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Utica Boilers TriFire TRB 3 Operation and Installation Manual

1. n LT STATUS HYDROSTAT ERAN fu MODEL 3250 i PRIORITY PUMP Ll ZRON 120VACTO TRANSFORMER L ZCON 120 VAC TO XFRM acus ERMA Y FROM BOILER N t en 28 zc ZN RSS gt Ieee ecce ecca ecca A Lupa fu i i zc R ERE 241 FE zh TO OIL RELAY aS 24VAC COIL BURNER 120 CONTACTS ds 4 poe 120 VAC INDIRECT WATER HEATER AQUASTAT ORTHERMOSTAT ZONE VALVE PUM PRIORITY 29 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 FROM SYSTEM TO SYSTEM SYSTEM CIRCULATOR WATER INLET gt X EXPANSION TANK CIRCULATOR LOCATION BOILER Figure 25 Bypass Piping Automatic Mixing Valve FROM SYSTEM WATER INLET EXPANSION TANK ALTERNATE CIRCULATOR LOCATION BOILER 30 10 HYDRONIC PIPING Figure 27 Bypass Piping 4 Way Valve Option With Circulator On Supply Side TO SYSTEM FROM SY
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3. __ OR THERMOSTAT CONTROL DATA PORT PRIORITY Q 90000000 ZONE 6 comon ELECTRONIC 00000000 5 o 0 5 24AC oi ro 5 PRIORITY ON Loo Lo oJ Fo 30VA of fo oi ot a D ats tots fps fpi CUL COMMON xx ZR ZC o a C 2 2 tose ue EX PRIORITY ON LI 10 ARM 4P ZC ZR Ron Ho 2 CONTROL WITH PRIORITY 120 VAC TO OIL BURNER 120VAC COIL D 120VAC CONTACTS ED d 120 VAC 25 10 HYDRONIC PIPING Figure 23 Piping and Wiring Primary Secondary Multi Zone System Piping With Zone Valves And Domestic Hot Water With Zone Valve ZONE 4 ZONE 1 PRIORITY ZONE USE FULL PORT ZONE VALVE FOR OPTIMUM TANK PERFORMANCE ZONE CIRCULATOR 5 2 MAX 4 X DIAMETER 7 CLOSLEY SPACED TEES WATE
4. o of of Fo of Fo ets fpa fid C C C 45O PRIORITY ON COMMON QA TO EXTRA ZONE MODULE ra emag al ARM 4P CONTROL WITH PRIORITY LI ZC ZR 120 VAC TO OIL BURNER 23 10 HYDRONIC PIPING Figure 22 Primary Secondary Piping And Wiring With Circulators And Domestic Hot Water ZONE 1 PRIORITY ZONE p MAX 4 X DIAMETER CLOSELY SPACED TEES WATER INLET gt lt gt lt EXPANSION TANK BOILER BOILER PUMP 24 10 HYDRONIC PIPING HYDROSTAT MODEL 3250 Io Ue
5. Jn XO OR mie opel item ETE 9 is a 581 Z 019 5 TWNIWYAL INOYOL Ez El IASI Ei El IASI AAI 2002006 7 7 7 wy 7 Fri E ewe 202 Be 47 ca ej B B PRIORITY 6 on ISOLATED 212 BWITCH SWITCH TO OIL BURNER 120 VAC 20 10 HYDRONIC PIPING Figure 19 Multi Zone Piping and Wiring With Zone Valves And Domestic Hot Water Priority With Zone Valve CH amp DHW SYSTEM CIRCULATOR ZONE 1 PRIORITY ZONE USE FULL PORT ZONE VALVE FOR OPTIMUM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR SEE FIGURE 20 BOILER EXPANSION TANK ZONE VALVE PUM EATER LODS LN PRIORITY LAQUASIAT ZRZC ORTHERMOSTAT DPM 2 OPTION SWITCHES ananasa 24VAC FROM TRANSFORMER 24 VAC R STATUS PRIORITY ON PRIMARY PUMP PRIORITY PUMP ZR ON HYDROSTAT 3250 120VACTO TRANSFORMER
6. 58 Parts 62 Waranty inden EI 68 ARE qui E nS 70 1 INTRODUCTION 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 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 cov ered 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 e Limit 220 F maximum operating control with integral low water cut off Temperature and pressure gauge 30 psi relief valve e Drain valve N
7. e om om 2202 os Dom TABLE 13b BECKETT ECR PART NUMBERS ECR Oil Burner Part Number Less Cover ECR Oil Burner Part Number with Cover Becket Oil Burner Model AFG70MQASN 240007144 240007232 AFG70MQSSN 240009377 240009385 AFG70MSASN 240009378 240009386 48 17 OIL BURNER NOZZLE amp 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 Firing Pump Pressure Head Insertion Combus Nozzle Air 8 AFUE Rate g Pressure Switch ae GPH tion liner Type PST Setting Setpoint 86 0 0 75 Oval Delavan 0 60x60B 150 1 5 0 65 WC 4095 6 Slot 0 Oval 0 75x60B 0 65 WC 8 95 55 4 0 5 0 Post Purge TABLE 14b BECKETT ECR PART NUMBERS Beckett Oil Burner ECR Oil Burner Model Part Number NX70LC 240007531 49 17 OIL BURNER NOZZLE amp 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 Firing Com Boiler Mode
8. Riello Boiler Cil ECR Oil Burner Model Burner Part Number Model 4075 40BF3 240007528 4095 40BF5 240009407 4110 40BF5 240009408 5100 40BF5 240007529 5115 40BF5 240009409 5135 40BF5 240009410 6130 40BF5 240007530 17 OIL BURNER NOZZLE amp 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 INSER erring COMBUS NOZZLE TION RATE TION TYPE DEPTH LINER Rated AFUE Efficiency HEAD E BAR SETTING 3 3 5115 NONE DELAVAN 0 85 45 5135 NONE DANFOSS 1 10 x 60 AB TIMINGS Pre Purge z 15 seconds Post Purge Carline ECR Oil Burner Burner Part Model Number Boiler Model 4075 EZ LF 240010357 4095 EZ LF 240010357 4110 EZ LF 240010357 5100 EZ LF 240010357 5115 EZ LF 240010357 5135 EZ LF 240010357 52 18 MAINTENANCE A 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 qualified service agency at least once every 12 months to assure safe trouble free operation and maximum efficiency NOTICE Verify proper operation after servicing
9. TRIFIRE SERIES II High Efficiency BOILERS Oil Fired Hot Water Boiler Models INSTALLATION OPERATION amp MAINTENANCE MANUAL TRB4075 TRB4095 TRB4110 TRB5100 TRB5115 TRB5135 TRB6130 TRB6145 TRB6165 TRB7165 TRB7180 TRB7190 ENERGY STAR fan amed CERTIFIED H US Manufactured by ECR International Inc AN 2201 Dwyer Avenue Utica NY 13501 e r web site www ecrinternational com An ISO 9001 2008 Certified Company P N 240009350 Rev E 12 2014 IEIRE OIL FIRED CAST IRON HOT WATERIBOIPER Models TRB5100 TRB6130 Per Energy Star specifications AFUE is rounded to the nearest whole percentage point As such these products qualify for Energy Star B 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 42 1 2 DIMENSIONS 1 1 4 NPTSUPPLY FLUE SEE CHART FOR SIZE DIMENSIONS Flue Size Dimension Sections Inches 18 3 8 46 5 13 21 5 8 56 5 13 24 7 8 64 TABLE OF CONTENTS 5 2 Safety InfODYE IO axcrcoedusadeubertieadrartavayiuacancheasnlad
10. elelee ss ra 2 FAG ELIGE RUF EYEE I fof AZ 4CP ESE ES Es 9 24VAC COIL 120VAC CONTACTS TO OIL BS BURNER ime N 82 26 aR 10 HYDRONIC PIPING Figure 20 Piping and Wiring Multizone System With Zone Valves And Domestic Hot Water Priority With Circulator ZONE 4 USE FULL PORT ZONE VALVE CH CIRCULATOR US ZONE 1 PRIORITY ZONE CIRCULATOR BOILER EXPANSION TANK INDIRECT WATER HEATER AQUASTAT ORTHERMOSTAT ZONE VALVE PUMP IORITY 24VAC FROM n Ir Ir TRANSFORMER 7 c 24 VAC He Ule Ulo 22 7 amp fous HYDROSTAT PRIORITY ON PRIM X MODEL 3250 Ee PRIORITY PUMP E ZONE VALVE 120VACTO BRIORITY TRANSFORMER DPM 2 120 VAC TO XFRM 120VAC RY Y FROM BOILER
11. 4 9 40 OIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM DAMAGE MINIMUM 1 2 IPS OR 1 2 O D COPPER TUBING OIL BURNER 4 REFER TO LOCAL RETURNEINE CODE Table 5 TWO STAGE UNITS TWO PIPE SYSTEMS SEE FIGURE 15 Maximum Length of Tubing R 3 8 O D 1 2 O D Tubing 3 GPH Tubing 3 GPH 0 93 FT 100 FT 2 85 FT 100 FT 4 77 FT 100 FT 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 12 ANTIFREEZE IN THE SYSTEM 12 1 Antifreeze added to boilers must be nontoxic and must be of type specifically 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 Table 7 PIPING WATER VOLUMES COPPER Number of Total Volume PIPE SIZE PIPE STEEL PIPE Boiler Section Gallons FACTOR FACTOR 3 6 DE 82 5 63 5 5 4 3 34 40 0 36 0 6 5 1 i 23 3 292 7 5 9 i 15 3 12 8 1 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 55 13 ELECTRICAL Electrical shock hazard Turn OFF electrical power supply at service panel before making electrical
