Utica Boilers Trifire Trb 3 Operation And Installation Manual

2015-05-20

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

TRIFIRE SERIES II

High E󰮐ciency

Oil Fired Hot Water Boiler

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Models

TRB4075

TRB4095

TRB4110

TRB5100

TRB5115

TRB5135

TRB6130

TRB6145

TRB6165

TRB7165

TRB7180

TRB7190

TRIFIRE OIL-FIRED CAST IRON HOT WATER BOILER

Per Energy Star specications, AFUE

is rounded to the nearest whole

percentage point. As such, these

products qualify for Energy Star.

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

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

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

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

notice and without incurring any obligation, whatsoever.

Models

TRB5100

TRB6130

DIMENSIONS

Sections

Flue Size

Inches

(cm)

Dimension

Inches

(cm)

4 5 (13) 18 3/8 (46)

5 5 (13) 21 5/8 (56)

6 5 (13) 24 7/8 (64)

7 6 (15) 28 1/8 (72)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Check Out Certicate..................... ...............................................................................70

TABLE OF CONTENTS

1.1 OIL FIRED BOILERS

Boiler is low pressure, sectional cast iron constructed

and tested for maximum working pressure of 65 psi in

accordance with A.S.M.E. (American Society of Mechanical

Engineers) Section IV Standards for cast iron heating

boilers. Capacity rated in accordance with AHRI (Hydronics

Institute).

Boiler is pressure red natural draft (chimney vented)

oil red hot water boiler comprised of cast iron sections,

available with 4, 5, 6 or 7 sections. Sections are held

together by push nipples and threaded rods.

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 ring #2 fuel oil from 0.75

gph up to 1.90 gph.

Boilers include -

• Limit, 220° F maximum, operating control with integral

low water cut off.

• Temperature and pressure gauge

• 30 psi relief valve

• Drain valve

1 - INTRODUCTION

WARNING

Installations of boilers and venting shall be done

only by a qualied expert and in accordance with

this manual. Installing or venting a boiler or any

other oil appliance with improper methods or

materials may result in serious injury or death due

to re or to asphyxiation from poisonous gases

such as carbon monoxide which is odorless and

invisible.

NOTICE

Surface rust on cast iron sections may be attributed

to manufacturing process as well as condensation

during storage. Surface rust is normal and does not

affect performance or life of boiler.

2 - SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualied agency.

WARNING

Fire, explosion, asphyxiation and electrical shock

hazard. Improper installation could result in death

or serious injury. Read this manual and understand

all requirements before beginning installation.

WARNING

Modication, substitution or elimination of factory

equipped, supplied or specied components could

result in death or serious injury.

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided,

WILL result in death or serious injury

This is the safety alert symbol. Symbol alerts you to

potential personal injury hazards. Obey all safety messages

following this symbol to avoid possible injury or death.

2.2 Become Familiar With Symbols Identifying

Potential Hazards.

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 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:

• Installation by licensed plumber or gas tter.

WARNING

Construction materials of appliance and products

of combustion and fuel contain alumina, silica,

heavy metals, carbon monoxide, nitrogen

oxides, aldehydes and /or other toxic or harmful

substances which can cause death or serious injury

and which are known to the State of California to

cause cancer, birth defects and other reproductive

harm. Always use proper safety clothing,

respirators and equipment when servicing or

working nearby the appliance.

WARNING

Product contains berglass wool and refractory

ceramic bers. Possible cancer hazard. May cause

irritation to skin, eyes and respiratory tract. To

avoid this hazard, wear a dust mask and gloves

when handling berglass and ceramic bers.

NOTICE

Used to address practices not related to personal

injury.

3.1 Installation and Operation

Do not operate unit if any control, switch, components

or devices have been underwater or subject to water

damage.

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

electricity and oil supply to boiler when working on it.

Inspect oil line and connections for leaks.

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

result in early failure of boiler sections, and result in a

potentially dangerous situation.

Never vent boiler into enclosed space. Always vent to

the outside. Never vent to another room or inside a

building.

Verify adequate air supply for complete combustion.

Relief valve automatically lifts open when system

pressure exceeds 30 psi. Before installing relief valve

read manufacturer’s instructions. Pipe relief valve to a

safe location. Check with authorities having jurisdiction.

Consider system total water volume, temperature,

initial ll pressure and arrangement when sizing and

installing expansion tank. Improperly installed and

sized expansion tank may result in frequent lifting of

relief valve or other heating system problems. Follow

expansion tank manufacturer guidelines for installation,

and sizing.

Boiler manufacturer recommends initial ll pressure of

10-12 psi. For higher ll pressures increase expansion

tank’s air charge to match ll pressure.

10.

Purge heating system of air and gases is critical for

proper circulation and quiet performance. Once the air

is purged, for boiler installations using oat type vents,

air vents should be closed for normal operation. If air

is heard or noticed by loss of heat, purge system and

open vents for short period of time.

3.2 Prior To Installing The Boiler

• Verify you have selected right size boiler with proper

capacity. AHRI rating of boiler selected should be greater

than or equal to calculated peak heating load (heat loss)

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

hot water heating systems. Use heat loss calculations

based on approved methods. See Figure 1, Page 8

• Boiler must be supplied with proper oil supply and oil

piping, sufcient fresh combustion air, and suitable

electrical supply.

• Connect boiler to suitable venting and piping systems

adequate to distribute heating load.

• Installation is not complete unless pressure relief valve

is installed 3/4” tapping located in supply piping.

• Thermostat must be properly located and installed

• Failure to pipe boiler correctly may result in excessive

noise or other related problems.

Existing Water System Evaluation

A good system will prevent oxygen contamination of boiler

water.

Causes of oxygen contamination may be:

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

leaks.

B. Absorption through open tanks and ttings.

C. Oxygen permeable materials in the distribution

system.

To insure long product life, oxygen sources must be

eliminated.

Take the following measures:

A. Repair system leaks.

B. Eliminate open tanks from the system.

C. Eliminate and/or repair ttings which allow oxygen

absorption.

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

3 - BEFORE YOU START

GPH = U.S. Gallons per Hour

Mbh = 1000 Btu (British thermal units) per hour.

psi = Pounds per square inch

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

hydrostatically tested for maximum working pressure of 65 psi in accordance with the latest revision of the A.S.M.E.

(American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.

AFUE= Annual Fuel Utilization Efciency

Heating Capacity and AFUE based on 13.1% CO2 (13.5% CO2 at 0.95 GPH and 1.10 GPH), -0.02” w.c. draft in breech, and

# 1 smoke or less. Testing is done in accordance with U.S. DOE (Department of Energy) test procedure.

Heating Capacity indicates amount of heat available after subtracting losses up the stack. Remaining heat is available

to heat water. Small portion is heat from jacket and surfaces of boiler and this heat stays in structure. Net AHRI rating

represents portion of remaining heat applied to heat radiation or terminal units (i.e. nned tube baseboard, cast iron

radiators, radiant oor, etc.). Difference between Heating Capacity and Net AHRI Rating, called piping and pickup

allowance, establishes reserve for heating volume of water in system and offsetting heat losses from system piping. Net

AHRI ratings shown are based on piping and pickup factor of 15% in accordance with AHRI Standard as published by

Hydronics Institute.

Net AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building

or area(s) served by boiler and associated hot water heating systems. Consult manufacturer before selecting boiler for

installations having unusual piping and pickup requirements.

4 - RATINGS & CAPACITIES

Table 1 RATINGS & CAPACITIES

OIL-FIRED HOT WATER BOILERS

Number

Sections

Firing

Rate

[GPH]

Input

[Mbh]

Heating

Capacity

[Mbh]

Net

AHRI

Rating

[Mbh]

*MAWP

Water

[psi]

AFUE

[%]

Min. relief

Valve

Capacity

[Mbh]

Max.

Water

Temp

[°F]

Chimney

Liner Size

Round

[Inches]

Chimney

Liner

Size

[Square

Inches]

Flue

Size

[Inches]

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

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

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

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

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

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

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

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

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

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

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

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

Boiler is suitable for installation on combustible

ooring. Do not install boiler on carpeting.

Locate boiler in front of nal position before removing

crate.

Locate unit so vent pipe connection to chimney will be

short and direct.

For basement installation, provide solid elevated base,

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

encountered on oor around boiler.

Provide recommended service clearance, if applicable,

as follows:

• Clearance from Jacket Front Panel

24” for servicing burner

• Clearance from Jacket Side Panels

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

mounted, otherwise 2” with burner removed.

• Clearance From Jacket Rear Panel

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

this dimension will also be controlled by horizontal to

vertical to horizontal smoke pipe arrangement. See

Figure 1

Minimum clearances to combustible material see

Figure 1 and Table 2.

Table 2 - BOILER CLEARANCES

Unit Combustible

Clearance

Accessibility,

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 ue.

Fresh air for combustion and ventilation must be 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 ue pipe. If Type

L vent is used, clearance may be reduced to minimum

required by vent pipe manufacturer.

15”

Figure 1 - Clearances to Combustible Construction

5 - LOCATING THE BOILER

WARNING

Fire hazard. Do not be install on carpeting. Failure

to follow these instructions could result in death or

serious injury.

6 - INSTALLATION REQUIREMENTS

NOTICE

Shut off manual fuel supply valve if burner is shut

down for extended period of time.

Figure 2 - General Requirements For A Typical Installation

LIMIT

RELIEF

VALVE

CHECK LOCAL CODES FOR

MAXIMUM DISTANCE FROM

FLOOR, OR OTHER ALLOWABLE

SAFE POINT OF DISCHARGE.

Determine volume of space (boiler room). Rooms

communicating directly with the space in which

appliances are installed, through openings not furnished

with doors, are considered a part of the space.

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

Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round the

result to the nearest 1000 BTU/hr.

Determine type of space. Divide Volume by total input

of all appliances in space. If the result is greater than

or equal to 50 ft3/1000 BTU/hr, then it is considered

an unconned space. If the result is less than 50

ft3/1000 BTU/hr, then the space is considered a

conned space.

When a boiler is located in an unconned space of a

conventionally constructed building, fresh air inltration

through cracks around windows and doors normally

provides adequate air for combustion and ventilation.

Provide outdoor air for boiler located in a conned

space or an unconned space in a building of unusually

tight construction. Outdoor air may be provided with

the use of two permanent openings which communicate

directly or by duct with the outdoors or spaces

(ventilated crawl or attic) freely communicating with

the outdoors. Locate one opening within 12 inches

of top of space. Locate remaining opening within 12

inches of bottom of space. Size each opening per the

following:

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

conned space: Use indoor air if two permanent

openings communicate directly with additional space(s)

of sufcient volume such that the combined volume of

all spaces meet criteria for unconned space. Size each

opening for minimum free area of 1 square inch per

1,000 BTU per hour input of all equipment in spaces,

but not less than 100 square inches.

