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18

A. 

Pressure Control - Remove cover and note pressure 

setting. With boiler operating, decrease setting. 

When setting is lower than boiler pressure, control 

will open and turn off boiler. After checking pressure 

control, reset control to original setting.

B. 

Mechanical Low Water Cut-off - May be checked by 

opening blow-off valve on lower portion of cut-off 

body while boiler is running. This will drain water 

from boiler and break circuit to burner.

Refill boiler to its normal water line.  
C. Primary Control and Flame Sensor - Check

1. 

Flame Failure

 - Simulate by shutting off oil supply 

with hand valve while burner is on. Sixty seconds after  

flameout, safety switch locks out, ignition stops, motor 

stops and oil valve - when used - closes. To restart, open 

oil supply valve and reset safety switch.

2. 

Ignition Failure

 - With burner off, close oil supply 

valve and run through start-up procedure. Safety 

switch should lock out as in flame failure.

3. 

Power Failure

 - Turn off main power supply switch 

while burner is operating. When burner stops, restore 

power and burner should start. If operation is not as 

described as above, check wiring and controls.

Preventative maintenance of oil fired boiler reduces 

operating costs. Boiler and vent pipe should be inspected 

for accumulation of soot or scale deposits periodically 

but at least once every year before start of each heating 

season. When soot is present on section walls and 

flueways, improper combustion will result, causing 

additional sooting and scaling until flueways are completely 

closed. To remove soot and scale from flueways, remove 

top jacket panel, top clean-out plate, open burner swing 

door. See

 

Figure #14

.

OPERATING INSTRUCTIONS

Opening Burner Swing Door

1. 

Turn off power to boiler and allow boiler to cool down.

2. 

Disconnect power cable at factory supplied burner 

electrical disconnect. See

 

Figure #14

.

3. 

Loosen screws on sides of lower front jacket panel. 

See 

Figure 6

.

 Pull bottom part of lower front panel forward 

and lift lower front panel up and off boiler. See

 

Figure 

#14

.

4. 

Close oil valve and disconnect oil line from burner. See 

Figures #12 - #13

.

IMPORTANT:

 

Do not open swing door with oil line 

attached.

5. 

Remove nut from swing door stud on right hand side of 

door.

6. 

Swing open burner and door to left. Using flue brush, 

brush soot and scale into combustion space where it 

can be removed through swing door opening.

NOTICE

Use caution when vacuuming in chamber area. 

Damage to chamber could result.

Recommend replacing nozzle at start of each heating 

season. Lubricate burner motor and circulator motor - if 

required - with few drops of good grade of light motor 

oil. Do not over oil. Have qualified service person service 

burner and check controls and check electrodes for carbon 

or cracks in insulators. Burners should be adjusted to 

produce conditions shown in 

"Startup and Adjustment of Oil 

Burner."

Closing The Burner Swing Door

1. 

Swing burner and door to right until insulation is 

slightly compressed and stud is exposed.

2. 

Attach nut to stud and tighten it until built in stop 

contacts mounting door.

3. 

Reconnect oil line to burner.

4. 

Replace lower jacket panel, and tighten screws.

5. 

Connect power cable at factory supplied burner 

electrical disconnect.

6. 

Turn on power to boiler and bleed oil line.

Summary of Contents for Dunkirk ESC-3090S

Page 1: ...LLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company PATENT 7 823 544 MODELS ESC 3090S ESC 3090ST ESC 4125S ESC 4125ST ESC 5185S ESC 5185ST ESC 6210S ESC 6210ST Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com ...

Page 2: ...harness burner electric disconnect plastic cover 2 supply tapping 1 return tapping skim port and primary control NOTE For tankless heater units add tankless hot water coil and low limit control DIMENSIONS Boiler No Length of Flush Jacket Front of Jacket to Center Line of Flue Outlet Flue Outlet Diameter A B C ESC 3090 16 6 6 ESC 4125 20 8 6 ESC 5185 23 10 7 ESC 6210 27 85 8 Figure 1 DIMENSIONS ...

Page 3: ... British Thermal Unit 3 Net AHRI Steam Ratings based on piping and pick up allowance of 1 333 Consult manufacturer before selecting boiler for installations having unusual piping and pick up requirements such as intermittent system operation extensive piping etc 4 Heating Capacity and AFUE based on 13 0 CO2 with 0 02 W C draft over fire and 1 smoke or less Tested in accordance with U S Department ...

Page 4: ...n and operation WARNING Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Do not obstruct air openings to boiler room Modification substitution or elimination of factory equipped supplied or specified components could result in personal injury or the loss of life WARNING Indicates a hazardous situation which if not avoided could result in de...

Page 5: ...echanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME No CSD 1 Locate boiler in front of final position before removing crate Provide level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical Allow 24 inches in front top and right hand side for servicing and cleaning or removing tankl...

Page 6: ... of the openings to which they are connected 4 When air for combustion and room ventilation is from inside buildings the confined space shall be provided with two permanent openings one starting 12 inches from the top and one 12 inches from the bottom of the enclosed space Each opening shall have a minimum free area of 1 square inch per 1 000 BTU per hour of the total input rating of all appliance...

Page 7: ...ce Figure 5 C If horizontal ducts are used each opening shall have a minimum free area 1 square inch per 2 000 BTU per hour total input rating of all appliances in the enclosed space Figure 6 D When ducts are used they shall be of the same cross sectional area as the free area of the area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 ...

Page 8: ...t plug or place any obstruction in discharge line Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing Allow complete drainage of valve and discharge line Install safety valve with spindle in vertical position Do not install shutoff valve between boiler and safety valve Support safety valve discharge piping Be short and straight as possible Terminat...

Page 9: ...9 1 Suggested piping for steam heating system can be seen in Figure 7 Actual piping may vary based on system design and local conditions Figure 7 SUPPLY AND RETURN PIPING ...

Page 10: ...d 10 for the suggested piping for a modular steam boiler PIPING FOR BUILT IN DOMESTIC HOT WATER HEATER PIPING FOR BUILT IN DOMESTIC HOT WATER HEATER COLD WATER IN UNTEMPERED HOT FLOW REGULATOR TEMPERING VALVE COLD WATER DOMESTIC HOT WATER T P VALVE UNTEMPERED HOT WATER TO AUTOMATIC WASHER CONTROL WATER INSTALLED BELOW CENTER LINE OF BOILER HOT CONNECTION Figure 8 SUPPLY AND RETURN PIPING DANGER Wa...

Page 11: ...ATE PUMP TO RECEIVER TANK STEAM MAIN TRAP PUMPED RETURN TO SYSTEM FROM RECEIVER TANK FROM RECEIVER TANK STOP VALVE TO RECEIVER TANK STOP VALVE Figure 9 RETURN GRAVITY RETURN 2 TO SYSTEM STOP VALVE BLOWOFF VALVE STOP VALVE CHECK VALVE OPTIONAL STEAM MAIN WATER LINE 28 Figure 10 SUGGESTED PIPING FOR MODULAR STEAM BOILERS GRAVITY RETURN SUPPLY AND RETURN PIPING ...

Page 12: ...ry or metallic chimney liner Unlined chimney will have leaks that will cause poor chimney performance no draft and could result in positive pressure in the combustion chamber Horizontal portions of venting system should not exceed 10 feet in length Horizontal lengths over 10 ft will have a negative effect on chimney performance Extend chimney at least 2 ft above any portion of building within 10 f...

Page 13: ...ings on suction line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle Do not run overhead fuel lines from tank to oil burner Fuel Pump Connections Fuel pump connections and by pass should be made according to instructions attached to fuel pump If tank is more than 20 from boiler install two stage fuel unit in place of single stage pump supplied as s...

Page 14: ...team Wiring on next page Thermostat Installation 1 Thermostat should be installed on inside wall about four feet above floor 2 NEVER install thermostat on outside wall 3 Do not install thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures television fireplaces or chimneys 4 Check thermostat operation by raising and lowering thermostat as required to start and ...

Page 15: ...0VA 1K1 Relay Contacts Wire Connection TR 2 Transformer 120V 24V 50VA 1K2 Relay Contacts LWCO Low Water Cut Off LGV24 Volt Gas Valve LS Limit Switch EWF Electric Water Feeder PS Pressure Switch MS Manual Switch PG Power Generator NOTE Not all components listed are used in all control systems WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Install...

Page 16: ... burns instantly or death by scalding Refill boiler to its normal water line Operating Instructions Start of heating season have venting system inspected Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints Repair if necessary Remove vent pipe at base of chimney or flue and using mirror check for obstruction and verify compliance to latest revision of the NFP...

Page 17: ...trol circuit after burner adjustments have been made for satisfactory performance 2 Check electrode setting they may have been jarred out of position during transportation 3 Lubricate burner motor if necessary 4 Set room thermostat to call for heat or jump thermostat contacts on boiler control 5 Open all oil line valves 6 Turn service switch on Burner should start 7 On one pipe fuel systems only b...

Page 18: ...closed To remove soot and scale from flueways remove top jacket panel top clean out plate open burner swing door See Figure 14 OPERATING INSTRUCTIONS Opening Burner Swing Door 1 Turn off power to boiler and allow boiler to cool down 2 Disconnect power cable at factory supplied burner electrical disconnect See Figure 14 3 Loosen screws on sides of lower front jacket panel See Figure 6 Pull bottom p...

Page 19: ...e each month of the heating season Before seasonal start up it is advisable to have a qualified service agency check boiler for soot and scale in flues change oil filter and nozzle clean burner and re adjust burner input rate to maintain proper operation and high operating efficiency On steam boilers verify boiler is filled to water line as indicated in Figure 14 Gauge valves should be normally op...

Page 20: ... be restricted or blocked Periodic inspection and tightening of the tankless heater cover plate bolts will reduce the risk of leaks See parts 3 and 5 under Coil and Cover Plate Replacement Parts Electronic Low Water Cut Off Operation of the probe and control should be checked with the burner on by draining the water via the drain on the bottom of the boiler This will drain the water quickly from t...

Page 21: ...nce X Inspect Oil Line Size Leaks X Inspect Electrical Connections X Install New Filter X Room Make up Air X Electrode Setting X Proper Light Off Hot Cold X Controls and Safety Devices X Nozzle Size Angle Type Pump Pressure Vacuum Line Voltage Motor Amps Smoke Test Draft Overfire In Flue CO2 or O2 Flue Gas Temperature Measure with instruments and record results below SERVICE CHECKLIST ...

Page 22: ...22 NOTES ...

Page 23: ...23 Company Address Phone Company Name Tech Initials Service Performed Date SERVICE RECORD ...

Page 24: ...creases This feature is equipped with an override which is provided primarily to permit 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 f...

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