Kenmore 3ES135 Owner’s Manual

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Installation

• Operation

• RepairParts

Theseinstructionsmustbeaffixedonoradjacenttotheboiler.DUNKIRKBOILERS

DUNKIRK,NEWYORK14048- 716366-5500

MEMBER: The llydronies Institute

I/2" NPT

TANKLESS

HEATER

, o i

F , t , t i

, t , * ,

3/4 _ NPT

_LOW UMIT

CONTROL ON COIL PLATE

I/2" NPT

PRESSURETROL

PRESSURE GAUGE

COMBINATION

1-1/2" NPT RETURN

2-I/2" NPT

SUPPLY

iq°p

5/4" ASNE

POP SAFETY

VALVE

27"

WATER

IJNE

i-i/2" NPT

i SKIM TAPPING

,-V2 ° NPTi

RETURN

LEFT SIDE

FRONT

REAR

EMPIRE OIL-FIRED STEAM BOILER RATINGS

BOILER MODEL NO.

With Without

Tankless Tankless

No.

9ec.

Coil Cotl

3ESt O0C 3ES100 3 3ES1.25C 3ES1,25 3 3ES1.35C 3ES1.35 3 4ES1,50C 4ES1,50 4 4ES1.75C 4ES1 75 4 4ES1.85C 4ES1.85 4

Input

*MBH

140 175

189

2!0

245 259

Nesting

Capacity

*MBH

118 145 156 177

204 215

* MBH = 1,000 BTUpet hour

BTUH = British Thermal Unit Per Hour GPH _ Gallons per Hour Oil at 140,000 BTU per Gallon

** Heating Capacity is based on a 13% CO2 with a -,02' w.c, draft over fire, and a #1 smoke or less. The testing on the boilers

was done in accordance with lhe DOE. (Department of Energy) test procedure

NewYorkCityMEANumber134-98-E Selectionofboilersizeshouldbe basedupon"Net1=8=RRatingbeing

equaltoorgreaterthanthesq.ft.of radiationalreadyinstalledinthe building.

TheNetI=B=R Ratingsshownarebasedonanallowanceof1.333in accordancewiththefactorsshownonthe 1=B=RStandardas publishedby TheHydronicsInstitute.

Net

I=B-R

Rating

"MBH

89 109 117 133

153

161

Not I-S-R

Rating

Sq. Ft,

Radiation

371 454

488 554

638 671

*Tonldelm

Cell

Ratings

GPM*

2.75 3,10

3.25

3.50

3.85 4,00

Typl©al

Chimney

Size and

Height

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 20'

Theseboilersmusthavea non-combustiblebaseifinstalledon acombustible floor.Two-inchcladlitepadmaybeused.Theseboilersarelowpressure

sectionalcastironboilersconstructedandhydrostaticallytestedfora maximum workingpressureof 15psiin accordancewithA.SME. (AmericanSocietyof MechanicalEngineers)SectionIVStandardsfor castironheatingboilers.They arecapacityratedinaccordancewiththecodeofthe1=B=R(Hydronics

Institute).

CIMF31SIONS- INCHES

A B C

16% 7 9 16½ 7 9

16% 7 9 20% 8 11 20% 8 11 20% 8 11

RulesforSafeInstallationandOperation

1. Readthe Owner'sManualforSafeOperationcarefully.Failuretofollow therulesforsafeoperationandtheinstructionscancausea malfunctionof the boilerand result in death,_rious bodily injury, and/or property

damage.

2. Checkyourlocalcodesandutilityrequirementsbeforeinstallation.The installationmustbeinaccordancewiththeirdirectives,orfollowNFPA31

- InstallationofOilBurningEquipment,latestrevision.

3. Beforeservicing,allowboilertocool.Nwaysshutoffanyelectricityand oiltoboilerwhenworkingonit.Thiswillpreventanyelectricalshocksor

burns.

4. Inspectoillineandconnectionsforleaks.

This boiler has been designed for residentialinstallations. If used for commercial

applications,alljurisdictionalrequirementsmustbe met.This mayrequirewiringandlor pipingmodifications.Themanufactureris notresponsibleforany changesto the original

design.

5. Be certainoil burnernozzleis size required.Overfiringwill resultin earlyfailureofthe boilersections.Thiswill causedangerousoperation.

