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

...

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

,?__,_g_,',,_& .......................................................

_!._,_,, ,

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

_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]

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

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,

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 _

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

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

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£

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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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

+ 22 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual