Dunkirk 5EW1.20, 4EW.90, 3EW.75, 4EW1.25, 3EW.65, 4EW1.50, 5EW2.00, 3EW1.00, 5EW1.75 User manual

Dunkirk 5EW1.20, 4EW.90, 3EW.75, 4EW1.25, 3EW.65, 4EW1.50, 5EW2.00, 3EW1.00, 5EW1.75 User manual

[

Owner'sManual

MODELNO.

3E W.65

3EW. 75

3EWI';O0

4EW.90

4EWl ;25

4EW1.50

5EWl.20

5EW1.75

5EW2.00

CAUTION

Read aft instructions carefully before starting the installation.

Save this manual for reference.

Off-Fired

Hot Water

Boiler

Installation

• Operation

Repair Parts

KENNMORE CAST IRON BOILERS

FULL ONE YEAR WARRANTY ON HOT WATER AND GAS STEAM CAST IRON BOILERS

For one (1) year from the date of installation, when this boiler is installed and maintained in accordance with our instructions. Sears will repair defects in material or workmanship in the boiler, free of charge.

LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS

After one (1} year and through twelve (12) years from the date of installation,Sears will furnish a replacement heat exchanger, if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS

After one (!) year and through twenty (20) years from the date of installation, Sears will furnish a replacement heat exchanger if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY tn addition to any warranty extended to you on the Sears merchandise involved, which warranty becomes effective the date the merchandise is installed, should the workmanship of any Sears arranged installation prove faulty within one year, Sears will, upon notice from you, cause such faults to be corrected at no additional cost to you

FOR WARRANTY SERVICE, SIMPLY CONTACT THE NEAREST SEARS STORE OR SERVICE

CENTER THROUGHOUT THE UNITED STATES. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

IMPORTANT

The following are the responsibilities of the user and are not covered by the Warranty

1 Filter clearing or replacement

2 Damage to unit or unsatisfactory operation due to improper cleaning or use of unit in corroswe atmosphere

3 Damage to unit or unsatisfactory operation due to blown fuses or inadequate or _nterrupted electrical protective devices

4 Damage to unit caused by the use of components or other accessones not compatible with the unit

5. If the unit is removed from the place it was originally installed, this Warranty becomes void.

6 Damage to the unit caused by accident, abuse, negligence, misuse, riot, fire, flood, or acts of God

SEARS ROEBUCK AND COMPANY

D/817WA

Hoffman Estates, IL 60179

INTRODUCTION

The Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron sections.

The Empire

Water nipples.

boiler is available with 3, 4, or 5 cast iron sections.

These sections are held together by cast iron push

The Empire Water boiler is capable of firing #2 fuel oil from 0.65 gph up to 2.00 gph.

Boilers may be purchased with or without the following options: a Beckett AFG, Carlin EZ, or Rie[lo 40 oil burner, a Taco or Grundfos circulator with isolation valves, a tankless coil for domestic hot water.

All packaged boilers include a swing door, Honeywell aquastat, temperature and pressure gage, relief valve, drain valve, 2 Delevan oil nozzles for multiple firing rates (only when purchasing a burner), flue brush, and an extra boiler tap for an expansion tank or air elimination.

--*-- 2o

I/2"

TIE_ml

GAUGIE

PRIESSUR_ r

i j

UMIT

CONTROL

(W_lh=_t

Tanklos=

,7

.l/a"

RIEU.O

T3

3/4"

BIECKETT

OR

CARUN

A t I P-'f

I I I--.-.I

'_ WATIER

OUTLET

OPTIONAL

TANKLESS

J

HEATER

WITH 1/2"

NPT

CONNECTIONS

RIEUIEF

VALVIE

"_

36"

1/4"

RETURN

NIPPLE

&

RIEDUCING

TEE

FRONT VIEW oll)

LIMIT

CONTROL

(_Bh

Tonkiel= co==)

BURN

DRAIN

VALVE

(Furnished)

RIGHT

SIDE

VIEW

WITH

SWING

DOOR

BACK VIEW

BOILER

RATINGS AND

CAPACITIES

BOIIiR

Wlill

IANK[ISS

('Oil niw (_5I ¸

MOI)EI.NO

WIIIIOU

IANKIESS

('OIl

3[!W65Z

31,W 751

31!WI

OttI ¸

4[iw 90T

41!WI

251

41LWl 501

5EWI 20'I

5EWI.75

I

5[-W2 00"[

3EW 75Z

3EWI IRIZ

4EW 99Z

4EWI

25Z

4EWl 50Z

5EWI 20Z

5EWI 75Z

SEW200Z

I

-

NO

Sli('

4

4

5

5

5

3

4

3

3

INPUI

+M[_II

175

210

168

245

280

91

105

140

126

**llliA'[

ING

( APA('IIY

*MBH

80

92

II9

II[

150

178

147

209

236

NET

I=B:R

RA'I IN(i

*MBH

70

80

103

97

130

155

128

182

205

HRING

RA'II_

+GPH

0.65

075

100

090

I +25

150

1+20

1.75

2 00

A t: tJ I

_+

863

852

83 4

860

839

82.4

865

836

820

MINIMUM

CHIMNEY

SIZE / HEIGHT

8" X 8" X 15'

8" X 8"X 15'

8" X 8" X 15'

8" X 8" X 15'

8" X 8" X 15'

8" X 8" X ] 5'

8" X 8" X 15'

8" X 8" X 15'

8" X 8" X 20'

DIMENSIONS

A

14+1/2

14-1/2

14-1/2

17-3/4

17-314

17-3/4

21

21

21

6

6

6

6

6

6

B

6

6

6

(inches)

*MBH 1,000 BTU per hour

BTU

British Thermal Unit

+'*Heating Capacity based on 13% CO2 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

_GPB Gallons of Energy) test procedure.

per hour oil at 140,000 BTU per gallon

+ _A F U E. = Annual Fuel Utilization Efficiency based upon DOE test procedure.

C

8

8

8

9-5/8

9-5/8

9-5/8

1 I-I/2

11-1/2

[ I-I/2

These low pressure oil fired hot water boilers are constructed and hydrostatically tested for a maximum working pressure of 50 psig (pounds per square inch gage) in accordance with A.S.M.E.

(American Society of Mechanical

Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.

The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack.

Most of this remaining heat is available to heat water.

A small portion is heat from the jacket and surfaces of the boiler, and it is assumed that this heat stays in the structure.

The Net I=B=R Rating represents the portion of the remaining heat that can be applied to heat the radiation or terminal units (i.e. finned tube baseboard, cast iron radiators, radiant floor, etc.).

The difference between the Heating Capacity and the Net I=B=R Rating, called the piping and pickup allowance, establishes a reserve for heating the volume of water in the system and offsetting heat losses from the system piping.

The Net I=B-R Ratings shown are based on a piping and pickup factor of 1.15

in accordance with the I-B-R Standard as published by the Hydronics Institute.

The Net I=B=R Rating of the boiler selected should be greater than or equal to the calculated peak heating load (heat loss) for the building or area(s) served by the boiler and associated hot water heating systems.

The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements.

Boilers with the same number of sections are identical to each other except for their firing rate.

The firing rate is deternuned by the nozzle size in the oil burner and the oil pressure at the nozzle.

For example: Models 3E.65Z,

3E.75Z, and 3El .00Z

are the same boiler, without a tankless coil, except for the firing rate of the oil burner.

Models 4E.90T, 4El .25T, and 4El.50T

are the same boiler, with a tankless

coil,

except for the firing rate of the oil burner.

Each boiler rating plate shows three possible model nutnbcrs for a given boiler configuration.

The actual model tmnaber is determined by the firing rate of the oil burner.

Boilers that are factory packaged include two nozzles for two firing rates.

These boilers operate on #2 Heating Oil.

RULES FOR SAFE INSTALLATION AND OPEIL_TION

1.

Read the Owner's Manual for Safe Operation carefidly.

Failure to tbllow tile rules tbr sale operation and the instructions can cause a malflmction of the boiler and resuh in death, serious bodily injury, and/or property damage.

2.

Check your local codes and utility requirements before installation.

The installation nmst be in accordance with their directives, or follow NFPA 31 - Installation of Oil Burning Eqnipment, latest revision.

3.

Before serTicing, allow boiler to cool.

Always shut offany 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.

Overfiring will result in early failure of the boiler sections.

This will cause dangerous operation.

6.

Never vent this boiler into an enclosed space.

Always vent to the outside.

Never vent to another room or inside a building.

7.

Be sure there is adequate air supply for complete combustion.

8.

Follow a 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.

11. Be aware when piping the relief valve that if the system pressure exceeds the safe limit of 30 pounds per square inch, the relief valve will automatically lift open.

Lifting of the relief valve can discharge large quantities of steam and hot water, which may damage the surroundings.

Before installing the relief valve read the manufacturer's instructions and maintenance section of the manual on relief valves.

12. Installation and sizing of the expansion tank must consider the heating systems total water volume, temperature, boiler initial fill pressure, and system arrangement.

An improperly installed and sized expansion tank may result in frequent lifting of the relief valve or other heating system problems.

For proper installation, sizing, and maintenance of the expansion tank follow the guidelines established by

Dunkirk Radiator Corporation and the expansion tank manufacturer.

13. Expansion tank performance and life expectancy can be hindered by overfilling the boiler.

Dunkirk

Radiator Corporation recommends an initial fill pressure of 10-12 psig.

For higher fill pressures the expansion tank's air charge will need to be increased to match the fill pressure.

Consult the manufacturer's guidelines for sizing and selection.

14. Purging the heating system of air and gases when first putting the boiler's into service is critical for proper circulation and quiet performance.

Once the air and gases are purged, for boiler installations using float type vents, the air vents should be closed for normal operation.

