Utica Boilers TriFire TRB 3 Operation and Installation Manual

Download

Page 1

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]

Page 2

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.

Page 3

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)

Page 4

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

Page 5

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

Page 6

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

Page 7

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.

Page 8

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.

Page 9

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

Page 10

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.

Page 11

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.

Page 12

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

Page 13

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

Page 14

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.

Page 15

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

Page 16

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

Page 17

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

Page 18

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.

Page 19

10 - HYDRONIC PIPING

Figure 17 - Standard Near Boiler Piping

Piping Diagram Legend

Page 20

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

Page 21

ZONE VALVE / PUMP

10 - HYDRONIC PIPING

Figure 19 - Multi-Zone Piping and Wiring With Zone Valves And Domestic Hot Water Priority (With

Zone Valve)

(SEE FIGURE 20)

FIGURE 19

HYDROSTAT MODEL 3250

TO OIL BURNER

24VAC FROM

TRANSFORMER

120VAC TO

TRANSFORMER

RELAY 24VAC COIL

120VAC CONTACTS

24 VAC

120 VAC TO XFRM

120VAC

N L

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

TANK

CONTROL

PRIMARY PUMP

L N

TO DPM-2

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

PRIORITY

FROM BOILER

PUMP

L N

ZCZR

AZ-4CP

CIRC

TT T T T T T T

Z1 Z2 Z3 Z4

ZC ON

1 2

43 1 3

PRI ZONE 1

ZONE VALVE

DHW ZONE

VALVE

T-STAT

2 4

ZONE 2

T-STAT

1 2 3 4 21 3 4

ZONE 3

ZONE VALVE

PRIORITY ZR-ZC DPM-2

OPTION SWITCHES

KEY

ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2

OPTION SWITCHES

ZONE 4

OFF

Page 22

ZONE VALVE / PUMP

10 - HYDRONIC PIPING

Figure 20 - Piping and Wiring Multizone System With Zone Valves And Domestic Hot Water Priority

(With Circulator)

FIGURE 20

HYDROSTAT MODEL 3250

TO OIL

BURNER

24VAC FROM TRANSFORMER

120VAC TO

TRANSFORMER

24 VAC

120 VAC TO XFRM

120VAC

N L

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

TANK

CONTROL

PRIMARY PUMP

L N

TO DPM-2

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

PRIORITY

FROM BOILER

PUMP

L N

ZCZR

AZ-4CP

TT T T T T T T

Z1 Z2 Z3 Z4

ZC ON

1 2

43 1 3

PRI ZONE 1

CIRC

ZONE VALVE

DHW CIRC

T-STAT

2 4

ZONE 2

T-STAT

1 2 3 4 21 3 4

ZONE 3

ZONE VALVE

PRIORITY ZR-ZC DPM-2

OPTION SWITCHES

ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2

OPTION SWITCHES

ZONE 4

KEY

OFF

Page 23

10 - HYDRONIC PIPING

Figure 21 - Piping and Wiring Multi-Zone System With Circulators And Domestic Hot Water Priority

FIGURE 21

HYDROSTAT MODEL 3250

TO OIL

BURNER

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

30 VA

ARM-4P

CONTROL WITH

PRIORITY

ELECTRONIC

FUSE

24AC

COMMON

ISOLATED

SWITCH

CONTROL

DATA PORT

X-X

TANK

T-STAT

PRIORITY

ZONE

TWTRTWTRTWTRTWT

THERMOSTATS

1 32 4

PRIORITY ON

ZR-ZC

ZONE 1

ZONE 2

L2N1L N L

ZCXZR

CIRC

DHW CIRC

T-STAT

ZONE 3

CIRC

T-STAT

ZONE 4ZONE 3ZONE 2

ZONE 4

N4L N

ZONE 4ZONE 3ZONE 2PRIORITY

CIRC

PRIORITY ON

L N

120 VAC

COMMON

24 VAC

@ 1VA

TO EXTRA

ZONE MODULE

Page 24

MAX = 4 X DIAMETER

CLOSELY - SPACED TEES

BOILER PUMP

10 - HYDRONIC PIPING

Figure 22 - Primary/Secondary Piping And Wiring With Circulators And Domestic Hot Water

Page 25

10 - HYDRONIC PIPING

FIGURE 22

HYDROSTAT MODEL 3250

BLR CIRC

TO OIL

BURNER

RELAY 120VAC COIL 120VAC CONTACTS

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

30 VA

ARM-4P

CONTROL WITH

PRIORITY

ELECTRONIC

FUSE

24AC

COMMON

ISOLATED

SWITCH

DATA PORT

X-X

TANK

CONTROL

PRIORITY ON

ZR-ZC

ZCXZR

T-STAT

PRIORITY

ZONE

TWTRTWTRTWTRTWT

ZONE 1

THERMOSTATS

1 32 4

ZONE 2

L2N1L N L

CIRC

ZONE 3

T-STAT

ZONE 4ZONE 3ZONE 2

ZONE 4

N4L N

ZONE 4ZONE 3ZONE 2PRIORITY

CIRC

DHW CIRC

PRIORITY ON

L N

120 VAC

COMMON

24 VAC

@ 1VA

TO EXTRA

ZONE MODULE

Page 26

ZONE 1 (PRIORITY ZONE)*

* USE FULL PORT ZONE

VALVE.

FOR OPTIMUM TANK

PERFORMANCE,

CONSIDER USING ZONE

CIRCULATOR.

BOILER

PUMP

MAX = 4 X DIAMETER

CLOSLEY - SPACED

TEES

10 - HYDRONIC PIPING

Figure 23 - Piping and Wiring Primary/Secondary Multi Zone System Piping With Zone Valves

And Domestic Hot Water (With Zone Valve)

SEE FIGURE 24

Page 27

FIGURE 23

ZONE VALVE / PUMP

HYDROSTAT MODEL 3250

10 - HYDRONIC PIPING

TANK

CONTROL

24VAC FROM TRANSFORMER

120VAC TO

TRANSFORMER

24 VAC

120 VAC TO XFRM

120VAC

N L

PRIMARY PUMP

L N

TO DPM-2

PRIORITY

FROM BOILER

PUMP

L N

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP

X-X CONTACT

ZR ON

ZC ON

ZCZR

T-STAT

TT T T T T T T

Z1 Z2 Z3 Z4

T-STAT

OPTION SWITCHES

PRIORITY ZR-ZC DPM-2

OPTION SWITCHES

KEY

OFF

ZONE VALVE / PUMP

PRIORITY

ZR-ZC

DPM-2

RELAY 24VAC COIL

120VAC CONTACTS

AZ-4CP

CIRC

1 2

PRI ZONE 1

DHW ZONE VALVE

43 1 3

2 4

ZONE 2

ZONE VALVE

1 2 3 4 21 3 4

ZONE 3

ZONE 4

ZONE VALVE

TO OIL

BURNER

BLR

CIRC

Page 28

ZONE VALVE

MAX = 4 X DIAMETER

CLOSELY - SPACED

TEES

10 - HYDRONIC PIPING

Figure 24 - Piping And Wiring Primary/Secondary Piping With Zone Valves And Domestic Hot Water

(With Circulator)

Page 29

FIGURE 24

ZONE VALVE / PUMP

HYDROSTAT MODEL 3250

10 - HYDRONIC PIPING

TANK

CONTROL

24VAC FROM TRANSFORMER

120VAC TO

TRANSFORMER

24 VAC

120 VAC TO XFRM

120VAC

N L

PRIMARY PUMP

L N

TO DPM-2

PRIORITY

FROM BOILER

PUMP

L N

INDIRECT WATER HEATER, AQUASTAT OR THERMOSTAT

STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP X-X CONTACT ZR ON

ZC ON

ZCZR

T-STAT

TT T T T T T T

Z1 Z2 Z3 Z4

T-STAT

OPTION SWITCHES

PRIORITY ZR-ZC DPM-2

OPTION SWITCHES

KEY

OFF

ZONE VALVE / PUMP PRIORITY ZR-ZC DPM-2

TO OIL BURNER

RELAY 24VAC COIL 120VAC CONTACTS

AZ-4CP

CIRC

DHW

CIRC

1 2 PRI ZONE 1

43 1 3

2 4

ZONE 2

ZONE

VALVE

1 2 3 4 21 3 4

ZONE 3

ZONE 4

ZONE

VALVE

ZONE VALVE

BLR CIRC

Page 30

10 - HYDRONIC PIPING

Figure 26 Bypass Piping (Fixed Low Temperature Only)

Adjust two throttling valves to maintain at least 130°F - 140°F in boiler return.

TO SYSTEM

WATER INLET

SYSTEM

CIRCULATOR

EXPANSION

TANK

BOILER

FROM SYSTEM

V2V1

ALTERNATE

CIRCULATOR

LOCATION

Figure 25 - Bypass Piping Automatic Mixing Valve

TO SYSTEM

WATER INLET

EXPANSION

TANK

BOILER

FROM SYSTEM

ALTERNATE

CIRCULATOR

LOCATION

Page 31

10 - HYDRONIC PIPING

SHUT OFF

VALVES

SHUT OFF

VALVES

BOILER

SUPPLY MAIN TO

COMBINED HEATING

& COOLING SYSTEM

RETURN MAIN FROM COMBINED HEATING

& COOLING SYSTEM

CIRCULATOR

WATER CHILLER

AIR CUSHION TANK

Figure 27 - Bypass Piping (4-Way Valve Option With Circulator On Supply Side)

TO SYSTEM

FROM SYSTEM

WATER INLET

EXPANSION

TANK

BOILER

Figure 28 - Recommended Piping for Combination Heating and Cooling (Refrigeration) System

ALTERNATE

CIRCULATOR

LOCATION

Page 32

11 - FUEL SUPPLY PIPING

11.1 Installation of oil tank and piping shall conform to requirements of authority having jurisdiction or in absence of such requirements National Board of Fire Underwriters . In addition, refer to NFPA 31 (U.S.) or CSA B139 (Canada)

Installation of oil storage tank, vent, ll pipe and

caps shall conform to requirements of authority having jurisdiction.

• In no case should vent pipe be smaller than 1¼" I.P.S.

• Fill pipe should not be less than 2" I.P.S.

• Suction line from tank to burner should be one

continuous piece of tubing to prevent air entering line

• Suction line, must be ⅜" O.D. copper tubing for runs of 50 feet or less, and ½" O.D. for longer runs.

• Use oil return line, same size as the suction line, on installations where bottom of tank is below fuel unit of burner.

• Bury oil lines or protect from mechanical injury.

• Flare ttings on all oil lines are required. Compression

ttings on suction line often allow air to be drawn into fuel pump, making it difcult to maintain oil pressure at

nozzle.

• Do not run overhead fuel lines from tank to oil burner.

• Follow instructions, attached to fuel pump, for fuel pump and by-pass connections.

• Install two stage fuel unit if tank is more than 20' from boiler in place of single stage pump supplied as standard equipment with burner. Verify rotation and speed are identical and pump is suitable for burner horsepower rating.

• Install oil line lter and shut-off valve in suction line.

• Install Shut-off valves in both suction and return lines at

burner for convenience in servicing burner.

• Allow extra tubing at burner so burner may be removed from boiler for cleaning without disconnecting tubing. See Figure 29 and 29.

• Use exible oil lines so burner swing door can be opened without disconnecting oil supply piping.

Figure 30 - Double Pipe Oil Line

Table 5 - TWO STAGE UNITS,

TWO PIPE SYSTEMS (SEE FIGURE 15)

LIFT

“H”

0 93 FT. 100 FT.

2 85 FT. 100 FT.

4 77 FT. 100 FT.

Maximum Length of Tubing “R”

3/8” O.D.

Tubing (3 GPH)

1/2” O.D.

Tubing (3 GPH)

Figure 29 - Single Pipe Oil Line

6 69 FT. 100 FT.

8 60 FT. 100 FT.

10 52 FT. 100 FT.

12 44 FT. 100 FT.

14 36 FT. 100 FT.

16 27 FT. 100 FT.

18 --- 76 FT.

Page 33

12 - ANTIFREEZE IN THE SYSTEM

12.1 Antifreeze added to boilers must be nontoxic,

and must be of type specically 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. See Table 6 and 7.

Table 6 - BOILER WATER VOLUMES

Number of

Boiler Section

Total Volume

(Gallons)

4 3.6 5 4.3 6 5.1 7 5.9

Table 7 - PIPING WATER VOLUMES

PIPE SIZE

COPPER

PIPE

FACTOR

STEEL 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.

Page 34

13 - 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.

SEE APPROPRIATE ADDENDUM FOR WIRING

DIAGRAMS

13.1 Electrical wiring shall conform to requirements of authority having jurisdiction or in absence of such requirements ANSI/NFPA No. 70, in Canada shall be in accordance with the Canadian Electrical Code C22.2.

Run separate electrical circuit from entry box with fused disconnect switch in this circuit.

Never “jump out” or make inoperative any safety or operating controls.

Page 35

14 - CHIMNEY AND VENTING CONNECTIONS

14.1 Chimney Venting

Oil red boilers with connections to vents or chimneys,

vent installation shall conform to requirements of authority having jurisdiction or in absence of such requirements NFPA 31 Installation Of Oil Burning Equipment (U.S.) or CSA B139 (Canada) and applicable provisions of local building codes.

Installation shall conform to requirements of NFPA31 – Standard for the Installation of OilBurning Equipment and NFPA 211 – Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances for installations and requirements of CSA B139 – Installation Code for Oil-burning Equipment. (Installations in Canada).

Ensure sufcient draft during heating season to allow for safe evacuation of ue gasses.

Boiler can be vented into reclay tile-lined masonry chimney or type L vent or factory built chimney that

complies with type HT requirements of UL103. See Figure 32, Page 37

Chimney Inspection – Prior to installation of any new or replacement fuel burning equipment chimney shall be

inspected by qualied service agency.

A. De-rating may cause condensation on interior

walls of chimney and boiler. Loose mortar can be

indication of history of condensing ue gases upon inside walls of chimney. Do not install chimney until

it meets requirements of NFPA 211 or CSA B139.

B. Unlined Chimney – Do not install boiler if chimney

is constructed of brick only. Only approved clay

liners or listed chimney lining systems shall be used

as specied in NFPA 31 or CSA B139.

C. Abandoned Openings – Seal Openings through

chimney wall that are no longer used in accordance to NFPA 211.

D. Clean Chimney – Chimney shall be free of all loose

debris.

Install draft regulator at least 18” above breech; 18”

of straight run up-stream of regulator ensures proper operation.

Draft Regulator – Use supplied draft regulator with this appliance. Do not use any other draft regulator. See

Figure 31, Page 37

Table 8 - Recommended Minimum Chimney Sizes

FIRING RATE

(gph)

0.60 -1.30 15 8” x 8” 6” 6 ¾” x 6 ¾”

1.31 -1.80 15 8” x 8” 7” 6 ¾” x 6 ¾”

1.81 -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

LIN ER

INSIDE

Page 36

14 - CHIMNEY AND VENTING CONNECTIONS

14.2 Vent and Vent Connector

Vent connector should be kept as short as possible.

Horizontal length of vent connector should not be

greater than 10 feet.

Type L Vent pipe or other suitable material may be

used for vent connector if ue temperature is less than

570° F.

4,5 & 6 section boilers have sheet metal ue collar

spacer included in accessory carton for attaching 5”

diameter vent connector to cast iron ue collar. For 7 section boiler, 6” diameter vent connector attaches directly to cast iron ue collar.

Attach vent connector and ue adaptor ring to cast iron ue collar with three screws. Pre-drill cast iron ue collar to prevent cracking.

Canadian versions have vent spill switch kit included.

Inspect chimney and connector annually for signs of debris and corrosion. Loose mortar at base of chimney may be sign of condensate damage to chimney.

Inspect base of chimney for any signs of seepage.

Discoloration may be a sign of chimney damage. Have

repaired immediately.

Contact qualied service agent immediately to examine

damage and correct. Operation of damaged chimney

may cause venting failure and force ue gases into living space.

If chimney is to be re-lined, use recommendations in NFPA31, Appendix E or CSA B139.

Table 9 - Pressure Drop Between

Over-Fire & Breech

Sections Inches WC

4 0.03-0.05 5 0.05-0.08 6 0.09-0.16 7 0.07-0.16

14.4 Stack Temperature

Higher stack temperature, greater amount of draft generated. Lower stack temperature not only reduces amount of draft created but also increases possibility

ue gases could condense in chimney connector or

stack.

Consult NFPA 31 and CSA B139 for information for

appropriate choice of venting materials. Chimney may have to be lined to create sufcient draft, or chimney may have to be lined to prevent corrosion of masonry chimney. Consult qualied service agency for chimney

requirements in your area.

Bafes – Efciency of boiler is based on insertion of ue bafes supplied with 4,5 & 6 section units. Bafes are installed in 3rd pass (two inner ueways). Refer to “8 - Boiler Assembly” on page 13 for bafe installation. Remove bafes to increase stack temperature.

Remove bafes if any signs of condensation in chimney or chimney connector. Removing bafes may not

address condensation.

