Dunkirk 3EW.65T, 3EW.65Z, 3EW.75T, 3EW.75Z, 3EW1.00T Installation Guide

...

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Page 1

Hodels

SERIES

3EW,65 3EW,75

3EWI,O0

4EW,90

4EW1,25 4EW1,50

SEW1,20 5EW1,75

OIL-FIRED CAST IRON

HOT WATER

INSTALLATION, OPERATION

& HAINTENANCE HANUAL

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_!._,_,, ,

_',!_,._;_#_ ::::::::::::::::::::::::::::::.............

_i:_'_,_;_! ..........................................

_._,_.',_rL_

Maximum Allowable

Working Pressure 50 psi.

Manufactured by:

ECR international, inc.

220! DwyerAwnue. Utica NY 13501 web s_te www ecnnternat/onal corn

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

Page 2

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 fired 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 firing #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, flue brush, and extra boiler tap for expansion tank or air elimination.

Boiler installation shall be completed by qualified 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.

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

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.

Used to address practices not related to personal injury.

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Figure 1 = Dimensions

2&5000 --

TEMR/

PRESSUiqE

GAUGE "_'_

36.01 iO0

LIMIT

/ CONTROL

I_/CO NTROL

LOW LIMIT

(With

Tank_ess CoiU}

O&BURNER

17 1/2"

RIELLO

13 3/4' BECKETT

OR CARLiN

1 1/4"

_,#,,#ATER

OUTLET

"_)PTIONA L

I"ANKLESS COIL

WAT£R HEATER WITH 1/2" NPT

CONNE£T_ONS

RELIEF

VALVE

OUTLET_

DRAIN

VALVE

(Furnished)

RIGHT SIDE VIEW WITH SWING DOOR

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 15"

I 1/4 '_ REIURN

N_PP_ E & REDUCING

/_' FRONT VIEW

>>3EW.65 80 70 86,3

>>3EW.75 92 80 85,2

3EW1.00 120 104 84,0

>>4EW.90 111 97 86,0 >>4EWl,25 151 131 85,0

4EWl.50 179 156 84,0

>>5EWl.20 147 128 86,5

5EWl.75 210 183 84,3

* Mbh = 1,000 BTU per hour [BTU = BHtish Thermal Unit] **Heating Capacity based on 13% CO2 with a 0.02" w.c. draft over fire, 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 off at 140,000 BTU per gaflon ++A.F.U.E. = Annual Fuel Utilization Efficiency 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 instaflations having unusual piping and pickup requirements, such as intermittent system operation, extensive

piping systems, etc.

> > As Energy 5tar Partner, manufacturer has determined this product meets Energy 5tar guidelines for energy efficiency.

BACKVIEW

Page 4

This boiler has been designed for residential

installations. Tf used for commercial applications, all jurisdictional requirements must be met. This may require wiring and/or piping modifications. Manufacturer is not responsible for any changes to

the original design.

1, 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.

2, 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.

3, Before servicing, allow boiler to cool. Always shut off

any electricity and oil to boiler when working on it,

4, Inspect oil line and connections for leaks. 5, Be certain oil burner nozzle is the size required. Over-

firing will result in early failure of the boiler sections. This will cause dangerous operation.

6, Never vent this boiler into enclosed space. Always vent

to outside. Never vent to another room or inside a building.

7, Be sure there is adequate air supply for complete

combustion.

8. Follow regular service and maintenance schedule for

efficient and safe operation.

9. Keep boiler area clean and free of combustible material,

gasoline and other flammable vapors and liquids.

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

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Tnstall 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 fill 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 overfilling the boiler. Recommend initial fill pressure of 10-12 psig. For higher fill pressures expansion tank's air charge will need to be increased to match fill pressure. Consult manufacturer's guidelines for sizing and selection.

14. Purging the heating system of air and gases when first putting boiler into service is critical for proper circulation and quiet performance. Once air and gases are purged, for boiler installations using float 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 DRJ_ININGS

OR ANY OIL CONTAINING GASOLINE,

Page 5

Complete Prior To Installing Boiler.

Verify you have selected the right size boiler with proper capacity. AHRI rating of boiler selected 2. 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 3. 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, sufficient 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.

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 floor can become wet or damp.

Maintain clearances for fire 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.

Fire hazard. Do not install boiler on combustible

flooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

Figure 2 = Clearances

24" Min.

6" Min./l 8"

With Coil

Floor supporting boiler must be noncombustible and sufficiently stable. If it is combustible, place boiler on 2" concrete patio blocks or 2" Cladlite PadT", Blocks or pad must be under entire boiler to protect

the floor.

, 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.

Top

Left Side

Right Side

Base Front

Back

All distances measured from the cabinet of the boiler.

6 _

24"

non-combustible

18"

18 _

24"

18 _

Page 6

MIN. 2" I.D.

VENT PIPE

OVERCURRENT

PROTECTED

SAFETY SWITCH

2" FILL

PIPE

ENTRANq SWITCH

LINESTO

APPLIANCES

SERVICE LINE

ELECTRIC LINE

FILL VALVE

AND SHUTOFF

DIAPHRAGM EXPANSION TANK

REGULATOR

VENT

PIPE

DRAFT

"11

SHUT OFF

VALVE

OIL FILTER

OIL LINES J

OILTANK

TO OUTSIDE

TO RADIATION

OIL BURNER

FOUNDATIONS

RELIEFVALVE

CIRCULATING PUMP IN RETURN LINE OR AFTER THE EXPANSION TANK

GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION

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EXAMPLE 2: Boiler Located in Confined Space

Asphyxiation, fire hazard. Do not obstruct air openings to combustion area. Follow instructions

below, to maintain adequate combustion air.

Install outside air intake if you use fireplace 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 Unconfined 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 fit tightly. Do not caulk

cracks around windows.

An unconfined space is defined 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.

A, All Air from Inside the Building: Confined space shall be provided with two permanent openings communicating directly with additional room(s) of sufficient volume so the combined volume of all spaces meets the criteria for unconfined 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 confined 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 FREEopening. Metal grilles have about 60% FREEopening. To find Iouvered area needed, multiply free opening required by 1.7 (130 x 1.7 = 221.0 sq. in. Iouvered area). In this example, two grilles each having 8"

x 30" (240 sq. in.) Iouvered area would be used.

Figure 4 - Air Openings For Boiler Located In

Confined Space (Utility Room)

VENTILATING

Page 8

All Air from Outdoors: Confined 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

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.

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.

Figure 5 = Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In

Tightly Constructed Houses

3 V2"x 12" 144,000 36,000 i08,000

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 _" mesh screen, wood louvers,

or metal louvers.

12" CL£A£

Page 9

Installation of boiler for new heating system, Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains first. After all heating system piping and components have been installed, make final 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 figures on next pages.

Equip hot water boiler installed above radiation level with low water cut off device. Periodic inspection is necessary, as is flushing of float type devices, per

low water cut off manufacturer's specific 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 fittings and parts.

Install drain valve provided with boiler in return tee. See figure 6.

Install Safety Relief valve in rear section using ¾" nipple and street elbow provided with boiler. See figure

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 3/4"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

• Significant 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 floor 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.

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Page 10

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 #i

SHUTOFF VALVE BOILER

AUTOMATIC

rILL VALVE

ADJUST THE TWO THROTTLING VALVES TO |

MAINTAIN AT LEAST 120 DEGREES FER_NHE_T iN THE BOH_ER RETURN THE THROTTUNG VALP_ES

ARE USED FOR BYPASS PIPING, IF REQUIRED

THROTTLING VALVE

FILLTROL VITH AIR PURGER

CIRCULATOR PUMP

THROTTUNG VALVE

SUPPLY TO SYSTEM

ISOL,AS_ON VALVES

Page 11

Figure 8 =System Piping Arrangement Zoning With Zone Valves

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

CIRCULATOR CAN ALSO BE INSTALLED

ON RETURN PIPING.

> PIPING ARRANGED FOR"POWER PURGING"

AIR OUT OF SYSTEM PIPING, REFER TO THIS MANUAL'S SECTION ON "FILLING THE

SYSTEM WITH WATER" OPTION #1

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Page 12

Figure 9 = System Piping Arrangement Zoning With Circulators

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PIPING ARRANGED FOR"POWER PURGING"

AIR OUT OF SYSTEM PIPINGI REFER TO THIS MANUAL'S SECTION ON "FILLING

THE SYSTEM WITH WATER" OPTION #1

B_L_A bK/IN/I V AL "dE;

FLHW CHECK VALVE

ZOI_@E OIRCUL #_TQR

F_E"_ _:_N FROM SYS _EN

T_HL AT[ON 'VALVE:

gJPPL1

" SYSTD4

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Page 13

Figure 10 = System Piping Arrangement Alternate Near Boiler Piping

> PER THIS MANUALI USE OPTION #2 IN

"FILLING THE SYSTEM WITH WATER"

DIAPHRAGH EXPANSION TANK HOUNTED

OFF THE BOILER

> THIS PIPING ARRANGEMENT CAN BE USED

WITH ZONE VALVES OR ZONE

CIRCULATOR ON SUPPLY PIPING PUMPS

CIRCULATORS

AWAY FROM EXPANSION TANK

F] i TRIll / Ti =If i Ui:;;![II.R!

Page 14

Tankless Coil Piping Arrangement

Boilersmay be factorypackaged with tankless heater

coil see figure below. Coil provides instantaneous heating

of water for domestic use if proper burner and water supply

line controls are used. Tankless coils are meant to provide

domestic hot water for intermittent draws, not continuous flow.

Do not use tankless coil if your water is excessively hard with lime or other deposits which will

accumulate inside the coil.

When using tankless coil, boiler is configured so Honeywell

L7248 operates with Honeywell L4006 low limit mounted

on well installed in tankless heater. Mount factory wired low

limit on well.

Tempering valve (mixing valve) is recommended as shown

below. Flow restrictor may be required on tankless coil inlet piping so that flow rates are matched to boiler heat input (see table).

Water temperatures exceeding 125°F will cause severe burns instantly or death by scalding.

3EW.65 3EW.75

3EW1.00

4EW.90 4EW1.25 4EW1.50

5EW1.20 5EW1.75

-1:Gallons of water per minute heated from 40 °F to 140°F with 200 °F boiler water temperature, intermittent draw

0.65

0.75

1.00

0.90

1.25

1.50

1.20

1.75 4.00

105 140 126

175

210

168

245

2.90

3.00

3.25

3.15

3.50

3.75

3.45

Figure 11 =Tankless Coil Piping Arrangement

Lit,_TEMPERES H_T _TATER

AU OMAT]C D_SHWAt!tHER ECT

TAI', KLESS COIL

CENTER LINE

OF COLD TAP

LII'4IT CBNTRBL

TEMPERING

VA VE

SHU T- OFF

VALVE

TEPPERED HOT

WATER

COLD WATER ZNLET

Page 15

Antifreeze added to boilers must be nontoxic, and

must be of type specifically intended for use in closed hydronic heating systems, Under no circumstances

should automotive antifreeze be used, Antifreeze used

in any boiler may reduce capacity by 10% or more and increase fuel consumption, Tankless coil performance

will fall as concentration of antifreeze is increased, Refer to boiler and piping water volumes tables,

3 9.6

4 11.6

5 13.7

½" 82.5 63.5 ¾" 40.0 36.0

1" 23.3 22.2

1 ¼" 15.3 12.8 1 ½" 10.8 9.5

2" 6.2 5.8

Divide total length of piping in feet by appropriate factor in table to determine volume in gallons,

Page 16

For oil fired boilers for connections to vents or chimneys,

vent installations shall be in accordance with applicable

provisions of INSTALLATION OF OIL BURNING EQUIPMENT, NFPA31 latest revision, and applicable provisions of local building codes.

Fire Hazard. Maintain minimum vent pipe clearance

of 18" from surface of vent to wood and other combustible materials. Failure to comply may result

in death or serious injury.

Fresh air (ventilation) is important to proper

venting. Ventilation and venting are two parts of the same system. Inadequate ventilation will result in

inadequate venting. Always be sure to have enough

ventilation to support proper venting.

Check your chimney to make certain that it is right size, properly constructed and in good condition. See Table "Recommended Minimum Chimney Sizes".

For additional chimney design and sizing information, consult the National Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211.

Chimney Connector And Draft Regulator

• Venting the boiler requires 6" diameter chimney connector pipe and use of manufacturer provided draft regulator.

• Regulator, when properly installed, automatically controls the draft.

• Install in horizontal section of pipe, may also be installed in angled or vertical section of pipe.

• Verify "top" of regulator is at the top and short pipe section which holds the vane is horizontal.

• Even though locating draft regulator close to chimney reduces noise, install draft regulator as close as practicable to the boiler,

• Install chimney connector, start at boiler with vertical pipe, elbow, then install draft regulator horizontally.

• When regulator is in place, start at chimney and work back to the regulator.

• Join the two sections with draw-band.

• Horizontal pipe must slope up toward the chimney at least 1/4, inch per linear foot of venting.

• Chimney connector must not leak and must be firmly supported.

• Join each section with at least two sheet metal screws. Support every second section with a stovepipe wire.

0.60 1.30 15 8"x8"

1.31 1.80 15 8"x8"

1.81 2.00 20 8" x 8"

For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.

6" 6 ¾"x 6 ¾" 7" 6 ¾"x 6 ¾"

8" 6 ¾"x 6 ¾"

Page 17

Figure 12 -Typical Chimney Connection

MUST BE AT LEAST

INCHES THICK -

AND BE

HUST SLOPE UP

AT LEAST I/4, INCH

PER KOOT OF

HORZZONTALo

MINIMUM HEIGHT: MuST SEAT LEAST 3 FT HIGHER THAN HIGHEST PART OF

PASSAGE THROUGH ROOE MUST BE AT LEAST 2 FT HIGHER THAN ANY NEIGHBORING OBJECT WITHIN 10 FT.

MUST HAVE AN UNOBSTRUCTED TOP OPENING

THIHBLE

BRAF REGULATOR

VANE

ALTERNATE POSITIONS

Page 18

Electrical shock hazard. Turn OFF electrical power supply

at service panel before making electrical connections.

Failure to do so could result in death or serious injury.

Thermostat

Install 24 Volt thermostat (not provided) in proper location.

Location of thermostat has effect on boiler system operation. Follow instructions included with thermostat.

Grounding

Permanently ground boiler according to local codes and latest revision of the National Electrical Code. Run 14

gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

Electric Power Supply

Installation must comply with the latest revision of the National Electrical Code, any other national, state, or local codes or regulations. Connect 115 volt electrical supply to L1 and L2 terminals

on limit and two thermostat wires to T and T terminals on same limit. See wiring diagram page 28.

Run separate circuit from separate over current protection device in your electrical service entrance panel. Minimum

15 ampere circuit. Locate shutoff switch at boiler. Turn off

during any maintenance. Solder and tape or securely fasten connections with wire nuts.

Oil Burner Wiring For boilers packaged with oil burners, burners are wired at the factory. For boilers shipped without a burner, wiring connections are shown in the electrical wiring diagrams of

this manual.

Page 19

How A Hot Water System Operates

Entire heating system (boiler, piping, and radiation units) is filled with water. As water in the boiler is heated, it is circulated from top of boiler through supply main to

radiation units. Cooler water in radiation units flows back through return piping through return main into the boiler.

This arrangement provides positive and rapid response to the thermostat.

Filling The System With Water

OPTION #1 This method utilizes boiler piping as shown in figure on page 6.

main shutoff valve, isolation valves, and zone

valves (if applicable). If bypass piping is installed,

also close two throttling valves. Leave boiler service shutoff valve (if installed) and balancing valves to each heating zone _.

._ following valves in order: drain valve for power

purging, isolating valves before and after boiler circulator (if applicable), both throttling valves (if applicable), and then open fill line shutoff valve. Water will fill bypass piping and push air through piping and out power purging drain valve. When power purging drain valve runs air free, close bypass piping throttling

valve (leaving throttling valve to supply piping fully

open).

OPTION #2

• Close air vents on all radiation units.

• Open valves to radiation units. Verify boiler drain valve, expansion tank drain cock, and air bleed screw on expansion tank drain fitting are closed.

• Open fill valve on piping to expansion tank.

• Open water inlet to boiler and leave it open.

• Open air vent on lowest radiation unit.

• When all air has escaped and water starts to flow from vent, close it.

• Go to next radiation unit, and repeat this process until finishing with highest radiation unit.

• If heating system has automatic vents, this manual venting is unnecessary but it will speed up proper filling of the system.

If system is a closed expansion tank system, automatic fill valve is needed. Leave automatic fill valve open to refill system automatically as needed. Note initial fill pressure on boiler's temperature / pressure gauge, which should be 10-15 psig. Any lowering of pressure from its initial fill pressure indicates loss of water due to leakage. Automatic fill valve should then compensate for this water pressure loss. If it does not, manually open this valve to refill system until needle is again pointing to same pressure reading. Instructions are packaged with

valve.

Next, _ isolation valve (or zone valve) to first zone. Water will fill piping and push any air out power purging drain valve. When power purging drain valve runs air free, close isolation valve or zone valve). Repeat this procedure for remaining heating zones.

Once all zones are filled with water and purged of air,

power purging drain valve and fill line shut off valve, _ main shutoff valve, and _ throttling valves and balancing valves as required.

Page 20

Start: Fill entire system with water. Vent all air from system following section for Filling The Boiler.

Fuel

Units And Oil Lines:

Install oil line(s) to oil burner.

Recommend using heavy wall copper tubing and flared fittings, not compression fittings.

All connections and joints must be absolutely airtight. Use an appropriate non=hardening thread sealing compound on the threaded connections, not Teflon tape.

See fuel unit data sheet furnished with the burner for sizing, lift, and length of tubing recommendations.

Oil burner is equipped with single stage fuel unit with bypass plug removed for single pipe installation. Satisfactory where fuel supply is on same level as or above burner permitting gravity flow of oil. Per NFPA 31 requirements, never exceed 3 psig pressure to inlet side of

fuel unit. When necessary to lift oil to burner, two pipe installation

is required. Run return line between fuel unit and oil supply. When two pipe installation is used, bypass plug (furnished with burner) must be installed in fuel unit. Refer to fuel unit instructions furnished with burner for specific instructions on installing bypass plug. Do not exceed fuel unit manufacturer's recommendations for running vacuum.

If lift exceeds 14 feet for Beckett or Carlin burners

or 11 feet for Riello burners, two stage fuel unit is

required with return line.

Air Supply For Combustion;

• Do not install boiler in rooms with insufficient air, unless corrective steps are taken.

• It may be necessary to install windows or cut holes in a door to rooms used for supply air to obtain sufficient combustion air and prevent less than atmospheric air pressure in that room.

• If there is a lack of combustion air, burner flame will be dark orange and formation of soot will occur in heating

unit.

• In buildings of conventional frame, brick, or stone construction that do not have utility rooms, basement windows, or stair doors, air infiltration is normally adequate to provide enough air for combustion and for operation of barometric draft control.

• Room used for supplying combustion air should be isolated from any area served by exhaust fans.

• Refer back to the section on Fresh Air For Combustion

for additional sizing guidelines.

Draft Regulators: Barometric draft regulator is required for controlling draft through boiler. Mount barometric draft regulator in chimney connector. Refer back to section on "Chimney And Chimney Connections". Once draft regulator is installed, use draft gauge to adjust to proper opening:

A. Combustion chamber over fire draft will be

approximately 0.01" WC to 0.02" WC.

B. Stack draft will be approximately 0.02" WC. to

0.04" WC.

C. Larger installation, greater draft will be required in

stack to obtain desired over fire draft.

Install oil filter of adequate size inside building between tank shutoff valve and oil burner. For ease of servicing,

locate shutoff valve and filter near oil burner.

Page 21

NozzlesAnd Electrodes: Use proper size, spray angle,

and spray pattern nozzle. Refer to recommended nozzle selection charts.

To install nozzle, remove nozzle line electrode assembly, if necessary remove retention ring assembly, and install and tighten nozzle. Take care not to damage electrode insulators or bend electrode tips. After installing nozzle, reassemble nozzle line electrode assembly and set electrode tip spacing.

Depending on burner type, electrode tip spacing may need to be set prior to reassembling nozzle line electrode assembly.

Refer to following pages for setting electrode tip spacing.

Final Burner Adjustments: Final burner adjustments must be made using combustion test instruments. Refer to 3.

"Burner Settings". Set burner accordingly.

• Check draft over fire to verify it is between 0.01" WC 4. and 0.02" WC, adjust draft as necessary.

• After operating 10 minutes to warm up boiler, use combustion test equipment to take smoke reading in

flue pipe between boiler and draft regulator. 5.

• Smoke reading should be zero to trace (Shell Bacharach Scale).

• A new boiler requires more than 10 minutes to burn 6. clean due to oil film on new heat exchanger.

• If smoke reading is zero, gradually close burner's air adjustment to obtain smoke reading showing trace smoke reading. Once smoke reading is trace, measure

CO2and as insurance margin increase air to sufficiently reduce CO2by 1/2% to 1%.

If clean fire cannot be obtained, it is necessary to verify burner head and electrode alignment. Proper electrode alignment figures are presented on following pages. If fire continues to be smoky, replace nozzle with correct replacement. Once burner is completely adjusted, burner should be started and stopped several times to assure good operation with no fluttering or rumbling. Verify there are no oil leaks and record nozzle size, oil pressure, combustion readings, and air settings on tag or label attached to burner or, boiler.

Oil Burner Maintenance= For Beckett AFG, Carlin EZ1 or EZ2, and the Riello 40 F3, F5, or F10 perform following preventative maintenance annually, preferably prior to heating season.

Oil Burner Motor For Beckett and Carlin burners, add 2 - 3 drops of non-detergent electric motor oil to each oil cup located at front and rear of motor (Riello burners are permanently lubricated). Excessive oiling will shorten life expectancy of motor.

Fuel Filter Replace to prevent contaminated fuel from reaching nozzle. Partially blocked fuel filter can cause premature failure of fuel pump.

Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to nozzle.

Ignition Electrodes Clean and adjust per manufacturer's recommendations, to maintain reliable ignition of oil.

Nozzle Replace to maintain safe and reliable combustion efficiency. Replace with nozzle as required

in charts located in this manual. Fan and Blower Housing Must be kept clean, free of

dirt, lint and oil to maintain proper amount of air fuel requires to burn.

7. Check Final Burner Adjustments.

If any component parts must be replaced, always use parts recommended by burner manufacturer.

Page 22

Figure 13 =Burner Adjustments and Settings

4',F5 UW",,/EF/ /AA]ASL_ (V)l/ AI}S

_8 LiE_ D 41-24S£/}N #, Di_4E_SI lhl_

_.._..KEIT AFG /AAIAf:>L,L F_EAZ ADjjS"I"F'Et',TSAND ,.E T L ,:t,s

'\ DIME;NS ::]i,;q'q"

SEE A O/E

Page 23

Burn, scald hazard. Do not attempt to start the

burner when excess oil has accumulated, when the unit is full of vapor, or when the combustion chamber is very hot.

Locate thermostat five feet above the floor on inside wall. Locate thermostat to sense average room temperature,

avoid the

You or your installer must follow these instructions carefully.

Adjust Operating Controls: Use the following settings for first adjustment:

High Limit:

Baseboard and Convectors 200°F

Standing Radiators 180°F

Low Limit (when used) 1400 ( increase if hotter domestic water is required, low limit set point must be at least 20°F less than high limit set point)

Adjust Thermostat Heat Anticipator To: 0.2 Amps

Check Thermostat Operation:

Follow instructions included with your thermostat.

Behind

doors

Fireplace

TV sets

Radios

Concealed pipes

Corners &

alcoves

Lamps

Direct sunlight

Kitchens

When temperature on thermostat is set above indicated thermostat temperature, boiler's burner should start. Verify that when room temperature reaches selected temperature setting, thermostat should turn boiler's burner off, and once room temperature falls few degrees boiler starts operating

again.

Do not start burner unless all cleanout doors are secured in place.

Concealed pipes

or ducts

Stairwells drafts

Doors drafts

Unheated room

on other side of

wall

Page 24

Annually: Recommend flue passages, combustion

chamber area (target wall, fire door insulation,

durablanket), burner adjustment, control operation, and

boiler seals (fire door gasket or silicone seal, cast iron

sectional seals, flue collector) be checked once each year

by trained Service Technician.

Diaphragm Expansion Tank-" Tank may become water logged. Frequent automatic opening of safety relief

valve indicates water logging. High boiler temperature

accompanied by unusually low radiation unit temperature (and "knocking" noises) indicates excess air in the tank. To correct this condition, replace diaphragm expansion tank.

Before The Start Of Each Heating Season (or when system has been shut down for extended periods of time) recheck whole system for water, oil, and vent piping leaks.

Replace or patch any leaks or faulty seals. Vent Pipe= Visually inspect entire venting system once a

month for any signs of leakage, deterioration, or soot build up. If vent pipe shows any signs of leaking or deterioration, replace it immediately. If it shows any signs of soot build up, clean vent pipe and have burner settings and combustion checked by trained Service Technician.

Safety Relief Valve= Valve should open automatically when system pressure exceeds pressure rating (usually 30 psi) of safety relief valve. Should valve ever fail to open under this condition, shut down the system, Drain system until system pressure is reduced below safety relief valve pressure rating, Contact Service Technician to replace the valve and inspect heating system to determine cause, may indicate equipment malfunction, Safety relief valve should be tested monthly during heating season, Prior to testing, make certain discharge pipe is properly connected to valve outlet and arranged so as to contain and safely dispose of boiler discharge, Hold trip lever fully open for at least five seconds in order to flush free any sediment that may lodge on valve seat. Permit valve to snap shut. Refer to valve manufacturer's instructions packaged for more details,

Water System: If system is to remain out of service during freezing weather, drain it completely (water left in

system may freeze and will crack pipes and/or boiler).

Tankless Coil (Or Cover Plate) Gasket: Gasket

should be checked at least twice year for leakage, replace if necessary. If gasket is replaced, make sure that when coil plate (or cover plate) is reattached, ten nuts are torqued in alternating pattern to insure equal force is applied to entire gasket creating good seal. Nuts should be torqued so gasket does not squeeze out from behind the plate.

Oil Burner= Oil burner maintenance is listed in this manual under "Operating The Boiler".

Never burn garbage or paper in the unit, never leave combustible material around it.

Conventional Expansion Tank: Tank may become

water logged or may receive excess air, Frequent automatic opening of safety relief valve indicates water logging, High boiler temperature accompanied by unusually low radiation unit temperature (and "knocking" noises) indicates excess air in the tank, To correct either condition, close valve between boiler and tank. Drain tank until empty, Check all tank plugs and fittings, tighten as necessary, Open valve between boiler and tank, Water will rise to normal height in tank if system has automatic fill valve, otherwise manually refill system,

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Page 25

Oil Boiler Cleaning:

Shut off all electrical power to boiler / burner and shut off fuel oil supply.

Remove vent pipe from top of boiler. Inspect pipe and chimney for signs of corrosion and deterioration. Clean out base of chimney. If vent pipe shows any signs of corrosion or deterioration, replace it immediately. If chimney damage or deterioration is discovered, contact

a service technician.

Remove top jacket panel screws (5), brass wing nuts (2) holding flue collector top, and flue collector top. Inspect gasket on underside of flue collector and replace as necessary.

Before beginning to clean flue passageways, insure combustion chamber blanket is covered. If blanket is

not covered prior to cleaning, replace blanket once cleaning is completed.

With access to flue passageways, remove soot from fireside surfaces by brushing diagonally through flue passages (see drawing below). Brushing can be made easier by cutting end of flue brush off and inserting it into drill. When brushing, take care to not damage target wall with flue brush.

Carefully vacuum soot accumulations from combustion chamber area, take care to not damage any of refractory or blanket insulation. To gain

access to combustion chamber first check that shut off valve on fuel oil line is closed and disconnect

fuel oil line. Open swing door by removing whiz lock

nut holding door shut.

Inspect target wall, fire door refractory, and combustion chamber blanket (when included) for cracking and deterioration. If there are signs of cracking or deterioration, replace refractory or blanket before reassembling burner / front plate.

Inspect door's braided gasket for wear and damage. Replace when necessary with braided gasket of

same material and size.

9. Inspect and clean oil burner.

Important operating and maintenance requirements:

• Keep your boiler and the area around it clean

• Never burn refuse or any material other than specified fuel in your boiler

Figure 14 = Brush Diagonally Through Flue

Passages

Page 26

These are general instructions for cleaning an oil burner, For specifics, consult burner

manufacturer's instructions.

Electrical shock hazard. Turn OFF electrical power supply

at service panel before making electrical connections.

Failure to do so could result in death or serious injury.

1. Verify all electrical power to boiler / burner and fuel supply to burner are shut off.

With swing door open, clean any soot accumulations from end of burner and if applicable burner head.

Remove burner drawer assembly, clean electrodes and then reset electrode spark gap per manufacturer's

recommendations.

4. Replace oil nozzle with same size and type recommended for use on this boiler.

Install burner drawer assembly make sure head location (and size if applicable) are per manufacturer's recommendations. If burner being used has damaged head, replace head with same head recommended for

use on this boiler.

6. Inspect and clean oil burner blower wheel.

Remove oil pump cover and clean / replace pump screen. Carefully reassemble insuring pump cover creates proper seal.

8. Securely fasten swing door shut.

9. Replace fuel filter (if applicable).

10. Connect electrical and fuel supplies.

11. Fire burner, check for proper combustion using combustion test equipment and making adjustments as necessary.

12. Insure all safety controls and operating controls are functioning properly.

Page 27

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You may avoid inconvenience and service calls by checking these points before you call for service:

Thermostat is not set correctly Reset thermostat

Check flame. If it is yellow, the burner is not getting enough air.

Burner is not operating properly

Or, if flame is blue and noisy and seems to lift off the burner, the

burner is getting too much air. Contact your service technician.

No electric power to boiler

Controls out of adjustment

Radiators not heating

Circulating pump not running

Poor electrical contact

Chimney flue is blocked

Corrosion and/or deposits on seat.

Water logged expansion tank

Check over-current protection. Check to be sure electric power supply circuit is "ON".

Reset according to instructions.

Open radiator vents to excess air. Check flow control valve (if

used). It may be in closed position. Check over-current protection. Check relay operation. Check all control terminals and wire joints.

Have the chimney professionally cleaned.

Open valve manually. Allow water to run and clear valve seat.

Drain tank, see instructions.

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Page 28

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THERMOSTAT

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PRIMARY CONTROL

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IONITER (BLUiWHT) L2 (WHT)

MOTOR (ORG) L2 (WHT)

LIMIT (BLK) L2 (WriT)

VALVE (Vl)

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CAD CELL (YEL)

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Page 29

THERMOSTAT

24 VOLT

(BY INSTALLER)

LIMITSENSOR

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LOWLIMIT

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ONLY)

BURNER,/ CONTROL

RIELLO

PRIMARYCONTROL

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CIRCULATOR

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Page 30

HAIN AIR VENT: for down flow systems or diaDhragj:n=

_oe exoansion tanks (not provided)_

Before system is filled with water, there is air in pipes and radiation units, Some air will be trapped as system is filled,

It is possible to eliminate most of this air through air vents on radiation units, Main air vent will speed and simplify this process, Install main air vent on highest point in supply main when all radiation is below top of boiler,

AUTOMATIC FILL VALVE (not Drovided_ For safe, efficient operation, hot water system must be

filled with water. Adding new water, when needed can be done manually (by use of hand valve in water supply line). This requires regular attention to system's needs. Automatic fill valve or pressure reducing valve accomplishes this without attention. Install in supply line on hot water

boilers only. Valve operates through water pressure differentials. It does not require electrical connection.

BURNER SOLENOID VALVE (provided).

Beckett and Carlin oil burner's use standard solenoid valve. Upon burner shut down, standard solenoid valve stops

flow of oil to nozzle. Without solenoid valve, oil pump continues to pump oil to burner nozzle until burner motor winds down below pumps cutoff speed. Riello oil burner has delay solenoid valve. Delay solenoid valve provides same shut down action as standard solenoid valve, plus

on burner start up delay solenoid valve remains closed for additional 15 seconds. Allows burner fan motor to pre- purge combustion chamber and oil pump to bring supply oil pressure up to its set point helping to provide clean light

off.

LIHIT CONTROL (DrovidedJ Refer to manufacturer instructions provided with limit control

Water temperature limit control in limit is adjustable and may be set: as low as 140°F so long as return water temperatures to boiler are no less than 120°F, or as high as 220°F so long as boiler and heating system have adequate

circulation to remove heat from boiler otherwise steam may be created in boiler. Refer back to "System Piping" section

for more information.

CIRCULATOR (orovidedL

Every forced hot water system requires circulator. Separate circulator or zone valve is required for each zone, if there are two or more zones. Circulator must have capacity to provide circulation required by heating system. Circulator should be connected to supply main and must be wired into boiler's electrical system. See "System Piping" section

for piping configurations with circulator located on supply

main piping using zone circulators or zone valves. When piping is arranged with zone circulators and no bypass piping, circulator provided with boiler may be used as zone circulator. Both piping arrangements allow circulator

to pump away from expansion tank and show how piping

should be arranged to allow heating system to be easily purged of air.

Taco 007 Pump Curve

FLOW - M:g/H

1 3 4 5

1_0

- 120

-3

< i

1O0

-1 2

-80

DRAIN VALVE (provided]

Drain valve is manually operated valve provides means of draining all water from boiler and heating system. It should be installed in reducing tee where return line enters boiler.

0 4 8 12 16 20 24

FLOW - GPM

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Page 31

NOTES

Page 32

DUNKIRK BOILERS

2201 Dwyer Avenue, Utica NY 13501

web site"www,ecrinternational,com