Page 1
Model No.
3KW0.60
3KW0.75
3KW1.00
KEYSTONE SERIES II
OIL-FIRED
CAST IRON HOT WATER BOILER
INSTALL ATION, OPER ATION
4KW.90
4KW1.25
4KW1.50
5KW1.20
5KW1.75
5KW2.00
& MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N# 240009460, Rev. B [08/2014]
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TABLE OF CONTENTS
Introduction ................................................................................................................................ 3
Boiler Ratings And Capacities ........................................................................................................ 4
Safe Installation And Operation ..................................................................................................... 5
Before You Start .......................................................................................................................... 6
Installation Requirements ............................................................................................................. 7
Fresh Air For Combustion.............................................................................................................. 8
System Piping ........................................................................................................................... 10
Antifreeze In The System .......................................................................................................... 15
Chimney And Chimney Connections ............................................................................................. 15
Electrical Connections ................................................................................................................ 17
Equipment And Accessories ........................................................................................................ 18
Filling The Boiler ...................................................................................................................... 20
Operating The Boiler ................................................................................................................. 21
Checking And Adjusting Controls ................................................................................................. 22
Maintenance ............................................................................................................................. 24
Oil Boiler / Burner Cleaning Instructions ...................................................................................... 25
Oil Burner Maintenance And Cleaning ........................................................................................... 26
Service Hints ............................................................................................................................ 27
Electrical Wiring ........................................................................................................................ 28
Sequence Of Operation............................................................................................................... 30
Beckett Oil Burner, Nozzle, And Air Setting .................................................................................... 31
These instructions
must be afxed on or
adjacent to the boiler.
OIL FIRED BOILERS
These boilers are low pressure, sectional cast iron boilers constructed
and hydrostatically tested for a maximum working pressure of 50 psi in
accordance with A.S.M.E. (American Society of Mechanical Engineers)
Section IV Standards for cast iron heating boilers.
WARNING
!
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
Save this manual
for reference.
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INTRODUCTION
Boiler is a natural draft oil red hot water boiler comprised
of cast iron sections. Boiler is available with 3, 4, or 5 cast
iron sections. Sections are held together by cast iron push
nipples.
Figure 1 - Dimensions
Boiler is capable of ring #2 fuel oil from 0.60 gph
up to 2.00 gph. All packaged boilers include, limit,
temperature and pressure gauge, safety relief valve,
drain valve, ue brush, and an extra boiler tapping for
expansion tank or air elimination.
BOILER RATINGS AND CAPACITIES
OIL-FIRED HOT WATER BOILERS
RATINGS & CAPACITIES
BOILER
MODEL
3KW0.60 • 3 0.60 84 74 64 8”x8”x15’ 86.1* 17 3/4 6 9 3/4
3KW0.75 3 0.75 105 92 80 8”x8”x15’ 85.6* 17 3/4 6 9 3/4
3KW1.00 • 3 1.00 140 120 104 8”x8”x15’ 84.4 17 3/4 6 9 3/4
4KW.90 • 4 0.90 126 111 97 8”x8”x15’ 86.0* 21 6 11 3/8
4KW1.25 • 4 1.25 175 153 133 8”x8”x15’ 85.9* 21 6 11 3/8
4KW1.50 4 1.50 210 181 157 8”x8”x15’ 85.1* 21 6 11 3/8
5KW1.20 • 5 1.20 168 147 128 8”x8”x15’ 86.1* 24 1/4 6 13
5KW1.75 5 1.75 245 210 183 8”x8”x15’ 85.0* 24 1/4 6 13
5KW2.00 • 5 2.00 280 239 208 8”x8”x20’ 84.0 24 1/4 6 13
• These ring rates available only with alternate ring rate kits.
** MBH = 1,000 Btu Per Hour BTU = British Thermal Unit
*** Heating capacity based on 13% CO2 with 0.02” W.C. draft over re, and #1 smoke or less. Testing was done
in accordance with D.O.E. (Department Of Energy) test procedure.
† GPH = Gallons Per Hour Of Oil At 140,000 Btu Per Gallon
†† A.F.U.E. = Annual fuel utilization efciency based upon D.O.E. Test procedure.
* As Energy Star Partner, manufacturer has determined this product meets Energy Star guidelines for energy
efciency.
Net AHRI Water Ratings based on piping allowance of 1.15. Consult manufacturer before selecting a boiler for
installations having unusual piping and pickup requirements, such as intermittent system operation, extensive
piping systems, etc.
No.
of
Sections
Firing
Rate
†GPH
Input
**MBH
***
Heating
Capacity
**MBH
AHRI
Rating
**MBH
3
Net
Minimum
Chimney
Size/Height
A.F.U.E.
††
Dimensions (Inches)
A B C
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BOILER RATINGS AND CAPACITIES
These low pressure oil red hot water boilers are
constructed and hydrostatically tested for maximum
working pressure of 50 psig (pounds per square inch)
in accordance with the latest revision of the A.S.M.E.
(American Society of Mechanical Engineers) Boiler and
Pressure Vessel Code Section IV Standards for heating
boilers.
Heating Capacity indicates amount of heat available after
subtracting losses up the stack. Most of this remaining
heat is available to heat water. A small portion is heat from
the jacket and boiler surface and it is assumed that this
heat stays in the structure. Net AHRI Rating represents
portion of remaining heat that can be applied to heat
radiation or terminal units (i.e. nned tube baseboard,
cast iron radiators, radiant oor, etc.). Difference between
Heating Capacity and Net AHRI Rating, called piping and
pickup allowance, establishes reserve for heating volume
of water in the system and off-setting heat losses from
system piping. Net AHRI Rating of the boiler selected
should be greater than or equal to calculated peak heating
load (heat loss) for building or area(s) served by the
boiler and associated hot water heating systems. Consult
manufacturer before selecting boiler for installations having
unusual piping and pickup requirements.
Boilers with same number of sections are identical to each
other except for their ring rate. Firing rate is determined
by nozzle size in oil burner. For example: Models
3KW0.60Z, 3KW0.75Z and 3KW1.00Z are the same boiler,
except for ring rate of oil burner.
These boilers operate on #2 Heating Oil. Alternate ring
rate kits are available for 3 section, 4 section and 5 section
boilers.
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SAFE INSTALLATION AND OPERATION
Boiler installation shall be completed by qualied agency.
Become familiar with symbols identifying
potential hazards.
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
NOTICE
Used to address practices not related to personal
injury.
1.
