DUNKIRK Boiler Manual L0612228

User Manual: DUNKIRK DUNKIRK Boiler Manual DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides

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EMPIRE STEAM II
OIL-FIRED CAST IRON BOILER
MODEL NUMBERS:
ESB0365 ESB3100.
ESB4125 ESB4150.
ESB5175 ESB5200.
ESB6225 ESB7275

DUNKIRK
85 Middle Road
Dunkirk, NY 14048
Phone (716) 366-5500
Fax. 1716) 366-1209
www. dunkirk corn

ECR

International

An ISO 9001-2000

Certified

Brand

)C_

Company

P/N 1305029, Rev

! 0 [08/04]

P/N# 1305029,

Rev

1 0 [08/04]

• Printed

in USA • Made In USA

MPORTANT:
OMPLETELY
Safety Symbols

and Warnings

Read the following
before mstalhngll

instructlons_

Ratings, Data, and Dimensions
Installation Procedure
Ventilation and Combustion Air

3
4
5

Connecting Supply and Return Piping Steam
Venting System Inspection and Installation
Oil Tank and Piping

7
8
8

Electrical Wiring
Thermostat Operation
Normal Sequence of Operation
Operating Instructions
Maintenance
Procedures

9
9
11
11
14

Replacement
Parts List
Service Checklist

15
20

KEEP THIS
BOILER
RETAIN
FORMANUAL
FUTURE NEAR
REFERENCE

1. Keep boiler

area clear

and free from

bustible
materials,
gasoline
mable vapors and liquids.
2. DO NOT obstruct

and other

air openings

comflam-

to the boiler

room.

3. Modification,

substitution

or elimination

factory equipped,
supplied
or specified
components may result in property damage, personal injury or the loss of life.
4. TO THE OWNER - Installation

and service

this boiler
installer.

by a qualified

must

be performed

5. TO THE INSTALLER - Leave all instructions
with the boiler for future reference.
The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels

6. When this product is installed in the Commonwealth
of Massachusetts
the installation
must

be performed

_Licensed
ndicates

an imminently

hich, if not avoided,

hazardous

WILL result

dicates

a potentially

in death

Gas Fitter.

hazardous

situation

result

in death

I
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.

_..

ndicates
a potential
hich, if not avoided,

hazardous
situation
I
MAY result in minor or I

oderate injury. It may also
gainst unsafe practices.

or I

COULD

Plumber

situation'_

r!o,s
!nj,,y:

hich, if not avoided,
serious
injury,

by a Licensed

be used

to alert

I
.t)

0@
Tested

For

15 LBS

ASME
/_,,or kllig

Pressure

iiiiiiiii,1_teiaimiiiiiiiiiii!

wa_er

iii/iSq_are!iiiil

ESB0365

0.65

246

8x8x15

140

.60 80B

ESB3100

1.00

140

116

363

101

8x8x15

140

.85 80B

ESB4125

1.25

175

145

109

454

126

8x8x15

140

ESB4150

1.50

210

170

128

533

148

8x8x15

140

ESB5175

1.75

245

202

152

633

176

8x8x15

140

1.50 80B

ESB5200

2.00

280

227

170

708

197

8x8x15

140

1.75 70B

ESB6225

2.25

315

251

188

783

218.3

8x12x15

140

2.00 45B

ESB7275

2.75

385

307

230

958

267.1

8x12x15

140

2.25 45B

NOTES:
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.

A.S.H.E

PRESSURE

f_RELZEF

VALVE

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"
V

TANKLESS

WATER

HEATER CAPACITIES

ESB0365
ESB3100

0.65
1.00

L-24
L-24

ESB4125

1.25

ESB4150

1.50

ESB5175

Available

on request
4.5

11
11

8
8

L-24

4.5

L-24

4.5

1.75

L-24

5.0

ESB5200

2.00

L-24

5.0

ESB6225

2.25

L-24

5.0

ESB7275

2.75

L-24

5.0

12
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.)

control.

(NOTE:

For tankless

heater

units, add tankless

hot water coil, and 4006 limit

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

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.

Where required

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

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.

carpeting or vinyl flooring. Minimum
combustible
construction are:

clearances

TOP ........................................
24 IN.
FRONT ...................................
24 IN.
FLUE CONNECTOR
................ 9 IN.
REAR .....................................
24 IN.

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.

LEFT SIDE ...............................
RIGHT SIDE ............................
MINIMUM CLEARANCES
CONSTRUCTION

6 IN.
241N.

TO COMBUSTIBLE

(AS SEEN FROM ABOVE)
T
24"

Allow 24 inches in the front, top and right hand side
for servicing and cleaning, or removing
tankless
water heating coil.
• 6" _24"--

It is recommended

that 24 inches be allowed in back

of boiler for convenience
used.

when

skimming

24"

[

hole is
NOTE:

When installed

in a utility room, the door should

wide enough to allow the largest boiler part to enter,
or to permit replacement of another appliance such
as a water heater.

