Dunkirk Empire II User manual

II
OIL-FIRED CAST IRON HOT WATER
BOILERS
Installation
Operation
Repair Parts
EPA DOE
Saving The Earth Saving Your Money
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

INTRODUCTION
The Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron
sections. The Empire Water boiler is available with 3, 4, or 5 cast iron sections. These
sections are held together by cast iron push nipples.
The Empire Water boiler is capable of firing #2 fuel oil 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
when purchasing a burner), flue brush, and an extra boiler tap for an expansion tank or air
elimination.
36J 000
I[/4 _//
RETURN
NIPPLE &
REIIUCING
TEE
--20,5000_
TEHP,/
PRESSURE
FRDNT VIEW
(Without
Tank{ess
Cold
L[NIT
OIL
17 I/2 _
RIELLO
13 3/4"
BECKETT
0R CARLIN
--WATER
OUTLET
RIGHT SIDE VIEW
WITH SWING DOOR
dPT[ONAL
TANKLESS
COIL
WATER
HEATER
WITH i/2 _ NPT
CONNECTIONS
RELIEF
VALVE
OUTLET--__
BACK VIEW

BOILER MODEL NO.
WITH WITHOUT
TANKLESS TANKLESS
COIL COIL
>>3EW.65T >>3EW.65Z
>>3EW.75T >>3EW.75Z
3EW 1.00T 3EW 1.00Z
>>4EW.90T >>4EW.90Z
4EW1.25T 4EW1.25Z
4EW1.50T 4EW1.50Z
>>5EW1.20T >>5EW1.20Z
5EW 1.75T 5EW 1.75Z
5EW2.00T 5EW2.00Z
*MBH = 1,000 BTU per hour BTU = British Thermal
NET DIMENSIONS - (inches)
NO. INPUT **HEATING I=B=R FIRING MINIMUM
SEC. *MBH CAPACITY RATING RATE A.F.U.E. CHIMNEY
*MBH *MBH +GPH ++ SIZE/HEIGHT A B C
3 91 80 70 0.65 86.3 8" X 8" X I5" I4-1/2 6 8
3 105 92 80 0.75 85.2 8" X 8" X I5" 14-I/2 6 8
3 140 II9 I03 1.00 83.4 8" X 8" X I5" 14-I/2 6 8
4 126 I11 97 0.90 86.0 8" X 8" X I5" 17-3/4 6 9-5/8
4 175 I50 130 1.25 83.9 8"X 8" X I5" 17-3/4 6 9-5/8
4 210 I78 155 1.50 82.4 8"X 8" X I5" 17-3/4 6 9-5/8
5 168 I47 I28 1.20 86.5 8" X 8" X 15" 2I 6 I1-1/2
5 245 209 I82 1.75 83.6 8" X 8" X 15" 2I 6 I1-1/2
5 280 236 205 2.00 82.0 8" X 8" X 20" 2I 6 11-1/2
Unit
**Heating Capacity based on I3% CO2 with a -0.02" w.c. draft over fire, and a #1 smoke or less. Testing was done in accordance with the
D.O.E. (Department of Energy) test procedure.
+GPH = Gallons per hour oil at I40,000 BTU per gallon
++A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure.
>>Asan Energy Star Partner, Dunkirk Radiator Corporation has determined that this product meets Energy Star Guidelines for Energy Efficiency.
The City of New York MEA #191-99-F
These low pressure oil fired hot water boilers are constructed and hydrostatically tested for
a maximum working pressure of 50 psig (pounds per square inch gage) in accordance with
AS.ME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code
Section IV Standards for heating boilers.
The Heating Capacity indicates the amount of heat available after subtracting the losses up
the stack. Most of this remaining heat is available to heat water. A small portion is heat from
the jacket and surfaces of the boiler and it is assumed that this heat stays in the structure.
The Net I=B=R Rating represents the portion of the remaining heat that can be applied to
heat the radiation or terminal units (i.e. finned tube baseboard, cast iron radiators, radiant
floor, etc.). The difference between the Heating Capacity and the Net I=B=R Rating, called
the piping and pickup allowance, establishes a reserve for heating the volume of water in the
system and offsetting heat losses from the system piping. The Net I=B=R Ratings shown
are based on a piping and pickup factor of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net I=B=R Rating of the boiler selected should be
greater than or equal to the calculated peak heating load (heat loss) for the building or
area(s) served by the boiler and associated hot water heating systems. The manufacturer
should be consulted before selecting a boiler for installations having unusual piping and
pickup requirements.
Boilers with the same number of sections are identical to each other except for their firing
rate. The firing rate is determined by the nozzle size in the oil burner and the oil pressure at
the nozzle. For example: Models 3E.65Z, 3E.75Z, and 3EI.00Z are the same boiler, without
a tankless coil, except for the firing rate of the oil burner. Models 4E.90T, 4E1.25-1-, 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 are
factory packaged include two nozzles for two firing rates. These boilers operate on #2
Heating Oil. This fire rate does not come with additional nozzles or heads for the
burner. The 3 & 4 section units are packaged with two nozzles. They can be field
converted to low fire rates by utilizing the low fire kit.

RULES FOR SAFE INSTALLATION AND OPERATION
1. Read the Owner's Manual for Safe Operation carefully. Failure to follow the rules for
safe operation and the instructions can cause a malfunction of the boiler and result in death,
serious bodily injury, and/or property damage.
2. Check your local codes and utility requirements before installation. The installation must
be in accordance with their directives, or follow NFPA 31 - Installation of Oil Burning
Equipment, latest revision.
3. Before servicing, allow boiler to cool. Always shut off any electricity and oil to boiler when
working on it.
4. Inspect oil line and connections for leaks.
5. Be certain oil burner nozzle is the size required. Overfiring will result in early failure of the
boiler sections. This will cause dangerous operation.
6. Never vent this boiler into an enclosed space. Always vent to the outside. Never vent to
another room or inside a building.
7. Be sure there is adequate air supply for complete combustion.
8. Follow a regular service and maintenance schedule for efficient and safe operation.
9. Keep boiler area clean and free of combustible material, gasoline and other flammable
vapors and liquids.
10. Oil burners are not do-it-yourself items. This boiler must be installed and serviced by
qualified professionals using combustion test instruments.
11. Be aware when piping the relief valve that if the system pressure exceeds the safe limit
of 30 pounds per square inch, the relief valve will automatically lift open. Lifting of the
relief valve can discharge large quantities 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 expansion tank may result in frequent lifting of the relief valve
or other heating system problems. For proper installation, sizing, and maintenance of the
expansion tank follow the guidelines established by Dunkirk Boilers and the expansion
tank manufacturer.
13. Expansion tank performance and life expectancy can be hindered by overfilling the boiler.
Dunkirk Boilers recommends an initial fill pressure of 10-12 psig. For higher fill pressures
the expansion tank's air charge will need to be increased to match the fill pressure.
Consult the manufacturer's guidelines for sizing and selection.
14. Purging the heating system of air and gases when first putting the boiler into service is
critical for proper circulation and quiet performance. Once the air and gases are purged,
for boiler installations using float type vents, the air vents should be closed for normal
operation. If air is heard or noticed by a loss of heat, purge the system and open the
vents for a short period of time.
WARNING
This boiler has been designed for residential installations. If used for commercial applications,
all jurisdictional requirements must be met. This may require wiring and/or piping
modifications. The manufacturer is not responsible for any changes to the original design.
IDO NOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE. I

BEFORE YOU START
Complete all of the following prior to installing the boiler.
A.Check to be sure you have selected the right size boiler with the proper capacity. The I=B=R rating
of the boiler selected should be greater than or equal to the calculated peak heating load (heat
loss) for the building or area(s) served by the boiler and associated hot water heating systems.
See boiler rating and capacity table previously listed in this manual. Any heat loss calculations
used should be based on approved methods.
B. Boiler must be supplied with the proper oil supply and oil piping, sufficient fresh combustion air,
and a suitable electrical supply.
C.Boiler must be connected to a suitable venting system and a piping system adequate to distribute
the heating load.
D.Athermostat must be properly located and installedfor control of the heating system.
If there are any doubts as to the various requirements, check with local authorities and obtain
professional help where needed. The OPERATING INSTRUCTIONS, FINAL CHECKS AND
ADJUSTMENTS, and MAINTENANCE sections in this manual are vital to the proper and safe
operation of the heating system. Take the time to be sure they are all done.
LOCATING THE BOILER
1. Place the boiler in a 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, servicing, inspection, or
replacement of any parts that normally may require such attention. Boilers must be installed at least
6" from combustible material on all sides and above. Allow at least 24" front clearance for servicing.
5. Fresh air for combustion must be available at the front of the boiler. Fresh air for ventilation must be
available to the front AND rear of the boiler. Air passages must be free of obstructions at all times.
Ventilating and combustion air must enter boiler room without restrictions.
6. The floor supporting the boiler must be non-combustible and sufficiently stable. If it is combustible,
place the boiler on 2" concrete patio blocks or 2" Cladlite Pad TM. The blocks or pad must be under
the entire boiler to protect the floor.
7. Be sure installation is in accordance with the requirements of the local authorities having
jurisdiction. Compliance with these regulations is required. In the absence of local codes, follow
NFPA 31 - Installation of Oil Burning Equipment, latest revision.
MINIMUM CLEARANCE DIMENSIONS
i i_ iTM i b1ii,i _, ii__i_i i i-oTM ii [i,i_i:: i
: _ iR[iNT
_ i,i]i [,,i. i i_i:,i:• _,,_,,,"iili i i C[ ilili i:: :: :i
, iiiiiiiiiiiiili
t
4

IALWAYS KEEP THE MANUAL FUEL SUPPLY VALVE SHUT OFF, IF THE I
I
BURNER IS SHUT DOWN FORAN EXTENDED PERIOD OF TIME.
INSTALLATION REQUIREMENTS
BVERCURRENT
PROTECTED
SAFETY SWITCH ---
2 _ FILL
PIPE --I
NIN, 2" ID,
VENT PIPE--,\
S
\
SHUTDFF O_L TANK 1
/
OIL
J
OIL LINES -x
SERVICE
J
L]NES_O OTHER
APPLIANCES
TD DUTS]DE
ELECTRIC LINE
FDUN_ATIONS
FILL VALVE
AND SHUTOFF
DIAPHRAGM
EXPANSION TANK
]}RAPT
REGULAI @R _
VENT
PIPE _'_-
RELIEF
RAD[ATIHN
RAIJIATION
CIRCULATING
PUMP IN
RETURN LINE
OR AFTER THE
EXPANSION
TANK
--- C
--- H
I
H
N
-- E
-- y
GENERAL PRINCIPAL REQUIREHENT3 FE]R A TYPICAL INSTALLATZE]N

FRESH AIR FOR COMBUSTION
WARNING
Be sure to provide enough fresh air for combustion. Enough air ensures proper combustion and
assures that no hazard will develop due to the lack of oxygen.
I NOTE
If you use a fireplace or a kitchen or a bathroom exhaust fan, you should install an outside air
intake. These devices will rob the boiler and water heater of combustion air.
You must provide enough fresh air to assure proper combustion. The fire in the boiler uses
oxygen. It must have a continuous supply. The air in the house contains only enough oxygen to
supply the burner for a short time. Outside air must enter the house to replace the air used by
the burner. Study the following examples 1 and 2 to determine your fresh air requirements.
I
EXAMPLE 1: Boiler Located in Unconfined Space
If your boiler is in an open area (unpartitioned basement) in a conventional house, the air that leaks
through the cracks around the doors and windows will usually be adequate to provide airfor
combustion. The doors should notfit tightly.Do not caulk the cracks around the windows.
An unconfined space is defined as a space whose volume is not less than 50 cubic 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 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 1,000 Btu
per hour of the total input rating of all combustion equipment in the confined space, but not less
than 100 square inches. One opening shall be within 12 inches of the top and one within 12
inches of the bottom of the enclosure.
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 inches of
FREE opening. Metal grilles have about 60% FREE opening. To find the Iouvered area needed,
multiply the free opening required by 1.7 (130 x 1.7 =221.0 sq. in. Iouvered area). In this
example, two grilles each having an 8"x 30" (240 sq. in.) Iouvered area would be used.
AIR OPENINGS FOR BOILER LOCATED IN CONFINED SPACE {CLOSET OR UTILITY ROOMi

B= All Air from Outdoors: The confined space shall be provided with two permanent
openings, one commencing within 12 inches of the top and 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) that freely communicate with the
outdoors.
1. When directly communicating with the outdoors, each opening shall have a minimum
free area of one square inch per 4,000 Btu per hour of total input rating of all
equipment in the enclosure.
2. When communicating with the outdoors through vertical ducts, each opening shall
have a minimum free area of one square inch per 4,000 Btu per hour of total input
rating of all 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 dimension of rectangular
air ducts shall be not less than three inches.
FRES
D/C
FRESH AIR DUCT CAPACITIES FOR DUCTS SUPPLYING FRESH AIR TO BOILER IN
TIGHTLY CONSTRUCTED HOUSES
Fresh Air 1/4"Mesh Screen Wood Louvers Metal Louvers
Duct Size (Btuh)* (Btuh)* (Btuh)*
3-½" x 12" 144,000 36,000 108,000
8" x 8" 256,000 64,000 192,000
8"x 12" 384,000 96,000 288,000
8"x 16" 512,000 128,000 384,000
*Btuh = British Thermal Units per hour based on opening covered by _¼"mesh
screen, wood louvers, or metal louvers.
7

SYSTEM PIPING
1. When the installation of the boiler is for a new heatinq system, first install all of the radiation
units (panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating
system piping and components have been installed, make final connection of the system piping to
the boiler. It is recommended to mount the circulating pump on the supply side piping, such that it
pumps away from the expansion tank. Refer to the figures on the next pages.
2. A hot water boiler installed above radiation level must be equipped with a low water cut off
device. A periodic inspection is necessary, as is flushing of float type devices, per low water cut off
manufacturers specific instructions.
3. The packaqed boiler unit is set up with 1-1/4" NPT supply and return pipinq from the front of
the boiler. The boiler supply and return piping can be moved to the rear of the boiler. The boiler
should not be piped return line to the front, supply line to the rear, or vice versa, as this will cause
the boiler water to short circuit the heat exchanger. Piping connections may require additional
fittings and parts.
4. The relief valve is meant to be installed inthe back side of the 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 safety relief
valve shall conform to the ANSI/ASME Boiler and Pressure Vessel Code, Section IV.The manu-
facturer is not responsible for any water damage.
5. When connectinq the cold water supply to the pressure reducing valve, make sure that a clean
water supply is available. When the water supply is from a well or pump, a sand strainer should
be installed at the pump.
6. The minimum boiler supply water temperature setting on the aquastat is 140°R If the boiler is
used in a heating system where supply water temperatures below 140°F are desired, a suitable
method, such as the use of bypass piping shown in the figure below, a 3 way or 4 way mixing
valve, or some other means needs to be used to ensure return water temperatures to the boiler
are no less than 120°F. When the boiler is operated with return water temperatures less than
120°F, condensation may form in the boiler and venting. This condensation is corrosive and can
eventually cause severe damage to the boiler and venting system.
RETJRN FROM SFSTEM
-RDJJST THE TWO THROTTLING _'ALvES TD
H_NTAIN /_T LEbST 20 DEGREES FER NHEIT
ARE b_:EiI _WR B_F_S PIPING, IF REQUIRED
/// lh iHE I_B]LER RE_bRN IHE fHRQI ILIN6 v#_LvES
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
, r
I _z,_ THRDT LING V//VE
\\ \ \ ( SUPPLf TO
F LLTROL _ITII \\X "SYSTEH
AR PCRGER \ \_
FILL LINE wITH //} kISOLATION _v ALVES
3HUIBF F VALVE_

SYSTEM PIPING ARRANGEMENT 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
RETURN FROM S¥_TEN
SHUTOFF VALVE
BOILER SERVICE--
---AQUASTAT
\
FILLTROL WITH
AIR PURGER
FILL LINE WiTH
SHUTOFF VALVE"
l
SUPPLY TO
SYSTEM
CIRCULATOR
PUNP
BALANCING VALVE
._ ZONE VALVE
SUPPLY TO
SYSTEM
VALVES
BOILER
DRAIN
VALVE_-

SYSTEM PIPING ARRANGEMENT - 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
SHUTOFF VALVE
BOILER SERVICE_
/
J
I
SUPPLY TO
SYSTEM
\\\
FILLTROL WITH '\
AIR PURGER
FiLL LINE WITH /
SHUTOFF VALVE_
IBALANCING VALVE
FLOW CHECK VALVE
ZONE CIRCULATOR
ISOLATION VALVE
SUPPLY TO
SYSTEM
BOILER
BRAIN
10

SYSTEM PIPING ARRANGEMENTALTERNATE 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
RETURN PROM SYSTEM
ISOLATION
VALVES
BOILER
DRAIN
SHUTOFF VALVE
BOILER SERVICE ]
/
SUPPLY TO
SYSTEM
LINE WITH
SHUTOFF VALVE
LOCATE CIRCULATOR PUHP HERE WHEN SYSTEM
PIPING USES ZONE VALVES, IF SYSTEM PIPING
USES ZONE CIRCULATORS_ USE THIS CIRCULATOR
AS A ZONE CIRCULATOR
11

,Boilers may be factory packaqed with a tankless heater coil see figure below. This
coil provides instantaneous heating of water for domestic use - if proper burner and
water supply line controls are used. Tankless coils are meant to provide domestic hot
water for intermittent draws, not continuous flow.
IMPORTANT
Do not use a tankless coil if your water is excessively hard with
lime or other deposits which will accumulate inside the coil.
When using a tankless coil, the boiler has been configured so the Honeywell L8124C
Combination Hi/Low Limit Aquastat Relay mounts on a thermowell (provided)which
needs 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 heat input (see table
below).
Boiler Burner Firing Input Tank less
Model Rate (gph) (MBH) Rating (gpm):l:
3EW.65T 0.65 91 2.90
3EW.75T 0.75 105 3.00
3EW1.00T 1.00 140 3.25
4EW.90T 0.90 126 3.15
4EW 1.25T 1.25 175 3.50
4EW1.50T 1.50 210 3.75
5EW 1.20T 1.20 168 3.45
5EW1.75T 1.75 245 4.00
5EW2.00T 2.00 280 4.25
Gallons of water per minute heated from 40°F to 140°F with
200°F boiler water temperature, intermittent draw
UNTEMPERED H_T WATER
([D AU _HAT]C ])ISHW_:_SHER EC],>
CENTER LINE
BF CDLD TAP
/
TEHPERED HDT
WATER
I 1 EMPERING
VALVE
E]NTRE]L
'dELL
12

.Antifreeze added to boilers must be non-toxic, and must be of a type specifically
intended for use in closed hydronic heating systems. Under no circumstances should
automotive antifreeze be used. Antifreeze used in any boiler may reduce capacity by
10% or more and increase fuel consumption. Tankless coil performance will fall as
concentration of antifreeze is increased. Refer to boiler and piping water volumes tables
in this manual.
BOILER WATER VOLUMES
Number of Total Volume
Boiler Section (Gallons)
3 9.6
4 11.6
5 13.7
PIPING WATER VOLUMES
COPPER PIPE STEEL PIPE
PIPE SIZE FACTOR FACTOR
½" 82.5 63.5
¾" 40.0 36.0
1" 23.3 22.2
1-IA" 15.3 12.8
1-½" 10.8 9.5
2" 6.2 5.8
Divide total length of piping in feet by appropriate factor
in table to determine volume in gallons.
13

Foroil-firedboilersforconnectionstoventsorchimneys,ventinstallationsshallbein
accordancewithapplicableprovisionsofINSTALLATIONOFOILBURNINGEQUIPMENT,
NFPA-31-latestrevision,andapplicableprovisionsoflocalbuildingcodes.
CHIMNEYAND CHIMNEY CONNECTIONS
This is a very important part of your heating system. No boiler, however efficient its design,
can perform satisfactorily if the chimney that serves it is inadequate. Check your chimney to
make certain that it is the right size, properly constructed and in sound condition.
It is cheaper to rebuild a poor chimney than to pay excessive fuel bills. If yours is an old
chimney, a new steel liner or a new prefabricated chimney may be the best solution. The
following chart shows recommended minimum chimney sizes based on Table 3 and Figure 6
of the I=B=R Testing and Rating Standard for Heating Boilers, Sixth Edition, June 1989.
RECOMMENDED MINIMUM CHIMNEY SIZES
FIRING RATE
(gph)
0.60- 1.30
1.31 - 1.80
1.81 - 2.00
For elevations abo,
CHIMNEY
HEIGHT (ft)
15
15
2O
NOMINAL
CHIMNEY
8" x 8"
8" x 8"
8" x 8"
2,000 feet above sea level, a_
ROUND LINER-
INSIDE
6"
7"
8"
d 3 feet to the chimn
SQUARE LINER-
INSIDE
6_3/4,,x 6_3/4,,
6_3/4,,x 6_3/4,,
6_3/4"x 6_3/4-
y heights.
For additional chimney design and sizing information, consult the ASHRAE 1996 HVAC
Systems and Applications Handbook, Chapter 30, Gas Vent and Fireplace Systems; or the
National Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances, ANSI/
NFPA211.
CHIMNEY CONNECTOR AND DRAFT REGULATOR
Venting the boiler requires a 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 horizontal. Even though locating the
draft regulator close to the chimney reduces noise, install the draft regulator as close as
practicable to the boiler.
To install the chimney connector, start at the boiler with a vertical pipe and then elbow - then
install the draft regulator making it horizontal. When the regulator is in place, start at the
chimney and work back to the regulator. Join the two sections with a drawband. The
horizontal pipe must slope up toward the chimney at least 1/4 inch per linear foot of venting.
The chimney connector must not leak and must be firmly supported. Join each of the
sections with at least two sheet-metal screws. Support every second section with a
stovepipe wire.
Maintain a minimum vent pipe clearance of 18" from the surface of the vent to wood
and other combustible materials. 14

TYPICAL CHIMNEY CrINNECTIF1N
BE REQUIRED MINIMUM
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 f
UNDI_STRUCTED TOP OPENING
MUST BE AT LEAST 4
INCHES THICK -
AND BE
MUST SLOPE UP
AT LEAST i,/4 INCH
PER FOOT OF
HORIZONTAL RUN_
DRAVBAND
LAST PIECE
INSTALLED
\\
IN
THIMBLE
DRAFT REGULATOR
VANE
ALTERNATE POSITIONS
TOP
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ELECTRICAL CONNECTIONS
Thermostat
Install a 24-volt thermostat (not provided) in a proper location. The location of the thermostat has an
important effect on boiler system operation. BE SURE TO FOLLOW THE INSTRUCTIONS
INCLUDED WITH THE THERMOSTAT.
Groundinq
Permanently ground the boiler according to local codes and the National Electrical Code. Run a 14
gauge or heavier copper wire from the boiler to a grounded connection in the service panel or a
properly driven and electrically grounded ground rod.
WARNING
Turn off electric power at fuse box before making any line voltage connections.
Follow local electrical codes.
Electric Power Supply
All electrical work must conform to your local codes as well as the National 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 LI 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 circuit from a separate overcurrent protection device in your electrical service en-
trance panel. This should be a 15 ampere circuit. Locate a shut-off switch at the boiler. It must be
turned off during any maintenance. Solder and tape or securely fasten these connections with wire
nuts.
Oil Burner Wirina
For boilers packaged with oil burners, the burners are wired at the factory. For boilers shipped knock-
down or packaged without a burner, wiring connections are shown in the electrical wiring diagrams of
this manual.
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EQUIPMENT AND OPTIONAL ACCESSORIES
RELIEF VALVE (provided)
Each low pressure hot water heating boiler is provided with arelief valve for over pressure
protection of the boiler and heating system. The relief valve will open when the pressure in
the boiler rises to 30 psig. Each relief valve is provided with a lifting device for testing and
should be tested monthly during the heating season. Discharge piping should be provided
from the outlet side of the relief valve so as to prevent scalding or other hazardous
situations. The discharge piping must remain full size and end at a safe point.
CONVENTIONAL EXPANSION TANK (not provided)
In a properly assembled system, the expanding water flows into an expansion tank. The
expansion tank should be sized correctly, because an improperly installed or sized expansion
tank may result in frequent lifting of the relief valve or other heating system problems. It is
important to install the tank higher than the boiler top and that the connecting pipe rise
continuously up to the tank so air can bubble itself up through it.
An expansion tank is filled with air. The air compresses as water expands, thus forming an
air pressure cushion. This "spring-like" cushion serves to maintain correct operating water
pressure regardless of water temperature. This assures a "full measure" of water, even in
the highest radiation unit of the system. The tank also serves as a trap for excess air in the
system. The air can cause noises in the pipes and inefficient circulation in the radiators if left
in the piping system.
It is possible for a tank to become "water-logged" (filled with water). It can also become
overfilled with air when filling the system with new water. Fittings provided 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 frequent lifting of the relief valve or other heating system problems.
The tank typically comes with a 10-12 psig air charge. This is the same as the pressure
produced in the system by an automatic fill valve set to fill the boiler to 10-12 psig with fresh
water. When the system is first filled, the tank will contain little or no water. As the water is
heated, and system pressure increases, the water expands into the tank and compresses
the air in the tank. This compressed air cushion permits the water in the system to expand
as the temperature changes and assures a "full measure" of water, even in the highest
radiation unit of the system.
The diaphragm type expansion tank can be mounted on the air purger fitting or at any other
convenient place in the supply or return line. It is recommended to locate the diaphragm type
expansion tank (a) in the supply line with the circulator located after the expansion tank or
(b) off the 3/4" tapping provided on the top of the rear casting with the circulator mounted
directly off the boiler's supply piping connection. This configuration allows the circulator to
"pump away" from the expansion tank for improved air elimination and system performance.
The air eliminator fitting or air purger is not provided. The air eliminator fitting or air purger is
used to help remove air from the system before it reaches the radiators. It should be
installed in the supply line. Air left in the system can cause noises in the pipes and inefficient
circulation in the radiators.
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MAIN AIR VENT: for down flow systems or diaohraam tvoe exoansion tanks (not
orovided_ Before a system is filled with water, there is air in the pipes and radiation units.
Some of the air will be trapped as the system is filled. It is possible to eliminate most of this
air through the air vents on the radiation units. A main air vent will speed and simplify this
process. The main air vent should be installed on the highest point in the supply main when
all radiation is below the top of the boiler.
AUTOMATIC FILL VALVE (not provided)
For safe, efficient operation, a hot water system must be filled with water. Adding new
water, when needed can be done manually (by use of a hand valve in the water supply line).
This requires regular attention to the system's needs. An automatic fill valve or pressure
reducing valve accomplishes this without attention. It is installed in the supply line on hot
water boilers only. The valve operates through water pressure differentials. It does not
require an electrical connection.
BURNER SOLENOID VALVE (provided)
The Beckett and Carlin oil burner's use a standard solenoid valve. Upon burner shut down, a
standard solenoid valve stops the flow of oil to the nozzle. Without the solenoid valve, the oil
pump continues to pump oil to the burner nozzle until the burner motor winds down below the
pumps cut-off speed. The Riello oil burner has a delay solenoid valve. The delay solenoid
valve provides the same shut down action as the standard solenoid valve, plus on burner
start up the delay solenoid valve remains 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 boiler are no less than 120°F, or
as high as 240°F so long as the boiler and heating system have adequate circulation to
remove the heat from the boiler otherwise steam may be created in the boiler. Refer back to
SYSTEM PIPING section for more information.
DRAIN VALVE (provided)
The drain valve is a manually operated valve that provides a means of draining all the water
from the boiler and heating system. It should be installed in the reducing tee where the
return line enters the boiler.
CIRCU LATOR (Drovided_
Every forced hot water system requires a circulator. A separate circulator or zone valve is
required for each zone, if there are two or more zones. The circulator must have the capacity
to provide the circulation required by the heating system. The circulator should be connected to
the supply main and must be wired into the boiler's electrical system. See the SYSTEM
PIPING section for piping configurations with the circulator located on the supply main piping
using zone circulators or zone valves. When the piping is arranged with zone circulators and no
bypass piping, the circulator provided with the boiler may be used as a zone circulator. Both
piping arrangements allow the circulator to pump away from the expansion tank and show how
the piping should be arranged to allow the heating system to be easily purged of air.
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FILLING THE BOILER
HOW A HOT WATER SYSTEM OPERATES
The entire heating system (boiler, piping, and radiation units) is filled with water. As the
water in the boiler is heated, it is circulated from the top of the boiler through the supply
main to the radiation units. The cooler water in the radiation units flows back through the
return piping through the return main into the boiler. This arrangement provides positive and
rapid response to the thermostat.
FILLING THE SYSTEM WITH WATER
OPTION #1- This method utilizes the boiler piping as shown in the figure on the previous page.
a) Close the main shutoff valve, isolation valves, and zone valves (if applicable). If bypass piping
is installed, also close the two throttling valves. Leave the boiler service shutoff valve (if
installed) and the balancing valves to each heating zone fully open.
b) Open the following valves in order: the drain valve for power purging, isolating valves
before and after the boiler circulator (if applicable), both throttling valves (if applicable),
and then open the fill line shutoff valve. Water will fill the bypass piping and push the air
through the piping and out the power purging drain valve. When the power purging drain
valve runs air free, close the bypass piping throttling valve (leaving the throttling valve to
the supply piping fully open).
c) Next, open the isolation valve (or zone valve) to the first zone. Water will fill the piping and
push any air out the power purging drain valve. When 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 adiust the throttling
valves and balancing valves as required.
OPTION #2 - Close the air vents on all radiation units. Open the valves to the radiation units.
Make sure the boiler drain valve, expansion tank drain cock, and the air bleed screw on the
expansion tank drain fitting are closed. Open the fill valve on the piping to the expansion
tank. Open the water inlet to the boiler and leave it open. Open the air vent on the lowest
radiation unit. When all the air has escaped and water starts to flow from the vent, close it.
Go to the next radiation unit, and repeat this process until finishing with the highest radiation
unit. If the heating system has automatic vents, this manual venting is unnecessary but it will
speed up the proper filling of the system.
If the system is a closed expansion tank system, an automatic fill valve is needed. Leave the
automatic fill valve open to refill the system automatically as needed. Note the initial fill
pressure on the boiler's temperature /pressure gauge, which should be 10-15 psig. Any
lowering of the pressure from its initial fill pressure indicates a loss of water due to leakage.
The automatic fill valve should then compensate for this water pressure loss. If it does not,
manually open this valve to refill the system until the needle is again pointing to the same
pressure reading. Instructions are packaged with the valve.
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