ECR Durnkirk EMPIRE II Series Instruction manual

EMPIRE II
SERIES II
An ISO 9001-2008 Certified Company
P/N# 240009549, Rev. A [04/2012]
Manufacturedby:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
OIL-FIRED CAST IRON
HOT WATER
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Maximum Allowable
Working Pressure 50 psi.
Models
3EW.65
3EW.75
3EW1.00
4EW.90
4EW1.25
4EW1.50
5EW1.20
5EW1.75
5EW2.00

2
Introduction
Empire Water boiler is a natural draft oil fired hot water
boiler comprised of cast iron sections. Empire Water
boiler is available with 3, 4, or 5 cast iron sections. These
sections are held together by cast iron push nipples.
Empire Water boiler is capable of firing #2 fuel oil from
0.65 gph up to 2.00 gph. All packaged boilers include a
swing door, Honeywell limit, temperature and pressure
gauge, safety relief valve, drain valve, flue brush, and extra
boiler tap for expansion tank or air elimination.
SAFETY NOTICES
Boiler installation shall be completed by qualified agency.
NOTICE
Used to address practices not related to personal
injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
!
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
This is the safety alert symbol. Symbol alerts you
This is the safety alert symbol. Symbol alerts you
to potential personal injury hazards. Obey all safety
to potential personal injury hazards. Obey all safety
messages following this symbol to avoid possible injury or
messages following this symbol to avoid possible injury or
death.
death.
Become familiar with symbols identifying
Become familiar with symbols identifying
potential hazards.
potential hazards.
Safety Notices.............................................. 2
Boiler Ratings And Capacities ......................... 3
Fresh Air For Combustion............................... 7
System Piping .............................................. 9
Chimney And Chimney Connections .............. 16
Typical Chimney Connection......................... 17
Electrical Connections ................................. 18
Filling The Boiler ....................................... 19
Operating The Boiler ................................. 20
Checking And Adjusting Controls .................. 23
Maintenance .............................................. 24
Oil Boiler Cleaning Instructions .................... 25
Oil Burner Cleaning..................................... 26
Service Hints ............................................. 27
Electrical Wiring ......................................... 28
Equipment And Optional Accessories ............. 29

3
BOILER RATINGS AND CAPACITIES
BOILER
MODEL NO.
Without
Tankless Coil
INPUT **HEATING
CAPACITY
*Mbh
‡NET
AHRI
RATING
WATER
*Mbh
A.F.U.E.
++ NO. SEC.
MINIMUM
CHIMNEY
SIZE/
HEIGHT
DIMENSIONS
(inches)
+gph *Mbh AB C
»3EW.65 0.65 91 80 70 86.3 3 8” X 8” X 15” 14½ 6 8
»3EW.75 0.75 105 92 80 85.2 3 8” X 8” X 15” 14½ 6 8
3EW1.00 1.00 140 120 104 84.0 3 8” X 8” X 15” 14½ 6 8
»4EW.90 0.90 126 111 97 86.0 4 8” X 8” X 15” 17¾ 6 9⅝
»4EW1.25 1.25 175 151 131 85.0 4 8” X 8” X 15” 17¾ 6 9⅝
4EW1.50 1.50 210 179 156 84.0 4 8” X 8” X 15” 17¾ 6 9⅝
»5EW1.20 1.20 168 147 128 86.5 5 8” X 8” X 15” 21 6 11½
5EW1.75 1.75 245 210 183 84.3 5 8” X 8” X 15” 21 6 11½
5EW2.00 2.00 280 236 205 82.0 5 8” X 8” X 20” 21 6 11½
* Mbh = 1,000 BTU per hour [BTU = British Thermal Unit]
**Heating Capacity based on 13% CO
2
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 140,000 BTU per gallon
++A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure.
‡ Net AHRI Water Ratings based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler
for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive
piping systems, etc.
>> As Energy Star Partner, manufacturer has determined this product meets Energy Star guidelines for energy efficiency.
BOILER RATINGS AND CAPACITIES
Figure 1 - Dimensions

