Dunkirk 3EW.65, 3EW.75, 3EW1.00, 4EW.90, 4EW1.50 Installation, Operation & Maintenance Manual

...

EMPIRE II

Models

3EW.65 3EW. 7 5

3EW1.00

4EW .90 4EW1.25 4EW1.50 5EW1.20 5EW1. 7 5

SERIES

OIL-FIRED CAST IRON

HOT WATER

INSTALLA TION, OP ERATI ON

& MAINTENANCE MANU AL

An ISO 9001-2008 Certified Company

Maximum Allowable

Working Pressure 50 psi.

Manufacturedby:

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com

P/N# 240009549, Rev. B [10/2012]

SAFETY NOTICES

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

Become familiar with symbols identifying potential hazards.

Safety Notices .............................................. 2

Boiler Ratings And Capacities .........................3

Fresh Air For Combustion............................... 7

System Piping .............................................. 9

Chimney And Chimney Connections .............. 16

Typical Chimney Connection ......................... 17

Electrical Connections ................................. 18

Filling The Boiler ....................................... 19

Operating The Boiler ................................. 20

Checking And Adjusting Controls .................. 23

Maintenance .............................................. 24

Oil Boiler Cleaning Instructions .................... 25

Oil Burner Cleaning ..................................... 26

Service Hints ............................................. 27

Electrical Wiring ......................................... 28

Equipment And Optional Accessories ............. 29

Introduction

Empire Water boiler is a natural draft oil ﬁ red hot water boiler comprised of cast iron sections. Empire Water boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push nipples.

Empire Water boiler is capable of ﬁ ring #2 fuel oil from

0.65 gph up to 2.00 gph. All packaged boilers include a swing door, Honeywell limit, temperature and pressure gauge, safety relief valve, drain valve, ﬂ ue brush, and extra boiler tap for expansion tank or air elimination.

Boiler installation shall be completed by qualiﬁ ed agency.

Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

Figure 1 - Dimensions

BOILER RATINGS AND CAPACITIES

BOILER

MODEL NO.

Without

Tankless Coil

INPUT

**HEATING

CAPACITY

+gph *Mbh AB C

*Mbh

‡NET AHRI

RATING

WATER

*Mbh

A.F.U.E.++NO.

SEC.

MINIMUM

CHIMNEY

SIZE/

HEIGHT

»3EW.65 0.65 91 80 70 86.3 3 8” X 8” X 15” 14½ 6 8

»3EW.75 0.75 105 92 80 85.2 3 8” X 8” X 15” 14½ 6 8

3EW1.00 1.00 140 120 104 84.0 3 8” X 8” X 15” 14½ 6 8

»4EW.90 0.90 126 111 97 86.0 4 8” X 8” X 15” 17¾ 6 9⅝

»4EW1.25 1.25 175 151 131 85.0 4 8” X 8” X 15” 17¾ 6 9⅝

4EW1.50 1.50 210 179 156 84.0 4 8” X 8” X 15” 17¾ 6 9⅝ »5EW1.20 1.20 168 147 128 86.5 5 8” X 8” X 15” 21 6 11½ 5EW1.75 1.75 245 210 183 84.3 5 8” X 8” X 15” 21 6 11½

* Mbh = 1,000 BTU per hour [BTU = British Thermal Unit] **Heating Capacity based on 13% CO2 with a 0.02” w.c. draft over ﬁ re, and a #1 smoke or less. Testing was done in

accordance with the D.O.E. (Department of Energy) test procedure. + gph = Gallons per hour oil at 140,000 BTU per gallon ++A.F.U.E. = Annual Fuel Utilization Efﬁ ciency based upon D.O.E. test procedure. ‡ Net AHRI Water Ratings based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler

for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

As Energy Star Partner, manufacturer has determined this product meets Energy Star guidelines for energy efﬁ ciency.

DIMENSIONS

(inches)

SAFE INSTALLATION AND OPERATION

NOTICE

This boiler has been designed for residential installations. If used for commercial applications, all jurisdictional requirements must be met. This may require wiring and/or piping modiﬁ cations. Manufacturer is not responsible for any changes to the original design.