Failure to follow rules for safe operation and
instructions can cause a malfunction of the boiler and
result in death, serious bodily injury, and/or property
damage.
2.
Check your local codes and utility requirements before
installation. Installation must be in accordance with
their directives, or follow NFPA 31 Installation of Oil
Burning Equipment, latest revision.
3.
Before servicing, allow boiler to cool. Shut off any
electricity and oil to boiler when working on it.
4.
Inspect oil line and connections for leaks.
5.
Verify oil burner nozzle is the size required. Over-ring
will result in early failure of boiler sections. This will
cause dangerous operation.
6.
Never vent this boiler into enclosed space. Always vent
to outside. Never vent to another room or inside a
building.
7.
Verify there is adequate air supply for complete
combustion.
8.
Follow regular service and maintenance schedule for
efcient, safe and reliable operation.
9.
Keep boiler area clean and free of combustible
material, gasoline and other ammable vapors and
liquids.
10.
Oil burners are not do-it-yourself items. Boiler must be
installed and serviced by qualied professionals using
combustion test instruments.
!
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
11.
Be aware when piping safety relief valve if system
pressure exceeds safe limit of 30 pounds per square
inch, safety relief valve will automatically lift open.
Lifting of safety relief valve can discharge large
quantities of steam and hot water, which may damage
surroundings. Before installing safety relief valve read
manufacturer’s instructions and maintenance section of
manual on safety relief valves.
12.
Installation and sizing of the expansion tank must
consider heating systems total water volume,
temperature, boiler initial ll pressure, and system
arrangement. Improperly installed and sized expansion
tank may result in frequent lifting of safety relief
valve or other heating system problems. For proper
installation, sizing, and maintenance of expansion tank
follow guidelines established by boiler manufacturer
and expansion tank manufacturer.
13.
Expansion tank performance and life expectancy can be
hindered by overlling the boiler. Boiler manufacturer
recommends initial ll pressure of 10-12 psig. For
higher ll pressures expansion tank’s air charge will
need to be increased to match ll pressure. Consult
manufacturer’s guidelines for sizing and selection.
14.
Purging heating system of air and gases when
rst placing boiler into service is critical for proper
circulation and quiet performance. Once air and gases
are purged, for boiler installations using oat type
vents, air vents should be closed for normal operation.
If air is heard or noticed by loss of heat, purge system
and open vents for short period of time.
NOTICE
This boiler has been designed for residential
installations. If used for commercial applications,
all jurisdictional requirements must be met. This
may require wiring and/or piping modications.
Manufacturer is not responsible for any changes to
the original design.
DO NOT USE GASOLINE CRANKCASE DRAININGS
OR ANY OIL CONTAINING GASOLINE.
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BEFORE YOU START
BEFORE YOU START
BOILER LOCATION
Complete following prior to installing boiler.
A. Verify you have selected right size boiler with proper
1.
capacity. AHRI rating of boiler selected should be
greater than or equal to calculated peak heating load
2.
(heat loss) for building or area(s) served by boiler
and associated hot water heating systems. See boiler
rating and capacity table previously listed. Any heat
loss calculations used should be based on approved
methods.
3.
4.
B. Supply boiler with proper oil supply and oil piping,
sufcient fresh combustion air, and suitable electrical
supply.
C. Connect boiler to suitable venting system and piping
system adequate to distribute heating load.
D. Thermostat must be properly located and installed for
control of heating system.
5.
If there are any doubts as to requirements, check with local authorities and obtain professional help where needed.
Operating Instructions, Checks And Adjustments, And
Maintenance sections in this manual are vital to proper and
safe operation of heating system. Take time to be sure they
are all done.
Place boiler in location centralized with piping system
and as close to chimney as possible.
Boiler must be level. If necessary use metal shims
beneath boiler’s feet.
Use raised base if oor can become wet or damp.
Maintain clearances for re safety as well as
servicing. Maintain 18” clearance 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.
Allow fresh air for combustion at front of boiler.
Allow fresh air for ventilation to front and rear of
boiler. Air passages must be free of obstructions at
all times. Ventilating and combustion air must enter
boiler room without restrictions.
!
WARNING
Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
Figure 2 - Clearances
Boiler
6”
Front
Min.
24” Min.
6”
Min.
24”
Min.
6.
Floor supporting boiler must be noncombustible and
sufciently stable. If ooring is combustible, place
boiler on 2” concrete patio blocks or 2” Cladlite
Pad™. Blocks or pad must be under entire boiler to
protect oor.
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
BOILER CLEARANCES
Unit
Top 6” 18”
Right Side 24” 24”
Left Side 6”
Base Non-combustible
Front 24”
Back 6”
All distances measured from the cabinet of the boiler.
Combustible
Clearance
Accessibility,
Cleaning, and
Servicing
Flue to
Combustible
Clearance
18”
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Figure 3 - Boiler With Piping System
ALWAYS KEEP MANUAL FUEL SUPPLY VALVE SHUT OFF IF
BURNER IS SHUT DOWN FOR EXTENDED PERIOD OF TIME.
INSTALLATION REQUIREMENTS
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FRESH AIR FOR COMBUSTION
!
WARNING
Asphyxiation, re hazard. Do not obstruct air
EXAMPLE 2: Boiler Located in Conned Space
A. All Air from Inside the Building: Conned space
openings to combustion area. Follow instructions
below, to maintain adequate combustion air.
NOTICE
Install outside air intake if you use replace or
kitchen or bathroom exhaust fan. These devices rob
boiler and water heater of combustion air.
Provide enough fresh air to assure proper combustion. Fire
in the boiler uses oxygen. It must have continuous supply.
Air in the house contains only enough oxygen to supply
burner for short time. Outside air must enter house to
replace air used by the burner. Study following examples 1
and 2 to determine your fresh air requirements.
EXAMPLE 1: Boiler Located in Unconned Space
If your boiler is in open area (non partitioned basement) in
conventional house, air that leaks through cracks around
doors and windows will usually be adequate to provide air
for combustion. Doors should not t tightly. Do not caulk
cracks around windows.
Unconned space is dened as space whose volume is not
less than 50 cubic feet per 1,000 Btu per hour of total input
rating of all appliances installed in that space.
shall be provided with two permanent openings
communicating directly with additional room(s) of
sufcient volume so that combined volume of all spaces
meets criteria for unconned space. Total input of all
combustion equipment installed in combined space
shall be considered in making this determination. Each
opening shall have minimum free area of one square
inch per 1,000 Btu per hour of total input rating of all
combustion equipment in conned space, but not less
than 100 square inches. One opening shall be within 12
inches of top and one within 12 inches of bottom of the
enclosure.
