Kenmore 3ES135 User Manual BOILER Manuals And Guides L0312042

DUNKIRK Boiler Manual L0312042 DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides

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O|L-F|REDCAST |RON STF.AM

BO|
Installation
• Operation
• RepairParts

Theseinstructions
mustbe affixedon or adjacentto theboiler.DUNKIRKBOILERS
DUNKIRK,NEWYORK14048- 716 366-5500
MEMBER: The llydronies Institute

I/2"

NPT

TANKLESS
HEATER

I/2"
NPT
PRESSURETROL
PRESSURE
GAUGE
COMBINATION

2-I/2"
NPT
SUPPLY

iq°p

5/4"

ASNE

POP

SAFETY

VALVE

3/4 _ NPT
_LOW
UMIT
CONTROL ON
COIL PLATE

27"
1-1/2"
RETURN

F ,

WATER

NPT

i-i/2"
NPT
SKIM TAPPING

IJNE

'L
,-V2 ° NPTi
RETURN

LEFT

SIDE

REAR

FRONT

EMPIRE OIL-FIRED STEAM BOILER RATINGS
BOILER MODEL NO.

With
Tankless
Coil
3ESt O0C
3ES1.25C
3ES1.35C
4ES1,50C
4ES1.75C
4ES1.85C

Without
Tankless
Cotl
3ES1 00
3ES1,25
3ES1.35
4ES1,50
4ES1 75
4ES1.85

No.
9ec.

3
3
3
4
4
4

Input
*MBH

140
175
189
2!0
245
259

Nesting
Capacity
*MBH

Net
I=B-R
Rating
"MBH

Not I-S-R
Rating
Sq. Ft,
Radiation

*Tonldelm
Cell
Ratings
GPM*

118
145
156
177
204

89
109
117
133
153

371
454
488
554
638

215

161

671

2.75
3,10
3.25
3.50
3.85
4,00

Typl©al
Chimney
Size and
Height

8"
8"
8"
8'
8"

x
x
x
x
x

8' x
8' x
8' x
8' x
8" x

15'
15'
15'
15'
15'

8" x 8' x 20'

CIMF31SIONS- INCHES
A

16%
16½
16%
20%
20%
20%

7
7
7
8
8
8

9
9
9
11
11
11

* MBH = 1,000 BTU pet 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
Selectionof boilersizeshouldbe basedupon"Net1=8=RRatingbeing
equalto or greaterthanthe sq.ft. of radiationalreadyinstalledin the
building.
TheNet I=B=R Ratingsshownare basedon an allowanceof 1.333in
accordance
withthefactorsshownon the 1=B=RStandardas publishedby
TheHydronicsInstitute.

Theseboilersmusthavea non-combustible
baseif installedon a combustible
floor.Two-inchcladlitepad maybe used.Theseboilersare lowpressure
sectionalcastironboilersconstructed
andhydrostatically
testedfora maximum
workingpressureof 15psiin accordance
with A.SME. (AmericanSocietyof
MechanicalEngineers)SectionIVStandardsfor castironheatingboilers.They
are capacityratedin accordancewiththecodeof the1=B=R(Hydronics
Institute).

Rulesfor Safe Installationand Operation

1. Readthe Owner'sManualfor SafeOperationcarefully.Failureto follow
the rulesfor safeoperationandtheinstructions
cancausea malfunction
of
the boiler and result in death, _rious bodily injury, and/or property
damage.

5. Be certain oil burnernozzleis size required.Overfiringwill result in
earlyfailureofthe boilersections.Thiswill causedangerousoperation.

2. Checkyour localcodes and utilityrequirementsbeforeinstallation.The
installationmustbe in accordancewiththeirdirectives,or followNFPA31
- Installation
of Oil BurningEquipment,
latestrevision.

7. Be surethereis adequateair supplyfor completecombustion.

3. Beforeservicing,allowboilerto cool.Nwaysshut offanyelectricityand
oil to boilerwhenworkingon it. Thiswill preventanyelectricalshocksor
burns.

6. Never vent this boiler into an enclosedspace.Alwaysvent to the
outside.Nevervent to anotherroomor insidea building.

8. Followa regutarserviceand maintenance
scheduleforefficientand
safeoperation.
9. Keepboilerareacleanandfreeof combustiblematerial,gasolineand
otherflammablevaporsand liquids.

4. Inspectoil lineandconnectionsforleaks.

This boiler has been designed for residential installations. If used for commercial
applications,all jurisdictionalrequirementsmust be met. This may requirewiringandlor
piping modifications.The manufactureris not responsiblefor any changesto the original
design.

BeforeYou Start

Check to be sure you have the dght size boiler before starting the
installation.See ratingand capacitytableon precedingpage.Checkthe
ratingplateon the boiler.
You must see that the boiler is suppliedwith the properoil, fresh air for
combustion,and a suitable electricalsupply.Also, the boiler must be
connectedto a suitableventingsystemand an adequatepiping system.
Finally,a thermostat,properlylocated,is neededfor controlof the heating
system.If you haveany doubtsas to the variousrequirements,
checkwith
local authorities and obtain professional help where needed. THE
OPERATING INSTRUCTIONS and THE FINAL CHECKS AND
ADJUSTMENTS
are vital to the properand safe operationof the heating
system.Takethetimeto be suretheyare all done.

Thefollowingstepsareall necessaryfor properinstallationandsafe
operationof yourboiler.
1.

