Dunkirk ESC-3090S Instruction manual

Dmkj'
MODELS
ESC-3090S
ESC-3090ST
ESC-4125S
ESC-4125ST
ESC-5185S
ESC-5185ST
ESC-6210S
ESC-6210ST
ESC IV STEAM SERIES 4
OIL-FIREDCASTIRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
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PATENT 7,823,544
/\_ /
_' M,E 1
H
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue. Utica NY 13501
web site: www.ecnnternat/onal.com P/N 240009804, Rev. A [10/2012]

Figure #1
35,3/4"
A,S,M,E
RELIEF PRESSURE VALVE
ELWC[]
CYCLE GUARD
OIL BURNER
PRESSURE
ESC-3090 163/8'' 61/2'' 6"
ESC-4125 20¼" 81/2'' 6"
ESC-5185 23%" 101/2' 7"
ESC-6210 271/2'' 85/16'' 8"
Boiler model number on rating plate includes suffix 'S' or 'ST'.
STANDARD EOUIPMENT: Crated boiler, flush jacket, oil burner,
target wall/liner, safety valve, steam water level gauge, steam
pressure gauge, steam pressure control, low water cut-off, drain
valve, wiring harness, burner electric disconnect, plastic cover, 2"
supply tapping, 11/2'' return tapping, skim port, and primary control.
(NOTE: For tankless heater units, add tankless hot water coil, and
low limit control.)

Boiler Model 1 3 M n Natura Draft
. O,IBurnerInput() INetAHRIRat,ngs()l _:. _I
_umoer _mmney b_ze
Capacity A.RU.E.
WITHOUT WITH .... I ..... (2) MBH(4) ISteam ' Sq. Ft. I _ . I _ . Rating
TA.K'ESS,TANKLESS._'"" I 'v'°" I I MBH SteamI "°un°I _quareI
ESC-3090S ESC-309OST o.9o 126 106 80 333 6 8"x8"x15' 82.0
ESC-4125S ESC-4125ST 1.25 175 147 110 458 6 8"x8"x15' 82.0
ESC-5185S ESC-5185ST 1.85 259 216 162 675 8 8"x8"x15' 82.0
ESC-6210S ESC-6210ST 2.10 294 247 185 771 8 8"x8"x15' 82.0
NOTES:
1)Burner input is based on an oil heating value of 140,000 Btu/gal.
2)MBH = 1000 Btu per hour [Btu = British Thermal Unit].
3)Net AHRI Steam Ratings based on piping and pick-up allowance of 1.333. Consult manufacturer before selecting boiler for
installations having unusual piping and pick-up requirements, such as intermittent system operation, extensive piping, etc.
4)Electrical service is 120 Volts, 15 Amps, 60 Hz
iLine
ESC-3090ST 2 11
ESC-4125ST 4½ 13
ESC-5185ST 4½ 15
ESC-6210ST 4½ 17

Dimensions ........................................................ 2
Ratings, Data ..................................................... 3
Safety Symbols .................................................. 4
Locating The Boiler ............................................. 5
Ventilation And Combustion Air ............................ 6
Supply And Return Piping .................................... 8
Venting System Inspection & Installation ............. 12
Oil Tank And Piping ........................................... 13
Electrical Wiring ............................................... 14
Operating Instructions ....................................... 16
Maintenance Procedures .................................... 19
Service Checklist .............................................. 21
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
IMPORTANT: Read and understand the following
instructions COMPLETELY before installing.
Installations of boilers and venting shall be done
only by qualified expert and in accordance with this
manual. Installing or venting a boiler or any other
gas appliance with improper methods or materials
could result in serious injury or death due to fire
or to asphyxiation from poisonous gases such as
carbon monoxide which is odorless and invisible.
Keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors and
liquids.
Do not obstruct air openings to boiler room.
Modification, substitution or elimination of factory
equipped, supplied or specified components could
result in personal injury or the loss of life.
i_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!_!!iii__iiiiiiiiiiiiiiii_i!_!i_iii!:_ii!i!_ii!i!_i_!i_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!iiiii!iiiiiiiliiiiiii!i!i!ii!iliow.er InstaIIationandserviceofthisboilermust
be performed by a qualified installer.
The following defined symbols are used throughout this
manual to notify reader of potential hazards of varying risk
levels. Installer - Leave all instructions with the boiler for
future reference.
Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury.
When this product is installed in the Commonwealth
of Massachusetts the installation must be performed
by a Licensed Plumber or Licensed Gas Fitter.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
,i_ CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
Indicates information which should be followed to
ensure proper installation and operation.
PATENT 7,823,544

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•Installations shall 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 of final position before removing
crate.
•Provide level solid base as near chimney as possible
and centrally located with respect to heat distribution
system as practical.
•Allow 24 inches in front, top and right hand side for
servicing and cleaning, or removing tankless water
heating coil.
•Recommend 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 largest boiler part to enter, or to
permit replacement of another appliance such as water
heater.
•Install boiler such that oil ignition system components
are protected from water (dripping, spraying, rain etc.)
during appliance operation and service.
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY
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 24IN.
NOTE:Clearance for accessshould exceedfire protection
clearance.
Figure #2 -Hinimum Clearances To Combustible
Construction (as seen from above)
BACK
FRONT

Asphyxiation, fire hazard. Do not obstruct air
openings to combustion area. Follow instructions
below, to maintain adequate combustion air.
126 26 126 32 63
175 35 175 44 88
259 52 259 65 130
294 59 294 74 147
* A space whose 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 whose volume is 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)
1. Ventilation of boiler room must be adequate enough to
provide sufficient air to properly support combustion,
venting and maintain safe ambient temperatures under
normal operating conditions.
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 any
doubt, install air supply provisions for combustion
and ventilation in accordance with Chapter 5, Air for
Combustion and Ventilation, of NFPA 31, Standard
for the Installation of Oil Burning Equipment. 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 all
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.
,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 of all 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. See Figure #3.
Figure #3
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
f.. CHIMNEY
OR
L TYPE VENT PIPE
BASEBOARD _h

,
,
When the boiler is installed in a confined space and
all 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
#4)
B. When communicating with the outdoors by means
of vertical ducts, each opening shall have a
minimum free area Z square inch per 4,000 BTU
per hour of total input rating of all appliances in the
enclosed space. (Figure #5)
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 #6)
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.
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 will 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.
Figure #5
C iq I M_iNE Y
OR
PI_PE

Burn or Scald Hazard. Discharge line shall be installed to safety valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.
Discharge line shall:
• Connect to safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum
distance from floor or allowable safe point of discharge.
• Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.
• Have no intervening shutoff valve between safety valve and discharge to atmosphere. Do not plug or
place any obstruction in discharge line.
• Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.
• Allow complete drainage of valve and discharge line.
• Install safety valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety valve.
• Support safety valve discharge piping.
• Be short and straight as possible.
• Terminate with plain end, not threaded.
• Constructed of material suitable for exposure to temperatures of 375 ° F (191°C); or greater.
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.
Figure 4 -Safety Valve
SAFETY VALVE
DTSCHARGI
pTpTNG
Check local codes
for maximum
distance from
floor or other
allowable safe
point of discharge
t
6" Above Floor

1. Suggested piping for steam heating system can be
seen in Figure #7. Actual piping may vary based on
system design and local conditions.
Figure #7
NOTE: BOTH 2" SUPPLY TAPPINGS MUST
BE: USED, ALL NEAR BOILER SUPPLY HEADER
P_PING MUST BE A M_N|MUM OF 2". DO NOT
REDUCE,
OPTIONAL ONE OR TWO
TAKE°OFFS TO SYSTEM
HEADER
3 SECTION: 2 °
4 SECTION: 2A12"
5_ 6 7 SECTION: 3 '_
12" MIN
11/2" MINIMUM, IF RETURN
PIPING IS LARGER,
INCORPORATE SIZE TO EQUAL
THE RETURN PIPE SIZE,
SUPPLY
CONNECTION
SKiM TAPPING
ON SACK
OF BOILER
CLOSE NIPPLE
HARTFORD LOOP
CONNECTION
"RETURN MAIN
CLEANOUT TEE'S
FROM BOTTOM OF BOILER

,
,
See Figure #8 for typical piping for domestic hot water
heater.
• Automatic mixing valve must be installed on tankless
heater outlet. Install per valve manufacturer's
instructions.
• Install adjustable flow restrictor in cold water inlet
due to varying water conditions.
See Figures #9 and #10 for the suggested piping for
a modular steam boiler.
Water temperatures exceeding 125°F will cause
severe burns instantly or death by scalding.
Figure #8
PIPING FOR BUILT-IN
DOMESTIC HOT WATER HEATER
UNTEMPERED HOT WATER TO
__..._UTOM ATI C WASHER
UNTEMPERED _ TEMPERING VALVE
HOTWATER "-'_ _ INSTALLED BELOW CENTER
_ LINE OF BOILER HOT
IL; FI F
COLD WATER IN J

Figure #9 SUGGESTED PIPING FOR MODULAR STEAM BOILERS - PUMPED RETURN
F& TTRAPHIGH
LEVEL"SPILL"
(DONOTUSEWITH
CONDENSATEPUMP)
STOP
VALVE
TO
RECEIVER
CHECK TAN£
VALVE
FROM SOLENOID
RECEIVER VALVE
TANK (OPTIONAL)
STOP
VALVE
BLOWOFF
VALVE
TO
SYSTEM
TRAP
RECEIVER
TANK
FROM
RECEIVER.s,
TANK_
Figure #10 SUGGESTED PIPING FOR MODULAR STEAM BOILERS - GRAVITY RETURN
STOP
VALVE
CHECK
VALVE
(OPTIONAL)'_
BLOWOFF
-- VALVE
WATER
LINE

Boiler is to be vented by natural draft and shall not
be connected into any portion of mechanical draft
operating system under positive pressure.
° 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.
• Install boiler into chimney having a masonry or metallic
chimney liner.
• Unlined chimney will have leaks that will cause poor
chimney performance (no draft), and could result in
positive pressure in the combustion chamber.
• Horizontal portions of venting system should not
exceed 10 feet in length. Horizontal lengths over 10 ft.
will have a negative effect on chimney performance.
• Extend chimney at least 2 ft. above any portion of
building within 10 ft. Producing a -.02 inch W.C. draft
in the combustion chamber. See Figure #11.
• See Ratings Table page 3 for recommended minimum
chimney or vent sizes.
• Inadequate draft causes 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 oil fired water heater is vented into same flue as boiler,
provide separate hole into chimney whenever possible.
When this isn't possible, use "Y" connection in flue pipe,
using separate draft regulator for each unit.
When chimney does not provide adequate draft to handle
input from water heater and boiler simultaneously, wire
units so only one will operate at a time, favoring water
heater.
Figure #11
_-- MORETHAN10'(3.1 M)
_ 10' (3.1 M)
HEIGHTABOVEANY
ROOFSURFACEWITHIN
10' (3.1 M)
HORIZONTALLY
''ll
I I CHIMNEY3' (.92M)
I II /GASVENTOR
I II / TYPELVENT
!-t--
! !

Tank Installation
•Install oil tank and piping in accordance with 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 vent pipe be smaller than 11/4'' I.P.S.
Fill pipe should not be less than 2" I.P.S.
Suction Line Installation
• Suction line from tank to burner should be one
continuous piece of tubing to prevent air entering line.
° Suction line, must be %" O.D. copper tubing for runs of
50 feet or less, and 1/2"O.D. for longer runs.
Oil Line Installation
° Oil return line, same size as suction line, must be used
on any installation where bottom of tank is below fuel
unit of burner.
• Bury oil lines or protect from mechanical injury.
• Flare fittings on all oil lines are recommended.
Compression fittings on suction line often allow air to
be drawn into fuel pump, making it difficult to maintain
oil pressure at nozzle.
. Do not run overhead fuel lines from tank to oil burner.
Fuel Pump Connections
° Fuel pump connections and by-pass should be made
according to instructions attached to fuel pump.
° If tank is more than 20' from boiler, install two stage
fuel unit in place of single stage pump supplied as
standard equipment with burner.
, Verify rotation and speed are the same and pump is
suitable for burner horsepower rating,
Install oil line filter and shut-off valve in the suction line.
Install shut-off valves in both suction and return lines at
the burner for convenience in servicing burner.
Allow extra tubing at burner so burner may be removed
from boiler for cleaning without disconnecting tubing. An
optional flexible oil line is available. See Figures #12 -
#13.
Figure #12 Typical Installation Single Pipe Oil
System Figure #13 Typical Installation Two Pipe Oil System
REFER T_ LOCAL
COD_ DI, INE t,_UST BE _URIE} DR
OTHER%_ZSE PRDTECTED FRD_4
D_MAGE _dZNIML_-_ lie '_ IP3 OR
/P DD, CF/PPER TUi-_TNG

Electrical shock hazard. Turn OFF electrical power sup-
ply at service panel before making electrical connections.
Failure to do so could result in death or serious injury.
Electrical wiring must conform with the latest revisions 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-energized
controls, no outside source of electric power shall be
connected to the circuit of this system. (See "Steam
Wiring" on next page.)
Thermostat Installation
1. Thermostat should be installed on inside wall about
four feet above fioor.
2. NEVER install thermostat on outside wall.
3. Do not install thermostat where it will be affected by
drafts, hot or cold pipes, sunlight, lighting fixtures,
television, fireplaces, or chimneys.
4. Check thermostat operation by raising and lowering
thermostat as required to start and stop burner.
5. Instructions for final adjustment of thermostat
are packaged with thermostat (adjusting heating
anticipator, calibration, etc.).

STEAMWIRINGW/BECKE-FIBURNER
FIELD INSTALLED
VXT-120 VVATER FEEDER
F ....................... CG450 ELVVCO PA404
TRANSFORMER
Thermostat (Millivolt)
Thermostat (24 Volt)
Thermostat (Line Voltage)
Transformer (120V/24V/40VA)
Transformer (120V/24V/50VA)
Volt Gas Valve
Pressure Switch
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Manual Reset Pressure Switch
Control Terminal
Relay Coil
Relay Contacts
Relay Contacts
Limit Switch
Manual Switch
Circulator
Energy Cut-Off
Pilot Safety Coil
Wire Connection
Low Water Cut Off
Electric Water Feeder
Power Generator
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.

Sequence Of Operation
On call for heat, thermostat will actuate, completing the
circuit to the boiler. In turn, the ignition systems are
activated and ignition will begin.
In event of a low water condition, an automatic low water
cut-off device will interrupt power between the low water
cut-off and burner. Burner remains off until low water
condition is corrected, (i.e., manually restore boiler water
or utilize water feeder device which automatically restores
water to its normal operating level).
Installer- Before putting boiler in operation, test
mechanical low water cut-off device for proper operation.
While burner is on, open blow-off valve located in lower
portion of cut-off body. This will drain water quickly from
cut-off body and break circuit to burner. If it does not,
replace control.
Water temperatures exceeding 125°F will cause
severe burns instantly or death by scalding.
Refill boiler to its normal water line.
Figure #14
ELECTRONIC LOW
WATER CUT OFF PRESSURE RELIEF
-- VALVE TOP JACKET
PANEL
LINE
INSPECTION
28"
LOWER FRONT
JACKET PANEL--
BURNER
ELECTRICAL
DISCONNECT
MOUNTING
SCREWS
(BOTH SIDES)
Operating Instructions
• Start of heating season have venting system inspected.
Check vent pipe from boiler to chimney for signs
of deterioration by rust or sagging joints. Repair if
necessary.
• Remove vent pipe at base of chimney or flue and, using
mirror, check for obstruction and verify compliance to
latest revision of the NFPA 211.
• Operate lever of safety valve on boiler periodically to
verify it is functioning properly. See Figure #14.
• Safety relief valve should open before steam pressure
exceeds 15 psi. reading on the gauge. If this pressure
is exceeded and safety relief valve leaks steam when
boiler is operating at normal pressures, immediately
replace. Corrosion can build up rapidly at valve seat
and prevent its functioning as a safety device.

Start-Up And Adjustment Of Oil Burner
(See oil burner instructions for nozzle and electrode setting)
Do not set fire visually.
Instruments are only reliable method to determine proper
air adjustments.
Improperly adjusted burner causes soot and high fuel bills
because of incomplete combustion of the fuel oil. This may
then require excessive boiler maintenance, service costs,
and in some instances, house cleaning or redecorating.
Consult a qualified service mechanic to make proper
adjustments with smoke tester, CO2 indicator, and draft
gauge. Bacharach or Dwyer test kits include these
instruments.
1. Check oil burner nozzle to verify it is tight in adapter.
Burner mounting bolts should be tight.
2. Check electrode setting, they may have been jarred out
of position during transportation.
3. Lubricate burner motor if necessary.
4. Set room thermostat to call for heat, or jump
thermostat contacts on boiler control.
5. Open all oil line valves.
6. Turn service switch on. Burner should start.
7. On one pipe fuel systems only, bleed pump as soon as
burner starts. Allow oil to run until all traces of air in
suction line disappear.
8. Turn "OFF" burner and install pressure gauge port on
pump.
9. Start burner again and check oil pressure for 140 Ibs.
Adjust if necessary.
ESC-3090 L1 -- 33/8 0.75-60°B 150 1 3
ESC-4125 Vl 0 23/4 1.10-60°B 140 1 8
ESC-5185 F12 -- 23/4 1.50-70°B 150 2 10
ESC-6210 F16 .... 1.75-70°B 145 2 10
* Boiler model number on rating plate includes suffix 'S' or 'ST'.
IMPORTANT." Check safety control circuit after burner adjustments have been made for satisfactory performance.

A. Pressure Control - Remove cover and note pressure
setting. With boiler operating, decrease setting.
When setting is lower than boiler pressure, control
will open and turn off boiler. After checking pressure
control, reset control to original setting.
B. Mechanical Low Water Cut-off - May be checked by
opening blow-off valve on lower portion of cut-off
body while boiler is running. This will drain water
from boiler and break circuit to burner.
Refill boiler to its normal water line.
C. Primary Control and Flame Sensor -Check
1. Flame Failure -Simulate by shutting off oil supply
with hand valve while burner is on. Sixty seconds after
flameout, safety switch locks out, ignition stops, motor
stops and oil valve -when used -closes. To restart, open
oil supply valve and reset safety switch.
2. Ionition Failure -With burner off, close oil supply
valve and run through start-up procedure. Safety
switch should lock out as in flame failure.
3. Power Failure -Turn off main power supply switch
while burner is operating. When burner stops, restore
power and burner should start. If operation is not as
described as above, check wiring and controls.
Preventative maintenance of oil fred boiler reduces
operating costs. Boiler and vent pipe should be inspected
for accumulation of soot or scale deposits periodically
but at least once every year before start of each heating
season. When soot is present on section walls and
flueways, improper combustion will result, causing
additional sooting and scaling until flueways are completely
closed. To remove soot and scale from flueways, remove
top jacket panel, top clean-out plate, open burner swing
door. See Figure #14.
Opening Burner Swing Door
1. Turn off power to boiler and allow boiler to cool down.
2. Disconnect power cable at factory supplied burner
electrical disconnect. See Figure #14.
3. Loosen screws on sides of lower front jacket panel. See
Figure 6. Pull bottom part of lower front panel forward
and lift lower front panel up and off boiler. See Figure
#14.
4. Close oil valve and disconnect oil line from burner. See
Figures #12 - #13.
IMPORTANT: Do not open swing door with oil fine
attached.
5. Remove nut from swing door stud on right hand side of
door.
6. Swing open burner and door to left. Using flue brush,
brush soot and scale into combustion space where it
can be removed through swing door opening.
Use caution when vacuuming in chamber area.
Damage to chamber could result.
Recommend replacing nozzle at start of each heating
season. Lubricate burner motor and circulator motor - if
required - with few drops of good grade of light motor
oil. Do not over oil. Have qualifed service person service
burner and check controls and check electrodes for carbon
or cracks in insulators. Burners should be adjusted to
produce conditions shown in "Startup and Adjustment of Oil
Burner."
Closing The Burner Swing Door
1. Swing burner and door to right until insulation is
slightly compressed and stud is exposed.
2. Attach nut to stud and tighten it until built in stop
contacts mounting door.
3. Reconnect oil line to burner.
4. Replace lower jacket panel, and tighten screws.
5. Connect power cable at factory supplied burner
electrical disconnect.
6. Turn on power to boiler and bleed oil line.

Burnandscaldhazard. VerifyBoilerisoff and
cooledbeforeperformingmaintenance.Havea
qualifiedserviceagentperformmaintenance.Failure
to followthese instructionscouldresultin deathor
seriousinjury.
Before seasonal start up it is advisable to have a qualified
service agency check boiler for soot and scale in flues,
change oil filter and nozzle, clean burner and re-adjust
burner input rate to maintain proper operation and high
operating efficiency.
On steam boilers verify boiler is filled to water line as
indicated in Figure #14. Gauge valves should be normally
open. To remove dirt from gauge glass petcock may be
opened to flush out the glass.
Radiator valves on one-pipe steam system must be either
wide open or tightly shut. Do not attempt to regulate room
temperature by partially closing the radiator valve.
Air vents on steam radiators and the supply main release
air from the system. If radiators do not heat satisfactorily,
make sure the air vents are clean and operational.
The lever of the pressure relief valve on the boiler (Figure
#14) should be operated periodically to make sure that it
is functioning properly.
Safety valve should open before the steam pressure
exceeds the 15 psi. reading on the gauge. (Figure #14)
If this pressure is exceeded and the safety valve does not
open, it must be replaced. If the safety valve leaks steam
when the boiler is operating at normal pressures, it should
be immediately replaced. Corrosion can build up rapidly
at the valve seat and prevent its functioning as a safety
device.
If the water in a steam boiler appears to be dirty or oily, or
the water level in the gauge glass fluctuates considerably,
the boiler should be cleaned. A competent service person
will use approved cleaning compounds and properly clean
and flush out the boiler. He/she should also clean or replace
air vents and traps, clean flue passages and check for
proper operation of all controls and safety devices.
The venting system should be inspected at the start of each
heating season. Check the vent pipe from the boiler to the
chimney for signs of deterioration by rust or sagging joints.
Repair if necessary.
Impurities in boiler water of a steam boiler may cause
foaming and an unsteady water line, or prevent steam
generation. They may result in objectionable odors
escaping from the vents on water boilers. This condition
is caused by oil, grease, and sediment from pipe fittings
collecting within the boiler and can be remedied only by
giving the boiler a thorough cleaning.
BOILERS SHOULD BE CLEANED BY SKIMMING OR
BLOWING DOWN,
Do not leave Boiler unattended during cleaning/
skimming process.
Skimming Off Impurities
Some of the impurities in the boiler water will float on the
water and must be skimmed off.
With the boiler empty and cool, slowly begin to add water.
After water has entered boiler - never before - turn "on"
oil burner and adjust water flow so that the water being
added is kept just below boiling point. Avoid boiling and
turbulence.
Gradually raise hot water level to skimming hole (Figure #7)
installed on the rear section of the boiler being careful not to
raise it above the opening of the hole. Skim until there are no
impurities. Repeat the process if necessary.
Water may be checked to make sure it is free from oil by
drawing off a sample at the skimming hole. If the sample
is reasonably free from oil, it will not froth when boiled on
stove. This test does not indicate the amount of sediment
which may lay in the bottom of the boiler. It is therefore
necessary that the boiler be further cleaned by "blowing
down."
Blowing Down The Boiler
Before blowing down the boiler, fill it to the water line.
Turn on burner and allow five pounds of steam pressure to
build up. Run a temporary connection from one of the drain
valves to a nearby sewer. Connect to a drain valve on the
opposite end of the boiler from feed water inlet, if possible.
Shut off the oil burner, open drain valve and blow down the
entire contents of boiler.
Allow boiler to thoroughly cool and slowly refill to water
line. Repeat as many times as required until blow off water
is clear. Owner should blow down boiler at least once each
month of the heating season.

Using Cleaning Compound
If an exceptional amount of dirt or sludge seems to be
present in the boiler, a boiler cleaning compound made by
a reputable manufacturer may be used according to the
instructions of the manufacturer of the compound. When
any type of cleaning compound is used, care must be taken
to thoroughly flush all traces of the compound out of the
boiler.
Following blow down allow the boiler to cool. Add fresh
water slowly. Be certain to blow enough times as required
to remove compounds from system.
The area around the boiler must be kept clear and free
of combustible materials, gasoline and other flammable
vapors and liquids.
The free flow of combustion and ventilation air to the boiler
and boiler room must not be restricted or blocked.
Periodic inspection and tightening of the tankless heater/
cover plate bolts will reduce the risk of leaks. See parts 3 and
5 under "Coil and Cover Plate Replacement Parts."
Electronic Low Water Cut-Off
Operation of the probe and control should be checked, with
the burner on, by draining the water via the drain on the
bottom of the boiler. This will drain the water quickly from
the boiler and break the circuit to the burner. If it does not
inspect the probe for scaling. If scaling is present, clean off
the probe, refill the boiler until the ELWCO is satisfied, and
perform the check again.
It is suggested that a qualified service agency be employed
to make an annual inspection of the boiler and heating
system. They are experienced in making the inspections
outlined above and, in the event repairs or corrections are
necessary, can make the proper changes for safe operation
of the boiler.