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O | L - F | REDCAST | RON STF . AM BO | Installation • Operation • RepairParts Theseinstructionms ustbeaffixedonoradjacentto theboiler . DUNKIRKBOILERS DUNKIRK , NEWYORK14048 - 716366 - 5500 MEMBER : The llydronies Institute
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I / 2 " NPT TANKLESS I / 2 " NPT HEATER 5 / 4 " ASNE PRESSURETROL 2 - I / 2 " NPT PRESSURE GAUGE SUPPLY POP SAFETY COMBINATION VALVE \ iq ° p i , o i 3 / 4 _ NPT i - i / 2 " NPT T _ LOW UMIT 35 CONTROL ON i SKIM TAPPING 27 " COIL PLATE WATER 1 - 1 / 2 " NPT IJNE RETURN i F , t , t i , t , * , ' L _ l , - V2 ° NPTi RETURN REAR LEFT SIDE FRONT EMPIRE OIL - FIRED STEAM BOILER RATINGS BOILER MODEL NO . Net Not I - S - R * Tonldelm CIMF31SIONS - INCHES Typl © al No . I = B - R Cell Input Nesting Rating Chimney With Without 9ec . * MBH Size and Capacity Rating Sq . Ft , Ratings Tankless Tankless GPM * A B C * MBH " MBH Radiation Height Coil Cotl 3ESt O0C 3ES1 00 3 118 89 371 2.75 8 " x 8 ' x 15 ' 16 % 7 9 140 16 ½ 7 9 3ES1.25C 3ES1,25 3 145 109 454 3,10 8 " x 8 ' x 15 ' 175 16 % 7 9 3ES1.35C 3ES1.35 3 189 156 117 488 3.25 8 " x 8 ' x 15 ' 20 % 8 11 4ES1,50C 4ES1,50 4 2 ! 0 177 133 554 3.50 8 ' x 8 ' x 15 ' 204 153 638 3.85 8 " x 8 " x 15 ' 20 % 8 11 4ES1.75C 4ES1 75 4 245 20 % 8 11 4ES1.85C 4ES1.85 4 259 215 161 671 4,00 8 " x 8 ' x 20 ' * MBH = 1,000 BTUpet hour BTUH = British Thermal Unit Per Hour GPH _ Gallons per Hour Oil at 140,000 BTU per Gallon * * Heating Capacity is based on a 13 % CO2 with a - , 02 ' w . c , draft over fire , and a # 1 smoke or less . The testing on the boilers was done in accordance with lhe DOE . ( Department of Energy ) test procedure Theseboilersmusthavea non - combustibbleaseif installedon acombustible NewYorkCityMEANumber134 - 98 - E floor . Two - inchcladlitepadmaybeused . Theseboilersarelowpressure Selectionof boilersizeshouldbe basedupon " Net1 = 8 = RRatingbeing sectionacl astironboilersconstructedandhydrostaticalltyestedfora maximum equalto orgreaterthanthe sq . ft . of radiationalreadyinstalledinthe workingpressureof 15psiin accordancewithA . SME . ( AmericanSocietyof building . MechanicaEl ngineersS ) ectionIVStandardsfor castironheatingboilers . They arecapacityratedinaccordancewiththecodeof the1 = B = R ( Hydronics TheNetI = B = R Ratingsshownarebasedonanallowanceof 1.333in Institute ) . accordancewiththefactorsshownonthe 1 = B = RStandardas publishedby TheHydronicsInstitute .
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RulesforSafeInstallationandOperation 1 . Readthe Owner'sManualfor SafeOperationcarefully . Failureto follow 5 . Be certainoil burnernozzleis size required . Overfiringwill resultin the rulesfor safeoperationandtheinstructioncsancausea malfunctioonf earlyfailureofthe boilersectionsT . hiswill causedangerousoperation . the boilerand result in death , _ rious bodily injury , and / or property 6 . Nevervent this boiler into an enclosedspace . Alwaysvent to the damage . outside . Neverventto anotherroomor insidea building . 2 . Checkyour localcodesandutilityrequirementsbeforeinstallationT . he 7 . Besurethereis adequateairsupplyfor completecombustion . installationmustbe inaccordancewiththeirdirectiveso , rfollowNFPA31 8 . Followa regutarserviceandmaintenancescheduleforefficientand - Installatioonf OilBurningEquipmentla , testrevision . safeoperation . 3 . Beforeservicinga , llowboilerto cool . Nwaysshutoffanyelectricityand 9 . Keepboilerareacleanandfreeof combustiblematerialg , asolineand oilto boilerwhenworkingonit . Thiswill preventanyelectricasl hocksor otherflammablevaporsandliquids . burns . 4 . Inspectoillineandconnectionsforleaks . This boiler has been designed for residentialinstallations . If used for commercial applications , alljurisdictionalrequirementsmust be met . This mayrequirewiringandlor pipingmodificationsT . hemanufactureris notresponsibleforany changesto the original design . BeforeYouStart Check to be sure you have the dght size boiler before starting the Thefollowingstepsareallnecessaryfor properinstallationandsafe installation . See ratingand capacitytableon precedingpage . Checkthe operationof yourboiler . ratingplateonthe boiler . 1 . LOCATINGTHEBOILER You must see that the boileris suppliedwiththe properoil , freshair for 2 . OILSUPPLYANDPIPING combustion , and a suitableelectricalsupply . Also , the boiler must be connectedto a suitableventingsystemand an adequatepipingsystem . 3 . FRESHAIR FORCOMBUSTION Finally , a thermostatp , roperlylocated , is neededfor controlof the heating 4 . PIPINGCONNECTIONS system . If you haveany doubtsas to the variousrequirementsc , heckwith local authorities and obtain professional help where needed . THE 5 . CHIMNEY & VENTPIPECONNECTIONS OPERATING INSTRUCTIONS and THE FINAL CHECKS AND ADJUSTMENTSare vitalto the properandsafe operationof the heating 6 . ELECTRICALWIRING system . Takethetimeto besuretheyarealldone . 7 . THERMOSTATLOCATION 8 . CHECKING & ADJUSTING 9 . MAINTENANCE