12. 46 Standard Dimensions L2 Heads 5 32 Gap 1 4 Above Center SK9461 1 8 Nozzle to tip Beckett Check Adjust Z Dimension V1 Heads Figure 42 Leoding edge of heod Bock of heod to nozzle foce Hex heod screw Nozzle Adopter Acorn nut Heod Support Splined nut 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 34 Z dimension is factory set for burners shipped with air tube installed Even if factory set verify Z dimension has not been changed 1 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 figure 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 34 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 pe
13. 18 1 Annually Recommend qualified Service Agency check at lease once a year e Flue passages e Combustion chamber area target wall fire door insulation e Burner adjustment Operation of the controls e Boiler seals fire door gasket or silicone seal cast iron sectional seals flue collector Before start of each heating season or system has been shut down for extended period of time e Recheck whole system for water oil and vent piping leaks e Replace or patch any leaks or seals that are faulty e Inspect flue ways at least once a year Preferably at start of heating season e Inside of combustion chamber e Clean vent system and boiler flue 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 e Oil Burner and controls 18 2 Vent Pipe Visually inspect entire venting system once a month for any signs of leakage deterioration or soot build up If vent pipe shows any signs of leaking or deterioration replace it immediately If it shows any signs of soot build up clean vent pipe and have burner settings and combustion checked by qualified service agency 59 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 S
14. OIL BOILER BURNER CLEANING INSTRUCTIONS A 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 Fire burn asphyxiation hazard Turn off service switch to boiler to prevent accidental firing 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 1 Clean flueways Figure 46 Page 56 A Shut off power to burner B Access to combustion chamber remove swing door bolts If boiler is equipped with flexible fuel line s swing door open C Remove vent connector D Remove liners amp baffles if equipped from flue passages Baffles are installed in 3rd pass two inner flue ways E Clean 3rd Pass Insert 2 Dia x 42 long wire or fiber 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 flue way until clean Repeat operation for other 3rd pass flue way F Clean 2nd Pass Insert wire or fiber bristle brush into each of two 2
15. Important System must be checked by a qualified service agency prior to resuming operation 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 41 Q ECONOMY TARGET Economy feature is active limit control continually sets target temperatures below high limit setting to maximize fuel efficiency 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 fire again Note LED illuminates regularly during normal boiler operation Q TEST SETTINGS Button To Test Low Water Cut Off Press and hold Test Settings button for 5 seconds Display will read LCO LWCO TEST CO Red Low Water light should illuminate and burner circuit B1 and B2 should de energize Note Control must be in stalled 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 HL HIGH LIMIT SETTING v LOW LIMIT SETTING ECONOMY SETTING ELO CURRENT TARGET TEMPERATURE non v PRE PURGE
16. connections Failure to do so could result in death or serious injury CONNECTIONS 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 SEE APPROPRIATE ADDENDUM FOR WIRING DIAGRAMS 34 14 CHIMNEY AND VENTING CONNECTIONS 14 1 Chimney Venting Oil fired 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 Oil Burning 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 1 Ensure sufficient draft during heating season to allow for safe evacuation of flue gasses 2 Boiler can be vented into fireclay tile lined masonry chimney or type L vent or factory built chimney that complies with type HT requirements
17. mode cad cell is disregarded allowing technician to prime pump without having to jumper cad cell 7 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 Pushing reset button will Button Click Button Hold Button Hold press 1 second press 1 second press 15 seconds Reset from Soft Lockout Reset from Run Igniter shut off Valve on Delay Trial for Ignition Ignition Carry over Go to Pump Prime See Priming the Pump page 44 No Action Motor Off Delay Standby Exit Pump Prime mode and return to Standby Disable Burner Anytime burner is running press and hold reset button to disable burner Burner will remain off as long as button is held 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 Table 12 Genisys Control Status Lights Light Color On Continuously Flashing Red Restricted Hard Lockout Soft Lockout Flame Sensed during normal operation Control is in Pump Prime mode or 16 OPERATING THE BOILER SYSTEM START UP C After installing nozzle reassemble nozzle line NOTICE electrode assembly and set electrode tip spacing Before starting or
18. If the result is less than 50 ft 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 c
19. Reference indicotor Y Heod Nozzle Adopter Heod Support Leading edge of head conic shroud Splined nut 11 12 Heads See Figure 39 The important Z dimension is distance from leading edge of head to end of air tube This distance for L1 amp 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 1 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 figure 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 amp 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 Figure 40 Beckett Electrode Tip Adjustments
20. SETTING Pur Display will return to boiler temperature default if Test Settings button is not pressed for 5 seconds 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 17 Oil Burner Nozzle amp Air Settings on page 46 B Open all oil line valves C Attach a plastic hose to fuel pump vent fitting and provide a pan to catch the oil 2 Prime Pump and Start Oil Burner A Open bleed port fitting 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 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 Bleed pump until all froth and bubbles are purged I If desired terminate call for heat or hold reset button for at
21. chimney chimney wall insulation value dilution air and total volume of flue 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 flue gas by products to escape from draft regulator Draft is to be measured up stream of draft regulator See Burner Specifications Over fire 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 fire and breech Total pressure drop is difference between over fire draft and breech draft For example if over fire draft 0 05 INWC and breech draft 0 05 total pressure drop 0 05 0 05 0 10 INWC See Figure 33 Page 37 36 Table 9 Pressure Drop Between Over Fire amp 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 flue gases could condense in chimney connector or stack Consult NFPA 31 and CSA B139 for information for appropriate choice of venting mate
22. least one second to exit pump priming mode and return to standby mode 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 fitting 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 17 Oil Burner Nozzle amp Air Settings on page 46 42 Fire burn asphyxiation hazard Do not loosen or remove any oil line fittings while burner is in operation Failure to follow these instructions could result in death or serious injury 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 pref
23. manual reset low water cutoff and manual reset high limit may be required 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 e Installation by licensed plumber or gas fitter 3 BEFORE YOU START 3 1 Installation and Operation 1 10 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 firing 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 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 ex
24. prior to proceeding Remove control well from top of rear boiler section every five years and clean any scale or sediment deposits from all parts exposed to boiler water 18 MAINTENANCE Steps to inspect clean and or replace control well 1 Turn off electric service to boiler controls 2 Drain boiler water to level below tapping for control well 3 Remove low water cut off limit sensor from control well 4 Unscrew control well from tapping 5 Inspect portion of control well exposed to water for scale or sediment buildup 6 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 7 Clean pipe threads of probe to remove old hardened pipe dope and other foreign matter 8 Apply moderate amount of good quality pipe dope to pipe threads on control well leaving two end threads bare Do not use PTFE Teflon tape 9 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 18 9 Boiler And System Cleaning Instructions For Trouble Free Operation 1 Boiler and system other than exp
25. resetting control from restricted D Electrode tip spacing may need to be set prior to lockout state troubleshoot heating system for root reassembling nozzle line electrode assembly Refer cause s of lockout to figures on following pages for setting electrode tip spacing on Beckett 8 Genisys Control Resetting From Restricted or Hard Lockout 16 14 Check Thermostat Operation Thermostat A Make necessary repairs or adjustment to ensure location has important effect on operation of boiler system safe start condition A Follow instructions included with your thermostat before starting or resetting burner floor on inside wall B Thermostat should be located to sense average room temperature C If control continues to lock out without satisfied call for heat or fails motor relay check control enters Hard restricted Lockout in order to limit accumulation of Table 10 Thermostat locations to Avoid unburned oil in combustion chamber DEAD D To reset hold button down for 15 seconds until red SPOTS HOT SPOTS COLD SPOTS Concealed pipes Concealed pipes or ducts doors ie light turns off and yellow light turns on E Always verify control functions according to specifications before leaving installation site F Replace control if it does not operate as specified Stairwell drafts Door drafts 9 Genisys Control Disable Function Corners amp Unheated room Anytime burner is running press and hold reset button to alcov
26. water system must be filled 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 fill 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 59 21 6 Conventional Expansion Tank Not Provided In a properly assembled system expanding water flows into an expansion tank e Expansion tank should be sized correctly because im properly installed or sized expansion tank may result in frequent lifting of relief valve or other heating system problems It is important to install tank higher than top of boiler Connecting pipe from boiler to expansion tank shall rise continuously up to expansion tank so that air can rise into expansion tank Expansion tank is partially filled with air Air compresses as water expands thus forming an air pressure cushion This spring like cushion serves to maintain correct op erating water pressure regardless of water temperature This assures a full measure of water even in highest radiation unit of the system Tank also serves as trap for excess air in the system Air can cause noises in pipes and inefficient circulation in radiators if left in piping system It is possible for a tank to become waterlogge
27. 8 198 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 13 5 CO at 0 95 1 10 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 Stan
28. 90 F Temperature setting may be varied to suit requirements of installation Differentials are automatic and will vary based on control settings and boiler temperature Dynamic Display and Real Time Verification of Low Temperature Limit Setting OFF or 110 200 F Figure 34 Limit Temperature Setting Adjustments AM Diagnostic LEDs and Test Button Zone Indirect Switch Indicator Light announces heat call High Temperature Limit Setting 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 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 to lower setting example in a three zone house turn dial to 2 or 1 Conversely if boiler provides adequate heat added 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 ensur
29. B2 BLACK WIRE TO C1 C2 L1 CIRCULATOR 7 WIRING Figure 16 Drain Valve DRAIN VALVE 17 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 10096 without using alternating tightening method described above 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 e 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 amp 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 e Align round part of key hole slots of burner flange with burner door bolts Turn burner to lock in place e Tighten all 4 cap screws using diagonal sequence e Plug burner power cord into burner harness e Attach f
30. CTRIC LINE PRETEE TED SERVICE LINE SAFETY SWITCH z AUTO FILL VALVE EXPANSION TANK amp SHUTOFF ENTRANCE 2 FILL SWITCH PIPE MIN 2 VENT PIPE gt LINES TO OTHER 7 APPLIANCES TO OUTSIDE DIL BURNER SHUT OFF VALVE OIL FILTER FOUNDATIONS DIL LINES T CHECK LOCAL CODES FOR MAXIMUM DISTANCE FROM FLOOR OR OTHER ALLOWABLE SAFE POINT OF DISCHARGE NOTICE Shut off manual fuel supply valve if burner is shut down for extended period of time 10 7 FRESH AIR FOR COMBUSTION 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 ft 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 ft 1000 BTU hr then it is considered an unconfined space
31. OTICE 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 2 SAFETY INFORMATION 2 1 General Boiler installation shall be completed by qualified agency 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 Modification substitution or elimination of factory equipped supplied or specified components could result in death or serious injury Improper installation adjustment alteration service or maintenance could result in death or serious injury 2 2 Become Familiar With Symbols Identifying 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 Potential Hazards A DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury 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 Construction materials of appliance and products of combustion and fuel
32. R INLET a gt EXPANSION TANK 26 HYDROSTAT MODEL 3250 lo Lr o SA SE SEA gt 82 6 AR 120 VAC N TO OIL BURNER 24VAC COIL 10 HYDRONIC PIPING 24VAC FROM TRANSFORMER 120VACTO TRANSFORMER 120VAC CONTACTS INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT ZONE VALVE PUM PRIORITY ZR ZC DPM 2 27 10 HYDRONIC PIPING Figure 24 Piping And Wiring Primary Secondary Piping With Zone Valves And Domestic Hot Water With Circulator ZONE VALVE a ZONE 3 CIRCULATOR MAX 4 X DIAMETER CLOSELY SPACED TEES WATER INLET lt EXPANSION TANK BOILER PUMP BOILER 28 10 HYDRONIC PIPING 24 TRANSFORMER
33. RATING THE BOILER SYSTEM START UP 16 6 Activating Thermal Pre Purge optional Activation of this feature is not recommended for boilers with tankless coils e Limit has thermal pre purge feature to maximize efficiency 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 e During purge cycle display will indicate PUR If heat is not sufficient to satisfy thermostat control will energize burner e 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 1 Push and hold TEST SETTINGS button for 20 seconds 2 Display will read PURR On 3 To deactivate feature push and hold button a second time for 20 seconds 4 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 m
34. STEM EXPANSION TANK BOILER ALTERNATE CIRCULATOR LOCATION BOILER SHUT OFF VALVES AIR CUSHION TANK CIRCULATOR N SUPPLY MAIN TO RETURN MAIN FROM COMBINED HEATING COMBINED HEATING amp COOLING SYSTEM amp COOLING SYSTEM 31 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 fill pipe and caps shall conform to requirements of authority having jurisdiction In no case should vent pipe be smaller than 1 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 O D copper tubing for runs of 50 feet or less and 2 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 fittings on all oil lines are required Compression fittings on suction line often allow air to be drawn into fuel pump making it difficult 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 con
35. SYSTEM START UP IV After 60 second recycle period control will try to restart system Do not run boiler unattended until following procedure V After 15 second lockout time control will lock out is completed Failure to follow these instructions could burner and reset button will flash Verify burner result in minor or moderate injury motor and igniter are off and burner solenoid valve if used is not energized E Once burner is completely adjusted start and stop VI Open hand valve in oil line burner several times to assure good operation with no fluttering 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 VIII End call for heat boiler Figure 37 CAD Cell Location VII Click reset button and verify red light in reset button shuts off and burner lights Electrical shock hazard Following safety checks shall be completed by qualified agency Failure to do so could result in death or serious injury Control contains no field serviceable parts Do not attempt to take it apart Replace entire control if operation is not as described 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 5 Check Genisys Oil Primary Control in conventional
36. Y AND VENTING CONNECTIONS 14 2 Vent and Vent Connector 1 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 flue temperature is less than 570 F 4 5 amp 6 section boilers have sheet metal flue collar spacer included in accessory carton for attaching 5 diameter vent connector to cast iron flue collar For 7 section boiler 6 diameter vent connector attaches directly to cast iron flue collar Attach vent connector and flue adaptor ring to cast iron flue collar with three screws Pre drill cast iron flue 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 qualified service agent immediately to examine damage and correct Operation of damaged chimney may cause venting failure and force flue gases into living space If chimney is to be re lined use recommendations in NFPA31 Appendix E or CSA B139 14 3 Draft Natural draft generated through chimney is dependent on several factors including chimney height temperature of flue gases cross section area of
37. aaninsdandushantanataiad a A E E NRS 6 3 Before E 7 4 Ratings E E A E 8 5 Locating The adn Vade aua dna aaa ai aaia 9 5 Installation ANDE MODE 10 7 Fresh Air For ___ _____ 11 8 dc 13 9 Boiler System PIPING Dra PE edd QE 18 10 19 1l F el Supply PIpITj 32 12 Antifreeze In The 33 13 Electrical CONNGCUONS a date Fa a Ed d 34 14 Chimney And Venting CONNECTIONS in o MALE KO LA EO Kc o ia M a GE EE E S 35 38 16 Operating The Boiler System Start Up 39 17 Oil Burner Nozzle amp Air acair E 46 18 Malnternalbe bea tune 52 19 Oil Boiler Burner Cleaning Instructions 54 20 56 21 Equipment And ACCESSONIES 6 cake
38. aces 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 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 M BURNER WIRING RELIEF VALVE BACK OF BOILER 15 8 BOILER ASSEMBLY Figure 13 3rd Pass Baffles 2 Table 4 BAFFLES amp LINERS e m 4 oa 4 9 ub 1 SHAPE SHAPE NONE 9 V liner used only on Models 5115 and 5135 and only with Beckett NX burner other 5 section models and burner combinations use no liner 16 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 If optional manual reset high temperature limit is not used ensure supplied jumper is installed Connect the wiring harness from limit control to circulator See Figure 15 17 120 volt
39. all for heat this is flame shape air or water in fuel lines indicated by a steady on red LED H Shut down noise Post Purge timed 15 seconds should eliminate shut down noise 20 2 Oil Primary Control 1 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 flame out III Defective nozzle causing flame to be erratic IV Excessive airflow or draft causing flame to leave burner head V Excessive back pressure causing erratic flame K Control locks out after trial for Ignition TFI 57 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 cuit is ON There may be as many as 3 safety shut off switches installed Look for a red plate which may b
40. ansion 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 2 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 e Start firing boiler e Circulate water through entire system e Vent system including radiation Allow boiler water to reach operating temperature if possible Continue to circulate water for few hours e Stop firing boiler e 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 Refill system with fresh water 3 Add appropriate boiler water treatment compounds as recommended by your qualified water treatment company 4 Testing pH alkalinity after boiler and system have been cleaned and refilled 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 ch
41. case may become fire VII Oil valve stuck open or closed hazard C Dirt Fuel filter is required to prevent clogging nozzle isolate fuel problems disconnect fuel system and fire or nozzle strainer and produce poor spray pattern out of auxiliary container of clean fresh warm 2 fuel from nozzle oil from another source If burner runs successfully when D Water Water in fuel in large amounts will stall fuel drawing out of container problem is in fuel or fuel lines pump Water in fuel in smaller amounts will cause excessive wear on pump Water doesn t burn it chills the flame and causes smoke and unburned fuel to If flame is not established within 15 seconds of oil valve pass out of the combustion chamber and clog flue actuation known as Trial For Ignition or TFI soft lockout ways of the boiler will occur Soft lockout is indicated by flashing red LED located on oil primary control 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 NOTICE G Start up noise Late ignition is cause of start up Restricted lockout without retries will occur if flame noises If it occurs recheck for electrode settings is lost three times during one c
42. 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 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 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 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
43. d filled with water It can also become overfilled with air when filling system with new water Fittings on tank and in line to tank are for bleeding off excess air and water 21 7 Diaphragm Expansion Tank Not Provided Diaphragm type expansion tank takes place of conventional expansion tank e Carefully read instructions packed with your tank 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 Tank typically comes with 10 12 psi air charge Same as pressure produced in system by automatic fill valve set to fill boiler to 10 12 psi with fresh water When system is first filled tank will fill 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 Diaphragm type expansion tank can be mounted on air purger fitting 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 configuration allows circulator to pump away from expansion tank for improved air elimination and system performance Air eliminator fitting or air purger is
44. dard 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 5 LOCATING THE BOILER 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 flooring Do not install boiler on carpeting 2 Locate boiler in front of final 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 floor is not level or if water may be encountered on floor around boiler Provide recommended service clearance if applicable as follows e Clearance from Jacket Front Panel 24 for servicing burner e Clearance from Jacket Side Panels 24 for burner swing door if opened fully with burner mounted otherwise 2 with burner removed e 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 Figur
45. e 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 e Forced hot water systems require circulator e 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 configurations 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 e Circulator can be installed on return side of boiler if preferred 21 4 Main Air Vent Not Provided Before system is filled with water there is air in pipes and radiation units Some air will be trapped as system is filled 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 5 Automatic Fill Valve Not Provided Hot
46. e 1 Clearances to Combustible Construction FRONT VIEW 0 5254 0525552 5252525 9 2 90 525 ete e e xx 55550 xxx 5252 0525024 2 55 2 Table 2 2 x 5 OY 59595 2 gt gt e 2525 Se 590009 252505 es eX 5062 X 7 Fresh air for combustion and ventilation must avail able 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 flue pipe If Type L vent is used clearance may be reduced to minimum required by vent pipe manufacturer Table 2 BOILER CLEARANCES Accessibility ibl Unit ples Cleaning and Servicing 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 flue 6 INSTALLATION REQUIREMENTS Figure 2 General Requirements For A Typical Installation VERCURRENT ELE
47. e on the service switch Controls out of adjustment Reset according to instructions 3 Check over current protection Check relay operation Check power to Circulating pump not running circulator Poor electrical contact Check all control terminals and wire joints Chimney flue is blocked Have the chimney professionally cleaned RELIEF VALVE LEAKING POSSIBLE CAUSE WHAT TO DO Corrosion and or deposits on seat Open valve manually Allow water to run and clear valve 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 LIMIT CONTROL TROUBLESHOOTING GUIDE System Condition Diagnostic Condition Boiler is cold Display off 120 VAC system power Turn system power on house is cold Display 120 VAC at B1 B2 replace NEN leak s Boiler is hot Display on 120 VAC at C1 C2 120 vac at C1 C2 check wiring to house is cold pump Wiring OK is pump running If not replace pump If pump is running check for trapped air or closed zone valves Burner will not Display On Burner wired incorrectly L1 turn off black and Limit red are reversed See wiring diagram Re Wire burner for installed burner 58 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 temperatur
48. e 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 fire 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 39 Factory OFF 1 12 2 TI B2 1 ZR E 100 220 F Factory 190 F Economy Dial OFF or LO 1 2 3 4 5 Hl Differentials CAI are automatic and will vary based on control settings and boiler tem perature Figure 35 Setting Economy Feature SETTING OFF Disables economy function Will allow boiler to fire until hi limit temp is reached and re fire with a 10 subtractive differential LO 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 6 Recommended setting for Five zone systems Provides highest level of fuel savings 16 OPE
49. ee Equipment And Accessories section 18 5 Diaphragm Expansion Tank See 21 Equipment And Accessories on page 59 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 e Fuel Filter Replace to prevent contaminated fuel from reaching nozzle Partially blocked fuel filter can cause premature failure of fuel pump Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to nozzle e Ignition Electrodes Clean and adjust as per manufacturer s recommendations so as to maintain reliable ignition of oil e Nozzle Replace so as to maintain safe and reliable combustion efficiency Always replace with exact nozzle as required in charts See 17 Oil Burner Nozzle amp Air Settings on page 46 e Fan and Blower Housing Keep clean free of dirt lint and oil to maintain proper amount of air fuel requires to burn 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 Open safety valve to relieve all internal pressure
50. emicals if necessary to bring pH within specified range With this lower level of protection care must be exercised to eliminate all free oxygen in system 5 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 significantly 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 11 Attention To Boiler While Not In Operation NOTICE Fully drain boiler if not used during winter months to prevent freeze damage 1 Keep manual fuel supply valve shut off if burner is shut down for extended period of time 2 recondition heating system in fall season after prolonged shut down follow instructions outlined in See 15 Filling boiler on page 38 3 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 4 Keep boiler and area around it clean Never burn refuse or any material other than specified fuel in your boiler Have your boiler checked each year by qualified service agency 19
51. erred to 0 inches water column after chimney has reached operating temperature and while burner is running 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 confirm CO of 11 to 13 If flame appears stringy instead of solid fire try another nozzle of same type Flame should be solid and compact Turn off burner and remove pressure gauge Install gauge port bleeder plug and tighten Start burner again 4 Final Burner Adjustments Final burner 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 flue pipe between boiler and draft regulator Smoke reading should be zero to trace Shell Bacharach Scale New boiler may require more than 10 minutes to burn clean due to oil film on new heat exchanger If smoke reading is zero gradually close burner s air adjustment to obtain smoke reading showing trace smoke read ing Once smoke reading is trace measure CO and as insurance margin increase air to sufficiently reduce CO by 1 2 to 1 If clean fire cannot be obtained it is necessary to verify burner head alignment If fire continues to be smoky replace nozzle 16 OPERATING THE BOILER
52. ers or metal louvers FRESH AIR UPPER OPENING 12 LOWER OPENING 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 RN S f FRONT SECTION 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 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 EYEBOLT amp NUT AS HINGE EYEBOLT amp NUT AS HINGE 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 7 Open accessory carton and remove contents Identify NE components using illustrations throughout this section 22 may come off hinges if lifted when applicable to your installation 8 Remove top panel Remo
53. es Direct sunlight on other side of disable burner Burner will remain off as long as button is wall held 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 Remove jumper after following check 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 Use proper size spray angle and spray pattern nozzle A Referto 17 Oil Burner Nozzle amp 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 45 17 OIL BURNER NOZZLE amp AIR SETTINGS Figure 39 Beckett Electrode Tip Adjustments Standard Dimensions L1 V1 Heads 5 32 Gap 5 16 Above Center cup 1 16 Nozzle to ti L mM Spacing Beckett Check Adjust Zz Dimensions L1 amp L2 Heads Z Leoding edge of heod straight shroud Figure 41 Back of heod to nozzle foce Hex heod screw
54. estic hot water zone Install 34 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 10 HYDRONIC PIPING Figure 17 Standard Near Boiler Piping TO SYSTEM EXPANSION TANK BOILER CONTROL 3 J TEMPERATURE PRESSURE GAUGE NEN FRONT OF BOILER FROM SYSTEM DRAIN Piping Diagram Legend PRESSURE BALL VALVE HOSE BIB REDUCER VALVE AIR SEPARATOR FLOW CONTROL VAVLE a CHECK VALVE ZONE VALVE DRAIN PRESSURE VALVE RELIEF VALVE 10 HYDRONIC PIPING Figure 18 Piping and Wiring Single Zone System With Domestic Hot Water DHW Priority CH CIRCULATOR Ca q q WATER INLET EXPANSION DHW CIRCULATOR DHW Heater BOILER PRIORITY ZONE INDIRECT WATER HEATER AQUASTAT OR THERMOSTAT HYDROSTAT 9 Jm MODEL 3250 LINT 0 or d DATA PORT COMMON 24VAC
55. h 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 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 Pipe discharge of relief valve Installation of relief valve must be consistent with ANSI ASME Boiler and Pressure Vessel Code Section IV 14 Figure 8 Grommet E SENSOR IN WELL WITH GROMMET SS Figure 9 Relief Valve 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 amp 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 surf
56. ing method from non hinged side to hinged side cap screws to pull door tight equally Asphyxiation hazard A clean and unobstructed chimney flue 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 flue and clean before start of heating season 19 2 Oil Burner Cleaning Instructions Consult burner manufacturer s instructions 19 OIL BOILER BURNER CLEANING INSTRUCTIONS Figure 46 Cleaning the Boiler FLUE BRUSH os VACUUM 3RD PASS HOSE E BRUSH VACUUM HOSE FRONT VIEW COMBUSTION CHAMBER amp 2ND PASS 56 20 TROUBLESHOOTING 20 1 Combustion I No oil to burner Nozzles See 17 Oil Burner Nozzle amp Air Settings Shortened electrodes on page 46 III Clogged nozzles B Fuel leaks Any fuel leak between pump and nozzle IV Airflow too high is detrimental to good combustion results Look for V Ignitor module defective wet surfaces in air tube under ignitor and around air inlet Repair any such leaks as they may cause erratic VI CAD cell defective burning of fuel and in extreme
57. 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 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 18 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 e 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 e Any system including finned tube baseboard with priority dom
58. itch to boiler to prevent accidental firing of burner outside combustion chamber Disconnect ASME data label located on front lower leg of boiler Never exceed this pressure Do not plug relief burner power cord from wire harness in front jacket valve Tighten swing door fastener completely when service is complete Failure to follow instructions in this manual and understand all requirements could L It may be necessary to clean air vent assembly after few days of operation result in death or serious injury 3 Check controls wiring and burner Verify all connections are tight and burner is rigid all electrical 1 Inspect Installation Before Starting Burner connections have been completed and fuses installed 2 and oil tank is filled and oil lines have been tested A Verify venting water piping oil piping and electrical system are installed properly Refer to installation Instructions contained in this manual B Confirm all electrical water and oil supplies are turned off at source and vent is clear from obstructions 2 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
59. l Head i Rate bustion GPH Liner Nozzle Nozzle Mfr Type Setting Setting Efficiency Reverse 75 Oval Delavan 0 65x60W Lm pem pm om pm mm DR me oe mm emm wo Delavan 1 50 70 12 seconds Riello ECR Oil Riello ECR Oil Boiler Oil Burner Boiler Oil Burner Model Burner Part Model Burner Part Model Number Model Number 4075 40F3 240007502 6130 40F5 240007504 4095 40F3 240009399 6145 40F5 240009403 4110 40F5 240009400 6165 40F10 240009404 5100 40F5 240007503 7165 40F5 240007505 5115 40F5 240009401 7180 40F10 240009405 5135 40F5 240009402 7190 40F10 240009406 50 17 OIL BURNER NOZZLE amp 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 Rated Pressure Firing Head AFUE Boiler Model Rate bustion 5 Switch iu Type Depth GPH sure Setting Setting Setpoint Reverse Delavan 0 65x60W 0 25 WC 86 0 Lom pem en pm Oval Delavan 0 75x90B 0 25 WC ome o s m nm emm m n mm m Timings
60. ler water l 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 B C Repair system leaks Eliminate open tanks from the system Eliminate and or repair fittings which allow oxygen absorption Use non permeable materials in the heating system 4 RATINGS amp CAPACITIES EPIS Table 1 RATINGS amp CAPACITIES an al CERTIFIED www ahridirectory org OIL FIRED HOT WATER BOILERS 1 Chimney Numer Finne Peas i MAWE wae Liner 2148 Rate Capacity Water A Size Size 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 22
61. lexible oil hose included in parts box 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 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 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 final 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
62. nd 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 flue way until clean Repeat operation for other 2nd pass flue way 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 2 Clean combustion chamber and baffles Use wire or fiber bristle brush to clean surfaces of combustion chamber and baffles Vacuum all of loose debris in bottom of combustion chamber 3 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 4 Re assemble boiler A Insert liner and baffles if equipped into correct flue way Baffles are installed in 3rd pass Two inner flue 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 sufficient 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 tighten
63. nections 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 filter 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 flexible oil lines so burner swing door can be opened without disconnecting oil supply piping Figure 29 Single Pipe Oil Line APPROVED FITTINGS SWING JOINTS VENT PIPE BAROMETRIC DRAFT CONTROL REFER TO NATIONAL BOARD OF FIRE UNDERWRITERS o 1 FILLER 94 PIPE A 7 Minimum 4 4 OIL GAUGE P o OIL TANK E o 4 BOILER o 9 4 OIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM DAMAGE MINIMUM 3 8 IPS OR 3 8 O D COPPER TUBING SHUT OFF VALVE OIL FILTER 32 Figure 30 Double Pipe Oil Line 4 4 eLI TT i I if Tf i APPROVED e FITTINGS 9 BAROMETRIC P 1 DRAFT CONTROL 4 SHUT OFF VALVE 4 OIL FILTER SUCTION LINE a Uo o a 9
64. noid valve for pro grammed time Trial for Ignition Oil solenoid valve is energized Flame should be established within factory set trial for ignition time lockout time Lockout Control has shut down for one of following safety reasons Trial for ignition lockout time expired without flame being established Cad cell detected flame at end of Valve On Delay State To reset from hard lockout hold reset button 15 seconds until yellow light turns on Standby Trial for ignition Ignition carryover Ignition Carry over Once flame is established igniter remains on for 10 additional seconds to ensure flame stability Run Flame is sustained until call for heat is satisfied Burner is then sent to Motor Off Delay if applicable or it is shut down and sent to Standby Recycle If flame is lost while burner is firing control shuts down burner enters 60 second recycle delay and repeats ignition sequence Control will continue to recycle each time flame is lost until it reaches preset time allotment Control will then go into Hard Lockout instead of recycle Feature prevents excessive accu mulation of oil in the boiler firing chamber 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 Pump Prime Igniter and motor are on with solenoid valve energized for 4 minutes During Pump Prime
65. not provided Air eliminator fitting 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 inefficient circulation in radiators 21 EQUIPMENT AND ACCESSORIES Figure 47 Grundfos Pump Curve 5 15 4 3 10 2 9 5 FT 575 Zo Model Watts Volts Amps Capacitor Supplied with pump Supplied with pump Figure 48 Taco Pump Curve FLOW M H 1 2 3 4 5 6 7 8 9 10 35 1 H 10 30 9 009 lg t 25 mm T x 20 0014 6 5 15 a 4 10 3 2 2 5 0013 0012 003 006 008 005 007 001 0010 0 5 10 15 20 25 30 35 40 45 FLOW GP Model Volts Amps Capacitor 60 5 NOTES 62 SERVICE RECORD i euoud sseuppy Aueduio5 sjeniu 29 Aueduio5 221195 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
66. of UL103 See Figure 32 Page 37 FIRING RATE gph CHIMNEY HEIGHT ft Table 8 Recommended Minimum Chimney Sizes NOMINAL CHIMNEY 3 Chimney Inspection Prior to installation of any new replacement fuel burning equipment chimney shall be inspected by qualified service agency A De rating may cause condensation on interior walls of chimney and boiler Loose mortar can be indication of history of condensing flue 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 specified 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 4 Install draft regulator at least 18 above breech 18 of straight run up stream of regulator ensures proper operation 5 Draft Regulator Use supplied draft regulator with this appliance Do not use any other draft regulator See Figure 31 Page 37 ROUND RNC CE LINER INSIDE INSIDE 0 60 1 30 15 1 31 1 80 8 X 8 6 6 34 x 6 34 6 34 x 6 34 1 81 2 00 8 6 34 x 6 34 For elevations above 2 000 feet above sea level add 3 feet to the chimney heights 14 CHIMNE
67. ombined 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 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 VENTILATING GRILLE 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 Mesh Wood Metal Fresh Air Screen Louvers Louvers Fresh 3 V x 12 144 000 36 000 108 000 8 x8 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 mesh screen wood lou v
68. or replace if rope is damaged or if there is gap 1 1 4 x 3 4 x 1 1 4 between ends ELBOW 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 RELIEF VALVE 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 port facing front 13 Install Limit control amp 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 7 Control On Mounting Plug w Screw MOUNTING PLUG TIGHTEN SCREW 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 wit
69. pansion tank manufacturer guidelines for installation and sizing Boiler manufacturer recommends initial fill pressure of 10 12 psi For higher fill pressures increase expansion tank s air charge to match fill pressure 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 boi
70. power supply field wiring connects to limit control Provide appropriate overcurrent protection and service disconnect switch Wire power supply See Figure 15 Page 17 Connect green wire to grounding lug When installing wiring through hole in Limit use anti abrasion cable clamp Connect black hot wire to L1 of terminal block white N wire to L2 of terminal block 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 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 17 18 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 8 BOILER ASSEMBLY Figure 14 Circulator Wiring GREEN TO GROUND SCREW BLACK TO YELLOW WHITE TO WHITE Ensure all conduit is secured to prevent contact with flue pipe Figure 15 Limit Control Wiring THERMAL LWCO WIRE PIN RED WIRE TO B1 WHITE WIRE TO
71. rials Chimney may have to be lined to create sufficient draft or chimney may have to be lined to prevent corrosion of masonry chimney Consult qualified service agency for chimney requirements in your area Baffles Efficiency of boiler is based on insertion of flue baffles supplied with 4 5 amp 6 section units Baffles are installed in 3rd pass two inner flueways Refer to 8 Boiler Assembly on page 13 for baffle installation Remove baffles to increase stack temperature Remove baffles if any signs of condensation in chimney or chimney connector Removing baffles may not address condensation 14 CHIMNEY AND VENTING CONNECTIONS Figure 31 Proper Draft Regulator Locations Figure 32 Typical Chimney Locations Figure 33 Pressure Tapping for Checking Draft Minimum height must be at least Ft higher than highest part of passage through roof Must be at least 2 FT higher 1 4 TEST PORT than any neighboring FOR OVER FIRE object within 10 Ft Must MEASUREMENT have unobstructed top lt 2 opening d Must be at least 4 inches thick E and be tight Tight smooth Must slope up correctly sized at least 1 4 inch per foot of horizontal Sealed thimble ES SA Tight clean out door 37 15 FILLING BOILER Fire burn asphyxiation hazard Turn off service Boiler maximum operating pressure is posted on sw
72. riodically when servicing to ensure escutcheon plate has not been moved Reset Z dimension if you replace air tube or nozzle line assembly 2 17 OIL BURNER NOZZLE amp AIR SETTINGS Figure 43 Riello Electrode Setting Figure 44 Riello Turbulator Setting IMPORTANT THIS DIMENSIONS MUST BE OBSERVED AND VERIFIED 5 64 to 7 64 2 to2 5mm 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 first line is 4 and last line 0 On some models scale indicators are 0 and 3 Figure 45 Carlin Electrode Setting Flush to Nozzle adapter Clamp screw Retention ring assembly 47 17 OIL BURNER NOZZLE amp 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 iri Rated Boiler Head Static Nozzle on Air AFUE Model Type Plate vidi Type Je vies Efficiency liner PSI Setting 96 Jame we See oe pe Pot Po ae a he Tee EE as mm m as D
73. system installed as per piping diagrams to remove air from system when filling A Close shut off valve in boiler system piping between air separator and vertical purge valve 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 five gallon bucket or suitable floor 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 Open purge valve 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 filling 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 Confirm boiler and system have no water leaks 38 16 OPERATING THE BOILER SYSTEM START UP 16 1 Setting The Limit Control Setting can be verified using TEST SETTINGS button See Page 41 16 2 Setting High Limit To adjust turn HI TEMP dial unti desired setting is displayed See Figure 34 Overall range of High limit setting NL is from 100 F to 220 F 82 C to 104 C High limit HL on limit control is factory set at 1
74. 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 UTICA 2201 Dwyer Avenue BOILERS Utica NY 13501 web site www ecrinternational com
75. uch 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 40 16 OPERATING THE BOILER SYSTEM START UP Figure 36 LED Legend N e e N 28 Low water Indicates Limit Control is powered and temperature function is active 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 wWcOAcrivE 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 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 Orco LOW WATER Illuminates if boiler is in low water condition Limit control will prevent burner operation during this condition
76. ve sheet metal screws If reduced clearance prevents door from opening fully one securing top panel to jacket rear panel Slide top panel of the following can provide full access towards front of boiler and lift off of side panel Burner can be removed to allow full rotation of door 9 Locate shorter of two 1 1 4 adapters Thread thru Door with burner mounted can be lifted off hinges and insulation slot into supply port in rear of boiler Locate set aside during servicing 1 1 4 x 3 4 x 1 1 4 elbow and assemble onto adapter Door mounting hardware is reversible from left side Verify connections are tight with outlet facing directly hinge as shipped to right side hinge To reverse hinge up See Figure 6 arrangement See Figure 5 10 Locate longer of the two 1 1 4 adapters Assemble Lift door off mounting eye bolts and set aside Remove onto elbow 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 1 1 4 ADAPTER order to swing door open Figure 6 Adapter Assembled Onto Elbow 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
77. way Conduct these tests with flame A Preliminary steps present See Figure 37 1 Check wiring connections and power supply Flame Detection Range II Verify power is on to controls Normal 0 1600 ohms III Verify limit control is closed e Limited 1600 ohms to lockout IV Check contacts between igniter and electrodes E Power Failure Check After flame is established turn power off to control burner Burner should shut down safely When power is restored normal ignition sequence should be started V Check piping to oil tank B Safe Start Check 1 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 C Simulate Flame Failure And Ignition Failure I Initiate call for heat II After flame is established and burner igniter turns off close hand valve in oil supply line III At flame loss control will enter recycle mode Verify green light is flashing Control will remain in recycle for 60 seconds 43 16 OPERATING THE BOILER SYSTEM START UP Figure 38 Sequence of Operation 6 A B Ovaive on i 9 dela O Pump rime Lockout T Recycle Genisys Control Sequence of Operation Standby Burner is idle waiting for call for heat Valve On Delay Igniter and motor are on while control delays turning on oil sole

Utica Boilers TriFire TRB 3 Operation and Installation Manual

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