Clearance

protection

clearance.

for access

should

exceed

fire

COMBUSTION
AIR REQUIREMENTS
(Minimum Opening

4. When

Requirement)

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

91,000

100

140,000

140

175,000

175

210,000

210

106

245,000

245

122

280,000

280

140

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)

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)

i ¸
jl

TYr=_

C_O_NE'_
VErsT

VENf

_'i "' E

r_pE

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

space, in a building
air for combustion

is installed

in an unconfined

of unusually tight construction,
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.

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)

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 4)

/
CiUTLET

AE_
!/ENI

PEPE
\/ENTZLATZON
LOUVERS

FOR

UNIIEATED
CRAWL

SPACE
/
VE_S

INLET
AZR

PIPE

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 in the
enclosed

space.

(Figure

iJ!llllll![Li_l/ll]llll_

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
minimum dimension of rectangular
not be less than 3 inches.

connect. The
air ducts shall

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
I FIGURE 3 I

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

1. Suggestedpipingfor steam heatingsystemcan
beseeninFigure5.Actualpipingmayvarybasedon
systemdesignand local conditions.
2. For further piping information
installation piping guide.
NOTE,
PI_I.G
_UCL

B_T_
_UST

3"
_E

sUPPLY
_

refer to the I=B=R

T_PPING_

MINIMUM

_IUST
_".

4. See Figures 7 and 8 for the suggested
a modular steam boiler.

SUGGESTED
PIPING FOR MODULAR
BOILERS - GRAVITY RETURN

HOT
TO
WASHER

_N/_M_E_ED
I_ST_LLE_

COLD

WATER

hot

piping for

STEAM

I FIGURE 7 I

PIPING FOR BUILT-IN
DOMESTIC HOT WATER HEATER

UNTEMPERED
WATER
AUTOHAT:C

piping for domestic

SUGGESTED
PIPING FOR MODULAR
BOILERS - PUMPED RETURN

NOT

I FIGURE 5 I

3. See Figure 6 for typical
water heater.

BELOW

CENTE_

-_/

I FIGURe: 6 1

I FIGURE 8 I

STEAM

Connect flue pipe same size as boiler outlet to
chimney, sloping upward continuously
toward the
chimney approximately
1/4" per foot. Bolt or screw
joints together to avoid sag.
If an oil fired water heater is vented into the same flue
Inspect chimney to make certain it is constructed
according to the latest revision of the NFPA 211.
Local regulations
may differ from this code and
should be checked. Where there is a conflict, the
local code will prevail.
The boiler must be installed into a chimney
has a masonry or metallic chimney liner.

which

as the boiler, provide a separate hole into the chimney
whenever possible. When this isn't possible, use a
"Y" connection in the flue pipe, using a separate draft
regulator for each unit. When a chimney will not
provide adequate draft to handle the input from the
water heater and boiler simultaneously,
wire the
units so that only one wilt operate at a time, favoring
the water heater.

q&o'

An unlined chimney wilt have leaks that wilt cause
poor chimney performance
(no draft), and could
result in a positive
chamber.

pressure

in the

I_,_

The chimney

should extend

on the

C3._

ANY

M)
J.O'(3,1

Roo_ GuR_AOE
WITHIN

(

.8.f.

"CHIMNEY

Horizontal portions of the venting system should not
exceed 10 feet in length. Horizontal lengths over 10
effect

ABOVE

NO_E
THAN
HORIZONTALLY

_._{
M

a negative

HEZGHT

le"

combustion
RIDGE

ft. will have
performance.

(3,_

c , 9;2.

GAS

i 1-t
I

M )
VENT

TYI_E

(

. 6,L

MIN.
OR
VENT

MIN.

chimney

at least 2 ft. above any

portion of the building within 10 ft. (Figure 9) It should
produce a -.02 inch W.C. draft in the combustion
chamber. See "Chimney or Vent Sizes" chart for
recommended
minimum and maximum chimney or
vent sizes.
Inadequate draft will cause improper combustion,
resulting in dirty flue ways and high fuel bills.

Oil tank and piping should be installed in accordance
with the National Board of Fire Underwriters
and
local regulations. Oil storage tank, vent, fill pipe and
caps should be as prescribed by local codes. In no
case should the vent pipe be smaller than 1-1/4"
I.P.S. The fill pipe should not be less than 2" I.P.S.
The suction line from the tank to the burner should be
one continuous piece of tubing to prevent air entering the line. The suction line, must be 3/8" O.D.
copper tubing for runs of 50 feet or less, and 1/2"
O.D. for longer runs. An oil return line, same size as

CHIMNEY OR VENT SIZES
ROUND
BTU/HR INPUT
INCHES
MIN MAX
91,,_0"0"140_00_
175,000 - 210,000
7
8
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii

315,000

SQUARE

INCHES
MIN I MAX

HEIGHT

(FT)
MIN MAX

8x8 I 8x10

8x8 I 8x12

r_;

the suction line, must be used on any installation
where the bottom of the tank is below the fuel unit of
the burner. Oil lines should be buried or otherwise
protected from mechanical injury. Flare fittings on all
oil lines are recommended.
Compression
fittings on
the suction line often allow air to be drawn into the
fuel pump, making it difficult to maintain oil pressure
at the nozzle. Do not run overhead fuel lines from
tank to oil burner.
Fuel pump connections and by-pass should be made
according to instructions attached to the fuel pump.

If tankis morethan20' fromthe boiler,a two stage
fuel unit should be installedin place of the single
stage pump suppliedas standardequipmentwith
the burner.Makecertainthe rotationandspeedare
the same and the pump is suitablefor the burner
horsepowerrating.

An oil linefilterandshut-offvatveshouldbe installed
inthesuctionline.Shut-offvatvesshouldbeinstalled
in boththe suctionandreturnlines at the burnerfor
convenienceinservicingburner.Allow extratubing
at burnerso burnermay be removedfrom boilerfor
cleaningwithoutdisconnectingtubing.(Figures 1011) An optional

TYPICAL INSTALLATION
SINGLE PIPE OIL SYSTEM

flexible oil line is available.

TYPICAL INSTALLATION
TWO PIPE OIL SYSTEM

/
_EFER

TO
CODE

,\
\

LOCAL

[)AHA(

[

1/2

Electrical wiring must conform with the latest revisions of the National Electrical Code, ANSI/NFPA

1. When an external

source is utilized,

the boiler, when installed, MUST BE electrically
grounded in accordance with these requirements.

1. Thermostat should be installed
about four feet above the floor.

3. Do not install a thermostat
fireplaces,

COPPER

I/'2

TtJBZrJG

2. Install a fused disconnect
switch between
boiler and meter at a convenient location.

on an inside wall

3. When the boiler is equipped with self-energized controls, no outside sou rce of electric power
shall be connected to the circuit of this system.
(See "Steam
Wiring W/MM #67 Mechanical
LWCO" on next page.)

4. Check thermostat operation by raising and lowering thermostat
as required to start and stop the
burner.

on an outside watt.
where it will be affected

by drafts, hot or cold pipes, sunlight,
television,

having jurisdiction.

electrical

2. NEVER install a thermostat

"1 I Ni¢ltJbl

L''G°"E'll

IFIGURE
101

No. 70, and/or local authority

or chimneys.

lighting fixtures,

5. Instructions for the final adjustment of the thermostat are packaged with the thermostat
(adjusting
heating anticipator, calibration, etc.).

TI-I --2

R7|84

#67

1032

LWCO
CAD

CELL

\1/

I I
I I
L1

BURNER
JUNCTION
YELLDW

BOX

BLACK

120V
60
HZ
SUPPLY

BLACK
DK

GREEN
LT

BLUE

ORANGE

WHITE
PURPLE
WHITE

_URNER
DISCONNECT

BLACK

WHITE

SOLENOID

BLACK
BURNER
MOTOR

OIL
BURNER
TRANSFORMER
WHITE

COMPONENT CODING
Thermostat (Millivolt)
Thermostat (24 Volt)
Thermostat (Line Voltage)
Transformer (120V/24V/40VA)
Transformer (120V/24V/50VA)
Volt Gas Valve
Pressure Switch
WIRING
[ :

Manual Reset
Control

Pressure

Terminal

Switch

Circulator
Energy Cut-Off

Relay Coil
Relay Contacts

Pilot Safety Coil
Wire Connection

Relay Contacts
Limit Switch

Low Water Cut Off
Electric Water Feeder

Manual Switch

Power Generator

CODE
Line Voltage

By Factory

Low Voltage

By Factory

Line Voltage By Installer
Low Voltage By Installer

NOTE: Not all components

listed are used in all control systems,

On a call for heat, the thermostat

will actuate,

com-

pleting the circuit to the boiler. In turn, the ignition
systems are activated and ignition wilt begin.
In the event of a low water condition, an automatic
low water cut-off device will interrupted
power between the low water cut-off and the burner. The
burner will remain off until the low water condition is

IMPORTANT

TO THE INSTALLER

- Before putting

the boiler in operation, test the mechanical tow water
cut-off device for proper operation. While burner is
on, open the blow-off valve located in the lower
portion of the cut-off body. This will drain the water
quickly from the cut-off body and break the circuit to
the burner.

If it does not, replace

control.

corrected,
(i.e., manually
restore boiler water or
utilize a water feeder device which wilt automatically
restore water to its normal operating

level).

The venting system should be inspected at the start
of each heating season. Check the vent pipe from

The pressure relief valve should open before the
steam pressure exceeds the 15 lb. reading on the

the boiler to the chimney for signs of deterioration
rust or sagging joints. Repair if necessary.

gauge. If this pressure is exceeded and the pressure
relief valve leaks steam when the boiler is operating
at normal pressures,
it should be immediately
replaced. Corrosion can build up rapidly at the valve
seat and prevent its functioning as a safety device.

Remove the vent pipe at the base of the chimney or
flue and, using a mirror, check for obstruction
and
verify compliance
211.

to the latest revision of the NFPA

The lever of the pressure relief valve (Figure 12) on
the boiler should be operated periodically to make
sure that it is functioning

(See oil burner

instructions

for nozzle

and electrode

setting).

properly.

DO NOT SET FIRE VISUALLY.

.......................

Instruments
determine
improperly

are the only reliable
method to
proper
air adjustments.
An
adjusted
burner causes soot and

high
fuel
bills
because
of incomplete
combustion
of the fuel oil. This in turn may
req u ire excessive
boiler maintenance,
service
costs, and in some instances, house cleaning
or redecorating.
mechanic
should

A competent
service
be consulted
to make the

( .....

proper adjustments
with a smoke
indicator, and draft gauge. NOTE:
\0 r Dwyer

test kits include these

tester, CO 2
Bacharach

instruments;,

A. Check oil burner nozzle to make certain it is tight
in adapter. Burner mounting bolts should be tight.
B. Check electrode
jarred out of position
C. Lubricate

burner

setting, as they may have been
during transportation.
motor if necessary.

D. Set room thermostatto call for heat, or jump H. Turn "OFF"burner and install pressuregauge
thermostatcontactson the boilercontrol.
port on pump.
E. Openall oil linevalves.

I. Startburneragainandcheckoil pressurefor 140
Ibs.Adjustif necessary.

F. Turn serviceswitchon. Burnershouldstart.
G. On one pipe fuel systemsonly, bleed pumpas
soonas burnerstarts.Allowoil to rununtilalltraces
of air in the suctionlinedisappear.

A 1/4" diameter slot is provided in the inspection cover plate to take draft readings in the combustion
chamber. (Figure 12) A 1/4" diameter hole will be required in the flue pipe between the boiler and barometric
damper (if used) to take draft, CO2, smoke and temperature
readings. Adjust air shutter on oil burner to
obtain a "trace" of smoke. Measure CO 2at this point. Increase air adjustment to lower CO 2 approximately
one percent. Check to insure minimum negative .02 w.c., (water column), "overfire" draft and zero smoke.
If -.02 w.c. "overfire" draft can not be maintained,
venting or the chimney.

changes

and/or

The following tables are provided as a guideline for initial start-up.
combustion
instruments as previously mentioned.
RIELLO

SETTINGS

.....
_le

Da_

modifications

may be required

Final adjustments

in the

MUST be made using

; P_

ESB3100

F-5

3.6

150 PSi

.85 80W

ESB4125

F-5

150 PSI

1.10 60W

ESB4150

F-5

150 PSI

1.25 60W

ESB5200

F-10

150 PSI

1.75 80B

.85-1.00
1.10-1.25
1.10-1.25
1.65-1.75

.85 70B
1.10 70B
1.25 70B
1.75 70B

CARLI N SETTINGS

ESB3100
ESB4125
ESB4150
ESB5200

EZ-1
EZ-1
EZ-1
EZ-2

0.85
1.00-1.10
1.25-1.35
1.75

150
150
150
150

PSI
PSI
PSI
PSI

BECKETT SETTINGS

ESB3100
ESB4125
ESB4150
ESB5200
ESB6225
ESB7275
NOTES:
(1) Model ESB6225

AFG
AFG
AFG
AFG
CF375
CF375

1
1
2
5
4
4

5
8
6
5
6
6

140
140
140
140
140
140

PSi
PSI
PSI
PSI
PSI
PSI

3-3/8U
2-3/4"
2-3/4"
3U
L1
L1

needs a head setting of 1 and ESB7275 needs a head setting

(2) Nozzle sizes with an H designation

Check

safety

control

.85 80B
1.10 80B
1.25 80B
1.75 70B H
2.00 45B
2.25 45B

of 2.

are Hago brand, all others are Delevan.