Louvers and Grilles of Ventilation Ducts

A. All outside openings should be screened and

louvered. Screens used should not be smaller than

1/4 inch mesh. Louvers will prevent the entrance of

rain and snow.

B. Free area requirements need to consider the

blocking effect of louvers, grilles or screens

protecting the openings. If the free area of the

louver or grille is not known, assume wood louvers

have 20-25% free area and metal louvers and grilles

have 60-75% free area.

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

position, or interlocked with the equipment to open

automatically during equipment operation.

Figure 3 - Air Openings For Boiler Located In

Conned Space (Utility Room)

7 - FRESH AIR FOR COMBUSTION

WARNING

Asphyxiation, re hazard. Do not obstruct air

openings to combustion area. Follow instructions

below, to maintain adequate combustion air.

NOTICE

Install outside air intake if used with a replace or

kitchen or bathroom exhaust fan. These devices rob

boiler and water heater of combustion air.

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

Table 3 - FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS

Fresh Air

Duct Size

¼” Mesh

Screen

Wood

Louvers

Metal

Louvers

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

3 ½” x 12” 144,000 36,000 108,000

8” x 8” 256,000 64,000 192,000

8” x 12” 384,000 96,000 288,000

8” x 16” 512,000 128,000 384,000

*Btuh = British Thermal Units per hour based on

opening covered by ¼” mesh screen , wood lou-

vers, or metal louvers.

Figure 4 - Fresh Air Openings

7 - FRESH AIR FOR COMBUSTION

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 oor.

5. Open burner swing door

Proper method to closing

and securing burner swing door opened for inspection,

cleaning or eld service.

A. Loosen and remove non-hinged side latching

hardware.

B. Remove hinged side latching hardware.

C. Door can be swung to full open position

approximately 90 to 120 degrees with the burner

mounted providing there is 22” of clearance to the

adjacent wall.

NOTICE

Burner door may come off hinges if lifted when

opened.

If reduced clearance prevents door from opening fully, one

of the following can provide full access:

• Burner can be removed to allow full rotation of door.

Door with burner mounted can be lifted off hinges and

set aside during servicing.

• Door mounting hardware is reversible from left side

hinge (as shipped) to right side hinge. To reverse hinge

arrangement. See Figure 5.

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

mounting eye bolts from left side. Move door mounting

eye bolts to right side. Tighten both sets of hardware.

Lift door and place integral cast hinge pins on door into

slotted mounting bracket holes.

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

order to swing door open.

6. Inspect Swing door insulation and rope gasket.

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

distribute rope around perimeter of door groove

do not bunch or overhang. There must not be

a gap where two ends of rope meet. Repair or

replace if rope is damaged or if there is gap

between ends.

B. Inspect burner swing door insulation for damage.

C. Combustion chamber and raised portion between

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

in door insulation as designed.

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

8 - BOILER ASSEMBLY

5/8 BOLT

(BOLT INTO FRONT SECTION)

EYEBOLT & NUT

AS HINGE

EYEBOLT & NUT

AS HINGE

Figure 5 - Reversible Hinge

NOTICE

For purpose of these instructions, all pipe

connections shall use pipe dope or Teon tape to

assure water tight connections unless otherwise

instructed. Steps 6 thru 16, Figure 10, Page 15.

7. Open accessory carton

and remove contents. Identify

components using illustrations

throughout this section

applicable to your installation.

8. Remove top panel

. Remove sheet metal screws

securing top panel to jacket rear panel. Slide top panel

towards front of boiler and lift off of side panel.

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

. Thread thru

insulation slot into supply port in rear of boiler. Locate

1 1/4 x 3/4 x 1 1/4 elbow and assemble onto adapter.

Verify connections are tight with outlet facing directly

up. See

Figure 6

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

. Assemble

onto elbow.

Figure 6 - Adapter Assembled Onto Elbow

1 1/4” ADAPTER

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

ELBOW

RELIEF VALVE

NOTICE

Do not install valve between boiler and controls

manifold or relief valve.

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

long female adapter with 3/4” tapping

facing toward

front of boiler and joint is water tight.

12. Install Limit control mounting plug

in upper 3/4”NPT

port facing front.

13. Install Limit control & harness assembly

. Loosen

mounting screw on bottom of limit control.

A. Mount control on mounting plug and tighten screw

to secure control. See

Figure 7.

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

inserted to bottom of control well in top of rear

boiler section and secured with grommet. See

Figure 8.

C. Route thermal limit/LWCO sensor wire to control

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

Page 17.

Figure 7 - Control On Mounting Plug w/Screw

WARNING

Burn and scald hazard. Relief valve could

discharge steam or hot water during operation.

Check local codes for maximum distance from oor

or allowable safe point of discharge. Installation of

relief valve shall be consistent with ANSI/ASME Boiler

and Pressure Vessel Code, Section IV.

14. Install Relief Valve.

See

Figure 9

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

NOT install shutoff valves, plugs or caps.

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

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

outlet facing directly up. Install relief valve with outlet

facing horizontally.

C. Pipe discharge of relief valve. Installation of relief

valve must be consistent with ANSI/ASME Boiler and

Pressure Vessel Code, Section IV.

Figure 8 - Grommet

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

models)

. See Table 4, Page 16.

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

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

See

Figures 11 & 12

. Liner should be ush with front

edge of heat exchanger ns.

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

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

way such that position tab touches casting between

2nd and 3rd Pass ue way. See

Figure 13, Page 16.

Efciency of boiler is based on insertion of ue way bafes

in 4, 5 and 6 section units. Bafes will generate lower gross

stack temperatures entering chimney. This has the potential

under certain operating conditions to cool ue gases below

dew point, creating condensation on interior chimney and

chimney connector surfaces. Remove bafes to increase

stack temperature if there are any signs of condensation in

chimney or chimney connector. Removing bafes alone may

not address condensation depending on other boiler and

heating system operating conditions.

NOTICE

Flue gas condensate is corrosive, which requires

special consideration and must be addressed

immediately.

8 - BOILER ASSEMBLY

TIGHTEN

SCREW

MOUNTING

PLUG

SENSOR IN WELL

WITH GROMMET

Figure 9 - Relief Valve

Figure 10 - Supply Piping and Control Assembly

8 - BOILER ASSEMBLY

NOTICE

Do not install valves between boiler and controls manifold

or relief valve.

BACK OF BOILER

RELIEF VALVE

LIMIT CONTROL

WITH INTEGRAL

LOW WATER

CUT OFF

THERMAL/ LWCO

WIRE

BURNER WIRING

16. Connect Field Wiring.

See “13 - Electrical

Connections” on page 34.

A. Route wire harness from burner to Limit control

through rear jacket panel. See

Figure 15, Page 17.

Connect molex plug on burner wire harness to its

receptacle on limit control.

B. If optional manual reset high temperature limit is not

used, ensure supplied jumper is installed.

C. Connect the wiring harness from limit control to

circulator. See

Figure 15, Page 17.

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

control. Provide appropriate overcurrent protection

and service disconnect switch.

E. Wire power supply. See

Figure 15, Page 17

Connect green wire to grounding lug. When

installing wiring through hole in Limit, use anti-

abrasion cable clamp. Connect black “hot” wire to L1

of terminal block, white “N” wire to L2 of terminal

block.

17. Install top panel.

Place on top of side panels. Position

tabs in top panel into slots in side panels. Push top

panel toward back of boiler. Install rear panel screws.

18. Install drain valve

. Install drain valve with hose

connection facing right or left. This allows clearance

for swing door to open and close with drain and

hose attached. Verify connection is water tight. See

Figure 16, Page 17.

19. Close burner swing door

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

pressure directly to door while re-installing securing

hardware with your opposite hand. Always install

non-hinged side latching hardware rst, then install

hinged side hardware. Apply additional pressure

while hand tightening hardware as far as possible,

then release pressure.

Table 4

- BAFFLES & LINERS

Sections Liner Liner

Length Bafes

4Oval 4” 9”

5** V SHAPE 9” 12”

6 V SHAPE 12” 15”

7 V SHAPE 14” NONE

** 9” V liner used only on Models 5115 and 5135

and only with Beckett NX burner. All other 5 section

models and burner combinations use no liner.

Figure 11 - Oval Liner

Figure 12 - V-Shaped Liner

Figure 13 - 3rd Pass Bafes

8 - BOILER ASSEMBLY

Figure 14 - Circulator Wiring

8 - BOILER ASSEMBLY

Figure 15 - Limit Control Wiring

NOTICE

Ensure all conduit is secured to prevent contact with

ue pipe

Figure 16 - Drain Valve

B. Use hand wrench to tighten door hardware and start

with non-hinged side. Use alternating tightening

method from non-hinged side to hinged side to

tighten door equally until sealed without applying

excessive torque. Never tighten hinged side ange

bolt rst or tighten either piece of hardware 100%

without using alternating tightening method

described above.

NOTICE

When securing burner swing door, make sure door is

drawn-in equally on both sides.

Failure to follow the prescribed procedure could

cause thread damage to casting or a leak in the

door seal. If hinged side is tightened before the

unhinged side, the hinged side of door cannot

be drawn to provide an air-tight seal. Applying

excessive torque will only cause thread damage.

20. Install oil burner.

• Check oil nozzle in burner for size, angle and type,

inspect electrode settings, check head setting, check air

band and air shutter settings.

See “Oil Burner, Nozzle,

& Air Settings” on page 49.

• DO NOT install burner without gasket. Place oil burner

gasket on face of burner swing door with 4 burner

ange bolts installed part way.

• Align round part of key hole slots of burner ange with

burner door bolts. Turn burner to lock in place.

• Tighten all 4 cap screws using diagonal sequence.

• Plug burner power cord into burner harness.

• Attach exible oil hose included in parts box.

THERMAL/

LWCO

WIRE

BLACK

WIRE TO

WHITE

WIRE TO

RED

WIRE

TO B1

DRAIN

VALVE

BLACK

YELLOW

GREEN TO

GROUND

SCREW

WHITE

C1, C2

CIRCULATOR

WIRING

9.1 Connect System Supply And Return Piping

To Boiler

Connect system supply and return piping to correct

boiler ttings.

Size system circulator to supply sufcient ow (GPM)

to allow 20°F temperature differential in system.

When sizing system circulator, use single most

restrictive zone to determine maximum pressure

drop.