LOCATINGTHE BOILER

OILSUPPLYAND PIPING

FRESHAIR FORCOMBUSTION

PIPINGCONNECTIONS

CHIMNEY& VENTPIPECONNECTIONS

ELECTRICALWIRING

THERMOSTATLOCATION

CHECKING&ADJUSTING

MAINTENANCE

Locatingthe Boiler

If your boiler is partof a plannedheatingsystem,locateit as nearlyas
possiblewhereshownon yourplan. If boiler is to be part of an existing
system,it is usuallybest to put it wherethe old one was. If you plan to
changelocation,youwill needadditionalmaterialsas wellas an adequate
base.Thefollowingrulesapply:
1. The boilermustbe leveland locatednearpiping.
2. Usea raisedbaseif f]oorcanbecomewet or damp.
3. Thevent pipeconnectionshouldbe as shortaspossible.
4. Maintainclearancesforfiresafetyas wellasservicing.SeeFigure2 for
minimumclearances.18"clearancemustbe maintainedat a sidewhere
passageis requiredfor accessto anothersidefor cleaning,servicing,
inspection,or replacementof anypartsthat normallymay requiresuch
attention.Boilersmustbe installedat least6" fromcombustiblematerial
on all sidesand above.Allowat least24"front clearancefor servicing.
Allowat least18"left sideclearancefor servicingboilersequippedwith
a tanklesscoil.
5. FRESHAIRfor combustionmustbe availableatthefrontof theboiler.
FRESHAIRfor ventilationmustbe availableto thefrontANDrearof

6. The floor suppo_ng the boiler must be non-combustible.
If it is
combustible,placethe boileron 2" cladlitepad.The pad mustbe under
theentireboilerto protectthefloor.
7. Besureinstallation
is in accordancewiththe requirements
ofthe local
authoritieshavingjurisdiction.Compliance
withtheseregulationsis
required.In theabsenceof localcodes,followNFPA31 - Insbtlationof
OilBurningEquipment.

the boiler.Air passagesmustbefreeofobstructions
at alltimes.
Ventilatingandcombustion
air mustenterboilerroomwithout
restrictions.

6" MIN.

•

I_//

I-----2,

18" WITH COIL

I BOILER

_" 6" MIN.

.,.. ------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 air for 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.Thesedeviceswill robthe boiler
andwaterheaterof combustionair.

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 must enter the house to replace that used by the burner. Study
foIIowing exampIes 1 and 2 to determine your fresh air requirements.
EXAMPLE 1: Boiler Located in Unconfined Space
If your boiler is in an open area (unpartitioned basement) in a 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 caulk the cracks around the windows.
An unconfined space is defined as a space whose volume is not lessthan 50

3. Whencommunicating
with the outdoorsthroughhorizontalducts,each
openingshall havea minimumfree area of one squareinch per
2,000 Btu per hour of total input ratingof all equipmentin the
enclosure.
4. Whenductsare used,they shallbe of the samecross-sectional
area
as the freeareaof the openingstowhichtheyconnect.Theminimum
dimensionof rectangularair ductsshal{be notlessthanthreeinches.

cubic feet per 1,000 Btu 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 sufficient volume 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

VENTILATING
GRII.LE

-'_--i
I

,11

considered in making this determination. Each opening shall have a
minimum free area of one square inch per 1,000 Btu per hour of the total
AIR GRILLE
_
input rating of all combustionequipment in the confinedspace, but not less
than 100 square inches. One opening shall be within 12 inches of the top
and one within 12 inchesof the bottom of the enclosure. See Figure 4.
Example: Your boiler is rated at 100,000 Btu per hour. The water heater
Fresh Air Duct Capacities for Ducts Supplying Fresh Air to
is rated at 30,000 Btu per hour. The total is 130,000 Btu per hour. You boiler in tightly constructed houses. British Thermal Units per
need two grilles, each with 130 square inchesof FREE opening. Metal hour Input (Btuh)*.
grilles have about 60% FREE area. To find the Iouveredarea needed,
Fresh Air
1/4"Mesh
Wood
Metal
multiply the FREE area required by 1.7 (130 x 1.7 = 221.0 sq. in.
Duct Size
Screen Btuh
Louvers Stuh
Louvers Btuh
Iouvered area). In thisexample two grilles, each having an 8" x 30" (240
31/2" x 12"
144,000
36,000
108,000
sq. in,) Iouvered area would be used. Fig. 4 shows the grille locations.
8 * x 8"
256,000
64,000
!92,000
B. All Air from Outdoors: The confined space shall be provided with two
8" x 12"
384,000
96,000
288,000
permanent openings, one commencing within 12 inches of the top and
8" x 16"
512,0O0
128,000
384,000
one commencing within 12 inches of the bottom of the enclosure. The
*Based
on
opening
covered
by
IA"
mesh
screen,
wood
louvers,
or
mela{
louvers
openings shall communicate directly, or by ducts, with the outdoors or
spaces (crawl or attic)thatfreely communicatewith the outdoors.
1. When directly communicatingwith the outdoors, each opening shall have
a minimum free area of one square inchper 4,000 Btu per hour of total
input rating of all equipment in the enclosure.
2. When communicatingwith the outdoors through ve_cal ducts, each
opening shall have a minimum free area of one square inch per 4,000
Btu per hour of total input rating of all equipmentin the enclosure.

FRESH

Boilers With Tankless Heater Coil

Boilersmaybefactorypackagedwith a tanklessheatercoil.Theuseof this
coileliminatesthe needfor a hot waterstoragetank.Instantaneous
heatingof
water in the coil will providea flow of hotwaterfor domesticuse - if proper
watersupplylinecontrolsare used.
IMPORTANT
Do not usea tanklesscoil if yourwateris excessivelyhardwith limeor
otherdepositswhichwillaccumulateinsidethecoil.

Forsummerrunningwithcoilyou needto fill boilerwith waterand addthe
L6006limitcontrolto the coil.This will maintainwatertemperaturein the
boilerand bringthe burneron whennecessary.
TANKLESSCOlL PIPING
Pipingis shownin Figure7B.A temperingvalve(mixingvalve) is
recommended.