Example: Your boiler is rated at 100,000 Btu per hour.
Water heater is rated at 30,000 Btu per hour. Total
is 130,000 Btu per hour. You need two grilles, each
with 130 square inches of FREE opening. Metal grilles
have about 60% FREE opening. To nd louvered area
needed, multiply free opening required by 1.7 (130 x
1.7 = 221.0 sq. in. louvered area). In this example,
two grilles each having 8” x 30” (240 sq. in.) louvered
area would be used.
Figure 4 - Air Openings For Boiler Located In
Conned Space (Utility Room)
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FRESH AIR FOR COMBUSTION
3.
B. All Air from Outdoors: Conned space shall
be provided with two permanent openings,
one commencing within 12 inches of top and
another commencing within 12 inches of bottom
of enclosure. Openings shall communicate
directly, or by ducts, with outdoors or spaces
(crawl or attic) that freely communicate with
outdoors.
1.
When directly communicating with outdoors, each
opening shall have 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
free area of one square inch per 4,000 Btu per
hour of total input rating of all equipment in the
enclosure.
Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In
Tightly Constructed Houses
When communicating with outdoors through
horizontal ducts, each opening shall have
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 same cross
sectional area as free area of openings to which
they connect. Minimum dimension of rectangular
air ducts shall be not less than three inches.
FRESH AIR DUCT CAPACITIES
THROUGH LOUVERS
Fresh Air
¼” Mesh
Screen
Wood
Louvers
Metal
Louvers
Duct Size
(Btuh)* (Btuh)* (Btuh)*
3 ½” x 12” 144,000 36,000 108,000
8” x 8” 256,000 64,000 192,000
8” x 12” 384,000 96,000 288,000
8” x 16” 512,000 128,000 384,000
*Btuh = British Thermal Units per hour based on
opening covered by ¼” mesh screen , wood louvers,
or metal louvers.
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SYSTEM PIPING
1.
Installation of boiler for new heating system,
Install all of radiation units (panels, radiators,
baseboard, or tubing) and supply and return mains
rst. After all heating system piping and components
have been installed, make nal connection of system
piping to boiler. It is recommended to mount circulating
pump on supply side piping, such that it pumps away
from expansion tank. Refer to gures on next pages.
6.
Verify clean cold water supply is available when
connecting to pressure reducing valve. Use sand
strainer or pump strainer when water supply is from
well.
Low Design Water Temperature Systems (Below 140°
F) And Large Water Content Systems
2.
Equip hot water boiler installed above radiation
level with low water cut off device. Periodic inspection
is necessary, as is ushing of oat type devices, per low
water cut off manufacturer’s specic instructions.
3.
Packaged boiler is set up with 1¼” NPT supply
and return piping from front of boiler. Boiler supply
and return piping can be moved to rear of boiler. Boiler
should not be piped return line to front, supply line
to rear, or vice versa, will cause boiler water to short
circuit heat exchanger. Piping connections may require
additional ttings and parts.
4.
Install drain valve provided with boiler in return tee.
See gure on page 3.
5.
Install Safety Relief valve in rear section using ¾”
nipple and street elbow provided with boiler. See gure
6.
A. Install safety relief valve with spindle in vertical
position.
B. Do not install shutoff valve between boiler and
safety relief valve.
C. Install discharge piping from safety relief valve.
• Use ¾” or larger pipe.
Signicant condensation may form in this boiler and/
or venting system if boiler is operated with return
temperatures of less than 120° F.
Condensation is corrosive and can eventually cause damage
to boiler and venting system. Minimum design return water
temperature to prevent this condensation in boiler and
venting is 120°F.
Boiler used in heating system where design water
temperatures below 140°F are desired (e.g. radiant oor
heating), a 3-way or 4-way mixing valve or suitable
alternative (e.g. Bypass Piping Arrangement shown
in diagram on following page) is required to prevent
low temperature (below return 120°F) return water
from entering boiler. When using mixing valve, follow
manufacturer’s installation instructions.
Boiler connected to system having large water content
(such as former gravity system), use of Bypass Piping
Arrangement shown in diagram on following page is
suggested.
Figure 6 - Safety Relief Valve Installation
• Use pipe suitable for temperatures of 375°F
(191°C) or greater.
• Individual boiler discharge piping shall be
independent of other discharge piping.
• Size and arrange discharge piping to avoid
reducing safety relief valve relieving capacity
below minimum relief valve capacity stated on
rating plate.
• Run pipe as short and straight as possible to
location protecting user from scalding and properly
drain piping.
• Install union, if used, close to safety relief valve
outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
Follow instructions
to install discharge
piping from safety
relief valve to drain.
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SYSTEM PIPING
Figure 7 - Bypass Piping Arrangement Diagram
> LOW DESIGN WATER TEMPERATURE
SYSTEMS
> LARGE WATER CONTENT SYSTEMS
> PIPING ARRANGED FOR “POWER
PURGING” AIR OUT OF THE SYSTEM
PIPING, REFER TO THIS MANUAL’S
SECTION ON “FILLING THE SYSTEM
WITH WATER” OPTION #1
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SYSTEM PIPING
Figure 8 - System Piping Arrangement Zoning With Zone Valves
> CIRCULATOR ON SUPPLY PIPING PUMPS AWAY
FROM EXPANSION TANK
NOTE: CIRCULATOR CAN ALSO BE INSTALLED
ON RETURN PIPING.
> PIPING ARRANGED FOR “POWER PURGING”
AIR OUT OF SYSTEM PIPING, REFER TO THIS
MANUAL’S SECTION ON “FILLING THE SYSTEM
WITH WATER” OPTION #1
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SYSTEM PIPING
Figure 9 - System Piping Arrangement Zoning With Circulators
> CIRCULATOR ON SUPPLY PIPING PUMPS
AWAY FROM EXPANSION TANK.
NOTE: CIRCULATOR CAN ALSO BE INSTALLED
ON RETURN PIPING.
> PIPING ARRANGED FOR “POWER PURGING”
AIR OUT OF SYSTEM PIPING, REFER TO THIS
MANUAL’S SECTION ON “FILLING THE SYSTEM
WITH WATER” OPTION #1
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SYSTEM PIPING
Tankless Coil Piping Arrangement
Boilers may be factory packaged with tankless heater
coil see gure below. 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, not continuous
ow.
NOTICE
Do not use tankless coil if your water is excessively
hard with lime or other deposits which will
accumulate inside the coil.
Boiler congured so Honeywell L4006A Low Limit mounts
on control well (provided). Mount factory-wired low limit
control on tankless coil. Tempering valve (mixing valve) is
also recommended as shown in gure below. Flow restrictor
may be required on tankless coil inlet piping so ow rates
are matched to boiler heat input (see table).
!
DANGER
Water temperatures exceeding 125°F will cause
severe burns instantly or death by scalding.
Boiler
Model
Burner
Firing
Rate (gph)
Input
(MBH)
Tank less
Rating
(gpm)‡
3KW0.60C 0.60 84 2.85
3KW0.75C 0.75 105 3.00
3KW1.00C 1.00 140 3.25
4KW.90C 0.90 126 3.15
4KW1.25C 1.25 175 3.50
4KW1.50C 1.50 210 3.75
5KW1.20C 1.20 168 3.45
5KW1.75C 1.75 245 4.00
5KW2.00C 2.00 280 4.25
‡ Gallons of water per minute heated from 40°F to 140°F
with
200°F boiler water temperature, intermittent draw
Figure 10 -Tankless Coil Piping Arrangement
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ANTIFREEZE IN THE SYSTEM
Antifreeze must be nontoxic, type specically intended
for use in closed hydronic 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
Number of
Boiler Section
Total Volume
(Gallons)
3 9.6
4 11.6
5 13.7
CHIMNEY AND CHIMNEY CONNECTIONS
For oil red boilers for connections to vents or chimneys,
vent installations shall be in accordance with applicable
provisions of INSTALLATION OF OIL BURNING EQUIPMENT,
NFPA31 latest revision, and applicable provisions of local
building codes.
PIPING WATER VOLUMES
PIPE SIZE
COPPER PIPE
FACTOR
½” 82.5 63.5
¾” 40.0 36.0
1” 23.3 22.2
1 ¼” 15.3 12.8
1 ½” 10.8 9.5
2” 6.2 5.8
Divide total length of piping in feet by appropriate factor
in table to determine volume in gallons.
For additional chimney design and sizing information,
consult latest revision of the ASHRAE HVAC Systems and
Applications Handbook, Gas Vent and Fireplace Systems; or
the National Standard for Chimneys, Fireplaces, Vents and
Solid Fuel Burning Appliances, ANSI/NFPA 211.
STEEL PIPE
FACTOR
NOTICE
Fresh air (ventilation) is important to proper
venting. Ventilation and venting are two parts of the
same system. Inadequate ventilation will result in
inadequate venting. Always be sure to have enough
ventilation to support proper venting.
This is a very important part of your heating system. Check
your chimney to make certain that it is right size, properly
constructed and in sound condition.
Following chart shows recommended minimum chimney
sizes.
RECOMMENDED MINIMUM CHIMNEY SIZES
FIRING RATE
(gph)
0.60 1.30 15 8” x 8” 6” 6 ¾” x 6 ¾”
1.35 1.80 15 8” x 8” 7” 6 ¾” x 6 ¾”
1.85 2.00 20 8” x 8” 8” 6 ¾” x 6 ¾”
For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.
CHIMNEY
HEIGHT (ft)
NOMINAL
CHIMNEY
ROUND
LINER INSIDE
SQUARE
LINER INSIDE
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ALTERNATE POSITIONS
TOP
TOP
DRAFT REGULATOR
VANE
CRIMPED END
BALANCED WEIGHT
DRAWBAND
LAST PIECE
INSTALLED
MUST SLOPE UP
AT LEAST 1/4 INCH
PER FOOT OF
HORIZONTAL RUN
MUST BE AT LEAST 4
INCHES THICK -
AND BE TIGHT.
TIGHT
CLEAN-OUT
DOOR
SEALED IN
THIMBLE
TIGHT, SMOOTH,
CORRECTLY SIZED.
Minimum Height:
Must be 3 FT higher than
highest part of passage through roof.
Must be at least 2 FT higher than
any neighboring object within 10 FT.
Must have unobstructed top opening
.
TYPICAL CHIMNEY CONNECTION
CHIMNEY AND CHIMNEY CONNECTIONS
CHIMNEY CONNECTOR AND DRAFT
REGULATOR
Boiler venting requires 6” diameter chimney connector pipe
and use of draft regulator packed with boiler. Regulator
controls draft automatically. Preferred installation is in
horizontal section of pipe, may also install in angled or
vertical section of pipe. Verify “top” of regulator is at top
Chimney connector installation, start at boiler with vertical
pipe and elbow. Install draft regulator making it horizontal.
Slope horizontal pipe up toward chimney at least 1/4 inch
per linear foot of venting. Chimney connector must not leak
and must be rmly supported. Join each section with at
least two sheet metal screws. Support every second section
with stove-pipe wire.
and short pipe section which holds vane is horizontal.
Install draft regulator as close as practicable to boiler.
Fire Hazard. Maintain minimum vent pipe clearance of
18” from surface of vent to wood and other combustible
materials. Failure to comply may result in death or
serious injury.
Figure 11 -
Typical Chimney Connection
!
WARNING
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ELECTRICAL CONNECTIONS
!
WARNING
Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections.
Failure to do so could result in death or serious injury.
THERMOSTAT
Install 24 Volt thermostat (not provided) in proper location.
Location of thermostat has effect on boiler system operation.
Follow instructions included with thermostat.
GROUNDING
Permanently ground boiler according to local codes and
latest revision of the National Electrical Code. Run 14
gauge or heavier copper wire from boiler to grounded
connection in service panel or properly driven and
electrically grounded ground rod.
ELECTRIC POWER SUPPLY
Installation must comply with the latest revision of the
National Electrical Code, any other national, state, or local
codes or regulations.
Connect 115 volt electrical supply to L1 and L2 terminals
on limit and two thermostat wires to T and T terminals on
same limit. See wiring diagrams, pages 28 & 29.
Run separate circuit from separate over current protection
device in your electrical service entrance panel. Minimum
15 ampere circuit. Locate shutoff switch at boiler. Turn off
during any maintenance. Solder and tape or securely fasten
connections with wire nuts.
OIL BURNER WIRING
For boilers packaged with oil burners, burners are factory
wired.
17
Page 18
EQUIPMENT AND ACCESSORIES
!
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
RELIEF VALVE (provided)
Each low pressure hot water heating boiler is provided
with a safety relief valve for over pressure protection of
boiler and heating system. Safety relief valve opens when
pressure in boiler rises to 30 psig. Safety relief valve is
provided with lifting device for testing and should be tested
monthly during heating season. Provide discharge piping
from outlet side of safety relief valve to prevent scalding or
other hazardous situations. Discharge piping must remain
full size and terminate at safe point.
CONVENTIONAL EXPANSION TANK (not provided)
Size expansion tank correctly an improperly installed or
sized expansion tank may result in frequent lifting of safety
relief valve or other heating system problems. Install tank
higher than top of boiler. Connecting pipe from boiler to
expansion tank shall rise continuously up to expansion tank
so that air can rise into expansion tank.
Expansion tank is partially lled with air. Air compresses
as water expands, thus forming air pressure cushion. This
“spring-like” cushion serves to maintain correct operating
water pressure regardless of water temperature. This
assures “full measure” of water, even in highest radiation
unit of system. Tank also serves as trap for excess air in
system. Air causes noises in pipes and inefcient circulation
in radiators if left in piping system.
DIAPHRAGM EXPANSION TANK (not provided)
Diaphragm type expansion tank takes the place of
conventional expansion tank. Read instructions packed with
your tank assembly. Size and correctly install expansion
tank, an improperly installed or sized expansion tank may
result in frequent lifting of safety relief valve or other
heating system problems.
Tank typically comes with 10-12 psig air charge. Same as
pressure produced in system by automatic ll valve set
to ll boiler to 10-12 psig with fresh water. When system
is rst lled, tank lls partially with water. As water is
heated, and system pressure increases, water expands into
tank and compresses air in tank. Compressed air cushion
permits system water to expand as temperature changes
and assures “full measure” of water, even in highest system
radiation.
Mount diaphragm type expansion tank on air purger tting
or any other convenient place in supply or return line.
Recommend locating diaphragm type expansion tank in
supply line with circulator located after expansion tank.
Conguration allows circulator to “pump away” from
expansion tank for improved air elimination and system
performance. Air eliminator tting or air purger is not
provided. Use air eliminator tting or air purger to help
remove air from system before it reaches radiators. Install
in supply line. Air left in system can cause noises in pipes
and inefcient circulation in radiators.
It is possible for a tank to become “waterlogged” (lled
with water). It can also become overlled with air when
lling system with new water. Fittings provided on tank and
in line to tank are for bleeding off excess air and water.
18
Page 19
EQUIPMENT AND ACCESSORIES
MAIN AIR VENT: (not provided)
Before lling system with water, there is air in the pipes
and radiation units. Some air is trapped as system lled.
Eliminate most of this air through air vents on radiation
units. Main air vent speeds and simplies process. Install
main air vent on highest point in supply main.
AUTOMATIC FILL VALVE (not provided)
For safe, efcient operation, ll hot water system with
water. Adding new water, when needed can be done
manually (by use of hand valve in water supply line).
Requires regular attention to system’s needs. Automatic ll
valve or pressure reducing valve accomplishes this without
attention. Install in supply line on hot water boilers only.
Valve operates through water pressure differentials. Does
not require electrical connection.
BURNER SOLENOID VALVE (provided)
Beckett oil burners use standard solenoid valve. Upon
burner shut down, standard solenoid valve stops ow of
oil to nozzle. Without solenoid valve, oil pump continues to
pump oil to burner nozzle until burner motor winds down
below pumps cutoff speed.
PIPING section for more information.
DRAIN VALVE (provided)
Drain valve is manually operated valve, provides means of
draining all water from boiler and heating system. Install in
reducing tee where return line enters boiler.
CIRCULATOR (provided)
Forced hot water system requires circulator. Separate
circulator or zone valve is required for each zone, if there are
two or more zones. Circulator must have capacity to provide
circulation required by heating system. Connect circulator
to supply main and wired into boiler’s electrical system. See
System Piping section for piping congurations with circulator
located on supply main piping using zone circulators or zone
valves. Piping arranged with zone circulators and no bypass
piping, circulator provided with boiler may be used as zone
circulator. Both piping arrangements allow circulator to pump
away from expansion tank and show how piping should be
arranged to allow heating system to be easily purged of
air. Circulator can be installed on return side of boiler if
preferred.
LIMIT CONTROL (provided) Refer to manufacturer
instructions provided with limit control
Water temperature limit control in limit is adjustable and
may be set: as low as 140°F, as long as return water
temperatures to boiler are no less than 120°F, or as high
as 220°F and as long as boiler and heating system have
adequate circulation to remove heat from boiler otherwise
steam may be created in boiler. Refer back to SYSTEM
Figure 12 -
Grundfos Pump
The pump curve for the furnished Grundfos UP 15-42 F pump is shown below:
5
4
3
2
1
m Head
15
10
5
0
Head (feet)
Model Watts Volts Amps Capacitor
UP 15-42F 85 115 0.74 10µF/180V
19
US GPM
5 10 15 20
3
m /h
1 2 3 4 5
Page 20
FILLING THE BOILER
HOT WATER SYSTEM OPERATION
Entire heating system (boiler, piping, and radiation units)
is lled with water. As boiler water boiler is heated, it
is circulated from top of boiler through supply main to
radiation units. Cooler water in radiation units ows back
through return piping through return main into boiler. This
arrangement provides positive and rapid response to the
thermostat.
FILLING SYSTEM WITH WATER
OPTION #1 Method utilizes boiler piping as shown in
gures in the “System Piping” section.
a) Close main shutoff valve, isolation valves, and zone
valves (if applicable). If bypass piping is installed, also
close two throttling valves. Leave boiler service shutoff
valve (if installed) and balancing valves to each heating
zone fully open.
b) Open following valves in order: drain valve for power
purging, isolating valves before and after boiler circulator (if
applicable), both throttling valves (if applicable), and then
open ll line shutoff valve. Water will ll bypass piping and
push air through piping and out power purging drain valve.
When power purging drain valve runs air free, close bypass
piping throttling valve (leaving throttling valve to supply
piping fully open).
OPTION #2 Close air vents on all radiation units.
Open valves to radiation units. Verify boiler drain valve,
expansion tank drain cock, and air bleed screw on
expansion tank drain tting are closed. Open ll valve on
piping to expansion tank. Open water inlet to boiler and
leave open. Open air vent on lowest radiation unit. When all
air has escaped and water starts to ow from vent, close it.
Go to next radiation unit, and repeat this process nishing
with highest radiation unit. If heating system has automatic
vents, manual venting is unnecessary but will speed up
proper lling of system.
If system is closed expansion tank system, automatic ll
valve is needed. Leave automatic ll valve open to rell
system automatically as needed. Note initial ll pressure
on boiler’s temperature/pressure gauge should be 10-15
psig. Any lowering of pressure from its initial ll pressure
indicates loss of water due to leakage. Automatic ll valve
should compensate for this water pressure loss. If it does
not, manually open this valve to rell system until needle is
again pointing to same pressure reading. Instructions are
packaged with valve.
c) Next, open isolation valve (or zone valve) to rst zone.
Water lls piping and pushes any air out power purging drain
valve. When power purging drain valve runs air free, close
isolation valve (or zone valve). Repeat this procedure for
remaining heating zones.
d) Once all zones are lled with water and purged of air,
close power purging drain valve and ll line shut off valve,
open main shutoff valve, and adjust throttling valves and
balancing valves as required.
20
Page 21
OPERATING THE BOILER
DO NOT TAMPER WITH THE UNIT OR CONTROLS
IMPORTANT: Installer follow these instructions care-
fully.
STARTING: Fill system with water. Vent all air from system
following section “FILLING THE BOILER”.
FUEL UNITS AND OIL LINES: Install oil line(s) to oil
burner. Use heavy wall copper tubing and ared ttings,
do not use compression ttings. All connections and joints
must be airtight. Use appropriate non-hardening thread
sealing compound on threaded connections, not Teon
tape. See fuel unit data sheet furnished with burner for
sizing, lift, and length of tubing recommendations.
Original equipment oil burner (when furnished) is equipped
with single stage fuel unit with bypass plug removed for
single pipe installation. This is satisfactory where fuel
supply is on same level as, or above burner, permitting
gravity ow of oil. Per NFPA31 requirements, never exceed
3 psig pressure to inlet side of fuel unit. When necessary
to lift oil to burner, two-pipe installation is required. Run
return line between fuel unit and oil supply. When two-pipe
installation is used, bypass plug (furnished with burner)
must be installed in fuel unit. Refer to fuel unit instructions
furnished with burner for specic instructions on installing
bypass plug. Do not exceed fuel unit manufacturer’s
recommendations for running vacuum.
DRAFT REGULATORS: Barometric draft regulator is
required for controlling draft through boiler. Barometric
draft regulator is mounted in chimney connector.
Refer back to section on “CHIMNEY AND CHIMNEY
CONNECTIONS”. Once draft regulator is installed, use
draft gauge to adjust to proper opening: combustion
chamber over re draft will be approximately -0.01” WC to
-0.02” WC and stack draft will be approximately -0.02” WC.
to -0.04” WC. On larger installation, greater draft may be
required in stack to obtain desired over re draft.
NOZZLES AND ELECTRODES: Use proper size, spray
angle, and spray pattern nozzle. Refer to recommended
nozzle selection charts at end of this manual. To install
nozzle, remove nozzle line electrode assembly, if necessary
remove retention ring assembly, and install and tighten
nozzle. Take care not to damage electrode insulators or
bend electrode tips. After installing nozzle, reassemble
nozzle line electrode assembly and set electrode tip
spacing. Electrode tip spacing may need to be set prior
to reassembling nozzle line electrode assembly. Refer to
gures on following pages for setting electrode tip spacing
on Beckett.
FINAL BURNER ADJUSTMENTS: Final burner
adjustments must be made using combustion test
instruments. Initial settings for burner are shown at back of
this manual.
Set burner accordingly. Check draft over re to verify
NOTE: If lift exceeds 14 feet for Beckett burners, two stage
fuel unit is required with return line.
Install oil lter of adequate size inside building between
tank shutoff valve and oil burner. For ease of servicing,
locate shutoff valve and lter near oil burner.
AIR SUPPLY FOR COMBUSTION: Do not install boiler
in rooms with insufcient air, unless corrective steps are
taken. It may be necessary to install windows or cut holes
in door to rooms used for supply air to obtain sufcient
combustion air and prevent less than atmospheric air
pressure in that room. If there is lack of combustion air,
burner ame will be dark orange and formation of soot
will occur in heating unit. In buildings of conventional
frame, brick, or stone construction that do not have utility
rooms, basement windows, or stair doors, air inltration is
normally adequate to provide enough air for combustion
and for operation of barometric draft control. Room used
for supplying combustion air should be isolated from any
area served by exhaust fans. Refer back to the section on
“FRESH AIR FOR COMBUSTION” for additional sizing
guidelines.
it is between -0.01” WC and -0.02” WC, adjust draft as
necessary. After operating 10 minutes to warm up boiler,
use combustion test equipment to take smoke reading in
ue pipe between boiler and draft regulator. Smoke reading
should be zero to trace (Shell Bacharach Scale). A new
boiler may require more than 10 minutes to burn clean due
to oil lm on new heat exchanger. If smoke reading is zero,
gradually close burner’s air adjustment to obtain smoke
reading showing trace smoke reading. Once smoke reading
is trace, measure CO2 and as insurance margin increase air
to sufciently reduce CO2 by 1/2% to 1%.
If clean re cannot be obtained, it will be necessary
to verify burner head and electrode alignment. Proper
electrode alignment gures are presented on following
pages. If re continues to be smoky, replace nozzle with
correct replacement.
Once burner is completely adjusted, burner should be
started and stopped several times to assure good operation
with no uttering or rumbling. Verify there are no oil leaks
and record nozzle size, oil pressure, combustion readings,
and air settings on tag or label that can be attached to
burner or, boiler.
21
Page 22
OPERATING THE BOILER
Figure 13 - Beckett AFG Burner Electrode
Adjustments Variable (V1, L1) Heads
Boiler
Model
All 1/16” 7/32” - 9/32”
Dimension “N”
(electrode to
nozzle)
Dimension “H”
(head to nozzle)
Figure 14 -
Adjustments and Settings
Beckett AFG Variable (V1) Head
Dimension “Z” For L1, V1 Heads
1 ¾”
CHECKING AND ADJUSTING CONTROLS
Instructions for Limit control provided are included with boiler.
IMPORTANT: Installer follow these instructions carefully.
ADJUST OPERATING CONTROLS: Use following
settings for rst adjustment:
High Limit:
Baseboard and Convectors 180°F
Standing Radiators 180°F
Low Limit (when used) 140º ( increase if hotter domestic
water is required, but low limit set point must be at least
20°F less than high limit set point).
When low limit is used:
Boilers factory equipped with tankless coil are factory set.
ADJUST THERMOSTAT HEAT ANTICIPATOR PER
LIMIT INSTRUCTIONS.
Do not attempt to start burner when excess oil
has accumulated, when unit is full of vapor, or
when combustion chamber is very hot.