Boiler used in connection with refrigeration systems,

install boiler so chilled medium is piped in parallel with

heating boiler using appropriate valves to prevent

chilled medium from entering boiler. See

Figure 28,

Page 31

If boiler is connected to heating coils located in air

handling units exposed to refrigerated air, equip boiler

piping with ow control valves to prevent gravity

circulation of boiler water during operation of cooling

system.

Limit control includes low water cutoff function, sensing

water level at control well in top of the rear boiler

section. Periodic inspection and testing is necessary

per instructions provided with limit control.

When installation of boiler is for new heating system,

install all radiation units (panels, radiators, baseboard,

or tubing) and supply and return mains. After heating

system piping and components have been installed,

make nal connection of system piping to boiler.

Recommend mount circulating pump on supply side

piping, such that it pumps away from expansion tank.

Hot water boiler installed above radiation level must

be equipped with low water cut off device. This boiler

is factory equipped with low water cutoff. Periodic

inspection is necessary, per manufacturer’s specic

instructions.

When connecting cold water supply to pressure

reducing valve, make sure clean water supply is

available. When water supply is from well or pump,

install sand strainer at pump.

9.2 Bypass Piping

See Piping Diagrams for illustrations for this section.

Bypass piping may be required for applications listed

below. Failure to do so may cause damage due to thermal

shock and sustained condensation within the boiler.

Protect boiler from sustained operation of return water

temperatures lower than 130°F (54C). Occasionally,

temperatures as low as 70°F (21C) may return back to

boiler when a zone that has not been activated for some

time is opened. However, most residential systems with

nned-tube (aluminum-copper) baseboard radiation

contain low volume of water and will not adversely affect

boiler. Systems with nned-tube baseboard radiation

typically do not require bypass.

Bypass piping details shown in piping diagrams must be

used for any one of following conditions:

• All large water content systems, including cast iron

standing radiators, cast iron baseboard, converted

two-pipe steam systems, converted gravity circulation

systems and other similar systems.

• Any system, including nned-tube baseboard, with

priority domestic hot water zone.

Install ¾ inch bypass line as shown in piping diagrams

for

systems identied above.

Bypass valve cannot protect boiler from sustained

condensing operation for low temperature applications such

as radiant oor heating. These types of system require

active controls that prevent return of cold return water to

boiler.

Refer to Radiant Professional’s Alliance (RPA)

www.radiantprofessionalsalliance.org for piping

recommendations for non-condensing boiler applications.

9 - BOILER SYSTEM PIPING

Figure 17 - Standard Near Boiler Piping

10 - HYDRONIC PIPING

Piping Diagram Legend

DHW Heater

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

10 - HYDRONIC PIPING

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

T-STAT

ZONE 2

PRIORITY

CONTROL

ARM-2P

ISOLATED

SWITCH

X1 X1

ISOLATED

SWITCH

PRIORITY

120VAC CIRCULATORS

X2 L1

ZONE 2

LN N

WITH

X-X

PRIORITY ON

++ZONE 1

FUSE

ELECTRONIC

DATA PORT T

W1RTW

PRIORITY

ZONE

120 VAC

L N

PRIORITY ON

ZONE 2

ZONE MODULE

TO EXTRA

24 VAC @ 1 VA

2TR

COMMON

THERMOSTAT

6 TO 7 INCH LBS

TORQUE TERMINAL SCREWS

CIRC

DHW

CIRC

120 VAC

TO OIL

BURNER

HYDROSTAT

MODEL 3250

FIGURE 18

(SEE FIGURE 20)

CIRC

DHW ZONE

VALVE

120 VAC

TO OIL

BURNER

120VAC

N L

PRIMARY

PUMP

L N

PRIORITY

PUMP

L N

FROM BOILER

ZCZR

120 VAC

TO XFRM

24 VAC

TO DPM-2

X-X CONTACT

ZR ON

PRIORITY PUMP

PRIMARY PUMP

PRIORITY ON

STATUS

ZC ON

PRI ZONE 1

1 2

ZONE 4

43 1 3

ZONE 2

2 4

ZONE 3

1 2 3 4 21 3 4

OPTION SWITCHES

ZR-ZC

DPM-2

ZONE VALVE / PUMP

PRIORITY

Z1 Z2 Z3 Z4

TT T T T T T T

AZ-4CP

120VAC TO

TRANSFORMER

24VAC FROM

TRANSFORMER

ZONE

VALVE

ZONE

VALVE

T-STAT

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

HYDROSTAT

MODEL 3250

ZONE

VALVE

RELAY

24VAC COIL

120VAC CONTACTS

FIGURE 19

OPTION SWITCHES

ZONE VALVE / PUMP

ZR-ZC

DPM-2

PRIORITY

OFF

KEY

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

Zone Valve)

10 - HYDRONIC PIPING

CIRC

120 VAC

TO OIL

BURNER

120VAC

N L

PRIMARY

PUMP

L N

PRIORITY

PUMP

L N

FROM BOILER

ZCZR

120 VAC

TO XFRM

24 VAC

TO DPM-2

X-X CONTACT

ZR ON

PRIORITY PUMP

PRIMARY PUMP

PRIORITY ON

STATUS

ZC ON

PRI ZONE 1

1 2

ZONE 4

43 1 3

ZONE 2

2 4

ZONE 3

1 2 3 4 21 3 4

OPTION SWITCHES

ZR-ZC

DPM-2

ZONE VALVE / PUMP

PRIORITY

Z1 Z2 Z3 Z4

TT T T T T T T

AZ-4CP

120VAC TO

TRANSFORMER

24VAC FROM

TRANSFORMER

ZONE

VALVE

ZONE

VALVE

ZONE

VALVE

T-STAT

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

HYDROSTAT

MODEL 3250

DHW

CIRC

FIGURE 20

OPTION SWITCHES

ZONE VALVE / PUMP

ZR-ZC

DPM-2

PRIORITY

KEY

OFF

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

(With Circulator)

10 - HYDRONIC PIPING

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

T-STAT

CIRC

120 VAC

TO OIL

BURNER

HYDROSTAT

MODEL 3250

ZONE 3

ISOLATED

SWITCH

ARM-4P

CONTROL WITH

PRIORITY

30 VA

COMMON

24AC

1L N L

ZONE 1

PRIORITY ON

X-X

ZR-ZC

ZONE 2

DATA PORT

120 VAC

L N L N

ZONE MODULE

TO EXTRA

PRIORITY ON

ZONE 4

COMMON

1 32 4

ZONE 4ZONE 3ZONE 2

ZONE

PRIORITY

THERMOSTATS

24 VAC

@ 1VA

ZONE 4ZONE 3ZONE 2PRIORITY

ELECTRONIC

FUSE

ZONE 3

ZONE 1

ZONE 2

ZONE 4

TWTRTWTRTWTRTWTR

CIRC

DHW

CIRC CIRC

T-STAT

FIGURE 21

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

10 - HYDRONIC PIPING

MAX = 4 X DIAMETER

CLOSELY - SPACED TEES

BOILER

PUMP

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

10 - HYDRONIC PIPING

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

T-STAT

CIRC

120 VAC

TO OIL

BURNER

HYDROSTAT

MODEL 3250

ZONE 3

ISOLATED

SWITCH

ARM-4P

CONTROL WITH

PRIORITY

30 VA

COMMON

24AC

1L N L

ZONE 1

PRIORITY ON

X-X

ZR-ZC

ZONE 2

DATA PORT

120 VAC

L N L N

ZONE MODULE

TO EXTRA

PRIORITY ON

ZONE 4

COMMON

1 32 4

ZONE 4ZONE 3ZONE 2

ZONE

PRIORITY

THERMOSTATS

24 VAC

@ 1VA

ZONE 4ZONE 3ZONE 2PRIORITY

ELECTRONIC

FUSE

ZONE 3

ZONE 1

ZONE 2

ZONE 4

TWTRTWTRTWTRTWTR

CIRC

DHW

CIRC

T-STAT

FIGURE 22

RELAY

120VAC COIL

120VAC CONTACTS

BLR

CIRC

ZONE 1 (PRIORITY ZONE)*

* USE FULL PORT ZONE

VALVE.

FOR OPTIMUM TANK

PERFORMANCE,

CONSIDER USING ZONE

CIRCULATOR.

BOILER

PUMP

MAX = 4 X DIAMETER

CLOSLEY - SPACED

TEES

SEE FIGURE 24

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

And Domestic Hot Water (With Zone Valve)

10 - HYDRONIC PIPING

CIRC

120 VAC

TO OIL

BURNER

120VAC

N L

PRIMARY

PUMP

L N

PRIORITY

PUMP

L N

FROM BOILER

ZCZR

120 VAC

TO XFRM

24 VAC

TO DPM-2

X-X CONTACT

ZR ON

PRIORITY PUMP

PRIMARY PUMP

PRIORITY ON

STATUS

ZC ON

PRI ZONE 1

1 2

ZONE 4

43 1 3

ZONE 2

2 4

ZONE 3

1 2 3 4 21 3 4

OPTION SWITCHES

ZR-ZC

DPM-2

ZONE VALVE / PUMP

PRIORITY

Z1 Z2 Z3 Z4

TT T T T T T T

AZ-4CP

120VAC TO

TRANSFORMER

24VAC FROM

TRANSFORMER

ZONE

VALVE

ZONE

VALVE

T-STAT

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

HYDROSTAT

MODEL 3250

FIGURE 23

DHW ZONE

VALVE

RELAY

24VAC COIL

120VAC CONTACTS

ZONE

VALVE

BLR

CIRC

OPTION SWITCHES

ZONE VALVE / PUMP

ZR-ZC

DPM-2

PRIORITY

OFF

KEY

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

(With Circulator)

ZONE VALVE

MAX = 4 X DIAMETER

CLOSELY - SPACED

TEES

10 - HYDRONIC PIPING

CIRC

120 VAC

TO OIL

BURNER

120VAC

N L

PRIMARY

PUMP

L N

PRIORITY

PUMP

L N

FROM BOILER

ZCZR

120 VAC

TO XFRM

24 VAC

TO DPM-2

X-X CONTACT

ZR ON

PRIORITY PUMP

PRIMARY PUMP

PRIORITY ON

STATUS

ZC ON

PRI ZONE 1

1 2

ZONE 4

43 1 3

ZONE 2

2 4

ZONE 3

1 2 3 4 21 3 4

OPTION SWITCHES

ZR-ZC

DPM-2

ZONE VALVE / PUMP

PRIORITY

Z1 Z2 Z3 Z4

TT T T T T T T

AZ-4CP

120VAC TO

TRANSFORMER

24VAC FROM

TRANSFORMER

ZONE

VALVE

ZONE

VALVE

ZONE

VALVE

T-STAT

CONTROL

TANK

OR THERMOSTAT

HEATER, AQUASTAT

INDIRECT WATER

HYDROSTAT

MODEL 3250

DHW

CIRC

RELAY

24VAC COIL

120VAC CONTACTS

FIGURE 24

OPTION SWITCHES

ZONE VALVE / PUMP

ZR-ZC

DPM-2

PRIORITY

OFF

KEY

BLR

CIRC

BOILER ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM FROM SYSTEM

V2V1

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE AIR SEPARATOR

ZONE VALVE

EXPANSION

TANK

WATER INLET

SYSTEM

CIRCULATOR

Figure 26 Bypass Piping (Fixed Low Temperature Only)

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

BOILER

WATER INLET

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM FROM SYSTEM

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE

3 WAY MIXING

VALVE

AIR SEPARATOR

HOSE BIB

EXPANSION

TANK

10 - HYDRONIC PIPING

Figure 25 - Bypass Piping Automatic Mixing Valve

BOILER ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM

FROM SYSTEM

CIRCULATOR

WATER INLET

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE AIR SEPARATOR

HOSE BIB FLOW CONTROL

VALVE

4-WAY MIXING

VALVE

EXPANSION

TANK

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

10 - HYDRONIC PIPING

SHUT OFF

VALVES

SHUT OFF

VALVES

BOILER

SUPPLY MAIN TO

COMBINED HEATING

& COOLING SYSTEM

RETURN MAIN FROM

COMBINED HEATING

& COOLING SYSTEM

CIRCULATOR

WATER CHILLER

AIR CUSHION

TANK

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

Figure 29 - Single Pipe Oil Line

Figure 30 - Double Pipe Oil Line

11 - FUEL SUPPLY PIPING

11.1 Installation of oil tank and piping shall conform

to requirements of authority having jurisdiction or in

absence of such requirements National Board of Fire

Underwriters . In addition, refer to NFPA 31 (U.S.) or

CSA B139 (Canada)

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

caps shall conform to requirements of authority

having jurisdiction.

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

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

• Suction line from tank to burner should be one

continuous piece of tubing to prevent air entering line

• Suction line, must be ⅜" O.D. copper tubing for runs of

50 feet or less, and ½" O.D. for longer runs.

• Use oil return line, same size as the suction line, on

installations where bottom of tank is below fuel unit of

burner.

• Bury oil lines or protect from mechanical injury.

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

ttings on suction line often allow air to be drawn into

fuel pump, making it difcult to maintain oil pressure at

nozzle.

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

• Follow instructions, attached to fuel pump, for fuel pump

and by-pass connections.

• Install two stage fuel unit if tank is more than 20' from

boiler in place of single stage pump supplied as standard

equipment with burner. Verify rotation and speed are

identical and pump is suitable for burner horsepower

rating.

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

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

burner for convenience in servicing burner.

• Allow extra tubing at burner so burner may be removed

from boiler for cleaning without disconnecting tubing.

See Figure 29 and 29.

• Use exible oil lines so burner swing door can be opened

without disconnecting oil supply piping.

Table 5 - TWO STAGE UNITS,

TWO PIPE SYSTEMS (SEE FIGURE 15)

LIFT

“H”

Maximum Length of Tubing “R”

3/8” O.D.

Tubing (3 GPH)

1/2” O.D.

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 FT.

12.1 Antifreeze added to boilers must be nontoxic,

and must be of type specically intended for use in closed

hydronic heating systems. Under no circumstances should

automotive antifreeze be used. Antifreeze used in any

boiler may reduce capacity by 10% or more and increase

fuel consumption. See Table 6 and 7.

Table 6 - BOILER WATER VOLUMES

Number of

Boiler Section

Total Volume

(Gallons)

4 3.6

5 4.3

6 5.1

7 5.9

Table 7 - PIPING WATER VOLUMES

PIPE SIZE

COPPER

PIPE

FACTOR

STEEL PIPE

FACTOR

½” 82.5 63.5

¾” 40.0 36.0

1” 23.3 22.2

1 ¼” 15.3 12.8

1 ½” 10.8 9.5

2” 6.2 5.8

Divide total length of piping in feet by

appropriate factor in table to determine volume

in gallons.

12 - ANTIFREEZE IN THE SYSTEM

13 - ELECTRICAL 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.

WARNING

Electrical shock hazard. Turn OFF electrical power

supply at service panel before making electrical

connections. Failure to do so could result in death

or serious injury.

SEE APPROPRIATE ADDENDUM FOR WIRING

DIAGRAMS

Table 8 - Recommended Minimum Chimney Sizes

FIRING RATE

(gph)

CHIMNEY

HEIGHT (ft)

NOMINAL

CHIMNEY

ROUND

LINER INSIDE

SQUARE

LINER

INSIDE

0.60 -1.30 15 8” x 8” 6” 6 ¾” x 6 ¾”

1.31 -1.80 15 8” x 8” 7” 6 ¾” x 6 ¾”

1.81 -2.00 20 8” x 8” 8” 6 ¾” x 6 ¾”

For elevations above 2,000 feet above sea level, add 3 feet to the chimney heights.

14.1 Chimney Venting

Oil red boilers with connections to vents or chimneys,

vent installation shall conform to requirements of

authority having jurisdiction or in absence of such

requirements NFPA 31 Installation Of Oil Burning

Equipment (U.S.) or CSA B139 (Canada) and

applicable provisions of local building codes.

Installation shall conform to requirements of

NFPA31 – Standard for the Installation of 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).

Ensure sufcient draft during heating season to allow

for safe evacuation of ue gasses.

Boiler can be vented into reclay tile-lined masonry

chimney or type L vent or factory built chimney that

complies with type HT requirements of UL103. See

Figure 32, Page 37

Chimney Inspection – Prior to installation of any new or

replacement fuel burning equipment chimney shall be

inspected by qualied service agency.

A. De-rating may cause condensation on interior

walls of chimney and boiler. Loose mortar can be

indication of history of condensing ue gases upon

inside walls of chimney. Do not install chimney until

it meets requirements of NFPA 211 or CSA B139.

B. Unlined Chimney – Do not install boiler if chimney

is constructed of brick only. Only approved clay

liners or listed chimney lining systems shall be used

as specied in NFPA 31 or CSA B139.

C. Abandoned Openings – Seal Openings through

chimney wall that are no longer used in accordance

to NFPA 211.

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

debris.

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

of straight run up-stream of regulator ensures proper

operation.

Draft Regulator – Use supplied draft regulator with this

appliance. Do not use any other draft regulator. See

Figure 31, Page 37

14 - CHIMNEY AND VENTING CONNECTIONS

14.2 Vent and Vent Connector

Vent connector should be kept as short as possible.

Horizontal length of vent connector should not be

greater than 10 feet.

Type L Vent pipe or other suitable material may be

used for vent connector if ue temperature is less than

570° F.

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

spacer included in accessory carton for attaching 5”

diameter vent connector to cast iron ue collar. For

7 section boiler, 6” diameter vent connector attaches

directly to cast iron ue collar.

Attach vent connector and ue adaptor ring to cast

iron ue collar with three screws. Pre-drill cast iron ue

collar to prevent cracking.

Canadian versions have vent spill switch kit included.

Inspect chimney and connector annually for signs of

debris and corrosion. Loose mortar at base of chimney

may be sign of condensate damage to chimney.

Inspect base of chimney for any signs of seepage.

Discoloration may be a sign of chimney damage. Have

repaired immediately.

Contact qualied service agent immediately to examine

damage and correct. Operation of damaged chimney

may cause venting failure and force ue gases into

living space.

If chimney is to be re-lined, use recommendations in

NFPA31, Appendix E or CSA B139.

14.3 Draft

• Natural draft generated through chimney is dependent

on several factors including, chimney height,

temperature of ue gases, cross section area of

chimney, chimney wall insulation value, dilution air and

total volume of ue gases. Operate boiler for at least 5

minutes before measuring draft.

• Minimum Draft at Breech – Draft induced by the

chimney must create at least a neutral pressure of 0

(zero) inches water column (INWC) at breech. Slightly

negative (i.e. suction) pressure is preferred. Pressure

at breech cannot be positive since this could create

condition that allows ue gas by-products to escape

from draft regulator. Draft is to be measured up stream

of draft regulator. See Burner Specications.

• Over-re Draft - Measure pressure at 1/4” NPT test port.

Three pass boilers have higher pressure drop than single

pass. Table 8A shows expected pressure drop between

over-re and breech. Total pressure drop is difference

between over-re draft and breech draft. For example,

if over-re draft = 0.05 INWC and breech draft = - 0.05,

total pressure drop = 0.05 - (-0.05) = 0.10 INWC. See

Figure 33, Page 37

Table 9 - Pressure Drop Between

Over-Fire & Breech

Sections Inches WC

4 0.03-0.05

5 0.05-0.08

6 0.09-0.16

7 0.07-0.16

14.4 Stack Temperature

Higher stack temperature, greater amount of draft

generated. Lower stack temperature not only reduces

amount of draft created but also increases possibility

ue gases could condense in chimney connector or

stack.

Consult NFPA 31 and CSA B139 for information for

appropriate choice of venting materials. Chimney may

have to be lined to create sufcient draft, or chimney

may have to be lined to prevent corrosion of masonry

chimney. Consult qualied service agency for chimney

requirements in your area.

Bafes – Efciency of boiler is based on insertion of

ue bafes supplied with 4,5 & 6 section units. Bafes

are installed in 3rd pass (two inner ueways). Refer to

“8 - Boiler Assembly” on page 13 for bafe installation.

Remove bafes to increase stack temperature.

Remove bafes if any signs of condensation in chimney

or chimney connector. Removing bafes may not

address condensation.

14 - CHIMNEY AND VENTING CONNECTIONS

Figure 31 - Proper Draft Regulator Locations

Figure 32 - Typical Chimney Locations

1/4”NPT TEST PORT

FOR OVER-FIRE

MEASUREMENT

Figure 33 - Pressure Tapping for Checking Draft

14 - CHIMNEY AND VENTING CONNECTIONS

Minimum height must be

at least 3 Ft higher than

highest part of passage

through roof. Must be

at least 2 FT higher

than any neighboring

object within 10 Ft. Must

have unobstructed top

opening.

Must be at least

4 inches thick -

and be tight.

Must slope up

at least 1/4

inch per foot of

horizontal run

Tight, smooth,

correctly sized

Sealed in

thimble

Tight clean-out

door

Balanced

Weight

Crimped

End

Draft Regulator

Vane

Inspect Installation Before Starting Burner.