_NT_pERE_

_OT WATER

LowLimit(whenused)- 140° F
Thesesettingscan be changedafteryou havesomeideahowthe system
responds.If moredomestichotwater is required,the low limitsettingcan
alsobe raised.

¢OL_ WATE_ _N_ET

WLV_

Installation-SystemPiping
Thenearboilerpiping,that is the pipingaroundthe boiler,mustbe considered
as partof the boilerfor properwaterlevelcontrol,andto producedrysteam.
Correctnearboilerpipingis crucialto the properoperationofthe boilerand
theheatingsystem.Followtheserecommendations
carefully.
1.Placeboilerin theselectedlocation,as nearchimneyaspossible.
2. Installthe pop safetyvalve,usingthe furnished3/a" 90" ell,intothe 3/4"
pipenippleon thebackof theboiler.Makea dischargepipe,using3/4"pipe
(not furnished)to carry the water or steamto a nearbydrain. Do not
connectthe dischargepipe directlyto a drain but leave an air gap. No
shutoffof any descriptionshallbeplacedbetweenthe popsafetyvalveand
the boiler,or ondischargepipes

betweensuchsafetyvalvesandthe atmosphere.Installationof thepop
safetyvalveshallconformto therequirements
of theANSI/ASMEBoiler
and Pressure Vessel Code, Section IV The manufactureris not
responsibleforanywaterdamage.
3. This boiler is equippedwith two 21/2" supplyconnectionson top and
two 1V2"returnconnections,one eachon frontand backsidesof the
boiler.Unusedconnectionsmust
4. Recommendednear boilerpipingfor gravityreturnsys-temsis shown
in Figure8. This configurationusesone supplyand onereturntapping.
Pipingoff bothboilertap-pingsis recommended
on units5 sectionand
larger.
Note:Usebothsupplytappingson boilers5 sectionandlarger.

PtPES_E

5. Forinstailerschoosingto usebothsupplytappings,Figure8A showsthe
correctwayto pipethis system.Figure8B showsthewrongwayto pipe
a headerwith tworisers.
, Headersmust be fitted with header offsetsor swingjoints, or be
equippedwith expansionjoints, so that thermal expansionand
contractionof the headerwill nat damagethe boiler.Headersshall
netbe welded.
, Systemtakeoffsfromthe headermustbe betweenthe equalizerand
theriserto the headernearesttheequalizer.Systemtakeoffs
must
neverbe betweentwo risers.

All boilersin gravityreturnsystemsmustbeequippedwitha Hartford
Loopasshownin Figures8 and 8A.

Whenpipingtheverticalrisersfromtheboilerto theheader,the bottom
of the headermustbe a minimumof 24 inchesabovethewater level
lineanthe rightsideofthe boiler(i.e.51 inchesabovethefloor).

Steamriser(s)andheadershallbe 272"pipe size.

10. Equalizerline shailbe minimum1 1/2"pipesize.
11. The boilerhasa 1V2"tappingin rearsecflanfarskimming.

6.Systemtakeoffsfromtheheadermustneverbe bull-headed.
Ifthesteam
maingoesin twodirections,theremustbe twotakeoffsfromtheheader,
onefor eachmain.

_EA_{ MAINS

MAIN VENT
D_Y RETURN
M_[N

HART_ORO

CLOSE
N|PPLE

THIS,

PIPING

COMMON

INCORRECT

SHOW

MISTAKES

L
©

12. The near boiler piping shall includea 1 1/2" ball valve in the return
pipingas shownin Figure8A far bottomblowdawnanddraining.
13. Forgravityreturnsystems,thebottomof theloweststeamcarrying
pipe,be ita dryreturn,or theend ofthesteammain,mustbe at least
28"abovethenormalwaterlevellinean thedghtsideof theboiler.
This is knownas "DimensionA."
14. Forpumpedreturnsystems,followthecondensatepumpor bailerfeed
pumpmanufacturer's
instructions
for properinstallation
and hookup.
15. Inconnectingthecoldwarer supplyto thewaterinletvalve,makesure
that a deanwatersupplyis available.Whenthewatersupplyis froma
wellor pump,a sandstrainershouldbe installedatthe pump.
FOR USEWITH COOLINGUNITS
A.

This boiler, when used in connection with chilled water systems, must
be installed so that the chilled water is piped in parallel with the heating
boiler. Appropriate valves must be used to prevent the chilled water
from entering the heating boiler (Fig. g).

B. Whenthis boileris connectedto heatingcoilslocatedin air handlingunit.,
where they may be exposedto refrigeratedair circulation,the piping
systemshall be equippedwith flow controlvalves or other automatic
meansto preventgravitycirculationof the boilerwater duringthe coolinc
cycle.

'_rd,.vE8 A & m

VALVES C & Q
_R

_OUNG

Chimneyand ChimneyConnection

CHECKYOURCHIMNEY
Followlocalcodes.In the absenceof localcodes,followANSI/NFPA31
Installation
of OilBurningEquipment,
latestedition.
This is a very importantpartof yourheatingsystem.Noboiler,however
efficientits design,canperformsatisfactorily
if thechimneythatservesit is
inadequate.Checkyourchimneyto makecertainthat it isthe rightsize,
properlyconstructedand in soundcondition.
It is cheaperto rebuilda poorchimneythanto payexcessivefuelbills.If
yoursis an old masonrychimney,a newsteellineror a new
prefabricated
chimneymaybe thebestsolution.Thefollowingchartshows
recommended
minimumchimneysizesbasedon Table3 and Figure6 of
the I:B:R Testing and RatingStandardfor 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.

