelowwatercut-offshutsofftheburnerwhenthewaterlevelis
belowasafepoint.Theburnerwillstartwhenthewaterisrefilledtoa
minimumsafelevel.

WATERFEEDER(Optional)

Awaterfeederworkswiththelowwatercut-off(LWCO)tomaintaina
minimumsafelevelofwaterforboileroperation.It'susedtokeeptheboiler

runningbycompensatingforminorevaporativesteamleaks,andtoprevent
freeze-upsif thehomeownersareawayanda returnlineshouldspringa

leak,Theautomaticwaterfeederisa safetydevice,nota
convenienceitem.Itisnotdesignedto maintaina "normal"waterline.The

waterfeederdoesnottaketheplaceofa responsiblepersonmonitoringand
maintainingthe"normal"waterline.Steamboilersrequirepersonal

attention.

Four electric water feedersare offeredby McDonnell-Millerwhichare
compatiblewiththe 67D-1LWCO.The model#101Aand #WF2-U-120
waterfeedersareusedwith120voltwiringcircuits,asfoundanthissteam

boiler.The McDonnell-Millermodel#101A-24and#WF2-U-24areused
with 24 volt circuits,whichmay be usefulin a retrofitinstallationwhich

alreadyhasa 120voltto 24volttransformer.
TheWF2-U-120and WF2-U-24(Uni-Match)waterfeedersareequipped

witha solidstateelectroniccontrolwhichfeedswaterwhensignaledbythe
LWCO.Thewaterfeedrate isfieldadaptablefar 1,2, or 4 gpm.These
waterfeedershavean adjustableslideswitchtomatchthetimingcyclean
theLWCO.Whenusinga McDonnell-MillerLWCOtheslideswitchneeds
toselectposition#1.The timingcyclecreatesaninitialdwellperiodofone

minuteto allowcondensateto be returnedto the boiler.If afterthedwell
periodthewaterhasnatreachedtheminimumsafelevelandcompletedthe

LWCOcircuit,thenwateris fedat theselectedflowratefaroneminute.The
dwellpedodistheninitiatedagainfar oneminute.Ifthewaterlevelhasstill

not reachedthe minimumsafe level,then wateris addedagain at the
selectedflowrateforoneminute.Thiscyclecontinuesuntilwaterreaches
the minimumsafe levelandthe circuitis completed.DunkirkRadiator
recommendsusingaUni-Matchwaterfeederataflawrateof1or2gpm.If
the steamboilerrequireshigherflowrateson a regularbasisa service

technicianshouldbenotified.
The1OlAwaterfeedermaybe used,howeverthewaterfeed rateistoo

high and needsto be regulatedor throttled.The IO1Awillfeedupto 6
gpm,muchgreaterthanthedesiredflowrateof 1-2gpm.Also,thereisno
dwellperiodto providea marginfor condensateto returnto the boiler.
Thesetwofactorsincreasethechancesofoverfeedingwaterto thesteam

boiler.Excessivewaterinthesteamboilerwillproducenoise
Consultthe water feedermanufacturer'sinstallationguidelinesfor more

detailson waterfeederselection,recommendedpipingarrangement,and
start up procedures. Dunkirk Radiator supports McDonnell-Miller's

recommendationtoarrangetheinstalledpipingsoa brokenuniontest can
beimplemented.

DRAINVALVE

Thismanualvalveprovidesa meansofdrainingallwaterfromtheboilerand
system.Itshouldbeinstalledinthe3/a"teewherethewatersupplyline
enterstheboiler(Fig.8).Youcanalsousethisvalveto lowerthewaterlevel
ifit istoo high.

STEAMVENTS

Beforea steamsystemwill operateproperly,suitablesteamventsmustbe

installedin eachradiatoras wellasthe returnmain.Somesystemsrequire
steamtrapsinthereturnlineat theradiationunit.

The"Hartfordloop"isa pipingarrangementwhichmustbeincluded(Fig.8)
forproperoperationofthesteamsystem.

BOILERSWITHTANKLESSCOILSONLYFlowRegulatorandWater

TemperingValve

Ifyouhavea TanklessCoilfordomestichotwater,thesetwopartscanbe

used.Thiswillprovideyouinstantaneoushotwaterthatis neither

scaldinghotnormerelytepid.The FlowRegulatorisplacedinthecoldwater
linetothecoil.It assuresa steadyflowofwatersothatthecoilcanproperly
heatit. It prevents"spurts"of "half-heated"water.Thisisimportantwherethe
waterpressureisexcessivelyhighorvariable.TheWaterTemperingValve
is atee whichis connectedata junctionbetweenthehotwaterlinefromthe
coilandacoldwaterbranchfromthesupplyline.Itmixeshotandcoldwater
as requiredto furnisha temperedsupplyof watertothe house.Thewater
willbejustthe righttemperatureforyouruse.Thisisimportanton a steam
systemto preventscaldingtemperaturesat thefaucets.Bothpartsareself-

containedandautomatic.

Starting Your Boiler

HOWASTEAMSYSTEMOPERATES

Thewaterintheboilerisheateduntilit reachestheboilingpoint.Asthe
waterboilsit turnsintosteam.Thesteamrisesfromthetopof thewater
throughthesupplymainto theradiationunits.As it passesthroughthe

radiatorsitreleasesitsheatandcondensesintowater.Thewaterreturns
tothe boilerthroughthe returnmain.

FILLINGSYSTEMWITHWATER

Onsteamheatingsystemstheboileris partiallyfilledwithwater.Itisvery

importantto theproperoperationoftheentiresystemthatyourboilerbe
filledto theproperlevel.Thecorrectwaterlevelon coldstartconditionis
abouthalfwayupthe glasswaterlevelgaugeasmarkedon theboiler
jacket.Tofill:

1.Closetheboilerdrainvalve.

2. Openthevalvesat thetopandbottomoftheglasswaterlevelgauge.

Alsoopenthedrainvalveatthe bottomofthegauge.

3. OpenthefilIvalveandatlowwatertorunintotheboiler.

WARNING- Neverrunwater intoahotemptyboiler,

4.Allowboilertofill untilwaterrunsoutthe gaugedrainvalve.Then

closethegaugedrainvalve.

5.Continuetofillboileruntilwaterreachestheindicatedwaterline.This

Checking and Adjusting

isabouthalfwayuptheglasstube.Alwayskeepthewateratthislevel
whensystemisoff.

IMPORTANT

Skimminga newsteamboileronan existingsystemmustbedoneseveral
timesto removeall oil,greaseandsediment.Thereshouldbe a teewitha
plugpipedtothesupplylineoftheboilerinordertoproperlyskimtheboiler.
Wheneverthewaterin the glassgaugebecomesdiscolored,yourboiler

shouldbeskimmed.
Whenskimming,makesureto pipetheopenendof thetee tothefloorora

drainto preventanyonefrom beingburnedbythe steamand hotwater
whichwillbereleased.

TheFloatLowWaterCut-offshouldbe blowndownafterskimming.Following
blowdown,allowtheboilertocoolandthenaddfreshwaterslowly.

Thefloatchamberof thelowwatercut-offmustbeflushedcleanandmaintained
clearof sedimentto allowfree movementof the float.This mustbe done

frequentlyduring initial operationof the boilerand at least once per week
thereafter.Followinstructionsontagattachedto control.Neverthrottlea steam
radiatorvalve on a one-pipesystem.It mustbe fully openor fully closed.
Otherwisewaterisheldintheradiatorunits.Thiswillcauseknockingsounds.
Skimmingmayberequiredagainafterafewdaysoperation.

CHECKINGCONTROLS

To checkthe LowWaterCut-Off,turnoff powerto theboileror turnthe
thermostatdown to the lowestsetting.Drainwaterto belowthe visible

bottomof thewatergaugeglass.Turnpoweronandturnthe thermostatto
callfor heat.Whenthe boilerisequippedwiththefloattypeLWCO,theoil

burnershouldnotrunonacallfor heatwhenthewaterislow.
To check the pressurelimit, run the boileruntil the pressurereaches

systemdemand.Thenturn the pressurescrewanddropthe pressure
settinguntiltheboilershutsdown.Thiswillshowthatthe pressurelimitis
operatingproperly.