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

electrical system are installed properly. Refer to

installation Instructions contained in this manual.

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

are turned off at source and vent is clear from

obstructions.

Fill Heating System With Water.

A. Failure to clean system can result in clogged air

vents, circulator damage and seized zone valves.

Clean heating system if boiler water is dirty. Refer to “18 -

Maintenance” on page 53 for proper cleaning instructions

for water boilers.

Fill entire heating system with water and vent air from

system.

Use following procedure on series loop or multi-zoned

system installed as per

piping diagrams

, to remove air

from system when lling:

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 ve gallon bucket

or suitable oor drain or outdoor area.

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

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

E. Open purge valve.

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

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

valve or shut-off valve. Open valve to next zone

to be purged. Repeat this step until all zones have

been purged. At completion, open all valves.

H. Close purge valve, continue lling system until

pressure gauge reads 12 psi. Close shut-off valve

in cold water supply piping.

I. Open shut off valve in boiler system piping.

J. Remove hose from purge valve.

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

L. It may be necessary to clean air vent assembly

after few days of operation.

Check controls, wiring and burner. Verify all

connections are tight and burner is rigid, all electrical

connections have been completed and fuses installed,

and oil tank is lled and oil lines have been tested.

15 - FILLING BOILER

WARNING

Fire, burn, asphyxiation hazard. Turn off service

switch to boiler to prevent accidental ring of

burner outside combustion chamber. Disconnect

burner power cord from wire harness in front jacket.

Tighten swing door fastener completely when

service is complete. Failure to follow instructions in

this manual and understand all requirements could

result in death or serious injury.

NOTICE

Boiler maximum operating pressure is posted on

ASME data label located on front lower leg of boiler.

Never exceed this pressure. Do not plug relief

valve.

Figure 34 - Limit

16 - OPERATING THE BOILER - SYSTEM START-UP

16.1 Setting The Limit Control

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

See Page 41.

16.2 Setting High Limit

To adjust, turn HI TEMP dial

until desired setting is

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

is from 100°F to 220°F (82° C to 104° C). High limit

(HL) on limit control is factory set at 190°F. Temperature

setting may be varied to suit requirements of installation.

Differentials are automatic and will vary based on control

settings and boiler temperature.

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 ensure the boiler supplies

adequate temperature to heat indirect tank.

16.5 Setting Zone/Indirect Switch

When installing with indirect water heater, zone/indirect

switch must be set in the I position, calls to ZC-ZR will

bypass thermal targeting feature and allow boiler to re to

high limit setting to heat indirect tank.

Indirect signal must be separate from all heating zone

signals.

If you choose not to separate indirect signal from heating

zones, turn off economy feature to ensure boiler supplies

adequate temperature to indirect tank.

Figure 35 - Setting Economy Feature

SETTING

OFF

Disables economy function. Will allow boiler to

re until hi-limit temp is reached and re-re

with a 10° subtractive differential.

Provides lowest level of fuel savings. Use this

setting only if the house does not stay warm at

higher settings.

Recommended setting for single zone systems.

Recommended setting for Two zone systems.

Recommended setting for Three zone systems.

Recommended setting for Four zone systems.

Recommended setting for Five zone systems.

Provides highest level of fuel savings.

16 - OPERATING THE BOILER - SYSTEM START-UP

16.6 Activating Thermal Pre-Purge (optional)

Activation of this feature is not recommended for boilers

with tankless coils.

• Limit has thermal pre-purge feature to maximize

efciency. When activated, control will purge higher

boiler temperatures down to 135°F at start of any

thermostat call and supply latent energy in boiler to

heating zone calling.

• During purge cycle, display will indicate PUR.

• If heat is not sufcient to satisfy thermostat, control will

energize burner.

• Feature works with single and multi-zone heating

systems utilizing circulators or zone valves. No change

in wiring is needed.

To Activate Thermal Pre-Purge

Push and hold TEST/SETTINGS button for 20 seconds.

Display will read PURR On.

To deactivate feature, push and hold button a second

time for 20 seconds.

Display will read PURR OFF.

16.7 Control Action On System Start-Up

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

establishes 145°F target temperature. To test high limit

shut-off function, economy dial must be turned to off.

Once tested, restore economy setting.

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

satisfy heat load.

To reduce potential for condensing, control will allow boiler

to heat to 120°F prior to energizing the circulator.

16.8 How Thermal Targeting Works

Thermal targeting technology analyzes thermostat activity

and continually evaluates how much heat the house

requires.

When it is very cold outside, heat demand is high and limit

control will raise boilers target temperature to provide heat.

When outside temperature is mild, heat demand is low.

Limit control will lower boiler’s target temperature saving

fuel.

Figure 36 - LED Legend

TEMP ACTIVE Indicates Limit Control is

powered and temperature function is active.

TEMP HI TEMP Illuminates when boiler water

temperature reaches high limit setting. Remains

lit until water temperature falls 10°F. Limit control

prevents burner operation while this LED is on. See

Differential explanation page 39.

LWCO ACTIVE Indicates low water cut-off

(LWCO) function of limit control is active. Boiler

is factory equipped with Hydrolevel electro-well,

enabling control’s low water cut-off function. LED will

be on at all times when control is powered.

Important: If control well is replaced with a well

other than Electro-Well, LED will not illuminate

indicating control is not providing low water cut-off

functionality.

WARNING

Burn and scald hazard. Do not add water until boiler

has fully cooled. Failure to follow these instructions

could result in death or serious injury.

LWCO LOW WATER Illuminates if boiler is in

low water condition. Limit control will prevent burner

operation during this condition.

Important: System must be checked by a qualied

service agency prior to resuming operation.

ECONOMY ACTIVE Indicates thermal targeting

function is active and limit control will reduce boiler

temperature to conserve fuel. Economy feature is

activated using the Economy dial. See “How Thermal

Targeting Works” this page.

16 - OPERATING THE BOILER - SYSTEM START-UP

ECONOMY TARGET Economy feature is active,

limit control continually sets target temperatures

below high limit setting to maximize fuel efciency.

When boiler water reaches target temperature, LED

illuminates and burner shuts down. Boiler water will

continue to circulate and heat the house as long as

thermostat call continues. LED will stay lit until boiler

temperature drops below differential set point at

which point boiler will be allowed to re again.

Note: LED illuminates regularly during normal boiler

operation.

TEST/SETTINGS Button

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

Settings button for 5 seconds. Display will read LCO.

LWCO TEST

LCO

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:

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

Settings button is not pressed for 5 seconds.

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, & Air Settings” on page 46.

B. Open all oil line valves.

C. Attach a plastic hose to fuel pump vent tting and

provide a pan to catch the oil.

2. Prime Pump and Start Oil Burner

A. Open bleed port tting on fuel pump.

B. Initiate a call for heat

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

approximately 15 seconds until yellow light turns on.

Indicates button has been pressed long enough.

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

starts up again.

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

still on. This transitions control to dedicated pump

priming mode, during which the motor, igniter and

valve are powered for four minutes. Yellow light will

be on.

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

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

for at least one second to exit pump priming mode

and return to standby mode.

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

control will automatically return to standby mode.

III. If prime is not established during four minute pump

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

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

pump is fully primed and oil is free of bubbles.

D. Terminate call for heat and control will resume normal

operation. Close bleed port tting on fuel pump.

E. Adjust oil pressure.

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

pressure gauge may be installed in either bleeder port

or nozzle port.

II. Initiate call for heat.

III. Locate oil pressure adjusting screw and turn screw

to obtain proper pump pressure, refer to

“17 - Oil

Burner, Nozzle, & Air Settings” on page 46

16 - OPERATING THE BOILER - SYSTEM START-UP

3. Preliminary Oil Burner Adjustments

A. Adjust Draft Regulator for breech draft of -0.05

(preferred) to 0 inches water column after chimney

has reached operating temperature and while burner is

running.

B. Use smoke tester and adjust air if necessary for

minimum smoke (not to exceed trace) with minimum

of excess air. Check using suitable instrumentation to

conrm CO2 of 11 to 13%. If ame appears stringy

instead of solid re, try another nozzle of same type.

Flame should be solid and compact.

C. Turn off burner and remove pressure gauge. Install

gauge port/bleeder plug and tighten. Start burner

again.

4. Final Burner Adjustments

: 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

ue pipe between boiler and draft regulator. Smoke

reading should be zero to trace (Shell Bacharach

Scale).

C. New boiler may require more than 10 minutes to burn

clean due to oil lm on new heat exchanger. If smoke

reading is zero, gradually close burner’s air adjustment

to obtain smoke reading showing trace smoke read-

ing. Once smoke reading is trace, measure CO2 and

as insurance margin increase air to sufciently reduce

CO2 by 1/2% to 1%.

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

verify burner head alignment. If re continues to be

smoky, replace nozzle.

WARNING

Fire, burn, asphyxiation hazard. Do not loosen

or remove any oil line ttings while burner is in

operation. Failure to follow these instructions could

result in death or serious injury.

WARNING

Fire, burn, asphyxiation hazard. Do not attempt

to start burner when oil has accumulated in

combustion chamber or unit is full of vapor, or

hot. Check operation of all boiler controls before

installation of boiler is completed. Failure to follow

these instructions could result in death or serious

injury.

E. Once burner is completely adjusted, start and stop

burner several times to assure good operation with no

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

record nozzle size, oil pressure, combustion readings,

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

boiler.

CAUTION

Do not run boiler unattended until following procedure

is completed. Failure to follow these instructions could

result in minor or moderate injury.

5. Check Genisys Oil Primary Control.

A. Preliminary steps

I. Check wiring connections and power supply.

II. Verify power is on to controls.

III. Verify limit control is closed.

IV. Check contacts between igniter and electrodes.

V. Check piping to oil tank.

B. Safe Start Check

I. Place jumper across cad cell terminals.

II. Initiate call for heat.

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

continuously and control remains in standby mode.

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

Simulate Flame Failure And Ignition Failure

I. Initiate call for heat.

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

close hand valve in oil supply line.

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

green light is ashing. Control will remain in recycle

for 60 seconds.

16 - OPERATING THE BOILER - SYSTEM START-UP

WARNING

Electrical shock hazard. Following safety checks shall

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

could result in death or serious injury.

NOTICE

Control contains no eld serviceable parts. Do not

attempt to take it apart. Replace entire control if

operation is not as described.

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

restart system.

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

burner and reset button will ash. Verify burner,

motor and igniter are off and burner solenoid valve (if

used) is not energized.

VI. Open hand valve in oil line.

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

shuts off and burner lights.