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Locatingthe Boiler If your boileris partof a plannedheatingsystem , locateit as nearlyas 6 . The floor suppo _ ng the boiler must be non - combustibleI . f it is possiblewhereshownon yourplan . If boileris to be part of an existing combustiblep , lacethe boileron 2 " cladlitepad . The padmustbeunder theentireboilerto protectthefloor . system , it is usuallybestto put it wherethe old onewas . If you planto 7 . Besureinstallationis inaccordancewiththe requirementosfthe local changelocationy , ouwill needadditionalmaterialsas wellas an adequate base . Thefollowingrulesapply : authoritieshavingjurisdictionC . ompliancewiththeseregulationsis requiredI . n theabsenceof localcodes , followNFPA31 - Insbtlationof 1 . The boilermustbe levelandlocatednearpiping . 2 . Usea raisedbaseif f ] oorcanbecomewetordamp . OilBurningEquipment . 3 . Theventpipeconnectionshouldbeas shortaspossible . 4 . Maintainclearancesforfiresafetyas wellasservicing . SeeFigure2for minimumclearances1 . 8 " clearancemustbemaintainedat a sidewhere passageis requiredfor accessto anothersidefor cleaning , servicing , inspectiono , r replacemenot f anypartsthatnormallymayrequiresuch attentionB . oilersmustbe installedat least6 " fromcombustiblematerial onallsidesandabove . Allowat least24 " frontclearancefor servicing . Q 6 " MIN . 18 " WITH COIL Allowat least18 " leftsideclearancefor servicingboilersequippedwith atanklesscoil . • _ 5 . FRESHAIRfor combustionmustbeavailableatthefrontof theboiler . FRESHAIRfor ventilationmustbeavailableto thefrontANDrearof _ " 6 " MIN . " I _ / / . I BOILER the boiler . Airpassagesmustbefreeofobstructionast alltimes . I - - - - - 2 , . , . . - - - - - - FI RO . T Ventilatingandcombustioanirmustenterboilerroomwithout restrictions . 6 " MIN . m _ SeRVraceL _ NeLL , . - - - - - - e _ . ec _ rRic F _ LPtFE ] I I [ s _ , rrc _ GENERAL PRINCIPAL REQUiREMEnTS FOR A TYPICAL INSTALLATION
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Fresh Air for Combustion WARNING NOTE Be sure to provide enough fresh airfor combustion . Enough air ensures If you use a fireplaceor a kitchenor bathroomexhaustfan , you shouldinstallan outsideair intake . Thesedeviceswill robthe boiler proper combustion and assures that no hazard will develop due to andwaterheaterof combustionair . the lackof oxygen . 3 . Whencommunicatinwgiththe outdoorsthroughhorizontadlucts , each You must provide for enough fresh air to assure proper combustion . The fire openingshall havea minimumfree area of one squareinch per in the boiler uses oxygen . It must have a continuous supply . The air in a 2,000 Btu per hour of totalinput ratingof all equipmentin the house contains only enough oxygen to supply the burner for a short time . enclosure . Outside air must enter the house to replace that used by the burner . Study 4 . Whenductsareused , theyshallbeof the samecross - sectionaalrea foIIowingexampIes 1 and 2 to determine your fresh air requirements . as the freeareaof the openingstowhichtheyconnectT . heminimum EXAMPLE 1 : Boiler Located in Unconfined Space dimensionof rectangulaarirductsshal { benotlessthanthreeinches . If your boiler is in an open area ( unpartitioned basement ) ina conventional house , the air that leaks through the cracks around doors and windows will usually be adequate to provide air for combustion . The doors should not fit tightly . Do not 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 VENTILATING - ' _ - - i GRII . LE I with two permanent openings communicating directly with an additional i I ' 1 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 i , 11 II ' , considered in making this determination . Each opening shall have a minimum free area of one square inch per 1,000Btu per hourof thetotal AIR GRILLE _ input ratingof 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 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 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 FRESH Btu per hour of total input ratingof all equipmentin theenclosure .
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Boilers With Tankless Heater Coil Boilersmaybefactorypackagedwithatanklessheatercoil . Theuseof this coileliminatesthe needfor ahot waterstoragetank . Instantaneouhseatingof 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 _ NT _ pERE _ _ OT WATER Pipingis shownin Figure7B . A temperingvalve ( mixingvalve ) is recommended . LowLimit ( whenused ) - 140 ° F Thesesettingscan bechangedafteryou havesomeideahowthe system responds . If moredomestichotwateris requiredt , he low limitsettingcan alsoberaised . ¢ OL _ WATE _ _ N _ ET WLV _
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Installation - SystemPiping betweensuchsafetyvalvesandthe atmosphereI . nstallationof thepop Thenearboilerpipingt , hatis the pipingaroundthe boiler , mustbeconsidered safetyvalveshallconformto therequirementosf theANSI / ASMEBoiler as partof the boilerfor properwaterlevelcontrol , andto producedrysteam . and Pressure Vessel Code , Section IV The manufactureirs not Correctnearboilerpipingis cruciatlo the properoperationofthe boilerand responsibleforanywaterdamage . theheatingsystem . Followtheserecommendationcsarefully . 3 . Thisboileris equippedwithtwo 21 / 2 " supplyconnectionson top and 1 . Placeboilerintheselectedlocationa , s nearchimneyaspossible . two 1V2 " returnconnectionso , neeachon frontand backsidesof the 2 . Installthe popsafetyvalve , usingthe furnished3 / a " 90 " ell , intothe 3 / 4 " boiler . Unusedconnectionsmust pipenippleonthebackof theboiler . Makea dischargepipe , using3 / 4 " pipe 4 . Recommendednearboilerpipingfor gravityreturnsys - temsis shown ( not furnished ) to carrythe wateror steamto a nearbydrain . Do not in Figure8 . Thisconfigurationusesonesupplyandonereturntapping . connectthe dischargepipe directlyto a drain but leave an air gap . No Pipingoff bothboilertap - pingsis recommendedon units5 sectionand shutoffof any descriptionshallbeplacedbetweenthe popsafetyvalveand larger . the boiler , or ondischargepipes Note : Usebothsupplytappingsonboilers5 sectionandlarger . PtPES _ E
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7 . All boilersingravityreturnsystemsmustbeequippedwitha Hartford 5 . Forinstailerschoosingto usebothsupplytappings , Figure8Ashowsthe LoopasshowninFigures8 and8A . correctwayto pipethissystem . Figure8Bshowsthewrongwayto pipe a headerwithtworisers . 8 . Whenpipingtheverticalrisersfromtheboilerto theheadert , he bottom of the headermustbea minimumof 24inchesabovethewaterlevel , Headersmust be fitted with headeroffsetsor swingjoints , or be lineanthe rightsideofthe boiler ( i . e . 51inchesabovethefloor ) . equippedwith expansionjoints , so that thermalexpansionand contractionof the headerwill nat damagethe boiler . Headersshall 9 . Steamriser ( s ) andheadershallbe272 " pipesize . netbewelded . 10 . Equalizelrineshailbeminimum1 1 / 2 " pipesize . , Systemtakeoffsfromthe headermustbebetweenthe equalizear nd 11 . The boilerhasa 1V2 " tappinginrearsecflanfarskimming . theriserto the headernearesttheequalizerS . ystemtakeoffms ust neverbe betweentworisers . 6 . Systemtakeoffsfromtheheadermustneverbe bull - headedI . fthesteam maingoesintwodirectionst , heremustbetwotakeoffsfromtheheader , onefor eachmain . _ EA _ { MAINS MAIN VENT D _ Y RETURN M _ [ N CLOSE HART _ ORO N | PPLE
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THIS , PIPING tS INCORRECT TO SHOW COMMON MISTAKES L © 12 . The near boilerpipingshall includea 1 1 / 2 " ballvalvein the return B . Whenthis boileris connectedto heatingcoilslocatedin air handlingunit . , pipingas showninFigure8Afar bottomblowdawnanddraining . where they may be exposedto refrigeratedair circulation , the piping systemshall be equippedwith flow controlvalves or other automatic 13 . Forgravityreturnsystemst , hebottomof theloweststeamcarrying meansto preventgravitycirculationof the boilerwaterduringthe coolinc pipe , beita dryreturn , ortheendofthesteammain , mustbeat least cycle . 28 " abovethenormalwaterlevellineanthedghtsideof theboiler . Thisis knownas " DimensionA . " 14 . Forpumpedreturnsystemsf , ollowthecondensatepumporbailerfeed pumpmanufactureri'snstructionfsor properinstallationandhookup . 15 . Inconnectingthecoldwarer supplyto thewaterinletvalve , makesure thata deanwatersupplyis availableW . henthewatersupplyis froma ' _ rd , . vE8 A & m wellor pump , asandstrainershouldbeinstalledatthe pump . FORUSEWITHCOOLINGUNITS VALVES C & Q _ R _ OUNG 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 ) .
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ChimneyandChimneyConnection CHECKYOURCHIMNEY Followlocalcodes . In the absenceof localcodes , followANSI / NFPA31 MUST BE REQUIRED MIN * IMUM HEIGHT , MUST BE Installatioonf OilBurningEquipmentla , testedition . AT LEAST 3 FT . HIGHER Thisis averyimportanpt artof yourheatingsystem . Noboiler , however THAN HIGHEST PART OF PASSAGE THROUGH efficientitsdesign , canperformsatisfactoriliyf thechimneythatservesit is ROOF . MUST BE AT inadequateC . heckyourchimneyto makecertainthatit isthe rightsize , LEAST 2 FT . HIGHER THAN ANY NEIGHBORING properlyconstructedandinsoundcondition . OBJECT . MUST HAVE AN Itis cheaperto rebuilda poorchimneythanto payexcessivefuelbills . If UNOBSTRUCTED TOP OPENING , yoursis anoldmasonrychimney , a newsteellineror a new prefabricatecdhimneymaybethebestsolutionT . hefollowingchartshows recommendemd inimumchimneysizesbasedonTable3andFigure6 of the I : B : R TestingandRatingStandardfor HeatingBoilers , Sixth Edition , June1989 . MUST BE AT LEAST 4 INCHES THICK - AND BE LINED . FIECOMMENDED MtNiMUM _ IMNEY SIZES _ l _ CHFM _ I _ ER _ LNER ; = ! : _ ! NNqY ' i _ DE I _ . 60 - i 30 15 8 " × 8 ' 6 ' 6 : 5 _ x 6 _ ' ALTERNATE POSITIONS 13Iol 80 15 8 ' x 8 " 7 ' , 6 _ f ; _ " × 6 _ ! 4 " TOP i , 81o2,00 20 I [ : < ] re # _ @ : ( Y ) 88 _ ee 2 , # _ if , , 8J3 _ es _ _ i , ad _ 3 feetIo cblm _ qeYhe _ gP4 _ I L [ _ ! et la Fiqure 1 @ t _ , TIGHT . SMOOTH , CORRECTLY SIZED . Foradditionaclhimneydesignandsizinginformationc , onsulttheASHRAE II 1996HVACSystemsandApplicationsHand - bookC , hapter30 , Chimney , t I GasVentandFireplaceSystems ; ortheNationaSl tandardfor Chimneys , FireplacesV , entsandSolidFuelBurningAppliancesA , NSI / NFPA211 . 1 CHIMNEYCONNECTORANDDRAFTREGULATOR MUSTSLOPEUP & LEDIN AT LEAST 1 / THIMBLE PER FOOT OF Yourboilerrequires7 " diameterchimneyconnectorpipeon 3 section , 8 " HORIZONTALRUN DRAWBAND diameterchimneyconnectorpipeon 4 section . Youmustalso use a dralt TIGHT LAST PIECE regulatorpackedwithboiler . Properlyinstalled , the regulatorwill controlthe INSTALLED DOOR draftautomaticallyIt . is betterto installit ina horizontaslectionofthe pipe ; but it maybeinanangledorverticasl ection . Justmakecertainthatthe " top " is at top - andthattheshortpipesectionwhichholdsthe Vaneis horizontalI . nstall it ascloseaspracticableto theboiler . To instaltlhechimneyconnectors , tartatthe boilerandpreferablytakeoff DRAFT REGULATOR fromthefluecollectorcollarwithanelbow - theninstallthedraftregulator VANE next , makingit horizontaWl . hentheregulatoris inplace , startatthe chimney andworkbackto theregulator . JointhetwosectionswithaDrawbandT . he horizontapl ipemustslopeuptowardthe chimneyat least1 / 4inchperfoot.It mustnotleakandmustbefirmlysupportedJ . oinsectionswithat leasttwo sheet - metaslcrews . Supporteverysecondsectionwitha stovepipewire . MINIMUMVENTPIPECLEARANCE Woodandothercombustiblematerialsmustnotbecloserthan18 " fromany BALANCEDWEIGHT surfaceoftheventpipe .
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EquipmaenndOt ptionAaclcesso - rWieshaTtheDy o POPSAFETYVALVE 67D - t LOWWATERCUT - OFF Youmusthavea popsafetyvalveonyourboiler . Steamexpandsas it is heated . Thefloat - typelowwatercut - offshutsofftheburnerwhenthewaterlevelis Ifthereisno placeforthe steamto expandinto , pressurewillbuildupinsidethe belowasafepoint . Theburnerwillstartwhenthewateris refilledto a boilerandsystem . Shouldthishappent , he popsafetyvalvewillautomatically minimumsafelevel . openat a pre - determinepdressureT . hiswill relievethestrainontheboilerand WATERFEEDER ( Optional ) system . Runa pipefromthesafetyvalveoutlet ( pipemustbesamesizeasoutlet Awaterfeederworkswiththe lowwatercut - off ( LWCO ) to maintaina andtheopenendmustnot bethreaded ) to an opendrain , tub orsink , or other minimumsafelevelofwaterforboileroperationI . t'susedto keepthe boiler suitabledrainagepointnotsubjecttofreezing . Failureto dosomaycausewater runningby compensatinfgor minorevaporativesteamleaks , andto prevent damageorinjuryshouldreliefvalvereleaseD . o notcapoffthedrainlinefrom freeze - upsif thehomeownersareawayanda returnlineshouldspringa thisvalve ! Eachpopsafetyvalveis providedwitha liftingdevicefortestingand leak , Theautomaticwaterfeederis a safetydevice , nota shouldbetestedmonthlyduringthe heatingseason . Referto safetyvalve convenienceitem . Itis notdesignedto maintaina " normal " waterline . The manufacturer'isnstructionpsackagedwithsafetyvalve . waterfeederdoesnottaketheplaceof a responsiblepersonmonitoringand STEAMPRESSUREGAUGE maintainingthe " normal " waterline . Steamboilersrequirepersonal attention . Everysystemshouldhavea pressuregaugeinstalledinthe boiler . Thisgauge enablesyouto monitotrhe pressureinthesystem . Ifthesafetydevicesfailto shut Four electric water feedersare offeredby McDonnell - Millewr hichare offyourboileratthepropersettingsn , otifyyourservicetechnicianimmediately compatiblewiththe 67D - 1 LWCO . The model # 101Aand # WF2 - U - 120 waterfeedersareusedwith120voltwiringcircuits , asfoundanthissteam WATERLEVELGAUGE boiler . The McDonnell - Millemr odel # 101A - 24and # WF2 - U - 24are used Thewaterlevelin theboilercanbeseenthroughtheglasstubeinthewater with 24 volt circuits , which may be usefulin a retrofitinstallationwhich levelgaugeatsideof boiler . Correctcoldboilerwaterlevelis stampedonside alreadyhasa 120voltto 24volttransformer . jacketpanel . Whenmakingsteam , thewaterlevelwilldroponeto threeinches . The WF2 - U - 120and WF2 - U - 24 ( Uni - Matchw ) aterfeedersareequipped Thewaterlevelshouldbecheckedregularly . witha solidstateelectroniccontrolwhichfeedswaterwhensignaledbythe STEAMPRESSURECONTROL LWCO . The waterfeed rate is field adaptablefar 1 , 2 , or 4 gpm . These waterfeedershave an adjustableslideswitchto matchthe timingcyclean Thesteampressurelimitcontrol ( pressuretrosl ) hutsofftheoilto theburnerifthe the LWCO . Whenusinga McDonnell - MilleLrWCOthe slideswitchneeds steampressureintheboilerreachesthecut - offsetpoin ( ti . e . thesumofthecut - in to selectposition # 1 . The timingcyclecreatesaninitialdwellperiodof one andthedifferentiasletpoints ) B . urnerretireswhenthe steampressuredropsto minuteto allowcondensateto be returnedto the boiler . If afterthe dwell thecut - insetpoint . Systempressurerequirementasrebasedonthesizeand periodthewaterhasnat reachedthe minimumsafelevelandcompletedthe conditionof thepipes , andtheload . LWCOcircuit , thenwateris fedat theselectedflowratefaroneminuteT . he Forgoodsystemoperation , the cut - insettingof the pressuretroslhouldnever dwellpedodis theninitiatedagainfar oneminute . Ifthewaterlevelhasstill be less than twice the system pressuredrop . In a typical singlefamily not reachedthe minimumsafe level , then wateris addedagain at the residencewith a cleanonepipeheatingsystemand castiron radiation , this selectedflowratefor oneminute . Thiscyclecontinuesuntilwaterreaches meansthatthecut - inwillusuallybesetattheminimumsetting , i . e . _ / 2psi . the minimumsafe level and the circuitis completed . DunkirkRadiator Steamradiationis usuallysizedbased on squarefeet of equivalentdirect recommendsusinga Uni - Matchwaterfeederata flawrateof 1or2gpm.If radiation ( EDR ) . Thisis basedon a steampressurein the radiatorofjust less the steamboilerrequireshigherflow rateson a regularbasisa service than 1 psi . Therefore , in our examplesystemfromabove , we would setthe technicianshouldbenotified . differentiaal djustmenatt 1psi , i.e.thesteampressurerequiredinthe radiators . The 1OlAwaterfeedermaybe used , howeverthe waterfeed rate is too Thiswillgiveusa cut - offsetpoindt 1 _ 12psi . high and needsto be regulatedor throttled . The IO1Awillfeed upto 6 The aboveis an exampleof a typicalonepipesystem . Forlargersystemsor gpm , muchgreaterthanthe desiredflowrate of 1 - 2gpm.Also , thereis no othertypesof systemssuchas two pipesystemso , r systemswithconvectors dwell periodto providea marginfor condensateto returnto the boiler . or fan coil units , the pressuretroslettingswill needto be determinedon a Thesetwofactorsincreasethechancesof overfeedingwaterto the steam system - by - systembasis . boiler . Excessivewaterinthesteamboilerwillproducenoise The cut - insetpointis determinedbythe systempressuredropto the furthest Consultthe water feeder manufacturer'sinstallationguidelinesfor more radiatoror terminalunit . Doublethe systempressuredropas a safetyfactor , detailson waterfeederselection , recommendedpipingarrangementa , nd resultinginthe rulethatthe cut - insettingshouldneverbe lessthantwicethe start up procedures . Dunkirk Radiator supports McDonnell - Miller's systempressuredrop . recommendatiotno arrangethe installedpipingso a brokenuniontest can Thedifferentiaslet # oinits thesteampressurerequiredat theterminahl eating beimplemented . units . DRAINVALVE Nowyour boilerwill operatein the correctpressurerange . It will maintain Thismanualvalveprovidesa meansof drainingallwaterfromtheboilerand enoughsteampressureto sendthe steamoutto the furthestradiatora , ndnot system . Itshouldbeinstalledinthe3 / a " teewherethewatersupplyline go overtheoptimumsteampressurethatisrequiredat theradiators . enterstheboiler ( Fig . 8 ) . Youcanalsousethisvalveto lowerthewaterlevel ifit istoo high .
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STEAMVENTS scaldinghotnormerelytepid . The FlowRegulatoirs placedinthecoldwater lineto thecoil . It assuresa steadyflowof watersothatthe coilcanproperly Beforea steamsystemwill operateproperly , suitablesteamventsmustbe heatit . It prevents " spurts " of " half - heatedw " ater . Thisisimportanwt herethe installedin eachradiatoras wellas the returnmain . Somesystemsrequire waterpressureis excessivelyhighorvariable . TheWaterTemperingValve steamtrapsinthereturnlineat theradiationunit . is atee whichis connectedat a junctionbetweenthe hotwaterlinefromthe The " Hartfordloop " is a pipingarrangemenwt hichmustbeincluded ( Fig . 8 ) coilandacoldwaterbranchfromthesupplyline . Itmixeshotandcoldwater for properoperationofthesteamsystem . as requiredto furnisha temperedsupplyof waterto the house . The water BOILERSWITHTANKLESSCOILSONLYFlowRegulatorandWater will bejustthe righttemperaturefor youruse . Thisis importanot n a steam TemperingValve systemto preventscaldingtemperaturesat the faucets . Bothpartsare self - Ifyouhavea TanklessCoilfordomestichotwater , thesetwopartscanbe containedandautomatic . used . Thiswill provideyouinstantaneouhsotwaterthatis neither Starting Your Boiler HOWA STEAMSYSTEMOPERATES isabouthalfwayuptheglasstube . Alwayskeepthewaterat thislevel The waterintheboileris heateduntilit reachesthe boilingpoint . As the whensystemisoff . waterboilsit turnsintosteam . Thesteamrisesfromthe top of the water throughthe supplymainto the radiationunits . As it passesthroughthe IMPORTANT radiatorsit releasesitsheatandcondensesintowater . Thewaterreturns to the boilerthroughthe returnmain . Skimminga newsteamboileronan existingsystemmustbedoneseveral FILLINGSYSTEMWITHWATER timesto removeall oil , greaseandsedimentT . hereshouldbe a teewitha Onsteamheatingsystemsthe boileris partiallyfilledwithwater . Itis very plugpipedto thesupplylineof theboilerinorderto properlyskimthe boiler . importantto the properoperationof theentiresystemthatyourboilerbe Wheneverthe waterin the glassgaugebecomesdiscoloredy , our boiler filledto the properlevel . Thecorrectwaterlevelon coldstartconditionis shouldbeskimmed . about halfwayupthe glasswaterlevelgaugeas markedon the boiler Whenskimming , makesureto pipethe openendof thetee to thefloorora jacket . Tofill : drainto preventanyonefrom beingburnedby the steamand hot water 1 . Closethe boilerdrainvalve . whichwillbereleased . 2 . Openthevalvesat thetopandbottomoftheglasswaterlevelgauge . Alsoopenthedrainvalveatthe bottomofthegauge . TheFloatLowWaterCut - offshouldbe blowndownafterskimming . Following 3 . OpenthefilIvalveandatlowwaterto runintotheboiler . blowdowna , llowthe boilerto coolandthenaddfreshwaterslowly . WARNING - Neverrunwater intoa hotemptyboiler , Thefloatchamberof the lowwatercut - offmustbeflushedcleanandmaintained 4 . Allowboilertofill untilwaterrunsoutthe gaugedrainvalve . Then clear of sedimentto allowfree movementof the float . This must be done closethegaugedrainvalve . frequentlyduring initial operationof the boilerand at least once per week 5 . Continuetofill boileruntilwaterreachestheindicatedwaterline . This thereafterF . ollowinstructionsontag attachedto control . Neverthrottlea steam radiator valve on a one - pipesystem . It must be fully openor fully closed . Otherwisewateris heldintheradiatorunits . Thiswillcauseknockingsounds . Skimmingmayberequiredagainafterafewdaysoperation . Checking and Adjusting CHECKINGCONTROLS OIL BURNERADJUSTMENT To checkthe Low WaterCut - Off , turnoff powerto the boileror turn the Suggestednozzlesand preliminaryburnersettingsarefoundon page20 . thermostadt own to the lowestsetting . Drainwaterto belowthe visible Referto your oil burnerownersmanualfor checkingand adjustingthe burner . bottomof thewatergaugeglass . Turnpoweronandturnthe thermostatto call for heat . Whenthe boileris equippedwiththe floattypeLWCO , the oil ADJUSTOPERATINGCONTROLSInstructionfsor eachcontroal nd burnershouldnotrunonacallfor heatwhenthe waterislow . burnerareincluded . To check the pressurelimit , run the boileruntil the pressurereaches Betthermostahteatanticipatoart . 20 . Instrucfionfsorthefinaladjustmenotf system demand . Then turn the pressurescrew and dropthe pressure thethermostaat repackagedwiththethermostat . settinguntilthe boilershutsdown . Thiswill showthatthe pressurelimitis CHECKTHERMOSTATOPERATION operatingproperly . When setabovetemperatureindicatedon the thermometerb , oilerburner If you haveinstalledyourown boiler , we recommendthat youcall for an should start . Makecertainthe thermostatturnsoff the boilerwhenroom inspectionby a service technician . The peace of mind and assured temperaturereachesthe selectedsettingand startsthe boileroperating performanceare well worththe cost involved . He can quicklymakethe whenroomtemperaturefallsafewdegrees . necessarychecksandadjustments . Finallys , etthethermostaftor thedesiredtemperatureS . peciacl onditionsin yourhomeandthe locationofthethermostawt illgovernthissetting .
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MaintainingYour Boiler Itis causedby anycombinationofthefollowing : Checkthe waterlevel every day or two . Verifythe watertine shownby 1 . Threadingoilandorganicmatterinthe boilerwater . ( Mineraol il , orcore operatingthe drainvalvean the gauge . Be suretop and bottom valves sanddoesnotcausesurging . ) on gaugeare alwaysopen so that actualwater levelwill be shown atalltimes , 2 . Faultyquickventsthatdonot releaseair untila sizeablepressureis built POPSAFETYVALVE up - replace . Ifdirty , cleansothatyoucan easilyblowthroughvalve . 3 . Improperheader design - whensteam flows in oppositedirectionof Thisvalveshouldopenautomaticallwy henthe steampressureexceedsthe equalizerlineon " Hartfordloop . " Generallya 15 " horizontarlunbetween safelimit ( perinstructionspackagedwithvalve ) . Shouldit everfail to open riser andmaintakeoffwill allowentrainedwaterto falloutof thesteam undertheseconditions , shut downyour system . Havethe valvereplaced vaporso it can returnto boiler . ( Seepage7 , Fig . 8 ) immediatelyT , he pop safetyvalve shouldbe tested monthlyduringthe 4 . Adjustmenotf steamlimitcontrolto a wide differentiainl creasesdifficultyif heatingseason . Referto thevalvemanufactureflisnstructionspackagedwith quickventsare oldstyle , slow - releasingtypeor dirty . Alwayssetsteam thepopsafetyvalve . LOWWATERCUT - OFF limitcontrodl ifferentiaals lowas possible . 5 . Soapanddetergentscauseextremesurging - cleanthoroughlyby The LowWaterCut - offwillin _ rrupttheelectricacl urrentto theburnerwhen skimmingtheboiler . the waterlinein the boilerdropsto a low level . It is veryimportantto keep CAUTION the floatchamberfreefromsedimenta , conditionessentiatlo dependability . Neverrefilla hotboilerwithcoldwater - thedangerof thermasl hockmay To keep any accumulationfrom interferingwith floatactionis to " BLOW crackasection . DOWN " or flushoutthe controlregularlyT . hismustbedonetwo - threetimes CAUTION thefirstweekafterinstallationandoncea weekthereafterduringthe heating Neverallowelectricianor oil burnermechanicsto tryout theirwork by season . Doit whiletheboileris inoperation . Firstnotewaterlevelin gauge turningon oil burnerfor evenone secondunlessboileris filledto the glass . Openblow - offvalveat bottomof control , waterwill pourout , flushing properoperatinglevel . awaysediment . Drainuntilwateris clear , abouta pail , thenclosevalve . If SYSTEMCHECKSAFTERFIRSTSTARTING - STEAMSYSTEMS waterlevelingaugeglasshasdropped , addwaterto boilerto restorelevel . Consultlow water cut - offmanufacturersinstructionsincludedwith boiler . Read the instructionspackagedwithyour controlsand makechecksand adjustmentsaccordinglyS . tart the burnerand set the Thermostatfor the NOTE : Openingblow - offvalvecheckscut - offoperationtoo . As floatdrops desiredroomtemperatureW . henadjustingtheSteamPressurecontrolw , atch withfallingwaterlevel , burnerswill shutoff . Aftervalveis closedandnormal the steamPressureGaugeanduse its pressurereading - as itwill bemore operatingconditionsarerestored , burnerswillresumefiring . accuratethanthe control . ( Anydifferencebetweenthe twowillbeduetotheir Boilersshouldnot be drainedbetweenheatingseasons . Onlywhen the differenltocation . ) waterin the systembecomesdirtyshouldthe boilerbe drained , flushedor BOILERWATERTREATMENT boiledout , andrefilled . Steamboilersmaybeentirelyfilledwithwaterduring thesummermonthsto excludeair . In closedhotwaterheatingsystemsn , egligibleamountsof makeupwaterare CLEANINGYOURBOILER used , and watertreatmentis not required . In steam systemswhere the systemistight , freefromleaks , andall the steamis returnedto the boileras Undernormaloperatingconditionsw , iththe burnersproperlyadjusted , we condensatet , heamountof makeupwateris small . Again , watertreatmentis recommendthat you have the flue passages , burneradjustment , and notrequired . operationof the controls checked once each year by a Service Technician . On steam systemswith less than 90 % of the steam beingreturnedas condensateo , rwithveryhardor corrosivemakeupwater , treatmentmaybe Before the start of each season ( orwheneversystemhas been desirable . Followthe recommen - dationosf the ASME ( AmericanSocietyof shutdownfor sometime ) recheckthe wholesystemfor leaks . . . andrecheck MechanicaEl ngineers ) Boilerand PressureVesselCode , SectionVl , latest the boilerandventpipefor leaks . Replaceor patchany boilersealsthatare version . faulty . BETWEENHEATINGSEASONS BOILERFLUEPASSAGES Boilersshouldnot bedrainedbetweenheatingseasons . Boilersinclosedhot Flue Passagesbetweensectionsshouldbeexaminedyearlyandcleaned . waterheatingsystemsmaybeleftas is . Steamboilersshouldbeentirelyfilled Removevent pipe . Raisetop panelof boilerandswingoutto exposeflue withwaterduringthesummermonthsto excludeair . 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 .
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Oil Boiler / BurnerCleaningInstructions 1 . ShutoffalIelectricapI owertotheboiler / burnear ndshutofffuel supply . 2 . Removethe sheetmetalsmokepipefromthetop d the boiler . Inspect pipeandchimneyfor signsof corrosionanddeteriorationC . leanbase ofchimney . \ 3 . Removetopjacketpanel . 4 . Removethe twobrasswingnutsholdingtheflueccllectofrop . oooooooooooo ooooooo 5 . Checkthegasketonthe undersideof thefluecollectorandreplaceas % % % ° ° % % ° 2 ° necessary . ° j ° o ° 2o % % % ° 2o ° Co ° 2o 6 . Removethe oil burner ( threecapscrews ) . - OR - ° ° ° ° % 02 ° % ° o % % ° ° ° 0 % % ° Oo ° Removethe oil burner / firedoorassembly ( fourhex nuts ) . This is the recommendedmethod , as it allows full accessto the combustion chamberandlesspotentiadl amageto thetargetwallduringthecleaning process . 7 . Removethe burnerdrawerassemblyC . leanany sootaccumulations . 8 . Replacetheburnernozzlewiththe exactsizeandtyperecommended for us onthisboiler . Note : Changingto adifferentfiringrate , otherthanis recommendedo , rtype of nozzlemaychangethe performanceof this boilerand / orcausea hazardouscondition . 9 . Cleanelectrodeassemblyandsetelectrodesasperburner manufacturerrsecommendations . 10 . Reinstalldrawerassemblyandcheckfor properheadlocationas per 14 . Reinstaltlheburner / firedoorassembly . the manufacturerr'secommendations . 11 . Inspectthetargetwail , blanket , andfiredoorinsulationforcrackingand 15 . Reinstaltlhefluecollectortopandsecurewiththetwobrasswingnuts . deteriorationI . f thereis anysignsof crackingor deteriorationr , eplace 16 . ReinstaltIhetopjacketpanel . Reconnectht efluepipe . beforereassemblintghe boiler . 12 . Removesootfromfiresidesurfacesby brushingdiagonallythroughthe 17 . Inspectandcleantheoil burnerblowerwheel . flue passages ( see drawing ) . Care should be taken so as not to 18 . Oilthe burnermotor ( DONOTOVEROIL } . damagethetargetwallwiththefluebrush . 13 . Carefullyvacuumsootaccumulationfsromthecombustionchamber 19 . Removethe oilpumpcoverandclean / replacethepumpscreen . Carefully area , beingparticularlycarefulnottodamagethetargetwailandblanket reassemble . withthevacuum . Targetwallandblanketmustbeingoodconditionand 20 . Replacethefuelfilter ( ifapplicable ) . correctlyinstalledto insurepropercombustion . 21 . Reconnectthe electricaal ndfuelsupplies . 22 . Fire the burner , checkingfor propercombustionusingcombustiontest equipmentm , akingadjustmentass necessary . 23 . Insurethatallsafetycontrolsandoperatingcontrolsarefunctioning properly . IMPORTANTOPERATINGANDMAINTENANCEREQUIREMENTSKEEPYOURBOILERANDTHEAREAAROUNDIT CLEANNEVERBURNREFUSEORANYMATERIALOTHERTHANTHESPECIFIEDFUELINYOURBOILERHAVEYOUR BOILERCHECKEDEACHYEARBYA QUALIFIEDTECHNICIAN
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_ u 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 8 . Cean all flue passages and _ ' he ' _ nt pipe , Nave burner c _ ea _ d and read ueted , Bu _ ler may not _ iitng at proper C _ eek _ e _ f _ e size if there is _ y doubt , re [ @ 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 _ Check o , . , _ ercurreetprotection Check to _ sure power supply circuit is " ON , OonttoIs o _ t of adjustment 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 .
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OPTIONAL LOW LIMIT CONTROL FOR BOILERS OIL BURNER WITH TANKLESS COIL PRIMARY RELAY HONEYWELLTROL PRESSURE _ TO 24v COLORCODE PART NO . 146 - 62 - 015 THERMOSTAT BK = BI _ CK BL = BLUE W = WHITE G = GREEN \ z z i _ = WIRE NUT LOW VOLTAGE WiRiNG HARNESS NOT FURNISHED pART NO , - 146 - 34 - O47 \ _ PRESSURETROL TO LWC . O HARNESS - GROUND SCREW PART NO , 433 - 00 - 873 PART NO . 1 € 6 - 54 - B02 2 X 4 JUNCTION - UNE VOLTAGE ( GROUND ) PART NO , _ 45 - 31 - O82 • LINE VOLTAGE ( NEUT . LEAD ) HANDY BOX COVER ( NOT SHOWN ) PART N0 . _ 46 - 61 - 121 PART NO - 433 - 00 - 872 L BURNER TO L . WC . O . HARNESS LOCK - NUT ( 2 PART NO . I / 2 " CLOSE PART NO . 146 - 07 - 030 LINE VOLTAGE ( NOT LEAD ) # 2 TERMINAL LWCO PART NO , 433 - - 00 - - 874 WH _ E FROM OIL BURNER ' tJ BLACK LEAD 4 X 4 OIL BURNER FROM OiL BURNER JUNCTION BOX McDONNELL M _ LLER LW . C . O 67D - 1 LW * C , O , PART NO . 146 - 26 - 042 W _ RING TERMINAL DETAIL
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" _ p _ r _ Tsr _ kle _ _ i _ K _ t4340 _ 14 ( ir _ l : _ s coJ _ _ , 8 { , and b _ l _ ) 4 L _ !
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( 1 _ 69BI0 ! )
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SUGGESTED NOZZLES AND SETTINGS FOR BECKETT AFG - M OIL BURNER SERIES PUMP OIL BOILER NOZZLE ACTUAL HEAD AIR AIR PRESSURE BURNER MODEL ADJUSTMENT SHUTTER BAND ( psig ) MODEL 0,85 - 60 ° W 1.00 3ES1.00 ( C ) ! 40 1 10 AFG - 50MB 1,10 - 70 ° B 1.25 3ES1,25 ( 0 ) 140 1 10 1 AFG - 50MD 1,20 - 70 ° B 1.35 3ES ! . 35 ( C ) ! 40 1 10 2 AFG - 50MD 1,25 - 60 ° B 1.50 4ES1,50 ( C ) 140 1 I0 2 AFG - 50MD 4ES1,75 ( C ) 1,50 - 60 ° B 1.75 140 3 10 3 AFG - 50MD 4ES1,85 ( 0 ) 1.75 - 60 ° B 1.85 140 3 10 4 AFG - 50MD FOR RIELLO R40 OIL BURNER SERIES ACTUAL PU M P AI R OIL BOILER NOZZLE TURBULATOR MODEL ( DELEVAN ) INPUT PRESSURE SETTING GATE EBURNERL RATE ( gph ) ( psig ) SETTING MOD 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 [ ACTUAL PUMP AIR BAND OIL BOILER NOZZLE I HEAD PRESSURE SET BURNER INPUT MODEL POINT MODEL ( DELEVAN ) ! RATE ( gph ) ( psig ) SETTING EZ - 1 HP 0.85 - 1.00 0.65 0.85x70ow 1.00 150 3ES1.00 ( C ) 0.90 EZ - 1 HP 1.25 150 0.85 - 1.00 1.00x70 ° W 3ES1,25 ( C ) 1 . ! 0 EZ - I HP 150 1,10 - 1.25 1 , ! Ox70 ° W 1.35 3ES1.35 ( C ) EZ - 1 HP 1.10 - 1.25 1,10 1.25x60 ° W 1.50 150 4ES1.50 ( C ) EZ - 2 HP 0.85 - ! . 00 1,65 150 1,25x60 ° W 1.50 4ES1,50 ( C ) 1.65 EZ - 2 HP 1.50 1.65 150 1.35x60 ° W 4ES1,65 ( C ) 2.00 EZ - 2 HP 1.85 150 ! , 50 1,50x60 ° W 4ES1,85 ( 0 ) I All burners fired at an over fire pressure of - 0,02 " wc . Burner insertion depth of 2 - 1 / 8 " allows burner tip to tial start up only , Final adjustment must be ! be 1 / 4 " behind insulation , I NOTE : These settings are intended for ini - made using combustion test instruments , i