Dunkirk 3ES1.25 Owner's manual

Brand: Dunkirk

Model: 3ES1.25

Category: Water heaters & boilers

Type: Owner's manual

This manual is also suitable for

3ES135

O|L-F|REDCAST |RONSTF.AM

BO|

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 , * ,

LEFT SIDE

3/4 _ NPT

_LOW UMIT

CONTROL ON

COIL PLATE

I/2" NPT

PRESSURETROL

PRESSURE GAUGE

COMBINATION

1-1/2" NPT

RETURN

FRONT

27"

WATER

IJNE

2-I/2" NPT

SUPPLY

iq°p

i-i/2" NPT

i SKIM TAPPING

,-V2 ° NPTi

RETURN

REAR

5/4" ASNE

POP SAFETY

VALVE

EMPIRE OIL-FIRED STEAM BOILER RATINGS

BOILER MODEL NO.

With Without

Tankless Tankless

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

* MBH = 1,000 BTUpet hour

No.

9ec.

Input

*MBH

140

175

189

2!0

245

259

Nesting

Capacity

*MBH

118

145

156

177

204

215

Net

I=B-R

Rating

"MBH

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 20'

CIMF31SIONS- INCHES

A B C

16% 7 9

16½ 7 9

16% 7 9

20% 8 11

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.ofradiationalreadyinstalledinthe

building.

TheNetI=B=RRatingsshownarebasedonanallowanceof1.333in

accordancewiththefactorsshownonthe1=B=RStandardaspublishedby

TheHydronicsInstitute.

Theseboilersmusthavea non-combustiblebaseifinstalledon acombustible

floor.Two-inchcladlitepadmaybeused.Theseboilersarelowpressure

sectionalcastironboilersconstructedandhydrostaticallytestedfora maximum

workingpressureof 15psiin accordancewithA.SME. (AmericanSocietyof

MechanicalEngineers)SectionIVStandardsforcastironheatingboilers.They

arecapacityratedinaccordancewiththecodeofthe1=B=R(Hydronics

Institute).

RulesforSafeInstallationandOperation

1. Readthe Owner'sManualforSafeOperationcarefully.Failuretofollow

therulesforsafeoperationandtheinstructionscancausea malfunctionof

the boilerand result in death, _rious bodilyinjury, and/or property

damage.

2. Checkyourlocalcodesandutilityrequirementsbeforeinstallation.The

installationmustbe inaccordancewiththeirdirectives,orfollowNFPA31

- InstallationofOilBurningEquipment,latestrevision.

3. Beforeservicing,allowboilertocool.Nwaysshutoffanyelectricityand

oiltoboilerwhenworkingonit.Thiswillpreventanyelectricalshocksor

burns.

4. Inspectoillineandconnectionsforleaks.

5. Be certainoil burnernozzleis size required.Overfiringwillresultin

earlyfailureoftheboilersections.Thiswillcausedangerousoperation.

6. Nevervent this boiler intoan enclosedspace.Alwaysvent to the

outside.Neverventtoanotherroomor insidea building.

7. Besurethereisadequateairsupplyforcompletecombustion.

8. Followa regutarserviceandmaintenancescheduleforefficientand

safeoperation.

9. Keepboilerareacleanandfreeofcombustiblematerial,gasolineand

otherflammablevaporsandliquids.

This boiler has been designedfor residentialinstallations. If used for commercial

applications,alljurisdictionalrequirementsmustbemet.Thismayrequirewiringandlor

pipingmodifications.Themanufacturerisnotresponsibleforanychangestothe original

design.

BeforeYouStart

Check to be sure you have the dght size boiler beforestartingthe

installation.See ratingand capacitytableon precedingpage.Checkthe

ratingplateontheboiler.

You mustseethat 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 youhaveanydoubtsasto thevariousrequirements,checkwith

local authorities and obtain professionalhelp where needed. THE

OPERATING INSTRUCTIONSand THE FINAL CHECKS AND

ADJUSTMENTSare vitalto the properandsafe operationof theheating

system.Takethetimetobesuretheyarealldone.

Thefollowingstepsareallnecessaryforproperinstallationandsafe

operationofyourboiler.

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 wheretheold onewas.If youplanto

changelocation,youwillneedadditionalmaterialsaswellasan adequate

base.Thefollowingrulesapply:

1. Theboilermustbe levelandlocatednearpiping.

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.Allowatleast24"frontclearanceforservicing.

Allowatleast18"leftsideclearanceforservicingboilersequippedwith

atanklesscoil.

5. FRESHAIRforcombustionmustbeavailableatthefrontoftheboiler.

FRESHAIRforventilationmustbeavailabletothefrontANDrearof

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.Intheabsenceoflocalcodes,followNFPA31- Insbtlationof

OilBurningEquipment.

Q 6" MIN. 18" WITH COIL

• _

_" 6" MIN. "

I_// . I BOILER

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

NOTE

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.

If you use a fireplaceor a kitchenor bathroomexhaustfan, you

shouldinstallan outsideair intake.Thesedeviceswillrobthe boiler

andwaterheaterofcombustionair.

You must provide for enough fresh air to assure proper combustion. 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 mustenter the house to replace that used by the burner. Study

foIIowingexampIes 1and 2 to determineyour fresh air requirements.

EXAMPLE 1:Boiler Located in Unconfined Space

If your boiler isin 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 isdefinedas a space whose volume isnot lessthan 50

cubic feet per 1,000 Btu per hour of the total inputrating of all appliances

installedin thatspace.