VIII. End call for heat.

Figure 37 - CAD Cell Location

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

with use of Genisys display module or Genisys

contractor tool. If not available, cad cell leads can

be unplugged from control and resistance measured

in conventional way. Conduct these tests with ame

present. See Figure 37.

Flame Detection Range

• Normal (0-1600 ohms)

• Limited (1600 ohms to lockout)

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

turn power off to control / burner. Burner should shut

down safely. When power is restored, normal ignition

sequence should be started.

Genisys Control Sequence of Operation

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

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

control delays turning on oil solenoid valve for pro-

grammed time.

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

Flame should be established within factory set trial for

ignition time (“lockout time”).

D. Lockout. Control has shut down for one of following

safety reasons:

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

being established.

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

State.

To reset from hard lockout, hold reset button 15

seconds until yellow light turns on.

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

igniter remains on for 10 additional seconds to ensure

ame stability.

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

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

it is shut down and sent to Standby.

G. Recycle. If ame is lost while burner is ring, control

shuts down burner, enters 60 second recycle delay,

and repeats ignition sequence. Control will continue to

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

time allotment. Control will then go into Hard Lockout

instead of recycle. Feature prevents excessive accu-

mulation of oil in the boiler ring chamber.

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

turned off and control delays turning motor off for set

motor-off delay time before control returns to standby.

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

valve energized for 4 minutes. During Pump Prime

mode, cad cell is disregarded, allowing technician to

prime pump without having to jumper cad cell.

Genisys Control Reset Button Operation

See Table 11 for action control takes when reset button is

pressed for different lengths of time during various burner

operation states.

16 - OPERATING THE BOILER - SYSTEM START-UP

Figure 38 - Sequence of Operation

Table 11 - Genisys Control Reset Button Operation

If burner is in below

state:

Pushing reset button will:

Button Click

(press < 1 second)

Button Hold

(press > 1 second)

Button Hold

(press 15+ seconds)

Lockout Reset from Soft Lockout Reset from Restricted (Hard)

Lockout

Valve-on Delay, Trial for

Ignition, Ignition Carry-

over

Go to Pump Prime

See

“Priming the Pump” page 44

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.

Run (Igniter shut off) No Action

Motor-Off Delay, Standby No Action

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

Table 12 - Genisys Control Status Lights

Light Color On Continuously Flashing

Red Restricted (Hard) Lockout Soft Lockout

Green Flame Sensed during normal operation

(Possible stray light during standby) Recycle

Yellow Control is in Pump Prime mode or

reset button currently held for 15+ seconds. N/A

NOTICE

Before starting or resetting control from restricted

lockout state, troubleshoot heating system for root

cause(s) of lockout.

Genisys Control - Resetting From Restricted

or Hard Lockout.

A. Make necessary repairs or adjustment to ensure

safe start condition.

B. Ensure appliance is free of oil and oil vapors

before starting or resetting burner

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

heat, or fails motor relay check, control enters Hard

(restricted) Lockout in order to limit accumulation of

unburned oil in combustion chamber.

D. To reset, hold button down for 15 seconds until red

light turns off and yellow light turns on.

E. Always verify control functions according to

specications before leaving installation site.

F. Replace control if it does not operate as specied.

Genisys Control - Disable Function

Anytime burner is running, press and hold reset button to

disable burner. Burner will remain off as long as button is

held.

WARNING

Remove jumper after following check.

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

page 44.

B. To install nozzle, remove nozzle line electrode

assembly, if necessary remove retention ring

assembly, install and tighten nozzle. Be careful not to

damage electrode insulators or bend electrode tips.

16 - OPERATING THE BOILER - SYSTEM START-UP

C. After installing nozzle, reassemble nozzle line

electrode assembly and set electrode tip spacing.

D. Electrode tip spacing may need to be set prior to

reassembling nozzle line electrode assembly. Refer

to gures on following pages for setting electrode tip

spacing on Beckett.

16.14 Check Thermostat Operation:

Thermostat

location has important effect on operation of boiler system.

A. Follow instructions included with your thermostat.

Typically, thermostat is located about ve feet above

oor on inside wall.

B. Thermostat should be located to sense average room

temperature.

Table 10 - Thermostat locations to Avoid

DEAD

SPOTS HOT SPOTS COLD SPOTS

Behind

doors

Concealed pipes Concealed pipes

or ducts

Fireplace

TV sets Stairwell drafts

Corners &

alcoves

Radios Door drafts

Lamps Unheated room

on other side of

wall

Direct sunlight

Kitchens

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.

Figure 39 - Beckett Electrode Tip Adjustments

Standard Dimensions (L1, V1) Heads

Figure 40 - Beckett Electrode Tip Adjustments

Standard Dimensions (L2) Heads

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Figure 41 - Beckett Check/Adjust “Z”

Dimensions L1 & L2 Heads

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

V1 Heads

L1/L2 Heads

See Figure 39. The important “Z” dimension is distance

from leading edge of head to end of air tube. This distance

for L1 & L2 heads is 1-3/8” if the tube has a straight shroud

or 1-3/4” if air tube has conic shroud. “Z” dimension is fac-

tory set for burners shipped with air tube installed. Even if

factory set, verify “Z” dimension has not been changed.

Use following procedure to adjust “Z” dimension, if it is

not correct:

• Turn off power to burner.

• Disconnect oil connector tube from nozzle line.

• Refer to gure above. Loosen splined nut from nozzle

line. Loosen hex head screw securing escutcheon

plate to burner housing.

• Place end of ruler at leading edge of head and, using

straight edge across end of airtube, measure distance

to end of tube. A Beckett T501 gauge may also be

used.

• Slide nozzle line forward or back until this dimension

is 1-3/8” for L1 & L2 heads if tube has straight

shroud, or 1-3/4” if air tube has conic shroud.

• Tighten hex head screw to secure escutcheon plate to

burner chassis. Then tighten splined nut and attach

oil connector tube.

Recheck “Z” dimension periodically when servicing to

ensure escutcheon plate has not been moved. Reset

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

assembly.

V1 heads

See Figure 40. The important “Z” dimension is distance

from leading edge of head to end of air tube. This distance

for V1 heads is 1-¾”. “Z” dimension is factory set for

burners shipped with air tube installed. Even if factory set,

verify “Z” dimension has not been changed.

Use following procedure to adjust “Z” dimension, if it is

not correct:

• Turn off power to burner.

• Disconnect oil connector tube from nozzle line. Refer

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

Loosen hex head screw securing escutcheon plate to

burner housing.

• Loosen acorn nut. Move head adjusting plate until

“0” lines up with reference indicator on housing, and

tighten hex head screw. Place end of ruler at leading

edge of head and, using straight edge across end of

air tube, measure distance to end of tube. A Beckett

T501 gauge may also be used.

• Slide the nozzle line forward or back until this

dimension is 1-¾” for V1 heads. Tighten acorn nut.

• Tighten hex head screw to secure head adjusting

plate to burner chassis. Then tighten splined nut and

attach oil connector tube.

Recheck “Z” dimension periodically when servicing to

ensure escutcheon plate has not been moved. Reset

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

assembly.

Figure 43 - Riello Electrode Setting Figure 44 -Riello Turbulator Setting

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Turbulator Setting

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

(3) is aligned with correct index number as per

Burner Settings Table.

B. Tighten RETAINING NUT (1).

NOTE: Zero and four are scale indicators only.

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

models, scale indicators are 0 and 3.

Figure 45 - Carlin Electrode Setting

TABLE 13a: BECKETT CHIMNEY PRELIMINARY BURNER SETTINGS

Boiler

Model

Head

Type

Static

Plate

Inser-

tion

Depth

Firing

Rate

[GPH]

Com-

bustion

liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pressure

[PSI]

“Z”

Head

Setting

Air

Band

Air

Shutter

Rated

AFUE

Efciency

[%]

4075 L2

3.375U 2.625 0.75

Oval

Dela-

van

0.65x60B 140 N/A 0 7 86.0

4095 L2

3.375U 2.625 0.95

Oval

Dela-

van

0.85x60B 125 N/A 1 10 85.0

4110 L1

N/A 2.625 1.10

Oval Hago 0.90x60B 150 N/A

1 10 84.0

5100 L2

3.375U 2.625 1.00

None Delavan 0.85x60B 140

N/A 2 10 86.5

5115 6

Slot

N/A 2.5 1.15

V5 Hago 1.00x60B 140

N/A 1.5 N/A 85.0

5135 6

Slot

N/A 2.5 1.35

V5 Delavan 1.10x60B 150

N/A 2.0 N/A 84.0

6130 V1

2.75M 2.625 1.30

V6 Danfoss 1.10x60AS 140

0 4 5 86.5

6145 V1

2.75M 2.625 1.45

V6 Danfoss 1.10x45AS 175

2 3 5 85.0

7165 V1

2.75M 2.625 1.65

V7 Danfoss 1.25x45AS 175

2 4 7 86.0

Timings

Pre-purge 15 seconds

Post-Purge 15 seconds

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 13 - Beckett Chimney Vent Preliminary Burner Settings

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

instruments.

TABLE 13b: BECKETT /ECR PART NUMBERS

Boiler

Model

Becket Oil

Burner Model

ECR Oil

Burner Part

Number

with Cover

ECR Oil

Burner Part

Number

Less Cover

4075 AFG70MQASN 240007144 240007232

4095 AFG70MQSSN 240009377 240009385

4110 AFG70MSASN 240009378 240009386

5100 AFG70MQASN 240007145 240007233

5115 NX70LF 240009379 240009387

5135 NX70LF 240009380 240009388

6130 AFG70MKAQN 240007146 240007234

6145 AFG70MKAQN 240009381 240009389

7165 AFG70MKAQN 240007183 240007235

TABLE 14a: BECKETT DIRECT VENT PRELIMINARY BURNER SETTINGS

Boiler

Model

Head

Type

Insertion

Depth

Firing

Rate

[GPH]

Combus-

tion liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pressure

[PSI]

A i r

Setting

Pressure

Switch

Setpoint

Rated

AFUE

Efciency

[%]

4075 6 Slot

2.5" 0.75

Oval

Delavan

0.60x60B 150 1.5 0.65" WC 86.0

4095

6 Slot

2.5" 0.95

Oval

Hago

0.75x60B 155

4.0

0.65" WC 85.0

5100 6 Slot

2.5" 1.00

None Delavan 0.75x45B 175

4.0 0.85" WC 86.5

5115 6 Slot

2.5" 1.15

V5 Hago 1.00x60B 140

1.8 0.85" WC 85.0

5135 6 Slot

2.5" 1.35

V5 Delavan 1.10x60B 150

2.5 0.85" WC 84.0

6130 9 Slot

2.5" 1.30

V6 Danfoss 1.00x45B 175

2.0 0.65" WC 86.5

Timings

Pre-purge 15 seconds

Post-Purge 2 minutes

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

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

TABLE 14b: BECKETT/ECR PART NUMBERS

Boiler

Model

Beckett

Oil Burner

Model

ECR Oil Burner

Part Number

4075 NX70LC 240007531

4095

NX70LC

240009393

5100 NX70LC 240007532

5115

NX70LF

240009395

5135

NX70LF

240009396

6130 NX70LD 240007533

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

instruments.

