Filling The Boiler - Dunkirk 3EW.65 Installation, Operation & Maintenance Manual

Oil-fired cast iron hot water empire ii series
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How A Hot Water System Operates
Entire heating system (boiler, piping, and radiation units)
is fi lled 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 fl ows 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
fi gure 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 fi ll line shutoff valve. Water
will fi ll 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 fi rst
zone. Water will fi ll 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 fi lled with water and purged of air,
close power purging drain valve and fi ll line shut off
valve, open main shutoff valve, and adjust throttling
valves and balancing valves as required.

FILLING THE BOILER

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 fi tting are closed.
• Open fi ll 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 fl ow from
vent, close it.
• Go to next radiation unit, and repeat this process until
fi nishing with highest radiation unit.
• If heating system has automatic vents, this manual
venting is unnecessary but it will speed up proper fi lling
of the system.
If system is a closed expansion tank system, automatic fi ll
valve is needed. Leave automatic fi ll valve open to refi ll
system automatically as needed.
Note initial fi ll pressure on boiler's temperature / pressure
gauge, which should be 10-15 psig. Any lowering of
pressure from its initial fi ll pressure indicates loss of water
due to leakage. Automatic fi ll valve should then compensate
for this water pressure loss. If it does not, manually open
this valve to refi ll system until needle is again pointing to
same pressure reading. Instructions are packaged with
valve.
19

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