Utica Boilers TriFire TRB 3 Operation and Installation Manual

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Models

TRB4075

TRB4095

TRB4110

TRB5100

TRB5115

TRB5135

TRB6130

TRB6145

TRB6165

TRB7165

TRB7180

TRB7190

An ISO 9001-2008 Certified Company

TRIFIRE SERIES II

High Efficiency

OilFiredHotWaterBoiler

INSTALLATION,OPERATION& MAINTENANCE MANUAL

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com

P/N# 240009350, Rev. E [12/2014]

TRIFIRE OIL-FIRED CASTIRONHOT WATER BOILER

Models

TRB5100

TRB6130

Per Energy Star specifications, 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 specifications outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.

2

DIMENSIONS

 

DIMENSIONS

 

 

Flue Size

 

Dimension

Sections

Inches

 

A

 

Inches

 

(cm)

 

 

 

(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)

3

 

 

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 Certificate..................... ...............................................................................

70

4

1 - INTRODUCTION

! WARNING

Installations of boilers and venting shall be done only by a qualified 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 fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

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.

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 fired natural draft (chimney vented) oil fired 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.

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 firing #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

5

2 - SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualified 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

Modification, substitution or elimination of factory equipped, supplied or specified 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 fiberglass wool and refractory ceramic fibers. Possible cancer hazard. May cause irritation to skin, eyes and respiratory tract. To avoid this hazard, wear a dust mask and gloves when handling fiberglass and ceramic fibers.

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.

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. Such applicable requirements take precedence over general instructions of this manual.

!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.

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.

! 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.

2.6 Requirements for Commonwealth of Massachusetts:

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

• Installation by licensed plumber or gas fitter.

6

3 - BEFORE YOU START

3.1 Installation and Operation

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

2.Before servicing, allow boiler to cool. Always shut off any electricity and oil supply to boiler when working on it.

3.Inspect oil line and connections for leaks.

4.Verify oil burner nozzle is proper size. Over-firing will result in early failure of boiler sections, and result in a potentially dangerous situation.

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

6.Verify adequate air supply for complete combustion.

7.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.

8.Consider system total water volume, temperature, initial fill 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.

9.Boiler manufacturer recommends initial fill pressure of 10-12 psi. For higher fill pressures increase expansion tank’s air charge to match fill 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 float 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, sufficient 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.

1.Causes of oxygen contamination may be:

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

B.Absorption through open tanks and fittings.

C.Oxygen permeable materials in the distribution system.

2.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 fittings which allow oxygen absorption.

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

7

4 - RATINGS & CAPACITIES

Table 1 RATINGS & CAPACITIES

OIL-FIRED HOT WATER BOILERS

Number

Firing

 

Heating

Net

*MAWP

 

Min. relief

Max.

Chimney

Chimney

Flue

Input

AHRI

AFUE

Valve

Water

Liner Size

Liner

of

Rate

Capacity

Water

Size

Size

[Mbh]

Rating

[%]

Capacity

Temp

Round

Sections

[GPH]

[Mbh]

[psi]

[Square

[Inches]

 

 

 

 

[Mbh]

 

 

[Mbh]

[°F]

[Inches]

Inches]

 

 

 

 

 

 

 

 

 

 

 

 

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

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 fired 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 Efficiency

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. finned tube baseboard, cast iron radiators, radiant floor, 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.

8

5 - LOCATING THE BOILER

 

 

 

7. Fresh air for combustion and ventilation must be avail-

! WARNING

 

 

 

able at boiler. Ventilating and combustion air must

Fire hazard. Do not be install on carpeting. Failure

 

 

 

enter boiler room without restrictions.

to follow these instructions could result in death or

 

8. Installation shall conform to requirements of authority

serious injury.

 

having jurisdiction or in absence of such requirements

1. Boiler is suitable for installation on combustible

in United States, follow NFPA 31 Installation of Oil

Burning Equipment. In Canada, use CSA B 139, latest

flooring. Do not install boiler on carpeting.

revision.

 

 

 

 

2. Locate boiler in front of final position before removing

 

 

 

 

9. Clearance to venting is for single wall flue pipe. If Type

crate.

L vent is used, clearance may be reduced to minimum

3. Locate unit so vent pipe connection to chimney will be

required by vent pipe manufacturer.

 

 

short and direct.

 

 

 

 

 

4. For basement installation, provide solid elevated base,

 

 

 

 

 

such as concrete, if floor is not level, or if water may be

 

 

 

 

 

encountered on floor around boiler.

 

 

 

 

 

 

 

Table 2 - BOILER CLEARANCES

5. Provide recommended service clearance, if applicable,

 

 

 

 

 

Accessibility,

as follows:

 

Combustible

 

Unit

 

Cleaning,

• Clearance from Jacket Front Panel

 

Clearance

 

24” for servicing burner

 

 

and Servicing

 

 

 

• Clearance from Jacket Side Panels

 

 

 

 

 

Top

12” (32 cm)

 

24” (61 cm)

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

 

 

 

 

 

Right Side

2” (5 cm)

 

24” (61 cm)

mounted, otherwise 2” with burner removed.