TABLE 15: RIELLO 40F CHIMNEY VENT PRELIMINARY BURNER SETTINGS

Boiler Model Head Type

Inser-

tion

Depth

Firing

Rate

[GPH]

Com-

bustion

Liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pres-

sure

[PSI]

Head

Setting

Air

Setting

Rated

AFUE

Efciency

[%]

4075

Reverse 2.75" 0.75

Oval Delavan

0.65x60W 150 1 3.6 86.0

4095

Standard 1.75" 0.95

Oval Delavan

0.75x90B 175 3 5.3 85.0

4110

Standard 1.75" 1.10

Oval Delavan

1.00x90B 125 1 3.1 84.0

5100

Standard 2.75" 1.00

None Delavan

0.75x60B 175 1 2.4 86.5

5115

Standard 1.75" 1.15

None Delavan

1.00x80B 130 2 2.8 85.0

5135

Standard 1.75" 1.35

None Delavan

1.20x80B 125 3 3.4 84.0

6130

Standard 2.75" 1.30

V6 Delavan

1.00x45B 175 2 3.6 86.5

6145

Standard 1.75" 1.45

V6 Delavan

1.25x70B 135 4 4.0 85.0

6165

Standard 1.75" 1.65

V6 Delavan

1.25x80B 175 2 2.8 84.0

7165

Standard 2.75" 1.65

V7 Delavan

1.35x60B 150 4 8.0 86.0

7180

Standard 1.75" 1.80

V7 Delavan

1.35x70B 175 2 3.4 85.0

7190

Standard 1.75" 1.90

V7 Delavan

1.50x70B 160 3 3.2 84.0

Timings

Pre-purge 12 seconds

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 15 - Riello 40F Chimney Vent Preliminary Burner Settings

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

instruments.

Boiler

Model

Riello

Oil

Burner

Model

ECR Oil

Burner

Part

Number

4075 40F3

240007502

4095 40F3

240009399

4110 40F5

240009400

5100 40F5

240007503

5115 40F5

240009401

5135 40F5

240009402

Boiler

Model

Riello

Oil

Burner

Model

ECR Oil

Burner

Part

Number

6130 40F5

240007504

6145 40F5

240009403

6165 40F10

240009404

7165 40F5

240007505

7180 40F10

240009405

7190 40F10

240009406

Table 16: RIELLO 40BF DIRECT VENT PRELIMINARY BURNER SETTINGS

Boiler Model Head

Type

Inser-

tion

Depth

Firing

Rate

[GPH]

Com-

bustion

Liner

Nozzle

Mfr.

Nozzle

Type

Pump

Pres-

sure

[PSI]

Head

Setting

Air

Setting

Pressure

Switch

Setpoint

Rated

AFUE

Efciency

[%]

4075

Reverse 2.75" 0.75

Oval Delavan

0.65x60W 150 3 5.0 0.25" WC 86.0

4095

Standard 1.75" 0.95

Oval Delavan

0.75x90B 175 1 4.0 0.25" WC 85.0

4110

Standard 1.75" 1.10

Oval Delavan

1.00x90B 125 2 5.0 0.25" WC 84.0

5100

Standard 2.75" 1.00

None Delavan

0.75x60B 175 1 5.0 0.80" WC 86.5

5115

Standard 1.75" 1.15

None Delavan

1.00x80B 130 2 5.8 0.80” WC 85.0

5135

Standard 1.75" 1.35

None Delavan

1.20x80B 125 4 5.8 0.80” WC 84.0

6130

Standard 2.75" 1.30

V6 Delavan

1.00x45B 175 2 8.0 0.90" WC 86.5

Timings

Pre-purge 12 seconds

Post-Purge 45 seconds

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

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

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

instruments.

Boiler

Model

Riello

Oil

Burner

Model

ECR Oil Burner

Part Number

4075 40BF3

240007528

4095 40BF5

240009407

4110 40BF5

240009408

5100 40BF5

240007529

5115 40BF5

240009409

5135 40BF5

240009410

6130 40BF5

240007530

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.

17 - OIL BURNER, NOZZLE, & AIR SETTINGS

TABLE 1 - CARLIN SETTINGS

BOILER

NO.

INSER-

TION

DEPTH

FIRING

RATE

COMBUS-

TION

LINER

NOZZLE

MFR.

NOZZLE

TYPE

PUMP

PRESSURE

[PSI]

HEAD

BAR

A I R

B A N D

SETTING

Rated

AFUE

Efciency

[%]

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

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

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

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

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

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

TIMINGS

Pre-Purge 15 seconds

Post Purge 15 seconds

Boiler

Model

Carline

Burner

Model

ECR Oil

Burner Part

Number

4075 EZ-LF

240010357

4095 EZ-LF

240010357

4110 EZ-LF

240010357

5100 EZ-LF

240010357

5115 EZ-LF

240010357

5135 EZ-LF

240010357

18.1 Annually

Recommend qualied Service Agency check at lease once a

year:

• Flue passages,

• Combustion chamber area (target wall, re door

insulation)

• Burner adjustment,

• Operation of the controls,

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

sectional seals, ue collector)

Before start of each heating season (or system has been

shut down for extended period of time)

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

leaks.

• Replace or patch any leaks or seals that are faulty

• Inspect ue ways at least once a year- Preferably at

start of heating season.

• Inside of combustion chamber.

• Clean vent system and boiler ue ways if soot or scale

has accumulated. When cleaning, take precaution

to avoid damage to burner swing door insulation. If

damaged, or if there is evidence of previous damage,

burner swing door insulation must be replaced

immediately.

• Oil Burner and controls.

18.2 Vent Pipe

Visually inspect entire venting system once a month for any

signs of leakage, deterioration, or soot build up.

If vent pipe shows any signs of leaking or deterioration,

replace it immediately.

If it shows any signs of soot build up, clean vent pipe and

have burner settings and combustion checked by qualied

service agency.

18.3 Relief Valve

• Test relief valve for proper operation. Refer to valve

manufacturer’s instructions packaged with relief valve.

18.4 Conventional Expansion Tank

See “Equipment And Accessories” section.

18.5 Diaphragm Expansion Tank

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

18.6 WATER SYSTEM

Drain system completely if system is to remain out of

service during freezing weather. Water left in system will

freeze and crack pipes and/or boiler.

18.7 Oil Burner Maintenance

Beckett AFG, perform following preventative maintenance

annually, preferably prior to heating season.

• Fuel Filter Replace to prevent contaminated fuel from

reaching nozzle. Partially blocked fuel lter can cause

premature failure of fuel pump.

• Fuel Pump Unit Replace pump screen and clean pump

unit to maintain fuel delivery to nozzle.

• Ignition Electrodes Clean and adjust as per

manufacturer’s recommendations, so as to maintain

reliable ignition of oil.

• Nozzle Replace so as to maintain safe and reliable

combustion efciency. Always replace with exact nozzle

as required in charts. See “17 - Oil Burner, Nozzle, &

Air Settings” on page 46.

• 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

WARNING

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

prior to proceeding.

Remove control well from top of rear boiler section every

ve years and clean any scale or sediment deposits from all

parts exposed to boiler water.

18 - MAINTENANCE

DANGER

Before servicing, turn off electrical power to boiler

at service switch. Turn off fuel supply to burner

Failure to comply will result in death or serious

injury.

NOTICE

Perform regular service and maintenance by

qualied service agency at least once every 12

months to assure safe, trouble free operation

and maximum efciency.

NOTICE

Verify proper operation after servicing.

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

Turn off electric service to boiler controls.

Drain boiler water to level below tapping for control

well.

Remove low water cut-off/limit sensor from control

well.

Unscrew control well from tapping.

Inspect portion of control well exposed to water for

scale or sediment buildup.

Light deposits may be removed by wiping control well

with damp cloth. Wiping probe with cloth soaked in

vinegar will remove more tenacious lime deposits.

Clean pipe threads of probe to remove old, hardened

pipe dope and other foreign matter.

Apply moderate amount of good quality pipe dope to

pipe threads on control well, leaving two end threads

bare. Do not use PTFE (Teon) tape.

Reinstall control well into tapping.

10.

Reinsert low water cutoff/limit sensor in control well

and secure with grommet.

11.

Fill system with water and purge.

12.

Restore electric service to boiler.

13.

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

free oxygen.

14.

Warning – before returning boiler to service: Follow

low water cut-off test procedure in

Figure 36, Page 41.

18.9 Boiler And System Cleaning Instructions

For Trouble Free Operation

Boiler and system (other than expansion tank) must

be full of water for satisfactory operation. Add water

to system until boiler pressure gauge registers 12 psi.

Water should come out of all air vents when opened.

Wash Oil and grease which accumulate in new hot

water boiler out in following manner:

• Shut off valves have been installed between boiler

return manifold and system, to minimize amount of

system draining.

• Drain boiler to level below relief valve tapping.

• Remove relief valve using extreme care to avoid

damaging it.

• Add appropriate amount of recommended boil out

compound.

• Replace relief valve.

• Fill entire system with water and purge.

• Start ring boiler.

• Circulate water through entire system.

• Vent system, including radiation.

• Allow boiler water to reach operating temperature, if

possible.

• Continue to circulate water for few hours.

• Stop ring boiler.

• Drain system in manner and to location that hot water

can be discharged safely.

• Remove plugs from all available returns and wash

water side of boiler as thoroughly as possible, using

high-pressure water stream.

• Rell system with fresh water.

Add appropriate boiler water treatment compounds

as recommended by your qualied water treatment

company.

Testing pH /alkalinity after boiler and system have

been cleaned and relled as previously described, test

pH of water in system. Can be done with pH test kit.

pH should be higher than 7 but lower than 11. Add

appropriate water treatment chemicals, if necessary, to

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

protection, care must be exercised to eliminate all free

oxygen in system.

Boiler is now ready to be put into service.

18.10 Frequent Water Addition

Frequent water additions, although unusual for water boiler,

are sign of leaky system. Excessive amounts of make up

water supplied to boiler can signicantly shorten life of

boiler. Amount of water varies with contamination level of

water. Repair leak and consult with your water treatment

specialist for recommendations.