4
1. Read the Owner’s Manual for Safe Operation. Failure
to follow rules for safe operation and instructions can
cause malfunction of boiler and result in death, serious
bodily injury, and/or property damage.
2. Check your local codes and utility requirements before
installation. 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. Over-
firing will result in early failure of the boiler sections.
This will cause dangerous operation.
6. Never vent this boiler into enclosed space. Always vent
to outside. Never vent to another room or inside a
building.
7. Be sure there is adequate air supply for complete
combustion.
8. Follow 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.
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
11. Be aware when piping the safety relief valve if system
pressure exceeds safe limit of 30 pounds per square
inch, the safety relief valve will automatically lift
open. Lifting of the safety relief valve can discharge
large quantities of steam and hot water, which may
damage the surroundings. Before installing the safety
relief valve read the manufacturer’s instructions and
maintenance section of the manual on safety relief
valves.
12. Installation and sizing of the expansion tank must
consider heating systems total water volume,
temperature, boiler initial fill pressure, and system
arrangement. Improperly installed and sized expansion
tank may result in frequent lifting of the safety
relief valve or other heating system problems. For
proper installation, sizing, and maintenance of the
expansion tank follow guidelines established by tank
manufacturer.
13. Expansion tank performance and life expectancy can
be hindered by overfilling the boiler. Recommend initial
fill pressure of 10-12 psig. For higher fill pressures
expansion tank’s air charge will need to be increased to
match fill pressure. Consult manufacturer’s guidelines
for sizing and selection.
14. Purging the heating system of air and gases when
first putting boiler into service is critical for proper
circulation and quiet performance. Once air and gases
are purged, for boiler installations using float type
vents, air vents should be closed for normal operation.
If air is heard or noticed by loss of heat, purge system
and open vents for short period of time.
SAFE INSTALLATION AND OPERATION
NOTICE
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.
Manufacturer is not responsible for any changes to
the original design.
DO NOT USE GASOLINE CRANKCASE DRAININGS
OR ANY OIL CONTAINING GASOLINE.

5
Complete Prior To Installing Boiler.
A. Verify you have selected the right size boiler with
proper capacity. AHRI rating of boiler selected
should be greater than or equal to calculated peak
heating load (heat loss) for building or area(s)
served by 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 proper oil supply
and oil piping, sufficient fresh combustion air, and
suitable electrical supply.
C. Boiler must be connected to suitable venting system
and piping system adequate to distribute heating
load.
D. Properly locate and install thermostat for heating
system control.
Any doubts as to requirements, check with local authorities
and obtain professional help where needed. OPERATING
INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and
MAINTENANCE sections in this manual are vital to the
proper and safe operation of the heating system.
1. Place boiler in location centralized with the piping
system and as close to chimney as possible.
2. Boiler must be level. If necessary use metal shims
beneath boiler’s feet.
3. Use raised base if floor can become wet or damp.
4. Maintain clearances for fire safety as well as
servicing. 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 front
of the boiler. Fresh air for ventilation must be
available to front and rear of boiler. Air passages
must be free of obstructions at all times. Ventilating
and combustion air must enter boiler room without
restrictions.
WARNING
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
6. Floor supporting boiler must be noncombustible and
sufficiently stable. If it is combustible, place boiler
on 2” concrete patio blocks or 2” Cladlite Pad™.
Blocks or pad must be under entire boiler to protect
the floor.
7. Installation shall be 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.
BOILER CLEARANCES
Unit Combustible
Clearance
Accessibility,
Cleaning, and
Servicing
Flue to
Combustible
Clearance
Top 6” 18”
18”
Left Side 24” 24”
Right Side 6”
Base non-combustible
Front 18”
Back 6”
All distances measured from the cabinet of the boiler.
24” Min.
6”
Min.
6”
Min.
6” Min./18”
With Coil
Boiler
Front
LOCATING THE BOILER
Figure 2 - Clearances

6
OIL TANK
C H I M N E Y
ELECTRIC LINE
VENT
PIPE
DRAFT
REGULATOR
DIAPHRAGM EXPANSION TANK
AUTOMATIC
FILL VALVE
AND SHUTOFF
RELIEF VALVE
TO RADIATION
FROM RADIATION
CIRCULATING
PUMP IN RETURN LINE
OR AFTER THE
EXPANSION
TANK
S
HUT OFF
VALVE
OIL FILTER
OIL LINES
FOUNDATIONS
TO OUTSIDE
LINES TO OTHER APPLIANCES
SERVICE LINE
OVERCURRENT
PROTECTED
SAFETY SWITCH
2" FILL
PIPE
MIN. 2" I.D.
VENT PIPE
ENTRANCE SWITCH
OIL BURNER
GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION
LOCATING THE BOILER
Figure 3 - Boiler With Piping System

