U.S. Boiler Company EMP Series Service manual

109529-03 - 11/19
As an ENERGY STAR®Partner, U.S. Boiler Company
has determined that the EMP series meet the
ENERGY STAR®guidelines for energy efficiency
established by the United States Environmental
Protection Agency (EPA).
Installation, Operating and Service Instructions for
EMP • High Efficiency
• Oil-Fired, 3-Pass
• Water Boiler
• Natural Draft or Direct Vent
(140E thru 224E)
Models:
• EMP84E
• EMP115E
• EMP140E
• EMP182E
• EMP224E
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
9700609
Manual Contents Page
Pre-installation..........................7
Packaged Boiler Assy. - Trim..............10
Water Boiler Piping .....................18
Natural Draft Venting ....................21
Direct Venting / Air Intake Piping ..........25
Electrical..............................32
Oil Piping .............................35
System Start-Up........................37
Operation .............................44
Maintenance and Service Instructions .....49
Boiler Cleaning ........................51
Troubleshooting........................53
Service Parts ..........................58
Burner Specifications ...................70

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All boilers must be installed in accordance with National, State and Local Plumbing, Heating and
Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ
from this instruction manual. Authorities having jurisdiction should be consulted before installations
are made.
In all cases, reference should be made to the following Standards:
The following terms are used throughout this manual to bring attention to the presence of hazards of
various risk levels, or to important information concerning product life.
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fire
places, Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1,
“Controls and Safety Devices for Automatically Fired Boilers”, for assembly and
operations of controls and safety devices.
D. All wiring on boilers installed in the USA shall be made in accordance with the
National Electrical Code and/or Local Regulations.
IMPORTANT INFORMATION - READ CAREFULLY
NOTICE This boiler has a limited warranty, a copy of which is included with this boiler. The warranty for this boiler
is valid only if the boiler has been installed, maintained and operated in accordance with these instructions.
Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation
during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.
NOTICE: Indicates special instructions on
installation, operation, or maintenance which
are important but not related to personal injury
hazards.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
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IMPORTANT
This boiler is equipped with a feature that saves energy by reducing the boiler water
temperature as the heating load decreases. This feature is equipped with an override
which is provided primarily to prevent the use of an external energy management
system that serves the same function. THIS OVERRIDE MUST NOT BE USED
UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.
• This boiler is not used for any space heating.
• This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/HR or greater.
• This boiler is equipped with a tankless coil.

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DANGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other
appliance.
!
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
Read and understand all instructions, including all those contained in component manufacturers manuals
which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this boiler.
Keep this manual and literature in legible condition and posted near boiler for reference by owner and service
technician.
• This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in
this manual.
• Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable
installer or service agency.
• All heating systems should be designed by competent contractors and only persons knowledgeable in the
layout and installation of hydronic heating systems should attempt installation of any boiler.
• Installation is NOT complete unless a pressure relief valve is installed into the tapping located on top of Shell
Assembly in the front left corner - See Water Piping and Trim Section of this manual for additional details.
• It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when installation is complete including verifying that the limit sensor is fully installed
(seated in bottom of Well).
• Failure to properly install Limit Sensor may result in property damage, personal injury or loss of life due to
elevated operating temperatures and/or pressures.
• This boiler is suitable for installation on combustible flooring. DO NOT install boiler on carpeting.
• DO NOT tamper with or alter the boiler or controls.
• Inspect flueways at least once a year - preferably at the start of the heating season. The inside of the
combustion chamber, the vent system and boiler flueways should be cleaned if soot or scale has
accumulated.
• When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged, or if
there is evidence of previous damage, burner swing door insulation must be replaced immediately.
• Oil Burner and Controls must be checked at least once a year or as may be necessitated.
• DO NOT operate unit with jumpered or absent controls or safety devices.
• DO NOT operate unit if any control, switch, component, or device has been subject to water.
• Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and other
reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working
nearby the appliance.
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WARNING
This boiler contains very hot water under high pressure. DO NOT unscrew any pipe fittings nor attempt to
disconnect any components of this boiler without positively assuring the water is cool and has no pressure.
Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent
scald injuries. DO NOT rely on the pressure and temperature gauges to determine the temperature and
pressure of the boiler. This boiler contains components which become very hot when the boiler is operating.
DO NOT touch any components unless they are cool.
• This boiler must be properly vented. The boiler must be connected to an approved chimney or vent system
in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate
chimney or vent system. The chimney must be inspected for any obstructions and cleaned prior to each
heating season. A clean and unobstructed chimney flue is necessary to produce the minimum draft required
to safely evacuate noxious fumes that could cause personal injury or loss of life. DO NOT operate boiler with
the absence of an approved vent system. Evidence of loose debris and or condensate induced stains at the
base of the chimney flue, connector or smokepipe joints may be signs of condensing flue gases. Flue gas
condensate is corrosive, which requires special consideration and must be addressed immediately. Refer to
"Natural Draft Venting (Chimney)" listed in Table of Contents below.
• This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
• This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service.
If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold
weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if
the boiler is inoperative.
• This boiler is designed to burn No. 2 fuel oil only. DO NOT use gasoline, crankcase drainings, or any oil
containing gasoline. Never burn garbage or paper in this boiler. DO NOT convert to any solid fuel (i.e. wood,
coal). DO NOT convert to any gaseous fuel (i.e. natural gas, LP). All flammable debris, rags, paper, wood
scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of fire hazards.
• All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe
property damage, personal injury or loss of life. Before opening swing door turn off service switch to boiler to
prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fasteners
completely when service is completed.
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Figure 1: EMP Water Boiler
*NOTE: This Dimension increases and is controlled by smoke pipe arrangement.

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Table 1A: Dimensional Data (see Figure 1)
Table 1B: Rating Data
Boiler Model
No.
Dimensions See Figure 1 Water Content
- Gallons
Heat Transfer
Surface Area -
Sq. Ft.
Actual
Shipping
Weight (LB.)
“A” “B” “C”
EMP84E/115E 16-5/8” 24” 5” 7.70 13.29 430
EMP140E 22-5/8” 24” 6” 11.08 20.29 545
EMP182E 28-5/8" 30" 6" 14.46 27.29 658
EMP224E 34-5/8” 36” 7” 17.84 34.29 771
NOTE: 1. Maximum Working Pressure: Water: 30 PSI Shipped From Factory (Standard),
40 PSI Optional, 50 PSI Optional
Boiler Model
No.
Burner
Capacity DOE
Heating
Capacity
(MBH)
(2)
NET AHRI
Ratings
Water
(MBH)
(3)
AFUE %
Minimum Chimney
Recommendations Direct Vent System
GPH MBH
(1)
Round
In. Dia.
Rectangle
In. x In.
Height
Ft. Model
Vent
Connector
Dia. Inch
EMP84E 0.60 84 74 64 87 6 8 x 8 15 N/A N/A
EMP115E 0.80 115 101 87 87 6 8 x 8 15 N/A N/A
EMP140E 1.00 140 123 107 87 6 8 x 8 15 FDVS-56 5
EMP182E 1.30 182 160 139 87 7 8 x 8 15 FDVS-56 5
EMP224E 1.60 224 197 171 87 7 8 x 8 15 FDVS-56 6
(1) MBH refers to thousands of BTU per hour.
(2) Based on Standard Test prescribed by the United States Department of Energy at combustion conditions of
13.0% CO2.
(3) Net AHRI water ratings based on a piping and pickup allowance of 1.15. Consult with manufacturer before
selecting a boiler having unusual piping and pickup requirements, such as intermittent system operation,
extensive piping systems, etc.

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Figure 2A: Chimney Vent - Minimum Installation Clearances To Combustible Materials (Inches)
A. INSPECT SHIPMENT carefully for any signs of
damage.
1. All equipment is carefully manufactured,
inspected and packed. Our responsibility
ceases upon delivery of crated boiler to the
carrier in good condition.
2. Any claims for damage or shortage in shipment
must be filed immediately against the carrier
by the consignee. No claims for variances
from, or shortage in orders, will be allowed by
the manufacturer unless presented within sixty
(60) days after receipt of goods.
B. LOCATE BOILER in front of final position before
removing crate. See Figure 1.
1. LOCATE so that vent pipe connection to
chimney will be short and direct.
2. BOILER IS SUITABLE FOR INSTALLATION
ON COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.
3. FOR BASEMENT INSTALLATION, provide a
solid elevated base, such as concrete, if floor
is not level, or if water may be encountered on
floor around boiler.
4. PROVIDE RECOMMENDED SERVICE
CLEARANCE, if applicable, as follows:
a. Clearance from Jacket Front Panel -
• 24” for servicing burner
• 24” for flueway cleaning (EMP84E -
140E)
• 30” for flueway cleaning (EMP182E)
• 36" for flueway cleaning (EMP224E)
b. Clearance from Jacket Side Panels -
• 19” for burner swing door, if opened
fully with burner mounted, otherwise 1”
with burner removed
• 12” access clearance to service rear of
boiler if right side clearance is less
than 12”
• 3” minimum if right side clearance is 12”
or larger to access and service rear of
boiler.
c. Clearance from Jacket Rear Panel -
• 12” minimum for rear smokebox
cleaning
(Note: This dimension will also be
controlled by horizontal to vertical to
horizontal smokepipe arrangement -
Chimney Vent (see Figures 2A and 10).
• 24” for rear smoke box cleaning and
disconnecting vent pipe from boiler
adaptor for servicing (if required) -
Direct Vent (see Figures 2B).
5. For minimum clearances to combustible
materials. See Figures 2A and 2B.
NOTES: 1. Listed clearances comply with American National Standard ANSI/NFPA 31, Standard for the Installation of Oil Burning Equipment.
2. EMP boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances cannot be
reduced for alcove or closet installations.
3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31 standard.
1Pre-Installation

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NOTICE:
Clearance to venting is for single wall
vent pipe. If Type L vent is used, clearance may
be reduced to the minimum required by the vent
pipe manufacturer.
C. PROVIDE COMBUSTION AND VENTILATION
AIR. Local and National Codes may apply and
should be referenced.
WARNING
Adequate combustion and ventilation air must
be provided to assure proper combustion and
to maintain safe ambient air temperatures.
Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, fabric softeners,
etc.) are used or stored.
1. Determine volume of space (boiler room).
Rooms communicating directly with the
space in which the appliances are installed,
through openings not furnished with doors, are
considered a part of the space.
Volume(ft3) = Length(ft) x Width(ft) x Height(ft)
2. Determine total input of all appliances in the
space.
Add inputs of all appliances in the space and
round the result to the nearest 1000 BTU per
hour.
3. Determine type of space. Divide Volume by
total input of all appliances in space. If the
result is greater than or equal to 50 ft3/1000
BTU per hour, then it is considered an
unconfined space. If the result is less than
50 ft3/1000 BTU per hour then the space is
considered a confined space.
4. For boiler located in an unconfined space of a
conventionally constructed building, the fresh
air infiltration through cracks around windows
and doors normally provides adequate air for
combustion and ventilation.
5. For boiler located in a confined space or an
unconfined space in a building of unusually
tight construction, provide outdoor air.
a. Outdoor air for combustion may be
provided with an optional Fresh Air
Accessory Kit (ONLY AVAILABLE WITH
BECKETT BURNER).Plastic cover
applications, P/N 102119-01. Refer to Fresh
Air Accessory Kit instructions for installation
and air intake piping details.
or
b. Outdoor air may be provided with the
use of two permanent openings which
communicate directly or by duct with the
outdoors or spaces (crawl or attic) freely
communicating with the outdoors. Locate
remaining opening within 12 inches of
bottom of space. Minimum dimension of air
opening is 3 inches. Size each opening per
following:
Figure 2B: Direct Vent - Minimum Installation Clearances To Combustible Materials (Inches)
1Pre-Installation (continued)
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Table 2: Direct Vent Configuration
Components
i. Direct communication with outdoors.
Minimum free area of 1 square inch per
4,000 BTU per hour input of all equipment in
space.
ii. Vertical ducts. Minimum free area of 1
square inch per 4,000 BTU per hour input
of all equipment in space. Duct cross-
sectional area shall be same as opening
free area.
iii. Horizontal ducts. Minimum free area of 1
square inch per 2,000 BTU per hour input
of all equipment in space. Duct cross-
sectional area shall be same as opening
free area.
Alternate method for boiler located within
confined space. Use indoor air if two
permanent openings communicate directly
with additional space(s) of sufficient volume
such that be combined volume of all spaces
meet criteria for unconfined space. Size
each opening for minimum free area of 1
square inch per 1,000 BTU per hour input of
all equipment in spaces, but not less than
100 square inches.
6. Louvers and Grilles of Ventilation Ducts
a. All outside openings should be screened
and louvered. Screens used should not be
smaller than 1/4 inch mesh. Louvers will
prevent the entrance of rain and snow.
b. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of
the louver or grille is not known, assume
wood louvers have 20-25 percent free area
and metal louvers and grilles have 60-75
percent free area.
c. Louvers and grilles must be fixed in the
open position, or interlocked with the
equipment to open automatically during
equipment operation.
D. DIRECT VENT CONFIGURATIONS requires:
1. Beckett NX Burner
2. Direct Vent Conversion Kit
3. Double Wall Flex Oil Vent Pipe(FOVP).
Horizontal ducts. Minimum free area of 1
square inch per 2,000 BTU per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
Alternate method for boiler located within
confined space. Use indoor air if two
permanent openings communicate directly
with additional space(s) of sufficient volume
such that combined volume of all spaces
meet criteria for unconfined space. Size
each opening for minimum free area of 1
square inch per 1,000 BTU per hour input of
all equipment in spaces, but not less than
100 square inches.
4. Louvers and Grilles of Ventilation Ducts
a. All outside openings should be screened
and louvered. Screens used should not be
smaller than 1/4 inch mesh. Louvers will
prevent the entrance of rain and snow.
b. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of
the louver or grille is not known, assume
wood louvers have 20-25 percent free area
and metal louvers and grilles have 60-75
percent free area.
c. Louvers and grilles must be fixed in the
open position, or interlocked with the
equipment to open automatically during
equipment operation.
D. DIRECT VENT CONFIGURATIONS requires:
1. Beckett NX Burner
2. Direct Vent conversion Kit
3. Double Wall Flex Oil Vent Pipe (FOVP)
Boiler
Model No.
Beckett NX
Oil Burner
Part No.
Direct Vent
Conversion
Kit Part No.
FOVP Carton Part
No.
EMP140E 103896-03 102130-02
100212-02 - 10 ft.
EMP182E 103897-04 100214-02 - 20 ft.
EMP224E 103898-05 102130-03
100212-03 - 10 ft.
100214-03 - 20 ft.
1Pre-Installation (continued)

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A. REMOVE CRATE.
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other
inside protective spacers and bracing.
Remove miscellaneous parts carton.
B. REMOVE BOILER FROM SKID.
1. To reduce the risk of damage to boiler jacket,
use the following procedure to remove from
skid, see Figure 3:
Step 1. Boiler is secured to base with (4) 5/16”
cap screws, (2) in front and (2) in rear of
shipping skid, see Figure 3. Remove all
securing hardware.
Step 2. Place wooden block(s) 12” from rear
of skid as shown (one piece 4” x 4” x 16” lg.
or two pieces of 2” x 4” x 16” lg.)
Step 3. Insert 1” Sch. 40 pipe handles through
leg hole in front and rear legs. Center end
of pipe on wooden blocks as shown in
Figure 3.
NOTE: Pipe handles should extend a
minimum of 48” beyond jacket front panel
for best leverage.
Step 4. Using the pipe handles, lift boiler until
adjustable legs are elevated above the
deck boards.
Step 5. Remove skid from underneath the
boiler.
Step 6. Lower pipe handles until front
adjustable legs touch floor. If necessary,
place wooden blocks under front legs
before lowering to provide hand clearance.
Step 7. To lower rear of boiler, tilt unit slightly
forward by pushing on smokebox collar or
lift pipes protruding through rear legs until
wooden blocks can be removed (see Figure
3). Slowly allow the weight of the boiler to
tilt backward until rear legs rest on floor.
Step 8. If wooden block was placed under
front legs, lift pipe handles, remove wooden
block and lower front legs to floor. Remove
pipe handles.
CAUTION
Do not drop boiler. Do not bump boiler jacket
against floor.
C. MOVE BOILER TO PERMANENT POSITION
by sliding or walking.
D. PROCEDURE TO OPEN, CLOSE AND
SECURE BURNER SWING DOOR
Throughout this manual you will be instructed to
open and close the burner swing door for various
reasons. There is a proper and improper method
to closing and securing the burner swing door
opened for inspection, cleaning or field service.
Figure 3: Packaged Boiler Removal from Skid
2Packaged Boiler Assembly - Trim
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Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured
• Lift door off mounting bracket and set
aside.
• Remove mounting bracket and
hardware from left side.
• Remove upper jacket front panel
retaining screw (5/16” x 1/2” lg. Phillip
Pan head machine screw) from right
side of door and re-install in vacated
upper mounting bracket tapping. Do
not tighten.
• Move lower jacket panel retaining
screw from right side to left tapping.
Do not tighten.
• Rotate door mounting bracket 180°.
Insert 5/16” cap screw through top
hole in bracket and install in upper
vacated jacket hole on right side of
door.
• Install second 5/16” cap
through bracket hole into lower
vacated tapping on right side.
• Tighten both sets of hardware to
secure jacket and mounting bracket.
• Lift door and place integral cast hinge
pins on door into slotted mounting
bracket holes.
2. Perform routine inspection, service or cleaning
as necessary.
2Packaged Boiler Assembly - Trim (continued)
1. TO OPEN BURNER SWING DOOR
(see Figures 4A and 4B).
Step 1. Loosen but do not remove left side
latching hardware (3/8” x 1-3/4” lg. tap bolt).
Step 2. Loosen and remove right side latching
hardware (3/8” x 1-3/4” lg. tap bolt and
washer).
Step 3. Remove left side latching hardware
(3/8” x 1-3/4” lg. tap bolt and washer).
Step 4. Disconnect burner power cord from
receptacle located in lower right corner of
jacket front panel.
Step 5. Door can be swung to the fully open
position, approximately 90° to 120°, with the
burner mounted providing that there is 19”
of clearance to the adjacent wall, see Figure
1.
NOTE: If reduced clearance prevents the
door from opening fully, one of the following
can provide full access:
a. Burner can be removed to allow full
rotation of door.
b. Door with burner mounted can be lifted
off mounting bracket and set aside
during servicing.
c. The door mounting hardware is
reversible from left side hinge (as
shipped) to right side hinge.
To reverse hinge arrangement (see
Figure 4A):

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Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
2Packaged Boiler Assembly - Trim (continued)

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3. To close Burner Swing Door (see Figures 4A
and 4B):
Step 1. From the fully open position, rotate
Burner Swing Door to the closed position.
Step 2. If necessary, place your right hand
under the burner air tube to lift upward. Lift
the door up unto the built-in cast ramp/door
rest (protruding from the bottom of the front
section casting - see Figure 4A).
Step 3. Use one hand to help hold door in
position by lifting up on rear burner housing
or applying pressure directly to the door
while re-installing the securing hardware
with your opposite hand. Always install
right side latching hardware (3/8”-16 x
1-3/4” lg. tap bolt and flat washer) first,
then install left side hinge hardware (3/8”-
16 x 1-3/4” lg. tap bolt and flat washer)
second. Apply additional pressure while
hand tightening the hardware as far as
possible, then release the pressure.
NOTICE:
When securing burner swing door
make sure door is drawn-in equally on both sides.
Step 4. Use a hand wrench to tighten door
hardware and always start with the right
side cap screw first. Use an alternating
tightening method from right side tap bolt to
left side tap bolt to tighten door equally until
sealed without applying excessive torque.
Never tighten left side flange bolt first or
tighten either piece of hardware 100%
without using the alternating tightening
method described above.
Failure to follow the prescribed procedure
could cause thread damage to casting or
a leak in the door seal. If left side tap bolt
is tightened before right side tap bolt, right
side of door can not be drawn-in to provide
an air tight seal, as shown in Figure 4C.
Applying excessive torque will only cause
thread damage.
E. INSPECT SWING DOOR INSULATION AND
ROPE GASKET.
1. Open burner swing door using procedure
previously outlined in Paragraph D of this
section.
2. Inspect fiberglass rope located on the swing
door. The rope must be evenly distributed
around the perimeter of the door groove and
cannot bunch or overhang. There must not be
a gap where the two ends of the rope meet.
Repair or replace if the rope is damaged or if
there is a gap between the ends.
3. Inspect burner swing door insulation for
damage and proper type.
Figure 4C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed
2Packaged Boiler Assembly - Trim (continued)

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a. By design, cast bars on front section between
the combustion chamber and between the left
and right side 2nd and 3rd pass flueway should
make an impression in door insulation to seal
the chambers.
b. By design, door insulation on model
EMP224E will have two (2) by-pass pockets
cast into the insulation centered on the bar
between the combustion chamber and 3rd
pass flueways.
On models EMP84E thru EMP182E these
pockets should not be present. If insulation
is damaged or not of proper type regarding
pockets, it must be replaced.
4. Do not close and secure door at this time,
proceed to Field Assembly Details, Paragraph
F.
F. FIELD ASSEMBLY OF BOILER TRIM Open
miscellaneous parts carton and remove contents.
Identify the components using the illustrations
(see Figure 5 thru 8) throughout the assembly
sequence outlined below as it applies to your
installation.
1. Install return manifold and relief valve, refer to
Figure 5.
Step a. Locate the return pipe fittings and
injector. Apply sealant to the 2" NPT
injector threads. Insert injector into 2"
Figure 5: Return Manifold and Relief Valve Assembly Details
NPT upper rear tapping on rear section.
Thread 2" NPT x 1-1/2" Reducing Elbow
onto 2" NPT injector. Apply thread
sealant to the 1-1/2" NPT nipple. Thread
1-1/2" nipple into 1-1/2" NPT end of
reducing elbow. Thread 1-1/2" NPT x
1-1/2" NPT x 3/4" NPT Tee onto 1-1/2"
NPT nipple. Tighten pipe fittings until
relief valve orientation is correct for your
installation and joints are watertight.
Note: Based on system return piping and
access to service boiler, see Figures
1, 9A and 9B, predetermine if manifold
orientation is to be positioned for
vertical, horizontal left or horizontal right
side return piping as shown in Figure 5.
Step b. Install relief valve using 3/4" NPT
tapping on tee. Relief valve must
be installed in vertical position. If
orientation of return manifold is for:
• 1-1/2" NPT vertical return piping -
Install 3/4" NPT x 90º street ell (not
furnished) inot 3/4" NPT tapping on
tee. Install relief valve vertically into
street ell. See Figure 9.
• 1-1/2" NPT horizontal left or right
side return piping - Install relief valve
vertically in 3/4" NPT tapping on tee.
See Figure F4.
2Packaged Boiler Assembly - Trim (continued)

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Figure 6: Piping Arrangement for Drain Valve and Indirect Water Heating Return
Step c. Pipe discharge of relief valve as
shown in Figures 9A and 9B. Installation
of the relief valve must be consistent
with ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
WARNING
Safety valve discharge piping must be piped
near floor to eliminate potential of severe burns.
Do not pipe in any area where freezing could
occur. Do not install any shut-off valves, plugs
or caps.
2. Install drain valve and indirect water heater
return piping, see Figure 6.
Step a. Apply pipe sealant to both ends of
1-1/4" NPT x 5" lg. nipple. Thread nipple
into 1-1/4" NPT lower rear tapping on rear
section.
Step b. Thread 1-1/4" x 1-1/4" x 3/4" NPT tee
on opposite end of 5" lg. nipple installed in
Step a.
NOTE: Based on access for servicing
and location of sewer or floor drain, when
tightening these fittings, determine if drain
valve is to be located on the left or right
side.
Tighten nipple and tee into 1-1/4" NPT lower
rear tapping or rear section until joints are
water tight for desired position.
Step c. Apply sealant to 3/4" NPT thread on
drain valve. Thread into 3/4" NPT tapping
on side outlet of tee. Use hex nut portion to
tighten valve until water tight.
Step d. If an Alliance™ SL water heater is
connected to system, do not install 1-1/4"
NPT pipe plug. Connect piping as shown in
Figures 9A and 9B, as applicable. Also refer
to Alliance™ SL instructions for additional
information.
3. Installing stainless steel flueway baffles. Baffle
requirements differ from model to model, see
Table 3.
NOTE: Read caution statement before proceeding.
Step a. Install stainless steel baffles provided
in miscellaneous parts carton as follows,
refer to Table 3 and Figure 7:
2Packaged Boiler Assembly - Trim (continued)
!

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Figure 7: Baffle Orientation in Flueways
Table 3: Baffle Usage
Boiler
Model
Baffle Usage
2nd Pass 3rd Pass Combustion
Chamber
EMP84E [2]
P/N 1020660-01 None None
EMP115E [2]
P/N 109902-01
[2]
P/N 100081-01
[1]
P/N 109901-01
EMP140E [2]
P/N 100042-01 None None
EMP182E
EMP224E
• Model EMP84 - To install flueway baffle
in 2nd pass on left side of boiler, hold
baffle with word "Left" readable at the
top. Slide baffle in flueway until position
tab touches fins on left side of 2nd pass
flueway. To install flueway baffle in 2nd
pass flueway on right side of boiler, hold
baffle with word "Right" readable at the
top. Slide baffle in flueway until position
tab touches fins on right side of 2nd pass
flueway.
• Model EMP115E - To install flueway baffle
in 3rd pass on left side of boiler, hold
baffle with word "Left" readable at the
top. Slide baffle in flueway until position
tab touches fins on left side of 3rd pass
flueway. To install flueway baffle in 3rd
pass flueway on right side of boiler, hold
baffle with word "Right" readable at the
top. Slide baffle in flueway until position
tab touches fins on right side of 3rd pass
flueway. To install flueway baffle in 2nd
pass of left side of boiler, hold baffle with
word "Left" readable at the top. Slide
baffle until position tab touches fins
on left side of 3rd pass flueway. To install
flueway baffle in 2nd pass flueway on right
side of boiler, hold baffle with word "Right"
readable at the top. Slide baffle in flueway
until position tab touches fins on right
side of 3rd pass flueway.
2Packaged Boiler Assembly - Trim (continued)
CAUTION
These baffles will generate higher efficiencies
and lower stack temperatures. Under certain
conditions, a lower gross stack temperature
entering the chimney has the potential to
be cooled below the dew point and create
condensate on interior surfaces. Flue gas
condensate is corrosive, which requires
special consideration and must be addressed
immediately.
DO NOT install baffles until you have read
Sections IV, "Venting" completely.
!
To install combustion chamber ring, place
ring in first section of combustion chamber.

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Step c. Remove three (3) 5/16-18 x 3/4 lg.
cap screw from burner swing door used for
mounting burner.
Step d. Thread (1) 5/16-18 x 3/4 lg. cap screw,
approximately three (3) full turns, into
tapping located at 12:00 o’clock on burner
swing door.
Step e. Insert oil burner into the opening of
burner swing door. Align and engage keyhole
slot in burner flange over head of protruding
cap screw installed in previous Step. Rotate
burner to the right to lock flange behind head
of cap screw.
Step f. Align holes and install two (2) remaining
cap screws. Level burner and fully tighten all
three (3) screws.
Step g. Plug burner power cord into Burner
Receptacle.
Step h. Check oil nozzle in burner for size, angle
and spray type; inspect electrode settings and
head/air plate setting. Refer to Tables 9A, 9B
and Section X.
• Models EMP140E, EMP182E and
EMP224E - To install flueway baffle in
2nd pass flueway on left side of boiler,
hold baffle with word "Left" readable
at the top. Slide baffle in flueway until
position tab touches fins on right side
of 2nd pass flueway. To install flueway
baffle in 2nd pass flueway on right side
of boiler, hold baffle with word "Right"
readable at the top. Slide baffle in flueway
until position tab touches fins on left side
of 2nd pass flueway.
NOTE: 2nd and 3rd pass flueway baffle are not
interchangeable.
4. Close the burner swing door and securely
seal the door to the boiler front section by
reinstalling the hardware and securing the
door using procedure previously outlined in
Paragraph D of this section.
NOTICE: When securing burner swing door
make sure door is drawn-in equally on both sides.
5. Install oil burner. (See Figure 8)
Step a. Open burner carton and remove
contents.
Step b. Place oil burner gasket on burner and
align holes.
Figure 8: Beckett Oil Burner Installation
2Packaged Boiler Assembly - Trim (continued)
CAUTION
Do not install burner without gasket.
!

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A.EVALUATE THE EXISTING WATER
SYSTEM.
Design a piping system and install boiler which
will prevent oxygen contamination of boiler water
and frequent water additions.
1. There are many possible causes of oxygen
contamination such as:
a. Addition of excessive make-up water as a
result of system leaks.
b. Absorption through open tanks and fittings.
c. Oxygen permeable materials in the
distribution system.
2. In order to insure long product life, oxygen
sources must be eliminated. This can
be accomplished by taking the following
measures:
a. Repairing system leaks to eliminate the
need for addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which
allow oxygen absorption.
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
WARNING
System supply and return piping must be
connected to correct boiler manifolds.
U. S. Boiler Company recommends sizing the
system circulator to supply sufficient flow (GPM)
to allow a 20°F temperature differential in the
system. When sizing the system circulator, the
most restrictive single zone should be used to
determine maximum pressure drop.
CAUTION
Maintain minimum ½ inch clearance from hot
water piping to combustible materials.
3. In order to insure long product life, operate boiler
at appropriate flow rate to minimize areas of
overheating.
a. Design system to ensure that the flow is above
the limit called for in Table 5.
b. Maintain a constant boiler pressure of 12 PSI.
WARNING
Do not operate boiler below minimum volumetric
flow rates.
B. CONNECT SYSTEM SUPPLY AND RETURN
PIPING TO BOILER. See Figures 9A and 9B.
Also, consult I=B=R Installation and Piping Guides.
1. If boiler is used with an Alliance™ SL Indirect Fired
Domestic Water Heater, install the Alliance™ SL as
a seperate heating zone. Refer to the Allaince™ SL
Installation, Operating, and Service Instructions,
for additional information.
2. The EMP is designed to withstand thermal shock
from return water temperatures as low as 100ºF,
but prolonged return temperatures of below 135ºF
can cause excessive flue gas condensation and
damage the boiler and/or venting system.
Use a boiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures
may be encountered (i.e. converted gravity
circulation system, etc.) The bypass should be
the same size as the supply and return lines
with valves located in the bypass and return
line as illustrated in Figures 9A and 9B in order
to regulate water flow for maintenance of higher
boiler water temperature.
3. If it is required to perform a long term pressure
test to the hydronic system, the boiler should
first be isolated to avoid pressure loss due to the
escape of trapped air.
To perform a long term pressure test including
the boiler, ALL trapped air must first be removed
from the boiler.
A loss of pressure during such a test, with no
visible water leakage, is an indication that the
boiler contained trapped air.
Boiler Model No. Flow Rate (Gal / Min)
EMP84E 4.5
EMP115E 4.5
EMP140E 8.0
EMP182E 10.0
EMP224E 12.0
Table 4: Minimum Flow Rate
3Water Boiler Piping
NOTICE: Failure to pipe boiler as specified in this
manual may result in excessive system noise.
!
!
!

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Figure 9A: Recommended Water Piping for Circulator Zoned Heating Systems
3Water Boiler Piping (continued)

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Figure 9B: Recommended Water Piping for Zone Valve Zoned Heating Systems
3Water Boiler Piping (continued)