Read the Owner’s Manual for Safe Operation. Failure to follow rules for safe operation and instructions can cause malfunction of boiler and result in death, serious bodily injury, and/or property damage.

Check your local codes and utility requirements before installation. Installation must be in accordance with their directives, or follow NFPA 31 Installation of Oil Burning Equipment, latest revision.

Before servicing, allow boiler to cool. Always shut off any electricity and oil to boiler when working on it.

Inspect oil line and connections for leaks.

Be certain oil burner nozzle is the size required. Overﬁ ring will result in early failure of the boiler sections. This will cause dangerous operation.

Never vent this boiler into enclosed space. Always vent to outside. Never vent to another room or inside a building.

Be sure there is adequate air supply for complete combustion.

Follow regular service and maintenance schedule for efﬁ cient and safe operation.

Keep boiler area clean and free of combustible material, gasoline and other ﬂ ammable vapors and liquids.

10.

Oil burners are not do-it-yourself items. This boiler must be installed and serviced by qualiﬁ ed professionals using combustion test instruments.

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

11.

Be aware when piping the safety relief valve if system pressure exceeds safe limit of 30 pounds per square inch, the safety relief valve will automatically lift open. Lifting of the safety relief valve can discharge large quantities of steam and hot water, which may damage the surroundings. Before installing the safety relief valve read the manufacturer’s instructions and maintenance section of the manual on safety relief valves.

12.

Installation and sizing of the expansion tank must consider heating systems total water volume, temperature, boiler initial ﬁ ll pressure, and system arrangement. Improperly installed and sized expansion tank may result in frequent lifting of the safety relief valve or other heating system problems. For proper installation, sizing, and maintenance of the expansion tank follow guidelines established by tank manufacturer.

13.

Expansion tank performance and life expectancy can be hindered by overﬁ lling the boiler. Recommend initial ﬁ ll pressure of 10-12 psig. For higher ﬁ ll pressures expansion tank’s air charge will need to be increased to match ﬁ ll pressure. Consult manufacturer’s guidelines for sizing and selection.

14.

Purging the heating system of air and gases when ﬁ rst putting boiler into service is critical for proper circulation and quiet performance. Once air and gases are purged, for boiler installations using ﬂ oat type vents, air vents should be closed for normal operation. If air is heard or noticed by loss of heat, purge system and open vents for short period of time.

DO NOT USE GASOLINE CRANKCASE DRAININGS

OR ANY OIL CONTAINING GASOLINE.

LOCATING THE BOILER

Complete Prior To Installing Boiler.

A. Verify you have selected the right size boiler with

proper capacity. AHRI rating of boiler selected

should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. See boiler rating and capacity table previously listed in this manual. Any heat loss

calculations used should be based on approved methods.

B. Boiler must be supplied with proper oil supply

and oil piping, sufﬁ cient fresh combustion air, and suitable electrical supply.

C. Boiler must be connected to suitable venting system

and piping system adequate to distribute heating

load.

D. Properly locate and install thermostat for heating

system control.

Any doubts as to requirements, check with local authorities and obtain professional help where needed. OPERATING INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and MAINTENANCE sections in this manual are vital to the

proper and safe operation of the heating system.

Fire hazard. Do not install boiler on combustible ﬂ ooring or carpeting. Failure to follow these instructions could result in death or serious injury.

Place boiler in location centralized with the piping system and as close to chimney as possible.

Boiler must be level. If necessary use metal shims beneath boiler’s feet.

Use raised base if ﬂ oor can become wet or damp.

Maintain clearances for ﬁ re safety as well as servicing. 18” clearance must be maintained at a side where passage is required for access to another side for cleaning, servicing, inspection, or replacement of any parts that normally may require such attention. Boilers must be installed at least 6” from combustible material on all sides and above. Allow at least 24” front clearance for servicing.

Fresh air for combustion must be available at front of the boiler. Fresh air for ventilation must be

available to front and rear of boiler. Air passages

must be free of obstructions at all times. Ventilating and combustion air must enter boiler room without restrictions.