If air is heard or noticed by a loss of heat, purge the system and open the vents for a short period of time.

WARNING

This

boiler has been designed for residential

all jurisdictional modifications.

requirements

The

manufacturer

must be met.

installations.

This is not responsible may

If used for commercial

require

wiring

for any changes and/or piping to the original

applications,

design.

I DO NOT USE GASOLINE CRANKCASE

DRAININGS

OR ANY OIL CONTAINING

GASOLINE.

[

BEFORE YOU START

Complete all of the following prior to installing the boiler.

A.

Check to be sure you have selected the right size boiler with the proper capacity.

The I=B=R rating of the boiler selected should be greater than or equal to the calculated peak heating load (heat loss) for the building or area(s) served by the 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 rdust be supplied with the proper oil supply and oil piping, sufficient fresh combustion air, and a suitable electrical supply.

C.

Boiler must be connected to a suitable venting system and a piping system adequate to distribute the heating load.

D.

A thermostat must be properly located and installed for control of the heating system.

If there are any doubts as to the various requirements, check with local authorities and obtain professional help where needed.

The OPERATING INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and MAINTENANCE sections in this manual are vital to the proper and safe operation of the heating system.

Take the time to be sure they are all done.

LOCATING THE BOILER

1.

Place the boiler in a location centralized with the piping system and as close to the chimney as possible.

2.

The boiler must be level.

If necessary use metal shims beneath the boiler's feet.

3.

Use a raised base if the floor can become wet or damp.

4.

Maintain clearances for fire safety as well as servicing.

An 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 the front of the boiler.

Fresh air for ventilation must be available to the front AND rear of the boiler.

Air passages must be free of obstructions at all times.

Ventilating and combustion air must enter boiler room without restrictions.

6.

The floor supporting the boiler must be non-combustible and sufficiently stable.

If it is combustible, place the boiler on 2" concrete patio blocks or 2" Cladlite

TM

Pad.

The blocks or pad must be under the entire boiler to protect the floor.

7.

Be sure installation is 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.

MINIMUM CLEARANCE DIMENSIONS

f_

I co'

41

O

24" MIN.

_[

6" MIN.

+

BOILER v _FRONT t

6" MIN.

/ 18" WITH COIL

A_

L 6" MIN.

t "q

,'x.

_C

C

4

ALWAYS KEEP TILE NL_NUAL FUEL SUPPLY VALVE SHUT OFF, IF THE

BUI_NER IS SHUT DOWN FOR AN EXTENDED

PERIOD

OF TIa_clE.

I_NSTALLATION REQUIRELMENTS

1

SHUT OFF

VALVE

OIL RLTER

2**

FI LL PiPE

MIN 2"

VENT PIPE

LINES TO OTHER

APPLIANCES

TO OUTSIDE

OIL

TANK

ELECTRIC

LINE

AUTOMATIC

FILL VALVE

NOSHUTOFF

EXPANSION

DRAFT

REGULATO_

TANK

VENT

PiPE

RELIEF VAI

,TION

,FROM RADIATION

CIRCULATIHG

RETURN

LINE

OR AbTER TI-I]£

EXPANSION

TANK

FRESH AIR FOR COMBUSTION

Be sure to provide enough fresh air for combustion.

combustion

Enough air ensures proper and assures

that

WARNING due to the lack of oxygen.

I

I

If you use a fireplace or a kitchen or a bathroom exhaust fan, you should install an outside air intake.

These devices

NOTE and water heater of combustion air.

[

You must provide enough flesh air to assure proper combustion.

The fire in the boiler uses oxygen.

It must have a continuous supply.

The air in the house contains only enough oxygen to supply the burner for a short time.

Outside air must enter the house to replace the 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 (unpartitioned basement) in a conventional house, the air that leaks through the cracks around the doors and windows will usually be adequate to provide air for combustion.

The doors should not fit tightly.

Do not caulk the cracks around the windows.

An unconfined space is defined as a space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of the total input rating of all appliances installed in that space.

EXAMPLE 2: Boiler Located in Confined Space

A.

All Air

from

Inside

the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.

The total input of all combustion equipment installed in the combined space shall be considered in making this determination.

Each opening shall have a minimum free area of one square inch per 1,000 Btu per hour of the 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 the top and one within 12 inches of the bottom of the enclosure.

Example:

Your boiler is rated at 100,000 Btu per hour.

The water heater is rated at 30,000 Btu per hour.

The total is I30,000 Btu per hour.

You need two grilles, each with 130 square inches of FREE opening.

Metal grilles have about 60% FREE opening.

To find the louvered area needed, multiply the free opening required by 1.7 (130

x 1.7 = 221.0 sq. in. louvered area).

In this example, two grilles each having an 8" x 30" (24-0 sq. in.) louvered area would he used.

AIR OPENINGS FOR BOILER LOCATED IN CONFINED SPACE (CLOSET OR UTILITY ROOM)

VENTILATING

GRILLE

I'

COMBUSTION

AIR

GRILLE

6

I

I

I

I

1

B.

All Air from Outdoors: commencing within

The confined

12 inches space shall be provided of the top and commencing within with two permanent

12 inches openings, of the bottom of the one enclosure.

The openings shall communicate attic) that freely communicate directly, with the outdoors.

or by ducts, with the outdoors or spaces (crawl

or

1.

When directly communicating with the outdoors, each opening shall have a 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 the outdoors through vertical ducts, each opening shall have a minimum flee, 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 the outdoors through horizontal ducts, each opening shall have a 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 the same cross-sectional which inches.

they connect.

The minimum dimension of rectangular area as the free area of the openings to air ducts shall be not less than three

FRESH

AIR

FRESH AIRDUCTCAPACITIESFORDUCTSSUPPLYINGFRESH

CONSTRUCTED HOUSES

_RTOBOILERINTIGHTLY

Fresh Air

Duct Size

3J/2 '" x 12"

8" x 8"

8" x 12"

8"x 16"

¼" Mesh

Screen

(Btuh)*

144,000

256,000

384,000

512,000

Wood Louvers

(Btuh)*

36,000

64,000

96,000

128,000

Metal

Louvers

(Btuh)*

108,000

192,000

288,000

384,000

*Btuh = British Thermal Units per hour based on opening covered by ¼" mesh screen, wood louvers, or metal louvers.

SYSTEM

PIPING

I.

When the installation of the boiler is for a new heating

system,

first instal! all of the radiation units

(panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating system piping

and components have been installed, make final connection of the system piping to the boiler.

It is

recommended to mount the circulating pump on the supply side piping, such that it pumps away from the expansion tank.

Refer to the figures on the next pages.

2.

A hot water boiler installed

above radiation

level must be equipped with a low water cut off device.

A periodic inspection is necessary, as is flushing of float type devices, per low water cut off manufacturers specific instructions.

.

The packaged

boiler unit is set up with 1-1/4" NPT supply and return piping

from the front of the boiler.

The boiler supply and return piping can be moved to the rear of the boiler.

The boiler should not be piped return line to the front, supply line to the rear, or vice versa, as this will cause the boiler water to short circuit the heat exchanger.

Piping connections

may require additional fittings and parts.

,

The relief valve is meant to be installed in the back side of the rear section using the 3/4" nipple and street ell provided in the parts bag.

Connect a discharge pipe of the same pipe size (3/4") to carry any water away to a drain.

Do not connect directly to a drain, but leave an air gap.

No shutoffof any description shall be placed between the safety relief valve and the boiler, or on discharge pipes between such safety valves and the atmosphere.

Installation on the safety relief valve shall conform to the ANSI/ASME Boiler and Pressure

Vessel Code, Section IV. The manufacturer is not responsible for any water damage.

5.

When connecting

the cold water supply to the pressure reducing valve, make sure that a clean water supply is available.

When the water supply is from a well or pump, a sand strainer should be installed at the pump.

.

The minimum

boiler supply

water temperature

heating system where supply water temperatures setting below on the aquastat

140°F is 140°F.

are desired, a suitable

If the boiler method, is used such in a as, the use of bypass piping shown in the figure below, a 3 way or 4 way mixing valve, or some other means needs to be used to ensure return water temperatures to the boiler are no less than 120°F.

When the boiler is operated with return water temperatures

This condensation is corrosive less than and can eventually

120°F, cause condensation severe damage may form in the boiler to the boiler and venting and venting.

system.

RETURN FROM SYSTEM

I

MAINTAINAT LEAST 12O'F IN THE

i/_ADJUST

ARE USED FOR BYPASSPIPING,IF REQUIRED.