7
Provide enough fresh air to assure proper combustion.
Fire in the boiler uses oxygen. It must have continuous
supply. Air in the house contains only enough oxygen to
supply burner for short time. Outside air must enter the
house to replace air used by the burner. Study the following
examples 1 and 2 to determine your fresh air requirements.
EXAMPLE 1: Boiler Located in Unconfined Space
If your boiler is in an open area (un-partitioned basement)
in conventional house, air that leaks through cracks around
doors and windows will usually be adequate to provide air
for combustion. Doors should not fit tightly. Do not caulk
cracks around windows.
An unconfined space is defined as space whose volume is
not less than 50 cubic feet per 1,000 Btu per hour of total
input rating of all appliances installed in that space.
EXAMPLE 2: Boiler Located in Confined Space
A. All Air from Inside the Building: Confined
space shall be provided with two permanent openings
communicating directly with additional room(s) of sufficient
volume so the combined volume of all spaces meets the
criteria for unconfined space. Total input of all combustion
equipment installed in combined space shall be considered
in making this determination. Each opening shall have
minimum free area of one square inch per 1,000 Btu per
hour of 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 top and one within 12
inches of bottom of the enclosure.
Example: Your boiler is rated at 100,000 Btu per hour.
Water heater is rated at 30,000 Btu per hour. 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 louvered area needed, multiply
free opening required by 1.7 (130 x 1.7 = 221.0 sq. in.
louvered area). In this example, two grilles each having 8”
x 30” (240 sq. in.) louvered area would be used.
FRESH AIR FOR COMBUSTION
WARNING
Asphyxiation, fire hazard. Do not obstruct air
openings to combustion area. Follow instructions
below, to maintain adequate combustion air.
!
NOTICE
Install outside air intake if you use fireplace or
kitchen or bathroom exhaust fan. These devices rob
boiler and water heater of combustion air.
Figure 4 - Air Openings For Boiler Located In
Confined Space (Utility Room)

8
B. All Air from Outdoors: Confined space shall
be provided with two permanent openings, one
commencing within 12 inches of top and commencing
within 12 inches of bottom of enclosure. Openings
shall communicate directly, or by ducts, with outdoors
or spaces (crawl or attic) that freely communicate with
outdoors.
1. When directly communicating with outdoors, each
opening shall have 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 outdoors through
vertical ducts, each opening shall have 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 outdoors through
horizontal ducts, each opening shall have
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 same cross
sectional area as free area of openings to which
they connect. Minimum dimension of rectangular
air ducts shall be not less than three inches.
FRESH AIR DUCT CAPACITIES
THROUGH LOUVERS
Fresh Air
Duct Size
¼” Mesh
Screen Wood Louvers Metal Louvers
(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.
FRESH AIR FOR COMBUSTION
Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In
Tightly Constructed Houses

9
1. Installation of boiler for new heating system,
Install all of radiation units (panels, radiators,
baseboard, or tubing) and supply and return mains
first. After all heating system piping and components
have been installed, make final connection of system
piping to boiler. It is recommended to mount circulating
pump on supply side piping, such that it pumps away
from expansion tank. Refer to figures on next pages.
2. Equip hot water boiler installed above radiation
level with low water cut off device. Periodic inspection
is necessary, as is flushing of float type devices, per
low water cut off manufacturer’s specific instructions.
3. Packaged boiler is set up with 1¼” NPT supply
and return piping from front of boiler. Boiler supply
and return piping can be moved to rear of boiler. Boiler
should not be piped return line to front, supply line
to rear, or vice versa, will cause boiler water to short
circuit heat exchanger. Piping connections may require
additional fittings and parts.
4. Install drain valve provided with boiler in return tee.
See figure 6.
5. Install Safety Relief valve in rear section using ¾”
nipple and street elbow provided with boiler. See figure
3.
A. Install safety relief valve with spindle in vertical
position.
B. Do not install shutoff valve between boiler and
safety relief valve.
C. Install discharge piping from safety relief valve.
• Use ¾” or larger pipe.
• Use pipe suitable for temperatures of 375°F
(191°C) or greater.
• Individual boiler discharge piping shall be
independent of other discharge piping.
• Size and arrange discharge piping to avoid
reducing safety relief valve relieving capacity
below minimum relief valve capacity stated on
rating plate.
• Run pipe as short and straight as possible to
location protecting user from scalding and properly
drain piping.
• Install union, if used, close to safety relief valve
outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
Low Design Water Temperature Systems (Below 140°
F) And Large Water Content Systems
• Significant condensation may form in this boiler and/
or venting system if boiler is operated with return
temperatures of less than 120°F.
• Condensation is corrosive and can eventually cause
damage to boiler and venting system. Minimum design
return water temperature to prevent this condensation in
boiler and venting is 120°F.
• Boiler used in heating system where design water
temperatures below 140°F are desired (e.g. radiant floor
heating), a 3-way or 4-way mixing valve or suitable
alternative (e.g. Bypass Piping Arrangement shown
in diagram on following page) is required to prevent
low temperature (below return 120°F) return water
from entering boiler. When using mixing valve, follow
manufacturer’s installation instructions.
• Boiler connected to system having large water content
(such as former gravity system), use of Bypass Piping
Arrangement shown in diagram on following page is
suggested.
SYSTEM PIPING
6. Verify clean cold water supply is available when
connecting to pressure reducing valve. When water
supply is from well or pump, a sand strainer should be
installed at the pump.
Figure 6 - Safety Relief Valve Installation
Follow Instructions
to install discharge
piping from safety
relief valve to drain.

10
> LOW DESIGN WATER TEMPERATURE
SYSTEMS
> LARGE WATER CONTENT SYSTEMS
> PIPING ARRANGED FOR “POWER
PURGING” AIR OUT OF THE SYSTEM
PIPING, REFER TO THIS MANUAL’S
SECTION ON “FILLING THE SYSTEM
WITH WATER” OPTION #1
SYSTEM PIPING
Figure 7 - Bypass Piping Arrangement Diagram

11
SYSTEM PIPING
> CIRCULATOR ON SUPPLY PIPING PUMPS
AWAY FROM EXPANSION TANK
NOTE:CIRCULATORCANALSOBEINSTALLED
ON RETURN PIPING.
>PIPING ARRANGED FOR “POWER PURGING”
AIR OUT OF SYSTEM PIPING, REFER TO
THIS MANUAL’S SECTION ON “FILLING THE
SYSTEM WITH WATER” OPTION #1
Figure 8 - System Piping Arrangement Zoning With Zone Valves

12
> CIRCULATOR ON SUPPLY PIPING PUMPS
AWAY FROM EXPANSION TANK
> PIPINGARRANGEDFOR“POWERPURGING”
AIR OUT OF SYSTEM PIPING, REFER TO
THIS MANUAL’S SECTION ON “FILLING
THE SYSTEM WITH WATER” OPTION #1
SYSTEM PIPING
Figure 9 - System Piping Arrangement Zoning With Circulators

13
> 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
SYSTEM PIPING
Figure 10 - System Piping Arrangement Alternate Near Boiler Piping

14
Boiler
Model
Burner
Input
Rate (gph)
Input
(MBH)
Tankless
Rating
(gpm)‡
3EW.65 0.65 91 2.90
3EW.75 0.75 105 3.00
3EW1.00 1.00 140 3.25
4EW.90 0.90 126 3.15
4EW1.25 1.25 175 3.50
4EW1.50 1.50 210 3.75
5EW1.20 1.20 168 3.45
5EW1.75 1.75 245 4.00
5EW2.00 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
SYSTEM PIPING
Boilers may be factory packaged with tankless heater
coil see figure below. 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.
NOTICE
Do not use tankless coil if your water is excessively
hard with lime or other deposits which will
accumulate inside the coil.
When using tankless coil, boiler is configured so Honeywell
L7248 operates with Honeywell L4006 low limit mounted
on well installed in tankless heater. Mount factory wired low
limit on well.
Tempering valve (mixing valve) is recommended as shown
below. Flow restrictor may be required on tankless coil inlet
piping so that flow rates are matched to boiler heat input
(see table).
DANGER
Water temperatures exceeding 125°F will cause
severe burns instantly or death by scalding.
!
Tankless Coil Piping Arrangement
Figure 11 -Tankless Coil Piping Arrangement

15
Antifreeze added to boilers must be nontoxic, and
must be of 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.
BOILER WATER VOLUMES
Number of
Boiler Section Total Volume (Gallons)
3 9.6
4 11.6
5 13.7
PIPING WATER VOLUMES
PIPE SIZE COPPER PIPE
FACTOR STEEL PIPE FACTOR
½” 82.5 63.5
¾” 40.0 36.0
1” 23.3 22.2
1 ¼” 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.
SYSTEM PIPING ARRANGEMENT

16
Chimney Connector And Draft Regulator
• Venting the boiler requires 6” diameter chimney
connector pipe and use of manufacturer provided draft
regulator.
• Regulator, when properly installed, automatically
controls the draft.
• Install in horizontal section of pipe, may also be
installed in angled or vertical section of pipe.
• Verify “top” of regulator is at the top and short pipe
section which holds the vane is horizontal.
• Even though locating draft regulator close to chimney
reduces noise, install draft regulator as close as
practicable to the boiler.
• Install chimney connector, start at boiler with vertical
pipe, elbow, then install draft regulator horizontally.
• When regulator is in place, start at chimney and work
back to the regulator.
• Join the two sections with draw-band.
• Horizontal pipe must slope up toward the chimney at
least 1/4 inch per linear foot of venting.
• Chimney connector must not leak and must be firmly
supported.
• Join each section with at least two sheet metal screws.
Support every second section with a stovepipe wire.
RECOMMENDED MINIMUM CHIMNEY SIZES
FIRING RATE
(gph) CHIMNEY HEIGHT (ft) NOMINAL CHIMNEY ROUND LINER INSIDE SQUARE LINER INSIDE
0.60 1.30 15 8” x 8” 6” 6 ¾” x 6 ¾”
1.31 1.80 15 8” x 8” 7” 6 ¾” x 6 ¾”
1.81 2.00 20 8” x 8” 8” 6 ¾” x 6 ¾”
For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.
CHIMNEY AND CHIMNEY CONNECTIONS
For oil fired boilers for connections to vents or chimneys,
vent installations shall be in accordance with applicable
provisions of INSTALLATION OF OIL BURNING EQUIPMENT,
NFPA31 latest revision, and applicable provisions of local
building codes.
NOTICE
Fresh air (ventilation) is important to proper
venting. Ventilation and venting are two parts of the
same system. Inadequate ventilation will result in
inadequate venting. Always be sure to have enough
ventilation to support proper venting.
Check your chimney to make certain that it is right size,
properly constructed and in good condition.
See Table “Recommended Minimum Chimney Sizes”.
For additional chimney design and sizing information,
consult the National Standard for Chimneys, Fireplaces,
Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211.
WARNING
Fire Hazard. Maintain minimum vent pipe clearance
of 18” from surface of vent to wood and other
combustible materials. Failure to comply may result
in death or serious injury.
!

17
TYPICAL CHIMNEY CONNECTION
Figure 12 -
Typical Chimney Connection

18
ELECTRICAL CONNECTIONS
Thermostat
Install 24 Volt thermostat (not provided) in proper location.
Location of thermostat has effect on boiler system operation.
Follow instructions included with thermostat.
Grounding
Permanently ground boiler according to local codes and
latest revision of the National Electrical Code. Run 14
gauge or heavier copper wire from boiler to grounded
connection in service panel or properly driven and
electrically grounded ground rod.
Electric Power Supply
Installation must comply with the latest revision of the
National Electrical Code, any other national, state, or local
codes or regulations.
Connect 115 volt electrical supply to L1 and L2 terminals
on limit and two thermostat wires to T and T terminals on
same limit. See wiring diagram page 28.
Run separate circuit from separate over current protection
device in your electrical service entrance panel. Minimum
15 ampere circuit. Locate shutoff switch at boiler. Turn off
during any maintenance. Solder and tape or securely fasten
connections with wire nuts.
Oil Burner Wiring
For boilers packaged with oil burners, burners are wired
at the factory. For boilers shipped without a burner, wiring
connections are shown in the electrical wiring diagrams of
this manual.
WARNING
Electrical shock hazard. Turn OFF electrical power supply
at service panel before making electrical connections.
Failure to do so could result in death or serious injury.
!

19
How A Hot Water System Operates
Entire heating system (boiler, piping, and radiation units)
is filled with water. As water in the boiler is heated, it
is circulated from top of boiler through supply main to
radiation units. Cooler water in radiation units flows back
through return piping through 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 boiler piping as shown in
figure on page 6.
A. Close main shutoff valve, isolation valves, and zone
valves (if applicable). If bypass piping is installed,
also close two throttling valves. Leave boiler service
shutoff valve (if installed) and balancing valves to
each heating zone fully open.
B. Open following valves in order: drain valve for power
purging, isolating valves before and after boiler
circulator (if applicable), both throttling valves (if
applicable), and then open fill line shutoff valve. Water
will fill bypass piping and push air through piping and
out power purging drain valve. When power purging
drain valve runs air free, close bypass piping throttling
valve (leaving throttling valve to supply piping fully
open).
C. Next, open isolation valve (or zone valve) to first
zone. Water will fill piping and push any air out power
purging drain valve. When power purging drain valve
runs air free, close isolation valve or zone valve).
Repeat this procedure for remaining heating zones.
D. Once all zones are filled with water and purged of air,
close power purging drain valve and fill line shut off
valve, open main shutoff valve, and adjust throttling
valves and balancing valves as required.
OPTION #2
• Close air vents on all radiation units.
• Open valves to radiation units. Verify boiler drain
valve, expansion tank drain cock, and air bleed screw
on expansion tank drain fitting are closed.
• Open fill valve on piping to expansion tank.
• Open water inlet to boiler and leave it open.
• Open air vent on lowest radiation unit.
• When all air has escaped and water starts to flow from
vent, close it.
• Go to next radiation unit, and repeat this process until
finishing with highest radiation unit.
• If heating system has automatic vents, this manual
venting is unnecessary but it will speed up proper filling
of the system.
If system is a closed expansion tank system, automatic fill
valve is needed. Leave automatic fill valve open to refill
system automatically as needed.
Note initial fill pressure on boiler’s temperature / pressure
gauge, which should be 10-15 psig. Any lowering of
pressure from its initial fill pressure indicates loss of
water due to leakage. Automatic fill valve should then
compensate for this water pressure loss. If it does not,
manually open this valve to refill system until needle is
again pointing to same pressure reading. Instructions are
packaged with valve.
FILLING THE BOILER

20
Air Supply For Combustion:
• Do not install boiler in rooms with insufficient air, unless
corrective steps are taken.
• It may be necessary to install windows or cut holes in
a door to rooms used for supply air to obtain sufficient
combustion air and prevent less than atmospheric air
pressure in that room.
• If there is a lack of combustion air, burner flame will be
dark orange and formation of soot will occur in heating
unit.
• In buildings of conventional frame, brick, or stone
construction that do not have utility rooms, basement
windows, or stair doors, air infiltration is normally
adequate to provide enough air for combustion and for
operation of barometric draft control.
• Room used for supplying combustion air should be
isolated from any area served by exhaust fans.
• Refer back to the section on Fresh Air For Combustion
for additional sizing guidelines.
Draft Regulators: Barometric draft regulator is required
for controlling draft through boiler. Mount barometric draft
regulator in chimney connector. Refer back to section on
“Chimney And Chimney Connections”. Once draft regulator
is installed, use draft gauge to adjust to proper opening:
A. Combustion chamber over fire draft will be
approximately 0.01” WC to 0.02” WC.
B. Stack draft will be approximately 0.02” WC. to
0.04” WC.
C. Larger installation, greater draft will be required in
stack to obtain desired over fire draft.
Start: Fill entire system with water. Vent all air from
system following section for Filling The Boiler.
Fuel Units And Oil Lines:
• Install oil line(s) to oil burner.
• Recommend using heavy wall copper tubing and
flared fittings, not compression fittings.
• All connections and joints must be absolutely airtight.
Use an appropriate non-hardening thread sealing
compound on the threaded connections, not Teflon
tape.
• See fuel unit data sheet furnished with the burner for
sizing, lift, and length of tubing recommendations.
Oil burner is equipped with single stage fuel unit
with bypass plug removed for single pipe installation.
Satisfactory where fuel supply is on same level as or
above burner permitting gravity flow of oil. Per NFPA 31
requirements, never exceed 3 psig pressure to inlet side of
fuel unit.
When necessary to lift oil to burner, two pipe installation
is required. Run return line between fuel unit and oil
supply. When two pipe installation is used, bypass plug
(furnished with burner) must be installed in fuel unit. Refer
to fuel unit instructions furnished with burner for specific
instructions on installing bypass plug. Do not exceed fuel
unit manufacturer’s recommendations for running vacuum.
NOTICE
If lift exceeds 14 feet for Beckett or Carlin burners
or 11 feet for Riello burners, two stage fuel unit is
required with return line.
Install oil filter of adequate size inside building between
tank shutoff valve and oil burner. For ease of servicing,
locate shutoff valve and filter near oil burner.
OPERATING THE BOILER