WARNING

Figure 2 - Clearances

6”

Min.

6”

Min.

Boiler Front

24” Min.

6” Min./18”

With Coil

Floor supporting boiler must be noncombustible and sufﬁ ciently stable. If it is combustible, place boiler on 2” concrete patio blocks or 2” Cladlite Pad™. Blocks or pad must be under entire boiler to protect the ﬂ oor.

Installation shall be in accordance with the requirements of the local authorities having jurisdiction. Compliance with these regulations is required. In the absence of local codes, follow NFPA 31 Installation of Oil Burning Equipment, latest revision.

BOILER CLEARANCES

Unit

Top 6” 18”

Left Side 24” 24”

Right Side 6”

Base non-combustible

Front 18”

Back 6”

Combustible

Clearance

All distances measured from the cabinet of the boiler.

Accessibility,

Cleaning, and

Servicing

Flue to

Combustible

Clearance

18”

LOCATING THE BOILER

Figure 3 - Boiler With Piping System

AUTOMATIC

CHI

DRAFT

REGULATOR

AND SHUTOFF

FILL VALVE

DIAPHRAGM

EXPANSION TANK

PIPE

VENT

MNE

RELIEF VALVE

TANK

OR AFTER THE

RETURN LINE

EXPANSION

TO RADIATION

FROM RADIATION

CIRCULATING

PUMP IN

ELECTRIC LINE

SERVICE LINE

PROTECTED

OVERCURRENT

OIL BURNER

FOUNDATIONS

LINES TO OTHER

APPLIANCES

ENTRANCE

SWITCH

TO OUTSIDE

GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION

SAFETY SWITCH

2" FILL

PIPE

VENT PIPE

MIN. 2" I.D.

OIL TANK

VALV E

HUT OFF

OIL LINES

OIL FILTER

FRESH AIR FOR COMBUSTION

WARNING

Asphyxiation, ﬁ re hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air.

NOTICE

Install outside air intake if you use ﬁ replace or kitchen or bathroom exhaust fan. These devices rob boiler and water heater of combustion air.

Provide enough fresh air to assure proper combustion. Fire in the boiler uses oxygen. It must have continuous supply. Air in the house contains only enough oxygen to supply burner for short time. Outside air must enter the house to replace air used by the burner. Study the following examples 1 and 2 to determine your fresh air requirements.

EXAMPLE 1: Boiler Located in Unconﬁ ned Space

If your boiler is in an open area (un-partitioned basement) in conventional house, air that leaks through cracks around doors and windows will usually be adequate to provide air for combustion. Doors should not ﬁ t tightly. Do not caulk cracks around windows. An unconﬁ ned space is deﬁ ned as space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of total input rating of all appliances installed in that space.

EXAMPLE 2: Boiler Located in Conﬁ ned Space

A. All Air from Inside the Building: Conﬁ ned

space shall be provided with two permanent openings communicating directly with additional room(s) of sufﬁ cient volume so the combined volume of all spaces meets the criteria for unconﬁ ned space. Total input of all combustion equipment installed in combined space shall be considered in making this determination. Each opening shall have minimum free area of one square inch per 1,000 Btu per hour of total input rating of all combustion equipment in the conﬁ ned space, but not less than 100 square inches. One opening shall be within 12 inches of top and one within 12 inches of bottom of the enclosure. Example: Your boiler is rated at 100,000 Btu per hour. Water heater is rated at 30,000 Btu per hour. Total is 130,000 Btu per hour. You need two grilles, each with 130 square inches of FREE opening. Metal grilles have about 60% FREE opening. To ﬁ nd louvered area needed, multiply free opening required by 1.7 (130 x 1.7 = 221.0 sq. in. louvered area). In this example, two grilles each having 8”

x 30” (240 sq. in.) louvered area would be used.