EXAMPLE 2: Boiler Located in Confined Space

A, All Air from Inside the Building: The confined space shallbe 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 100squareinches. One openingshall be within 12 inches ofthe top

andone within 12 inchesof the bottomof theenclosure.See Figure4.

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 130square 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 (crawl or attic)thatfreelycommunicatewith the outdoors.

1.When directly communicatingwith the outdoors,each opening shall have

a minimumfree area of one squareinchper 4,000 Btu per hour of total

inputratingof all equipmentin theenclosure.

2. When communicatingwith the outdoors through ve_cal ducts, each

opening shall have a minimumfree area of one square inch per 4,000

Btu perhour of total input ratingof all equipmentin theenclosure.

3.Whencommunicatingwiththeoutdoorsthroughhorizontalducts,each

openingshall havea minimumfreearea of one squareinchper

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

enclosure.

4. Whenductsareused,theyshallbeof thesamecross-sectionalarea

asthefreeareaoftheopeningstowhichtheyconnect.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"

1/4"Mesh

Screen Btuh

144,000

256,000

384,000

512,0O0

Wood

Louvers Stuh

36,000

64,000

96,000

128,000

Metal

Louvers Btuh

108,000

!92,000

288,000

384,000

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

FRESH

Boilers With Tankless Heater Coil

Boilersmaybefactorypackagedwithatanklessheatercoil.Theuseofthis

coileliminatestheneedforahotwaterstoragetank.Instantaneousheatingof

waterinthecoilwillprovidea flowof hotwaterfordomesticuse- ifproper

watersupplylinecontrolsareused.

IMPORTANT

Donotusea tanklesscoilif yourwaterisexcessivelyhardwithlimeor

otherdepositswhichwillaccumulateinsidethecoil.

Forsummerrunningwithcoilyouneedtofillboilerwithwaterandaddthe

L6006limitcontrolto the coil.Thiswill maintainwatertemperaturein the

boilerand bringtheburneronwhennecessary.

TANKLESSCOlLPIPING

Pipingisshownin Figure7B.A temperingvalve(mixingvalve)is

recommended.

LowLimit(whenused)- 140° F

Thesesettingscanbechangedafteryouhavesomeideahowthesystem

responds.If moredomestichotwateris required,the lowlimitsettingcan

alsoberaised.

_NT_pERE_ _OT WATER

¢OL_ WATE_ _N_ET

WLV_

Installation-SystemPiping

Thenearboilerpiping,thatisthepipingaroundtheboiler,mustbeconsidered

aspartoftheboilerforproperwaterlevelcontrol,andtoproducedrysteam.

Correctnearboilerpipingiscrucialtotheproperoperationoftheboilerand

theheatingsystem.Followtheserecommendationscarefully.

1.Placeboilerintheselectedlocation,asnearchimneyaspossible.

2. Installthepopsafetyvalve,usingthefurnished3/a" 90" ell,intothe3/4"

pipenippleonthebackoftheboiler.Makea dischargepipe,using3/4"pipe

(notfurnished)to carrythe wateror steamto a nearbydrain.Do not

connectthe dischargepipe directlyto a drain butleavean air gap.No

shutoffofanydescriptionshallbeplacedbetweenthepopsafetyvalveand

theboiler,orondischargepipes

betweensuchsafetyvalvesandtheatmosphere.Installationofthepop

safetyvalveshallconformtotherequirementsoftheANSI/ASMEBoiler

and Pressure Vessel Code, Section IV The manufactureris not

responsibleforanywaterdamage.

3.Thisboileris equippedwithtwo 21/2"supplyconnectionson topand

two 1V2"returnconnections,oneeachon frontand backsidesof the

boiler.Unusedconnectionsmust

4.Recommendednearboilerpipingfor gravityreturnsys-temsisshown

in Figure8.Thisconfigurationusesonesupplyandonereturntapping.

Pipingoff bothboilertap-pingsisrecommendedon units5 sectionand

larger.

Note:Usebothsupplytappingsonboilers5 sectionandlarger.

PtPES_E

5.Forinstailerschoosingto usebothsupplytappings,Figure8Ashowsthe

correctwayto pipethissystem.Figure8Bshowsthewrongwaytopipe

a headerwithtworisers.

, Headersmustbe fittedwith headeroffsetsor swingjoints,or be

equippedwith expansionjoints, so that thermalexpansionand

contractionofthe headerwillnatdamagetheboiler.Headersshall

netbewelded.

, Systemtakeoffsfromtheheadermustbebetweentheequalizerand

therisertotheheadernearesttheequalizer.Systemtakeoffsmust

neverbe betweentworisers.

6.Systemtakeoffsfromtheheadermustneverbe bull-headed.Ifthesteam

maingoesintwodirections,theremustbetwotakeoffsfromtheheader,

oneforeachmain.

7. All boilersingravityreturnsystemsmustbeequippedwitha Hartford

LoopasshowninFigures8 and8A.

8. Whenpipingtheverticalrisersfromtheboilertotheheader,thebottom

oftheheadermustbea minimumof 24inchesabovethewaterlevel

lineantherightsideoftheboiler(i.e.51inchesabovethefloor).

9. Steamriser(s)andheadershallbe272"pipesize.

10. Equalizerlineshailbeminimum1 1/2"pipesize.

11. Theboilerhasa 1V2"tappinginrearsecflanfarskimming.

_EA_{ MAINS

HART_ORO

N|PPLE

MAIN VENT

D_Y RETURN

M_[N

THIS, PIPING

COMMON

tS INCORRECT

MISTAKES

TO SHOW

12. The near boilerpipingshall includea 1 1/2"ballvalvein thereturn

pipingasshowninFigure8Afarbottomblowdawnanddraining.

13. Forgravityreturnsystems,thebottomoftheloweststeamcarrying

pipe,beita dryreturn,ortheendofthesteammain,mustbeatleast

28"abovethenormalwaterlevellineanthedghtsideoftheboiler.

Thisisknownas"DimensionA."

14. Forpumpedreturnsystems,followthecondensatepumporbailerfeed

pumpmanufacturer'sinstructionsforproperinstallationandhookup.

15. Inconnectingthecoldwarer supplytothewaterinletvalve,makesure

thata deanwatersupplyisavailable.Whenthewatersupplyisfroma

wellor pump,asandstrainershouldbeinstalledatthepump.

FORUSEWITHCOOLINGUNITS

This boiler, when used in connection with chilledwater systems,must

be installedso that the chilledwater is piped in parallel with the heating

boiler. Appropriate valves must be used to prevent the chilled water

from enteringthe heating boiler(Fig. g).

B.Whenthis boileris connectedto heatingcoilslocatedin air handlingunit.,

wherethey may be exposedto refrigeratedair circulation,the piping

systemshall be equippedwith flow controlvalvesor other automatic

meansto preventgravitycirculationoftheboilerwaterduringthecoolinc

cycle.

'_rd,.vE8 A & m

VALVESC & Q

_R _OUNG

ChimneyandChimneyConnection

CHECKYOURCHIMNEY

Followlocalcodes.Intheabsenceof localcodes,followANSI/NFPA31

InstallationofOilBurningEquipment,latestedition.

Thisisaveryimportantpartofyourheatingsystem.Noboiler,however

efficientitsdesign,canperformsatisfactorilyifthechimneythatservesitis

inadequate.Checkyourchimneytomakecertainthatitistherightsize,

properlyconstructedandinsoundcondition.

Itischeapertorebuilda poorchimneythantopayexcessivefuelbills.If

yoursisanoldmasonrychimney,a newsteellineror a new

prefabricatedchimneymaybethebestsolution.Thefollowingchartshows

recommendedminimumchimneysizesbasedonTable3andFigure6 of

theI:B:R TestingandRatingStandardfor HeatingBoilers,Sixth

Edition,June1989.

MUST BE REQUIRED MIN*

IMUM HEIGHT, MUST BE

AT LEAST 3 FT. HIGHER

THAN HIGHEST PART OF

PASSAGE THROUGH

ROOF. MUST BE AT

LEAST 2 FT. HIGHER

THAN ANY NEIGHBORING

OBJECT. MUST HAVE AN

UNOBSTRUCTED TOP

OPENING,

MUST BE AT LEAST

4 INCHES THICK -

AND BE LINED.

_l_ CHFM_ I

.60- i 30 15

13Iol 80 15

i,81o2,00 20

FIECOMMENDED MtNiMUM _IMNEY SIZES

=!:

_ER_ LNER;

_!NNqY' i_DE I_

8"×8 ' 6' 6:5_x 6_'

8' x 8" 7' , 6_f;_"× 6_!4"

[:<]re#_@:(Y)88_ee 2,#_ if,,8J3_es_ _i, ad_3 feetIocblm_qeYhe_gP4_

[_!et la Fiqure 1@t

Foradditionalchimneydesignandsizinginformation,consulttheASHRAE

1996HVACSystemsandApplicationsHand-book,Chapter30,Chimney,

GasVentandFireplaceSystems;ortheNationalStandardforChimneys,

Fireplaces,VentsandSolidFuelBurningAppliances,ANSI/NFPA211.

CHIMNEYCONNECTORANDDRAFTREGULATOR

Yourboilerrequires7"diameterchimneyconnectorpipeon 3 section,8"

diameterchimneyconnectorpipeon 4 section.Youmustalsouse a dralt

regulatorpackedwithboiler.Properlyinstalled,theregulatorwillcontrolthe

draftautomatically.Itisbettertoinstallitina horizontalsectionofthepipe;but

itmaybeinanangledorverticalsection.Justmakecertainthatthe"top"isat

top- andthattheshortpipesectionwhichholdstheVaneishorizontal.Install

itascloseaspracticabletotheboiler.

Toinstallthechimneyconnector,startattheboilerandpreferablytakeoff

fromthefluecollectorcollarwithanelbow- theninstallthedraftregulator

next,makingithorizontal.Whentheregulatorisinplace,startatthechimney

andworkbacktotheregulator.JointhetwosectionswithaDrawband.The

horizontalpipemustslopeuptowardthechimneyatleast1/4inchperfoot.It

mustnotleakandmustbefirmlysupported.Joinsectionswithatleasttwo

sheet-metalscrews.Supporteverysecondsectionwitha stovepipewire.

MINIMUMVENTPIPECLEARANCE

ALTERNATE POSITIONS

TOP

MUSTSLOPEUP

AT LEAST 1/

PER FOOT OF

HORIZONTALRUN

DRAWBAND

LAST PIECE

INSTALLED

I L

_,TIGHT. SMOOTH,

CORRECTLY SIZED.

&LEDIN

THIMBLE

TIGHT

DOOR

DRAFT REGULATOR

VANE

Woodandothercombustiblematerialsmustnotbecloserthan18"fromany BALANCEDWEIGHT

surfaceoftheventpipe.

EquipmentandOptionalAccessories-WhatTheyDo

POPSAFETYVALVE

Youmusthavea popsafetyvalveonyourboiler.Steamexpandsasitisheated.

Ifthereisno placeforthesteamtoexpandinto,pressurewillbuildupinsidethe

boilerandsystem.Shouldthishappen,thepopsafetyvalvewillautomatically

openata pre-determinedpressure.Thiswillrelievethestrainontheboilerand

system.Runa pipefromthesafetyvalveoutlet(pipemustbesamesizeasoutlet

andtheopenendmustnotbethreaded)toan opendrain,tuborsink,or other

suitabledrainagepointnotsubjecttofreezing.Failuretodosomaycausewater

damageorinjuryshouldreliefvalverelease.Donotcapoffthedrainlinefrom

thisvalve!Eachpopsafetyvalveisprovidedwitha liftingdevicefortestingand

shouldbetestedmonthlyduringtheheatingseason.Refertosafetyvalve

manufacturer'sinstructionspackagedwithsafetyvalve.

STEAMPRESSUREGAUGE

Everysystemshouldhavea pressuregaugeinstalledintheboiler.Thisgauge

enablesyoutomonitorthepressureinthesystem.Ifthesafetydevicesfailtoshut

offyourboileratthepropersettings,notifyyourservicetechnicianimmediately

WATERLEVELGAUGE

Thewaterlevelin theboilercanbeseenthroughtheglasstubeinthewater

levelgaugeatsideofboiler.Correctcoldboilerwaterlevelisstampedonside

jacketpanel.Whenmakingsteam,thewaterlevelwilldroponetothreeinches.

Thewaterlevelshouldbecheckedregularly.

STEAMPRESSURECONTROL

Thesteampressurelimitcontrol(pressuretrol)shutsofftheoiltotheburnerifthe

steampressureintheboilerreachesthecut-offsetpoint(i.e.thesumofthecut-in

andthedifferentialsetpoints).Burnerretireswhenthesteampressuredropsto

thecut-insetpoint.Systempressurerequirementsarebasedonthesizeand

conditionofthepipes,andtheload.

Forgoodsystemoperation,thecut-insettingofthepressuretrolshouldnever

be less than twicethe systempressuredrop. In a typicalsinglefamily

residencewith a cleanonepipeheatingsystemand castiron radiation,this

meansthatthecut-inwillusuallybesetattheminimumsetting,i.e._/2psi.

Steamradiationis usuallysizedbasedon squarefeet of equivalentdirect

radiation(EDR).Thisis basedon a steampressurein theradiatorofjust less

than1 psi.Therefore,in our examplesystemfromabove,wewouldsetthe

differentialadjustmentat1psi,i.e.thesteampressurerequiredintheradiators.

Thiswillgiveusa cut-offsetpointd 1_12psi.

Theaboveisanexampleofa typicalonepipesystem.Forlargersystemsor

othertypesofsystemssuchastwo pipesystems,or systemswithconvectors

or fan coil units,the pressuretrolsettingswill needto be determinedon a

system-by-systembasis.

The cut-insetpointisdeterminedbythesystempressuredroptothefurthest

radiatoror terminalunit.Doublethesystempressuredropasa safetyfactor,

resultinginthe rulethatthecut-insettingshouldneverbe lessthantwicethe

systempressuredrop.

Thedifferentialset#ointisthesteampressurerequiredattheterminalheating

units.

Nowyourboilerwill operatein the correctpressurerange.It will maintain

enoughsteampressuretosendthesteamouttothefurthestradiator,andnot

go overtheoptimumsteampressurethatisrequiredattheradiators.

67D-t LOWWATERCUT-OFF

Thefloat-typelowwatercut-offshutsofftheburnerwhenthewaterlevelis

belowasafepoint.Theburnerwillstartwhenthewaterisrefilledtoa

minimumsafelevel.

WATERFEEDER(Optional)

Awaterfeederworkswiththelowwatercut-off(LWCO)tomaintaina

minimumsafelevelofwaterforboileroperation.It'susedtokeeptheboiler

runningbycompensatingforminorevaporativesteamleaks,andtoprevent

freeze-upsifthehomeownersareawayanda returnlineshouldspringa

leak,Theautomaticwaterfeederisa safetydevice,nota

convenienceitem.Itisnotdesignedtomaintaina "normal"waterline.The

waterfeederdoesnottaketheplaceofa responsiblepersonmonitoringand

maintainingthe"normal"waterline.Steamboilersrequirepersonal

attention.

Four electricwater feedersare offeredby McDonnell-Millerwhichare

compatiblewiththe 67D-1LWCO.The model#101Aand #WF2-U-120

waterfeedersareusedwith120voltwiringcircuits,asfoundanthissteam

boiler.The McDonnell-Millermodel#101A-24and#WF2-U-24are used

with 24 volt circuits,which may be usefulin a retrofitinstallationwhich

alreadyhasa 120voltto 24volttransformer.

TheWF2-U-120and WF2-U-24(Uni-Match)waterfeedersareequipped

witha solidstateelectroniccontrolwhichfeedswaterwhensignaledbythe

LWCO.Thewaterfeedrateisfieldadaptablefar 1,2, or 4 gpm.These

waterfeedershavean adjustableslideswitchtomatchthetimingcyclean

theLWCO.Whenusinga McDonnell-MillerLWCOtheslideswitchneeds

toselectposition#1.Thetimingcyclecreatesaninitialdwellperiodofone

minuteto allowcondensateto be returnedto the boiler.If afterthedwell

periodthewaterhasnatreachedtheminimumsafelevelandcompletedthe

LWCOcircuit,thenwaterisfedattheselectedflowratefaroneminute.The

dwellpedodistheninitiatedagainfaroneminute.Ifthewaterlevelhasstill

not reachedthe minimumsafe level,then wateris addedagain at the

selectedflowrateforoneminute.Thiscyclecontinuesuntilwaterreaches

the minimumsafe leveland the circuitis completed.DunkirkRadiator

recommendsusinga Uni-Matchwaterfeederataflawrateof1or2gpm.If

the steamboilerrequireshigherflow rateson a regularbasisa service

technicianshouldbenotified.