If youhaveinstalledyourown boiler,we recommendthat youcallfor an

inspectionby a servicetechnician.The peace of mind and assured

performanceare wellworththe cost involved.Hecanquicklymakethe

necessarychecksandadjustments.

OIL BURNERADJUSTMENT

Suggestednozzlesandpreliminaryburnersettingsarefoundon page20.
Referto youroil burnerownersmanualfor checkingandadjustingthe

burner.

ADJUSTOPERATINGCONTROLSInstructionsfor eachcontroland

burnerareincluded.
Betthermostatheatanticipatorat.20.Instrucfionsforthefinaladjustmentof

thethermostatarepackagedwiththethermostat.
CHECKTHERMOSTATOPERATION

Whensetabovetemperatureindicatedon the thermometer,boilerburner
shouldstart. Makecertainthe thermostatturnsoff the boilerwhenroom

temperaturereachesthe selectedsettingand startsthe boileroperating
whenroomtemperaturefallsafewdegrees.

Finally,setthethermostatforthedesiredtemperature.Specialconditionsin

yourhomeandthelocationofthethermostatwillgovernthissetting.

MaintainingYourBoiler

Checkthe waterleveleverydayor two.Verifythe watertineshownby
operatingthe drainvalvean thegauge.Be suretop and bottom valves

on gaugeare alwaysopen so thatactualwater levelwill be shown
atalltimes,

POPSAFETYVALVE

Thisvalveshouldopenautomaticallywhenthesteampressureexceedsthe
safelimit(perinstructionspackagedwithvalve).Shoulditeverfailto open
undertheseconditions,shut downyoursystem.Havethevalvereplaced
immediately,The pop safetyvalve shouldbe testedmonthlyduringthe
heatingseason.Refertothevalvemanufactureflsinstructionspackagedwith
thepopsafetyvalve.

LOWWATERCUT-OFF

TheLowWaterCut-offwillin_rrupttheelectricalcurrenttotheburnerwhen
thewaterlinein the boilerdropsto a low level.It isveryimportanttokeep

thefloatchamberfreefromsediment,a conditionessentialto dependability.
To keep any accumulationfrom interferingwith floatactionis to "BLOW
DOWN"or flushoutthecontrolregularly.Thismustbedonetwo-threetimes
thefirstweekafterinstallationandonceaweekthereafterduringtheheating
season.Doitwhiletheboileris inoperation.Firstnotewaterlevelingauge
glass.Openblow-offvalveatbottomof control,waterwillpourout,flushing
awaysediment.Drainuntilwaterisclear,abouta pail,thenclosevalve.If
waterlevelingaugeglasshasdropped,addwaterto boilertorestorelevel.

Consultlow water cut-offmanufacturersinstructionsincludedwithboiler.
NOTE:Openingblow-offvalvecheckscut-offoperationtoo.As floatdrops

withfallingwaterlevel,burnerswillshutoff.Aftervalveisclosedandnormal
operatingconditionsarerestored,burnerswillresumefiring.
Boilersshouldnot be drainedbetweenheatingseasons.Onlywhenthe
waterin thesystembecomesdirtyshouldtheboilerbe drained,flushedor
boiledout,andrefilled.Steamboilersmaybeentirelyfilledwithwaterduring

thesummermonthsto excludeair.

CLEANINGYOURBOILER

Undernormaloperatingconditions,withthe burnersproperlyadjusted,we
recommendthat you have the flue passages,burneradjustment,and
operationof the controlschecked once each year by a Service

Technician.
Before the start of each season (orwheneversystemhasbeen

shutdownforsometime)recheckthe wholesystemforleaks...andrecheck
theboilerandventpipefor leaks.Replaceor patchanyboilersealsthatare
faulty.

BOILERFLUEPASSAGES

FluePassagesbetweensectionsshouldbeexaminedyearlyandcleaned.
Removevent pipe.Raisetoppanelof boilerandswingoutto exposeflue
collector.Removefluecollectortop. Cleanpassagewaysbetweensections

witha flexiblehandlewirebrush.Removedirtfomthebottomoftheboiler
and reassembleall parts.Be sureventpipeconnectionsto chimneyare

secureandnoobstructionsarepresent.