Figure 4 - Air Openings For Boiler Located In Conﬁ ned Space (Utility Room

)

FRESH AIR FOR COMBUSTION

B. All Air from Outdoors: Conﬁ ned space shall

be provided with two permanent openings, one commencing within 12 inches of top and commencing within 12 inches of bottom of enclosure. Openings shall communicate directly, or by ducts, with outdoors or spaces (crawl or attic) that freely communicate with outdoors.

1. When directly communicating with outdoors, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

2. When communicating with outdoors through vertical ducts, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

3. When communicating with outdoors through horizontal ducts, each opening shall have minimum free area of one square inch per 2,000 Btu per hour of total input rating of all equipment in the enclosure.

4. When ducts are used, they shall be of same cross sectional area as free area of openings to which they connect. Minimum dimension of rectangular air ducts shall be not less than three inches.

Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In Tightly Constructed Houses

FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS

Fresh Air

Duct Size

3 ½” x 12” 144,000 36,000 108,000

8” x 8” 256,000 64,000 192,000

8” x 12” 384,000 96,000 288,000

8” x 16” 512,000 128,000 384,000

*Btuh = British Thermal Units per hour based on

opening covered by ¼” mesh screen , wood louvers,

¼” Mesh

Screen

(Btuh)* (Btuh)* (Btuh)*

or metal louvers.

Wood

Louvers

Metal

Louvers

SYSTEM PIPING

Installation of boiler for new heating system,

Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains ﬁ rst. After all heating system piping and components have been installed, make ﬁ nal connection of system piping to boiler. It is recommended to mount circulating pump on supply side piping, such that it pumps away from expansion tank. Refer to ﬁ gures on next pages.

Equip hot water boiler installed above radiation level with low water cut off device. Periodic inspection

is necessary, as is ﬂ ushing of ﬂ oat type devices, per low water cut off manufacturer’s speciﬁ c instructions.

Packaged boiler is set up with 1¼” NPT supply and return piping from front of boiler. Boiler supply

and return piping can be moved to rear of boiler. Boiler should not be piped return line to front, supply line to rear, or vice versa, will cause boiler water to short circuit heat exchanger. Piping connections may require additional ﬁ ttings and parts.

Install drain valve provided with boiler in return tee.

See ﬁ gure 6.

Install Safety Relief valve in rear section using ¾”

nipple and street elbow provided with boiler. See ﬁ gure

3. A. Install safety relief valve with spindle in vertical

position.

B. Do not install shutoff valve between boiler and

safety relief valve.

C. Install discharge piping from safety relief valve.

• Use ¾” or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

Verify clean cold water supply is available when connecting to pressure reducing valve. When water

supply is from well or pump, a sand strainer should be installed at the pump.

Low Design Water Temperature Systems (Below 140° F) And Large Water Content Systems

• Signiﬁ cant condensation may form in this boiler and/ or venting system if boiler is operated with return temperatures of less than 120°F.

• Condensation is corrosive and can eventually cause damage to boiler and venting system. Minimum design return water temperature to prevent this condensation in boiler and venting is 120°F.

• Boiler used in heating system where design water temperatures below 140°F are desired (e.g. radiant ﬂ oor heating), a 3-way or 4-way mixing valve or suitable alternative (e.g. Bypass Piping Arrangement shown in diagram on following page) is required to prevent low temperature (below return 120°F) return water from entering boiler. When using mixing valve, follow manufacturer’s installation instructions.

• Boiler connected to system having large water content (such as former gravity system), use of Bypass Piping Arrangement shown in diagram on following page is suggested.

Figure 6 - Safety Relief Valve Installation

Follow Instructions to install discharge piping from safety relief valve to drain.

SYSTEM PIPING

Figure 7 - Bypass Piping Arrangement Diagram

> LOW DESIGN WATER TEMPERATURE

SYSTEMS

> LARGE WATER CONTENT SYSTEMS

> PIPING ARRANGED FOR “POWER

PURGING” AIR OUT OF THE SYSTEM PIPING, REFER TO THIS MANUAL’S SECTION ON “FILLING THE SYSTEM WITH WATER” OPTION #1

+ 22 hidden pages

Dunkirk 3EW.65, 3EW.75, 3EW1.00, 4EW.90, 4EW1.50 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual