Dunkirk ESB0365 Technical Document

EMPIRE STEAM II
OIL-FIRED CAST IRON BOILER
MODEL NUMBERS:
ESB0365 ESB3100.
ESB4125 ESB4150.
ESB5175 ESB5200.
ESB6225 ESB7275
,f
DUNKIRK
85 Middle Road
Dunkirk, NY 14048
Phone [phone]
Fax. [phone]
www. dunkirk corn
An ECR International Brand )C_ f
An ISO 9001-2000 Certified Company
P/N 1305029, Rev ! 0 [08/04]

P/N# 1305029, Rev
Safety Symbols and Warnings 2
Ratings, Data, and Dimensions 3
Installation Procedure 4
Ventilation and Combustion Air 5
Connecting Supply and Return Piping Steam 7
Venting System Inspection and Installation 8
Oil Tank and Piping 8
Electrical Wiring 9
Thermostat Operation 9
Normal Sequence of Operation 11
Operating Instructions 11
Maintenance Procedures 14
Replacement Parts List 15
Service Checklist 20
KEEP THIS MANUAL NEAR BOILER j_
RETAIN FOR FUTURE REFERENCE
The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels
ndicates an imminently hazardous situation'_
hich, if not avoided, WILL result in death or I
r!o,s!nj,,y: j
dicates a potentially hazardous situation I
hich, if not avoided, COULD result in death I
serious injury, j/
ndicates a potential hazardous situation I
hich, if not avoided, MAY result in minor or I
oderate injury. It may also be used to alert I
gainst unsafe practices. .t)
1 0 [08/04] • Printed in USA • Made In USA
MPORTANT: Read the following instructlons_
OMPLETELY before mstalhngll
1. Keep boiler area clear and free from com-
bustible materials, gasoline and other flam-
mable vapors and liquids.
2. DO NOT obstruct air openings to the boiler
room.
3. Modification, substitution or elimination of
factory equipped, supplied or specified com-
ponents may result in property damage, per-
sonal injury or the loss of life.
4. TO THE OWNER - Installation and service of
this boiler must be performed by a qualified
installer.
5. TO THE INSTALLER - Leave all instructions
with the boiler for future reference.
6. When this product is installed in the Com-
monwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
_Licensed Gas Fitter. J
All installations of boilers and venting should
be done only by a qualified expert and in
accordance with the appropriate Pennco
manual. Installing or venting a boiler or any
other gas appliance with improper methods
or materials may result in serious injury or
death due to fire or to asphyxiation from
poisonous gases such as carbon monoxide
which is odorless and invisible.
_.. J
0@
Tested For 15 LBS
ASME
/_,,or kllig Pressure

ESB0365 0.65
ESB3100 1.00
ESB4125 1.25
ESB4150 1.50
ESB5175 1.75
ESB5200 2.00
ESB6225 2.25
ESB7275 2.75
NOTES:
78
116
145
170
iiiiiiiii,1_teiaimiiiiiiiiiii!
59
87
109
128
246
363
454
533
wa_er
66 6
101 6
126 7
148 7
iii/iSq_are!iiiil
8x8x15
8x8x15
8x8x15
8x8x15
91 140 .60 80B
140 140 .85 80B
175 140
210 140
245 202 152 633 176 8 8x8x15 140 1.50 80B
280 227 170 708 197 8 8x8x15 140 1.75 70B
315 251 188 783 218.3 8 8x12x15 140 2.00 45B
385 307 230 958 267.1 8 8x12x15 140 2.25 45B
1. Add suffix"T" to denote boiler with tanktess heater•
2. I=B=R burner capacity is based on an oil heating value of 140,000 Btu/gat. and with 13% CO2.
3. Net ratings based on 170°F temperature in radiators and include 33% allowance for normal piping and pick-up toad. Consult manufacturer
for unusual piping and pick-up temperatures•
4. For altitudes above 2,000 ft. ratings maybe reduced at the rate of 4% for every 1,O00 ft. above sea level.
5. No771esizes with an H designation are Hago brand, all others are Delevan.
6. The electrical service is 120 Volts, 15 Amps, 60 Hz.
7. The MEA hum ber for the ESB series is 182-86E.
8. The MEA number for the AFG Beckett Burner used in the ESB series is 213-83-E.
DIMENSIONS (See FIG, A)
ESB-3S 16.375" 6.5" 6.0"
ESB4S 20.25" 8.5" 6.0"
ESB-5S 23.875" 10.25" 7.0"
ESB-6S 27.5" 8.3125" 8.0"
ESB-7S 31.125" 8.3125" 8.0"
TANKLESS WATER HEATER CAPACITIES
ESB0365 0.65 L-24 Available on request 11 8
ESB3100 1.00 L-24 4.5 11 8
ESB4125 1.25 L-24 4.5 13 9
ESB4150 1.50 L-24 4.5 13 9
ESB5175 1.75 L-24 5.0 15 10
ESB5200 2.00 L-24 5.0 15 10
ESB6225 2.25 L-24 5.0 17 11
ESB7275 2.75 L-24 5.0 19 12
A.S.H.E PRESSURE
f_RELZEF VALVE
V u
IFIG. A ]
STANDARD EQUIPMENT: Crated boiler, flush jacket, oil burner, target watt/liner, ASME relief valve, steam
water level gauge, steam pressure gauge, steam pressure control, mechanical low water cut-off, drain
valve, wiring harness, burner electric disconnect, plastic cover, 2" supply tapping, 1½" return tapping, skim
port, and primary control. (NOTE: For tankless heater units, add tankless hot water coil, and 4006 limit
control.)

All installations must conform to the requirements of
the authority having jurisdiction. Such applicable
requirements take precedence over the general
instructions of this manual.
Where required by the authority having jurisdiction,
the installation must conform to the American Society
of Mechanical Engineers Safety Code for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME No. CSD-1.
Locate boiler in front offinat position before removing
crate. Provide a level solid base as near chimney as
possible and centrally located with respect to the
heat distribution system as practical.
Allow 24 inches in the front, top and right hand side
for servicing and cleaning, or removing tankless
water heating coil.
It is recommended that 24 inches be allowed in back
of boiler for convenience when skimming hole is
used.
When installed in a utility room, the door should be
wide enough to allow the largest boiler part to enter,
or to permit replacement of another appliance such
as a water heater.
The boiler shall be installed such that the oil ignition
system components are protected from water
(dripping, spraying, rain etc.) during appliance
operation and service.
FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY- The boiler must not be installed on
carpeting or vinyl flooring. Minimum clearances to
combustible construction are:
TOP ........................................ 24 IN.
FRONT ................................... 24 IN.
FLUE CONNECTOR ................ 9 IN.
REAR ..................................... 24 IN.
LEFT SIDE ............................... 6 IN.
RIGHT SIDE ............................ 241N.
MINIMUM CLEARANCES TO COMBUSTIBLE
CONSTRUCTION (AS SEEN FROM ABOVE)
T
24"
• 6" _24"--
24"
[
NOTE: Clearance for access should exceed fire
protection clearance.

COMBUSTIONAIR REQUIREMENTS
(Minimum Opening Requirement)
91,000 19 100 23 46
140,000 28 140 35 70
175,000 35 175 44 88
210,000 42 210 53 106
245,000 49 245 61 122
280,000 56 280 61 140
A space w hose volume is not less than 50 cubic feet per 1000 BTU/Hour of all
appliances installed in that space (cubic feet of space = height x width x length)
** A space w hose volume is less than 50 cubic feet per I000 BTU/Hour of all
appliances installed in that space (cubic feet of space = height x w idth x length)
1. Ventilation of boiler room must be adequate
enough to provide sufficient air to properly support
combustion and venting.
2. When the boiler is located in an unconfined space
in a building of conventional construction frame,
masonry or metal, infiltration normally is adequate to
provide air for combustion and ventilation. However,
in any building which has been altered to conserve
energy or to minimize infiltration, the boiler area
should be considered as a confined space. If there is
anydoubt, install airsuppty provisions for combustion
and ventilation in accordance with section 5.3, Air for
Combustion and Ventilation, of the NFPA 54 1988
code, the recommendations that follow, or applicable
provisions of the local building codes.
3. When the boiler is installed in an unconfined
space, in a building of unusually tight construction,
air for combustion and room ventilation must be
obtained from outdoors or from spaces freely
communicating with the outdoors. A permanent
opening or openings having a total free area of not
less than 1 square inch per 5,000 BTU per hour of
total input rating of att appliances shall be provided.
Ducts may be used to convey make-up air from the
outdoors and shall have the same cross-sectional
area of the openings to which they are connected.
4. When air for combustion and room
ventilation is from inside buildings, the
confined space shall be provided with two
permanent openings, one starting 12 inches
from the top and one 12 inches from the
bottom of the enclosed space. Each opening
shall have a minimum free area of 1 square
inch per 1,000 BTU per hour of the total
input rating ofatl appliances in the enclosed
space, but must not be less than 100 square
inches. These openings must freely
communicate with the interior areas having
adequate infiltration from the outside.
(Figure 1)
J _ i ¸
jl f C_O_NE'_
iL TYr=_ VErsT r_pE
VENf _'i "' E
_J
I FIGURE 1 I
5. When the boiler is installed in a confined space
and atl air is provided from the outdoors, the confined
space shall be provided with two permanent openings,
one commencing within 12 inches from the top and
one commencing 12 inches from 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.
One of the following methods must be used to
provide adequate air for ventilation and combustion.
A. When directly communicating with the outdoors,
each opening shall have a minimum free area of
1 square inch per 4,000 BTU per hour of total
input rating of all equipment in the enclosure.
(Figure 2)

