Utica Boilers TriFire TRB 3 Operation and Installation Manual

TRIFIRE SERIES II

High E󱐰ciency

Oil Fired Hot Water Boiler

Models

TRB4075 TRB4095

TRB4110

TRB5100

TRB5115 TRB5135 TRB6130 TRB6145 TRB6165

TRB7165 TRB7180

TRB7190

INSTALLATION, OPERATION &

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# 240009350, Rev. E [12/2014]

TRIFIRE OIL-FIRED CAST IRON HOT WATER BOILER

Models

TRB5100 TRB6130

Per Energy Star specications, AFUE

is rounded to the nearest whole

percentage point. As such, these

products qualify for Energy Star.

Check our website frequently for updates: www.ecrinternational.com

Information and specications outlined in this manual in effect at the

time of printing of this manual. ECR International reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

DIMENSIONS

Dimension

Inches

(cm)

Sections

Flue Size

Inches

(cm)

4 5 (13) 18 3/8 (46) 5 5 (13) 21 5/8 (56) 6 5 (13) 24 7/8 (64) 7 6 (15) 28 1/8 (72)

TABLE OF CONTENTS

1 - Introduction .............................................................................................................. 5

2 - Safety Information..................................................................................................... 6

3 - Before You Start ........................................................................................................ 7

4 - Ratings & Capacities ..................................................................................................8

5 - Locating The Boiler .................................................................................................... 9

6 - Installation Requirements ......................................................................................... 10

7 - Fresh Air For Combustion .......................................................................................... 11

8 - Boiler Assembly ....................................................................................................... 13

9 - Boiler System Piping ................................................................................................ 18

10 - Hydronic Piping ..................................................................................................... 19

11 - Fuel Supply Piping ................................................................................................. 32

12 - Antifreeze In The System ....................................................................................... 33

13 - Electrical Connections ............................................................................................. 34

14 - Chimney And Venting Connections ........................................................................... 35

15 - Filling Boiler .......................................................................................................... 38

16 - Operating The Boiler - System Start-Up ................................................................... 39

17 - Oil Burner, Nozzle, & Air Settings ............................................................................. 46

18 - Maintenance ......................................................................................................... 52

19 - Oil Boiler /Burner Cleaning Instructions .................................................................... 54

20 - Troubleshooting ..................................................................................................... 56

21 - Equipment And Accessories .... ................................................................................58

Parts List ..................................... ................................................................................62

Warranty ..................................... ................................................................................68

Check Out Certicate..................... ...............................................................................70

1 - INTRODUCTION

WARNING

Installations of boilers and venting shall be done only by a qualied expert and in accordance with this manual. Installing or venting a boiler or any

other oil appliance with improper methods or materials may result in serious injury or death due

to re or to asphyxiation from poisonous gases

such as carbon monoxide which is odorless and

invisible.

1.1 OIL FIRED BOILERS

Boiler is low pressure, sectional cast iron constructed and tested for maximum working pressure of 65 psi in accordance with A.S.M.E. (American Society of Mechanical Engineers) Section IV Standards for cast iron heating boilers. Capacity rated in accordance with AHRI (Hydronics Institute).

Boiler is pressure red natural draft (chimney vented) oil red hot water boiler comprised of cast iron sections, available with 4, 5, 6 or 7 sections. Sections are held

together by push nipples and threaded rods.

NOTICE

Surface rust on cast iron sections may be attributed to manufacturing process as well as condensation during storage. Surface rust is normal and does not affect performance or life of boiler.

4,5 and some 6 section boilers may be factory equipped for direct vent installations. Direct vent instructions are covered in a separate supplemental instructions document.

Boiler models are capable of ring #2 fuel oil from 0.75

gph up to 1.90 gph.

Boilers include -

• Limit, 220° F maximum, operating control with integral low water cut off.

• Temperature and pressure gauge

• 30 psi relief valve

• Drain valve

2 - SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualied agency.

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.

WARNING

Modication, substitution or elimination of factory equipped, supplied or specied components could

result in death or serious injury.

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious injury.

WARNING

Construction materials of appliance and products of combustion and fuel contain alumina, silica,

heavy metals, carbon monoxide, nitrogen

oxides, aldehydes and /or other toxic or harmful substances which can cause death or serious injury and which are known to the State of California to

cause cancer, birth defects and other reproductive

harm. Always use proper safety clothing,

respirators and equipment when servicing or

working nearby the appliance.

WARNING

Product contains berglass wool and refractory ceramic bers. Possible cancer hazard. May cause

irritation to skin, eyes and respiratory tract. To

avoid this hazard, wear a dust mask and gloves when handling berglass and ceramic bers.

IMPORTANT: Read the following instructions COMPLETELY before installing!!

2.2 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.

2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements to ANSI/NFPA 31, “Installation of Oil Burning Equipment”. In Canada, Current Edition of Canadian Standards Association CSA B139, Installation Code for Oil Burning Equipment” for recommended installation practices. requirements take precedence over general instructions of this manual.

2.4 Current Edition of American National Standard ANSI/NFPA 211 “Chimneys, Fireplaces, Vents and

Solid Fuel Burning Appliances” for venting.

2.5 Where required by authority having jurisdiction,

installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff and manual reset high limit may be required.

2.6 Requirements for Commonwealth of Mas sachusetts:

Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to:

• Installation by licensed plumber or gas tter.

Such applicable

3 - BEFORE YOU START

3.1 Installation and Operation

Do not operate unit if any control, switch, components or devices have been underwater or subject to water

damage.

Before servicing, allow boiler to cool. Always shut off any

electricity and oil supply to boiler when working on it.

Inspect oil line and connections for leaks.

Verify oil burner nozzle is proper size. Over-ring will

result in early failure of boiler sections, and result in a potentially dangerous situation.

Never vent boiler into enclosed space. Always vent to the outside. Never vent to another room or inside a

building.

Verify adequate air supply for complete combustion.

Relief valve automatically lifts open when system pressure exceeds 30 psi. Before installing relief valve read manufacturer’s instructions. Pipe relief valve to a safe location. Check with authorities having jurisdiction.

Consider system total water volume, temperature, initial ll pressure and arrangement when sizing and

installing expansion tank. Improperly installed and sized expansion tank may result in frequent lifting of

relief valve or other heating system problems. Follow

expansion tank manufacturer guidelines for installation, and sizing.

Boiler manufacturer recommends initial ll pressure of 10-12 psi. For higher ll pressures increase expansion tank’s air charge to match ll pressure.

10.

Purge heating system of air and gases is critical for proper circulation and quiet performance. Once the air

is 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.

3.2 Prior To Installing The Boiler

• Verify you have selected right size boiler with proper capacity. AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss)

for building or area(s) served by boiler and associated

hot water heating systems. Use heat loss calculations

based on approved methods. See Figure 1, Page 8

• Boiler must be supplied with proper oil supply and oil

piping, sufcient fresh combustion air, and suitable

electrical supply.

• Connect boiler to suitable venting and piping systems adequate to distribute heating load.

• Installation is not complete unless pressure relief valve is installed 3/4” tapping located in supply piping.

• Thermostat must be properly located and installed

• Failure to pipe boiler correctly may result in excessive noise or other related problems.

Existing Water System Evaluation

A good system will prevent oxygen contamination of boiler

water.

Causes of oxygen contamination may be:

A. Addition of excessive make up water as a result of

leaks. B. Absorption through open tanks and ttings. C. Oxygen permeable materials in the distribution

system.

To insure long product life, oxygen sources must be eliminated.

Take the following measures:

A. Repair system leaks. B. Eliminate open tanks from the system. C. Eliminate and/or repair ttings which allow oxygen

absorption. D. Use non-permeable materials in the heating system.

4 - RATINGS & CAPACITIES

Table 1 RATINGS & CAPACITIES

OIL-FIRED HOT WATER BOILERS

Number

Sections

4 0.75 105 91 79 65 86.0 91 250 6 6 3/4 5

4 0.95 133 114 99 65 85.0 115 250 6 6 3/4 5

4 1.10 154 132 115 65 84.0 132 250 6 6 3/4 5

5 1.00 140 122 106 65 86.5 122 250 6 6 3/4 5

5 1.15 161 139 121 65 85.0 139 250 6 6 3/4 5

5 1.35 189 161 140 65 84.0 161 250 7 6 3/4 5

6 1.30 182 159 138 65 86.5 159 250 6 6 3/4 5

6 1.45 203 176 153 65 85.0 176 250 7 6 3/4 5

6 1.65 231 198 172 65 84.0 198 250 7 6 3/4 5

7 1.65 231 201 175 65 86.0 201 250 7 6 3/4 6

7 1.80 252 217 189 65 85.0 217 250 7 6 3/4 6

7 1.90 266 228 198 65 84.0 227 250 8 6 3/4 6

Firing

Rate

[GPH]

Input

[Mbh]

Heating

Capacity

[Mbh]

Net

AHRI

Rating

[Mbh]

*MAWP

Water

[psi]

AFUE

[%]

Min. relief

Valve

Capacity

[Mbh]

Max.

Water

Temp

[°F]

Chimney

Liner Size

Round

[Inches]

Chimney

Liner

Size

[Square

Inches]

Flue Size

[Inches]

GPH = U.S. Gallons per Hour Mbh = 1000 Btu (British thermal units) per hour. psi = Pounds per square inch

*MAWP = Maximum allowable working pressure. This low pressure oil red hot water boiler is constructed and

hydrostatically tested for maximum working pressure of 65 psi 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.

AFUE= Annual Fuel Utilization Efciency

Heating Capacity and AFUE based on 13.1% CO2 (13.5% CO2 at 0.95 GPH and 1.10 GPH), -0.02” w.c. draft in breech, and # 1 smoke or less. Testing is done in accordance with U.S. DOE (Department of Energy) test procedure.

Heating Capacity indicates amount of heat available after subtracting losses up the stack. Remaining heat is available to heat water. Small portion is heat from jacket and surfaces of boiler and this heat stays in structure. Net AHRI rating

represents portion of remaining heat 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 system and offsetting heat losses from system piping. Net AHRI ratings shown are based on piping and pickup factor of 15% in accordance with AHRI Standard as published by Hydronics Institute.

Net AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.

15”

5 - LOCATING THE BOILER

WARNING

Fire hazard. Do not be install on carpeting. Failure

to follow these instructions could result in death or serious injury.

Boiler is suitable for installation on combustible

ooring. Do not install boiler on carpeting.

Locate boiler in front of nal position before removing

crate.

Locate unit so vent pipe connection to chimney will be

short and direct.

For basement installation, provide solid elevated base, such as concrete, if oor is not level, or if water may be encountered on oor around boiler.

Provide recommended service clearance, if applicable,

as follows:

• Clearance from Jacket Front Panel

24” for servicing burner

• Clearance from Jacket Side Panels

24” for burner swing door, if opened fully with burner

mounted, otherwise 2” with burner removed.

• Clearance From Jacket Rear Panel

12” minimum for rear smoke box cleaning. (Note: this dimension will also be controlled by horizontal to

vertical to horizontal smoke pipe arrangement. See

Figure 1

Minimum clearances to combustible material see Figure 1 and Table 2.

Fresh air for combustion and ventilation must be available at boiler. Ventilating and combustion air must enter boiler room without restrictions.

Installation shall conform to requirements of authority

having jurisdiction or in absence of such requirements

in United States, follow NFPA 31 Installation of Oil Burning Equipment. In Canada, use CSA B 139, latest

revision.

Clearance to venting is for single wall ue pipe. If Type L vent is used, clearance may be reduced to minimum required by vent pipe manufacturer.

Table 2 - BOILER CLEARANCES

Accessibility,

Unit

Top 12” (32 cm) 24” (61 cm)

Right Side 2” (5 cm) 24” (61 cm)

Left Side 2” (5 cm) 24” (61 cm)

Floor Combustible No Requirement

Front 17” (43 cm) 24” (61 cm)

Back See Flue 18” (46 cm)

Flue 9” (23 cm) 9” (23 cm)

All distances measured from the boiler jacket or ue.

Combustible

Clearance

Cleaning,

and Servicing

Figure 1 - Clearances to Combustible Construction

6 - INSTALLATION REQUIREMENTS

LIMIT

Figure 2 - General Requirements For A Typical Installation

RELIEF VALVE

NOTICE

Shut off manual fuel supply valve if burner is shut

down for extended period of time.

CHECK LOCAL CODES FOR

MAXIMUM DISTANCE FROM

FLOOR, OR OTHER ALLOWABLE

SAFE POINT OF DISCHARGE.

7 - FRESH AIR FOR COMBUSTION

WARNING

Asphyxiation, re hazard. Do not obstruct air

openings to combustion area. Follow instructions below, to maintain adequate combustion air.

NOTICE

Install outside air intake if used with a replace or kitchen or bathroom exhaust fan. These devices rob

boiler and water heater of combustion air.

Determine volume of space (boiler room). Rooms

communicating directly with the space in which appliances are installed, through openings not furnished with doors, are considered a part of the space.

Volume (ft3) = Length (ft.) x Width (ft.) x Height (ft.)

Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round the result to the nearest 1000 BTU/hr.

Determine type of space. Divide Volume by total input

of all appliances in space. If the result is greater than or equal to 50 ft3/1000 BTU/hr, then it is considered an unconned space. If the result is less than 50 ft3/1000 BTU/hr, then the space is considered a

conned space.

When a boiler is located in an unconned space of a conventionally constructed building, fresh air inltration

through cracks around windows and doors normally

provides adequate air for combustion and ventilation.

Provide outdoor air for boiler located in a conned space or an unconned space in a building of unusually tight construction. Outdoor air may be provided with

the use of two permanent openings which communicate directly or by duct with the outdoors or spaces

(ventilated crawl or attic) freely communicating with

the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Size each opening per the following:

Alternate method for boiler located within

conned space: Use indoor air if two permanent openings communicate directly with additional space(s)

of sufcient volume such that the combined volume of all spaces meet criteria for unconned space. Size each

opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches.

Louvers and Grilles of Ventilation Ducts

A. All outside openings should be screened and

louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of

rain and snow.

B. Free area requirements need to consider the

blocking effect of louvers, grilles or screens

protecting the openings. If the free area of the

louver or grille is not known, assume wood louvers have 20-25% free area and metal louvers and grilles have 60-75% free area.

C. Louvers and grilles must be xed in the open

position, or interlocked with the equipment to open automatically during equipment operation.

Figure 3 - Air Openings For Boiler Located In

Conned Space (Utility Room)

A. Direct communication with outdoors:

Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space.

B. Vertical Ducts: Minimum free area of 1 square

inch per 4,000 BTU per hour input of all equipment

in space. Duct cross-sectional area shall be same

as opening free area.

C. Horizontal Ducts: Minimum free area of 1 square

inch per 2,000 BTU per hour input of all equipment

in space. Duct cross-sectional area shall be same

as opening free area.

7 - FRESH AIR FOR COMBUSTION

Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In Tightly Constructed Houses

Table 3 - FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS

Duct Size

3 ½” x 12” 144,000 36,000 108,000

Figure 4 - Fresh Air Openings

Fresh Air

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 lou-

¼” Mesh

Screen

(Btuh)* (Btuh)* (Btuh)*

vers, or metal louvers.

Wood

Louvers

Metal

Louvers

8 - BOILER ASSEMBLY

5/8 BOLT (BOLT INTO FRONT SECTION)

EYEBOLT & NUT AS HINGE

1. Remove Crate

A. Remove all fasteners at crate skid. B. Lift outside container and remove all other inside

protective spacers and bracing. Remove burner and

miscellaneous parts boxes.

2. Remove Boiler from skid

with 4 screws. Remove all securing hardware.

. Boiler is secured to base

3. Move boiler into permanent position by sliding or

walking into place.

4. Do not drop boiler. Do not bump boiler jacket

against oor.

5. Open burner swing door

and securing burner swing door opened for inspection,

cleaning or eld service.

A. Loosen and remove non-hinged side latching

hardware. B. Remove hinged side latching hardware. C. Door can be swung to full open position

approximately 90 to 120 degrees with the burner

mounted providing there is 22” of clearance to the

adjacent wall.

Proper method to closing

NOTICE

Burner door may come off hinges if lifted when opened.

If reduced clearance prevents door from opening fully, one of the following can provide full access:

• Burner can be removed to allow full rotation of door. Door with burner mounted can be lifted off hinges and set aside during servicing.

• Door mounting hardware is reversible from left side hinge (as shipped) to right side hinge. To reverse hinge

arrangement. See Figure 5.

• Lift door off mounting eye bolts and set aside. Remove

mounting eye bolts from left side. Move door mounting

eye bolts to right side. Tighten both sets of hardware. Lift door and place integral cast hinge pins on door into slotted mounting bracket holes.

Recommend hinges be on same side as exible oil line in

order to swing door open.

Figure 5 - Reversible Hinge

NOTICE

For purpose of these instructions, all pipe

connections shall use pipe dope or Teon tape to

assure water tight connections unless otherwise instructed. Steps 6 thru 16, Figure 10, Page 15.

7. Open accessory carton

components using illustrations applicable to your installation.

8. Remove top panel

securing top panel to jacket rear panel. Slide top panel towards front of boiler and lift off of side panel.

9. Locate shorter of two 1 1/4” adapters

insulation slot into supply port in rear of boiler. Locate 1 1/4 x 3/4 x 1 1/4 elbow and assemble onto adapter. Verify connections are tight with outlet facing directly up. See

Figure 6

10. Locate longer of the two 1 1/4” adapters

onto elbow.

Figure 6 - Adapter Assembled Onto Elbow

1 1/4” ADAPTER

and remove contents. Identify

throughout this section

. Remove sheet metal screws

. Thread thru

. Assemble

6. Inspect Swing door insulation and rope gasket.

A. Inspect ber rope located on swing door. Evenly

distribute rope around perimeter of door groove do not bunch or overhang. There must not be

a gap where two ends of rope meet. Repair or replace if rope is damaged or if there is gap

between ends. B. Inspect burner swing door insulation for damage. C. Combustion chamber and raised portion between

2nd and 3rd pass ue ways make an impression

in door insulation as designed.

D. Do not close and secure door at this time.

1 1/4 x 3/4 x 1 1/4

ELBOW

RELIEF VALVE

8 - BOILER ASSEMBLY

NOTICE

Do not install valve between boiler and controls manifold or relief valve.

11. Locate cast 1 1/4 x 1 1/4 x 3/4 tee and assemble on

long female adapter with 3/4” tapping front of boiler and joint is water tight.

12. Install Limit control mounting plug

port facing front.

13. Install Limit control & harness assembly

mounting screw on bottom of limit control. A. Mount control on mounting plug and tighten screw

to secure control. See Figure 7.

B. Conrm thermal limit/LWCO sensor bulb is fully

inserted to bottom of control well in top of rear boiler section and secured with grommet. See Figure 8.

C. Route thermal limit/LWCO sensor wire to control

and connect. See Figure 10, Page 15 and Figure 15, Page 17.

Figure 7 - Control On Mounting Plug w/Screw

facing toward

in upper 3/4”NPT

. Loosen

Figure 8 - Grommet

SENSOR IN WELL

WITH GROMMET

Figure 9 - Relief Valve

MOUNTING

PLUG

TIGHTEN

SCREW

WARNING

Burn and scald hazard. Relief valve could

discharge steam or hot water during operation.

Check local codes for maximum distance from oor

or allowable safe point of discharge. Installation of

relief valve shall be consistent with ANSI/ASME Boiler

and Pressure Vessel Code, Section IV.

14. Install Relief Valve.

A. DO NOT pipe in area where freezing can occur. DO

NOT install shutoff valves, plugs or caps.

B. Locate 3/4”NPT x 90° street elbow. Install elbow using

3/4” NPT tapping in supply piping. Install elbow with

outlet facing directly up. Install relief valve with outlet

facing horizontally.

C. Pipe discharge of relief valve. Installation of relief

valve must be consistent with ANSI/ASME Boiler and

Pressure Vessel Code, Section IV.

See

Figure 9

15. Check installation of liners and bafes (Not all

models)

A. Check oval (4 section only) or V-shaped (certain 5

section models and all 6 and 7 section models) liner. See

edge of heat exchanger ns.