6. Nevervent this boiler into an enclosedspace.Alwaysvent to the outside.Neverventto anotherroomor insidea building.

7. Besurethereisadequateairsupplyforcompletecombustion.

8. Followa regutarserviceandmaintenancescheduleforefficientand safeoperation.

9. Keepboilerareacleanandfreeofcombustiblematerial,gasolineand otherflammablevaporsandliquids.

BeforeYouStart

Check to be sure you have the dght size boiler beforestartingthe installation.See ratingand capacitytableon precedingpage.Checkthe

ratingplateontheboiler. You mustsee that theboileris suppliedwiththe properoil,freshair for

combustion,and a suitableelectricalsupply.Also, the boiler must be connectedto a suitableventingsystemand an adequatepipingsystem.

Finally,a thermostat,properlylocated,is neededforcontrolofthe heating system.If youhaveanydoubtsas to thevariousrequirements,checkwith local authorities and obtain professionalhelp where needed. THE

OPERATING INSTRUCTIONSand THE FINAL CHECKS AND ADJUSTMENTSare vitalto the properandsafe operationof the heating

system.Takethetimeto besuretheyarealldone.

Thefollowingstepsareallnecessaryforproperinstallationandsafe operationof yourboiler.

1. LOCATINGTHEBOILER

2. OILSUPPLYANDPIPING

3. FRESHAIR FORCOMBUSTION

4. PIPINGCONNECTIONS

5. CHIMNEY& VENTPIPECONNECTIONS

6. ELECTRICALWIRING

7. THERMOSTATLOCATION

8. CHECKING&ADJUSTING

9. MAINTENANCE

Locatingthe Boiler

If yourboileris partof a plannedheatingsystem,locateit as nearlyas

possiblewhereshownon yourplan.If boileris to be partof an existing system,it is usuallybestto put it wherethe old onewas.If youplanto

changelocation,youwill needadditionalmaterialsaswellasan adequate base.Thefollowingrulesapply:

1. The boilermustbelevelandlocatednearpiping.

2. Usea raisedbaseiff]oorcanbecomewetordamp.

3. Theventpipeconnectionshouldbeasshortaspossible.

4. Maintainclearancesforfiresafetyaswellasservicing.SeeFigure2for minimumclearances.18"clearancemustbemaintainedatasidewhere

passageisrequiredforaccessto anothersidefor cleaning,servicing, inspection,or replacementofanypartsthatnormallymayrequiresuch

attention.Boilersmustbe installedat least6"fromcombustiblematerial onallsidesandabove.Allowat least24"frontclearancefor servicing.

Allowat least18"leftsideclearanceforservicingboilersequippedwith

atanklesscoil.

5. FRESHAIRfor combustionmustbeavailableatthefrontoftheboiler. FRESHAIRfor ventilationmustbeavailabletothefrontANDrearof

theboiler.Airpassagesmustbefreeofobstructionsatalltimes.

Ventilatingandcombustionairmustenterboilerroomwithout restrictions.

6. The floor suppo_ng the boiler must be non-combustible.If it is combustible,placetheboileron 2" cladlitepad.Thepadmustbeunder

theentireboilertoprotectthefloor.

7. Besureinstallationisinaccordancewiththerequirementsofthelocal authoritieshavingjurisdiction.Compliancewiththeseregulationsis required.In theabsenceof localcodes,followNFPA31- Insbtlationof

OilBurningEquipment.

Q 6" MIN. 18" WITH COIL

• _

I_// . I BOILER

_" 6" MIN. "

I-----2, .,..------IFRO.T

6" MIN.

SeRVraceL_NeLL,.------e_.ec_rRic

F_LPtFE ] I I[ s_,rrc_

GENERAL PRINCIPAL REQUiREMEnTS FOR A TYPICAL INSTALLATION

Fresh Air for Combustion

WARNING

Be sure to provide enough fresh airfor combustion. Enough air ensures proper combustion and assures that no hazard will develop due to

the lackof oxygen.

You must providefor enough fresh air to assurepropercombustion.The fire in the boiler uses oxygen. It must have a continuous supply. The air in a house contains only enough oxygen to supply the burner for a short time. Outside air must enter the house to replace that used by the burner. Study foIIowingexampIes 1 and 2to determineyour fresh air requirements. EXAMPLE 1:Boiler Located in Unconfined Space

If your boiler is in an open area (unpartitioned basement) ina conventional house, the air that leaks through the cracks around doors and windows will usually be adequate to provide air for combustion. The doors should not fit tightly. Do not caulkthecracks aroundthe windows.

An unconfinedspace isdefined as aspace whose volume isnot lessthan 50 cubic feet per 1,000Btu per hour of the total inputrating of all appliances

installedin 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 sufficientvolume 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

minimumfree area of one square inch per 1,000Btu per hourof thetotal inputratingofall combustionequipment inthe confinedspace, but not less

than 100 squareinches. One opening shall be within 12 inches ofthe top

andonewithin 12 inchesof the bottom of theenclosure.See Figure 4. 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 inchesof FREE opening. Metal

grilles have about 60% FREE area. To find the Iouveredarea needed,

multiply the FREE area required by 1.7 (130 x 1.7 = 221.0 sq. in. Iouvered area). In thisexample twogrilles, each having an 8"x 30" (240 sq.in,) Iouvered area would be used. Fig. 4 shows the grille locations.

B. All Air from Outdoors: The confined space shall be provided with two

permanent openings, one commencing within 12 inches of the top and one commencing within 12 inches of the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawlor attic)thatfreely communicatewith the outdoors.

1.When directly communicatingwith the outdoors, each opening shall have a minimum free area of one squareinchper 4,000 Btu per hour of total

inputratingof all equipment in theenclosure.

2. When communicatingwith the outdoors through ve_cal ducts, each opening shall have a minimumfree areaof one square inch per 4,000 Btu perhour of total input ratingof all equipmentin theenclosure.

NOTE

If you use a fireplaceor a kitchenor bathroomexhaustfan,you

shouldinstallan outsideairintake.Thesedeviceswill robthe boiler andwaterheaterof combustionair.

3.Whencommunicatingwiththeoutdoorsthroughhorizontalducts,each openingshall havea minimumfreearea of onesquareinchper

2,000 Btu per hour of totalinput ratingof all equipmentin the enclosure.

4. Whenductsareused,theyshallbeof thesamecross-sectionalarea asthe freeareaof theopeningstowhichtheyconnect.Theminimum

dimensionofrectangularairductsshal{benotlessthanthreeinches.

VENTILATING -'_--i GRII.LE I

i I ' 1

i ,11 II ',

AIR GRILLE _

Fresh Air Duct Capacities for Ducts Supplying Fresh Air to boiler in tightly constructed houses. British Thermal Units per

hour Input (Btuh)*.

Fresh Air Duct Size

31/2"x 12" 8* x 8"

8" x 12" 8" x 16"

*Based on opening covered by IA" mesh screen, wood louvers, or mela{ louvers

1/4"Mesh

Screen Btuh

144,000 256,000

384,000 512,0O0

Wood

Louvers Stuh

36,000

64,000 96,000

128,000

FRESH

Metal

Louvers Btuh

108,000 !92,000 288,000 384,000

Boilers With Tankless Heater Coil

Boilersmaybefactorypackagedwithatanklessheatercoil.Theuseof this

coileliminatesthe needforahot waterstoragetank.Instantaneousheatingof waterinthecoil willprovidea flowof hotwaterfor domesticuse- ifproper watersupplylinecontrolsareused.

IMPORTANT

Donot usea tanklesscoilif yourwateris excessivelyhardwithlimeor otherdepositswhichwillaccumulateinsidethecoil.

Forsummerrunningwithcoilyou needtofill boilerwithwaterandaddthe L6006limitcontrolto the coil.Thiswill maintainwatertemperaturein the

boilerand bringtheburneronwhennecessary.

TANKLESSCOlL PIPING

PipingisshowninFigure7B.A temperingvalve(mixingvalve)is

recommended.

LowLimit(whenused)- 140° F

Thesesettingscanbechangedafteryouhavesomeideahowthe system responds.If moredomestichotwateris required,the lowlimitsettingcan

alsoberaised.

_NT_pERE_ _OT WATER

¢OL_ WATE_ _N_ET

WLV_

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