14.3 Draft

• Natural draft generated through chimney is dependent

on several factors including, chimney height, temperature of ue gases, cross section area of chimney, chimney wall insulation value, dilution air and total volume of ue gases. Operate boiler for at least 5

minutes before measuring draft.

• Minimum Draft at Breech – Draft induced by the chimney must create at least a neutral pressure of 0 (zero) inches water column (INWC) at breech. Slightly

negative (i.e. suction) pressure is preferred. Pressure at breech cannot be positive since this could create condition that allows ue gas by-products to escape from draft regulator. Draft is to be measured up stream of draft regulator. See Burner Specications.

• Over-re Draft - Measure pressure at 1/4” NPT test port. Three pass boilers have higher pressure drop than single

pass. Table 8A shows expected pressure drop between

over-re and breech. Total pressure drop is difference between over-re draft and breech draft. For example, if over-re draft = 0.05 INWC and breech draft = - 0.05,

total pressure drop = 0.05 - (-0.05) = 0.10 INWC. See Figure 33, Page 37

Page 37

1/4”NPT TEST PORT

14 - CHIMNEY AND VENTING CONNECTIONS

Figure 31 - Proper Draft Regulator Locations

Figure 32 - Typical Chimney Locations

Minimum height must be at least 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.

Must be at least 4 inches thick and be tight.

Must slope up at least 1/4 inch per foot of horizontal run

Tight, smooth, correctly sized

Sealed in thimble

Tight clean-out door

Figure 33 - Pressure Tapping for Checking Draft

FOR OVER-FIRE MEASUREMENT

Draft Regulator

Vane

Balanced Weight

Crimped

End

Page 38

15 - FILLING BOILER

WARNING

Fire, burn, asphyxiation hazard. Turn off service switch to boiler to prevent accidental ring of burner outside combustion chamber. Disconnect

burner power cord from wire harness in front jacket. Tighten swing door fastener completely when

service is complete. Failure to follow instructions in

this manual and understand all requirements could result in death or serious injury.

Inspect Installation Before Starting Burner.

A. Verify venting, water piping, oil piping, and

electrical system are installed properly. Refer to installation Instructions contained in this manual.

B. Conrm all electrical, water and oil supplies

are turned off at source and vent is clear from

obstructions.

Fill Heating System With Water.

A. Failure to clean system can result in clogged air

vents, circulator damage and seized zone valves.

Clean heating system if boiler water is dirty. Refer to “18 Maintenance” on page 53 for proper cleaning instructions for water boilers.

Fill entire heating system with water and vent air from

system. Use following procedure on series loop or multi-zoned system installed as per

from system when lling:

A. Close shut off valve in boiler system piping

between air separator and vertical purge valve.

piping diagrams

, to remove air

NOTICE

Boiler maximum operating pressure is posted on ASME data label located on front lower leg of boiler.

Never exceed this pressure. Do not plug relief valve.

L. It may be necessary to clean air vent assembly

after few days of operation.

Check controls, wiring and burner. Verify all connections are tight and burner is rigid, all electrical

connections have been completed and fuses installed, and oil tank is lled and oil lines have been tested.

B. Isolate all zones by closing zone valves or shut-off

valves in supply and return of each zone(s).

C. Attach hose to vertical purge valve in boiler system

supply piping. Terminate hose in ve gallon bucket or suitable oor drain or outdoor area.

D. Starting with one zone at a time, open zone valve

or shut-off valve in boiler supply and return piping.

E. Open purge valve.

F. Open shut-off valve in cold water supply piping.

G. When zone is completely purged of air, close zone

valve or shut-off valve. Open valve to next zone to be purged. Repeat this step until all zones have been purged. At completion, open all valves.

H. Close purge valve, continue lling system until

pressure gauge reads 12 psi. Close shut-off valve

in cold water supply piping.

I. Open shut off valve in boiler system piping.

J. Remove hose from purge valve.

K. Conrm boiler and system have no water leaks.

Page 39

16 - OPERATING THE BOILER - SYSTEM START-UP

16.1 Setting The Limit Control

Setting can be veried using TEST/SETTINGS button.

Figure 34 - Limit

See Page 41.

16.2 Setting High Limit

To adjust, turn HI

TEMP dial

displayed. See Figure 34. Overall range of High limit setting

is from 100°F to 220°F (82° C to 104° C). High limit (HL) on limit control is factory set at 190°F. Temperature

setting may be varied to suit requirements of installation. Differentials are automatic and will vary based on control

settings and boiler temperature.

until desired setting is

16.3 Setting Low Limit

• Low limit is designed to maintain temperature in boilers equipped with tankless coils used for domestic hot water. Low limit is factory set to OFF.

• For cold start operation, low limit must be turned to OFF.

16.4 Setting Economy Feature (See Figure 35)

• Economy feature is factory set for 1 zone heating

system. To adjust, turn ECONOMY dial D until number displayed equals number of heating zones.

• Do not include indirect water heaters in number of heating zones.

• Economy feature conserves fuel by reducing boiler temperature. If heating system is unable to supply needed heat to house, ECONOMY dial should be turned

Figure 35 - Setting Economy Feature

to lower setting. (example: in a three zone house, turn dial to 2 or 1).

• Conversely, if boiler provides adequate heat, added

SETTING

fuel savings can be achieved by selecting higher setting

(example: 4 or 5).

• If heating and indirect water heater signals were not separated when wiring the control, Economy feature should be turned off to ensure the boiler supplies adequate temperature to heat indirect tank.

16.5 Setting Zone/Indirect Switch

When installing with indirect water heater, zone/indirect switch must be set in the I position, calls to ZC-ZR will

bypass thermal targeting feature and allow boiler to re to

high limit setting to heat indirect tank.

Indirect signal must be separate from all heating zone signals.

If you choose not to separate indirect signal from heating zones, turn off economy feature to ensure boiler supplies adequate temperature to indirect tank.

OFF

1 2 3 4 5

Disables economy function. Will allow boiler to re until hi-limit temp is reached and re-re with a 10° subtractive differential.

Provides lowest level of fuel savings. Use this setting only if the house does not stay warm at higher settings.

Recommended setting for single zone systems.

Recommended setting for Two zone systems.

Recommended setting for Three zone systems.

Recommended setting for Four zone systems.

Recommended setting for Five zone systems.

Provides highest level of fuel savings.

Page 40

16 - OPERATING THE BOILER - SYSTEM START-UP

16.6 Activating Thermal Pre-Purge (optional)

Activation of this feature is not recommended for boilers with tankless coils.

• Limit has thermal pre-purge feature to maximize

efciency. When activated, control will purge higher

boiler temperatures down to 135°F at start of any thermostat call and supply latent energy in boiler to heating zone calling.

• During purge cycle, display will indicate PUR.

• If heat is not sufcient to satisfy thermostat, control will energize burner.

• Feature works with single and multi-zone heating

systems utilizing circulators or zone valves. No change

in wiring is needed.

To Activate Thermal Pre-Purge

Push and hold TEST/SETTINGS button for 20 seconds.

Display will read PURR On.

To deactivate feature, push and hold button a second

time for 20 seconds.

Display will read PURR OFF.

16.7 Control Action On System Start-Up

At initial start-up, with economy feature active, control

establishes 145°F target temperature. To test high limit shut-off function, economy dial must be turned to off.

Once tested, restore economy setting.

If heating demand is high, target will increase over time to

satisfy heat load.

To reduce potential for condensing, control will allow boiler to heat to 120°F prior to energizing the circulator.

16.8 How Thermal Targeting Works

Thermal targeting technology analyzes thermostat activity and continually evaluates how much heat the house

requires.

When it is very cold outside, heat demand is high and limit control will raise boilers target temperature to provide heat.

When outside temperature is mild, heat demand is low.

Limit control will lower boiler’s target temperature saving

fuel.

Page 41

16 - OPERATING THE BOILER - SYSTEM START-UP

Figure 36 - LED Legend

TEMP ACTIVE Indicates Limit Control is

powered and temperature function is active.

ECONOMY TARGET Economy feature is active,

limit control continually sets target temperatures

below high limit setting to maximize fuel efciency. When boiler water reaches target temperature, LED

illuminates and burner shuts down. Boiler water will continue to circulate and heat the house as long as

thermostat call continues. LED will stay lit until boiler

temperature drops below differential set point at

which point boiler will be allowed to re again. Note: LED illuminates regularly during normal boiler

operation.

TEST/SETTINGS Button

To Test Low Water Cut-Off: Press and hold Test/

Settings button for 5 seconds. Display will read LCO.

LWCO TEST

LCO

TEMP HI TEMP Illuminates when boiler water

temperature reaches high limit setting. Remains lit until water temperature falls 10°F. Limit control

prevents burner operation while this LED is on. See Differential explanation page 39.

LWCO ACTIVE Indicates low water cut-off

(LWCO) function of limit control is active. Boiler is factory equipped with Hydrolevel electro-well, enabling control’s low water cut-off function. LED will

be on at all times when control is powered. Important: If control well is replaced with a well

other than Electro-Well, LED will not illuminate indicating control is not providing low water cut-off

functionality.

WARNING

Burn and scald hazard. Do not add water until boiler

has fully cooled. Failure to follow these instructions could result in death or serious injury.

LWCO LOW WATER Illuminates if boiler is in

low water condition. Limit control will prevent burner

operation during this condition.

Important: System must be checked by a qualied service agency prior to resuming operation.

Red Low Water light should illuminate and burner circuit (B1 and B2) should de-energize. Note: Control must be installed with Electro-Well for low water cut-off functionality.

To View Current Settings: Press and release Test/

Settings button in short intervals to sequentially display the

following settings:

Display will return to boiler temperature (default) if Test/

Settings button is not pressed for 5 seconds.

ECONOMY ACTIVE Indicates thermal targeting

function is active and limit control will reduce boiler temperature to conserve fuel. Economy feature is activated using the Economy dial. See “How Thermal

Targeting Works” this page.

Page 42

16 - OPERATING THE BOILER - SYSTEM START-UP

16.9 Oil Burner - Beckett AFG

NOTICE

Instructions are for Beckett AFG with Beckett Genisys primary control. For other burners, refer to manufacturer’s manual.

Nozzle and air settings are given in Table 14 page

50.

For direct vent installation guide, see Direct Vent

Addendum.

1. Prepare Oil Burner Before Starting. (AFG)

A. Check burner air band, air shutter and head setting

(if equipped), readjust if necessary. See

Burner, Nozzle, & Air Settings” on page 46. B. Open all oil line valves. C. Attach a plastic hose to fuel pump vent tting and

provide a pan to catch the oil.

“17 - Oil

2. Prime Pump and Start Oil Burner

A. Open bleed port tting on fuel pump. B. Initiate a call for heat

I. After burner starts, press and hold reset button for

approximately 15 seconds until yellow light turns on.

Indicates button has been pressed long enough.

II. Release reset button. Yellow light turns off and burner

starts up again.

III. At burner startup, click reset button while igniter is

still on. This transitions control to dedicated pump

priming mode, during which the motor, igniter and

valve are powered for four minutes. Yellow light will

be on. C. Bleed pump until all froth and bubbles are purged.

I. If desired, terminate call for heat or hold reset button

for at least one second to exit pump priming mode

and return to standby mode.

II. At end of four minutes, yellow light will turn off and

control will automatically return to standby mode.

III. If prime is not established during four minute pump

priming mode, return to step 2.B.III. to re-enter pump

priming mode. Repeat steps 2.C.I. to 2.C.II. until

pump is fully primed and oil is free of bubbles.

D. Terminate call for heat and control will resume normal

operation. Close bleed port tting on fuel pump.

E. Adjust oil pressure.

I. When checking fuel unit’s operating pressure, reliable

pressure gauge may be installed in either bleeder port

or nozzle port.

II. Initiate call for heat.

III. Locate oil pressure adjusting screw and turn screw

to obtain proper pump pressure, refer to

Burner, Nozzle, & Air Settings” on page 46

“17 - Oil

WARNING

Fire, burn, asphyxiation hazard. Do not loosen or remove any oil line ttings while burner is in

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

WARNING

Fire, burn, asphyxiation hazard. Do not attempt

to start burner when oil has accumulated in

combustion chamber or unit is full of vapor, or

hot. Check operation of all boiler controls before installation of boiler is completed. Failure to follow these instructions could result in death or serious injury.

3. Preliminary Oil Burner Adjustments

A. Adjust Draft Regulator for breech draft of -0.05

(preferred) to 0 inches water column after chimney has reached operating temperature and while burner is running.

B. Use smoke tester and adjust air if necessary for

minimum smoke (not to exceed trace) with minimum of excess air. Check using suitable instrumentation to

conrm CO2 of 11 to 13%. If ame appears stringy instead of solid re, try another nozzle of same type.

Flame should be solid and compact.

C. Turn off burner and remove pressure gauge. Install

gauge port/bleeder plug and tighten. Start burner again.

4. Final Burner Adjustments

adjustments must be made using combustion test instruments.

A. Check draft breech to verify between 0.00” WC and

-0.05” WC, or otherwise adjust draft to -0.05” WC (or less than zero.)

B. 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).

C. 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 sufciently reduce

CO2 by 1/2% to 1%.

D. If clean re cannot be obtained, it is necessary to

verify burner head alignment. If re continues to be

smoky, replace nozzle.

: Final burner

Page 43

16 - OPERATING THE BOILER - SYSTEM START-UP

CAUTION

Do not run boiler unattended until following procedure

is completed. Failure to follow these instructions could result in minor or moderate injury.

E. Once burner is completely adjusted, start and stop

burner several times to assure good operation with no

uttering or rumbling. Verify there are no oil leaks,

record nozzle size, oil pressure, combustion readings,

and air settings on tag or label attached to burner or,

boiler.

WARNING

Electrical shock hazard. Following safety checks shall

be completed by qualied agency. Failure to do so

could result in death or serious injury.

NOTICE

Control contains no eld serviceable parts. Do not

attempt to take it apart. Replace entire control if operation is not as described.

5. Check Genisys Oil Primary Control.

A. Preliminary steps

I. Check wiring connections and power supply.

II. Verify power is on to controls.

III. Verify limit control is closed.

IV. Check contacts between igniter and electrodes.

V. Check piping to oil tank.

B. Safe Start Check

I. Place jumper across cad cell terminals.

II. Initiate call for heat.

III. Burner must not start. Verify green light is on

continuously and control remains in standby mode.

IV. End call for heat and remove cad cell jumper.

Simulate Flame Failure And Ignition Failure

I. Initiate call for heat.

II. After ame is established and burner igniter turns off,

close hand valve in oil supply line.

III. At ame loss, control will enter recycle mode. Verify

green light is ashing. Control will remain in recycle

for 60 seconds.

IV. After 60 second recycle period, control will try to

restart system.

V. After 15 second lockout time, control will lock out

burner and reset button will ash. Verify burner, motor and igniter are off and burner solenoid valve (if

used) is not energized.

VI. Open hand valve in oil line.

VII. Click reset button and verify red light in reset button

shuts off and burner lights.

VIII. End call for heat.

Figure 37 - CAD Cell Location

D. Cad Cell Check : Cad cell resistance can be checked

with use of Genisys display module or Genisys

contractor tool. If not available, cad cell leads can

be unplugged from control and resistance measured

in conventional way. Conduct these tests with ame

present. See Figure 37.

Flame Detection Range

• Normal (0-1600 ohms)

• Limited (1600 ohms to lockout)

E. Power Failure Check: After ame is established,

turn power off to control / burner. Burner should shut down safely. When power is restored, normal ignition sequence should be started.

Page 44

16 - OPERATING THE BOILER - SYSTEM START-UP

Figure 38 - Sequence of Operation

Genisys Control Sequence of Operation

A. Standby. Burner is idle, waiting for call for heat.

B. Valve-On Delay. Igniter and motor are on while

control delays turning on oil solenoid valve for pro-

grammed time.

C. Trial for Ignition. Oil solenoid valve is energized.

Flame should be established within factory set trial for

ignition time (“lockout time”). D. Lockout. Control has shut down for one of following

safety reasons:

I. Trial for ignition (lockout) time expired without ame

being established.

II. Cad cell detected ame at end of Valve On Delay

State.

To reset from hard lockout, hold reset button 15

seconds until yellow light turns on.

E. Ignition Carry-over. Once ame is established,

igniter remains on for 10 additional seconds to ensure

ame stability.

F. Run. Flame is sustained until call for heat is satised.

Burner is then sent to Motor-Off Delay, if applicable, or

it is shut down and sent to Standby.

G. Recycle. If ame is lost while burner is ring, control

shuts down burner, enters 60 second recycle delay, and repeats ignition sequence. Control will continue to

recycle each time ame is lost, until it reaches preset

time allotment. Control will then go into Hard Lockout

instead of recycle. Feature prevents excessive accumulation of oil in the boiler ring chamber.

H. Motor-Off Delay. If applicable, oil solenoid valve is

turned off and control delays turning motor off for set motor-off delay time before control returns to standby.

I. Pump Prime. Igniter and motor are on with solenoid

valve energized for 4 minutes. During Pump Prime

mode, cad cell is disregarded, allowing technician to

prime pump without having to jumper cad cell.

Genisys Control Reset Button Operation

See Table 11 for action control takes when reset button is

pressed for different lengths of time during various burner

operation states.

Table 11 - Genisys Control Reset Button Operation

If burner is in below

state:

Lockout Reset from Soft Lockout

Valve-on Delay, Trial for

Ignition, Ignition Carry-

over

Run (Igniter shut off) No Action

Motor-Off Delay, Standby No Action

Pump Prime No Action Exit Pump Prime mode and return to Standby

Light Color On Continuously Flashing

Red

Green

Yellow

Restricted (Hard) Lockout Soft Lockout

Flame Sensed during normal operation (Possible stray light during standby)

Control is in Pump Prime mode or reset button currently held for 15+ seconds.

“Priming the Pump” page 44

Button Click

(press < 1 second)

Go to Pump Prime

See

Table 12 - Genisys Control Status Lights

Pushing reset button will:

Button Hold

(press > 1 second)

Disable Burner: Anytime

burner is running, press and hold reset button to disable burner. Burner will remain off as long as button is held.

Recycle

N/A

Button Hold

(press 15+ seconds)

Reset from Restricted (Hard)

Lockout

Enables Pump Priming: After reset button has been held for 15 seconds, button can then be clicked during next ignition sequence to enter Pump Prime mode.

Page 45

16 - OPERATING THE BOILER - SYSTEM START-UP

NOTICE

Before starting or resetting control from restricted lockout state, troubleshoot heating system for root cause(s) of lockout.

Genisys Control - Resetting From Restricted or Hard Lockout.

A. Make necessary repairs or adjustment to ensure

safe start condition. B. Ensure appliance is free of oil and oil vapors

before starting or resetting burner

C. If control continues to lock out without satised call for

heat, or fails motor relay check, control enters Hard

(restricted) Lockout in order to limit accumulation of

unburned oil in combustion chamber. D. To reset, hold button down for 15 seconds until red

light turns off and yellow light turns on. E. Always verify control functions according to

specications before leaving installation site. F. Replace control if it does not operate as specied.

Genisys Control - Disable Function

Anytime burner is running, press and hold reset button to disable burner. Burner will remain off as long as button is held.

WARNING

Remove jumper after following check.

16.14 Check Thermostat Operation:

location has important effect on operation of boiler system.

C. After installing nozzle, reassemble nozzle line

electrode assembly and set electrode tip spacing.

D. 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.

Thermostat

A. Follow instructions included with your thermostat.

Typically, thermostat is located about ve feet above oor on inside wall.

B. Thermostat should be located to sense average room

temperature.

Table 10 - Thermostat locations to Avoid

DEAD

SPOTS

Behind

doors

Corners &

alcoves

C. Verify room temperature reaches selected

temperature setting, thermostat should turn boiler’s burner off, and once room temperature falls few degrees boiler starts operating again.

HOT SPOTS COLD SPOTS

Concealed pipes

Fireplace

TV sets Stairwell drafts

Radios Door drafts

Lamps

Direct sunlight

Kitchens

Concealed pipes

or ducts

Unheated room on other side of

wall

16.10 Check High Temperature Limit Control.

Jumper thermostat terminals. Allow burner to operate until shut down by limit. Installation is not considered complete until this check has been made.

16.11 Test Low Water Cut-Off Operation. See

Figure 36, Page 41.

16.12 If Controls Do Not Meet Requirements

replace control and repeat checkout procedures.

16.13 Nozzles And Electrodes

spray angle, and spray pattern nozzle.

A. Refer to “17 - Oil Burner, Nozzle, & Air Settings” on

page 44. B. To install nozzle, remove nozzle line electrode

assembly, if necessary remove retention ring

assembly, install and tighten nozzle. Be careful not to

damage electrode insulators or bend electrode tips.

: Use proper size,

Page 46

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Figure 39 - Beckett Electrode Tip Adjustments

Standard Dimensions (L1, V1) Heads

Figure 41 - Beckett Check/Adjust “Z”

Dimensions L1 & L2 Heads

Figure 40 - Beckett Electrode Tip Adjustments

Standard Dimensions (L2) Heads

Figure 42 - Beckett Check/Adjust ‘Z’ Dimension -

V1 Heads

L1/L2 Heads

See Figure 39. The important “Z” dimension is distance from leading edge of head to end of air tube. This distance for L1 & L2 heads is 1-3/8” if the tube has a straight shroud or 1-3/4” if air tube has conic shroud. “Z” dimension is fac-

tory set for burners shipped with air tube installed. Even if factory set, verify “Z” dimension has not been changed.

Use following procedure to adjust “Z” dimension, if it is not correct:

• Turn off power to burner.

• Disconnect oil connector tube from nozzle line.

• Refer to gure above. Loosen splined nut from nozzle line. Loosen hex head screw securing escutcheon plate to burner housing.

• Place end of ruler at leading edge of head and, using straight edge across end of airtube, measure distance to end of tube. A Beckett T501 gauge may also be used.

• Slide nozzle line forward or back until this dimension is 1-3/8” for L1 & L2 heads if tube has straight shroud, or 1-3/4” if air tube has conic shroud.

• Tighten hex head screw to secure escutcheon plate to burner chassis. Then tighten splined nut and attach oil connector tube.

Recheck “Z” dimension periodically when servicing to ensure escutcheon plate has not been moved. Reset

“Z” dimension if you replace air tube or nozzle line assembly.

V1 heads

See Figure 40. The important “Z” dimension is distance from leading edge of head to end of air tube. This distance for V1 heads is 1-¾”. “Z” dimension is factory set for

burners shipped with air tube installed. Even if factory set, verify “Z” dimension has not been changed.

Use following procedure to adjust “Z” dimension, if it is not correct:

• Turn off power to burner.

• Disconnect oil connector tube from nozzle line. Refer

to gure above. Loosen splined nut from nozzle line.

Loosen hex head screw securing escutcheon plate to burner housing.

• Loosen acorn nut. Move head adjusting plate until “0” lines up with reference indicator on housing, and tighten hex head screw. Place end of ruler at leading edge of head and, using straight edge across end of air tube, measure distance to end of tube. A Beckett T501 gauge may also be used.

• Slide the nozzle line forward or back until this dimension is 1-¾” for V1 heads. Tighten acorn nut.

• Tighten hex head screw to secure head adjusting plate to burner chassis. Then tighten splined nut and attach oil connector tube.

Recheck “Z” dimension periodically when servicing to ensure escutcheon plate has not been moved. Reset

“Z” dimension if you replace air tube or nozzle line assembly.

Page 47

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Figure 43 - Riello Electrode Setting

Figure 44 -Riello Turbulator Setting

Turbulator Setting

A. Loosen nut (1) turn SCREW (2) until INDEX MARKER

(3) is aligned with correct index number as per Burner Settings Table.

B. Tighten RETAINING NUT (1).

NOTE: Zero and four are scale indicators only.

From left to right, rst line is 4 and last line 0. On some

models, scale indicators are 0 and 3.

Figure 45 - Carlin Electrode Setting

Page 48

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 13 - Beckett Chimney Vent Preliminary Burner Settings

Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments.

TABLE 13a: BECKETT CHIMNEY PRELIMINARY BURNER SETTINGS

Boiler

Model

4075 L2

4095 L2

4110 L1

5100 L2

5115

5135

6130 V1

6145 V1

7165 V1

Head

Type

Slot

Static

Plate

3.375U 2.625 0.75

3.375U 2.625 0.95

N/A 2.625 1.10

3.375U 2.625 1.00

N/A 2.5 1.15

N/A 2.5 1.35

2.75M 2.625 1.30

2.75M 2.625 1.45

2.75M 2.625 1.65

Inser-

Depth

Timings

Pre-purge 15 seconds

tion

Firing

Rate

[GPH]

Com-

bustion

liner

Oval

Oval Hago 0.90x60B 150 N/A

None Delavan 0.85x60B 140

V5 Hago 1.00x60B 140

V5 Delavan 1.10x60B 150

V6 Danfoss 1.10x60AS 140

V6 Danfoss 1.10x45AS 175

V7 Danfoss 1.25x45AS 175

Nozzle

Mfr.

Dela-

van

Dela-

van

Nozzle

Type

0.65x60B 140 N/A 0 7 86.0

0.85x60B 125 N/A 1 10 85.0

Pump

Pressure

[PSI]

Setting

“Z”

Head

N/A 2 10 86.5

N/A 1.5 N/A 85.0

N/A 2.0 N/A 84.0

0 4 5 86.5

2 3 5 85.0

2 4 7 86.0

Air

Band

1 10 84.0

Air

Shutter

Rated

AFUE

Efciency

[%]

Post-Purge 15 seconds

TABLE 13b: BECKETT /ECR PART NUMBERS

Boiler Model

4075 AFG70MQASN 240007144 240007232

4095 AFG70MQSSN 240009377 240009385

4110 AFG70MSASN 240009378 240009386

5100 AFG70MQASN 240007145 240007233

5115 NX70LF 240009379 240009387

5135 NX70LF 240009380 240009388

6130 AFG70MKAQN 240007146 240007234

6145 AFG70MKAQN 240009381 240009389

Becket Oil

Burner Model

ECR Oil

Burner Part

Number

with Cover

ECR Oil

Burner Part

Number

Less Cover

7165 AFG70MKAQN 240007183 240007235

Page 49

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 14 - Beckett NX (Direct Vent) Preliminary Burner Settings

Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments.

TABLE 14a: BECKETT DIRECT VENT PRELIMINARY BURNER SETTINGS

Rated

AFUE

Efciency

[%]

Boiler

Model

Head

Type

Insertion

Depth

Firing

Rate

[GPH]

Combustion liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pressure

[PSI]

A i r

Setting

Pressure

Switch

Setpoint

4075 6 Slot

4095

5100 6 Slot

5115 6 Slot

5135 6 Slot

6130 9 Slot

6 Slot

2.5" 0.75

2.5" 0.95

2.5" 1.00

2.5" 1.15

2.5" 1.35

2.5" 1.30

Timings

Pre-purge 15 seconds

Post-Purge 2 minutes

Oval

None Delavan 0.75x45B 175

V5 Hago 1.00x60B 140

V5 Delavan 1.10x60B 150

V6 Danfoss 1.00x45B 175

Delavan

Hago

0.60x60B 150 1.5 0.65" WC 86.0

0.75x60B 155

4.0

4.0 0.85" WC 86.5

1.8 0.85" WC 85.0

2.5 0.85" WC 84.0

2.0 0.65" WC 86.5

0.65" WC 85.0

TABLE 14b: BECKETT/ECR PART NUMBERS

Boiler Model

4075 NX70LC 240007531

4095

5100 NX70LC 240007532

5115

5135

6130 NX70LD 240007533

Beckett

Oil Burner

Model

NX70LC

NX70LF

ECR Oil Burner

Part Number

240009393

240009395

240009396

Page 50

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 15 - Riello 40F Chimney Vent Preliminary Burner Settings

Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments.

TABLE 15: RIELLO 40F CHIMNEY VENT PRELIMINARY BURNER SETTINGS

Boiler Model Head Type

Inser-

tion

Depth

Firing

Rate

[GPH]

Com-

bustion

Liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pres-

sure

[PSI]

Head

Setting

Air

Setting

Rated

AFUE

Efciency

[%]

4075

4095

4110

5100

5115

5135

6130

6145

6165

7165

7180

7190

Reverse 2.75" 0.75

Standard 1.75" 0.95

Standard 1.75" 1.10

Standard 2.75" 1.00

Standard 1.75" 1.15

Standard 1.75" 1.35

Standard 2.75" 1.30

Standard 1.75" 1.45

Standard 1.75" 1.65

Standard 2.75" 1.65

Standard 1.75" 1.80

Standard 1.75" 1.90

Oval Delavan

None Delavan

V6 Delavan

V7 Delavan

0.65x60W 150 1 3.6 86.0

0.75x90B 175 3 5.3 85.0

1.00x90B 125 1 3.1 84.0

0.75x60B 175 1 2.4 86.5

1.00x80B 130 2 2.8 85.0

1.20x80B 125 3 3.4 84.0

1.00x45B 175 2 3.6 86.5

1.25x70B 135 4 4.0 85.0

1.25x80B 175 2 2.8 84.0

1.35x60B 150 4 8.0 86.0

1.35x70B 175 2 3.4 85.0

1.50x70B 160 3 3.2 84.0

Timings

Pre-purge 12 seconds

Riello Boiler Model

Oil

Burner

Model

4075 40F3

4095 40F3

4110 40F5

5100 40F5

5115 40F5

5135 40F5

ECR Oil

Burner

Part

Number

240007502

240009399

240009400

240007503

240009401

240009402

Riello

Boiler

Model

Oil

Burner

Model

6130 40F5

6145 40F5

6165 40F10

7165 40F5

7180 40F10

7190 40F10

ECR Oil

Burner

Part

Number

240007504

240009403

240009404

240007505

240009405

240009406

Page 51

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 16 - Riello 40BF (DIRECT VENT) Preliminary Burner Settings

Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments.

Table 16: RIELLO 40BF DIRECT VENT PRELIMINARY BURNER SETTINGS

Boiler Model

Head

Type

Inser-

tion

Depth

Firing

Rate

[GPH]

Com-

bustion

Liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pres-

sure

[PSI]

Head

Setting

Air

Setting

Pressure

Switch

Setpoint

Rated

AFUE

Efciency

[%]

4075

4095

4110

5100

5115

5135

6130

Reverse 2.75" 0.75

Standard 1.75" 0.95

Standard 1.75" 1.10

Standard 2.75" 1.00

Standard 1.75" 1.15

Standard 1.75" 1.35

Standard 2.75" 1.30

Timings

Pre-purge 12 seconds

Post-Purge 45 seconds

Oval Delavan

None Delavan

V6 Delavan

0.65x60W 150 3 5.0 0.25" WC 86.0

0.75x90B 175 1 4.0 0.25" WC 85.0

1.00x90B 125 2 5.0 0.25" WC 84.0

0.75x60B 175 1 5.0 0.80" WC 86.5

1.00x80B 130 2 5.8 0.80” WC 85.0

1.20x80B 125 4 5.8 0.80” WC 84.0

1.00x45B 175 2 8.0 0.90" WC 86.5

Riello Boiler Model

4075 40BF3

4095 40BF5

4110 40BF5

5100 40BF5

5115 40BF5

5135 40BF5

6130 40BF5

Oil

Burner

Model

ECR Oil Burner

Part Number

240007528

240009407

240009408

240007529

240009409

240009410

240007530

Page 52

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 17 - Carlin (CHIMNEY VENT) Preliminary Burner Settings

Burner settings provided are for initial startup only. Final adjustments must be made using combustion test instruments.

TABLE 1 - CARLIN SETTINGS

BOILER

NO.

4075 3.00” 0.75 OVAL DANFOSS 0.60 x 60 AS 160 0.60/0.65 25% 86.0

4095 3.00” 0.95 OVAL DELAVAN 0.75 x 45 W 160 0.75 35% 85.0

4110 3.00” 1.10 OVAL DELAVAN 0.85 x 60 A 165 0.75 50% 84.0

5100 3.00” 1.00 NONE HAGO 0.75 x 60 B 175 0.75 35% 86.5

5115 3.00” 1.15 NONE DELAVAN 0.85 x 45 A 180 0.85/1.00 40% 85.0

5135 3.00” 1.35 NONE DANFOSS 1.10 x 60 AB 150 1.10/1.25 45% 84.0

TIMINGS

Pre-Purge 15 seconds

Post Purge 15 seconds

INSER-

TION

DEPTH

FIRING

RATE

COMBUS-

TION

LINER

NOZZLE

MFR.

NOZZLE

TYPE

PUMP

PRESSURE

[PSI]

HEAD

BAR

A I R

B A N D

SETTING

Rated

AFUE

Efciency

[%]

Boiler Model

4075 EZ-LF

4095 EZ-LF

4110 EZ-LF

5100 EZ-LF

5115 EZ-LF

5135 EZ-LF

Carline Burner

Model

ECR Oil

Burner Part

Number

240010357

Page 53

18 - MAINTENANCE

DANGER

Before servicing, turn off electrical power to boiler at service switch. Turn off fuel supply to burner

Failure to comply will result in death or serious injury.

NOTICE

Perform regular service and maintenance by

18.3 Relief Valve

• Test relief valve for proper operation. Refer to valve manufacturer’s instructions packaged with relief valve.

18.4 Conventional Expansion Tank

See “Equipment And Accessories” section.

18.5 Diaphragm Expansion Tank

See “21 - Equipment And Accessories” on page 59.

qualied service agency at least once every 12

months to assure safe, trouble free operation

and maximum efciency.

NOTICE

Verify proper operation after servicing.

18.1 Annually

Recommend qualied Service Agency check at lease once a

year:

• Flue passages,

• Combustion chamber area (target wall, re door insulation)

• Burner adjustment,

• Operation of the controls,

• Boiler seals (re door gasket or silicone seal, cast iron

sectional seals, ue collector)

Before start of each heating season (or system has been shut down for extended period of time)

• Recheck whole system for water, oil, and vent piping leaks.

• Replace or patch any leaks or seals that are faulty

• Inspect ue ways at least once a year- Preferably at start of heating season.

• Inside of combustion chamber.

• Clean vent system and boiler ue ways if soot or scale has accumulated. When cleaning, take precaution

to avoid damage to burner swing door insulation. If damaged, or if there is evidence of previous damage,

burner swing door insulation must be replaced immediately.

• Oil Burner and controls.

18.2 Vent Pipe

18.6 WATER SYSTEM

Drain system completely if system is to remain out of service during freezing weather. Water left in system will

freeze and crack pipes and/or boiler.

18.7 Oil Burner Maintenance

Beckett AFG, perform following preventative maintenance

annually, preferably prior to heating season.

• Fuel Filter Replace to prevent contaminated fuel from

• Fuel Pump Unit Replace pump screen and clean pump

• Ignition Electrodes Clean and adjust as per

• Nozzle Replace so as to maintain safe and reliable

• Fan and Blower Housing Keep clean, free of dirt, lint

• Check burner settings and adjust as needed.

NOTE: If any component parts must be replaced, always use parts recommended by burner manufacturer.

18.8 Maintenance Of Optional Low Water Cut Off

Burn and scald hazard. Verify boiler is at zero

pressure before removing relief valve or control well.

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 qualied service agency.

Open safety valve to relieve all internal pressure

prior to proceeding.

Remove control well from top of rear boiler section every ve years and clean any scale or sediment deposits from all

parts exposed to boiler water.

reaching nozzle. Partially blocked fuel lter can cause

premature failure of fuel pump.

unit to maintain fuel delivery to nozzle.

manufacturer’s recommendations, so as to maintain reliable ignition of oil.

combustion efciency. Always replace with exact nozzle

as required in charts. See “17 - Oil Burner, Nozzle, & Air Settings” on page 46.

and oil to maintain proper amount of air fuel requires to burn.

WARNING

Page 54

18 - MAINTENANCE

Steps to inspect, clean and/or replace control well:

Turn off electric service to boiler controls.

Drain boiler water to level below tapping for control

well.

Remove low water cut-off/limit sensor from control

well.

Unscrew control well from tapping.

Inspect portion of control well exposed to water for scale or sediment buildup.

Light deposits may be removed by wiping control well

with damp cloth. Wiping probe with cloth soaked in

vinegar will remove more tenacious lime deposits.

Clean pipe threads of probe to remove old, hardened

pipe dope and other foreign matter.

Apply moderate amount of good quality pipe dope to

pipe threads on control well, leaving two end threads bare. Do not use PTFE (Teon) tape.

Reinstall control well into tapping.

10.

Reinsert low water cutoff/limit sensor in control well and secure with grommet.

11.

Fill system with water and purge.

12.

Restore electric service to boiler.

13.

Fire burner to heat water in boiler 180°F to drive off

free oxygen.

14.

Warning – before returning boiler to service: Follow

low water cut-off test procedure in

Figure 36, Page 41.

• Continue to circulate water for few hours.

• Stop ring boiler.

• Drain system in manner and to location that hot water can be discharged safely.

• Remove plugs from all available returns and wash water side of boiler as thoroughly as possible, using high-pressure water stream.

• Rell system with fresh water.

Add appropriate boiler water treatment compounds

as recommended by your qualied water treatment

company.

Testing pH /alkalinity after boiler and system have been cleaned and relled as previously described, test

pH of water in system. Can be done with pH test kit. pH should be higher than 7 but lower than 11. Add appropriate water treatment chemicals, if necessary, to

bring pH within specied range. With this lower level of

protection, care must be exercised to eliminate all free oxygen in system.

Boiler is now ready to be put into service.

18.10 Frequent Water Addition

Frequent water additions, although unusual for water boiler,

are sign of leaky system. Excessive amounts of make up water supplied to boiler can signicantly shorten life of boiler. Amount of water varies with contamination level of

water. Repair leak and consult with your water treatment specialist for recommendations.

18.9 Boiler And System Cleaning Instructions For Trouble Free Operation

Boiler and system (other than expansion tank) must be full of water for satisfactory operation. Add water to system until boiler pressure gauge registers 12 psi.

Water should come out of all air vents when opened.

Wash Oil and grease which accumulate in new hot water boiler out in following manner:

• Shut off valves have been installed between boiler return manifold and system, to minimize amount of system draining.

• Drain boiler to level below relief valve tapping.

• Remove relief valve using extreme care to avoid damaging it.

• Add appropriate amount of recommended boil out compound.

• Replace relief valve.

• Fill entire system with water and purge.

• Start ring boiler.

• Circulate water through entire system.

• Vent system, including radiation.

• Allow boiler water to reach operating temperature, if possible.

18.11 Attention To Boiler While Not In Operation

NOTICE

Fully drain boiler if not used during winter months

to prevent freeze damage.

Keep manual fuel supply valve shut off if burner is shut

down for extended period of time.

To recondition heating system in fall season after prolonged shut down, follow instructions outlined in See “15 - Filling boiler” on page 38.

Boiler contains controls which may cause boiler to shut

down and not restart without service. If damage due

to frozen pipes is a possibility, heating system should

not be left unattended in cold weather; or appropriate

safeguards and alarms should be installed on heating

system to prevent damage if boiler is inoperative.

Keep boiler and area around it clean. Never burn refuse or any material other than specied fuel in your boiler. Have your boiler checked each year by qualied service agency.

Page 55

19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS

DANGER

Before servicing, turn off electrical power to boiler at service switch. Turn off fuel supply to burner.

Failure to comply will result in death or serious injury.

WARNING

Fire, burn, asphyxiation hazard. Turn off service switch to boiler to prevent accidental ring of burner outside combustion chamber. Disconnect

burner power cord from wire harness in front jacket. Tighten swing door fastener completely when

service is complete. Failure to follow instructions in

this manual and understand all requirements could result in death or serious injury.

19.1 Oil Boiler Cleaning Instructions

Clean ueways. Figure 46, Page 56.

A. Shut off power to burner. B. Access to combustion chamber, remove swing door

bolts. If boiler is equipped with exible fuel line(s),

swing door open.

C. Remove vent connector.

D. Remove liners & bafes (if equipped) from ue

passages. Bafes are installed in 3rd pass (two inner ue ways.)

E. Clean 3rd Pass – Insert 2” Dia. x 42” long wire or ber

bristle brush into each of two 3rd passes. Using long strokes, push brush all the way through boiler until brush has exited the smoke box opening.

Pull brush all the way forward until it has exited front of boiler.

Continue this operation for entire height of ue way until clean. Repeat operation for other 3rd pass ue

way.

F. Clean 2nd Pass – Insert wire or ber bristle brush into

each of two 2nd passes. Using long strokes, push brush all the way through boiler until brush hits back

wall of reversing chamber. Pull brush all the way

forward until it has exited front of boiler.

Continue operation for entire height of ue way until clean. Repeat operation for other 2nd pass ue way.

Clean combustion chamber and bafes. Use wire

or ber bristle brush to clean surfaces of combustion chamber and bafes. Vacuum all of loose debris in

bottom of combustion chamber.

After cleaning: Vacuum all remaining debris as necessary. Inspect burner swing door insulation, and rope gasket for signs of damage. If damaged, replace as needed.

Re-assemble boiler.

A. Insert liner and bafes (if equipped) into correct ue

way. Bafes are installed in 3rd pass. (Two inner ue

ways) B. Inspect chimney and clean if necessary. C. Clean and re-attach vent connector onto rear of the

boiler with three screws.

NOTICE

When securing burner swing door verify door is drawn-in equally on both sides. Do not overtighten door bolts. Rope gasket will provide sufcient seal

when door is snugged into place.

D. Tighten swing door hardware to provide adequate

seal to rope gasket around perimeter of door. Use

alternating tightening method from non-hinged side to

hinged side cap screws to pull door tight equally.

WARNING

Asphyxiation hazard. A clean and unobstructed

chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely.

Inspect periodically throughout heating season for any obstructions. Failure to follow instructions in this manual and understand all requirements could result in death or serious injury.

NOTICE

Connect boiler to approved chimney in good

condition. Property damage could result if boiler is connected to dirty or inadequate chimney. Inspect

interior of chimney ue and clean before start of

heating season.

G. Do not start burner unless burner swing door and vent

connector are secured in place. H. Clean passage from combustion chamber to 2nd pass. I. Vacuum loose debris in bottom of combustion chamber

and smoke box.

19.2 Oil Burner Cleaning Instructions

Consult burner manufacturer’s instructions.

Page 56

19 - OIL BOILER/BURNER CLEANING INSTRUCTIONS

Figure 46 - Cleaning the Boiler

FLUE BRUSH

FRONT VIEW

FLUE BRUSH

BRISTLE

BRUSH

VACUUM

HOSE

3RD PASS

COMBUSTION CHAMBER & 2ND PASS

VACUUM

HOSE

Page 57

20 - TROUBLESHOOTING

20.1 Combustion

A. Nozzles- See “17 - Oil Burner, Nozzle, & Air Settings”

on page 46. B. Fuel leaks - Any fuel leak between pump and nozzle

is detrimental to good combustion results. Look for

wet surfaces in air tube, under ignitor, and around air

inlet. Repair any such leaks as they may cause erratic

burning of fuel and in extreme case may become re

hazard. C. Dirt - Fuel lter is required to prevent clogging nozzle

or nozzle strainer and produce poor spray pattern

from nozzle. D. Water - Water in fuel in large amounts will stall fuel

pump. Water in fuel in smaller amounts will cause

excessive wear on pump. Water doesn’t burn, it chills

the ame and causes smoke and unburned fuel to

pass out of the combustion chamber and clog ue

ways of the boiler. E. Cold Oil - If oil temperature approaching fuel pump is

40°F or cooler, poor combustion or delayed ignition

may result. Outside fuel tank above grade or fuel lines

in shallow bury may be the cause. F. High Altitude Installation - Air openings must be

increased at higher altitudes. Use combustion analyzer

and set to 11.5% for initial setting. G. Start up noise - Late ignition is cause of start up

noises. If it occurs recheck for electrode settings,

ame shape, air or water in fuel lines.

H. Shut-down noise - Post Purge timed 15 seconds

should eliminate shut-down noise.

I. No oil to burner.

II. Shortened electrodes

III. Clogged nozzles.

IV. Airow too high.

V. Ignitor module defective.

VI. CAD cell defective.

VII. Oil valve stuck open or closed.

To isolate fuel problems: disconnect fuel system and re out of auxiliary container of clean, fresh, warm #2 fuel

oil from another source. If burner runs successfully when drawing out of container problem is in fuel or fuel lines.

If ame is not established within 15 seconds of oil valve

actuation (known as Trial For Ignition or TFI) soft lockout

will occur. Soft lockout is indicated by ashing red LED

located on oil primary control.

NOTICE

Restricted lockout without retries will occur if ame

is lost three times during one call for heat. this is

indicated by a steady on red LED.

20.2 Oil Primary Control

I. Burner (control) will not come on.

I. No power to control.

II. Control is in soft lockout or restricted mode. Press

reset button for more than 1 second to exit soft

lockout. If control has recycled three times within

same call for heat, it will enter into restricted mode.

To reset from restricted mode, refer to Page 41 for

more details.

III. CAD Cell seeing light.

IV. CAD cell is defective.

J. Burner (control) will light, then shut down after short

time, then restart after one (1) minute.

I. CAD cell is defective.

II. Air leaking into oil line causing ame out.

III. Defective nozzle causing ame to be erratic.

IV. Excessive airow or draft causing ame to leave

burner head.

V. Excessive back pressure causing erratic ame.

K. Control locks out after trial for Ignition. (TFI)

Page 58

20 - TROUBLESHOOTING

IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .

POSSIBLE CAUSE WHAT TO DO

Thermostat is not set correctly Reset thermostat

Burner is not operating properly Adjust burner per instructions.

Check over-current protection. Check to be sure electric power supply cir-

No electric power to boiler

Controls out of adjustment Reset according to instructions.

cuit is “ON”. There may be as many as 3 safety shut-off switches installed. Look for a red plate which may be on the service switch.

Circulating pump not running

Poor electrical contact Check all control terminals and wire joints.

Chimney ue is blocked Have the chimney professionally cleaned.

Check over-current protection. Check relay operation. Check power to circulator.

RELIEF VALVE LEAKING . . .

POSSIBLE CAUSE WHAT TO DO

Corrosion and/or deposits on

seat.

Water logged expansion tank Drain tank, follow instructions to provide air buffer.

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.

Open valve manually. Allow water to run and clear valve seat.

LIMIT CONTROL TROUBLESHOOTING GUIDE

System Condition Diagnostic Condition Check Action

Boiler is cold,

house is cold.

Boiler is hot,

house is cold.

Burner will not

turn off.

Display off 120 VAC system power Turn system power on

Display on 24 VAC T-T No 24 V; replace control

24 V present; disconnect

thermostat, short T-T

120 VAC at B1-B2 • If no, replace

Low Water status light • If illuminated, nd and repair water

Display on 120 VAC at C1-C2 • 120 vac at C1-C2, check wiring to

Display On Burner wired incorrectly. L1

(black) and Limit (red) are

reversed. See wiring diagram

for installed burner.

Boiler starts, check wiring and thermostat

• If yes, check burner and wiring

leak(s).

pump

• Wiring OK, is pump running?

• If not, replace pump.

• If pump is running, check for trapped

air or closed zone valves.

Re-Wire burner.

Page 59

21 - EQUIPMENT AND ACCESSORIES

21.1 Limit Relay Control (provided)

Water temperature limit control in limit relay is adjustable. See Limit instructions for how to set limit temperature.

21.2 Drain Valve (provided)

Drain valve is manually operated valve, means of draining

all water from boiler and heating system. Installed in casting below burner door.

21.3 Circulator

• Forced hot water systems require 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.

• Circulator should be connected to supply main and must be wired into boiler’s electrical system. “9 - Boiler

System Piping” on page 18, for piping congurations

with circulator located on supply main piping using zone

circulators or zone valves.

• When piping is 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.

21.4 Main Air Vent: (Not Provided)

Before system is lled with water, there is air in pipes and radiation units. Some air will be trapped as system is lled. It is possible to eliminate most of this air through air vents on radiation units. Main air vent will speed and simplify this process. Main air vent should be installed on highest point

in supply main.

21.6 Conventional Expansion Tank (Not Provided)

In a properly assembled system, expanding water ows

into an expansion tank.

• Expansion tank should be sized correctly because im-

• It is important to install tank higher than top of boiler.

• Expansion tank is partially lled with air. Air compresses

• Tank also serves as trap for excess air in the system. Air

• It is possible for a tank to become “waterlogged” (lled

21.7 Diaphragm Expansion Tank (Not Provided)

Diaphragm type expansion tank takes place of conventional

expansion tank.

• Carefully read instructions packed with your tank

• Tank typically comes with 10-12 psi air charge. Same as

21.5 Automatic Fill Valve (Not Provided)

Hot water system must be lled with water. Adding new

water, when needed can be done manually (by use of hand

valve in water supply line). This 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. It does not require electrical connection.

• Diaphragm type expansion tank can be mounted on air

• Air eliminator tting or air purger is not provided. Air

properly installed or sized expansion tank may result in

frequent lifting of relief valve or other heating system

problems.

Connecting pipe from boiler to expansion tank shall rise continuously up to expansion tank so that air can rise into expansion tank.

as water expands, thus forming an air pressure cushion. This “spring-like” cushion serves to maintain correct operating water pressure regardless of water temperature.

This assures a “full measure” of water, even in highest

radiation unit of the system.

can cause noises in pipes and inefcient circulation in

radiators if left in piping system.

with water). It can also become overlled with air when lling system with new water. Fittings on tank and in line

to tank are for bleeding off excess air and water.

assembly. Expansion tank should be sized and installed correctly. Improperly installed or sized expansion tank

may result in frequent lifting of relief valve or other

heating system problems.

pressure produced in system by automatic ll valve set to ll boiler to 10-12 psi with fresh water. When system is rst lled, tank will ll partially with water. As water is

heated, and system pressure increases, water expands into tank and compresses air in the tank. This compressed air cushion permits water in the system to expand as temperature changes and assures “full measure” of water,

even in highest radiation unit of system.

purger tting or at any other convenient place in supply

or return line. It is recommended to locate diaphragm type expansion tank in supply line with circulator located

after expansion tank. This conguration allows circulator to “pump away” from expansion tank for improved air

elimination and system performance.

eliminator tting or air purger is used to help remove

air from system before it reaches radiators. It should be installed in supply line. Air left in system can cause noises

in pipes and inefcient circulation in radiators.

Page 60

21 - EQUIPMENT AND ACCESSORIES

Figure 47 - Grundfos Pump Curve

m Head

Head (feet)

US GPM

5 10 15 20

m /h

1 2 3 4 5

Model Watts Volts Amps Capacitor

UP 15-42F 85 115 0.74 10µF/180V*

*Supplied with pump

Figure 48 - Taco Pump Curve

Model Volts Amps Capacitor

007-F5 115 0.70 Supplied w/ pump

Page 61

NOTES

Page 62

NOTES

Page 63

SERVICE RECORD

Company Address & Phone #Company Name & Tech InitialsService PerformedDate

Page 64

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.

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com

Utica Boilers TriFire TRB 3 Operation and Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual