ECR DUNKIRK ESC3100, Installation, Operation & Maintenance Manual

Page 1: ...IRON BOILER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company DUNKIRK BOILERS 2201 Dwyer Ave Utica NY 13051 www ecrinternational com MODEL NUMBERS ESC3100 ESC4100 ESC4125 ESC4150 ESC5175 ESC5200 ESC6225 ESC7275 Patent 7 823 544 ...

Page 2: ...f not avoided may result in minor or moderate injury DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury WARNING 1 Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 DO NOT obstruct air openings to the boiler room 3 Modification substitution or elimination of factory equipped supplied or specif...

Page 3: ...Amps 60 Hz 7 MEA number for this boiler series is 182 86E 8 MEA number for the AFG Beckett Burner used in this boiler series are AF 156 77 E AFG 213 83 E AFII 85 24 92 E AFII 150 456 90 E 9 Output is Heating Capacity for units with input 300 Mbh and Gross Output for units 300 Mbh Ratings Data And Dimensions STANDARD EQUIPMENT Crated boiler flush jacket oil burner target wall liner ASME relief valv...

Page 4: ...isdiction the installation must conform to the American Society of Mechanical 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 a level solid base as near chimney as possible and centrally located with respect to the heat distribution system as practical WARNING Boilermayno...

Page 5: ...ea of the openings to which they are connected When air for combustion and room ventilation is from 4 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 applian...

Page 6: ...ng required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 free area and metal louvers and grills will have 60 75 free area Louvers and grills shall be fixed in the open position or interlocked with the boiler so that they are opened automatically during boiler operation When the boiler is installed in a confined spac...

Page 7: ...T TRAP HIGH LEVEL SPILL DO NOT USE WITH CONDENSATE PUMP TO RECEIVER TANK STEAM MAIN TRAP PUMPED RETURN TO SYSTEM FROM RECEIVER TANK FROM RECEIVER TANK STOP VALVE TO RECEIVER TANK STOP VALVE 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 WAT...

Page 8: ...ntain oil pressure at nozzle Do not run overhead fuel lines from tank to oil burner WARNING Boiler is to be vented by natural draft and shall not be connected into any portion of mechanical draft operating system under positive pressure Inspect chimney to make certain it is constructed according to the latest revision of the NFPA 211 Local regulations may differ from this code and should be checke...

Page 9: ...rical wiring must conform with the latest revisions of the National Electrical Code ANSI NFPA No 70 and or local authority having jurisdiction When an external electrical source is utilized the 1 boiler when installed MUST BE electrically grounded in accordance with these requirements oil tank and piping Install a fused disconnect switch between boiler and 2 meter at a convenient location When the...

Page 10: ...20V 24V 40VA 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 STEAM WIRING W BECKETT BURNER NOTE Not all components listed are used in all control systems WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Volt...

Page 11: ...11 STEAM WIRING W RIELLO BURNER WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Installer ...

Page 12: ...12 STEAM WIRING W CARLIN BURNER WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Installer ...

Page 13: ... The lever of the pressure relief valve Figure 14 on the boiler should be operated periodically to make sure that it is functioning properly MOUNTING BOTH SIDES LOWER FRONT JACKET PANEL PRESSURE RELIEF VALVE TOP JACKET PANEL 1 4 SLOT BURNER ELECTRICAL DISCONNECT 28 WATER ELECTRONIC LOW WATER CUT OFF INSPECTION COVER LINE SCREWS HOT The pressure relief valve should open before the steam pressure ex...

Page 14: ...ve been made for satisfactory performance RIELLO SETTINGS Boiler No Burner No Air Damper Pump Press Turb Nozzle Fur nished 3100 F 5 3 6 150 PSI 1 85 80W 4125 F 5 4 150 PSI 3 1 10 60W 4150 F 5 6 150 PSI 4 1 25 60W 5200 F 10 5 150 PSI 0 1 75 80B CARLIN SETTINGS Boiler No Burner No Air Damper Pump Press Head Bar Nozzle Fur nished 3100 EZ 1 0 85 150 PSI 85 1 00 85 70B 4125 EZ 1 1 00 1 10 150 PSI 1 10 ...

Page 15: ...riodically to make sure that it is functioning properly Refill boiler to its normal water line C Primary Control and Flame Sensor To Check Flame Failure 1 simulate by shutting off oil supply with hand valve while burner is on Sixty seconds after flame out the safety switch locks out ignition stops motor stops and oil valve when used closes To restart open oil supply valve and reset safety switch I...

Page 16: ... and other flammable vapors and liquids The free flow of combustion and ventilation air to the boiler and boiler room must not be restricted or blocked WARNING Discharge will be boiling hot water and steam The safety valve should open before the steam pressure exceeds the 15 lb reading on the gauge Figure 14 If this pressure is exceeded and the safety valve does not open it must be replaced If the...

Page 17: ... X Inspect and Clean Appliance 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 Service Record Date Nozzle Pump Pressure PSI Line Voltage Motor Amps Smoke Draft CO2 or O2 Flue Temp F Size Angle Type O F INF Controls and Safety Devices X Nozzle Size Angle Type Pump Pressure Vacuum Line Voltage Mo...

Page 18: ...GE WATER LEVEL 1 4 240007394 BRASS SIPHON OFF CENTER LOOP 62208 1 5 14693057 TEE BRASS 1 4 1 6 240007412 PIPE BRASS 1 4 x3 1 7 240007411 ELB BRASS 1 4 90 STREET 2 8 GA 003 00 GAUGE PRESSURE STEAM 1 9 240007160 ELWCO CG450 P 2060 CYCLE GUARD 1 10 SS 001 01 PRESSURE SWITCH PA404A 1009 1 11 1263012 HARN J BOX 22 BECKETT RIELLO 1 240007185 HARN J BOX STEAM CARLIN 12 240007187 HARN BRNR STEAM BECKETT 1...

Page 19: ...6701 Stud 5 16 18 x 2 4 5 2252501 Support Jacket Brkt 2 6 HW07001 Stud 5 16 x 18 x 1 3 7 HW06901 Nut 5 16 18 Wislock 8 8 HW 016 02 Drain 1 9 PF 004 04 Pipe Fit Bushing 1 x 1 10 2452906 Flue Collector 3 Sec 1 2452902 Flue Collector 4 Sec 2452903 Flue Collector 5 Sec 2452907 Flue Collector 6 Sec 2452908 Flue Collector 7 Sec 11 109007327 Baffle Assy H E Rear 1 ...

Page 20: ...03 Tie Rod x 20 6 Sec HW 025 09 Tie Rod x 23 7 Sec ITEM PART NO DESCRIPTION QTY 8 100 1 5 01 22 Push Nipple 3 Sec 2 22 Push Nipple 4 Sec 3 22 Push Nipple 5 Sec 4 22 Push Nipple 6 Sec 5 22 Push Nipple 7 Sec 6 9 MS 006 00 Rope Med Density 3 Sec 13 0 Rope Med Density 4 Sec 19 5 Rope Med Density 5 Sec 26 0 Rope Med Density 6 Sec 32 5 Rope Med Density 7 Sec 39 0 10 HW 008 03 Washer ID Flat 3 11 HW 003 ...

Page 21: ...803 Left Side Panel 4 Sec 21521804 21521804 21521809 21521804 Left Side Panel 5 Sec 21521805 21521805 21521810 21521805 Left Side Panel 6 Sec 21521806 21521806 21521811 21521806 Left Side Panel 7 Sec 21521807 21521807 21521812 21521807 Not Shown Jacket Replacement Kit 3 Sec 3001487AH 3001487C 3001487AC 3001487AD Jacket Replacement Kit 4 Sec 3001488AH 3001488C 3001488AC 3001488AD Jacket Replacement...

Page 22: ...1 BRNR BECK CF375 UT2602 NOZ 2 25 60B 1050006 BRNR F5 40 SERIES RIELLO 2 PCS BN07007 BRNR F10 40 SER RIELLO 3949071 NEW BRNR OIL EZ1 3100SE STE CARLIN NEW BRNR OIL EZ1 4100SE STE CARLIN NEW BRNR OIL EZ1 4125SE STE CARLIN NEW BRNR OIL EZ1 4150SE STE CARLIN NEW BRNR OIL EZ1 5200SE STE CARLIN 2 BN08001 BURNER OIL FLANGE GASKET 3616 1 3 CD 001 01 CAD CELL FOR BOILERS W BECKETT BURNERS ONLY 1 4 2400088...

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

Page 24: ...DUNKIRK BOILERS 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ecrinternational com web site www ecrinternational com ...