22
• With Honeywell L7248L control, set ELL parameter on
L7248L control to ON.
• With Hydrolevel 3250 control, Set Z-l switch on 3250
control to l position.
Page 23
CHECKING AND ADJUSTING CONTROLS
VERIFY THERMOSTAT OPERATION: Thermostat location
has important effect on operation of boiler system. Follow
instructions included with your thermostat. Thermostat is
located typically about ve feet above oor on inside wall.
Locate thermostat to sense average room temperature, so
avoid the following:
When temperature on thermostat is set above indicated
thermostat temperature, boiler’s burner should start.
Verify that once room temperature reaches selected
temperature setting, boiler’s burner shuts off, and once
room temperature falls few degrees boiler starts operating
again. Do not start burner unless all cleanout doors
are secured in place.
THERMOSTAT LOCATIONS TO AVOID
DEAD
SPOTS
Behind
doors
Corners &
alcoves
HOT SPOTS COLD SPOTS
Concealed pipes
Fireplace
TV sets
Radios Doors drafts
Lamps
Direct sunlight
Kitchens
Concealed pipes
Stairwells
Unheated room
on other side of
or ducts
drafts
wall
23
Page 24
MAINTENANCE
ANNUALLY: Recommend ue passages, combustion
chamber area (target wall, re door insulation,
durablanket), burner adjustment, operation of controls,
and boiler seals (re door gasket or silicone seal, cast iron
sectional seals, ue collector) checked once each year
by competent Service Technician. Before start of each
heating season (or when system has been shut down for
extended periods of time) recheck whole system for water,
oil, and vent piping leaks. Replace or patch any leaks or
seals that are faulty.
VENT PIPE: Visually inspect entire venting system
once a month for any signs of leakage, deterioration, or
soot build up. If vent pipe shows any signs of leaking or
deterioration, replace it immediately. If it shows any signs
of soot build up, clean vent pipe and have burner settings
and combustion checked by competent professional.
SAFETY RELIEF VALVE: Valve should open automatically
when system pressure exceeds pressure rating (usually 30
psi) of safety relief valve. Should valve ever fail to open
under this condition, shut down the system. Drain system
until system pressure is reduced below safety relief valve
pressure rating. Contact competent Service Technician to
replace valve and inspect heating system and determine
cause, this problem may indicate equipment malfunction.
Test safety relief valve monthly during heating season.
Prior to testing, verify discharge pipe is properly connected
to valve outlet and arranged to safely dispose of boiler
discharge. Hold trip lever fully open for at least ve
seconds in order to ush free any sediment lodged on
valve seat. Permit valve to snap shut. Refer to valve
manufacturer’s instructions packaged with valve for more
details.
CONVENTIONAL EXPANSION TANK: As noted in
“EQUIPMENT AND ACCESSORIES” section, this tank
may become water logged or may receive excess of air.
Frequent automatic opening of safety relief valve indicates
water logging. High boiler temperature accompanied by
unusually low radiation unit temperature (and “knocking”
noises) indicates excess air in the tank. To correct either
condition, close valve between boiler and tank. Drain the
tank until empty. Check all tank plugs and ttings, tighten
as necessary. Open valve between boiler and tank. Water
will rise to normal height in tank if system has automatic
ll valve, otherwise manually rell system.
DIAPHRAGM EXPANSION TANK: As noted in
“EQUIPMENT AND ACCESSORIES” section, tank may
become water logged. Frequent automatic opening of
safety relief valve indicates water logging. High boiler
temperature accompanied by unusually low radiation unit
temperature (and “knocking” noises) indicates excess air
in the tank. To correct this condition, replace diaphragm
expansion tank.
WATER SYSTEM: If system is to remain out of service
during freezing weather, always drain it completely (water
left in the system will freeze and crack pipes and/or boiler).
TANKLESS COIL (OR COVER PLATE) GASKET: This Check
gasket at least twice a year for leakage and replace if
necessary. If gasket is replaced, make sure when coil plate
(or cover plate) is reattached the ten nuts are torqued in
alternating pattern to ensure equal force is applied to entire
gasket creating a good seal.
Torque nuts to 23 ft-lbs so gasket does not squeeze out
from behind plate.
OIL BURNER: Oil burner maintenance is listed in this
manual under OPERATING THE BOILER.
Never burn garbage or paper in the unit, never leave
combustible material around it.
24
Page 25
OIL BOILER / BURNER CLEANING INSTRUCTIONS
OIL BOILER CLEANING:
1.
Shut off all electrical power to boiler / burner and shut
off fuel oil supply.
2.
Remove vent pipe from boiler top. Inspect pipe and
chimney for signs of corrosion and deterioration. Clean
out base of chimney. If vent pipe shows any signs
of corrosion or deterioration, replace immediately. If
chimney damage or deterioration is discovered, contact
competent professional.
3.
Remove top jacket panel screws (5), brass wing nuts
(2) holding ue collector top, and ue collector top. Inspect gasket on underside of ue collector and replace
as necessary.
4.
Before beginning to clean ue passageways, ensure
combustion chamber blanket is covered. If blanket is
not covered prior to cleaning, replace blanket once
cleaning is completed.
5.
With access to ue passageways, remove soot from
reside surfaces by brushing diagonally through ue
passages. Brushing is easier by cutting end of ue
brush off and inserting into a drill. When brushing, take
care not to damage target wall with ue brush. See
gure 15.
6.
Carefully vacuum soot accumulations from combustion
chamber area, be careful not to damage any refractory or blanket insulation. To gain access to combustion
chamber rst double check the shut off valve on fuel
oil line is closed and disconnect fuel oil line. Remove oil
burner from re door. Remove re door.
7.
Inspect target wall, re door refractory, and combustion chamber blanket (when included) for cracking and
deterioration. If there is signs of cracking or deterioration, replace refractory or blanket before reassembling
burner / front plate.
8.
Inspect door’s braided gasket for wear and damage.
Replace when necessary with braided gasket of same
material and size. See repairs parts manual.
9.
Inspect and clean oil burner.
Figure 15 -
Passages
Brush Diagonally Through Flue
Important operating and maintenance requirements:
• Keep boiler and area around it clean
• Never burn refuse or any material other than
specied fuel in your boiler
• Have your boiler checked each year by qualied
technician
25
Page 26
OIL BURNER MAINTENANCE AND CLEANING
OIL BURNER MAINTENANCE: For Beckett AFG, following
preventative maintenance items should be performed
annually, preferably prior to heating season.
1.
Fuel Filter Replace to prevent contaminated fuel from
reaching nozzle. Partially blocked fuel lter can cause
premature failure of fuel pump.
2.
Fuel Pump Unit Replace pump screen and clean pump
unit to maintain fuel delivery to nozzle.
3.
Ignition Electrodes Clean and adjust as per
manufacturer’s recommendations, to maintain reliable
ignition of oil.
4.
Nozzle Replace to maintain safe and reliable
combustion efciency. Always replace with exact nozzle
as required in charts in back of this manual.
5.
Fan and Blower Housing Keep clean, free of dirt, lint
and oil to maintain proper amount of air fuel requires to
burn.
6.
Check burner settings and adjust as needed.
NOTE: If component parts must be replaced, use parts
recommended by burner manufacturer.
These are general instructions for
cleaning an oil burner.
For specics, consult burner
manufacturer’s instructions.
1.
Verify all electrical power to boiler / burner and fuel
supply to burner are shut off.
2.
With oil burner removed from re door, clean any soot
accumulations from end of burner and if applicable
burner head.
3.
Remove burner drawer assembly, clean electrodes
and reset electrode spark gap per manufacturer’s
recommendations. Refer to section on OPERATING
THE BOILER Nozzles and Electrodes.
4.
Replace oil nozzle with same size and type
recommended for use on this boiler.
5.
Install burner drawer assembly making sure head
location (and size if applicable) are per manufacturer’s
recommendations. If burner being used has damaged
head, replace head with same head recommended for
use on this boiler.
6.
Inspect and clean oil burner blower wheel.
7.
Remove oil pump cover and clean / replace pump
screen. Carefully reassemble ensuring pump cover
makes proper seal.
8.
Securely fasten oil burner to re door.
9.
Replace fuel lter (if applicable).
10.
Reconnect electrical and fuel supplies.
11.
Fire burner, checking for proper combustion using
combustion test equipment and making adjustments
as necessary. Refer to section on OPERATING THE
BOILER Final Burner Adjustments.
12.
Insure all safety controls and operating controls are
functioning properly.
26
Page 27
SERVICE HINTS
You may avoid inconvenience and service calls by checking these points before you call for service:
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
POSSIBLE CAUSE WHAT TO DO
Thermostat is not set correctly Reset thermostat
Check ame. If it is yellow, the burner is not getting enough air.
Burner is not operating properly
Or, if ame is blue and noisy and seems to lift off the burner, the
burner is getting too much air. Contact your service technician.
No electric power to boiler
Controls out of adjustment Reset according to instructions.
Radiators not heating
Circulating pump not running Check over-current protection. Check relay operation.
Poor electrical contact Check all control terminals and wire joints.
Chimney ue is blocked Have the chimney professionally cleaned.
Circulator running when boiler
water temperature is below low
limit set point (tankless coil
boilers only)
POSSIBLE CAUSE WHAT TO DO
Corrosion and/or deposits on seat.
Water logged expansion tank Drain tank, see instructions.
Check over-current protection. Check to be sure electric power
supply circuit is “ON”.
Open radiator vents to excess air. Check ow control valve (if
used). It may be in closed position.
Honeywell L7248L control - conrm ELL parameter on L7248L
control set to ON.
Hydrolevel 3250 control - conrm Z-l switch on 3250 control set
to l position.
Refer to control instructions furnished with boiler.
RELIEF VALVE LEAKING . . .
Open valve manually. Allow water to run and clear valve seat.
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU
ARE UNABLE TO CORRECT.
27
Page 28
ELECTRICAL WIRING
Figure 16 -
Boiler Honeywell L7248L Control
*
28
* When low limit is used, set ELL parameter on L7248L Honeywell control to ON. Boilers factory equipped
with tankless coil are factory set to ON.
Page 29
ELECTRICAL WIRING
Figure 17 -
Boiler With Hydrolevel 3250 Control
*
29
* When low limit is used, set Z-l switch on 3250 Hydrolevel control to l position. Boilers factory equipped
with tankless coils are factory set to l position.
Page 30
SEQUENCE OF OPERATION
Sequence of Operation
• Thermostat calls for heat.
• Circulator turns on.
• Limit checks boiler water temperature. Burner ignition
delayed until limit determines call for heat cannot be met
by residual heat in boiler and heat distribution system.
A. See limit literature for additional information.
B. Burner delay by-passed for tankless heat call for
heat. Burner ignition begins immediately.
• Burner and circulator operation continues until
thermostat stops call for heat.
30
Page 31
BECKETT OIL BURNER, NOZZLE, AND AIR SETTING
BOILER
MODEL
3KW0.60* 0.60 AFG50MB L1 FIXED Yes 0 4 3 3/8” 0.60 x 70W 100
3KW0.75* 0.75 AFG50MB L1 FIXED Yes 0 8 3 3/8” 0.75 x 70B 100
3KW1.00 1.00 AFG50MB L1 FIXED No 0 10 3 3/8” 1.00 x 70B 100
4KW.90* 0.90 AFG50MD V1 0 No 0 5 2 3/4” 0.75 x 60B 140
4KW1.25 1.25 AFG50MD V1 0 No 1 10 2 3/4” 1.25 x 70B 100
4KW1.50* 1.50 AFG50MD V1 2 No 3 10 2 3/4” 1.50 x 60B 100
5KW1.20* 1.20 AFG50MD V1 1 No 1 8 2 3/4” 1.20 x 70B 100
5KW1.75* 1.75 AFG50MD V1 3 No 3 10 2 3/4” 1.75 x 60B 100
5KW2.00 2.00 AFG50MD V1 4 No 3 10 2 3/4” 2.00 x 60B 100
* “Alternate Firing Rate Kits” are needed in order to achieve these ring rates
** All nozzles are Delavan
FIRING
RATE
(GPH)
BURNER
MODEL
HEAD
HEAD
ADJUSTMENT
LOW FIRE
BAFFLE
AIR
BAND
AIR
SHUTTER
STATIC
PLATE
NOZZLE**
PRESSURE
NOTE: All burners use insertion depth of 2 ¼” and red at over-re draft of 0.02 inches w.c.
Burner settings provided are intended for initial start up only. Final adjustment must be made
using combustion test instruments.
PUMP
(PSI)
31
Page 32
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and
Conservation Act, this boiler is equipped with a feature that saves energy
by reducing the boiler water temperature as the heating load decreases.
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 for any space heating
• This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.
• This boiler is equipped with a tankless coil.
PENNCO BOILERS
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
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