/
CiUTLET _
AE_
!/ENI PEPE
INLET
AZR
\/ENTZLATZON
LOUVERS FOR
UNIIEATED
CRAWL SPACE
/
I FIGURE 2 1
B. When communicating with the outdoors by
means of vertical ducts, each opening shall have
a minimum free area I square inch per4,000 BTU
per hour of totat input rating ofatt appliances in the
enclosed space. (Figure 3)
I FIGURE 3 I
C. If horizontal ducts are used, each opening shall
have a minimum free area 1 square inch per
2,000 BTU per hour total input rating of all
appliances in the enclosed space. (Figure 4)
VE_S
PIPE \)
/
iJ!llllll![Li_l/ll]llll_ i
D. When ducts are used, they shall be of the same
cross sectional area as the free area of the area
of the openings to which they connect. The
minimum dimension of rectangular air ducts shall
not be less than 3 inches.
6. In calculating free area using louvers, grills or
screens for the above, consideration shall be given
to their blocking effect. Screens used shall not be
smaller than 1/4 inch mesh. If the free area through
a design of louver or grill is known, it should be used
in calculating the size opening required to provide
the free area specified. If the design and free area is
not known, it may be assumed that wood louvers wilt
have 20-25% free area and metal louvers and grills
will have 60-75% free area. Louvers and grills shall
be fixed in the open position or interlocked with the
boiler so that they are opened automatically during
boiler operation.

1.Suggestedpipingforsteamheatingsystemcan
beseeninFigure5.Actualpipingmayvarybasedon
systemdesignandlocalconditions.
2. For further piping information refer to the I=B=R
installation piping guide.
3. See Figure 6 for typical piping for domestic hot
water heater.
4. See Figures 7 and 8 for the suggested piping for
a modular steam boiler.
NOTE, B_T_ 3" sUPPLY T_PPING_ _IUST
PI_I.G _UST _E _ MINIMUM OF _". DO NOT
_UCL
IFIGURE 5 I
SUGGESTED PIPING FOR MODULAR STEAM
BOILERS - PUMPED RETURN
IFIGURE 7 I
PIPING FOR BUILT-IN
DOMESTIC HOT WATER HEATER
UNTEMPERED HOT
WATER TO
l AUTOHAT:C WASHER
_N/_M_E_ED
I_ST_LLE_ BELOW CENTE_
COLD WATER IN -_/
IFIGURe: 61
SUGGESTED PIPING FOR MODULAR STEAM
BOILERS - GRAVITY RETURN
IFIGURE 8 I

Inspect chimney to make certain it is constructed
according to the latest revision of the NFPA 211.
Local regulations may differ from this code and
should be checked. Where there is a conflict, the
local code will prevail.
The boiler must be installed into a chimney which
has a masonry or metallic chimney liner.
An unlined chimney wilt have leaks that wilt cause
poor chimney performance (no draft), and could
result in a positive pressure in the combustion
chamber.
Horizontal portions of the venting system should not
exceed 10 feet in length. Horizontal lengths over 10
ft. will have a negative effect on the chimney
performance.
The chimney should extend at least 2 ft. above any
portion of the building within 10 ft. (Figure 9) It should
produce a -.02 inch W.C. draft in the combustion
chamber. See "Chimney or Vent Sizes" chart for
recommended minimum and maximum chimney or
vent sizes.
Inadequate draft will cause improper combustion,
resulting in dirty flue ways and high fuel bills.
Connect flue pipe same size as boiler outlet to
chimney, sloping upward continuously toward the
chimney approximately 1/4" per foot. Bolt or screw
joints together to avoid sag.
If an oil fired water heater is vented into the same flue
as the boiler, provide a separate hole into the chimney
whenever possible. When this isn't possible, use a
"Y" connection in the flue pipe, using a separate draft
regulator for each unit. When a chimney will not
provide adequate draft to handle the input from the
water heater and boiler simultaneously, wire the
units so that only one wilt operate at a time, favoring
the water heater.
I_,_ NO_E THAN J.O'(3,1 H)
q&o' (3,_ M)
/HEZGHT ABOVE ANY
_._{ Roo_ GuR_AOEWITHIN
le" C3._ M)
HORIZONTALLY
RIDGE ( .8.f. M) "CHIMNEY 3"
c , 9;2. M )MIN.
MN. i l
I I GAS VENT OR
TYI_E L VENT 2'
I i ( . 6,L M MIN.
i 1-t
CHIMNEYOR VENT SIZES
ROUND
BTU/HR INPUT INCHES
MIN MAX
91,,_0"0"140_00_
175,000- 210,000 7 8
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii r_;
315,000 8 10
SQUARE HEIGHT
INCHES (FT)
MIN I MAX MIN MAX
8x8 I 8x10 15 40
8x8 I 8x12 15 50
Oil tank and piping should be installed in accordance
with the National Board of Fire Underwriters and
local regulations. Oil storage tank, vent, fill pipe and
caps should be as prescribed by local codes. In no
case should the vent pipe be smaller than 1-1/4"
I.P.S. The fill pipe should not be less than 2" I.P.S.
The suction line from the tank to the burner should be
one continuous piece of tubing to prevent air enter-
ing the line. The suction line, must be 3/8" O.D.
copper tubing for runs of 50 feet or less, and 1/2"
O.D. for longer runs. An oil return line, same size as
the suction line, must be used on any installation
where the bottom of the tank is below the fuel unit of
the burner. Oil lines should be buried or otherwise
protected from mechanical injury. Flare fittings on all
oil lines are recommended. Compression fittings on
the suction line often allow air to be drawn into the
fuel pump, making it difficult to maintain oil pressure
at the nozzle. Do not run overhead fuel lines from
tank to oil burner.
Fuel pump connections and by-pass should be made
according to instructions attached to the fuel pump.

Iftankismorethan20' fromtheboiler,a twostage
fuel unit shouldbe installedin placeof the single
stagepumpsuppliedas standardequipmentwith
theburner.Makecertaintherotationandspeedare
the sameandthepumpis suitablefor theburner
horsepowerrating.
Anoillinefilterandshut-offvatveshouldbeinstalled
inthesuctionline.Shut-offvatvesshouldbeinstalled
inboththesuctionandreturnlinesattheburnerfor
convenienceinservicingburner.Allowextratubing
atburnersoburnermayberemovedfromboilerfor
cleaningwithoutdisconnectingtubing.(Figures 10-
11) An optional flexible oil line is available.
TYPICAL INSTALLATION -
SINGLE PIPE OIL SYSTEM
IFIGURE101
TYPICAL INSTALLATION -
TWO PIPE OIL SYSTEM
/
_EFER TO LOCAL
CODE
,\\
[)AHA( [ "1 I Ni¢ltJbl I/'2
1/2 ' O _ COPPER TtJBZrJG
L''G°"E'll
Electrical wiring must conform with the latest revi-
sions of the National Electrical Code, ANSI/NFPA
No. 70, and/or local authority having jurisdiction.
1. When an external electrical source is utilized,
the boiler, when installed, MUST BE electrically
grounded in accordance with these requirements.
2. Install a fused disconnect switch between
boiler and meter at a convenient location.
3. When the boiler is equipped with self-ener-
gized controls, no outside sou rce of electric power
shall be connected to the circuit of this system.
(See "Steam Wiring W/MM #67 Mechanical
LWCO" on next page.)
1. Thermostat should be installed on an inside wall
about four feet above the floor.
2. NEVER install a thermostat on an outside watt.
3. Do not install a thermostat where itwill be affected
by drafts, hot or cold pipes, sunlight, lighting fixtures,
television, fireplaces, or chimneys.
4. Check thermostat operation by raising and lower-
ing thermostat as required to start and stop the
burner.
5. Instructions for the final adjustment of the thermo-
stat are packaged with the thermostat (adjusting
heating anticipator, calibration, etc.).

I I
I I
L1 L2
120V
60 HZ
SUPPLY
YELLDW
BLACK
GREEN
WHITE
_URNER
DISCONNECT
LT
#67
LWCO
CAD
CELL
\1/
BURNER
JUNCTION
BOX
R7|84 B 1032
BLACK
DK BLUE
ORANGE
PURPLE
WHITE
BLACK
COMPONENT CODING
Thermostat (Millivolt)
Thermostat (24 Volt)
Thermostat (Line Voltage)
Transformer (120V/24V/40VA)
Transformer (120V/24V/50VA)
Volt Gas Valve
Pressure Switch
OIL BURNER
TRANSFORMER
BLACK
WHITE
Manual Reset Pressure Switch
Control Terminal
Relay Coil
Relay Contacts
Relay Contacts
Limit Switch
Manual Switch
WHITE SOLENOID
BURNER
MOTOR
Circulator
Energy Cut-Off
Pilot Safety Coil
Wire Connection
Low Water Cut Off
Electric Water Feeder
Power Generator
TI-I --2
WIRING CODE
Line Voltage By Factory
[ : Low Voltage By Factory
Line Voltage By Installer
Low Voltage By Installer
NOTE: Not all components listed are used in all control systems,