Dunkirk ESC-3090S, ESC-4125S, ESC-4125ST, ESC-5185S, ESC-3090ST Installation, Operation & Maintenance Manual

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ESC IV STEAM SERIES 4

OIL-FIREDCASTIRON BOILER

MODELS

ESC-3090S

ESC-3090ST

ESC-4125S

ESC-4125ST

ESC-5185S

ESC-5185ST

ESC-6210S

ESC-6210ST

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

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PATENT 7,823,544

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Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue. Utica NY 13501
web site: www.ecnnternat/onal.com

P/N 240009804, Rev. A [10/2012]

Figure #1

35,3/4"

A,S,M,E

RELIEF

PRESSURE

VALVE

ELWC[]

CYCLE GUARD

OIL BURNER

PRESSURE

ESC-3090 163/8'' 61/2'' 6"
ESC-4125 20¼" 81/2'' 6"
ESC-5185 23%" 101/2' 7"

ESC-6210 271/2'' 85/16'' 8"

Boiler model number on rating plate includes suffix 'S' or 'ST'.

STANDARD EOUIPMENT: Crated boiler, flush jacket, oil burner,

target wall/liner, safety valve, steam water level gauge, steam
pressure gauge, steam pressure control, low water cut-off, drain
valve, wiring harness, burner electric disconnect, plastic cover, 2"
supply tapping, 11/2'' return tapping, skim port, and primary control.

(NOTE: For tankless heater units, add tankless hot water coil, and
low limit control.)

Boiler Model 1 3 M n Natura Draft

. O,IBurnerInput() INetAHRIRat,ngs()l _:. _ I

_umoer _mmney b_ze

Capacity A.RU.E.

WITHOUT WITH .... I ..... (2) MBH(4) I Steam ' Sq. Ft. I _ . I _ . Rating

TA.K'ESS,TANKLESS._'"" I 'v'°" I I MBH SteamI "°un°I _quareI

ESC-3090S ESC-309OST o.9o 126 106 80 333 6 8"x8"x15' 82.0

ESC-4125S ESC-4125ST 1.25 175 147 110 458 6 8"x8"x15' 82.0

ESC-5185S ESC-5185ST 1.85 259 216 162 675 8 8"x8"x15' 82.0

ESC-6210S ESC-6210ST 2.10 294 247 185 771 8 8"x8"x15' 82.0

NOTES:

1)Burner input is based on an oil heating value of 140,000 Btu/gal.

2)MBH = 1000 Btu per hour [Btu = British Thermal Unit].

3)Net AHRI Steam Ratings based on piping and pick-up allowance of 1.333. Consult manufacturer before selecting boiler for
installations having unusual piping and pick-up requirements, such as intermittent system operation, extensive piping, etc.

4)Electrical service is 120 Volts, 15 Amps, 60 Hz

ESC-3090ST 2 11
ESC-4125ST 4½ 13

ESC-5185ST 4½ 15
ESC-6210ST 4½ 17

iLine

Dimensions ........................................................ 2

Ratings, Data ..................................................... 3

Safety Symbols .................................................. 4

IMPORTANT: Read and understand the following
instructions COMPLETELY before installing.

Locating The Boiler ............................................. 5

Ventilation And Combustion Air ............................ 6

Supply And Return Piping .................................... 8

Venting System Inspection & Installation ............. 12

Oil Tank And Piping ........................................... 13

Electrical Wiring ............................................... 14

Operating Instructions ....................................... 16

Maintenance Procedures .................................... 19

Service Checklist .............................................. 21

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

Installations of boilers and venting shall be done
only by qualified expert and in accordance with this
manual. Installing or venting a boiler or any other
gas appliance with improper methods or materials

could result in serious injury or death due to fire
or to asphyxiation from poisonous gases such as

carbon monoxide which is odorless and invisible.

Keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors and
liquids.

Do not obstruct air openings to boiler room.

Modification, substitution or elimination of factory
equipped, supplied or specified components could

result in personal injury or the loss of life.

i_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!!iii__iiiiiiiiiiiiiiii_i!_!i_iii!:_ii!i!_ii!i!_i_!i_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!iiiii!iiiiiiiliiiiiii!i!i!ii!iliow.er InstaIIationandserviceofthisboilermust

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

levels. Installer - Leave all instructions with the boiler for

be performed by a qualified installer.

future reference.

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.

,i_ CAUTION

Indicates a hazardous situation which, if not

avoided, could result in minor or moderate injury.

Indicates information which should be followed to
ensure proper installation and operation.

When this product is installed in the Commonwealth
of Massachusetts the installation must be performed

by a Licensed Plumber or Licensed Gas Fitter.

PATENT 7,823,544

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• Installations shall 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.

Fire hazard. Do not install boiler on combustible

flooring or carpeting. Failure to follow these

instructions could result in death or serious injury.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY
Boiler must not be installed on carpeting or vinyl flooring.

Minimum clearances to combustible construction are:

• Locate boiler in front of final position before removing
crate.

• Provide level solid base as near chimney as possible
and centrally located with respect to heat distribution
system as practical.

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

• Recommend 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 largest boiler part to enter, or to
permit replacement of another appliance such as water

heater.

• Install boiler such that oil ignition system components
are protected from water (dripping, spraying, rain etc.)
during appliance operation and service.

TOP 24 IN.

FRONT 24 IN.

FLUE CONNECTOR 9 IN.

REAR 24 IN.

LEFT SIDE 6 IN.

RIGHT SIDE 24IN.

NOTE:Clearance for accessshould exceedfire protection

clearance.

Figure #2 - Hinimum Clearances To Combustible

Construction (as seen from above)

BACK

FRONT

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

126 26 126 32 63
175 35 175 44 88

259 52 259 65 130
294 59 294 74 147

* A space whose 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 whose volume is 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)

1. Ventilation of boiler room must be adequate enough to
provide sufficient air to properly support combustion,
venting and maintain safe ambient temperatures under
normal operating conditions.

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 any
doubt, install air supply provisions for combustion
and ventilation in accordance with Chapter 5, Air for
Combustion and Ventilation, of NFPA 31, Standard
for the Installation of Oil Burning Equipment. 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 all
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.

, 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 of all 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. See Figure #3.

Figure #3

f.. CHIMNEY

OR

L TYPE VENT PIPE

/
/
/

BASEBOARD _h

/
/

/
/
/
/
/

/
/

/
/
/
/

,

When the boiler is installed in a confined space and
all 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
#4)

B. When communicating with the outdoors by means

of vertical ducts, each opening shall have a
minimum free area Z square inch per 4,000 BTU
per hour of total input rating of all appliances in the
enclosed space. (Figure #5)

C. If horizontal 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 #6)

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.

,

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 will 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.

Figure #5

C iq I M_iNE Y

OR

PI_PE

Burn or Scald Hazard. Discharge line shall be installed to safety valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

• Connect to safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum
distance from floor or allowable safe point of discharge.

• Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.

• Have no intervening shutoff valve between safety valve and discharge to atmosphere. Do not plug or
place any obstruction in discharge line.

• Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.

• Allow complete drainage of valve and discharge line.

• Install safety valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety valve.

• Support safety valve discharge piping.

• Be short and straight as possible.

• Terminate with plain end, not threaded.

• Constructed of material suitable for exposure to temperatures of 375 ° F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.

Figure 4 - Safety Valve

SAFETY VALVE

DTSCHARGI

pTpTNG

Check local codes

for maximum
distance from
floor or other

allowable safe

point of discharge

t

6" Above Floor