SHUTOFF VALVE

BOILER SERVICE

DRAINVALVE

FOR POWER

PURGING

MAIN SHUTOFF

VALVE

AUTOMATIC

FILL VALVE

FILLTROLWITH

AIR

PURGER

CIRCULATOR

PUMP l l

_FILL

OffUNG VALVE

SUPPLY TO

SYSTEM

ISOLATIONVALVES

LINE WITH SHUTOFFVALVE

BOILER

DRAIN

VALVE

8

SYSTEM PIPING ARRANGEMENT

ZONING WITH

ZONE VALVES

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

>

PIPING ARRANGED

FOR "POWER P[VRGING"

AIR OUT OF SYSTEM PIPING, REFER TO THIS

MANUAL'S

SECTION

ON "FILLING

THE

SYSTEM

_,VITH WATER"

OPTION #1

BALANCINGVALVE

ZONE VALVE

RETURNFROM SYSTEM

IT

I RAIN VALVE

PURGING

MAIN SHUTOFF

VALVE

FILL VALVE

SUPPLY TO

SYSTEM

CIRCULATOR

PUMP

SHUTOFFVALVE

BOILER SERVICE

_._"-_ SUPPLYTO

SYSTEM

ISOLATIONVALVES

LiNE WITH SHUTOFFVALVE

FILLTROLWITH

AIR

PURGER

BOILER

DRAIN

VALVE

SYSTEM PIPING ARRANGEMENT

ZONING WITH CIRCULATORS

CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION

TANK

PIPING ARRANGED

FOR "POWER

PURGING"

AIR OUT OF SYSTEM PIPING, REFER

TO THIS

MANI_AL'S SECTION

ON "FILLING

THE

SYSTEM WITH WATER" OPTION #1

7

BALANCINGVALVE

FLOW CHECK VALVE

_ ZONE CIRCULATOR

_I ISOLATIONVALVE

RETURNFROMSYSTEM

[ _

DRAIN VALVE

FOR POWER

PURGING

MAIN SHUTOFF

VALVE

AUTOMATIC

FiLLVALVE

SUPPLY TO

SYSTEM

SHUTOFF VALVE

BOILERSERVICE

SUPPLY TO

SYSTEM

FILLTROLWITH

AIR PURGER

FILLLINEWITH SHUTOFF

VALVE

_QUASTA

BOILER

DRAIN

VALVE

R

I0

SYSTEM PIPING ARRANGEMENT

ALTERNATE NEAR BOILER PIPING

DIAPHRAGM

>

CIRCULATOR

EXPANSION

ON SUPPLY

TANK

PIPING

MOUNTED

PUMPS

OFF THE

AWAY

FROM

BOILER

EXPANSION TANK

PER THIS

MANUAL,

USE OPTION #2 IN "FILLING THE

SYSTEM

WITH \VATER"

THIS

PIPING ARRANGE_IENT CAN BE USED WITH ZONE

VALVES

OR ZONE CIRCULATORS

RETURN FROM SYSTEM

ISOLATION

VALVES

©

SHUTOFF VALVE

---BOILERSERVICE

CIRCULATOR

PUMP

AUTOMATIC

FILLVALVE

SUPPLY TO

SYSTEM

/

FILLLINEWITH

SHUTOFF VALVE

SHUTOFF VALVE

BOILERSERVICE

AOUASTAT

AIR PURGER

BOILER

DRAIN

VALVE

LOCATE CIRCULATORPUMP HERE WHEN SYSTEM

PIPINGUSES ZONE VALVES.IFSYSTEM PIPING

AS A ZONE CIRCULATOR

II

7.

Boilers may be factory

packaged with

a tanMess

heater

coil see figure below.

This 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, no_J continuous flow.

IMPORTANT

Do not use a tankless coil if your water is excessively lime or other deposits which will accumulate inside hard the coil.

with

When using a tankless coil, the boiler has been configured

Hi/Low Limit Aquastat Relay mounts on a thermowell so the Honeywell L8124C Combination

(provided) which needs to be installed in the 3/4" tapping on the tankless coil.

By mounting the aquastat on the coil, the tankless coil performance is maximized by making the burner respond more quickly to a call for domestic hot water.

A tempering valve (mixing valve) is also recommended as shown in figure below.

A flow restrictor may be required on the tankless coil inlet piping so that flow rates are matched to boiler heat input (see table below).

Boiler

Model

3EW.65T

3EW.75T

3EWI.00T

4EW.90T

4EW1.25T

4EW1.50T

5EW1.20T

5EW1.75T

5EW2.00T

Burner Firing

Rate (gph)

0.65

0.75

1.00

0.90

1.25

1.50

1.20

1.75

2.00

Input

(MBH)

91

105

140

126

175

210

168

245

28O

Tankless

Rating (gpm):_

2.90

3.00

3.25

3.15

3.50

3.75

3.45

4.00

4.25

:_ Gallons of water per minute heated from 40°F to 140°F with

200°F boiler water temperature, intermittent draw

UNTEM,_I[R[O HOT WAT[R

TANKLESS

COIL

OUT

-

CENTER LINE

OF COLO

TAp

L__t

_'Np

12

8.

Antifreeze

addedto boilers

must be non-toxic, and must be of a type specifically intended for use in closed b_ydronic 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 in this manual.

BOILER

WATER VOLUMES

PIPING WATER VOLUMES

Number

Boiler Sections

3

4

5 of

I

Total Volume

(Gallons)

9.6

11.6

13.7

PIPE SIZE

COPPER PIPE

FACTOR

STEEL PIPE

FACTOR

Y2"

¾"

1"

1-1/4"

1-1/2"

2"

82.5

40.0

23.3

15.3

10.8

6.2

63.5

36.0

22.2

12.8

9.5

5.8

Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.

13

accordance with applicable provisions of INSTALLATION OF OIL BURNING

I

or oil-fired boilers for connections

to vents or chimneys,

vent installations

shall be in

codes.

CHIMNEY AND CHIMNEY CONNECTIONS

This is a very important part of your heating system.

No boiler, however efficient its design, can perform satisfactorily if the chimney that serves it is inadequate.

Check your chimney to make certain that it is the right size, properly constructed and in sound condition.

It is cheaper to rebuild a poor chimney than to pay excessive fuel bills.

If yours is an old chimney, a new steel liner or a new prefabricated recommended minimum chimney chimney sizes may be the best based on Table solution.

3 and Figure

The following

6 of the I=B=R chart shows

Testing and Rating

Standard for Heating Boilers, Sixth Edition, June 1989.

RECOMMENDED MINIMUM CHIMNEY SIZES

FIRING RATE

(gph)

CHIMNEY

HEIGHT (ft)

NOMINAL

CHIMNEY

AREA

ROUND LINER -

INSIDE

DIAMETER I

SQUARE LINER -

INSIDE

DIMENSIONS

1.31 - 1.80

0.60 - 1.30

1.81 - 2.00

15

15

20

8" x 8"

8" x 8"

8" x 8"

7"

6"

8"

I

6-3/4" x 6-3/4"

6-3/4" x 6-3/4"

6-3/4" x 6-3/4"

:or elevations above 2,000 feet above sea level, add 3 feet to the chimney heights. See Figure below.

For additional chimney design and sizing information,

Applications Handbook, Chapter 30, Gas Vent consult and Fireplace the ASHRAE

Systems;

1996 HVAC or the National

Systems

Standard for and

Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211.

CHIMNEY

CONNECTOR

AND DRAFT REGULATOR

Venting the boiler requires a 6" diameter chimney connector pipe and using the draft regulator packed with the boiler.

Properly installed, the regulator will control the draft automatically.

It is better to install it in a horizontal section of pipe, but it may be installed in an angled or vertical section of pipe.

Make certain that the "top" of the regulator is at the top - and that the short pipe section which holds the vane is horizontal.

Even though locating the draft regulator close to the chimney reduces noise,

install

the draft regulator close as practicable to the boiler.

as

To install the chimney connector, start at the boiler with a vertical pipe and then elbow - then install the draft regulator making it horizontal.

When the regulator is in place, start at the chimney and work back to the regulator.

Join the two sections with a drawband.

The horizontal pipe must slope up toward the chimney at least 1/4 inch per linear foot of venting.

The chimney connector must not leak and must be firmly supported.

Join each of the sections with at least two sheet-metal screws.

Support every second section with a stovepipe wire.

Maintain

combustible

a minimum

materials.

vent pipe clearance of 18" from the surface of the vent to wood and other

14

TYPICAL

CHIMNEY CONNECTION

MUST BE AT LEAST 4

INCHES THICK-

AND BE TIGHT.

MUST SLOPE UP

AT LEAST 1/4 INCH

PER FOOT OF

HORIZONTAL RUN

DRAWBAND

LAST PIECE

INSTALLED

TIGHT, SMOOTH,

CORRECTLY SIZED.

I

!

I

• SEALED IN

THIMBLE

.TIGHT

CLEAN-OUT

DOOR

MUST BE REQUIRED MIN-

IMUM HEIGHT• MUST RE

AT LEAST 3 FT. HIGHER

THAN HIGHEST

PART QF

PASSAGE THROUGH

ROOF.

MUST BE AT

LEAST 2 FT. HIGHER

THAN ANY NEIGHBORING

OBJECT.

MUST HAVE AN

UNOBSTRUCTED TOP

OPENING.

DRAFT REGULAT(

VANE

CRIMPEDENO

BALANCED WEIGHT

ALTERNATE POSITIONS

. TOP

15

ELECTRICAL CONNECTIONS

Thermostat

Install a 24-volt thermostat (not provided) in a proper location.

The location of the thermostat has an important effect on boiler system operation.

BE SURE TO FOLLOW THE INSTRUCTIONS INCLUDED

WITH THE THERMOSTAT.

Grounding

Permanently

ground the boiler according to local codes and the National Electrical Code.

Run a 14 gauge or heavier copper wire from the boiler to a grounded connection in the service panel or a properly driven and electrically grounded ground rod.

I

WARNING

Turn off electric power at fuse box before making any line voltage connections.

Follow local electrical codes.

I

Electric

Power Supply

All electrical work must conform to your local codes as well as the National Electrical Code.

If you are not familiar with wiring and codes in general, have a competent electrician do this job.

On packaged boilers, the boiler controls are all wired at the factory.

You need only connect a 115 volt electrical supply to the L1 and L2 terminals on the aquastat relay and two thermostat wires to the T and T terminals on the same aquastat relay (see figure below).

Run a separate circuit from a separate overcurrent protection device in your electrical service entrance panel.

This should be a 15 ampere circuit.

Locate a shut-off switch at the boiler.

It must be turned offduring any maintenance.

Solder and tape or securely fasten these connections with wire nuts.

Oil Burner Wiring

For boilers packaged with oil burners, the burners are wired at the factory.

For boilers shipped knockdown or packaged without a burner, wiring connections are shown in the electrical wiring diagrams of this manua!.