 

 

 

 

 

Left Side

2” (5 cm)

 

24” (61 cm)

• Clearance From Jacket Rear Panel

 

Floor

Combustible

 

No Requirement

12” minimum for rear smoke box cleaning. (Note:

 

 

 

 

 

Front

17” (43 cm)

 

24” (61 cm)

this dimension will also be controlled by horizontal to

 

Back

See Flue

 

18” (46 cm)

vertical to horizontal smoke pipe arrangement. See

 

Flue

9” (23 cm)

 

9” (23 cm)

Figure 1.

 

All distances measured from the boiler jacket or flue.

6. Minimum clearances to combustible material see

 

 

 

 

 

 

 

 

 

 

Figure 1 and Table 2.

 

 

 

 

 

 

 

 

 

 

 

Figure 1 - Clearances to Combustible Construction

 

 

 

 

9

6 - INSTALLATION REQUIREMENTS

Figure 2 - General Requirements For A Typical Installation

NOTICE

Shut off manual fuel supply valve if burner is shut down for extended period of time.

RELIEF

VALVE

CHECK LOCAL CODES FOR MAXIMUM DISTANCE FROM

FLOOR, OR OTHER ALLOWABLE

SAFE POINT OF DISCHARGE.

10

7 - FRESH AIR FOR COMBUSTION

! WARNING

Asphyxiation, fire 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 fireplace or kitchen or bathroom exhaust fan. These devices rob boiler and water heater of combustion air.

1.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.)

2.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.

3.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 unconfined space. If the result is less than 50 ft3/1000 BTU/hr, then the space is considered a confined space.

4.When a boiler is located in an unconfined space of a conventionally constructed building, fresh air infiltration through cracks around windows and doors normally provides adequate air for combustion and ventilation.

5.Provide outdoor air for boiler located in a confined space or an unconfined 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:

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.

Alternate method for boiler located within confined space: Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that the combined volume of all spaces meet criteria for unconfined 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.

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

Figure 3 - Air Openings For Boiler Located In

Confined Space (Utility Room)

11

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

Fresh Air

¼” Mesh

Wood

Metal

Screen

Louvers

Louvers

Duct Size

 

 

 

(Btuh)*

(Btuh)*

(Btuh)*

 

 

 

 

 

3 ½” x 12”

144,000

36,000

108,000

 

 

 

 

8” x 8”

256,000

64,000

192,000

 

 

 

 

8” x 12”

384,000

96,000

288,000

 

 

 

 

8” x 16”

512,000

128,000

384,000

 

 

 

 

*Btuh = British Thermal Units per hour based on opening covered by ¼” mesh screen , wood louvers, or metal louvers.

Figure 4 - Fresh Air Openings

12

8 - BOILER ASSEMBLY

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. Boiler is secured to base with 4 screws. Remove all securing hardware.

3.Move boiler into permanent position by sliding or walking into place.

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

5.Open burner swing door. Proper method to closing and securing burner swing door opened for inspection, cleaning or field 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.

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 flexible oil line in order to swing door open.

6.Inspect Swing door insulation and rope gasket.

A.Inspect fiber 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 flue ways make an impression in door insulation as designed.

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

Figure 5 - Reversible Hinge

NOTICE

For purpose of these instructions, all pipe connections shall use pipe dope or Teflon tape to assure water tight connections unless otherwise instructed. Steps 6 thru 16, Figure 10, Page 15.

7.Open accessory carton and remove contents. Identify components using illustrations throughout this section applicable to your installation.

8.Remove top panel. Remove sheet metal screws 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. Thread thru 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. Assemble onto elbow.

Figure 6 - Adapter Assembled Onto Elbow

1 1/4” ADAPTER

1 1/4 x 3/4 x 1 1/4 RELIEF VALVE ELBOW

13

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 facing toward front of boiler and joint is water tight.

12.Install Limit control mounting plug in upper 3/4”NPT port facing front.

13.Install Limit control & harness assembly. Loosen mounting screw on bottom of limit control.

A.Mount control on mounting plug and tighten screw to secure control. See Figure 7.

B.Confirm 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 8 - Grommet

SENSOR IN WELL

WITH GROMMET

Figure 9 - Relief Valve

Figure 7 - Control On Mounting Plug w/Screw

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 floor 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. See Figure 9.

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.

15.Check installation of liners and baffles (Not all models). See Table 4, Page 16.

A.Check oval (4 section only) or V-shaped (certain 5 section models and all 6 and 7 section models) liner. See Figures 11 & 12. Liner should be flush with front edge of heat exchanger fins.

B.Flue way baffles (4, 5, 6 section only) are factory installed in 3rd pass. Insure baffles are inserted in flue way such that position tab touches casting between

2nd and 3rd Pass flue way. See Figure 13, Page 16.

Efficiency of boiler is based on insertion of flue way baffles in 4, 5 and 6 section units. Baffles will generate lower gross stack temperatures entering chimney. This has the potential under certain operating conditions to cool flue gases below dew point, creating condensation on interior chimney and chimney connector surfaces. Remove baffles to increase stack temperature if there are any signs of condensation in chimney or chimney connector. Removing baffles alone may not address condensation depending on other boiler and heating system operating conditions.

NOTICE

Flue gas condensate is corrosive, which requires special consideration and must be addressed immediately.

14

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

RELIEF VALVE

BACK OF BOILER

15

8 - BOILER ASSEMBLY

Figure 11 - Oval Liner

Figure 12 - V-Shaped Liner

Figure 13 - 3rd Pass Baffles

Table 4 - BAFFLES & LINERS

Sections Liner Liner Baffles

Length

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.

16.Connect Field Wiring. See “13 - Electrical Connections” on page 34.

A.Route wire harness from burner to Limit control through rear jacket panel. See Figure 15, Page 17. 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 Figure 15, Page 17.

D.120 volt power supply field wiring connects to limit control. Provide appropriate overcurrent protection and service disconnect switch.

E.Wire power supply. See Figure 15, Page 17. 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. Place on top of side panels. Position tabs in top panel into slots in side panels. Push top panel toward back of boiler. Install rear panel screws.

18.Install drain valve. Install drain valve with hose 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.

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

16

8 - BOILER ASSEMBLY

Figure 14 - Circulator Wiring

GREEN TO

GROUND

BLACK SCREW TO

YELLOW

WHITE

TO

WHITE

NOTICE

Ensure all conduit is secured to prevent contact with flue pipe

Figure 15 - Limit Control Wiring

THERMAL/

LWCO

WIRE

PIN

RED

WIRE

TO B1

BLACK

 

WHITE

 

WIRE TO

WIRE TO

 

C1, C2

B2

L1

CIRCULATOR

 

 

WIRING

 

 

 

 

Figure 16 - Drain Valve

DRAIN

VALVE

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 flange bolt first 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. See “Oil Burner, Nozzle, & Air Settings” on page 49.

DO NOT install burner without gasket. Place oil burner gasket on face of burner swing door with 4 burner flange bolts installed part way.

Align round part of key hole slots of burner flange 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 flexible oil hose included in parts box.

17

9 - BOILER SYSTEM PIPING

9.1 Connect System Supply And Return Piping

To Boiler

Connect system supply and return piping to correct boiler fittings.

Size system circulator to supply sufficient flow (GPM) to allow 20°F temperature differential in system.

When sizing system circulator, use single most restrictive zone to determine maximum pressure drop.

1.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 Figure 28,

Page 31.

2.If boiler is connected to heating coils located in air handling units exposed to refrigerated air, equip boiler piping with flow control valves to prevent gravity circulation of boiler water during operation of cooling system.

3.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.

4.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 final connection of system piping to boiler.

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

5.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 specific instructions.

6.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.

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 finned-tube (aluminum-copper) baseboard radiation contain low volume of water and will not adversely affect boiler. Systems with finned-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 finned-tube baseboard, with priority domestic hot water zone.

Install ¾ inch bypass line as shown in piping diagrams for systems identified above.

Bypass valve cannot protect boiler from sustained condensing operation for low temperature applications such as radiant floor 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.

18

10 - HYDRONIC PIPING

Figure 17 - Standard Near Boiler Piping

Piping Diagram Legend

19

10 - HYDRONIC PIPING

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

DHW Heater

FIGURE 18

 

 

 

 

 

 

 

 

 

 

 

INDIRECT WATER

 

 

TANK

 

 

 

 

 

 

HEATER, AQUASTAT

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

OR THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T-STAT

 

 

 

 

 

 

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

PRIORITY

 

ZONE 2

 

 

 

 

 

 

 

ZONE

 

COMMON

 

 

DATA PORT

+

 

 

 

 

 

TW

 

TR

TW

2 TR

 

 

1

 

 

 

ELECTRONIC

 

 

 

24 VAC @ 1 VA

 

 

FUSE

 

 

 

 

 

 

 

 

 

HYDROSTAT

 

 

 

 

 

ZONE 1

ZONE 2

SCREWSTERMINALTORQUE

MODEL 3250

 

+

 

+

+

 

 

 

 

 

 

LBSINCH7TO6

 

 

 

 

 

 

 

 

 

 

 

CT

 

 

 

 

 

 

 

 

 

 

 

 

PRIORITY ON

 

 

 

 

 

TO EXTRA

 

 

 

 

 

 

 

 

 

 

 

ZONE MODULE

 

 

X-X

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRIORITY ON

 

ARM-2P

 

 

 

 

 

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

 

WITH

X1

X1

X2

X2

L 1 N

L

2 N

L

N

 

PRIORITY

 

 

ISOLATED

ISOLATED

PRIORITY

 

ZONE 2

 

120 VAC

 

 

SWITCH

SWITCH

120VAC CIRCULATORS

 

 

 

 

 

 

 

 

 

 

 

 

 

CIRC

 

 

 

TO OIL

 

 

 

 

DHW

 

 

 

 

 

 

 

 

 

 

CIRC

 

 

 

 

 

 

BURNER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L

 

 

 

 

 

 

 

 

 

 

 

120 VAC

 

 

 

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

 

 

 

20

 

 

 

 

 

 

 

 

 

 

 

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