Dunkirk Empire II Installation, Operation, Repair And Parts Manual
EMPIRE II
OIL-FIRED CAST IRON HOT WATER
BOILERS
Installation
Operation
Repair Parts
These instructions must be affixed on or adjacent to the boiler.
DUNKIRK BOILERS
DUNKIRK, NEW YORK 14048 AREA CODE 716 366-5500
Saving The Earth Saving Your Money
MEMBER: The Hydronics Institute
INTRODUCTION
The Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron
sections. The Empire Water boiler is available with 3, 4, or 5 cast iron sections. These
sections are held together by cast iron push nipples.
The Empire Water boiler is capable of firing #2 fuel oil from 0.65 gph up to 2.00 gph. Boilers
may be purchased with or without the following options: a Beckett AFG, Carlin EZ, or Riello
40 oil burner, a Taco or Grundfos circulator with isolation valves, a tankless coil for domestic
hot water. All packaged boilers include a swing door, Honeywell aquastat, temperature and
pressure gage, relief valve, drain valve, 2 Delevan oil nozzles for multiple firing rates (only
when purchasing a burner), flue brush, and an extra boiler tap for an expansion tank or air
elimination.
1
BOILER MODEL NO. DIMENSIONS - (inches)
WITH WITHOUT NO. INPUT **HEATING I=B=R FIRING MINIMUM
TANKLESS TANKLESS SEC. *MBH CAPACITY RATING RATE A.F.U.E. CHIMNEY
COIL COIL *MBH *MBH +GPH ++ SIZE/HEIGHT A B C
»3EW.65T »3EW.65Z 3 91 80 70 0.65 86.3 8" X 8" X 15" 14-1/2 6 8
»3EW.75T »3EW.75Z 3 105 92 80 0.75 85.2 8" X 8" X 15" 14-1/2 6 8
3EW1.00T 3EW1.00Z 3 140 119 103 1.00 83.4 8" X 8" X 15" 14-1/2 6 8
»4EW.90T »4EW.90Z 4 126 111 97 0.90 86.0 8" X 8" X 15" 17-3/4 6 9-5/8
4EW1.25T 4EW1.25Z 4 175 150 130 1.25 83.9 8" X 8" X 15" 17-3/4 6 9-5/8
4EW1.50T 4EW1.50Z 4 210 178 155 1.50 82.4 8" X 8" X 15" 17-3/4 6 9-5/8
»5EW1.20T »5EW1.20Z 5 168 147 128 1.20 86.5 8" X 8" X 15" 21 6 11-1/2
5EW1.75T 5EW1.75 Z 5 245 209 182 1.75 83.6 8" X 8" X 15" 21 6 11-1/2
5EW2.00T 5EW2.00 Z 5 280 236 205 2.00 82.0 8" X 8" X 20" 21 6 11-1/2
*MBH = 1,000 BTU per hour BTU = British 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 oi l at 14 0,000 BTU per gallon
++A.F.U.E. = Annual Fuel Utilization Efficienc y based upon D.O.E . test procedure.
»As an Energy Star Partner, Dunkirk Radiator Corporation has determined that this product meets Energy Star Guidelines for Energy Efficiency.
NET
The City of New York MEA #191-99-F
These low pressure oil fired hot water boilers are constructed and hydrostatically tested for
a maximum working pressure of 50 psig (pounds per square inch gage) in accordance with
A.S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code
Section IV Standards for heating boilers.
The Heating Capacity indicates the amount of heat available after subtracting the losses up
the stack. Most of this remaining heat is available to heat water. A small portion is heat from
the jacket and surfaces of the boiler and it is assumed that this heat stays in the structure.
The Net I=B=R Rating represents the portion of the remaining heat that can be applied to
heat the radiation or terminal units (i.e. finned tube baseboard, cast iron radiators, radiant
floor, etc.). The difference between the Heating Capacity and the Net I=B=R Rating, called
the piping and pickup allowance, establishes a reserve for heating the volume of water in the
system and offsetting heat losses from the system piping. The Net I=B=R Ratings shown
are based on a piping and pickup factor of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net I=B=R Rating of the boiler selected should be
greater than or equal to the calculated peak heating load (heat loss) for the building or
area(s) served by the boiler and associated hot water heating systems. The manufacturer
should be consulted before selecting a boiler for installations having unusual piping and
pickup requirements.
Boilers with the same number of sections are identical to each other except for their firing
rate. The firing rate is determined by the nozzle size in the oil burner and the oil pressure at
the nozzle. For example: Models 3E.65Z, 3E.75Z, and 3EI.00Z are the same boiler, without
a tankless coil, except for the firing rate of the oil burner. Models 4E.90T, 4E1.25T, and
4E1.50T are the same boiler, with a tankless coil, except for the firing rate of the oil burner.
Each boiler rating plate shows three possible model numbers for a given boiler configuration.
The actual model number is determined by the firing rate of the oil burner. Boilers that are
factory packaged include two nozzles for two firing rates. These boilers operate on #2
Heating Oil. This fire rate does not come with additional nozzles or heads for the
burner. The 3 & 4 section units are packaged with two nozzles. They can be field
converted to low fire rates by utilizing the low fire kit.
2
RULES FOR SAFE INSTALLATION AND OPERATION
1. Read the Owners Manual for Safe Operation carefully. Failure to follow the rules for
safe operation and the instructions can cause a malfunction of the boiler and result in death,
serious bodily injury, and/or property damage.
2. Check your local codes and utility requirements before installation. The 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. Overfiring will result in early failure of the
boiler sections. This will cause dangerous operation.
6. Never vent this boiler into an enclosed space. Always vent to the outside. Never vent to
another room or inside a building.
7. Be sure there is adequate air supply for complete combustion.
8. Follow a 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.
11. Be aware when piping the relief valve that if the system pressure exceeds the safe limit
of 30 pounds per square inch, the relief valve will automatically lift open. Lifting of the
relief valve can discharge large quantities of steam and hot water, which may damage
the surroundings. Before installing the relief valve read the manufacturers instructions
and maintenance section of the manual on relief valves.
12. Installation and sizing of the expansion tank must consider the heating systems total
water volume, temperature, boiler initial fill pressure, and system arrangement. An improperly installed and sized expansion tank may result in frequent lifting of the relief valve
or other heating system problems. For proper installation, sizing, and maintenance of the
expansion tank follow the guidelines established by Dunkirk Boilers and the expansion
tank manufacturer.
13. Expansion tank performance and life expectancy can be hindered by overfilling the boiler.
Dunkirk Boilers recommends an initial fill pressure of 10-12 psig. For higher fill pressures
the expansion tanks air charge will need to be increased to match the fill pressure.
Consult the manufacturers guidelines for sizing and selection.
14. Purging the heating system of air and gases when first putting the boiler into service is
critical for proper circulation and quiet performance. Once the air and gases are purged,
for boiler installations using float type vents, the air vents should be closed for normal
operation. If air is heard or noticed by a loss of heat, purge the system and open the
vents for a short period of time.
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
modifications. The manufacturer is not responsible for any changes to the original design.
DO NOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE.
WARNING
3
BEFORE YOU START
Complete all of the following prior to installing the boiler.
A.Check to be sure you have selected the right size boiler with the proper capacity. The I=B=R rating
of the boiler selected should be greater than or equal to the calculated peak heating load (heat
loss) for the building or area(s) served by the 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 the proper oil supply and oil piping, sufficient fresh combustion air,
and a suitable electrical supply.
C.Boiler must be connected to a suitable venting system and a piping system adequate to distribute
the heating load.
D. A thermostat must be properly located and installed for control of the heating system.
If there are any doubts as to the various requirements, check with local authorities and obtain
professional help where needed. The OPERATING INSTRUCTIONS, FINAL CHECKS AND
ADJUSTMENTS, and MAINTENANCE sections in this manual are vital to the proper and safe
operation of the heating system. Take the time to be sure they are all done.
LOCATING THE BOILER
1. Place the boiler in a location centralized with the piping system and as close to the chimney as possible.
2. The boiler must be level. If necessary use metal shims beneath the boilers feet.
3. Use a raised base if the floor can become wet or damp.
4. Maintain clearances for fire safety as well as servicing. An 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.
5. Fresh air for combustion must be available at the front of the boiler. Fresh air for ventilation must be
available to the front AND rear of the boiler. Air passages must be free of obstructions at all times.
Ventilating and combustion air must enter boiler room without restrictions.
6. The floor supporting the boiler must be non-combustible and sufficiently stable. If it is combustible,
place the boiler on 2" concrete patio blocks or 2" Cladlite Pad. The blocks or pad must be under
the entire boiler to protect the floor.
7. Be sure installation is 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.
MINIMUM CLEARANCE DIMENSIONS
4
ALWAYS KEEP THE MANUAL FUEL SUPPLY VALVE SHUT OFF, IF THE
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.
INSTALLATION REQUIREMENTS
5
FRESH AIR FOR COMBUSTION
WARNING
Be sure to provide enough fresh air for combustion. Enough air ensures proper combustion and
assures that no hazard will develop due to the lack of oxygen.
NOTE
If you use a fireplace or a kitchen or a bathroom exhaust fan, you should install an outside air
intake. These devices will rob the boiler and water heater of combustion air.
You must provide enough fresh air to assure proper combustion. The fire in the boiler uses
oxygen. It must have a continuous supply. The air in the house contains only enough oxygen to
supply the burner for a short time. Outside air must enter the house to replace the 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 (unpartitioned basement) in a conventional house, the air that leaks
through the cracks around the doors and windows will usually be adequate to provide air for
combustion. The doors should not fit tightly. Do not caulk the cracks around the windows.
An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1,000 Btu
per hour of the total input rating of all appliances installed in that space.
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 sufficient volume 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 minimum free area of one square inch per 1,000 Btu
per hour of the 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 the top and one within 12
inches of the bottom of the enclosure.
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 inches of
FREE opening. Metal grilles have about 60% FREE opening. To find the louvered area needed,
multiply the free opening required by 1.7 (130 x 1.7 = 221.0 sq. in. louvered area). In this
example, two grilles each having an 8" x 30" (240 sq. in.) louvered area would be used.
AIR OPENINGS FOR BOILER LOCATED IN CONFINED SPACE (CLOSET OR UTILITY ROOM)
6
B. All Air from Outdoors: The confined space shall be provided with two permanent
openings, one commencing within 12 inches of the top and commencing within 12
inches of the bottom of the enclosure. The openings shall communicate directly, or by
ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the
outdoors.
1. When directly communicating with the outdoors, each opening shall have a 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 the outdoors through vertical ducts, each opening shall
have a 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 the outdoors through horizontal ducts, each opening shall
have a 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 the same cross-sectional area as the free
area of the openings to which they connect. The minimum dimension of rectangular
air ducts shall be not less than three inches.
FRESH AIR DUCT CAPACITIES FOR DUCTS SUPPLYING FRESH AIR TO BOILER IN
Fresh Air ¼" Mesh Screen Wood Louvers Metal Louvers
Duct Size (Btuh)* (Btuh)* (Btuh)*
3-½" x 12" 14 4,000 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 = Bri tish Thermal Uni ts per hour based on openi n g covered by ¼" mesh
screen , wood louvers, or metal louvers.
TIGHTLY CONSTRUCTED HOUSES
7
SYSTEM PIPING
1. When the installation of the boiler is for a new heating system, first install all of the radiation
units (panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating
system piping and components have been installed, make final connection of the system piping to
the boiler. It is recommended to mount the circulating pump on the supply side piping, such that it
pumps away from the expansion tank. Refer to the figures on the next pages.
2. A hot water
device. A periodic inspection is necessary, as is flushing of float type devices, per low water cut off
manufacturers specific instructions.
3. The
packaged boiler unit is set up with 1-1/4" NPT supply and return piping from the front of
the boiler. The boiler supply and return piping can be moved to the rear of the boiler. The boiler
should not be piped return line to the front, supply line to the rear, or vice versa, as this will cause
the boiler water to short circuit the heat exchanger. Piping connections may require additional
fittings and parts.
4.
The relief valve is meant to be installed in the back side of the rear section using the 3/4" nipple
and street ell provided in the parts bag. Connect a discharge pipe of the same pipe size (3/4") to
carry any water away to a drain. Do not connect directly to a drain, but leave an air gap. No
shutoff of any description shall be placed between the safety relief valve and the boiler, or on
discharge pipes between such safety valves and the atmosphere. Installation on the safety relief
valve shall conform to the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The manufacturer is not responsible for any water damage.
5. When connecting the cold water supply to the pressure reducing valve, make sure that a clean
water supply is available. When the water supply is from a well or pump, a sand strainer should
be installed at the pump.
6. The minimum boiler supply water temperature setting on the aquastat is 140°F. If the boiler is
used in a heating system where supply water temperatures below 140°F are desired, a suitable
method, such as the use of bypass piping shown in the figure below, a 3 way or 4 way mixing
valve, or some other means needs to be used to ensure return water temperatures to the boiler
are no less than 120°F. When the boiler is operated with return water temperatures less than
120°F, condensation may form in the boiler and venting. This condensation is corrosive and can
eventually cause severe damage to the boiler and venting system.
boiler installed above radiation level must be equipped with a low water cut off
8
SYSTEM PIPING ARRANGEMENT ZONING WITH ZONE VALVES
> CIRCULATOR ON SUPPLY PIPING PUMPS
AWAY FROM EXPANSION TANK
> PIPING ARRANGED FOR POWER PURGING
AIR OUT OF SYSTEM PIPING, REFER TO THIS
MANUALS SECTION ON FILLING THE SYSTEM
WITH WATER OPTION #1
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 PIPING, REFER TO THIS
MANUALS SECTION ON FILLING THE
SYSTEM WITH WATER OPTION #1
10
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