N H

It

115V 60 CYCLE

SUPPLY

,_24

VOLT

THERMOSTAT

II

AQUASTAT

RELAY

16

%_

__

SE_/ARS

KENNMORE CAST IRON BOILERS

FULL ONE YEAR WARRANTY ON HOT WATER AND GAS STEAM CAST IRON BOILERS

For one (1} year from the date of installation, when this boiler is installed and maintained in accordance with our instructions Sears will repair defects in material or workmanship in the boiler, free of charge.

LIMITED 12 YEAR WARRANTY ON STEAM CAST IRON BOILERS

After one (1) year and through twelve (12) years from the date o| installation,Sears will furnish a replacement heat exchanger, if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

LIMITED 20 YEAR WARRANTY ON HOT WATER CAST IRON BOILERS

After one (! } year and through twenty (20) years from the date of installation, Searswill furnisha replacement heat exchanger if the heat exchanger in the boiler is defective. YOU PAY FOR LABOR.

SEARS INSTALLATION WARRANTY

In addition to any warranty extended to you on the Sears merchandise involved, which warranty becomes effective the date the merchandise is installed, should the workmanship of any Sears arranged installation prove faulty within one year, Sears will, upon notice from you, cause such faults to be corrected at no additional cost to you

FOR WARRANTY SERVICE, SIMPLY CONTACT THE NEAREST SEARS STORE OR SERVICE

CENTER THROUGHOUT THE UNITED STATES. This warranty gives you specific legal rights,and you may also have other rights which vary from state to state

IMPORTANT

The following are the responsibilities of the user and are not covered by the Warranty

1 Filter clearing or replacement

2 Damage to unit or unsatisfactory operation due to improper cleaning or use of unit in corrosive atmosphere

3 Damage to unit or unsatisfactory operation due to blown fuses or _nadequate or interrupted electrical protective devices

4 Damage to unit caused by the use of components or other accessories not compatible with the unit

5 If the unit _s removed from the place it was originally installed, this Warranty becomes void

6 Damage to the unit caused by accident, abuse, negligence, m_suse, riot, fire, flood, or acts of God

SEARS ROEBUCK AND COMPANY

D/817WA

Hoffman Estates, IL 60179

MAIN AIR VENT:

for down flow systems

or diaphragm

type expansion tanks (not provided)

Before

a system is filled with water, there is air in the pipes and radiation units• Some of the air will be trapped as the system is filled.

It is possible to eliminate most of this air through the air vents on the radiation units• A main air vent will speed and simplify this process.

The main air vent should be installed on the highest point in the supply main when all radiation is below the top of the boiler.

AUTOMATIC FILL

VALVE

(not provided)

For safe, efficient operation, a hot water system must be filled with water.

Adding new water, when needed can be done manually (by use of a hand valve in the water supply line).

This requires regular attention to the system's needs.

An automatic fill valve or pressure reducing valve accomplishes this without attention.

It is installed in the supply line on hot water boilers only.

The valve operates through water pressure differentials.

It does not require an electrical connection.

BURNER SOLENOID VALVE

(provided)

The Beckett and Carlin oil burner's use a standard solenoid valve.

Upon burner shut down, a standard solenoid valve stops the flow of oil to the nozzle.

Without the solenoid valve, the oil pump continues to pump oil to the burner nozzle until the burner motor winds down below the pumps cut-offspeed.

The Riello oil burner has a dela£ solenoid valve.

The delay solenoid valve provides the same shut down action as the standard solenoid valve, plus on burner start up the delay solenoid valve remains closed for an additional 15 seconds.

This allows the burner fan motor to pre-purge the combustion chamber and the oil pump to bring the supply oil pressure up to its set point helping to provide a clean light off.

AQUASTAT RELAY CONTROL

(provided)

The water temperature limit control in the aquastat relay is adjustable and may be set: as low as 140°F so long as return water temperatures to the boiler are no less than 120°F, or as high as 240°F so long as the boiler and heating system have adequate circulation to remove the heat from the boiler otherwise steam may be created in the boiler.

Refer back to SYSTEM PIPING section for more information.

DRAIN

VALVE (provided)

The drain valve is a manually operated valve that provides a means of draining all the water from the boiler and heating system.

It should be installed in the reducing tee where the return line enters the boiler.

CIRCULATOR

(provided)

Every forced hot water system requires a circulator.

A separate circulator or zone valve is required for each zone, if there are two or more zones.

The circulator must have the capacity to provide the circulation required by the heating system.

The circulator should be connected to the supply main and must be wired into the boiler's electrical system.

See the SYSTEM PIPING section for piping configurations with the circulator located on the supply main piping using zone circulators or zone valves.

When the piping is arranged with zone circulators and no bypass piping, the circulator provided with the boiler may be used as a

zone circulator.

Both piping arrangements allow the circulator to pump away from the expansion tank and show how the piping should be arranged to allow the heating system to be easily purged of air.

18

FILLING THE BOILER

HOW A HOT WATER SYSTEM

OPERATES

The entire heating system (boiler, piping, and radiation units) is filled with water.

As the water in the boiler is heated, it is circulated from the top of the boiler through the supply main to the radiation units.

The cooler water in the radiation units flows back through the return piping through the 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 the boiler piping as shown in the figure on the previous page.

a)

Close

the main shutoffvalve, isolation valves, and zone valves (if applicable).

If bypass piping is installed, also close the two throttling valves.

Leave the boiler service shutoffvalve (if installed) and the balancing valves to each heating zone

fully

open.

b) Ooen the following valves in order: the drain valve for power purging, isolating valves before and after the boiler circulator (if applicable), both throttling valves (if applicable), and then open the fill line shutoff valve.

Water will fill the bypass piping and push the air through the piping and out the power purging drain valve.

When the power purging drain valve runs air free, close the bypass piping throttling valve (leaving the throttling valve to the supply piping f_lly open).

c) Next, ooen the isolation valve (or zone valve) to the first zone. Water will fill the piping and push any air out the power purging drain valve.

When the power purging drain valve rims air free, close the isolation valve or zone valve).

Repeat this procedure for the remaining heating zones.

d) Once all zones are filled with water and purged of air, close the power purging drain valve and fill line shut off valve, open the main shutoff valve, and adiust the throttling valves and balancing valves as required.

OPTION #2 - Close the air vents on all radiation units.

Open the valves to the radiation units.

Make sure the boiler drain valve, expansion tank drain cock, and the air bleed screw "on the expansion tank drain fitting are closed.

Open the fill valve on the piping to the expansion tank.

Open the water inlet to the boiler and leave it open.

Open the air vent on the lowest radiation unit.

When all the air has escaped and water starts to flow from the vent, close it.

Go to the next radiation unit, and repeat this process until finishing with the highest radiation unit.

If the heating system will speed up the proper filling of the system.

has automatic vents, this manual venting is unnecessary but it

If the system is a closed expansion tank system, an automatic fill valve is needed.

Leave the automatic fill valve open to refill the system automatically as needed.

Note the initial fill pressure on the boiler's temperature / pressure gauge, which should be 10-15 psig.

Any lowering of the pressure from its initial fill pressure indicates a loss of water due to leakage.

The automatic fill valve should then compensate for this water pressure loss.

If it does not, manually open this valve to refill the system until the needle is again pointing to the same pressure reading.

Instructions are packaged with the valve.

19

BECKETT OIL BURNER, NOZZLE, AND AIR SETTINGS

_BOILER

MODEL

3EW 65*

3EW.75

3EW1.00

4EW.90

4EW1.25

4EW1.50

5EW1.20

5EW1.75

5EW2.00

DELEVAN

OIL NOZZLE

0.50-80°B

0.65-70°B

0.85-70°B

O.75-80OA

1.00-80°A

1.25-80°A

1.00-60°13

1.5045°B

1.65-60°B

FIRING

RATE (gph)

0.65

0.75

1.00

0.90

1.25

1.50

1.20

1.75

2.00

HEAD-ADJ.

OR SETTING

F0 - 1 1/8

F3 - 1 1/8

F3 - 1 1/8

F3- 1 1/8

F6 - 1 1/8

F6 - 1 1/8

0

2

4

LOW FIRE

BAFFLE

YES

YES

NO

NO

NO

NO

NO

NO

NO

*To fire the 3EW.65 on rate, the oil pressure must be increased to 175 psig.

All Beckett oil burners for the EW boiler are factory preset at 140 psig.

AIR

SHUTTERIBAND

10/0

10/0

10/2

8/0

10/0

10/2

10/1.5

10/4

10/5

CARLIN OIL BURNER 1 NOZZLE,

AND AIR SETTINGS

BOILER

MODEL

3EW.65

3EW.75

3EW1.00

4EW.90

4EW1.25

4EW1.50

5EW1.20

5EW1.75

5EW2.00

DELEVAN

0.65_600B

0.85-60°B

0.75-60°B

1.00-60°B

1.25-60°B

1.00-60°B

1,50-60°B

1.65-70°B

FIRING

OIL NOZZLE

RATE (gph)

0.55-700B 0.65

0.75

1.00

0,90

1.25

t.50

1.20

1.75

2.00

HEAD

SETTING

0.50

0.60 / 0.65

0.85 / 1.00

0.75

0.85 / 1.00

1.10 / 1.25

0.85 / 1.00

1.50

1.65 / 1.75

AIR BAND

SET POINT

0.52

0.60

0.80

0.75

0.90

1.25

0.90

1.65

1.95

*All Carlin EZ-1 HP and EZ-2 HP oi] burners are factory preset at 150 psig.

CARLIN

BURNER*

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-2 HP

EZ-2 HP

RIELLO 40 OIL BURNER,

NOZZLE_ AND AIR SETTINGS

BOILER

MODEL

3EW.65

3EW.75

3EW1.00

4EW.90

4EW1.25

4EW 1.50

5EW1.20

5EW1.75

5EW2.00

DELEVAN

FIRING TURBULATOR / AIR OIL PRESSURE

OIL NOZZLE RATE (gph) SHUTTER SETTING

0.50-70°W

0.65-70°W

0.65

0.75

0.5 / 2.0

2.0 / 2.2

0.85-70°W

0.75-70°W

1.00-70°W

1.25-70°W

1.00

0.90

1.25

1.50

2.0 / 3.2

1.5 / 2.6

2.5 / 3.8

4.0 / 7.0

1.00-70°W

1.50-70°W

1.75-70°W

1.20

1.75

2.00

2.5 / 3.5

2.0 / 38

2.5 / 4.1

(PSIG)*

155

150

170

160

170

175

150

155

155

RIELLO 40

BURNER MODEL

F5

F5

F5

F5

F5

F5

F5

F10

F10

*All Riello 40 F5 and F10 oil burners are factory preset at 145 psig.

STATIC

PLATE

3-5/8

3-1/2

3-1/2

3-1/2

3-3/8

3-3/8

2-3/4

2-3/4

2-3/4

OIL

BURNER

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG F-HEAC

AFG 50 MD

AFG 50 MD

AFG 50 MD

I overfire draft of -0.02

inches w,c.

The burner settings provided

NOTE: All burners use an inserti°n depth °f 2-1/4'' and must be made using combustion test instruments.

I

38

NOZZLES

AND ELECTRODES: Use the proper size, spray angle, and spray pattern nozzle.

Refer to the recommended nozzle selection charts at the end of this manual.

To install a nozzle, remove the nozzle line electrode assembly, if necessary remove the retention ring assembly, and then install and tighten the nozzle.

Be careful not to damage the electrode insulators or the bend the electrode tips.

After installing the nozzle, reassemble the nozzle line electrode assembly and set the electrode tip spacing.

Depending on the bumer purchased, the electrode tip spacing may need to be set prior to reassembling the nozzle line electrode assembly.

Refer to the figures on the following pages for setting the electrode tip spacing on Beckett, Carlin, and Riello t_umers.

FINAL BURNER ADJUSTMENTS: Final burner adjustments must be made using combustion test instruments.

Initial settings for the burner are shown at the back of this manual.

Set the burner accordingly.

Check the draft over fire to verify that it is between M).01" WC and -0.02" WC, otherwise adjust the draft as necessary.

After operating 10 minutes to warm up the boiler, use the combustion test equipment to take a smoke reading in the flue pipe between the boiler and the draft regulator.

The smoke reading should be zero to a trace (Shell Bacharach Scale).

At times a new boiler requires more than 10 minutes to burn clean due to the oil film on the new heat exchanger.

If the smoke reading is zero, gradually close the burner's air adjustment to obtain a smoke reading showing a trace smoke reading.

Once the smoke reading is a trace, measure the COz and as an insurance margin increase the air to sufficiently reduce the CO2 by 1/2% to 1%.

Ira clean fire cannot be obtained, it will be necessary to verify the burner head and electrode alignment.

Proper electrode alignment figures are presented on the following pages.

If the fire continues to be smoky, replace the nozzle with a correct replacement.

Once the burner is completely adjusted, the burner should be started and stopped several times to assure good operation with no fluttering or rumbling.

Verify that there are no oil leaks and then record the nozzle size, oil pressure, combustion readings, and air settings on a tag or label that can be attached to the burner or boiler.

OIL BURNER

MAINTENANCE:

For the Becket/: AFG, Carlin EZ-1 or EZ-2, and the Riello 40 F3, F5, or

F10 the following preventative maintenance items should be performed annually, preferably prior to the heating season.

1.

Oil Burner Motor - For Beckett and Carlin burners, add 2 -3 drops of non-detergent electric motor oil to each oil cup located at the front and rear of the motor (Riello burners are permanently lubricated).

Excessive oiling will shorten the life expectancy of the motor.

2.

Fuel Filter - This should be replaced so as to prevent contaminated fuel from reaching the nozzle.

A partially blocked fuel filter can cause premature failure of the fuel pump.

3.

Fuel Pump Unit - Replace pump screen and clean pump unit to maintain fuel delivery to the nozzle.

4.

Ignition Electrodes - Clean and adjust as per manufacturer's recommendations, so as to maintain reliable ignition of oil.

5.

Nozzle - Replace so as to maintain safe and reliable combustion efficiency.

Always replace with the exact nozzle as required in the charts in the back of this manual.

6.

Fan and Blower Housing These must be kept clean, free of dirt, lint and oil so as to maintain the proper amount of air the fuel requires to burn.

7.

Check the final burner adjustments.

I NOTE: If any component parts must be replaced, always

I

I

i

2l

BECKETT AFG

BURaNER ELECTRODE

ADJUSTMENTS

BOILER

MODEL

5EW

DIMENSION

1/16"

"'N"

(electrode

to nozzle)

DIMENSION

VARIABLE

"H"

(head to nozzle)

7/32" to 9/32"

(VI)

HEADS

5132

GAP lMENSION

"}'1"

SEE BELOW--\_

,,.

.._.._CTROOE

"

" _ ..,a

LI or VI

HEAD

_.. _DIMEMBION

-N"

E B£LOW

BECKETT AFG

VARIABLE

(V1) HEAD ADJUSTMENTS

AND SETTINGS

_Lfrl LOC:I

w&Ja4_

/_" s_JUST,UK.(

A_lr T'Jll.(

).4[A0

BECKETT AFG BURNER ELECTRODE

ADJUSTMENTS F- HEADS

Burner F-Head Model

F0 thru F31

DIMENS1ON"N"

1/16"

(head to nozzle)

_ELECTROOE

.E

22

5/32" - 4 mm

,)-

5/64" to 7/64" or 2 to 2.5 m[__ "_

5/32" or 4 mm

E

E

5/32" to 13/64" or 4 to 5 mm _ i

I _

--

TO

23

CHECKING AND ADJUSTING CONTROLS

A boiler using a tankless coil is configured with a Honeywell L8124C Combination Hi/Low Limit Aquastat

Relay (refer back to the SYSTEM PIPING section for more details).

A boiler not using a tankless coil is configured with a Honeywell L8148A Hi Limit Aquastat Relay.

Instructions included with the boiler.

for the control provided are

IMPORTANT - You or your installer must follow

these

instructions carefully.

]

ADJUST adjustment:

OPERATING

High Limit:

CONTROLS: For both aqaustats,

Baseboard and Convectors - 200°F

Standing Radiators - 180°F use the following settings for the first

Low Limit (when used) - 140°F ( increase if hotter domestic water is required, but low limit set point must be at least 20°F less than the high limit set point)

Differential (when used) - 10°F

ADJUST THERMOSTAT HEAT ANTICIPATOR TO: 0.2 AMPS

CHECK THERMOSTAT OPERATION: The thermostat location has an important effect on the operation of the boiler system.

Be sure to FOLLOW THE INSTRUCTIONS included with your thermostat.

Typically the thermostat is located about five feet above the floor on an inside wall.

The thermostat should be located to sense average room temperature, so avoid the following:

DEAD SPOTS - behind doors, corners, and alcoves

HOT SPOTS - concealed pipes, fireplace, TV sets, radios, lamps, direct sunlight, kitchens

COLD SPOTS - concealed pipes or ducts, drafty stairwells or door ways, unheated room or wall of an unheated room

When the temperature on the thermostat is set above the indicated thermostat temperature, should start.

Make certain: once the room temperature reaches the selected temperature the boiler's burner setting, the thermostat should turn the boiler's burner off, and once the room temperature falls a few degrees the boiler starts operating again.

Do not start the burner unless all cleanout doors are secured in place.

Do not attempt to start the burner

when

excess

chamber

is very hot.

when the

I

I

I

24

MAINTENANCE

ANUALLY: To assure trouble-free operation, it is recommended that the flue passages, combustion chamber area (target wall, fire door insulation, durablanket), burner adjustment, operation of the controls, and boiler seals (fire door gasket or silicone seal, cast iron sectional seals, flue collector) be checked

once

each year by a competent Service Technician.

Before the start of each heating season

(or whenever the system has been shut down for extended periods of time) recheck the whole system for water, oil, and vent piping leaks.

Replace or patch any leaks or seals that are faulty.

VENT

PIPE: Visually

inspect the entire

venting system once a month for any signs of leakage, deterioration, or soot build up. If the vent pipe shows any signs of leaking or deterioration, replace it immediately.

If it shows any signs of soot build up, clean the vent pipe and have the burner settings and combustion checked by a competent professional.

RELIEF VALVE: This valve should open automatically when the system pressure exceeds the pressure rating (usually 30 psi) of the relief valve.

Should the valve ever fail to open under this condition, shut down the system.

Drain the system until system pressure is reduced below the relief valve pressure rating.

Then contact a competent Service Technician to replace the valve and inspect the heating system and determine the cause, as this problem may indicate an equipment malfunction.

The relief valve should be tested monthly during the heating season.

Prior to testing, make certain a discharge pipe is properly connected to the valve outlet and arranged so as to contain and safely dispose of boiler discharge.

Hold the trip lever fully open for at least five seconds in order to flush free any sediment that may lodge on the valve seat. Then permit the valve to snap shut. Refer to the valve manufacturer's instructions packaged with the valve for more details.

CONVENTIONAL

EXPANSION

TANK: As noted in the EQUIPMENT AND OPTIONAL

ACCESSORIES section, this tank may become water logged or may receive an excess of air. Frequent automatic opening of the relief valve indicates water logging.

A high boiler temperature accompanied by unusually low radiation unit temperature (and "knocking" noises) indicates excess air in the tank.

To correct either condition, close the valve between the boiler and the tank.

Drain the tank until empty.

Check all the tank plugs and fittings, tighten as necessary.