FOAMING,PRIMINGORSURGING

Thesetermsareusedtodescribeafluctuatingwaterline- whenwater
leavestheboiler.

Itiscausedby anycombinationofthefollowing:

1.Threadingoilandorganicmatterintheboilerwater.(Mineraloil, orcore
sanddoesnotcausesurging.)

2. Faultyquickventsthatdonot releaseairuntila sizeablepressureisbuilt
up- replace.Ifdirty,cleansothatyoucaneasilyblowthroughvalve.

3. Improperheader design - whensteamflowsinoppositedirectionof
equalizerlineon"Hartfordloop."Generallya 15"horizontalrunbetween

riserandmaintakeoffwill allowentrainedwaterto falloutofthesteam
vaporsoitcan returnto boiler.(Seepage7,Fig.8)

4.Adjustmentof steamlimitcontroltoawidedifferentialincreasesdifficultyif
quickventsare oldstyle,slow-releasingtypeor dirty.Alwayssetsteam
limitcontroldifferentialaslowaspossible.

5.Soapanddetergentscauseextremesurging-cleanthoroughlyby
skimmingtheboiler.

CAUTION

Neverrefilla hotboilerwithcoldwater-thedangerofthermalshockmay
crackasection.

CAUTION

Neverallowelectricianor oil burnermechanicsto tryouttheirwork by
turningon oil burnerfor evenonesecondunlessboileris filledto the
properoperatinglevel.

SYSTEMCHECKSAFTERFIRSTSTARTING- STEAMSYSTEMS

Readthe instructionspackagedwithyourcontrolsand makechecksand
adjustmentsaccordingly.Start the burnerand set the Thermostatfor the
desiredroomtemperature.WhenadjustingtheSteamPressurecontrol,watch
thesteamPressureGaugeanduseits pressurereading- asitwill bemore
accuratethanthecontrol.(Anydifferencebetweenthe twowillbeduetotheir
differentlocation.)

BOILERWATERTREATMENT

Inclosedhotwaterheatingsystems,negligibleamountsofmakeupwaterare
used,and watertreatmentis not required.In steam systemswherethe
systemistight,freefromleaks,andall the steamis returnedtotheboileras
condensate,theamountofmakeupwateris small.Again,watertreatmentis
notrequired.
On steamsystemswith lessthan 90% of the steambeingreturnedas
condensate,orwithveryhardor corrosivemakeupwater,treatmentmaybe
desirable.Followthe recommen-dationsof theASME(AmericanSocietyof
MechanicalEngineers)Boilerand PressureVesselCode,SectionVl, latest

version.

BETWEENHEATINGSEASONS

Boilersshouldnotbedrainedbetweenheatingseasons.Boilersinclosedhot
waterheatingsystemsmaybeleftas is.Steamboilersshouldbeentirelyfilled
withwaterduringthesummermonthsto excludeair.

Oil Boiler/BurnerCleaningInstructions

1. ShutoffalIelectricaIpowertotheboiler/burnerandshutofffuelsupply.

2. Removethesheetmetalsmokepipefromthetopd theboiler.Inspect
pipeandchimneyfor signsofcorrosionanddeterioration.Cleanbase
ofchimney.

3. Removetopjacketpanel.

4. Removethetwobrasswingnutsholdingtheflueccllectorfop.

5. Checkthegasketontheundersideof thefluecollectorandreplaceas
necessary.

6. Removetheoil burner(threecapscrews).-OR-
Removetheoil burner/firedoorassembly(fourhex nuts).Thisis the

recommendedmethod,as it allows full accessto the combustion
chamberandlesspotentialdamagetothetargetwallduringthecleaning

process.

7. Removetheburnerdrawerassembly.Cleananysootaccumulations.

8. Replacetheburnernozzlewiththeexactsizeandtyperecommended

forus onthisboiler.

Note:Changingto adifferentfiringrate,otherthanisrecommended,ortype

of nozzlemaychangethe performanceof this boilerand/orcausea
hazardouscondition.

9. Cleanelectrodeassemblyandsetelectrodesasperburner
manufacturersrecommendations.

10.Reinstalldrawerassemblyandcheckforproperheadlocationas per
themanufacturer'srecommendations.

11.Inspectthetargetwail,blanket,andfiredoorinsulationforcrackingand

deterioration.If thereisanysignsofcrackingor deterioration,replace
beforereassemblingtheboiler.

12.Removesootfromfiresidesurfacesbybrushingdiagonallythroughthe
flue passages(see drawing).Care shouldbe taken so as not to

damagethetargetwallwiththefluebrush.

13.Carefullyvacuumsootaccumulationsfromthecombustionchamber

area,beingparticularlycarefulnottodamagethetargetwailandblanket

withthevacuum.Targetwallandblanketmustbeingoodconditionand

correctlyinstalledtoinsurepropercombustion.

\

oooooooooooo

ooooooo

%%%°°%%°2°

°j°o°2o%%%°2o°Co°2o
°°°°%02°%°o%%°°°0%%°Oo°

14. Reinstalltheburner/firedoorassembly.

15. Reinstallthefluecollectortopandsecurewiththetwobrasswingnuts.

16. ReinstalIthetopjacketpanel.Reconnectthefluepipe.

17. Inspectandcleantheoil burnerblowerwheel.

18. Oilthe burnermotor(DONOTOVEROIL}.

19.Removetheoilpumpcoverandclean/replacethepumpscreen.Carefully
reassemble.

20.Replacethefuelfilter(ifapplicable).

21.Reconnecttheelectricalandfuelsupplies.

22. Fire the burner,checkingfor propercombustionusingcombustiontest

equipment,makingadjustmentsasnecessary.

23.Insurethatallsafetycontrolsandoperatingcontrolsarefunctioning
properly.

IMPORTANTOPERATINGANDMAINTENANCEREQUIREMENTSKEEPYOURBOILERANDTHEAREAAROUNDIT

CLEANNEVERBURNREFUSEORANYMATERIALOTHERTHANTHESPECIFIEDFUELINYOURBOILERHAVEYOUR

BOILERCHECKEDEACHYEARBYAQUALIFIEDTECHNICIAN

_u me_javowalir_o_nven_ and servi_ calls _ ch_ these potn(s _m _ c_l for _r_ce.

Bu _ler may not _ iitng at proper
re[@

Burner may be shortocyct ag,

po_r _ boile_

OonttoIs o_t of adjustment

What: to

Reset themsostat above room tem_raIu 8.
Cean all flue passages and _'he'_nt pipe,

Nave burner c_ea_d and read ueted,
C_eek _e_f_e size if there is _y doubt,

Have burner adjusted
S_ort-r_cting {too frequent off and on) of bu[ner will cause s,aoti_ _f_r ar_df

or burner bec_e dirty at frequent in_ervaJs,dter eorreotino Itre drt conditior_....

also correct _he@n_ro_setting (or other _se e#_:heehorbcV_c4i_'_gl

Check thefm_sM he_[ _ntio pa,tor_d _rre_ _tt_, if neces_ry, per ine_r_t_or_

Check o,.,_ercurreetprotection Check to _ sure power supply circuit is "ON,
Reset accordi_ to in_r_l_ie_s packed with coatro/&
Check a_icontrol term_inatsan_ w#e ioinls,

HAV_ YOUR 8_RVIC_ TECHNICIAN CHECK ANY PROBLE_ YOU ARE UNAI_LE _ CORRECT.

COLORCODE

BK = BI_CK

BL = BLUE

W = WHITE

G = GREEN

i_ =WIRE NUT

pARTNO, - 146-34-O47

2 X 4 JUNCTION

PART NO, _45-31-O82

HANDY BOX COVER (NOT SHOWN)

PART N0. _46-61-121

LOCK-NUT (2

PART NO.

