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 |RONSTF.AM

BO|

Installation

• Operation

•RepairParts

Theseinstructionsmustbeaffixedonoradjacentto theboiler.DUNKIRKBOILERS

DUNKIRK,NEWYORK14048- 716366-5500

MEMBER: The llydronies Institute

I/2" NPT

TANKLESS

HEATER

,o i

F , t ,ti

,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 3ES1 00 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 20'

CIMF31SIONS- INCHES

AB 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

Selectionof boilersizeshouldbe basedupon"Net1=8=RRatingbeing

equalto orgreaterthanthe sq.ft. of radiationalreadyinstalledinthe

building.

TheNetI=B=R Ratingsshownarebasedonanallowanceof 1.333in

accordancewiththefactorsshownonthe 1=B=RStandardas publishedby

TheHydronicsInstitute.

Theseboilersmusthavea non-combustiblebaseif installedon acombustible

floor.Two-inchcladlitepadmaybeused.Theseboilersarelowpressure

sectionalcastironboilersconstructedandhydrostaticallytestedfora maximum

workingpressureof 15psiin accordancewithA.SME. (AmericanSocietyof

MechanicalEngineers)SectionIVStandardsfor castironheatingboilers.They

arecapacityratedinaccordancewiththecodeof the1=B=R(Hydronics

Institute).

RulesforSafeInstallationandOperation

1. Readthe Owner'sManualfor SafeOperationcarefully.Failureto follow

the rulesfor safeoperationandtheinstructionscancausea malfunctionof

the boilerand result in death, _rious bodily injury, and/or property

damage.

2. Checkyour localcodesandutilityrequirementsbeforeinstallation.The

installationmustbe inaccordancewiththeirdirectives,orfollowNFPA31

- Installationof OilBurningEquipment,latestrevision.

3. Beforeservicing,allowboilerto cool.Nwaysshutoffanyelectricityand

oilto boilerwhenworkingonit.Thiswill preventanyelectricalshocksor

burns.

4. Inspectoillineandconnectionsforleaks.

5. Be certainoil burnernozzleis size required.Overfiringwill resultin

earlyfailureofthe boilersections.Thiswill causedangerousoperation.

6. Nevervent this boiler into an enclosedspace.Alwaysvent to the

outside.Neverventto anotherroomor insidea building.

7. Besurethereis adequateairsupplyfor completecombustion.

8. Followa regutarserviceandmaintenancescheduleforefficientand

safeoperation.

9. Keepboilerareacleanandfreeof combustiblematerial,gasolineand

otherflammablevaporsandliquids.

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

applications,alljurisdictionalrequirementsmust be met. This mayrequirewiringandlor

pipingmodifications.Themanufactureris notresponsibleforany changesto the original

design.

BeforeYouStart

Check to be sure you have the dght size boiler before starting the

installation.See ratingand capacitytableon precedingpage.Checkthe

ratingplateonthe boiler.

You must see that the boileris suppliedwiththe properoil, freshair for

combustion,and a suitableelectricalsupply.Also, the boiler must be

connectedto a suitableventingsystemand an adequatepipingsystem.

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

ADJUSTMENTSare vitalto the properandsafe operationof the heating

system.Takethetimeto besuretheyarealldone.

Thefollowingstepsareallnecessaryfor properinstallationandsafe

operationof yourboiler.

1. LOCATINGTHEBOILER

2. OILSUPPLYANDPIPING

3. FRESHAIR FORCOMBUSTION

4. PIPINGCONNECTIONS

5. CHIMNEY& VENTPIPECONNECTIONS

6. ELECTRICALWIRING

7. THERMOSTATLOCATION

8. CHECKING&ADJUSTING

9. MAINTENANCE

Locatingthe Boiler

If your boileris partof a plannedheatingsystem,locateit as nearlyas

possiblewhereshownon yourplan.If boileris to be partof an existing

system,it is usuallybestto put it wherethe old onewas. If youplanto

changelocation,youwill needadditionalmaterialsas wellas an adequate

base.Thefollowingrulesapply:

1. The boilermustbe levelandlocatednearpiping.

2. Usea raisedbaseif f]oorcanbecomewetordamp.

3. Theventpipeconnectionshouldbeas shortaspossible.

4. Maintainclearancesforfiresafetyas wellasservicing.SeeFigure2for

minimumclearances.18"clearancemustbemaintainedat a sidewhere

passageis requiredfor accessto anothersidefor cleaning,servicing,

inspection,or replacementof anypartsthatnormallymayrequiresuch

attention.Boilersmustbe installedat least6" fromcombustiblematerial

onallsidesandabove.Allowat least24"frontclearancefor servicing.

Allowat least18"leftsideclearancefor servicingboilersequippedwith

atanklesscoil.

5. FRESHAIRfor combustionmustbeavailableatthefrontof theboiler.

FRESHAIRfor ventilationmustbeavailableto thefrontANDrearof

the boiler.Airpassagesmustbefreeofobstructionsat alltimes.

Ventilatingandcombustionairmustenterboilerroomwithout

restrictions.

6. The floor suppo_ng the boiler must be non-combustible.If it is

combustible,placethe boileron 2" cladlitepad.The padmustbeunder

theentireboilerto protectthefloor.

7. Besureinstallationis inaccordancewiththe requirementsofthe local

authoritieshavingjurisdiction.Compliancewiththeseregulationsis

required.In theabsenceof localcodes,followNFPA31- Insbtlationof

OilBurningEquipment.

Q6" MIN. 18" WITH COIL

•_

_" 6" MIN. "

I_// .IBOILER

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 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 acontinuous supply. The air in a

house contains only enough oxygen to supply the burner for ashort time.

Outside air must enter the house to replace that used by the burner. Study

foIIowingexampIes 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) inaconventional

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 thecracks aroundthe windows.

An unconfinedspace is defined as a space whose volume is not lessthan 50

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

considered in making this determination. Each opening shall have a

minimum free area of one square inch per 1,000Btu per hourof thetotal

input rating of all combustionequipment inthe 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 theenclosure.See Figure 4.

Example: Your boiler is rated at 100,000 Btu per hour. The water heater

is rated at 30,000 Btu per hour. The total is 130,000 Btu per hour. You

need two grilles, each with 130 square inchesof FREE opening. Metal

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

multiply the FREE area required by 1.7 (130 x 1.7 = 221.0 sq. in.

Iouvered area). In thisexample twogrilles, each having an 8" x 30" (240

sq. in,) Iouvered area would be used. Fig. 4 shows the grille locations.

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

permanent openings, one commencing within 12 inches of the top and

one commencing within 12 inches of the bottom of the enclosure. The

openings shall communicate directly, or by ducts, with the outdoors or

spaces (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 ratingof all equipment in theenclosure.

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 ratingof all equipmentin theenclosure.

3. Whencommunicatingwiththe outdoorsthroughhorizontalducts,each

openingshall haveaminimumfree area of one squareinch per

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

enclosure.

4. Whenductsareused,theyshallbeof the samecross-sectionalarea

as the freeareaof the openingstowhichtheyconnect.Theminimum

dimensionof rectangularairductsshal{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.Theuseof this

coileliminatesthe needfor ahot waterstoragetank.Instantaneousheatingof

waterinthe coil will providea flowof hotwaterfor domesticuse - if proper

watersupplylinecontrolsareused.

IMPORTANT

Do not usea tanklesscoil if yourwateris excessivelyhardwithlimeor

otherdepositswhichwillaccumulateinsidethecoil.

Forsummerrunningwithcoilyou needto fill boilerwithwaterandaddthe

L6006limitcontrolto the coil.Thiswill maintainwatertemperaturein the

boilerand bringthe burneronwhennecessary.

TANKLESSCOlL PIPING

Pipingis shownin Figure7B.A temperingvalve(mixingvalve)is

recommended.

LowLimit(whenused)- 140° F

Thesesettingscan bechangedafteryou havesomeideahowthe system

responds.If moredomestichotwateris required,the low limitsettingcan

alsoberaised.

_NT_pERE_ _OT WATER

¢OL_ WATE_ _N_ET

WLV_

Installation-SystemPiping

Thenearboilerpiping,thatis the pipingaroundthe boiler,mustbeconsidered

as partof the boilerfor properwaterlevelcontrol,andto producedrysteam.

Correctnearboilerpipingis crucialto the properoperationofthe boilerand

theheatingsystem.Followtheserecommendationscarefully.

1.Placeboilerintheselectedlocation,as nearchimneyaspossible.

2. Installthe popsafetyvalve,usingthe furnished3/a" 90" ell,intothe 3/4"

pipenippleonthebackof theboiler.Makea dischargepipe,using3/4"pipe

(not furnished)to carrythe wateror steamto anearbydrain. Do not

connectthe dischargepipe directlyto adrain but leave an air gap. No

shutoffof any descriptionshallbeplacedbetweenthe popsafetyvalveand

the boiler,or ondischargepipes

betweensuchsafetyvalvesandthe atmosphere.Installationof thepop

safetyvalveshallconformto therequirementsof theANSI/ASMEBoiler

and Pressure Vessel Code, Section IV The manufactureris not

responsibleforanywaterdamage.

3. Thisboileris equippedwithtwo 21/2"supplyconnectionson top and

two 1V2"returnconnections,oneeachon frontand backsidesof the

boiler.Unusedconnectionsmust

4. Recommendednearboilerpipingfor gravityreturnsys-temsis shown

in Figure8. Thisconfigurationusesonesupplyandonereturntapping.

Pipingoff bothboilertap-pingsis recommendedon units5 sectionand

larger.

Note:Usebothsupplytappingsonboilers5 sectionandlarger.

PtPES_E

5. Forinstailerschoosingto usebothsupplytappings,Figure8Ashowsthe

correctwayto pipethissystem.Figure8Bshowsthewrongwayto pipe

a headerwithtworisers.

, Headersmust be fitted with headeroffsetsor swingjoints, or be

equippedwith expansionjoints, so that thermalexpansionand

contractionof the headerwill nat damagethe boiler.Headersshall

netbewelded.

, Systemtakeoffsfromthe headermustbebetweenthe equalizerand

theriserto the headernearesttheequalizer.Systemtakeoffsmust

neverbe betweentworisers.

6.Systemtakeoffsfromtheheadermustneverbe bull-headed.Ifthesteam

maingoesintwodirections,theremustbetwotakeoffsfromtheheader,

onefor eachmain.

7. All boilersingravityreturnsystemsmustbeequippedwitha Hartford

LoopasshowninFigures8 and8A.

8. Whenpipingtheverticalrisersfromtheboilerto theheader,the bottom

of the headermustbeaminimumof 24inchesabovethewaterlevel

lineanthe rightsideofthe boiler(i.e.51inchesabovethefloor).

9. Steamriser(s)andheadershallbe272"pipesize.

10. Equalizerlineshailbeminimum1 1/2"pipesize.

11. The boilerhasa 1V2"tappinginrearsecflanfarskimming.

_EA_{ MAINS

HART_ORO

N|PPLE

MAIN VENT

D_Y RETURN

M_[N

THIS, PIPING

COMMON

tS INCORRECT

MISTAKES

TO SHOW

©L

12. The near boilerpipingshall includea 1 1/2" ballvalvein the return

pipingas showninFigure8Afar bottomblowdawnanddraining.

13. Forgravityreturnsystems,thebottomof theloweststeamcarrying

pipe,beita dryreturn,ortheendofthesteammain,mustbeat least

28"abovethenormalwaterlevellineanthedghtsideof theboiler.

Thisis knownas "DimensionA."

14. Forpumpedreturnsystems,followthecondensatepumporbailerfeed

pumpmanufacturer'sinstructionsfor properinstallationandhookup.

15. Inconnectingthecoldwarer supplyto thewaterinletvalve,makesure

thata deanwatersupplyis available.Whenthewatersupplyis froma

wellor pump,asandstrainershouldbeinstalledatthe pump.

FORUSEWITHCOOLINGUNITS

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 enteringthe 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 boilerwaterduringthe coolinc

cycle.

'_rd,.vE8 A& m

VALVESC & Q

_R _OUNG

ChimneyandChimneyConnection

CHECKYOURCHIMNEY

Followlocalcodes.In the absenceof localcodes,followANSI/NFPA31

Installationof OilBurningEquipment,latestedition.

Thisis averyimportantpartof yourheatingsystem.Noboiler,however

efficientitsdesign,canperformsatisfactorilyif thechimneythatservesit is

inadequate.Checkyourchimneyto makecertainthatit isthe rightsize,

properlyconstructedandinsoundcondition.

Itis cheaperto rebuilda poorchimneythanto payexcessivefuelbills.If

yoursis anoldmasonrychimney,a newsteellineror a new

prefabricatedchimneymaybethebestsolution.Thefollowingchartshows

recommendedminimumchimneysizesbasedonTable3andFigure6 of

the I: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 feetIo cblm_qeYhe_gP4_

[_!et la Fiqure 1@t

Foradditionalchimneydesignandsizinginformation,consulttheASHRAE

1996HVACSystemsandApplicationsHand-book,Chapter30,Chimney,

GasVentandFireplaceSystems;ortheNationalStandardfor Chimneys,

Fireplaces,VentsandSolidFuelBurningAppliances,ANSI/NFPA211.

CHIMNEYCONNECTORANDDRAFTREGULATOR

Yourboilerrequires7" diameterchimneyconnectorpipeon 3 section,8"

diameterchimneyconnectorpipeon 4 section.Youmustalso use a dralt

regulatorpackedwithboiler.Properlyinstalled,the regulatorwill controlthe

draftautomatically.Itis betterto installit ina horizontalsectionofthe pipe;but

it maybeinanangledorverticalsection.Justmakecertainthatthe"top"is at

top- andthattheshortpipesectionwhichholdsthe Vaneis horizontal.Install

it ascloseaspracticableto theboiler.

To installthechimneyconnector,startatthe boilerandpreferablytakeoff

fromthefluecollectorcollarwithanelbow- theninstallthedraftregulator

next,makingit horizontal.Whentheregulatoris inplace,startatthe chimney

andworkbackto theregulator.JointhetwosectionswithaDrawband.The

horizontalpipemustslopeuptowardthe chimneyat least1/4inchperfoot.It

mustnotleakandmustbefirmlysupported.Joinsectionswithat leasttwo

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.Steamexpandsas it is heated.

Ifthereisno placeforthe steamto expandinto,pressurewillbuildupinsidethe

boilerandsystem.Shouldthishappen,the popsafetyvalvewillautomatically

openat a pre-determinedpressure.Thiswill relievethestrainontheboilerand

system.Runapipefromthesafetyvalveoutlet(pipemustbesamesizeasoutlet

andtheopenendmustnot bethreaded)to an opendrain,tub orsink,or other

suitabledrainagepointnotsubjecttofreezing.Failureto dosomaycausewater

damageorinjuryshouldreliefvalverelease.Do notcapoffthedrainlinefrom

thisvalve!Eachpopsafetyvalveis providedwitha liftingdevicefortestingand

shouldbetestedmonthlyduringthe heatingseason.Referto safetyvalve

manufacturer'sinstructionspackagedwithsafetyvalve.

STEAMPRESSUREGAUGE

Everysystemshouldhavea pressuregaugeinstalledinthe boiler.Thisgauge

enablesyouto monitorthe pressureinthesystem.Ifthesafetydevicesfailto shut

offyourboileratthepropersettings,notifyyourservicetechnicianimmediately

WATERLEVELGAUGE

Thewaterlevelin theboilercanbeseenthroughtheglasstubeinthewater

levelgaugeatsideof boiler.Correctcoldboilerwaterlevelis stampedonside

jacketpanel.Whenmakingsteam,thewaterlevelwilldroponeto threeinches.

Thewaterlevelshouldbecheckedregularly.

STEAMPRESSURECONTROL

Thesteampressurelimitcontrol(pressuretrol)shutsofftheoilto theburnerifthe

steampressureintheboilerreachesthecut-offsetpoint(i.e.thesumofthecut-in

andthedifferentialsetpoints).Burnerretireswhenthe steampressuredropsto

thecut-insetpoint.Systempressurerequirementsarebasedonthesizeand

conditionof thepipes,andtheload.

Forgoodsystemoperation,the cut-insettingof the pressuretrolshouldnever

be less than twice the system pressuredrop. In atypical singlefamily

residencewith acleanonepipeheatingsystemand castiron radiation,this

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

Steamradiationis usuallysizedbased on squarefeet of equivalentdirect

radiation(EDR).Thisis basedon a steampressurein theradiatorofjust less

than 1 psi.Therefore,in our examplesystemfromabove,we would setthe

differentialadjustmentat 1psi,i.e.thesteampressurerequiredinthe radiators.

Thiswillgiveusa cut-offsetpointd1_12psi.

The aboveis an exampleof a typicalonepipesystem.Forlargersystemsor

othertypesof systemssuchas two pipesystems,or systemswithconvectors

or fan coil units,the pressuretrolsettingswill needto be determinedon a

system-by-systembasis.

The cut-insetpointis determinedbythe systempressuredropto the furthest

radiatoror terminalunit.Doublethe systempressuredropas a safetyfactor,

resultinginthe rulethatthe cut-insettingshouldneverbe lessthantwicethe

systempressuredrop.

Thedifferentialset#ointis thesteampressurerequiredat theterminalheating

units.

Nowyour boilerwill operatein the correctpressurerange.It will maintain

enoughsteampressureto sendthe steamoutto the furthestradiator,andnot

go overtheoptimumsteampressurethatisrequiredat theradiators.

67D-t LOWWATERCUT-OFF

Thefloat-typelowwatercut-offshutsofftheburnerwhenthewaterlevelis

belowasafepoint.Theburnerwillstartwhenthewateris refilledto a

minimumsafelevel.

WATERFEEDER(Optional)

Awaterfeederworkswiththe lowwatercut-off(LWCO)to maintaina

minimumsafelevelofwaterforboileroperation.It'susedto keepthe boiler

runningby compensatingfor minorevaporativesteamleaks,andto prevent

freeze-upsif thehomeownersareawayanda returnlineshouldspringa

leak,Theautomaticwaterfeederis a safetydevice,nota

convenienceitem.Itis notdesignedto maintaina "normal"waterline.The

waterfeederdoesnottaketheplaceof a responsiblepersonmonitoringand

maintainingthe"normal"waterline.Steamboilersrequirepersonal

attention.

Four electric water feedersare offeredby McDonnell-Millerwhichare

compatiblewiththe 67D-1 LWCO.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.

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

witha solidstateelectroniccontrolwhichfeedswaterwhensignaledbythe

LWCO.The waterfeed rate is field adaptablefar 1, 2, or 4 gpm.These

waterfeedershave an adjustableslideswitchto matchthe timingcyclean

the LWCO.Whenusinga McDonnell-MillerLWCOthe slideswitchneeds

to selectposition#1.The timingcyclecreatesaninitialdwellperiodof one

minuteto allowcondensateto be returnedto the boiler.If afterthedwell

periodthewaterhasnat reachedthe minimumsafelevelandcompletedthe

LWCOcircuit,thenwateris fedat theselectedflowratefaroneminute.The

dwellpedodis theninitiatedagainfar oneminute.Ifthewaterlevelhasstill

not reachedthe minimumsafe level,then wateris addedagain at the

selectedflowratefor oneminute.Thiscyclecontinuesuntilwaterreaches

the minimumsafe level and the circuitis completed.DunkirkRadiator

recommendsusinga Uni-Matchwaterfeederata flawrateof 1or2gpm.If

the steamboilerrequireshigherflow rateson a regularbasisa service

technicianshouldbenotified.

The 1OlAwaterfeedermay be used,howeverthe waterfeed rate is too

high and needsto be regulatedor throttled.The IO1Awillfeed upto 6

gpm,muchgreaterthanthe desiredflowrate of 1-2gpm.Also,thereis no

dwell periodto provideamarginfor condensateto returnto the boiler.

Thesetwofactorsincreasethechancesof overfeedingwaterto the steam

boiler.Excessivewaterinthesteamboilerwillproducenoise

Consultthe water feeder manufacturer'sinstallationguidelinesfor more

detailson waterfeederselection,recommendedpipingarrangement,and

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

recommendationto arrangethe installedpipingso a brokenuniontest can

beimplemented.

DRAINVALVE

Thismanualvalveprovidesa meansof drainingallwaterfromtheboilerand

system.Itshouldbeinstalledinthe3/a"teewherethewatersupplyline

enterstheboiler(Fig.8).Youcanalsousethisvalveto lowerthewaterlevel

ifit istoo high.

STEAMVENTS

Beforea steamsystemwill operateproperly,suitablesteamventsmustbe

installedin eachradiatoras wellas the returnmain.Somesystemsrequire

steamtrapsinthereturnlineat theradiationunit.

The"Hartfordloop"is a pipingarrangementwhichmustbeincluded(Fig.8)

for properoperationofthesteamsystem.

BOILERSWITHTANKLESSCOILSONLYFlowRegulatorandWater

TemperingValve

Ifyouhavea TanklessCoilfordomestichotwater,thesetwopartscanbe

used.Thiswill provideyouinstantaneoushotwaterthatis neither

scaldinghotnormerelytepid.The FlowRegulatoris placedinthecoldwater

lineto thecoil.It assuresa steadyflowof watersothatthe coilcanproperly

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

waterpressureis excessivelyhighorvariable.TheWaterTemperingValve

is atee whichis connectedat a junctionbetweenthe hotwaterlinefromthe

coilandacoldwaterbranchfromthesupplyline.Itmixeshotandcoldwater

as requiredto furnisha temperedsupplyof waterto the house.The water

will bejustthe righttemperaturefor youruse.Thisis importanton a steam

systemto preventscaldingtemperaturesat the faucets.Bothpartsare self-

containedandautomatic.

Starting Your Boiler

HOWA STEAMSYSTEMOPERATES

The waterintheboileris heateduntilit reachesthe boilingpoint.As the

waterboilsit turnsintosteam.Thesteamrisesfromthe top of the water

throughthe supplymainto the radiationunits.As it passesthroughthe

radiatorsit releasesitsheatandcondensesintowater.Thewaterreturns

to the boilerthroughthe returnmain.

FILLINGSYSTEMWITHWATER

Onsteamheatingsystemsthe boileris partiallyfilledwithwater.Itis very

importantto the properoperationof theentiresystemthatyourboilerbe

filledto the properlevel.Thecorrectwaterlevelon coldstartconditionis

about halfwayupthe glasswaterlevelgaugeas markedon the boiler

jacket.Tofill:

1. Closethe boilerdrainvalve.

2. Openthevalvesat thetopandbottomoftheglasswaterlevelgauge.

Alsoopenthedrainvalveatthe bottomofthegauge.

3. OpenthefilIvalveandatlowwaterto runintotheboiler.

WARNING-Neverrunwater intoa hotemptyboiler,

4. Allowboilertofill untilwaterrunsoutthe gaugedrainvalve.Then

closethegaugedrainvalve.

5. Continuetofill boileruntilwaterreachestheindicatedwaterline.This

Checking and Adjusting

isabouthalfwayuptheglasstube.Alwayskeepthewaterat thislevel

whensystemisoff.

IMPORTANT

Skimminga newsteamboileronan existingsystemmustbedoneseveral

timesto removeall oil,greaseandsediment.Thereshouldbe a teewitha

plugpipedto thesupplylineof theboilerinorderto properlyskimthe boiler.

Wheneverthe waterin the glassgaugebecomesdiscolored,your boiler

shouldbeskimmed.

Whenskimming,makesureto pipethe openendof thetee to thefloorora

drainto preventanyonefrom beingburnedby the steamand hot water

whichwillbereleased.

TheFloatLowWaterCut-offshouldbe blowndownafterskimming.Following

blowdown,allowthe boilerto coolandthenaddfreshwaterslowly.

Thefloatchamberof the lowwatercut-offmustbe flushedcleanandmaintained

clear of sedimentto allowfree movementof the float. This must be done

frequentlyduring initial operationof the boilerand at least once per week

thereafter.Followinstructionsontag attachedto control.Neverthrottlea steam

radiator valve on a one-pipesystem.It mustbe fully openor fully closed.

Otherwisewateris heldintheradiatorunits.Thiswillcauseknockingsounds.

Skimmingmayberequiredagainafterafewdaysoperation.

CHECKINGCONTROLS

To checkthe Low WaterCut-Off,turnoff powerto the boileror turn the

thermostatdown to the lowestsetting.Drainwaterto belowthe visible

bottomof thewatergaugeglass.Turnpoweronandturnthe thermostatto

call for heat.Whenthe boileris equippedwiththe floattypeLWCO,the oil

burnershouldnotrunonacallfor heatwhenthe waterislow.

To checkthe pressurelimit, run the boileruntil the pressurereaches

system demand.Then turn the pressurescrew and dropthe pressure

settinguntilthe boilershutsdown.Thiswill showthatthe pressurelimitis

operatingproperly.

If you haveinstalledyourown boiler,we recommendthat youcall for an

inspectionby aservice technician.The peace of mind and assured

performanceare well worththe cost involved.He can quicklymakethe

necessarychecksandadjustments.

OIL BURNERADJUSTMENT

Suggestednozzlesand preliminaryburnersettingsarefoundon page20.

Referto your oil burnerownersmanualfor checkingand adjustingthe

burner.

ADJUSTOPERATINGCONTROLSInstructionsfor eachcontroland

burnerareincluded.

Betthermostatheatanticipatorat .20.Instrucfionsforthefinaladjustmentof

thethermostatarepackagedwiththethermostat.

CHECKTHERMOSTATOPERATION

When setabovetemperatureindicatedon the thermometer,boilerburner

should start. Makecertainthe thermostatturnsoff the boilerwhenroom

temperaturereachesthe selectedsettingand startsthe boileroperating

whenroomtemperaturefallsafewdegrees.

Finally,setthethermostatfor thedesiredtemperature.Specialconditionsin

yourhomeandthe locationofthethermostatwillgovernthissetting.

MaintainingYour Boiler

Checkthe waterlevel every day or two.Verifythe watertine shownby

operatingthe drainvalvean the gauge.Be suretop and bottom valves

on gaugeare alwaysopen so that actualwater levelwill be shown

atalltimes,

POPSAFETYVALVE

Thisvalveshouldopenautomaticallywhenthe steampressureexceedsthe

safelimit(perinstructionspackagedwithvalve).Shouldit everfail to open

undertheseconditions,shut downyour system.Havethe valvereplaced

immediately,The pop safetyvalve shouldbe tested monthlyduringthe

heatingseason.Referto thevalvemanufactureflsinstructionspackagedwith

thepopsafetyvalve.

LOWWATERCUT-OFF

The LowWaterCut-offwillin_rrupttheelectricalcurrentto theburnerwhen

the waterlinein the boilerdropsto a low level.It is veryimportantto keep

the floatchamberfreefromsediment,a conditionessentialto dependability.

To keep any accumulationfrom interferingwith floatactionis to "BLOW

DOWN"or flushoutthe controlregularly.Thismustbedonetwo-threetimes

thefirstweekafterinstallationandoncea weekthereafterduringthe heating

season.Doit whiletheboileris inoperation.Firstnotewaterlevelin gauge

glass.Openblow-offvalveat bottomof control,waterwill pourout,flushing

awaysediment.Drainuntilwateris clear,abouta pail,thenclosevalve.If

waterlevelingaugeglasshasdropped,addwaterto boilerto restorelevel.

Consultlow water cut-offmanufacturersinstructionsincludedwith boiler.

NOTE: Openingblow-offvalvecheckscut-offoperationtoo.As floatdrops

withfallingwaterlevel,burnerswill shutoff.Aftervalveis closedandnormal

operatingconditionsarerestored,burnerswillresumefiring.

Boilersshouldnot be drainedbetweenheatingseasons.Onlywhen the

waterin the systembecomesdirtyshouldthe boilerbe drained,flushedor

boiledout,andrefilled.Steamboilersmaybeentirelyfilledwithwaterduring

thesummermonthsto excludeair.

CLEANINGYOURBOILER

Undernormaloperatingconditions,withthe burnersproperlyadjusted,we

recommendthat you have the flue passages,burneradjustment,and

operationof the controls checked once each year by a Service

Technician.

Before the start of each season (orwheneversystemhas been

shutdownfor sometime)recheckthe wholesystemfor leaks...andrecheck

the boilerandventpipefor leaks.Replaceor patchany boilersealsthatare

faulty.

BOILERFLUEPASSAGES

Flue Passagesbetweensectionsshouldbeexaminedyearlyandcleaned.

Removevent pipe.Raisetop panelof boilerandswingoutto exposeflue

collector.Removefluecollectortop. Cleanpassagewaysbetweensections

witha flexiblehandlewire brush.Removedirt fomthe bottomof the boiler

and reassembleall parts.Be sure vent pipeconnectionsto chimneyare

secureandnoobstructionsarepresent.

FOAMING,PRIMINGORSURGING

Thesetermsareusedto describeafluctuatingwaterline- whenwater

leavestheboiler.

Itis causedby anycombinationofthefollowing:

1. Threadingoilandorganicmatterinthe boilerwater.(Mineraloil, orcore

sanddoesnotcausesurging.)

2. Faultyquickventsthatdonot releaseair untila sizeablepressureis built

up- replace.Ifdirty,cleansothatyoucan easilyblowthroughvalve.

3. Improperheader design - whensteam flows in oppositedirectionof

equalizerlineon"Hartfordloop."Generallya 15"horizontalrunbetween

riser andmaintakeoffwill allowentrainedwaterto falloutof thesteam

vaporso it can returnto boiler.(Seepage7, Fig.8)

4. Adjustmentof steamlimitcontrolto a wide differentialincreasesdifficultyif

quickventsare oldstyle,slow-releasingtypeor dirty.Alwayssetsteam

limitcontroldifferentialas lowas possible.

5. Soapanddetergentscauseextremesurging- cleanthoroughlyby

skimmingtheboiler. CAUTION

Neverrefilla hotboilerwithcoldwater- thedangerof thermalshockmay

crackasection.

CAUTION

Neverallowelectricianor oil burnermechanicsto tryout theirwork by

turningon oil burnerfor evenone secondunlessboileris filledto the

properoperatinglevel.

SYSTEMCHECKSAFTERFIRSTSTARTING-STEAMSYSTEMS

Read the instructionspackagedwithyour controlsand makechecksand

adjustmentsaccordingly.Start the burnerand set the Thermostatfor the

desiredroomtemperature.WhenadjustingtheSteamPressurecontrol,watch

the steamPressureGaugeanduse its pressurereading- as itwill bemore

accuratethanthe control.(Anydifferencebetweenthe twowillbeduetotheir

differentlocation.)

BOILERWATERTREATMENT

In closedhotwaterheatingsystems,negligibleamountsof makeupwaterare

used,and watertreatmentis not required.In steam systemswhere the

systemistight,freefromleaks,andall the steamis returnedto the boileras

condensate,theamountof makeupwateris small.Again,watertreatmentis

notrequired.

On steam systemswith less than 90% of the steam beingreturnedas

condensate,orwithveryhardor corrosivemakeupwater,treatmentmaybe

desirable.Followthe recommen-dationsof the ASME(AmericanSocietyof

MechanicalEngineers)Boilerand PressureVesselCode,SectionVl, latest

version.

BETWEENHEATINGSEASONS

Boilersshouldnot bedrainedbetweenheatingseasons.Boilersinclosedhot

waterheatingsystemsmaybeleftas is.Steamboilersshouldbeentirelyfilled

withwaterduringthesummermonthsto excludeair.

Oil Boiler/BurnerCleaningInstructions

1. ShutoffalIelectricaIpowertotheboiler/burnerandshutofffuel supply.

2. Removethe sheetmetalsmokepipefromthetop dthe boiler.Inspect

pipeandchimneyfor signsof corrosionanddeterioration.Cleanbase

ofchimney.

3. Removetopjacketpanel.

4. Removethe twobrasswingnutsholdingtheflueccllectorfop.

5. Checkthegasketonthe undersideof thefluecollectorandreplaceas

necessary.

6. Removethe oil burner(threecapscrews).-OR-

Removethe oil burner/firedoorassembly(fourhex nuts).This is the

recommendedmethod,as it allows full accessto the combustion

chamberandlesspotentialdamageto thetargetwallduringthecleaning

process.

7. Removethe burnerdrawerassembly.Cleanany sootaccumulations.

8. Replacetheburnernozzlewiththe exactsizeandtyperecommended

for us onthisboiler.

Note:Changingto adifferentfiringrate,otherthanis recommended,ortype

of nozzlemaychangethe performanceof this boilerand/orcausea

hazardouscondition.

9. Cleanelectrodeassemblyandsetelectrodesasperburner

manufacturersrecommendations.

10. Reinstalldrawerassemblyandcheckfor properheadlocationas per

the manufacturer'srecommendations.

11. Inspectthetargetwail,blanket,andfiredoorinsulationforcrackingand

deterioration.If thereis anysignsof crackingor deterioration,replace

beforereassemblingthe boiler.

12. Removesootfromfiresidesurfacesby brushingdiagonallythroughthe

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

damagethetargetwallwiththefluebrush.

13. Carefullyvacuumsootaccumulationsfromthecombustionchamber

area,beingparticularlycarefulnottodamagethetargetwailandblanket

withthevacuum.Targetwallandblanketmustbeingoodconditionand

correctlyinstalledto insurepropercombustion.

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. Oilthe burnermotor(DONOTOVEROIL}.

19. Removethe oilpumpcoverandclean/replacethepumpscreen.Carefully

reassemble.

20.Replacethefuelfilter(ifapplicable).

21.Reconnectthe electricalandfuelsupplies.

22. Fire the burner,checkingfor propercombustionusingcombustiontest

equipment,makingadjustmentsas necessary.

23. Insurethatallsafetycontrolsandoperatingcontrolsarefunctioning

properly.

IMPORTANTOPERATINGANDMAINTENANCEREQUIREMENTSKEEPYOURBOILERANDTHEAREAAROUNDIT

CLEANNEVERBURNREFUSEORANYMATERIALOTHERTHANTHESPECIFIEDFUELINYOURBOILERHAVEYOUR

BOILERCHECKEDEACHYEARBYA QUALIFIEDTECHNICIAN

_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

pART NO, - 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

\zz

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_RING TERMINAL DETAIL

'tJ WH_E

FROM OIL BURNER

BLACK LEAD

FROM OiL BURNER

McDONNELL M_LLER

L W.C.O

PART NO. 146-26-042

4X 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 M P 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 IHEAD

[

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

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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