Open the valve between the boiler and tank.

Water will rise to the normal height in the tank if the system has an automatic _l valve, otherwise manually refill the system.

DIAPHRAGM EXPANSION

TANK: As noted in the EQUIPMENT AND OPTIONAL

ACCESSORIES

section, this tank may become water logged.

Frequent automatic opening of the relief valve indicates water logging.

A high boiler temperature accompanied by unusually low radiation unit temperature (and

"knocking" noises) indicates excess air in the tank.

To correct this condition, replace the diaphragm expansion tank.

WATER SYSTEM: If the system is to remain out of service during freezing weather, always drain

it

completely (water left in to freeze will crack the pipes and/or boiler).

TANKLESS

COIL (OR COVER

PLATE) GASKET:

This gasket should be checked at least twice a year for leakage and replaced if necessary.

If the gasket is replaced, make sure that when the coil plate (or cover plate) is reattached that the ten nuts are torqued in an alternating pattern to ensure equal force is applied to the entire gasket creating a good seal. The nuts should be torqued such that the gasket does not squeeze out from behind the plate.

OIL BURNER:

Oil burner maintenance is listed in this manual under OPERATING

Never burn

garbage

or paper in the unit, and

never leave combustible material around it.

I

I

I

25

THE

BOILER.

OIL

BOILER

/ BURNER CLEANING

OIL BOILER

CLEANING:

INSTRUCTIONS

I.

Shut off all electrical power to the boiler / burner and shut off fuel oil supply.

2.

Remove the vent pipe from the top of the boiler.

Inspect the pipe and chimney for signs of corrosion and deterioration.

Clean out the base of the chimney.

If the vent pipe shows any signs of corrosion or deterioration, replace it immediately.

If chimney damage or deterioration is discovered, contact a c0mpet_nt professional.

3.

Remove the top jacket panel screws (5), the brass wing nuts (2) holding the flue collector top, and then the flue collector top.

Inspect the gasket on the underside of the flue collector and replace as necessary.

4.

Befbre beginning to clean the flue passageways, ensure that the combustion chamber blanket is covered.

If the blanket is not covered prior to cleaning, replace the blanket once cleaning is completed.

5.

Now with access to the flue passageways, remove the soot from the fireside surfaces by brushing diagonally through the flue passages (see drawing below).

Brushing can be made easier by cutting the end of the flue brush offand inserting it into a drill.

When brushing, care should be taken so as not to damage the target wall with the flue brush.

6.

Carefully

vacuum the soot accumulations from the combustion chamber area, being particularly careful to not damage any of the refractory or blanket insulation.

To gain access to the combustion chamber first double check that the shut offvalve on the fuel oil line is closed and then disconnect the fuel oil line.

Then open the swing door by simply removing the whiz lock nut holding the door shut.

7.

Now inspect the target wall, fire door refractory, and combustion chamber blanket (when included) for cracking and deterioration.

If there is any signs of cracking or deterioration, replace the refractory or blanket before reassembling the burner / front plate.

8.

Inspect the door's braided gasket for wear and damage.

Replace when necessary with braided gasket of the same material and size.

See repairs parts section of this manual.

9.

Now inspect and clean the oil burner.

X

%r22"2.22./.'.'22:. " ot6o*mQ*ttJ*.*, o6.

.o..o

66 ...

o

_, " °o'o'Z 4 °.°." ° °¢

°,'2.*.2.'-2.'.'.".'.

" °

{!!{!H!!!{!!!

IMPORTANT OPERATING AND MAINTENANCE REQUIREMENTS

KEEP YOUR

BOILER

AND THE

AREA AROUND IT CLEAN

NEVER

BURN REFUSE OR ANY MATERIAL OTHER THAN THE SPECIFIED

YOUR BOILER

FUEL IN

[lAVE

YOUR BOILER

C|IECKED

EACH YEAR BY A QUALIFIED TECHNICIAN

26

OIL BURNER CLEANING:

These are general instructions

for cleaning

an oil burner.

manufacturer's instructions.

For speci_'lcs, consult

the buruer

1.

Make sure all electrical power to the boiler / burner and the fuel supply to the burner are shut off.

2.

With the swing door open, clean any soot accumulations from the end of the burner and if applicable burner head.

3.

Remove the burner drawer assembly, clean the electrodes and then reset the electrode spark gap per the manufacturer's recommendations.

Refer back to the section in this manual on OPERATING THE

BOILER - Nozzles and Electrodes.

4.

Replace the oil nozzle with the exact same size and type recommended for use on this boiler.

5.

Reinstall the burner drawer assembly making sure the head location (and size if applicable) are per the manufacturer's recommendations.

If the burner being used has a damaged head, replace the head with the exact same head recommended for use on this boiler.

6.

Inspect and clean the oil burner blower wheel.

7.

Remove the oil pump cover and clean / replace the pump screen.

Carefully reassemble ensuring the pump cover makes a proper seal.

8.

Securely fasten the swing door shut.

9.

Replace the fuel filter (if applicable).

10. Reconnect the electrical and fuel supplies.

11. Fire the burner, checking for proper combustion using combustion test equipment and making adjustments as necessary.

Refer to the section in this manual on OPERATING THE BOILER - Final

Burner Adjustments.

12. Insure that all safety controls and operating controls are functioning properly.

27

SERVICE HINTS

You may avoid inconvenience and service calls by checking these points before you call for service.

Possible Cause

Thermostat is not set correctly

Boiler or Burner may be dirty

Burner may not be firing at proper rate

Burner may be short-cycling

No power to boiler

Controls out of adjustments

Radiators not heating

Circulating pump not running

Poor electrical contact.

What to do

Reset thermostat above room temperature.

Clean all flue passages and the vent pipe.

Have burner cleaned and readjusted.

Check nozzle size if there is any doubt.

Have burner adjusted.

Short-cycling (too frequent offand on) of burner will cause sooting.

If boiler and!or

burner become dirty at frequent intervals, after correcting the "dirty condition" also correct the aquastat control setting (or other cause of short- cycling).

Check thermostat heat anticipator and correct setting, if necessary, per instruction sheet packaged with thermostat.

Check overcurrent protection.

Check to be sure power supply circuit is "ON".

Reset according to instructions packed with controls.

Open radiator vents to vent excess air.

Check flow control valve (if used).

It may be in closed position.

Check relay operation.

Check all control terminals and wire joints.

Possible

Cause

[

1 What

to do

Oil burner fan wheeI may be dirty ] Clean fan wheel with a stiffbrush and cleaning solvent.

Readjust oil burner.

Draft regulator may be stuck Check to see if vane swings freely. Clean, if vane is stuck.

Possible Cause What to do

vents to vent the air.

Check expansion tank.

Possible Cause

Dirt on seat

Water logged expansion tank

What

to do

Open valve manuaIly.

Allow water to run and clear valve seat.

Drain tank. see instructions.

HAVE

YOUR

SERVICE TECHNICIAN CHECK ANY

PROBLEM

YOU ARE UNABLE TO CORRECT.

28

ELECTRICAL

BOILER WITH TANKLESS COIL AND

HONEYWELL

L8124C

AQUASTAT CONTROL

(BECKETT AFG BURNER SHOWN)

WIRING

BOILER WITHOUT

TANKLESS

COIL

HONEYWELL L8 ! 48A AQUASTAT CONTROL

(BECKETT AFG BURNER SHOWN)

24 VOLT

THERMOSTAT

NEUTRAL

HOT

_

120V

SUPPLY

BK W

i

I

:

I

?

I

:

PROTECTED OISCONNECT

ua12_c

[_

_ ®

mUASTAT

@j()[email protected]@

W

@

IGN.

TRANN

,.___

....

--

C_OA

COOC

B<-EU_X

0 -0R;C4GE

R--RED

W -WMr_

U_[

_0LT_C,E

F_LD

MRING

120v

POWER

SUPPLY

NEUTRAL

HOT

.,_,_,_L/_,,_

120/60/I OV_RCURR_NT

pROTECTED _SCONNECT

)(

24

THCRMO_fAT

9

VOlT

i:

--

L8148A

AQUASTAT

BK

) (_

W

IGN.

TRANS

I_ -gL/4:X

--

--

....

w -m4qlE

_

VqA.T,_CZ aJ_S

24 _.1_

II.

Fll_l

_ISeG

CIRCULATOR

OIL

VALVE

OIL 8URN[R

MOTOR

o

CIRCULATOR

OIL BURNER

MOTOR

O CAD

Service Company:

Serviceman:

Address:

Telephone:

29

BOILER WITH TANKLESS COIL AND

H ONEYWELL L8124C AQUASTAT CONTROL

(CARLIN EZ BURNER SHOWN)

BOILER WITHOUT TANKLESS COIL

HONEYWELL L8148A AQUASTAT CONTROL

(CARLIN EZ BURNER SHOWN)

24 VOLT

THERMOSTAT

N_UTRAL

.oT

_

120V

POWER

soP.LY

eK

w

] i

_

I i

r

I i

L8124C

_--_-'#'-([email protected]

AQUASTAT

@J_'_(_

IGN*

TRAN$

R W

k

CIRCULATOR

OIL

VALVE

@

OIL BURNER

MOTOR

BL

0

0

-

w -

_

24 _

CELL

120v

POWER

SUPPLy

N[UTRAL t20/60/1

RROT[CT[B

OVERCURRENT

DISCONNECT

___/-B'

24

VOLT

TN[RMOSTAT

d

L8148A

AQUASTAT

_--q

COLOR COOKE

--

....

81- -

EC.UE

0 -

_*_E

Y YIDJ.OW

W -

_talt

OJ,_ a,

2,= rOt'p3

Rf_D W_IN_

8K

8K

IGN.

TRAN$

BK

W OIL VALVE

OIL

BURNER

BK

CIRCULATOR

O

w

CAD

CELL

Service Company:

Serviceman:

Address:

Telephone:

30

BOILERWITH TANKLESSCOILAND

HONEYWELLL8124CAQUASTATCONTROL

(RIELLO40BURNERSHOWN)

BOILERWITHOUTTANKLESSCOIL

HONEYWELLL8148AAQUASTATCONTROL

(RIELLO40BURNERSHOWN)

120V pOWER

SUPPLY

120/6O/I OVERCURREHT

PROTECTED DISCONN[CT

L8124C

AOUASTAT

24

VOLT

THERMOSTAT

@

COLO_ COOL

BK-

R-

BLACX

RED

E_ 8K'G_m

B.8U_ tZOV

POWI[R

SUPPLY

.oT ---_

120/60/I

PROT[CTED

OV[RCURRgNT

D_CONNIECT

24 VOLT

TH[RMOSTAT

_

L

I

L8148A

AQUASTAT

--

....

CotJ_

_

BLACX

W -

,_fqE

Bt. BLUE

LINE _.IAGI[

FI_J_ WAeK;

iI _ _CAPAC[TOR

w BK

E

I

I wl

CIRCULATO R

I

COHTROL iS

FACTORY

WIRED Ire RIEkLO

7

BK

BK

CAPACITOR

Service Company:

Serviceman:

Address:

Telephone:

31

BOILER WITH TANKLESS COIL:

SEQUENCE OF OPERATION

INTERNAL WIRING FOR HONEYWELL

AQUASTAT LS124C

Aquastat hiI_h limit controller:

The aquastat control's high limit contacts open and rum off the burner when the boiler water temperature reaches the control's high limit set point.

The high limit contacts automatically reset alter the boiler water temperature drops past the set point by 10°F, which is a fixed_differential.

-_,_=_'_ _, I 2----

Aquastat

low limit and circulator control:

With the adjustable

differential at the minimum setting of 10°F:

On a boiler water temperature rise above the low limit set point, the burner circuit contacts (RB) break and the circulator circuit contacts

(RW) make.

On a boiler water temperature drop of 10aF below the low limit set point, the RB contacts make and the RW contacts break.

[_cu_roR t_

2

T

With the adjustable

differential setting greater than 10°F:

When the boiler water temperature is at (or below) the low limit set point, the RB contacts make and fire the burner and the RW contacts break leaving the circulator off.

The burner will fire until the boiler water temperature reaches the low limit set point _ the adjustable differential setting minus 10aF. At this point the RB contacts break stopping the burner and the RW contacts make.

With no call for space heating, operating in this way keeps the circulator off and allows the boiler to give preference to the domestic water heating requirements.

Example: Consider the boiler

water temperature

drops to 15OAF with the low limit set at 16OAF and the differential is set at 15°F.

The burner will

begin to fire.

When the aquastat probe senses a boiler water temperature

of l 65aF (15°F - lOaF = 5°F, then 160°F

+5°F = 165°F) the RB contacts

break and the RW contacts

make.

When the boiler water temperature

rises above the low limit / adjustable

differential setting and the thermostat controls call for domestic

space heating.

The sequence of operation for the burner and circulator is as follows:

1.

Thermostat calls for heat, completing circuit between terminals T & T on the aquastat controller, energizing the 1K relay coil.

2.

With the IK relay coil energized, contacts IK1 and 1K2 are closed.

Terminal B1 is energized, providing power to the oil burner primary control.

This, in turn, powers the ignition coil and burner motor.

3.

With the primary control energized, the burner operation starts and remains running as long as the cad cell senses flame.

In the event of flame failure or the flame is not fully proven within the trial for ignition period, the primary control will lockout and open the burner circuit.

This will require a manual startup of the burner.

4.

As long as flame is proven through the cad cell relay, the burner will remain on until the circuit is interrupted by the boiler water temperature reaching the aquastat's high limit setting (opening high limit contacts RB), or the thermostat is satisfied breaking the T-T circuit.

5.

Circulator pump is powered through terminal C1 and will mn when boiler water temperature is above the low limit setting and there is a call for heat from the thermostat.

If the boiler water temperature reaches the aquastat's high limit setting and high limit contact RB is de-energized, the burner stops but the circulator pump will continue to run, as long as, the thermostat calls for heat.

6.

Whenever the boiler water temperature reaches the aquastat's high limit setting, the high limit contact RB is de-energized shutting the burner off.

Then the boiler water temperature must fall 10°F below the aquastat's high limit setting for the high limit contacts RB to close and the burner to be energized.

7 When the thermostat is satisfied, the call for domestic space heating is ended.

Relay coil IK is de-energized, opening

I K I and [K2 contacts• Both the burner and circulator pump operation stop.

NOTE:

High limit setting must be a minimum of 20aF higher than the low limit setting.

2

SEQUENCE OF OPERATION

BOILER LESS TANKLESS COIL:

Aquastat high limit controller:

The aquastat control's high limit contacts open and turn offthe burner when the boiler water temperature reaches

the control's high limit set point. The high limit contacts automatically reset after the boiler water temperature drops past the set point by 10°F, which is a fixed differential.

INTERNAL WIRING FOR HONEYWELL AOUASTAT L8148A

JUMPE_

IK2

IKI

--

--

UNE "¢OI.T_E

CLa_

I,

)

When the thermostat controls call for domestic space heating.

The sequence of operation for the burner and circulator is as follows:

1.

Thermostat

calls for heat,

completing

circuit between

terminals

T & T on the aquastat controller,

energizing the

1K relay coil.

2.

With the 1K relay coil energized, contacts 1K1 and 1K2 are closed.

Terminals C1 and C2 are energized providing power to the circulator.

Terminal B1 is energized, providing power to the oil burner primary control.

This, in turn, powers the ignition coil and burner motor.

3.

With the primary control energized, the burner operation starts and remains running as long as the cad cell senses flame.

In the event of flame failure or the flame is not fully proven within the trial for ignition period, the primary control will lockout and open the burner circuit.

This will require a manual startup of the burner.

4.

As long as flame is proven through the cad cell relay, the burner will remain on until the circuit is interrupted by the boiler water temperature the thermostat is satisfied reaching breaking the aquastat's the T-T circuit.

high limit setting (opening high limit contacts BR), or

5.

If the boiler water temperature reaches the aquastat's high limit setting, the high limit contact BR is deenergized turning the burner off.

However, the circulator pump will continue to run, as long as, the thermostat calls for heat.

6.

After the high limit contact BR is de-energized, the boiler water temperature must fall 10°F below the aquastat's high limit setting for the high limit contacts BR to close and energize the burner.

7.

When the thermostat is satisfied, the call for domestic space heating is ended.

Relay coil 1K is de-energized, opening 1KI and 1K2 contacts.

Both the burner and circulator pump operation stop.

33

NOTES:

_O0-F _CX _IUCQ_C _U88_R _or S_ewH

REPAIR

PARTS

i

6ALLOON

SYMBOL K_Y i

[_1

NO

©

3

4

5

6

I

2

ITEM

10

11

12

13

14

7

8

9

15

16

19

20

21

22

DESCRIPTION 3EW

Water Boiler Back Section (EW-3) ¢03-00-008

Water Boiler Mddle Section

EW-2) 403-00-007

Empire Water Front SeclJon IEW-1)

403`00-006

Cast Iron Machined Nipples 2"

1/4" Tie Rods

Tie Rod 1/4"-20 Hex Head Nut

433-00-976

1464354302

146-95-041

5/16" x 70-1/2" Braided Rope

1/2" thick Ourablanket

Stainless

Target Wall

Steel 3/8" Flat Washer

Stainless Steel 318" Top Lock Nut

1-1/4" Solid Plug Inot shown)

433-00-956

146-19-003

146-30-031

Collector Base (plus items 11,12,13)

425-00-279

Insulation Tape (plus items 10,12,13)

425-09-279

Collector Top (plus items 10.1!,13)

425-00-279

8132" Brass Wing Nut 137-04-007

#14 x 3/4" Hex Washer Head Screw 146-96-070

Coil Housing Gasket

3 7 GPM Tankless Coil

146-93-064

146*27-020

17 Coi_ Housin 9 Cover Plate (not shown) 146-19-001

18 Stainless Steel 3/8"-16 x 1-1/2" Stud 146-95-113

146-95-114

146-95-115

146-93-126

Black Silicone Sealant (not shown) 146-05-020

4EW

403-06-008

406-06-007

403*00-006

433-00-976

145-05-051

146÷95-041

433-00-955

146-19-003

146-30-031

426-00-280

425-O0-280

426-00-280

137-04-007

146-96-07(3

146-93`064

146-27-020

146-1 9-001

146-95-113

146-95-114

146-95-115

146-93-126

146-06-020

SEW

¢06-00-008

403-06-007

403`06-006

433-06-976

146-05-053

145-96-041

433-00-955

146-19-003

145-30-031

425-00-281

426-00-281

425-00-281

137-04-007

146-95-070

145-93-064

146-27-020

146-19-001

146-95-113

146-95-114

146-96-115

146-93-126

146-06-020

Note: Item quantities marked XXX vary depending upon the number of sections.

Four cast iron nipples for first middle replacement section and two for each adddional section.

Ourablanket is sold as one oversized piece to be cut to fk the appropriate boiler-- 6"x12" (3EW), 9"x20" (4EW). 12"x20" (SEW).

Black silicone sealant is sold in 103 ounce cartridges.

34

REPAIR PARTS

BALLOON SYMBOL KEY

NO.

&NTITY

I

I

I

I

[_

I

___1

ITEM

4

5

6

7

8

1

2

3

9

10

11

12

DESCRIPTION

Empire Water Front Section (EW-1

3/8"-16 x 2-1/4" stud

3/8" Whizlock Nut

Swing Door Insulation

Swing Door Hinge

1/4" x 2" Round Head Rivet

3/8" x 1" Hex Head Serrated Flange Bolt

3/8" x 48" Fiberfrax Round Braid

Swing Door

ObServation Door

5/16" Lock Washer

3/8" x 3/8" Shoulder Bolt 5/16"-18 Thread

Pa_ #

403-00-006

146-95-125

146-95-126

146-14-014

403-00-010

146-95-121

146-95-124

433-00-905

403-00-009

403-00-014

146-95-123

146-95-122

35

REPAIR

PARTS

%

/

BALLOON 5YMBOL KEY

//--_TD4

_oI

ITEM

4

5

6

7

8

1

2

3

9

XX

DESCRIPTION

Right Side iacket

Panel

Back Jacket Panel

Top Jacket Panel

Left Side jacket Panel

Upper Front Jacket Panel

5/16" Acorn Nut

#10 x 1/2" Jacket Screw

Stand Off

Lower Front Jacket Panel {boiler w/swing door)

Complete Jacket for Boiler with Swing Door

3EW

4EW

425-00-244

425-00-245

425-00-269

425-00-254

425-00-264

425-00-269

425-00-255

425-00-265

425-00-267 425-00-267

146-95-04;

146-95-074

146-95-103

146-95-042 i146-95-074

146-95-103

425-00-268

425-00-289

425-00-268

425-00-290

5EW

425-00-246

425-00-269

425-00-256

425-00-266

425-00-267

146-95-042

146-95-074

146-95-103

425-00-268

425-00-291

36

/

4

I

(Without

Tankle_=

colt)

REPAIR PARTS

WATER

OUTLET

7

5

OPTIONAL

TANKLESS

COIL

WATER

HEATER

WITH 1/2" NPT

CONNECTIONS

j 3b

3a

3c

5a,5b

8

FRONT VIEW

Tankle==

Coil)

RIGHT

SIDE

VIEW

2a

2b

3a

3b

3c

.....

4

5a

5b

6

7

1

1

1

1

ITEM

1

1

.....

DESCRIPTION

Beckett AFG F-Head Oil Burner

Beckett AFG Variable Head Oil Burner

Beckett AFG F-Head Low Fire Kit (0.65 _ph)

Beckett AFG F-Head Low Fire Kit (0.90 9ph)

Cadin EZ-1Oil Burner

Carlin EZ-2 Oil Burner

Riello 40 F5 Oil Burner

Riello 40 F10 Oil Burner

L8148A-1124 Aquastat Control ( no tankless coil)

L8124C-!094

Aquastat Control (with tankless

Taco 007 Circulator coil)

1-1/4" Isolation Valves

Taco Circulator Gaskets

Taco 007 Circulator with Gaskets

Temperature / Pressure Gauge 2" Stem

1-1/4" x 2-1/2" Pipe Nipple

1-1/4" x 3/4" x 1-1/4" Reducing Tee

3/4" Drain Valve

3/4" Relief Valve

3EW 4EW

146-19-007 146-19-008

..........

5EW

.....

146-19-009

433-00-015

.....

..........

433-00-016 .....

146-19-005 146-19-005 146-19-005

..........

146-19-006

146-19-010 146-19-010 146-19-01G

..........

146-19-011

433-00-521 433-00-521 433-00-521

146-62-022 146-62-022 146-62-022

146-26-047 146-26-047 146-26-047

146-26-048 146-26-048 146-26-048

146-26-050 146-26-050 146-26-050

433-00-047 433-00-047 433-00-047

146-23-003 146-23-003 146-23-003

146-07-044 146-07-044 146-07-044

146-93-049 146-93-049 146-93-049

146-22-000 146-22-000 146-22-000

146-22-011 146-22-011 146-22-011

Note: Beckett AFG F-Head low fire kits include: static plate, burner head, and oil nozzle.

The temperature / pressure gauge connects to the boiler using a 3/4" x 1/4" bushing.

The relief valve connects to the boiler using a 3/4" x 2" nipple and a 3/4" street elbow.

37

BECKETT OIL BURNER_ NOZZLE, AND AIR SETTINGS

BOILER

MODEL

3EW.65"

3EW 75

3EW1.00

4EW.90

4EW1.25

4EW1.50

5EW1.20

5EW 1.75

5EW2.00

DELEVAN FIRING

OIL NOZZLE RATE (gph)

0.50-80°B

0.65-70°B

0.85-70°B

0.75-80°A

1.00-80°A

1.25-80°A

0 65

0.75

1.00

0.90

1.25

1.50

1.00-60°B

1.50-45°B

1.65-60°B

1.20

1.75

2.00

HEAD-ADJ,

OR SETTING

F0 - 1 1/8

F3 - 1 1/8

F3 - 1 II8

F3 - 1 1/8

F6 - 1 1/8

F6 - 1 1/8

0

2

4

*To fire the 3EW.65 on rate, the oil pressure must be increased to 175 psig.

All Beckett oil burners for the EW boiler are factory preset at 140 psig.

LOW FIRE

BAFFLE

YES

YES

NO

NO

NO

NO

NO

NO

NO

AIR

SHUTTER / BAND

10 / 0

10 / 0

10 / 2

8 / 0

10 / 0

10 / 2

10 / 1.5

10 / 4

10 / 5

STATIC

PLATE

3-5/8

3-1/2

3-1/2

3-1!2

3-3/8

3-3/8

2-3/4

2-3/4

2-3!4

OIL

BURNER

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG F-HEAD

AFG 50 MD

AFG 50 MD

AFG 50 MD

CARLIN OIL BURNER, NOZZLE, AND AIR SETTINGS

BOILER

DELEVAN FIRING

MODEL OIL NOZZLE RATE (gph)

3EW,65 0.55-70°B 0.65

3EW.75

0.65-60°B

0.75

3EW1,00

4EW.90

4EW1.25

4EW1.50

5EW 1.20

5EW1.75

5EW2.00

0.85-60°B

0.75-60°B

1.00-60°B

1.25-60°B

1.00*60_B

1.50-60°B

1.65-70°B

1.00

0.90

1.25

1.50

1.20

1.75

2.00

HEAD

SETTING

0.50

0.60 / 0.65

0.85 / 1.00

0.75

0.85 / 1.00

1.10 / 1,25

0.85 / 1.00

1.50

1.65 / 1.75

AIR BAND

SET POINT

0.52

0.60

0.80

0.75

0.90

1.25

0,90

1.65

1.95

*All Carlin EZ-1 HP and EZ-2 HP oil burners are factory preset at 150 psig.

CARLIN

BURNER*

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-1 HP

EZ-2 HP

EZ-2 HP

RIELLO 40 OIL BURNER_ NOZZLE,

AND AIR SETTINGS

BOILER

MODEL

3EW.65

3EW.75

3EW1.00

4EW.90

4EW1.25

4EW1.50

5EW1.20

5EW1.75

SEW2.00

DELEVAN FIRING TURBULATOR

/ AIR OIL PRESSURE

OIL NOZZLE RATE (gph)! SHUTTER SETTING

0,50-70°W 0.65

0.5 / 2.0

0.65-70°W 0.75

2.0 / 2.2

0.85-70°W

0.75-70°W

1.00-70°W

1.25-70°W

1.00

0.90

1.25

1.50

2.0 / 3.2

1.5 / 2.6

2.5 / 3.8

4.0 / 7.0

1.00-70°W

1.50-70°W

1.75-70°W

1.20

1.75

2.00

2.5 / 3.5

2.0 / 3.8

2.5/4.1

(PSIG)*

155

150

170

160

170

175

150

155

155

RIELLO 40

BURNER MODEL

F5

F5

F5

F5

F5

F5

F5

F10

F10

*All Riello 40 F5 and F10 oil burners are factory preset at 145 psig.

I overfire draft of -0.02

inches w.c.

The burner settings provided are intended

NOTE: for initial start up only.

Final adjustment

All burners use an insertion must be made depth of 2-1/4" and fired at a using combustion test instruments,

38

F_4-t_9

Oi/-Fired

Hot Water

Boiler

Owner's Manual

MODELNO.

3EW.65

3EW.7+5

3EWI:00"

4EI/V.-90.

4EW.1_25

4EWI'_50

5EW1.20

5EWi".75

5EW2.00

HOW TO ORDER

REPAIR PARTS

TELL SEARS YOU

WANT IT INSTALLED

THEN RELAX

Now that you have purchased your Bo_ler should a need ever exist for repair parts or serwce, simply coHtact an,!

Sears Service Center Be sum to prowde all t:'_ rt_r,,.,rll f,e_'tG when you call or ws_t

The model number of your Bo_ler 'wdl be tounc_ or', rl-,_ r_,_,.tel

plate on the s_de of the Boder

WHEN ORDERING

FOLLOWING

REPAIR

INFORMATION

PARTS.

ALWAYS GIVETHE

=PART NUMBER

• MODEL NUMBER

*PART

DESCRIPTION

eNAME

OF ITEM

All parts

hsted may be ordered

from art.,, Sears Se_,,'_ce

Center

If the parts you need are not slocked wdl be electronically transmitted locally, to a Sears your

Repair order

Paqs

D_stnbubon Center for handhng

When Sears arrar_ges the _nstaltat_on.

you car_ be sure tl_e

job is

done r_ghf We wdl arrange fc, r pr_Jlesslotlal workmanship and we II take care ot th_ _.rCre

proje{t

What's more dunng

irislallat_orl

you gel

,nstJted

t_rr,lect_o¢_ against property to workm(,ff-_ All yob damage arid also) a0ali_'_l acc_derrts haw to (J_) is talk t_,) yOIJ+ neare<t Sears store loday for ,ttelad,_d _lrl+)rmah_r_

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement