Dunkirk ESB0365, ESB3100, ESB4125, ESB4150, ESB5175 Installation Manual And Operating Instructions

EMPIRE STEAM II

OIL-FIRED CAST IRON BOILER

MODEL NUMBERS:
ESB0365 ESB3100.
ESB4125 ESB4150.
ESB5175 ESB5200.
ESB6225 ESB7275

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DUNKIRK
85 Middle Road

Dunkirk, NY 14048
Phone [phone]
Fax. [phone]

www. dunkirk corn

An ECR International Brand )C_ f

An ISO 9001-2000 Certified Company

P/N 1305029, Rev ! 0 [08/04]

P/N# 1305029, Rev

Safety Symbols and Warnings 2
Ratings, Data, and Dimensions 3

Installation Procedure 4

Ventilation and Combustion Air 5
Connecting Supply and Return Piping Steam 7

Venting System Inspection and Installation 8
Oil Tank and Piping 8

Electrical Wiring 9
Thermostat Operation 9
Normal Sequence of Operation 11
Operating Instructions 11

Maintenance Procedures 14
Replacement Parts List 15

Service Checklist 20

KEEP THIS MANUAL NEAR BOILER j_

RETAIN FOR FUTURE REFERENCE

The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels

ndicates an imminently hazardous situation'_

hich, if not avoided, WILL result in death or I

r!o,s!nj,,y: j

dicates a potentially hazardous situation I

hich, if not avoided, COULD result in death I

serious injury, j/

ndicates a potential hazardous situation I

hich, if not avoided, MAY result in minor or I

oderate injury. It may also be used to alert I

gainst unsafe practices. .t)

1 0 [08/04] • Printed in USA • Made In USA

MPORTANT: Read the following instructlons_

OMPLETELY before mstalhngll

1. Keep boiler area clear and free from com-
bustible materials, gasoline and other flam-

mable vapors and liquids.

2. DO NOT obstruct air openings to the boiler

room.

3. Modification, substitution or elimination of
factory equipped, supplied or specified com-

ponents may result in property damage, per-
sonal injury or the loss of life.

4. TO THE OWNER - Installation and service of
this boiler must be performed by a qualified

installer.

5. TO THE INSTALLER - Leave all instructions

with the boiler for future reference.

6. When this product is installed in the Com-
monwealth of Massachusetts the installation

must be performed by a Licensed Plumber or

_Licensed Gas Fitter.

J

All installations of boilers and venting should
be done only by a qualified expert and in
accordance with the appropriate Pennco
manual. Installing or venting a boiler or any
other gas appliance with improper methods

or materials may result in serious injury or
death due to fire or to asphyxiation from
poisonous gases such as carbon monoxide

which is odorless and invisible.

_.. J

0@

Tested For 15 LBS

ASME

/_,,or kllig Pressure

ESB0365 0.65
ESB3100 1.00
ESB4125 1.25
ESB4150 1.50
ESB5175 1.75
ESB5200 2.00
ESB6225 2.25
ESB7275 2.75

NOTES:

78
116
145
170

iiiiiiiii,1_teiaimiiiiiiiiiii!

59

87
109
128

246
363

454

533

wa_er

66 6

101 6
126 7
148 7

iii/iSq_are!iiiil

8x8x15
8x8x15
8x8x15
8x8x15

91 140 .60 80B
140 140 .85 80B
175 140

210 140
245 202 152 633 176 8 8x8x15 140 1.50 80B
280 227 170 708 197 8 8x8x15 140 1.75 70B
315 251 188 783 218.3 8 8x12x15 140 2.00 45B
385 307 230 958 267.1 8 8x12x15 140 2.25 45B

1. Add suffix"T" to denote boiler with tanktess heater•

2. I=B=R burner capacity is based on an oil heating value of 140,000 Btu/gat. and with 13% CO2.

3. Net ratings based on 170°F temperature in radiators and include 33% allowance for normal piping and pick-up toad. Consult manufacturer

for unusual piping and pick-up temperatures•

4. For altitudes above 2,000 ft. ratings maybe reduced at the rate of 4% for every 1,O00 ft. above sea level.

5. No771esizes with an H designation are Hago brand, all others are Delevan.

6. The electrical service is 120 Volts, 15 Amps, 60 Hz.

7. The MEA hum ber for the ESB series is 182-86E.

8. The MEA number for the AFG Beckett Burner used in the ESB series is 213-83-E.

DIMENSIONS (See FIG, A)

ESB-3S 16.375" 6.5" 6.0"
ESB4S 20.25" 8.5" 6.0"
ESB-5S 23.875" 10.25" 7.0"
ESB-6S 27.5" 8.3125" 8.0"
ESB-7S 31.125" 8.3125" 8.0"

TANKLESS WATER HEATER CAPACITIES

ESB0365 0.65 L-24 Available on request 11 8
ESB3100 1.00 L-24 4.5 11 8

ESB4125 1.25 L-24 4.5 13 9
ESB4150 1.50 L-24 4.5 13 9
ESB5175 1.75 L-24 5.0 15 10
ESB5200 2.00 L-24 5.0 15 10
ESB6225 2.25 L-24 5.0 17 11
ESB7275 2.75 L-24 5.0 19 12

A.S.H.E PRESSURE

f_RELZEF VALVE

V u

I FIG. A ]

STANDARD EQUIPMENT: Crated boiler, flush jacket, oil burner, target watt/liner, ASME relief valve, steam
water level gauge, steam pressure gauge, steam pressure control, mechanical low water cut-off, drain
valve, wiring harness, burner electric disconnect, plastic cover, 2" supply tapping, 1½" return tapping, skim

port, and primary control. (NOTE: For tankless heater units, add tankless hot water coil, and 4006 limit

control.)