B. Flue way bafes (4, 5, 6 section only) are factory

installed in 3rd pass. Insure bafes are inserted in ue

way such that position tab touches casting between

2nd and 3rd Pass ue way. See

Efciency of boiler is based on insertion of ue way bafes in 4, 5 and 6 section units. Bafes will generate lower gross

stack temperatures entering chimney. This has the potential

under certain operating conditions to cool ue gases below

dew point, creating condensation on interior chimney and

chimney connector surfaces. Remove bafes to increase

stack temperature if there are any signs of condensation in

chimney or chimney connector. Removing bafes alone may

not address condensation depending on other boiler and heating system operating conditions.

. See Table 4, Page 16.

Figures 11 & 12

. Liner should be ush with front

Figure 13, Page 16.

NOTICE

Flue gas condensate is corrosive, which requires

special consideration and must be addressed immediately.

8 - BOILER ASSEMBLY

Figure 10 - Supply Piping and Control Assembly

NOTICE

Do not install valves between boiler and controls manifold or relief valve.

LIMIT CONTROL

WITH INTEGRAL

LOW WATER

CUT OFF

THERMAL/ LWCO

WIRE

BURNER WIRING

BACK OF BOILER

RELIEF VALVE

Figure 11 - Oval Liner

8 - BOILER ASSEMBLY

16. Connect Field Wiring.

Connections” on page 34.

A. Route wire harness from burner to Limit control

through rear jacket panel. See Connect molex plug on burner wire harness to its receptacle on limit control.

B. If optional manual reset high temperature limit is not

used, ensure supplied jumper is installed.

C. Connect the wiring harness from limit control to

circulator. See

D. 120 volt power supply eld wiring connects to limit

control. Provide appropriate overcurrent protection and service disconnect switch.

See “13 - Electrical

Figure 15, Page 17.

Figure 12 - V-Shaped Liner

Figure 13 - 3rd Pass Bafes

E. Wire power supply. See

Connect green wire to grounding lug. When installing wiring through hole in Limit, use antiabrasion cable clamp. Connect black “hot” wire to L1 of terminal block, white “N” wire to L2 of terminal block.

17. Install top panel.

tabs in top panel into slots in side panels. Push top panel toward back of boiler. Install rear panel screws.

18. Install drain valve

connection facing right or left. This allows clearance for swing door to open and close with drain and hose attached. Verify connection is water tight. See

Figure 16, Page 17.

Place on top of side panels. Position

. Install drain valve with hose

19. Close burner swing door

A. Use one hand to hold door in position by applying

pressure directly to door while re-installing securing hardware with your opposite hand. Always install

non-hinged side latching hardware rst, then install

hinged side hardware. Apply additional pressure while hand tightening hardware as far as possible, then release pressure.

Figure 15, Page 17

Table 4

Sections Liner

4 Oval 4” 9”

5** V SHAPE 9” 12”

6 V SHAPE 12” 15”

7 V SHAPE 14” NONE

** 9” V liner used only on Models 5115 and 5135 and only with Beckett NX burner. All other 5 section models and burner combinations use no liner.

- BAFFLES & LINERS

Liner

Length

Bafes

8 - BOILER ASSEMBLY

Figure 14 - Circulator Wiring

GREEN TO

GROUND

BLACK

YELLOW

SCREW

WHITE

NOTICE

Ensure all conduit is secured to prevent contact with ue pipe

Figure 15 - Limit Control Wiring

THERMAL/

LWCO

WIRE

RED

WIRE

TO B1

B. Use hand wrench to tighten door hardware and start

with non-hinged side. Use alternating tightening method from non-hinged side to hinged side to tighten door equally until sealed without applying

excessive torque. Never tighten hinged side ange bolt rst or tighten either piece of hardware 100%

without using alternating tightening method

described above.

NOTICE

When securing burner swing door, make sure door is drawn-in equally on both sides.

Failure to follow the prescribed procedure could cause thread damage to casting or a leak in the door seal. If hinged side is tightened before the unhinged side, the hinged side of door cannot

be drawn to provide an air-tight seal. Applying excessive torque will only cause thread damage.

20. Install oil burner.

• Check oil nozzle in burner for size, angle and type, inspect electrode settings, check head setting, check air band and air shutter settings. & Air Settings” on page 49.

• DO NOT install burner without gasket. Place oil burner gasket on face of burner swing door with 4 burner

ange bolts installed part way.

• Align round part of key hole slots of burner ange with burner door bolts. Turn burner to lock in place.

• Tighten all 4 cap screws using diagonal sequence.

• Plug burner power cord into burner harness.

• Attach exible oil hose included in parts box.

See “Oil Burner, Nozzle,

BLACK

WIRE TO

C1, C2

CIRCULATOR

WIRING

Figure 16 - Drain Valve

WHITE

WIRE TO

DRAIN

VALVE

9 - BOILER SYSTEM PIPING

9.1 Connect System Supply And Return Piping

To Boiler

Connect system supply and return piping to correct

boiler ttings.

Size system circulator to supply sufcient ow (GPM)

to allow 20°F temperature differential in system.

When sizing system circulator, use single most

restrictive zone to determine maximum pressure

drop.

Boiler used in connection with refrigeration systems, install boiler so chilled medium is piped in parallel with

heating boiler using appropriate valves to prevent

chilled medium from entering boiler. See

Page 31

If boiler is connected to heating coils located in air handling units exposed to refrigerated air, equip boiler

piping with ow control valves to prevent gravity

circulation of boiler water during operation of cooling system.

Limit control includes low water cutoff function, sensing

water level at control well in top of the rear boiler

section. Periodic inspection and testing is necessary

per instructions provided with limit control.

When installation of boiler is for new heating system, install all radiation units (panels, radiators, baseboard, or tubing) and supply and return mains. After heating

system piping and components have been installed, make nal connection of system piping to boiler.

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

Hot water boiler installed above radiation level must be equipped with low water cut off device. This boiler

is factory equipped with low water cutoff. Periodic

inspection is necessary, per manufacturer’s specic

instructions.

When connecting cold water supply to pressure

reducing valve, make sure clean water supply is available. When water supply is from well or pump,

install sand strainer at pump.

Figure 28,

9.2 Bypass Piping

See Piping Diagrams for illustrations for this section.

Bypass piping may be required for applications listed below. Failure to do so may cause damage due to thermal shock and sustained condensation within the boiler.

Protect boiler from sustained operation of return water temperatures lower than 130°F (54C). Occasionally, temperatures as low as 70°F (21C) may return back to

boiler when a zone that has not been activated for some time is opened. However, most residential systems with nned-tube (aluminum-copper) baseboard radiation contain low volume of water and will not adversely affect boiler. Systems with nned-tube baseboard radiation

typically do not require bypass.

Bypass piping details shown in piping diagrams must be used for any one of following conditions:

• All large water content systems, including cast iron

standing radiators, cast iron baseboard, converted two-pipe steam systems, converted gravity circulation

systems and other similar systems.

• Any system, including nned-tube baseboard, with priority domestic hot water zone.

Install ¾ inch bypass line as shown in piping diagrams for

systems identied above.

Bypass valve cannot protect boiler from sustained

condensing operation for low temperature applications such

as radiant oor heating. These types of system require active controls that prevent return of cold return water to

boiler.

Refer to Radiant Professional’s Alliance (RPA) www.radiantprofessionalsalliance.org for piping recommendations for non-condensing boiler applications.

10 - HYDRONIC PIPING

Figure 17 - Standard Near Boiler Piping

Piping Diagram Legend

10 - HYDRONIC PIPING

Figure 18 - Piping and Wiring Single Zone System With Domestic Hot Water DHW Priority

DHW Heater

FIGURE 18

HYDROSTAT MODEL 3250

TO OIL

BURNER

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

ELECTRONIC FUSE

X-X

ARM-2P

CONTROL

WITH

PRIORITY

DATA PORT

X1 X1

ISOLATED

SWITCH

ISOLATED

SWITCH

CONTROL

PRIORITY ON

X2 L

TANK

DHW CIRC

THERMOSTAT

PRIORITY

ZONE

T+T

W1RTW

LN N

PRIORITY

120VAC CIRCULATORS

ZONE 1

ZONE 2

CIRC

T-STAT

ZONE 2

L N

120 VAC

COMMON

24 VAC @ 1 VA

TO EXTRA

ZONE MODULE

PRIORITY ON

TORQUE TERMINAL SCREWS

6 TO 7 INCH LBS

+ 44 hidden pages