FIECOMMENDED MtNiMUM _IMNEY
_l_

CHFM_ I

_ER_
_!NNqY'

.60- i 30
13Iol 80

15
15

i,81o2,00

i_DE

SIZES
LNER;

=!:

8"×8 '

6:5_x 6_'

8' x 8"

, 6_f;_"× 6_!4"

[:<]re#_@:(Y)88_ee 2,#_ if,,8J3_es_ _i,
[_!et la Fiqure 1@t

ALTERNATE

POSITIONS
TOP

ad_ 3 feetIo cblm_qeY
he_gP4_

Foradditionalchimneydesignandsizinginformation,consulttheASHRAE
1996HVACSystemsand ApplicationsHand-book,Chapter30,Chimney,
GasVentand FireplaceSystems;or theNationalStandardfor Chimneys,
Fireplaces,Ventsand SolidFuelBurningAppliances,ANSI/NFPA211.
CHIMNEYCONNECTORANDDRAFTREGULATOR
Your boiler requires7" diameterchimneyconnectorpipe on 3 section,8"
diameterchimneyconnectorpipe on 4 section.You mustalso use a dralt
regulatorpackedwith boiler.Properlyinstalled,the regulatorwill controlthe
draftautomatically.
It is betterto installit in a horizontalsectionofthe pipe;but
it maybe in an angledor verticalsection.Justmakecertainthatthe"top"is at
top- andthattheshortpipesectionwhichholdsthe Vaneis horizontal.Install
it ascloseaspracticable
to theboiler.
To installthechimneyconnector,startatthe boilerandpreferablytakeoff
fromthefluecollectorcollarwithan elbow- theninstallthedraftregulator
next,makingit horizontal.
Whentheregulatoris in place,startatthe chimney
andwork backto theregulator.Jointhetwo sectionswith a Drawband.The
horizontalpipemustslopeup towardthe chimneyat least1/4inchperfoot.It
mustnotleakandmustbe firmlysupported.
Joinsectionswithat leasttwo
sheet-metalscrews.Supporteverysecondsectionwitha stovepipewire.

_,TIGHT.
SMOOTH,
CORRECTLY
SIZED.

I
I
t
I

1
MUSTSLOPEUP
AT LEAST
1/
PER FOOT OF
HORIZONTALRUN
DRAWBAND
LAST PIECE
INSTALLED

&LEDIN
THIMBLE

TIGHT
DOOR

DRAFT
VANE

REGULATOR

MINIMUMVENTPIPECLEARANCE
Woodandothercombustiblematerialsmustnotbe closerthan18"fromany
surfaceofthevent pipe.

BALANCEDWEIGHT

Equipment
andOptional
Accessories
-What
They
Do

POPSAFETYVALVE
Youmusthavea popsafetyvalveon yourboiler.Steamexpandsas it is heated.
Ifthereisno placeforthe steamto expandinto,pressurewillbuildup insidethe
boilerand system.Shouldthis happen,the popsafetyvalvewillautomatically
openat a pre-determined
pressure.Thiswill relievethestrainon theboilerand
system.Runa pipefromthesafetyvalveoutlet(pipemustbe samesizeasoutlet
andtheopenend mustnot bethreaded)to an opendrain,tub or sink,or other
suitabledrainagepointnotsubjecttofreezing.Failureto do somaycausewater
damageor injuryshouldreliefvalve release.Do notcapoff thedrainlinefrom
this valve!Eachpop safetyvalveis providedwitha liftingdevicefortestingand
shouldbe testedmonthlyduringthe heatingseason.Referto safetyvalve
manufacturer's
instructions
packagedwithsafetyvalve.
STEAMPRESSUREGAUGE
Everysystemshouldhavea pressuregaugeinstalledin the boiler.Thisgauge
enablesyouto monitorthe pressurein thesystem.If thesafetydevicesfailto shut
off yourboileratthepropersettings,notifyyourservicetechnicianimmediately
WATERLEVELGAUGE
Thewaterlevelin theboilercanbeseenthroughtheglasstubein thewater
levelgaugeatsideof boiler.Correctcoldboilerwaterlevelis stampedon side
jacketpanel.Whenmakingsteam,thewaterlevelwilldroponeto threeinches.
Thewaterlevelshouldbe checkedregularly.
STEAMPRESSURECONTROL
Thesteampressurelimitcontrol(pressuretrol)
shutsofftheoil to theburnerifthe
steampressurein theboilerreachesthecut-offsetpoint(i.e.thesumofthecut-in
andthedifferentialsetpoints).Burnerretireswhenthe steampressuredropsto
thecut-insetpoint.Systempressurerequirements
arebasedon thesize and
conditionof thepipes,andtheload.
Forgood systemoperation,the cut-insettingof the pressuretrol
shouldnever
be less than twice the system pressuredrop. In a typical singlefamily
residencewith a cleanone pipe heatingsystemand castiron radiation,this
meansthatthecut-inwillusuallybeset attheminimumsetting,i.e._/2psi.
Steam radiationis usuallysized based on squarefeet of equivalentdirect
radiation(EDR).Thisis basedon a steampressurein the radiatorofjust less
than 1 psi. Therefore,in our examplesystemfrom above,we would set the
differentialadjustmentat 1 psi, i.e.thesteampressurerequiredin the radiators.
This willgiveusa cut-offsetpointd 1_12 psi.
The aboveis an exampleof a typicalone pipe system.Forlargersystemsor
othertypesof systemssuchas two pipesystems,or systemswith convectors
or fan coil units,the pressuretrolsettingswill needto be determinedon a
system-by-system
basis.
The cut-insetpointis determinedbythe systempressuredrop to the furthest
radiatoror terminalunit. Doublethe systempressuredropas a safetyfactor,
resultingin the rulethat the cut-insettingshouldneverbe lessthantwicethe
systempressuredrop.
Thedifferentialset#ointis thesteampressurerequiredat theterminalheating
units.

67D-t LOWWATERCUT-OFF
Thefloat-typelowwatercut-offshutsoff theburnerwhenthewaterlevelis
belowa safe point.Theburnerwillstartwhenthewateris refilledto a
minimumsafelevel.
WATERFEEDER(Optional)
A waterfeederworkswiththe lowwatercut-off(LWCO)to maintaina
minimumsafelevelofwaterforboileroperation.It'susedto keepthe boiler
runningby compensating
for minorevaporativesteamleaks,andto prevent
freeze-upsif thehomeownersare awayanda returnline shouldspringa
leak,The automaticwaterfeederis a safetydevice,not a
convenienceitem. Itis notdesignedto maintaina "normal"waterline.The
waterfeederdoesnottake theplaceof a responsiblepersonmonitoringand
maintainingthe"normal"waterline.Steamboilersrequirepersonal
attention.
Four electric water feeders are offered by McDonnell-Millerwhichare
compatiblewith the 67D-1 LWCO.The model#101A and #WF2-U-120
waterfeedersareusedwith 120volt wiringcircuits,asfoundan this steam
boiler.The McDonnell-Millermodel#101A-24and #WF2-U-24are used
with 24 volt circuits,which may be useful in a retrofitinstallationwhich
alreadyhasa 120voltto 24 volttransformer.
The WF2-U-120and WF2-U-24(Uni-Match)waterfeedersare equipped
with a solidstateelectroniccontrolwhichfeedswaterwhensignaledbythe
LWCO.The water feed rate is field adaptablefar 1, 2, or 4 gpm. These
water feedershave an adjustableslideswitchto matchthe timingcyclean
the LWCO.Whenusinga McDonnell-Miller
LWCOthe slideswitchneeds
to selectposition#1.The timingcyclecreatesan initialdwellperiodof one
minuteto allowcondensateto be returnedto the boiler.If afterthe dwell
periodthewaterhasnat reachedthe minimumsafeleveland completedthe
LWCOcircuit,thenwateris fedat theselectedflowratefarone minute.The
dwellpedodis theninitiatedagainfar oneminute.If thewaterlevelhasstill
not reachedthe minimumsafe level,then water is addedagain at the
selectedflow ratefor one minute.This cyclecontinuesuntilwaterreaches
the minimumsafe level and the circuitis completed.DunkirkRadiator
recommendsusinga Uni-Matchwaterfeederata flawrateof 1 or 2 gpm.If
the steamboiler requireshigherflow rates on a regularbasis a service
technicianshouldbe notified.
The 1OlA water feedermay be used,howeverthe waterfeed rate is too
high and needsto be regulatedor throttled.The IO1Awillfeed up to 6
gpm, muchgreaterthanthe desiredflow rate of 1-2 gpm.Also,thereis no
dwell periodto providea marginfor condensateto returnto the boiler.
Thesetwo factorsincreasethechancesof overfeedingwaterto the steam
boiler.Excessivewaterin thesteamboilerwillproducenoise
Consultthe water feeder manufacturer'sinstallationguidelinesfor more
detailson waterfeederselection,recommended
pipingarrangement,and
start up procedures. Dunkirk Radiator supports McDonnell-Miller's
recommendation
to arrangethe installedpipingso a brokenuniontest can
be implemented.

DRAINVALVE
Now your boiler will operatein the correctpressurerange.It will maintain
Thismanualvalveprovidesa meansof drainingall waterfrom theboilerand
enoughsteampressureto sendthe steamoutto the furthestradiator,and not
system.It shouldbe installedin the3/a"teewherethewatersupplyline
go overtheoptimumsteampressurethat isrequiredat theradiators.
enterstheboiler(Fig.8).You canalsousethis valveto lowerthewaterlevel
ifit istoo high.

STEAMVENTS
Beforea steamsystemwill operateproperly,suitablesteamventsmustbe
installedin eachradiatoras wellas the returnmain.Somesystemsrequire
steamtrapsin thereturnlineat theradiationunit.
The"Hartfordloop"is a pipingarrangementwhichmustbeincluded(Fig.8)
for properoperationofthesteamsystem.
BOILERSWITH TANKLESSCOILSONLY FlowRegulatorand Water
TemperingValve
If youhavea TanklessCoilfordomestichotwater,thesetwo partscanbe
used.Thiswill provideyouinstantaneous
hotwaterthat is neither

scaldinghotnormerelytepid.The FlowRegulatoris placedin thecoldwater
line to thecoil. It assuresa steadyflow of watersothat the coilcanproperly
heatit. It prevents"spurts"of "half-heated"
water.Thisisimportantwherethe
waterpressureis excessivelyhighor variable.TheWaterTemperingValve
is a tee whichis connectedat a junctionbetweenthe hotwaterlinefrom the
coiland a coldwaterbranchfromthesupplyline.It mixeshotandcoldwater
as requiredto furnisha temperedsupplyof waterto the house.The water
will be just the righttemperaturefor youruse. This is importanton a steam
systemto preventscaldingtemperaturesat the faucets.Bothpartsare selfcontainedandautomatic.

Starting Your Boiler
HOWA STEAMSYSTEMOPERATES
The waterin theboileris heateduntilit reachesthe boilingpoint.As the
waterboilsit turnsintosteam.Thesteamrisesfromthe top of the water
throughthe supplymainto the radiationunits.As it passesthroughthe
radiatorsit releasesits heatand condensesintowater.Thewaterreturns
to the boilerthroughthe returnmain.
FILLINGSYSTEMWITH WATER
On steamheatingsystemsthe boileris partiallyfilledwithwater.It is very
importantto the properoperationof theentiresystemthat yourboilerbe
filledto the properlevel.Thecorrectwaterlevelon coldstartconditionis
about halfwayup the glasswater levelgauge as markedon the boiler
jacket.Tofill:
1. Closethe boilerdrain valve.
2. Openthevalvesat thetopand bottomoftheglasswaterlevelgauge.
Alsoopenthedrainvalveatthe bottomofthegauge.
3. OpenthefilI valveandatlowwaterto run intotheboiler.
WARNING- Neverrunwater intoa hotemptyboiler,
4. Allowboilertofill untilwater runsoutthe gaugedrainvalve.Then
closethegaugedrainvalve.
5. Continuetofill boileruntilwaterreachestheindicatedwaterline.This

isabouthalfwayup theglasstube.Alwayskeepthewaterat thislevel
whensystemisoff.
IMPORTANT
Skimminga newsteamboileron an existingsystemmustbe doneseveral
timesto removeall oil,greaseand sediment.Thereshouldbe a teewith a
plug pipedto thesupplylineof theboilerin orderto properlyskimthe boiler.
Wheneverthe water in the glass gaugebecomesdiscolored,your boiler
shouldbeskimmed.
Whenskimming,makesureto pipethe openend of thetee to theflooror a
drain to preventanyonefrom being burnedby the steamand hot water
whichwillbe released.
TheFloatLowWaterCut-offshouldbe blowndownafterskimming.Following
blowdown,allowthe boilerto coolandthenaddfreshwaterslowly.
Thefloat chamberof the lowwatercut-offmustbe flushedcleanand maintained
clear of sedimentto allowfree movementof the float. This must be done
frequentlyduring initial operationof the boiler and at least once per week
thereafter.Followinstructionson tag attachedto control.Neverthrottlea steam
radiator valve on a one-pipesystem.It must be fully open or fully closed.
Otherwisewateris heldin theradiatorunits.This willcauseknockingsounds.
Skimmingmaybe requiredagainaftera few daysoperation.

Checking and Adjusting

CHECKINGCONTROLS

OIL BURNERADJUSTMENT

To checkthe Low Water Cut-Off,turnoff powerto the boileror turn the
thermostatdown to the lowestsetting.Drainwater to belowthe visible
bottomof thewatergaugeglass.Turnpoweron andturnthe thermostatto
call for heat.Whenthe boileris equippedwiththe floattype LWCO,the oil
burnershouldnotrun on a callfor heatwhenthe waterislow.

Suggestednozzlesand preliminaryburnersettingsare foundon page20.
Refer to your oil burner ownersmanualfor checkingand adjustingthe
burner.
ADJUSTOPERATINGCONTROLSInstructions
for eachcontroland
burnerare included.

To check the pressurelimit, run the boiler until the pressurereaches
system demand.Then turn the pressurescrew and drop the pressure
settinguntilthe boilershutsdown.This will showthat the pressurelimit is
operatingproperly.

Betthermostat
heatanticipator
at .20.Instrucfions
forthefinaladjustment
of
thethermostatarepackagedwiththethermostat.

If you haveinstalledyourown boiler,we recommendthat youcall for an
inspectionby a service technician.The peace of mind and assured
performanceare well worth the cost involved.He can quicklymake the
necessarychecksandadjustments.

When set abovetemperatureindicatedon the thermometer,boilerburner
should start. Make certainthe thermostatturns off the boilerwhenroom

CHECKTHERMOSTAT
OPERATION

temperaturereachesthe selectedsettingand startsthe boiler operating
whenroomtemperature
falls a few degrees.
Finally,set thethermostat
for thedesiredtemperature.Specialconditionsin
yourhomeandthe locationofthethermostat
willgovernthissetting.

MaintainingYour Boiler

It is causedby anycombinationofthefollowing:
1. Threadingoil andorganicmatterin the boilerwater.(Mineraloil, or core
sanddoesnotcausesurging.)
2. Faultyquickventsthat do not releaseair untila sizeablepressureis built
up - replace.If dirty,cleansothat youcan easilyblowthroughvalve.
3. Improper header design - whensteam flows in oppositedirectionof
Thisvalveshouldopenautomatically
whenthe steampressureexceedsthe
equalizerline on "Hartfordloop."Generallya 15"horizontalrun between
safe limit (per instructionspackagedwith valve).Shouldit everfail to open
riser and maintakeoffwill allowentrainedwater to falloutof thesteam
under these conditions,shut downyour system.Havethe valve replaced
vaporso it can returnto boiler.(Seepage7, Fig. 8)
immediately,The pop safety valve shouldbe tested monthlyduring the
4. Adjustmentof steamlimitcontrolto a wide differential
increasesdifficultyif
heatingseason.Referto thevalvemanufacturefls
instructionspackagedwith
quickventsare old style,slow-releasing
type or dirty.Alwaysset steam
thepop safetyvalve.
LOWWATERCUT-OFF
limitcontroldifferential
as lowas possible.
The LowWater Cut-offwillin_rrupttheelectricalcurrentto theburnerwhen 5. Soapand detergentscauseextremesurging- cleanthoroughlyby
skimmingtheboiler.
the waterline in the boilerdropsto a low level.It is very importantto keep
CAUTION
the floatchamberfreefrom sediment,a conditionessentialto dependability.
Neverrefilla hotboilerwith coldwater- thedangerof thermalshockmay
To keep any accumulationfrom interferingwith float actionis to "BLOW
cracka section.
DOWN"or flushoutthe controlregularly.This mustbe donetwo-threetimes
CAUTION
thefirstweekafterinstallationandoncea weekthereafterduringthe heating
Never allowelectricianor oil burnermechanicsto try out theirwork by
season.Doit whiletheboileris in operation.Firstnotewater levelin gauge
turningon oil burnerfor evenone secondunlessboiler is filledto the
glass.Openblow-offvalve at bottomof control,waterwill pourout, flushing
properoperatinglevel.
away sediment.Drainuntilwateris clear, abouta pail,thenclose valve.If
SYSTEMCHECKSAFTERFIRSTSTARTING- STEAMSYSTEMS
waterlevelin gaugeglass hasdropped,addwaterto boilerto restorelevel.
Consultlow water cut-off manufacturersinstructionsincludedwith boiler. Read the instructionspackagedwithyour controlsand make checks and
NOTE: Openingblow-offvalve checkscut-offoperationtoo. As floatdrops adjustmentsaccordingly.Start the burner and set the Thermostatfor the
withfallingwaterlevel,burnerswill shutoff.Aftervalveis closedand normal desiredroomtemperature.WhenadjustingtheSteamPressurecontrol,watch
the steamPressureGaugeand use its pressurereading- as itwill be more
operatingconditionsare restored,burnerswillresumefiring.
accuratethanthe control.(Anydifferencebetweenthe twowillbe duetotheir
Boilersshouldnot be drained betweenheatingseasons.Onlywhen the
differentlocation.)
waterin the systembecomesdirty shouldthe boilerbe drained,flushedor
boiledout, and refilled.Steamboilersmaybe entirelyfilledwithwaterduring BOILERWATERTREATMENT
thesummermonthsto excludeair.
In closedhotwaterheatingsystems,negligibleamountsof makeup waterare
CLEANINGYOURBOILER
used, and water treatmentis not required.In steam systemswhere the
systemistight,freefromleaks,andall the steamis returnedto the boileras
Undernormaloperatingconditions,with the burnersproperlyadjusted,we
condensate,theamountof makeup wateris small.Again,watertreatmentis
recommendthat you have the flue passages, burner adjustment,and
operationof the controls checked once each year by a Service notrequired.
Technician.
On steam systemswith less than 90% of the steam being returnedas
condensate,or with very hardor corrosivemakeup water,treatmentmaybe
Before the start of each season (or wheneversystemhas been
of the ASME(AmericanSocietyof
shutdownfor sometime)recheckthe wholesystemfor leaks...and recheck desirable.Followthe recommen-dations
MechanicalEngineers)Boilerand PressureVesselCode,SectionVl, latest
the boilerandvent pipefor leaks.Replaceor patchany boilersealsthat are
version.
faulty.
BETWEENHEATINGSEASONS
BOILERFLUEPASSAGES
Flue Passagesbetweensectionsshouldbe examinedyearlyand cleaned. Boilersshouldnot be drainedbetweenheatingseasons.Boilersin closedhot
waterheatingsystemsmaybe leftas is. Steamboilersshouldbe entirelyfilled
Removevent pipe.Raisetop panelof boilerand swing outto exposeflue
collector.Removefluecollectortop. Cleanpassagewaysbetweensections withwaterduringthesummermonthsto excludeair.
with a flexible handlewire brush.Removedirt fom the bottomof the boiler
Checkthe water level every day or two.Verify the water tine shown by
operatingthe drain valvean the gauge.Be sure top and bottom valves
on gaugeare alwaysopen so that actual water levelwill be shown
at all times,
POPSAFETYVALVE

and reassembleall parts.Be sure vent pipe connectionsto chimneyare
secureandno obstructionsarepresent.
FOAMING,PRIMINGORSURGING
Thesetermsareusedto describea fluctuatingwaterline- whenwater
leavestheboiler.

Oil Boiler/BurnerCleaningInstructions

1. Shutoff alIelectricaIpowertotheboiler/burnerandshut offfuel supply.
2. Removethe sheetmetalsmokepipefrom thetop d the boiler.Inspect
pipe and chimneyfor signs of corrosionand deterioration.Cleanbase
ofchimney.
3. Removetopjacketpanel.
4. Removethe two brasswingnutsholdingtheflueccllectorfop.
5. Checkthegasketon the undersideof thefluecollectorandreplaceas
necessary.

oooooooooooo
ooooooo

%%%°°%%°2°
°j°o°2o%%%°2o°Co°2o

6. Removethe oil burner(threecapscrews).-ORRemovethe oil burner/firedoor assembly(fourhex nuts).This is the
recommendedmethod,as it allows full access to the combustion
chamberandlesspotentialdamageto thetargetwallduringthecleaning
process.
7. Removethe burnerdrawerassembly.Cleanany sootaccumulations.
8. Replacetheburnernozzlewiththe exactsizeandtype recommended
for us onthis boiler.

°°°°%02°%°o%%°°°0%%°Oo°

Note:Changingto a differentfiringrate,otherthanis recommended,
or type
of nozzle may changethe performanceof this boiler and/orcausea
hazardouscondition.
9. Cleanelectrodeassemblyandset electrodesasper burner
manufacturers
recommendations.
10. Reinstalldrawerassemblyand checkfor properheadlocationas per
the manufacturer's
recommendations.

14.

Reinstalltheburner/firedoorassembly.

11. Inspectthetargetwail,blanket,andfiredoorinsulationforcrackingand
deterioration.
If thereis anysignsof crackingor deterioration,
replace
beforereassembling
the boiler.
12. Removesootfrom firesidesurfacesby brushingdiagonallythroughthe
flue passages(see drawing).Care should be taken so as not to
damagethetargetwallwith thefluebrush.
13. Carefullyvacuumsootaccumulations
fromthecombustionchamber
area,beingparticularlycarefulnottodamagethetargetwailandblanket
with thevacuum.Targetwalland blanketmustbein goodconditionand
correctlyinstalledto insurepropercombustion.

15.

Reinstallthefluecollectortopandsecurewiththetwobrasswingnuts.

16. ReinstalIthetopjacketpanel.Reconnect
thefluepipe.
17. Inspectand cleantheoil burnerblowerwheel.
18. Oilthe burnermotor(DONOTOVEROIL}.
19. Removethe oil pumpcoverandclean/replacethepumpscreen.Carefully
reassemble.
20.Replacethefuelfilter (ifapplicable).
21.Reconnectthe electricalandfuelsupplies.
22. Fire the burner,checkingfor proper combustionusingcombustiontest
equipment,makingadjustments
as necessary.
23. Insurethatall safetycontrolsandoperatingcontrolsarefunctioning
properly.

IMPORTANTOPERATINGANDMAINTENANCE
REQUIREMENTS
KEEPYOURBOILERANDTHE AREAAROUNDIT
CLEANNEVERBURNREFUSEORANY MATERIALOTHERTHANTHE SPECIFIEDFUELIN YOURBOILERHAVEYOUR
BOILERCHECKEDEACHYEARBYA QUALIFIEDTECHNICIAN

me_javowalir_o_nven_

and servi_ calls _ ch_

these potn(s _m

c_l for _r_ce.

What: to
Reset themsostat above room tem_raIu

Cean all flue passages and _'he'_nt pipe,
Nave burner c_ea_d and read ueted,
Bu _ler may not _ iitng at proper
re[@

C_eek _e_f_e size if there is _y doubt,
Have burner adjusted

Burner may be shortocyct ag,

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_

po_r

_ boile_

OonttoIs o_t of adjustment

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

to in_r_l_ie_s packed with coatro/&

Check a_i control term_inatsan_ w#e ioinls,

HAV_ YOUR 8_RVIC_

TECHNICIAN

CHECK ANY PROBLE_

YOU ARE UNAI_LE

CORRECT.

OPTIONAL LOW LIMIT
CONTROL FOR BOILERS
OIL BURNER
PRIMARY

WITH TANKLESS COIL

RELAY

HONEYWELL
PRESSURETROL _

COLORCODE
BK = BI_CK
BL = BLUE
W = WHITE
G = GREEN

PART NO.

TO 24v

146-62-015

THERMOSTAT

i_ =WIRE

LOW VOLTAGE WiRiNG HARNESS NOT FURNISHED

pART NO, - 146-34-O47
\
_PRESSURETROL
TO LWC.O
PART NO,
433-00-873

- GROUND SCREW
PART NO.
1€6-54-B02
2 X 4 JUNCTION
PART NO,
_45-31-O82
HANDY BOX COVER (NOT SHOWN)
PART N0.
_46-61-121

-UNE

VOLTAGE

HARNESS

(GROUND)

• LINE VOLTAGE (NEUT. LEAD)
PART NO

433-00-872

L BURNER TO L.WC.O.
LOCK-NUT
PART NO.

HARNESS

I/2" CLOSE
PART NO.
146-07-030

LINE
#2
PART

NO,

TERMINAL

LW*C,O,

W_RING TERMINAL DETAIL

VOLTAGE

(NOT

LEAD)

LWCO

433--00--874

'tJ
67D-1

NUT

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!

)

SUGGESTED
FOR BECKETT
BOILER

NOZZLE

NOZZLES AND SETTINGS
AFG-M OIL BURNER SERIES

PUMP
PRESSURE

ACTUAL

MODEL

(psig)
3ES1.00(C)

0,85-60°W

1.00

!40

3ES1,25(0)

1,10-70°B

1.25

140

3ES! .35(C)

1,20-70°B

1.35

4ES1,50(C)

1,25-60°B

4ES1,75(C)

4ES1,85(0)

HEAD
ADJUSTMENT

AIR
SHUTTER

AIR
BAN D

OIL
BURNER
MODEL

AFG-50MB

AFG-50MD

!40

AFG-50MD

1.50

140

AFG-50MD

1,50-60°B

1.75

140

AFG-50MD

1.75-60°B

1.85

140

AFG-50MD

FOR

RIELLO

ACTUAL

R40 OIL BURNER
PU M P

SERIES
OIL

NOZZLE
(DELEVAN)

3ES1,00(C)

0.85-60°W

1.00

150

2,0

3.00

3ES1,25(C)

1.00-60°W

1.25

165

2.5

3.60

3ESl.35(C)

1.10-60°W

1.35

165

3.5

4.25

4ES1.50(C)
4ES1.75(C)

1.25-60°W
1.50-60°W

1.50
1.75

160
145

1.5
1,5

2.60
3.25

FIO
FIO

4ES1.85(C)

1.50-60°W

1.85

160

2.0

3.40

FIO

INPUT
RATE (gph)

FOR

CARLIN

PRESSURE
(psig)

EZ OIL BURNER

TURBULATOR
SETTING

AI R

BOILER
MODEL

GATE
SETTING

BURNER
MODEL

SERIES

[

ACTUAL

BOILER

NOZZLE

MODEL

(DELEVAN)

3ES1.00(C)

0.85x70ow

1.00

3ES1,25(C)

1.00x70°W

1.25

INPUT
RATE (gph)

3ES1.35(C)

1, !Ox70°W

1.35

4ES1.50(C)

1.25x60°W

1.50

4ES1,50(C)

1,25x60°W

1.50

4ES1,65(C)

1.35x60°W

1.65

4ES1,85(0)

1,50x60°W

1.85

PUMP
PRESSURE
(psig)
150
150
150
150
150
150
150

SETTING

AIR BAND
SET
POINT

0.85-1.00

0.65

EZ-1 HP

0.85-1.00

0.90

EZ-1 HP

1,10-1.25

1 .!0

EZ-I HP

1.10-1.25

1,10

EZ-1 HP

0.85-!.00

1,65

EZ-2 HP

1.50

1.65

EZ-2 HP

! ,50

2.00

EZ-2 HP

HEAD

OIL
BURNER
MODEL

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,

tial start up only, Final adjustment must be
I NOTE: These settings are intended for inimade using combustion test instruments,

!
i

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Kenmore 3ES135 User Manual BOILER Manuals And Guides L0312042

DUNKIRK Boiler Manual L0312042 DUNKIRK Boiler Owner's Manual, DUNKIRK Boiler installation guides

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