(3) Information in above table uses Beckett model AFG burner for model numbers
model CF375 for model numbers 6225 and 7275.

IMPORTANT:

F3
F4
F6
F12
N/A
N/A

circuit

after burner

adjustments

have been

ESB365-5200

and Beckett

made for satisfactory

performance,

A. Pressure Control- Remove cover and note pressure
setting. With boiler operating, decrease the setting.
When the setting is lower than boiler pressure, the
control will open and turn offthe boiler. After checking
pressure control, reset control to original setting.
B. Mechanical

Low Water Cut-off-

May be checked

by opening the blow-off valve on the lower portion of
the cut-off body while the boiler is running. This will
drain the water from the boiler and break the circuit

2. Disconnect power cable at factory supplied burner
electrical disconnect. (Figure 12)
3. Loosen

screws

on the sides of the lower front

jacket panel. (Figure 6) Pull the bottom part of the
lower front panel forward and lift the lower front panel
up and off the boiler. (Figure 12)
4. Close oil valve (Figures
line from burner.

10-11) and disconnect

oit

to the burner.
_MPORTANT:

Do not open swing door with oil line attached,../)

WARNING
5. Remove nut from swing door stud on right hand
side of door.

Refill boiler to its normal water line.

6. Swing open burner and door to the left. Using a
flue brush, brush the soot and scale into the

C. Primary

combustion space where it can be removed through
the swing door opening.

Control

and Flame Sensor-

To Check:
1. Flame Failure - simulate by shutting off oil
supply with hand valve while burner is on. Sixty
seconds after flameout, the safety switch locks
out, ignition stops, motor stops and oil valve when used - closes. To restart, open oil supply
valve and reset safety switch.
2. Ignition Failure - With burner off, close oil supply
valve and run through start-up procedure, The
safety switch should lock out as in flame failure.
3. Power Failure - Turn off main power supply
switch while burner is operating.
When burner
stops, restore power and burner should start. If
operation is not as described as above, check

se caution

when vacuuming

tea. Damage
It is recommended

to chamber

in the chamber

could

result,

I
j)

to replace the nozzle at the start

of each heating season. Lubricate the burner motor
and circulator motor- if required - with a few drops of
a good grade of light motor oil. Do not over oil. Have
a competent service person service the burner and
check the controls and check the electrodes
for
carbon or cracks in the insulators. Burners should be
adjusted to produce the conditions
and Adjustment of Off Burner."

shown in "Startup

wiring and controls.
Preventative
operating

maintenance

dan oil fired boiler reduces

, Swing
burner and door to the right until insulation
is slightly compressed
and the stud is exposed.

costs. The boiler and vent pipe should be

inspected for accumulation of soot or scale deposits
periodically but at least once every year before the start
d each heating season. When soot is present on the
section walls and flueways, improper combustion will
result, causing additional sooting and scaling until

2. Attach nut to the stud and tighten it until the built
in stop contacts the mounting door.

flueways are completely closed. To remove soot and
scale from the flueways, remove top jacket panel, top
clean-out plate, open burner swing door. (Figure 12)

4. Replace lower jacket panel, and tighten the screws.

3. Reconnect

oil line to burner.

5. Connect the power cable at the factory
burner electrical disconnect.

supplied

6. Turn on power to boiler and bleed oil line.
1. Turn off power to boiler and allow boiter to coot down.

Beforeseasonalstart up it is advisableto have a
competentserviceagencycheckthe boilerfor soot
and scalein the flues, changeoil filter and nozzle,
clean the burner and readjustburner inputrate to
maintainhigh operatingefficiency.

The venting system should be inspected

On steam

foaming and an unsteady water line, or prevent
steam generation. They may result in objectionable
odors escaping from the vents on water boilers. This
condition is caused by oil, grease, and sediment

of each heating season. Check the vent pipe from
the boiler to the chimney for signs of deterioration by
rust or sagging joints. Repair if necessary.
Impurities in boiterwater

boilers

make certain the boiler is filled to

the water line as indicated in Figure 12. The gauge
cocks should be normally open. To remove dirt from
the gauge glass the petcock may be opened to flush
out the glass.

at the start

of a steam boiler may cause

from pipe fittings collecting within the boiler and can
be remedied only by giving the boiler a thorough
cleaning.
BOILERS SHOULD BE CLEANED
OR BLOWING DOWN.

The radiator valves on a one-pipe steam system
must be either wide open or tightly shut. Do not
attempt to regulate room temperature
by partially
closing the radiator valve.
Air vents on steam radiators and the supply main
release air from the system. If radiators do not heat
satisfactorily,
make sure the air vents are clean and
operational.
The lever of the pressure relief valve on the boiler
(Figure 12) should be operated periodically to make
sure that it is functioning properly.

BY SKIMMING

he boiler should not be left unattended
_,ing the cleaning
process.

dur
1

Some of the impurities in the boiter water will float on
the water and must be skimmed off.
With the boiler empty and cool, slowly begin to add
water. After water has entered boiler - never before
- turn "on" oil burner and adjust water flow so that the
water being added is kept just below boiling point.
Avoid boiling and turbulence.

The

safety

valve

should

open

before

the steam

Gradually raise hot water level to skimming hole
(Figure 6) installed on the rear section of the boiler

pressure exceeds the 15 lb. reading on the gauge.
(Figure 12) If this pressure is exceeded
and the
safety valve does not open, it must be replaced. If the
safety valve leaks steam when the boiler is operating
at
normal pressures,
it should be immediately

being careful not to raise it above the opening of the
hole. Skim until there are no impurities. Repeat the
process if necessary.

replaced. Corrosion can build up rapidly at the valve
seat and prevent its functioning as a safety device.
If the water in a steam boiler appears to be dirty or
oily, or the water level in the gauge glass fluctuates
considerably,
the boiler should be cleaned. A com-

oil by drawing off a sample at the skimming hole. If
the sample is reasonably free from oil, it will not froth
when boiled on stove. This test does not indicate the

petent service person will use approved cleaning
compounds
and properly clean and flush out the
boiler. He/she should also clean or replace air vents
and traps, clean flue passages and check for proper
operation of all controls and safety devices.

further

Water may be checked

to make sure it is free from

amount of sediment which may lay in the bottom of
the boiler. It is therefore necessary that the boiler be
cleaned

by "blowing

down."

Before blowing down the boiler, fill it to the water line.
Turn

on burner

and allow

five pounds

of steam

pressure to build up. Run a temporary connection
from one of the drain valves to a nearby sewer.
Connect to a drain valve on the opposite end of the
boiler from feed water inlet, if possible. Shut off the
oil burner, open drain valve and blow down the entire
contents of boiler.
Allow boiler to thoroughly cool and slowly refill to water
line. Repeat as many times as required until blow off
water is clear. Owner should blow down boiler at least

The free flow of combustion
boiler and boiler
blocked.

room

and ventilation

air to the

must not be restricted

Periodic inspection and tightening of the tanktess
heater/cover plate bolts will reduce the risk of leaks.
See parts 3 and 5 under "Coil and Cover Plate
Replacement

Parts."

once each month d the heating season.
Operation should be checked, with burner on, by
opening the blow-off valve located in the lower
portion of the low water cut-off body. This will drain
the water quickly from the cut-off body and break the
circuit to the burner. If it does not, replace the control.

If an exceptional amount of dirt or sludge seems to
be present in the boiler, a boiler cleaning compound
made by a reputable manufacturer
may be used
according to the instructions of the manufacturer
of
the compound.
When any type of cleaning compound is used, care must be taken to thoroughly
flush all traces of the compound out of the boiler.
Following

During the heating season, the blow-off valve on the
low water cut-off should be opened once a week to
flush out the sediment chamber so the device will be
free to function

properly.

(Figure

12) Use a pail to

catch the discharge.

blow down allow the boiler to coot. Add

fresh water slowly. Be certain to blow enough times
as required to remove compounds from system.
The area around the boiler must be kept clear and
free of combustible
materials, gasoline and other

It is suggested that a qualified service agency be
employed to make an annual inspection of the boiler
and heating system. They are experienced
in making the inspections outlined above and, in the event
repairs or corrections are necessary, can make the

flammable

proper changes

vapors

and liquids.

for safe operation

of the boiler.

1
2

HW-012.02
252-2-2.00

Bolt - 7/16-14x1½
Square Head
Gasket - B Tankless

202-2-1.00

Cowr

4
5

HW-013.01
252-3-1.02

Nut 7/16-14 Square
Tankless Coil L-24

8
1

&Q-020.03

Well ¾ x 1½ - 123870A

275-1-1.00

Harness

&Q-008.00

Control

Plate - B Tankless

- L4006A1827

Coil

8
1
1

BURNER

3
/
/

1
2
3

PF05501
GA-003.00
GA-004.00

Pipe Fit - Nipple ½" x 2" Brass
Gauge Pressure (Steam)
Gauge - Water Level

2
1
1

4
5

PF-025.01
PF-026.05
WC-011.00

Pipe Fit Tee 1/4"
Pipe Fit Nipple ½" x 3"
MLWCO #67-CH-3 24 Volt

1
1
1

275-2-3.01
753-1-3.00
28511301
28511201
SS-001.01

LWCO Assembly Steam*
Siphon 90° Black Iron
Harness ELWCO 24"
Harness Pressure Switch 30"
Pressure Switch PA404A-1009

1
1
1
1
1

1263012
28511801
1263013

Harness Bumer 22" (Beckett & RieIIo)
Harness Aquastat 41" (Carlin)
Burner Hamess 8" (Beckett)

6
7
8
9
10
11

1263011
28511901

Burner Hamess 8" (Riello)
Burner Harness 8" (Carlin)
* This includes MLWCO #2, 4, 5, 7, 8, 9, & 10

,--8
-i0

VR-002.02

Relief Val_ #15 ¾

2
3
4

PF-019.02
PF-005.01
HW06701

Pipe Fit Coupling ¾"
Pipe Fit Npl ¾ Close
Stud 5/16-18 x 2-3/8

1
1
4

5
6
7
8

2252501
HW07001
HW06901
HW-016.02

Support - Jacket Brkt
Stud 5/16" x 18 x 1-3/8"
Nut 5/16"-18 Wislock
Drain

2
3
8
1

PF-004.04
2452906
2452902
2452903
2452907
2452908

Pipe Fit Bushing 1!¼x ¾
Flue Collector - 3 Sec.
Flue Collector - 4 Sec.
Flue Collector - 5 Sec.
Flue Collector - 6 Sec.
Flue Collector - 7 Sec.

!
P

@
10

i
1

!00-5-10.0!

!00-!-8.01

1005110!

Rope, Med. Density - 3 Sec.

#60 Push Nipple - 3 Sec.
#60 Push Nipple - 4 Sec.

2
3

Rope, Med. Density - 4 Sec.
Rope, Med. Density - 5 Sec.

#60 Push Nipple - 5 Sec.

#60 Push Nipple - 6 Sec.
#60 Push Nipple - 7 Sec.
Center Section - 3 Sec.

5
6
1

Center Section - 4 Sec.
Center Section - 5 Sec.

2
3

Center Section - 6 Sec.
Center Section - 7 Sec.

4
5

10022201
10022202

3 Section Without
4 Section Without

Coil
Coil

5 Section Without
6 Section Without

Coil
Coil

7 Section Without

Coil

10
1!

10051202

Front Section Castover

10022203

5611508

Kit -Target Wall & Insulation Blanket

10022207

25511005
HW-025.05
HW-025.01

Insul Blanket !6x24 (6 & 7 Section)
Tie Rod ½ x 9 - 3 Sec.
Tie Rod ½ x !2½ - 4 Sec.

10022208
10022204
10022205

HW-025.02
HW-025.03

Tie Rod ½ x !6½ - 5 Sec.
Tie Rod ½ x 20½ - 6 Sec.

HW-025.09

Tie Rod ½ x 23½ - 7 Sec.

100-1-5.01

..iiii

Rear Section

10022206
10022209
10022210

#22 Push Nipple - 3 Sec.

#22 Push Nipple - 4 Sec.
#22 Push Nipple - 5 Sec.

3
4

#22 Push Nipple - 6 Sec.
#22 Push Nipple - 7 Sec.

5
6

13.0'
19.5'

Rope, Med. Density - 6 Sec.

26.0'
32.5'

HW-008.03

Rope, Med. Density - 7 Sec.
Washer ½ ID Flat

39.0'
3

HW-003.05

Nut ½-13 Hex Head

MS-006.00

3 Section With Tankless Coil
4 Section With Tankless Coil
5 Section With Tankless Coil
6 Section With Tankless Coil
7 Section With Tankless Coil

7
\
\

\
/
1

4
5
6

21522801
21522802
21522803
21522806
21522807
21521501

Top Panel Top Panel Top Panel Top Panel Top Panel Rear Panel

21523101
21523102
21523103
21523104
21523105
21524401
21524301

Right Side Panel - 3
Right Side Panel - 4
Right Side Panel - 5
Right Side Panel - 6
Right Side Panel - 7
Lower Cowl - Right
Lower Cowl - Left

21524101
21521803
21521804
21521805
21521806
21521807

Top Front Panel
Left Side Panel Left Side Panel Left Side Panel Left Side Panel Left Side Panel -

1
Sec.
Sec.
Sec.
Sec.
Sec.

1
1
1

3
4
5
6
7

& Plug

2552901

Mounting

2551901

Door Plug Replacement

2
3

HW-005,01
10011701

Screw t¼-20x½ Self-Tapping
Observation Door

2
1

25511101

Obs, Door Gasket

HW06801

t¼ x 1¾ Drive Lock

6
7

10011501
HW06701

Swing Door
5/16 x 18 x2-3/8 Stud

Insulation

Door Insulation

Sec.
Sec.
Sec.
Sec.
Sec.

2553301

Sec.
Sec.
Sec.
Sec.
Sec,

3
4
5
6
7

1
Pin

2
1
1

- Swing Door (Carlin &
1

2553303

Riello Burners)
Insulation - Swing Door (Beckett
AFG Burners)

10011301

Mounting

Door

iiiiiiiiii,i'iii

; iJ,i;il;il;i;2ii.iiiiiiilil
iii ; ;ii;i!Lii i iiiii`i` `i` ii;ii ii;ii!iii;ii
!i! ii;iii ii;i!
ii;ii iii;iii!iiii;iiiii!ii;iii ii;ii
iii!iiii;ii
iii!ii;ii
i iii!ii
ii;ii ii;ii
iii! iii;iiiii!ii
ii;ii iii!
ii;iii ii;ii
iii!iiii;iiiii!ii;ii
i iii!
i`i
BN04002

Burner Oil UT902 Beckett

(ESB3100)

BN04003

Burner Oil UT903 Beckett
Burner Oil UT904 Beckett
Burner Oil UT906 Beckett

(ESB4125)

BN04004
BN04006
BN08901
30A064202
BN07007
BN08401

(ESB4150)

(ESB5200)
Burner Oil UT1801 Beckett (ESB6225,
ESB7275)
Burner Oil Riello 40/F5 (ESB3100,
ESB4125,
ESB4150)
Burner Oil Riello 40/F10 (ESB5200)
Burner Oil Caflin
Burner Oil Caflin

EZ-1 (ESB3100)

BN08402
BN08403

Burner Oil Caflin

EZ-2 (ESB5200)

BN08001
CD-001.01

Burner Oil Flange

3
4

RY00701

Control

R7184B

Burners

Only)

EZ-1 (ESB4125,
Gasket

Cad Cell (For Boilers

ESB4150)

Burners

Only)

1032 (7456U) (For Boilers

1320004

Nozzle

.85 80B (ESB3100

1320006

Nozzle

1.10 80B (ESB4125

Beckett)

NZ-002.10

Nozzle

1.25 80B (ESB4150

Beckett)

NZ00206

Nozzle

1.75 80B (ESB5200

Beckett)

NZ01201

Nozzle

2.00 45B (ESB6225

Beckett)

14619346

Nozzle

2.25 45B (ESB7275

Beckett)

NZ00802

Nozzle

.85 80W (ESB3100

Riello)

1320012

Nozzle

1.10 60W (ESB4125

Riello)

NZ00804

Nozzle

1.25 60W (ESB4150

Riello)

NZ00206

Nozzle

1.75 80B (ESB5200

1320002

Nozzle

.85 70B (ESB3100

1320010

Nozzle

1.10 70B (ESB4125

Caflin)

NZ00904

Nozzle

1.25 70B (ESB4150

Caflin)

NZ00905

Nozzle

1.75 70B (ESB5200

Caflin)

AFG BURNER

1
1

#3616

w/Beckett

Beckett)

Riello)
Caflin)

PARTS

(Used on all boiler models with Beckett Burners except ESB6225 and ESB7275
_RT_
RP03801

;DE_RI_
Blast Tube AFG

RP03701

Fuel Pump,

2 Stage,

140 PSI, AFG

RP03702

Fuel Pump,

1 Stage,

140 PSI, AFG

3
4

BN07102
BN08001

Drawer Assembly
Burner Gasket

RP-015.00

Motor

RP-019.01

Transformer

BECKETT

CF375

1
2

BURNER

(Oil Line), AFG

PARTS

(Used on n_dels ESB6225 and ESB7275)
PART N_

DES _RI_ i_1'4
Fuel Pump,

Cleancut

RP04501

(21844U)

RP-015.00

Motor,

RP02001

Transformer

RP04601

Oil Burner Valve Coil Kit (21755U)

PSC (21805U)
(51771U)

....

Inspect Chimney and Flue Pipe
Inspect and Clean Appliance

[ X ]
[ X ]

Inspect Oil Line - Size/Leaks
Inspect Electrical Connections
Install New Filter
Room Make-up Air
Electrode Setting

[
[
[
[
[

Proper Light-Off (Hot & Cold)
Controls and Safety Devices
Nozzle-Size, Angle, Type
Pump PressureNacuum

[ X ]
[ X ]
[ * ]
[ * ]

Line Voltage/Motor
Amps
Smoke Test
Draft-Overfire/In
Flue

[
[
[

CO2 or 0 2

[ * ]

Flue Gas Temperature

[

* Measure
below.

with instruments

X
X
X
X
X

]
]
]
]
]

* ]
* ]
* ]
* ]

and record results

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Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 3, 2, 1, 4
Create Date                     : Fri Apr 20 15:54:49 2007
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DUNKIRK Boiler Manual L0612228

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