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Dunkirk Empire II, Installation, Operation, Repair And Parts Manual

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Dunkirk Empire II Installation, Operation, Repair And Parts Manual Download Page 13

11

SYSTEM PIPING ARRANGEMENT ALTERNATE NEAR BOILER PIPING

>  DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER

>  CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK

>  PER THIS MANUAL, USE OPTION #2 IN “FILLING THE SYSTEM WITH WATER”

>  THIS PIPING ARRANGEMENT CAN BE USED WITH ZONE VALVES OR ZONE

 CIRCULATORS

Summary of Contents for Empire II

Page 1: ...ir Parts These instructions must be affixed on or adjacent to the boiler DUNKIRK BOILERS DUNKIRK NEW YORK 14048 AREA CODE 716 366 5500 MEMBER The Hydronics Institute Saving The Earth Saving Your Money OIL FIRED CAST IRON HOT WATER BOILERS ...

Page 2: ......

Page 3: ...from 0 65 gph up to 2 00 gph Boilers may be purchased with or without the following options a Beckett AFG Carlin EZ or Riello 40 oil burner a Taco or Grundfos circulator with isolation valves a tankless coil for domestic hot water All packaged boilers include a swing door Honeywell aquastat temperature and pressure gage relief valve drain valve 2 Delevan oil nozzles for multiple firing rates only ...

Page 4: ...d 3EI 00Z are the same boiler without a tankless coil except for the firing rate of the oil burner Models 4E 90T 4E1 25T and 4E1 50T are the same boiler with a tankless coil except for the firing rate of the oil burner Each boiler rating plate shows three possible model numbers for a given boiler configuration The actual model number is determined by the firing rate of the oil burner Boilers that ...

Page 5: ...antities of steam and hot water which may damage the surroundings Before installing the relief valve read the manufacturer s instructions and maintenance section of the manual on relief valves 12 Installation and sizing of the expansion tank must consider the heating systems total water volume temperature boiler initial fill pressure and system arrangement An im properly installed and sized expans...

Page 6: ... location centralized with the piping system and as close to the chimney as possible 2 The boiler must be level If necessary use metal shims beneath the boiler s feet 3 Use a raised base if the floor can become wet or damp 4 Maintain clearances for fire safety as well as servicing An 18 clearance must be maintained at a side where passage is required for access to another side for cleaning servici...

Page 7: ...ALWAYS KEEP THE MANUAL FUEL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME 5 INSTALLATION REQUIREMENTS ...

Page 8: ...feet per 1 000 Btu per hour of the total input rating of all appliances installed in 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 to...

Page 9: ...ur of total input rating of all equipment in the enclosure 3 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of one square inch per 2 000 Btu per hour of total input rating of all equipment in the enclosure 4 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum...

Page 10: ...e rear section using the 3 4 nipple and street ell provided in the parts bag Connect a discharge pipe of the same pipe size 3 4 to carry any water away to a drain Do not connect directly to a drain but leave an air gap No shutoff of any description shall be placed between the safety relief valve and the boiler or on discharge pipes between such safety valves and the atmosphere Installation on the ...

Page 11: ...NGEMENT ZONING WITH ZONE VALVES CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 ...

Page 12: ...NGEMENT ZONING WITH CIRCULATORS CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 ...

Page 13: ...R PIPING DIAPHRAGM EXPANSION TANK MOUNTED OFF THE BOILER CIRCULATOR ON SUPPLY PIPING PUMPS AWAY FROM EXPANSION TANK PER THIS MANUAL USE OPTION 2 IN FILLING THE SYSTEM WITH WATER THIS PIPING ARRANGEMENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS ...

Page 14: ...eds to be installed in the 3 4 tapping on the tankless coil By mounting the aquastat on the coil the tankless coil performance is maximized by making the burner respond more quickly to a call for domestic hot water A tempering valve mixing valve is also recommended as shown in figure below A flow restrictor may be required on the tankless coil inlet piping so that flow rates are matched to boiler ...

Page 15: ...uel consumption Tankless coil performance will fall as concentration of antifreeze is increased Refer to boiler and piping water volumes tables in this manual Number of Total Volume Boiler Section Gallons 3 9 6 4 11 6 5 13 7 BOILER WATER VOLUMES PIPING WATER VOLUMES COPPER PIPE STEEL PIPE FACTOR FACTOR 82 5 63 5 40 0 36 0 1 23 3 22 2 1 15 3 12 8 1 10 8 9 5 2 6 2 5 8 in table to determine volume in...

Page 16: ...6 diameter chimney connector pipe and using the draft regulator packed with the boiler Properly installed the regulator will control the draft automatically It is better to install it in a horizontal section of pipe but it may be installed in an angled or vertical section of pipe Make certain that the top of the regulator is at the top and that the short pipe section which holds the vane is horizo...

Page 17: ...15 ...

Page 18: ...nal Electrical Code If you are not familiar with wiring and codes in general have a competent electrician do this job On packaged boilers the boiler controls are all wired at the factory You need only connect a 115 volt electrical supply to the Ll and L2 terminals on the aquastat relay and two thermostat wires to the T and T terminals on the same aquastat relay see figure below Run a separate circ...

Page 19: ...ed on the tank and in the line to the tank are for bleeding off excess air and water DIAPHRAGM EXPANSION TANK not provided The diaphragm type expansion tank takes the place of the conventional expansion tank Carefully read the instructions packed with your tank assembly The expansion tank should be sized and installed correctly because an improperly installed or sized expansion tank may result in ...

Page 20: ...emains closed for an additional 15 seconds This allows the burner fan motor to pre purge the combustion chamber and the oil pump to bring the supply oil pressure up to its set point helping to provide a clean light off AQUASTAT RELAY CONTROL provided The water temperature limit control in the aquastat relay is adjustable and may be set as low as 140 F so long as return water temperatures to the bo...

Page 21: ...hen the power purging drain valve runs air free close the isolation valve or zone valve Repeat this procedure for the remaining heating zones d Once all zones are filled with water and purged of air close the power purging drain valve and fill line shut off valve open the main shutoff valve and adjust the throttling valves and balancing valves as required OPTION 2 Close the air vents on all radiat...

Page 22: ...lin burners or 11 feet for Riello burners a two stage fuel unit is required with a return line Install an oil filter of adequate size inside the building between tank shutoff valve and the oil burner For ease of servicing locate the shutoff valve and filter near the oil burner AIR SUPPLY FOR COMBUSTION Do not install the boiler in rooms with insufficient air unless corrective steps are taken Occas...

Page 23: ...re cannot be obtained it will be necessary to verify the burner head and electrode alignment Proper electrode alignment figures are presented on the following pages If the fire continues to be smoky replace the nozzle with a correct replacement Once the burner is completely adjusted the burner should be started and stopped several times to assure good operation with no fluttering or rumbling Verif...

Page 24: ...22 ...

Page 25: ...23 RIELLO 40 F5 BURNER ELECTRODE ADJUSTMENTS RIELLO 40 F10 BURNER ELECTRODE ADJUSTMENTS CARLIN E Z BURNER ELECTRODE ADJUSTMENTS ...

Page 26: ...s an important effect on the operation of the boiler system Be sure to FOLLOW THE INSTRUCTIONS included with your thermostat Typically the thermostat is located about five feet above the floor on an inside wall The thermostat should be located to sense average room temperature so avoid the following DEAD SPOTS behind doors corners and alcoves HOT SPOTS concealed pipes fireplace TV sets radios lamp...

Page 27: ...ermit the valve to snap shut Refer to the valve manufacturer s instructions packaged with the valve for more details CONVENTIONAL EXPANSION TANK As noted in the EQUIPMENT AND OPTIONAL ACCESSORIES section this tank may become water logged or may receive an excess of air Frequent automatic opening of the relief valve indicates water logging A high boiler temperature accompanied by unusually low radi...

Page 28: ...by cutting the end of the flue brush off and inserting it into a drill When brushing care should be taken so as not to damage the target wall with the flue brush 6 Carefully vacuum the soot accumulations from the combustion chamber area being particularly careful to not damage any of the refractory or blanket insulation To gain access to the combustion chamber first double check that the shut off ...

Page 29: ...e on this boiler 5 Reinstall the burner drawer assembly making sure the head location and size if applicable are per the manufacturer s recommendations If the burner being used has a damaged head replace the head with the exact same head recommended for use on this boiler 6 Inspect and clean the oil burner blower wheel 7 Remove the oil pump cover and clean replace the pump screen Carefully reassem...

Page 30: ... is ON Controls out of adjustments Reset according to instructions packed with controls Circulating pump not running Check relay operation Poor electrical contact Check all controls terminals and wire joints IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT IF BURNER IS NOISY IF RADIATORS ARE NOISY HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT You may avoid inconve...

Page 31: ...ESS COILAND AND HONEYWELLL8124CAQUASTAT CONTROL BECKETTAFG BURNER SHOWN ELECTRICAL WIRING BOILERWITHOUTTANKLESSCOILANDAND HONEYWELLL8148AAQUASTAT CONTROL BECKETTAFG BURNER SHOWN Service Company Serviceman Address Telephone ...

Page 32: ... WITH TANKLESS COILAND HONEYWELLL8124CAQUASTAT CONTROL CARLIN EZ BURNER SHOWN BOILER WITHOUT TANKLESS COIL AND HONEYWELL L8148A AQUASTATCONTROL CARLIN EZ BURNER SHOWN Service Company Serviceman Address Telephone ...

Page 33: ... WITH TANKLESS COILAND HONEYWELL L8124CAQUASTATCONTROL RIELLO 40 BURNER SHOWN BOILER WITHOUT TANKLESS COIL AND HONEYWELLL8148A AQUASTATCONTROL RIELLO 40 BURNER SHOWN Service Company Serviceman Address Telephone ...

Page 34: ...sequence of operation for the burner and circulator is as follows 1 Thermostat calls for heat completing circuit between terminals T T on the aquastat controller energizing the 1K relay coil 2 With the 1K relay coil energized contacts 1K1 and 1K2 are closed Terminal B1 is energized providing power to the oil burner primary control This in turn powers the ignition coil and burner motor 3 With the p...

Page 35: ...e burner operation starts and remains running as long as the cad cell senses flame In the event of flame failure or the flame is not fully proven within the trial for ignition period the primary control will lockout and open the burner circuit This will require a manual startup of the burner 4 As long as flame is proven through the cad cell relay the burner will remain on until the circuit is inte...

Page 36: ...00 281 13 8 32 Brass Wing Nut 137 04 007 137 04 007 137 04 007 14 14 x 1 Hex Washer Head Screw 146 95 109 146 95 109 146 95 109 15 Coil Housing Gasket 146 93 064 146 93 064 146 93 064 16 3 7 GPM Tankless Coil 146 27 020 146 27 020 146 27 020 17 Coil Housing Cover Plate not shown 146 19 001 146 19 001 146 19 001 18 Stainless Steel 3 8 16 x 1 1 2 Stud 146 95 113 146 95 113 146 95 113 19 Stainless St...

Page 37: ...5 126 4 Swing Door Insulation 146 14 014 5 Swing Door Hinge 403 00 010 6 1 4 x 2 Round Head Rivet 146 95 121 7 3 8 x 1 Hex Head Serrated Flange Bolt 146 95 124 8 3 8 x 48 Fiberfrax Round Braid 433 00 905 9 Swing Door 403 00 009 10 Observation Door 403 00 014 11 5 16 Lock Washer 146 95 123 12 3 8 x 3 8 Shoulder Bolt 5 16 18 Thread 146 95 122 ...

Page 38: ...ide Jacket Panel 425 00 264 425 00 265 425 00 266 5 Upper Side Jacket Panel 425 00 267 425 00 267 425 00 267 6 5 16 Acorn Nut 146 95 042 146 95 042 146 95 042 7 10 x 1 2 Jacket Screw 146 95 074 146 95 074 146 95 074 8 Stand Off 146 95 103 146 95 103 146 95 103 9 Lower Front Jacket Panel boiler w swing door 425 00 268 425 00 268 425 00 268 XX Complete Jacket for Boiler with Swing Door 425 45 289 42...

Page 39: ...047 146 26 047 3b 1 1 4 Ball Valves 146 26 043 146 26 043 146 26 043 3c Taco Circulator Gaskets 146 26 050 146 26 050 146 26 050 1 1 4 Flange set with gaskets nuts and bolts 146 26 049 146 26 049 146 26 049 Taco 007 Circulator with Gaskets 433 00 047 433 00 047 433 00 047 4 Temperature Pressure Gauge 2 Stem 146 23 003 146 23 003 146 23 003 5a 1 1 4 x 2 1 2 Pipe Nipple 146 07 044 146 07 044 146 07 ...

Page 40: ...EW 65 on rate the oil pressure must be increased to 175 psig All Beckett oil burners for the EW boiler are factory preset at 140 psig BOILER DELEVAN FIRING HEAD AIR BAND CARLIN MODEL OIL NOZZLE RATE gph SETTING SET POINT BURNER 3EW 65 0 55 70 B 0 65 0 50 0 52 EZ 1 HP 3EW 75 0 65 60 B 0 75 0 60 0 65 0 60 EZ 1 HP 3EW1 00 0 85 60 B 1 00 0 85 1 00 0 80 EZ 1 HP 4EW 90 0 75 60 B 0 90 0 75 0 75 EZ 1 HP 4...

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