The1OlAwaterfeedermaybe used,howeverthewaterfeedrateistoo

high and needsto be regulatedor throttled.The IO1Awillfeedupto 6

gpm,muchgreaterthanthedesiredflowrateof1-2gpm.Also,thereisno

dwellperiodto providea marginfor condensateto returnto the boiler.

Thesetwofactorsincreasethechancesofoverfeedingwatertothesteam

boiler.Excessivewaterinthesteamboilerwillproducenoise

Consultthe water feedermanufacturer'sinstallationguidelinesfor more

detailson waterfeederselection,recommendedpipingarrangement,and

start up procedures.Dunkirk Radiator supports McDonnell-Miller's

recommendationtoarrangetheinstalledpipingsoa brokenuniontestcan

beimplemented.

DRAINVALVE

Thismanualvalveprovidesa meansofdrainingallwaterfromtheboilerand

system.Itshouldbeinstalledinthe3/a"teewherethewatersupplyline

enterstheboiler(Fig.8).Youcanalsousethisvalvetolowerthewaterlevel

ifitistoohigh.

STEAMVENTS

Beforea steamsystemwilloperateproperly,suitablesteamventsmustbe

installedin eachradiatoras wellasthe returnmain.Somesystemsrequire

steamtrapsinthereturnlineattheradiationunit.

The"Hartfordloop"isa pipingarrangementwhichmustbeincluded(Fig.8)

forproperoperationofthesteamsystem.

BOILERSWITHTANKLESSCOILSONLYFlowRegulatorandWater

TemperingValve

Ifyouhavea TanklessCoilfordomestichotwater,thesetwopartscanbe

used.Thiswillprovideyouinstantaneoushotwaterthatisneither

scaldinghotnormerelytepid.TheFlowRegulatorisplacedinthecoldwater

linetothecoil.It assuresa steadyflowofwatersothatthecoilcanproperly

heatit. It prevents"spurts"of "half-heated"water.Thisisimportantwherethe

waterpressureisexcessivelyhighorvariable.TheWaterTemperingValve

is ateewhichis connectedata junctionbetweenthehotwaterlinefromthe

coilandacoldwaterbranchfromthesupplyline.Itmixeshotandcoldwater

as requiredto furnisha temperedsupplyof watertothe house.Thewater

willbejusttherighttemperatureforyouruse.Thisisimportanton a steam

systemto preventscaldingtemperaturesatthefaucets.Bothpartsare self-

containedandautomatic.

Starting Your Boiler

HOWASTEAMSYSTEMOPERATES

Thewaterintheboilerisheateduntilit reachestheboilingpoint.Asthe

waterboilsit turnsintosteam.Thesteamrisesfromthetopofthewater

throughthesupplymainto theradiationunits.Asit passesthroughthe

radiatorsitreleasesitsheatandcondensesintowater.Thewaterreturns

totheboilerthroughthereturnmain.

FILLINGSYSTEMWITHWATER

Onsteamheatingsystemstheboileris partiallyfilledwithwater.Itisvery

importantto theproperoperationoftheentiresystemthatyourboilerbe

filledtotheproperlevel.Thecorrectwaterlevelon coldstartconditionis

abouthalfwayupthe glasswaterlevelgaugeasmarkedon theboiler

jacket.Tofill:

1.Closetheboilerdrainvalve.

2. Openthevalvesatthetopandbottomoftheglasswaterlevelgauge.

Alsoopenthedrainvalveatthebottomofthegauge.

3. OpenthefilIvalveandatlowwatertorunintotheboiler.

WARNING- Neverrunwaterintoa hotemptyboiler,

4.Allowboilertofilluntilwaterrunsoutthegaugedrainvalve.Then

closethegaugedrainvalve.

5.Continuetofillboileruntilwaterreachestheindicatedwaterline.This

Checking and Adjusting

isabouthalfwayuptheglasstube.Alwayskeepthewateratthislevel

whensystemisoff.

IMPORTANT

Skimminga newsteamboileronan existingsystemmustbedoneseveral

timestoremoveall oil,greaseandsediment.Thereshouldbe a teewitha

plugpipedtothesupplylineoftheboilerinordertoproperlyskimtheboiler.

Wheneverthewaterin the glassgaugebecomesdiscolored,yourboiler

shouldbeskimmed.

Whenskimming,makesuretopipetheopenendoftheteetothefloorora

drainto preventanyonefrom beingburnedbythe steamand hotwater

whichwillbereleased.

TheFloatLowWaterCut-offshouldbe blowndownafterskimming.Following

blowdown,allowtheboilertocoolandthenaddfreshwaterslowly.

Thefloatchamberofthelowwatercut-offmustbeflushedcleanandmaintained

clearof sedimentto allowfree movementof the float.This mustbe done

frequentlyduring initialoperationof the boilerand at least onceper week

thereafter.Followinstructionsontagattachedto control.Neverthrottlea steam

radiatorvalve on a one-pipesystem.It mustbe fully openor fully closed.

Otherwisewaterisheldintheradiatorunits.Thiswillcauseknockingsounds.

Skimmingmayberequiredagainafterafewdaysoperation.

CHECKINGCONTROLS

To checkthe LowWaterCut-Off,turnoff powerto theboileror turnthe

thermostatdownto the lowestsetting.Drainwaterto belowthevisible

bottomofthewatergaugeglass.Turnpoweronandturnthethermostatto

callforheat.WhentheboilerisequippedwiththefloattypeLWCO,theoil

burnershouldnotrunonacallforheatwhenthewaterislow.

To checkthe pressurelimit, run the boileruntil the pressurereaches

systemdemand.Thenturn the pressurescrewand dropthe pressure

settinguntiltheboilershutsdown.Thiswillshowthatthepressurelimitis

operatingproperly.

If youhaveinstalledyourownboiler,we recommendthat youcallforan

inspectionby a servicetechnician.The peace of mind and assured

performanceare wellworththe costinvolved.Hecanquicklymakethe

necessarychecksandadjustments.

OIL BURNERADJUSTMENT

Suggestednozzlesand preliminaryburnersettingsarefoundon page20.

Referto youroil burnerownersmanualfor checkingand adjustingthe

burner.

ADJUSTOPERATINGCONTROLSInstructionsforeachcontroland

burnerareincluded.

Betthermostatheatanticipatorat.20.Instrucfionsforthefinaladjustmentof

thethermostatarepackagedwiththethermostat.

CHECKTHERMOSTATOPERATION

Whensetabovetemperatureindicatedon the thermometer,boilerburner

shouldstart. Makecertainthe thermostatturnsoff the boilerwhenroom

temperaturereachesthe selectedsettingand startsthe boileroperating

whenroomtemperaturefallsafewdegrees.

Finally,setthethermostatforthedesiredtemperature.Specialconditionsin

yourhomeandthelocationofthethermostatwillgovernthissetting.

MaintainingYourBoiler

Checkthe waterlevelevery dayor two.Verifythe watertineshownby

operatingthedrainvalvean thegauge.Be suretop and bottom valves

on gaugearealwaysopen sothatactualwaterlevelwill beshown

atalltimes,

POPSAFETYVALVE

Thisvalveshouldopenautomaticallywhenthesteampressureexceedsthe

safelimit(perinstructionspackagedwithvalve).Shoulditeverfailto open

undertheseconditions,shut downyoursystem.Havethevalvereplaced

immediately,The pop safetyvalve shouldbe testedmonthlyduringthe

heatingseason.Refertothevalvemanufactureflsinstructionspackagedwith

thepopsafetyvalve.

LOWWATERCUT-OFF

TheLowWaterCut-offwillin_rrupttheelectricalcurrenttotheburnerwhen

thewaterlinein theboilerdropsto a lowlevel.It isveryimportanttokeep

thefloatchamberfreefromsediment,a conditionessentialto dependability.

To keepany accumulationfrom interferingwith floatactionis to "BLOW

DOWN"orflushoutthecontrolregularly.Thismustbedonetwo-threetimes

thefirstweekafterinstallationandoncea weekthereafterduringtheheating

season.Doitwhiletheboileris inoperation.Firstnotewaterlevelin gauge

glass.Openblow-offvalveatbottomof control,waterwillpourout,flushing

awaysediment.Drainuntilwaterisclear,abouta pail,thenclosevalve.If

waterlevelingaugeglasshasdropped,addwatertoboilertorestorelevel.

Consultlowwater cut-offmanufacturersinstructionsincludedwith boiler.

NOTE:Openingblow-offvalvecheckscut-offoperationtoo.Asfloatdrops

withfallingwaterlevel,burnerswillshutoff.Aftervalveisclosedandnormal

operatingconditionsarerestored,burnerswillresumefiring.

Boilersshouldnot be drainedbetweenheatingseasons.Onlywhenthe

waterin thesystembecomesdirtyshouldtheboilerbe drained,flushedor

boiledout,andrefilled.Steamboilersmaybeentirelyfilledwithwaterduring

thesummermonthstoexcludeair.

CLEANINGYOURBOILER

Undernormaloperatingconditions,withthe burnersproperlyadjusted,we

recommendthat you have the flue passages,burneradjustment,and

operationof the controlscheckedonce each year by a Service

Technician.

Before the start of each season (orwheneversystemhasbeen

shutdownforsometime)recheckthewholesystemforleaks...andrecheck

theboilerandventpipeforleaks.Replaceor patchanyboilersealsthatare

faulty.

BOILERFLUEPASSAGES

FluePassagesbetweensectionsshouldbeexaminedyearlyandcleaned.

Removevent pipe.Raisetoppanelof boilerandswingoutto exposeflue

collector.Removefluecollectortop. Cleanpassagewaysbetweensections

witha flexiblehandlewirebrush.Removedirtfomthebottomoftheboiler

and reassembleall parts.Be surevent pipeconnectionsto chimneyare

secureandnoobstructionsarepresent.

FOAMING,PRIMINGORSURGING

Thesetermsareusedtodescribeafluctuatingwaterline- whenwater

leavestheboiler.

Itiscausedbyanycombinationofthefollowing:

1.Threadingoilandorganicmatterintheboilerwater.(Mineraloil,orcore

sanddoesnotcausesurging.)

2. Faultyquickventsthatdonotreleaseair untila sizeablepressureisbuilt

up- replace.Ifdirty,cleansothatyoucaneasilyblowthroughvalve.

3. Improperheader design - whensteamflowsin oppositedirectionof

equalizerlineon"Hartfordloop."Generallya 15"horizontalrunbetween

riserandmaintakeoffwill allowentrainedwaterto falloutofthesteam

vaporsoitcanreturnto boiler.(Seepage7,Fig.8)

4.Adjustmentof steamlimitcontroltoa widedifferentialincreasesdifficultyif

quickventsare oldstyle,slow-releasingtypeor dirty.Alwayssetsteam

limitcontroldifferentialaslowaspossible.