I/2" CLOSE

PART NO. 146-07-030

HONEYWELL

PRESSURETROL _

PART NO. 146-62-015

- GROUND SCREW
PART NO. 1€6-54-B02

-UNE VOLTAGE (GROUND)

• LINE VOLTAGE (NEUT. LEAD)

\

_PRESSURETROL TO LWC.O HARNESS

PART NO, 433-00-873

OIL BURNER

PRIMARY RELAY

OPTIONAL LOW LIMIT

CONTROL FOR BOILERS
WITH TANKLESS COIL

\ z z

TO 24v

THERMOSTAT

LOW VOLTAGE WiRiNG HARNESS NOT FURNISHED

L BURNER TO L.WC.O. HARNESS

PART NO - 433-00-872

LINE VOLTAGE (NOT LEAD)

#2 TERMINAL LWCO

PART NO, 433--00--874

67D-1 LW*C,O,

W_RINGTERMINAL DETAIL

'tJ

WH_E

FROM OIL BURNER

BLACK LEAD

FROM OiL BURNER

McDONNELL M_LLER

L W.C.O

PART NO. 146-26-042

4 X 4 OIL BURNER
JUNCTION BOX

"_p_r_ Tsr_kle_ _i_ K_t4340_14 (ir_l:_s coJ_,_8{, and b_l_)

4

L_!

(1 _69BI0! )

BOILER

MODEL

3ES1.00(C)

3ES1,25(0)

3ES! .35(C)

4ES1,50(C)

4ES1,75(C)

4ES1,85(0)

SUGGESTED NOZZLES AND SETTINGS

FOR BECKETT AFG-M OIL BURNER SERIES

NOZZLE ACTUAL

0,85-60°W 1.00

1,10-70°B 1.25

1,20-70°B 1.35

1,25-60°B 1.50

1,50-60°B 1.75

1.75-60°B 1.85

PUMP

PRESSURE

(psig)

!40

140

!40

140

140

140

HEAD

ADJUSTMENT

1

1

1

3

3

AIR

SHUTTER

10
10

10
I0

10
10

AIR

BAND

1

1

2

2

3

4

OIL

BURNER

MODEL

AFG-50MB

AFG-50MD

AFG-50MD

AFG-50MD

AFG-50MD

AFG-50MD

FOR RIELLO R40 OIL BURNER SERIES

ACTUAL PU M P AI R OIL

BOILER NOZZLE TURBULATOR

MODEL (DELEVAN) INPUT PRESSURE SETTING GATE BURNER

RATE (gph) (psig) SETTING MODEL

3ES1,00(C) 0.85-60°W 1.00 150 2,0 3.00 F5
3ES1,25(C) 1.00-60°W 1.25 165 2.5 3.60 F5
3ESl.35(C) 1.10-60°W 1.35 165 3.5 4.25 F5

4ES1.50(C) 1.25-60°W 1.50 160 1.5 2.60 FIO
4ES1.75(C) 1.50-60°W 1.75 145 1,5 3.25 FIO

4ES1.85(C) 1.50-60°W 1.85 160 2.0 3.40 FIO

FOR CARLIN EZ OIL BURNER SERIES

BOILER NOZZLE I HEAD

[

MODEL (DELEVAN) ! SETTING

3ES1.00(C)
3ES1,25(C)

3ES1.35(C)
4ES1.50(C)

4ES1,50(C)
4ES1,65(C)

4ES1,85(0)

0.85x70ow

1.00x70°W
1, !Ox70°W

1.25x60°W
1,25x60°W

1.35x60°W
1,50x60°W

ACTUAL

INPUT

RATE (gph)

1.00

1.25

1.35

1.50

1.50

1.65

1.85

PUMP

PRESSURE

(psig)

150
150
150

150
150

150
150

0.85-1.00

0.85-1.00
1,10-1.25

1.10-1.25

0.85-!.00

1.50
! ,50

AIR BAND

SET

POINT

0.65

0.90

1.!0
1,10

1,65

1.65

2.00

OIL

BURNER

MODEL

EZ-1 HP

EZ-1 HP
EZ-I HP
EZ-1 HP

EZ-2 HP
EZ-2 HP
EZ-2 HP

All burners fired at an over fire pressure of -0,02"wc.

Burner insertion depth of 2-1/8" allows burner tip to
be 1/4" behind insulation, I NOTE: These settings are intended for ini-

I

tial start up only, Final adjustment must be

!

made using combustion test instruments, i