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Table of Contents
- 1 Repair Parts
- 2 Locating the Boiler
- 3 Installation Requirements
- 4 Fresh Air for Combustion
- 5 System Piping
- 6 Chimney and Chimney Connections
- 7 Electrical Connections
- 8 Filling the Boiler
- 9 Operating the Boiler
- 10 Checking and Adjusting Controls
- 11 Oil Burner Cleaning
- 12 Service Hints
- 13 Electrical Wiring
- 14 Sequence of Operations
- 15 Repair Parts
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Operation & Installation Manual
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Table of Contents
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Summary of Contents for Dunkirk Empire II
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Page 1: Repair Parts
OIL-FIRED CAST IRON HOT WATER B O I L E R S Installation Operation Repair Parts Saving The Earth Saving Your Money These instructions must be affixed on or adjacent to the boiler. DUNKIRK BOILERS DUNKIRK, NEW YORK 14048 • AREA CODE 716 366-5500... - Page 3 INTRODUCTION...
- Page 4 +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. »As an Energy Star Partner, Dunkirk Radiator Corporation has determined that this product meets Energy Star Guidelines for Energy Efficiency. The City of New York MEA #191-99-F...
- Page 5 RULES FOR SAFE INSTALLATION AND OPERATION...
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Page 6: Locating The Boiler
BEFORE YOU START LOCATING THE BOILER MINIMUM CLEARANCE DIMENSIONS... -
Page 7: Installation Requirements
ALWAYS KEEP THE MANUAL FUEL SUPPLY VALVE SHUT OFF, IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME. INSTALLATION REQUIREMENTS... -
Page 8: Fresh Air For Combustion
FRESH AIR FOR COMBUSTION EXAMPLE 1: Boiler Located in Unconfined Space EXAMPLE 2: Boiler Located in Confined Space... - Page 9 Fresh Air ¼" Mesh Screen Wood Louvers Metal Louvers Duct Size (Btuh)* (Btuh)* (Btuh)* 3-½" x 12" 144,000 36,000 108,000 8" x 8" 256,000 64,000 192,000 8" x 12" 384,000 96,000 288,000 8" x 16" 512,000 128,000 384,000 *Btuh = British Thermal Units per hour based on opening covered by ¼" mesh screen , wood louvers, or metal louvers.
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Page 10: System Piping
SYSTEM PIPING... - Page 11 SYSTEM PIPING ARRANGEMENT ZONING WITH ZONE VALVES...
- Page 12 SYSTEM PIPING ARRANGEMENT - ZONING WITH CIRCULATORS...
- Page 14 Boiler Burner Firing Input Tank less Model Rate (gph) (MBH) Rating (gpm)‡ 3EW.65T 0.65 2.90 3EW.75T 0.75 3.00 3EW1.00T 1.00 3.25 4EW.90T 0.90 3.15 4EW1.25T 1.25 3.50 4EW1.50T 1.50 3.75 5EW1.20T 1.20 3.45 5EW1.75T 1.75 4.00 5EW2.00T 2.00 4.25 ‡ Gallons of water per minute heated from 40°F to 140°F with 200°F boiler water temperature, intermittent draw...
- Page 15 COPPER PIPE STEEL PIPE Number of Total Volume PIPE SIZE FACTOR FACTOR Boiler Section (Gallons) ½" 82.5 63.5 ¾" 40.0 36.0 11.6 1" 23.3 22.2 13.7 1-¼" 15.3 12.8 1-½" 10.8 2" Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.
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Page 16: Chimney And Chimney Connections
CHIMNEY AND CHIMNEY CONNECTIONS FIRING RATE CHIMNEY NOMINAL ROUND LINER- SQUARE LINER- (gph) HEIGHT (ft) CHIMNEY INSIDE INSIDE 0.60 - 1.30 8" x 8" 6" 6-¾" x 6-¾" 1.31 - 1.80 8" x 8" 7" 6-¾" x 6-¾" 1.81 - 2.00 8"... -
Page 18: Electrical Connections
ELECTRICAL CONNECTIONS WARNING... - Page 19 EQUIPMENT AND OPTIONAL ACCESSORIES RELIEF VALVE (provided) CONVENTIONAL EXPANSION TANK (not provided) DIAPHRAGM EXPANSION TANK (not provided)
- Page 20 AUTOMATIC FILL VALVE (not provided)
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Page 21: Filling The Boiler
FILLING THE BOILER... -
Page 22: Operating The Boiler
OPERATING THE BOILER... -
Page 26: Checking And Adjusting Controls
CHECKING AND ADJUSTING CONTROLS... -
Page 29: Oil Burner Cleaning
OIL BURNER CLEANING:... -
Page 30: Service Hints
SERVICE HINTS You may avoid inconvenience and service calls by checking these points before you call for service. Possible Cause What to do Thermostat is not set correctly Reset thermostat above room temperature. Boiler or Burner may be dirty Clean all flue passages and the vent pipe. Have burner cleaned and readjusted. -
Page 31: Electrical Wiring
ELECTRICAL WIRING... -
Page 34: Sequence Of Operations
SEQUENCE OF OPERATIONS With the adjustable differential at the minimum setting of 10°F: NOTE: High limit setting must be a minimum of 20º higher than the low limit setting. - Page 35 SEQUENCE OF OPERATIONS INTERNAL WIRING FOR HONEYWELL AQUASTAT L8148A...
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Page 36: Repair Parts
REPAIR PARTS ITEM DESCRIPTION Water Boiler Back Section (EW-3) 403-00-008 403-00-008 403-00-008 Water Boiler Middle Section (EW-2) 403-00-007 403-00-007 403-00-007 Empire Water Front Section (EW-1) 403-00-006 403-00-006 403-00-006 Cast Iron Machined Nipples 2" 433-00-976 433-00-976 433-00-976 1/4" Tie Rods 146-05-002 146-05-051 146-05-053 Tie Rods 1/4"-20 Hex Head Nut... - Page 37 REPAIR PARTS ITEM DESCRIPTION Part# Empire Water Front Section (EW-1) 403-00-006 3/8" - 16 X 2-1/4" stud 146-95-125 3/8" Whizlock Nut 146-95-126 Swing Door Insulation 146-14-014 Swing Door Hinge 403-00-010 1/4" x 2" Round Head Rivet 146-95-121 3/8" x 1" Hex Head Serrated Flange Bolt 146-95-124 3/8"...
- Page 38 REPAIR PARTS ITEM DESCRIPTION Right Side Jacket Panel 425-00-244 425-00-245 425-00-246 Back jacket Panel 425-00-269 425-00-269 425-00-269 Top jacket Panel 425-00-254 425-00-255 425-00-256 Left Side Jacket Panel 425-00-264 425-00-265 425-00-266 Upper Side Jacket Panel 425-00-267 425-00-267 425-00-267 5/16" Acorn Nut 146-95-042 146-95-042 146-95-042...
- Page 39 REPAIR PARTS ITEM DESCRIPTION Beckett AFG F-Head Oil Burner 146-19-007 146-19-008 ----- Beckett AFG Variable Head Oil Burner ----- ----- 146-19-009 ----- Beckett AFG F-Head Low Fire Kit (0.65 gph) 433-00-015 ----- ----- ----- Beckett AFG F-Head Low Fire Kit (0.90 gph) ----- 433-00-016 -----...
- Page 40 BECKETT OIL BURNER, NOZZLE, AND AIR SETTING BOILER DELEVAN FIRING HEAD-ADJ. LOW FIRE STATIC MODEL OIL NOZZLE RATE (gph) OR SETTING BAFFLE SHUTTER/BAND PLATE BURNER 3EW.65* 0.50-80º B 0.65 F0 - 1 1/8 10/0 3-5/8 AFG F-HEAD 3EW.75 0.65-70º B 0.75 F3 - 1 1/8 10/0...