18.11 Attention To Boiler While Not In Operation

NOTICE

Fully drain boiler if not used during winter months

to prevent freeze damage.

Keep manual fuel supply valve shut off if burner is shut

down for extended period of time.

To recondition heating system in fall season after

prolonged shut down, follow instructions outlined in

See “15 - Filling boiler” on page 38.

Boiler contains controls which may cause boiler to shut

down and not restart without service. If damage due

to frozen pipes is a possibility, heating system should

not be left unattended in cold weather; or appropriate

safeguards and alarms should be installed on heating

system to prevent damage if boiler is inoperative.

Keep boiler and area around it clean. Never burn

refuse or any material other than specied fuel in your

boiler. Have your boiler checked each year by qualied

service agency.

18 - MAINTENANCE

19.1 Oil Boiler Cleaning Instructions

Clean ueways. Figure 46, Page 56.

A. Shut off power to burner.

B. Access to combustion chamber, remove swing door

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

swing door open.

C. Remove vent connector.

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

passages. Bafes are installed in 3rd pass (two inner

ue ways.)

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

bristle brush into each of two 3rd passes. Using long

strokes, push brush all the way through boiler until

brush has exited the smoke box opening.

Pull brush all the way forward until it has exited front

of boiler.

Continue this operation for entire height of ue way

until clean. Repeat operation for other 3rd pass ue

way.

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

each of two 2nd passes. Using long strokes, push

brush all the way through boiler until brush hits back

wall of reversing chamber. Pull brush all the way

forward until it has exited front of boiler.

Continue operation for entire height of ue way until

clean. Repeat operation for other 2nd pass ue way.

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.

Clean combustion chamber and bafes. Use wire

or ber bristle brush to clean surfaces of combustion

chamber and bafes. Vacuum all of loose debris in

bottom of combustion chamber.

After cleaning: Vacuum all remaining debris as

necessary. Inspect burner swing door insulation, and

rope gasket for signs of damage. If damaged, replace

as needed.

Re-assemble boiler.

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

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

ways)

B. Inspect chimney and clean if necessary.

C. Clean and re-attach vent connector onto rear of the

boiler with three screws.

NOTICE

When securing burner swing door verify door is

drawn-in equally on both sides. Do not overtighten

door bolts. Rope gasket will provide sufcient seal

when door is snugged into place.

D. Tighten swing door hardware to provide adequate

seal to rope gasket around perimeter of door. Use

alternating tightening method from non-hinged side to

hinged side cap screws to pull door tight equally.

19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS

WARNING

Fire, burn, asphyxiation hazard. Turn off service

switch to boiler to prevent accidental ring of

burner outside combustion chamber. Disconnect

burner power cord from wire harness in front jacket.

Tighten swing door fastener completely when

service is complete. Failure to follow instructions in

this manual and understand all requirements could

result in death or serious injury.

19.2 Oil Burner Cleaning Instructions

Consult burner manufacturer’s instructions.

WARNING

Asphyxiation hazard. A clean and unobstructed

chimney ue is necessary to allow noxious fumes

that could cause injury or loss of life to vent safely.

Inspect periodically throughout heating season for

any obstructions. Failure to follow instructions in

this manual and understand all requirements could

result in death or serious injury.

NOTICE

Connect boiler to approved chimney in good

condition. Property damage could result if boiler is

connected to dirty or inadequate chimney. Inspect

interior of chimney ue and clean before start of

heating season.

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.

VACUUM

HOSE

VACUUM

HOSE

BRISTLE

BRUSH

FLUE BRUSH

FRONT VIEW

3RD PASS

COMBUSTION CHAMBER & 2ND PASS

Figure 46 - Cleaning the Boiler

19 - OIL BOILER/BURNER CLEANING INSTRUCTIONS

20.1 Combustion

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

on page 46.

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

is detrimental to good combustion results. Look for

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

inlet. Repair any such leaks as they may cause erratic

burning of fuel and in extreme case may become re

hazard.

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

or nozzle strainer and produce poor spray pattern

from nozzle.

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

pump. Water in fuel in smaller amounts will cause

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

the ame and causes smoke and unburned fuel to

pass out of the combustion chamber and clog ue

ways of the boiler.

E. Cold Oil - If oil temperature approaching fuel pump is

40°F or cooler, poor combustion or delayed ignition

may result. Outside fuel tank above grade or fuel lines

in shallow bury may be the cause.

F. High Altitude Installation - Air openings must be

increased at higher altitudes. Use combustion analyzer

and set to 11.5% for initial setting.

G. Start up noise - Late ignition is cause of start up

noises. If it occurs recheck for electrode settings,

ame shape, air or water in fuel lines.

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

should eliminate shut-down noise.

20.2 Oil Primary Control

I. Burner (control) will not come on.

I. No power to control.

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

reset button for more than 1 second to exit soft

lockout. If control has recycled three times within

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

To reset from restricted mode, refer to Page 41 for

more details.

III. CAD Cell seeing light.

IV. CAD cell is defective.

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

time, then restart after one (1) minute.

I. CAD cell is defective.

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

III. Defective nozzle causing ame to be erratic.

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

burner head.

V. Excessive back pressure causing erratic ame.

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

I. No oil to burner.

II. Shortened electrodes

III. Clogged nozzles.

IV. Airow too high.

V. Ignitor module defective.

VI. CAD cell defective.

VII. Oil valve stuck open or closed.

To isolate fuel problems: disconnect fuel system and re

out of auxiliary container of clean, fresh, warm #2 fuel

oil from another source. If burner runs successfully when

drawing out of container problem is in fuel or fuel lines.

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

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

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

located on oil primary control.

20 - TROUBLESHOOTING

NOTICE

Restricted lockout without retries will occur if ame

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

indicated by a steady on red LED.

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.

No electric power to boiler

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

cuit is “ON”. There may be as many as 3 safety shut-off switches installed.

Look for a red plate which may be on the service switch.

Controls out of adjustment Reset according to instructions.

Circulating pump not running Check over-current protection. Check relay operation. Check power to

circulator.

Poor electrical contact Check all control terminals and wire joints.

Chimney ue 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 Check Action

Boiler is cold,

house is cold.

Display off 120 VAC system power Turn system power on

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

24 V present; disconnect

thermostat, short T-T Boiler starts, check wiring and thermostat

120 VAC at B1-B2 • If no, replace

• If yes, check burner and wiring

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

leak(s).

Boiler is hot,

house is cold.

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

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

turn off.

Display On Burner wired incorrectly. L1

(black) and Limit (red) are

reversed. See wiring diagram

for installed burner.

Re-Wire burner.

20 - TROUBLESHOOTING

21.6 Conventional Expansion Tank (Not

Provided)

In a properly assembled system, expanding water ows

into an expansion tank.

• Expansion tank should be sized correctly because im-

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 lled 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 inefcient circulation in

radiators if left in piping system.

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

with water). It can also become overlled with air when

lling system with new water. Fittings on tank and in line

to tank are for bleeding off excess air and water.

21.7 Diaphragm Expansion Tank (Not Provided)

Diaphragm type expansion tank takes place of conventional

expansion tank.

• 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 ll valve set

to ll boiler to 10-12 psi with fresh water. When system

is rst lled, tank will ll partially with water. As water is

heated, and system pressure increases, water expands

into tank and compresses air in the tank. This compressed

air cushion permits water in the system to expand as

temperature changes and assures “full measure” of water,

even in highest radiation unit of system.

• Diaphragm type expansion tank can be mounted on air

purger tting or at any other convenient place in supply

or return line. It is recommended to locate diaphragm

type expansion tank in supply line with circulator located

after expansion tank. This conguration allows circulator

to “pump away” from expansion tank for improved air

elimination and system performance.

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

eliminator tting or air purger is used to help remove

air from system before it reaches radiators. It should be

installed in supply line. Air left in system can cause noises

in pipes and inefcient circulation in radiators.

21.1 Limit Relay Control (provided)

Water temperature limit control in limit relay is adjustable.

See Limit instructions for how to set limit temperature.

21.2 Drain Valve (provided)

Drain valve is manually operated valve, means of draining

all water from boiler and heating system. Installed in

casting below burner door.

21.3 Circulator

• Forced hot water systems require circulator.

• Separate circulator or zone valve is required for each

zone, if there are two or more zones. Circulator must

have capacity to provide circulation required by heating

system.

• Circulator should be connected to supply main and

must be wired into boiler’s electrical system. “9 - Boiler

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

with circulator located on supply main piping using zone

circulators or zone valves.

• When piping is arranged with zone circulators and no

bypass piping, circulator provided with boiler may be

used as zone circulator. Both piping arrangements allow

circulator to pump away from expansion tank and show

how piping should be arranged to allow heating system to

be easily purged of air.

• Circulator can be installed on return side of boiler, if

preferred.

21.4 Main Air Vent: (Not Provided)

Before system is lled with water, there is air in pipes and

radiation units. Some air will be trapped as system is lled.

It is possible to eliminate most of this air through air vents

on radiation units. Main air vent will speed and simplify this

process. Main air vent should be installed on highest point

in supply main.

21.5 Automatic Fill Valve (Not Provided)

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

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

valve in water supply line). This requires regular attention

to system’s needs. Automatic ll valve or pressure reducing

valve accomplishes this without attention. Install in supply

line on hot water boilers only. Valve operates through

water pressure differentials. It does not require electrical

connection.

21 - EQUIPMENT AND ACCESSORIES

m Head

1 2 3 4 5

US GPM

5 10 15 20

m /h

Head (feet)

Model Watts Volts Amps Capacitor

UP 15-42F 85 115 0.74 10µF/180V*

*Supplied with pump

Figure 47 - Grundfos Pump Curve

Model Volts Amps Capacitor

007-F5 115 0.70 Supplied w/ pump

Figure 48 - Taco Pump Curve

21 - EQUIPMENT AND ACCESSORIES

NOTES

Company Address & Phone #Company Name & Tech InitialsService PerformedDate

SERVICE RECORD

UTICA BOILERS

2201 Dwyer Avenue

Utica NY 13501

web site: www.ecrinternational.com

IMPORTANT

In accordance with Section 325 (f) (3) of the Energy Policy and

Conservation Act, this boiler is equipped with a feature that saves energy

by reducing the boiler water temperature as the heating load decreases.

This feature is equipped with an override which is provided primarily to

permit the use of an external energy management system that serves the

same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water

temperature as the heating load decreases.

• This boiler is not used for any space heating

• This boiler is part of a modular or multiple boiler system having a total input of

300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

Utica Boilers Trifire Trb 3 Operation And Installation Manual

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