All installations must conform to the requirements of
the authority having jurisdiction. Such applicable
requirements take precedence over the general

instructions of this manual.

Where required by the authority having jurisdiction,
the installation must conform to the American Society

of Mechanical Engineers Safety Code for Controls
and Safety Devices for Automatically Fired Boilers,

ANSI/ASME No. CSD-1.

Locate boiler in front offinat position before removing
crate. Provide a level solid base as near chimney as
possible and centrally located with respect to the
heat distribution system as practical.

Allow 24 inches in the front, top and right hand side
for servicing and cleaning, or removing tankless
water heating coil.

It is recommended that 24 inches be allowed in back

of boiler for convenience when skimming hole is
used.

When installed in a utility room, the door should be
wide enough to allow the largest boiler part to enter,

or to permit replacement of another appliance such
as a water heater.

The boiler shall be installed such that the oil ignition
system components are protected from water
(dripping, spraying, rain etc.) during appliance
operation and service.

FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY- The boiler must not be installed on

carpeting or vinyl flooring. Minimum clearances to
combustible construction are:

TOP ........................................ 24 IN.

FRONT ................................... 24 IN.

FLUE CONNECTOR ................ 9 IN.

REAR ..................................... 24 IN.

LEFT SIDE ............................... 6 IN.

RIGHT SIDE ............................ 241N.

MINIMUM CLEARANCES TO COMBUSTIBLE

CONSTRUCTION (AS SEEN FROM ABOVE)

T

24"

• 6" _24"--

24"

[

NOTE: Clearance for access should exceed fire
protection clearance.

COMBUSTIONAIR REQUIREMENTS

(Minimum Opening Requirement)

91,000 19 100 23 46
140,000 28 140 35 70
175,000 35 175 44 88
210,000 42 210 53 106

245,000 49 245 61 122

280,000 56 280 61 140

A space w hose volume is not less than 50 cubic feet per 1000 BTU/Hour of all

appliances installed in that space (cubic feet of space = height x width x length)
** A space w hose volume is less than 50 cubic feet per I000 BTU/Hour of all

appliances installed in that space (cubic feet of space = height x w idth x length)

1. Ventilation of boiler room must be adequate
enough to provide sufficient air to properly support
combustion and venting.

2. When the boiler is located in an unconfined space
in a building of conventional construction frame,
masonry or metal, infiltration normally is adequate to
provide air for combustion and ventilation. However,
in any building which has been altered to conserve

energy or to minimize infiltration, the boiler area
should be considered as a confined space. If there is
anydoubt, install airsuppty provisions for combustion
and ventilation in accordance with section 5.3, Air for
Combustion and Ventilation, of the NFPA 54 1988

code, the recommendations that follow, or applicable
provisions of the local building codes.

3. When the boiler is installed in an unconfined
space, in a building of unusually tight construction,

air for combustion and room ventilation must be
obtained from outdoors or from spaces freely

communicating with the outdoors. A permanent
opening or openings having a total free area of not
less than 1 square inch per 5,000 BTU per hour of

total input rating of att appliances shall be provided.
Ducts may be used to convey make-up air from the

outdoors and shall have the same cross-sectional
area of the openings to which they are connected.

4. When air for combustion and room
ventilation is from inside buildings, the

confined space shall be provided with two
permanent openings, one starting 12 inches
from the top and one 12 inches from the

bottom of the enclosed space. Each opening
shall have a minimum free area of 1 square
inch per 1,000 BTU per hour of the total
input rating ofatl appliances in the enclosed
space, but must not be less than 100 square

inches. These openings must freely
communicate with the interior areas having
adequate infiltration from the outside.

(Figure 1)

J _ i ¸

jl f C_O_NE'_
iL TYr=_ VErsT r_pE

VENf _'i "' E

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I FIGURE 1 I

5. When the boiler is installed in a confined space
and atl air is provided from the outdoors, the confined

space shall be provided with two permanent openings,
one commencing within 12 inches from the top and
one commencing 12 inches from 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.
One of the following methods must be used to
provide adequate air for ventilation and combustion.

A. When directly communicating with the outdoors,

each opening shall have a minimum free area of
1 square inch per 4,000 BTU per hour of total
input rating of all equipment in the enclosure.
(Figure 2)

/

CiUTLET _

AE_

!/ENI PEPE

INLET

AZR

\/ENTZLATZON
LOUVERS FOR

UNIIEATED

CRAWL SPACE

/

I FIGURE 2 1

B. When communicating with the outdoors by

means of vertical ducts, each opening shall have
a minimum free area I square inch per4,000 BTU
per hour of totat input rating ofatt appliances inthe

enclosed space. (Figure 3)

I FIGURE 3 I

C. Ifhorizontal ducts are used, each opening shall
have a minimum free area 1 square inch per

2,000 BTU per hour total input rating of all
appliances in the enclosed space. (Figure 4)

VE_S

PIPE \)

/

iJ!llllll![Li_l/ll]llll_ i

D. When ducts are used, they shall be of the same
cross sectional area as the free area of the area

of the openings to which they connect. The
minimum dimension of rectangular air ducts shall

not be less than 3 inches.

6. In calculating free area using louvers, grills or
screens for the above, consideration shall be given
to their blocking effect. Screens used shall not be
smaller than 1/4 inch mesh. If the free area through
a design of louver or grill is known, it should be used

in calculating the size opening required to provide
the free area specified. If the design and free area is
not known, it may be assumed that wood louvers wilt
have 20-25% free area and metal louvers and grills

will have 60-75% free area. Louvers and grills shall

be fixed in the open position or interlocked with the
boiler so that they are opened automatically during
boiler operation.