5.Soapanddetergentscauseextremesurging- cleanthoroughlyby

skimmingtheboiler.

CAUTION

Neverrefilla hotboilerwithcoldwater- thedangerofthermalshockmay

crackasection.

CAUTION

Neverallowelectricianor oil burnermechanicsto tryouttheirwork by

turningon oil burnerfor evenone secondunlessboileris filledto the

properoperatinglevel.

SYSTEMCHECKSAFTERFIRSTSTARTING- STEAMSYSTEMS

Readthe instructionspackagedwithyourcontrolsand makechecksand

adjustmentsaccordingly.Start the burnerand set the Thermostatfor the

desiredroomtemperature.WhenadjustingtheSteamPressurecontrol,watch

thesteamPressureGaugeanduseits pressurereading- asitwillbemore

accuratethanthecontrol.(Anydifferencebetweenthetwowillbeduetotheir

differentlocation.)

BOILERWATERTREATMENT

Inclosedhotwaterheatingsystems,negligibleamountsofmakeupwaterare

used,and watertreatmentis not required.In steamsystemswherethe

systemistight,freefromleaks,andall thesteamis returnedtotheboileras

condensate,theamountofmakeupwaterissmall.Again,watertreatmentis

notrequired.

On steamsystemswith less than 90% of the steambeingreturnedas

condensate,orwithveryhardor corrosivemakeupwater,treatmentmaybe

desirable.Followthe recommen-dationsoftheASME(AmericanSocietyof

MechanicalEngineers)Boilerand PressureVesselCode,SectionVl, latest

version.

BETWEENHEATINGSEASONS

Boilersshouldnotbedrainedbetweenheatingseasons.Boilersinclosedhot

waterheatingsystemsmaybeleftasis.Steamboilersshouldbeentirelyfilled

withwaterduringthesummermonthstoexcludeair.

Oil Boiler/BurnerCleaningInstructions

1. ShutoffalIelectricaIpowertotheboiler/burnerandshutofffuelsupply.

2. Removethesheetmetalsmokepipefromthetopd theboiler.Inspect

pipeandchimneyforsignsofcorrosionanddeterioration.Cleanbase

ofchimney.

3. Removetopjacketpanel.

4. Removethetwobrasswingnutsholdingtheflueccllectorfop.

5. Checkthegasketontheundersideofthefluecollectorandreplaceas

necessary.

6. Removetheoil burner(threecapscrews).-OR-

Removetheoil burner/firedoorassembly(fourhexnuts).This is the

recommendedmethod,as it allows full accessto the combustion

chamberandlesspotentialdamagetothetargetwallduringthecleaning

process.

7. Removetheburnerdrawerassembly.Cleananysootaccumulations.

8. Replacetheburnernozzlewiththeexactsizeandtyperecommended

forusonthisboiler.

Note:Changingto adifferentfiringrate,otherthanisrecommended,ortype

of nozzlemaychangethe performanceof this boilerand/orcausea

hazardouscondition.

9. Cleanelectrodeassemblyandsetelectrodesasperburner

manufacturersrecommendations.

10.Reinstalldrawerassemblyandcheckforproperheadlocationasper

themanufacturer'srecommendations.

11.Inspectthetargetwail,blanket,andfiredoorinsulationforcrackingand

deterioration.If thereisanysignsofcrackingor deterioration,replace

beforereassemblingtheboiler.

12.Removesootfromfiresidesurfacesbybrushingdiagonallythroughthe

flue passages(see drawing).Care shouldbe taken so as not to

damagethetargetwallwiththefluebrush.

13.Carefullyvacuumsootaccumulationsfromthecombustionchamber

area,beingparticularlycarefulnottodamagethetargetwailandblanket

withthevacuum.Targetwallandblanketmustbeingoodconditionand

correctlyinstalledtoinsurepropercombustion.

oooooooooooo

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%%%°°%%°2°

°j°o°2o%%%°2o°Co°2o

°°°°%02°%°o%%°°°0%%°Oo°

14. Reinstalltheburner/firedoorassembly.

15. Reinstallthefluecollectortopandsecurewiththetwobrasswingnuts.

16. ReinstalIthetopjacketpanel.Reconnectthefluepipe.

17. Inspectandcleantheoil burnerblowerwheel.

18. Oiltheburnermotor(DONOTOVEROIL}.

19.Removetheoilpumpcoverandclean/replacethepumpscreen.Carefully

reassemble.

20.Replacethefuelfilter(ifapplicable).

21.Reconnecttheelectricalandfuelsupplies.

22. Firethe burner,checkingfor propercombustionusingcombustiontest

equipment,makingadjustmentsasnecessary.

23.Insurethatallsafetycontrolsandoperatingcontrolsarefunctioning

properly.

IMPORTANTOPERATINGANDMAINTENANCEREQUIREMENTSKEEPYOURBOILERANDTHEAREAAROUNDIT

CLEANNEVERBURNREFUSEORANYMATERIALOTHERTHANTHESPECIFIEDFUELINYOURBOILERHAVEYOUR

BOILERCHECKEDEACHYEARBYAQUALIFIEDTECHNICIAN

_u me_javowalir_o_nven_ and servi_ calls _ ch_ these potn(s _m _ c_l for _r_ce.

Bu _ler may not _ iitng at proper

re[@

Burner may be shortocyct ag,

po_r _ boile_

OonttoIs o_t of adjustment

What: to

Reset themsostat above room tem_raIu 8.

Cean all flue passages and _'he'_nt pipe,

Nave burner c_ea_d and read ueted,

C_eek _e_f_e size if there is _y doubt,

Have burner adjusted

S_ort-r_cting {too frequent off and on) of bu[ner will cause s,aoti_ _f_r ar_df

or burner bec_e dirty at frequent in_ervaJs,dter eorreotino Itre drt conditior_....

also correct _he@n_ro_setting (or other _se e#_:heehorbcV_c4i_'_gl

Check thefm_sM he_[ _ntio pa,tor_d _rre_ _tt_, if neces_ry, per ine_r_t_or_

Check o,.,_ercurreetprotection Check to _ sure power supply circuit is "ON,

Reset accordi_ to in_r_l_ie_s packed with coatro/&

Check a_icontrol term_inatsan_ w#e ioinls,

HAV_ YOUR 8_RVIC_ TECHNICIAN CHECK ANY PROBLE_ YOU ARE UNAI_LE _ CORRECT.

COLORCODE

BK = BI_CK

BL = BLUE

W = WHITE

G = GREEN

i_ =WIRE NUT

pARTNO, - 146-34-O47

2 X 4 JUNCTION

PART NO, _45-31-O82

HANDY BOX COVER (NOT SHOWN)

PART N0. _46-61-121

LOCK-NUT (2

PART NO.

I/2" CLOSE

PART NO. 146-07-030

HONEYWELL

PRESSURETROL _

PART NO. 146-62-015

- GROUND SCREW

PART NO. 1€6-54-B02

-UNE VOLTAGE (GROUND)

• LINE VOLTAGE (NEUT. LEAD)

_PRESSURETROL TO LWC.O HARNESS

PART NO, 433-00-873

OIL BURNER

PRIMARY RELAY

OPTIONAL LOW LIMIT

CONTROL FOR BOILERS

WITH TANKLESS COIL

\ z z

TO 24v

THERMOSTAT

LOW VOLTAGE WiRiNG HARNESS NOT FURNISHED

L BURNER TO L.WC.O. HARNESS

PART NO - 433-00-872

LINE VOLTAGE (NOT LEAD)

#2 TERMINAL LWCO

PART NO, 433--00--874

67D-1 LW*C,O,

W_RINGTERMINAL DETAIL

'tJ

WH_E

FROM OIL BURNER

BLACK LEAD

FROM OiL BURNER

McDONNELL M_LLER

L W.C.O

PART NO. 146-26-042

4 X 4 OIL BURNER

JUNCTION BOX

"_p_r_ Tsr_kle_ _i_ K_t4340_14 (ir_l:_s coJ_,_8{, and b_l_)

L_!

(1 _69BI0! )

BOILER

MODEL

3ES1.00(C)

3ES1,25(0)

3ES! .35(C)

4ES1,50(C)

4ES1,75(C)

4ES1,85(0)

SUGGESTED NOZZLES AND SETTINGS

FOR BECKETT AFG-M OIL BURNER SERIES

NOZZLE ACTUAL

0,85-60°W 1.00

1,10-70°B 1.25

1,20-70°B 1.35

1,25-60°B 1.50

1,50-60°B 1.75

1.75-60°B 1.85

PUMP

PRESSURE

(psig)

!40

140

!40

140

HEAD

ADJUSTMENT

AIR

SHUTTER

AIR

BAND

OIL

BURNER

MODEL

AFG-50MB

AFG-50MD

FOR RIELLO R40 OIL BURNER SERIES

ACTUAL PU MP AI R OIL

BOILER NOZZLE TURBULATOR

MODEL (DELEVAN) INPUT PRESSURE SETTING GATE BURNER

RATE (gph) (psig) SETTING MODEL

3ES1,00(C) 0.85-60°W 1.00 150 2,0 3.00 F5

3ES1,25(C) 1.00-60°W 1.25 165 2.5 3.60 F5

3ESl.35(C) 1.10-60°W 1.35 165 3.5 4.25 F5

4ES1.50(C) 1.25-60°W 1.50 160 1.5 2.60 FIO

4ES1.75(C) 1.50-60°W 1.75 145 1,5 3.25 FIO

4ES1.85(C) 1.50-60°W 1.85 160 2.0 3.40 FIO

FOR CARLIN EZ OIL BURNER SERIES

BOILER NOZZLE I HEAD

[

MODEL (DELEVAN) ! SETTING

3ES1.00(C)

3ES1,25(C)

3ES1.35(C)

4ES1.50(C)

4ES1,50(C)

4ES1,65(C)

4ES1,85(0)

0.85x70ow

1.00x70°W

1, !Ox70°W

1.25x60°W

1,25x60°W

1.35x60°W

1,50x60°W

ACTUAL

INPUT

RATE (gph)

1.00

1.25

1.35

1.50

1.65

1.85

PUMP

PRESSURE

(psig)

150

0.85-1.00

1,10-1.25

1.10-1.25

0.85-!.00

1.50

! ,50

AIR BAND

SET

POINT

0.65

0.90

1.!0

1,10

1,65

1.65

2.00

OIL

BURNER

MODEL

EZ-1 HP

EZ-I HP

EZ-1 HP

EZ-2 HP

All burners fired at an over fire pressure of -0,02"wc.

Burner insertion depth of 2-1/8" allows burner tip to

be 1/4" behind insulation, I NOTE: These settings are intended for ini-

tial start up only, Final adjustment must be

made using combustion test instruments, i

Dunkirk 3ES1.25 Owner's manual

Brand: Dunkirk

Model: 3ES1.25

Category: Water heaters & boilers

Type: Owner's manual

This manual is also suitable for

3ES135

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Dunkirk 3ES1.25 Owner's manual

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Dunkirk 3ES1.25 Owner's manual

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