TRIFIRE SERIES II

High Efficiency
Models Oil Fired Hot Water Boiler
TRB4075
TRB4095
INSTALLATION, OPERATION &
TRB4110
TRB5100
MAINTENANCE MANUAL
TRB5115
TRB5135 FOR US SALES ONLY
TRB6130
TRB6145
TRB6165
TRB7165
TRB7180
TRB7190

Manufactured by:

ECR International, Inc.

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

P/N 240009350, Rev. J [09/01/2017]

TRIFIRE OIL-FIRED CAST IRON HOT WATER BOILER

Models

TRB4075
TRB5100
TRB6130
TRB7165

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

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

2
 DIMENSIONS

DIMENSIONS

DIMENSIONS
Dimension
Flue Size Dimension "B"
"A" Inches
Sections Inches (cm)
Inches
(cm) (cm) Chimney Direct
Vent Vent
4 5 (13) 18 ⅜ (46.6) 1 ⅛ (32) ¾ (19)
5 5 (13) 21 ⅝ (54.8) 1 ⅛ (32) ¾ (19)
6 5 (13) 24 ⅞ (63.1) 1 ⅛ (32) ¾ (19)
7 6 (15) 28 ⅛ (71.3) ¾ (19) N/A

3 P/N 240009350 Rev. J [09/01/2017]

 TABLE OF CONTENTS

1 - Introduction............................................................................................................... 5
2 - Safety Information..................................................................................................... 6
3 - Before You Start......................................................................................................... 7
4 - Ratings & Capacities................................................................................................... 8
5 - Locating The Boiler..................................................................................................... 9
6 - Installation Requirements.......................................................................................... 10
7 - Fresh Air For Combustion........................................................................................... 11
8 - Boiler Assembly........................................................................................................ 13
9 - Boiler System Piping................................................................................................. 18
10 - Hydronic Piping...................................................................................................... 19
11 - Fuel Supply Piping.................................................................................................. 32
12 - Antifreeze In The System ........................................................................................ 33
13 - Electrical Connections.............................................................................................. 34
14 - Chimney And Venting Connections............................................................................ 35
15 - Filling Boiler........................................................................................................... 38
16 - Operating The Boiler - System Start-Up.................................................................... 39
17 - Oil Burner, Nozzle, & Air Settings.............................................................................. 46
18 - Maintenance.......................................................................................................... 53
19 - Oil Boiler / Burner Cleaning Instructions..................................................................... 55
20 - Troubleshooting...................................................................................................... 57
21 - Equipment And Accessories ..................................................................................... 59
Installation and Check Out Certificate .............................................................................. 63

4 P/N 240009350 Rev. J [09/01/2017]

 1 - INTRODUCTION

! WARNING NOTICE
Installations of boilers and venting shall be done Surface rust on cast iron sections may be attributed
only by a qualified expert and in accordance with to manufacturing process as well as condensation
this manual. Installing or venting a boiler or any during storage. Surface rust is normal and does not
other oil appliance with improper methods or affect performance or life of boiler.
materials may result in serious injury or death due
to fire or to asphyxiation from poisonous gases
such as carbon monoxide which is odorless and
invisible.

1. Oil Fired Boilers

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

Boiler is pressure fired natural draft (chimney vented)

oil fired hot water boiler comprised of cast iron sections,
available with 4, 5, 6 or 7 sections. Sections are held
together by metal push nipples and threaded rods.

4,5 and some 6 section boilers may be field equipped for

direct vent installations with use of direct vent burner
and venting kits. Direct vent instructions are covered in a
separate supplemental instruction document included with
direct vent venting kit.

Boiler models are capable of firing #2 fuel oil from 0.75

gph up to 1.65 gph.

Boilers include -
• Limit, 220° F maximum, operating control with integral
low water cut off.
• Temperature and pressure gauge
• 30 psi relief valve
• Drain valve

5 P/N 240009350 Rev. J [09/01/2017]

 2 - SAFETY INFORMATION

2.1 General
! WARNING
Boiler installation shall be completed by qualified agency.
Construction materials of appliance and products
of combustion and fuel contain alumina, silica,
! WARNING heavy metals, carbon monoxide, nitrogen
Fire, explosion, asphyxiation and electrical shock oxides, aldehydes and /or other toxic or harmful
hazard. Improper installation could result in death substances which can cause death or serious injury
or serious injury. Read this manual and understand and which are known to the State of California to
all requirements before beginning installation. cause cancer, birth defects and other reproductive
harm. Always use proper safety clothing,
! WARNING respirators and equipment when servicing or
Modification, substitution or elimination of factory working nearby the appliance.
equipped, supplied or specified components could
result in death or serious injury. ! WARNING
! WARNING Product contains fiberglass wool and refractory
ceramic fibers. Possible cancer hazard. May cause
Improper installation, adjustment, alteration, service irritation to skin, eyes and respiratory tract. To
or maintenance could result in death or serious avoid this hazard, wear a dust mask and gloves
injury. when handling fiberglass and ceramic fibers.

! CAUTION
Laceration, burn hazard. Metal edges and parts may IMPORTANT: Read the following instructions
COMPLETELY before installing!!
have sharp edges and/or may be hot. Use appropriate
personal protection equipment to include safety 2.3 Installation Shall Conform To Requirements
glasses and gloves when installing or servicing this Of Authority Having Jurisdiction Or In Absence
boiler. Failure to follow these instructions could result Of Such Requirements To ANSI/NFPA 31,
in minor or moderate injury. “Installation Of Oil Burning Equipment”.

2.2 Become Familiar With Symbols Identifying

2.4 Current Edition of American National Standard
Potential Hazards. ANSI/NFPA 211 “Chimneys, Fireplaces, Vents and
Solid Fuel Burning Appliances” for venting.
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages 2.5 Where required by authority having
following this symbol to avoid possible injury or death. jurisdiction, installation shall conform to Standard
for Controls and Safety Devices for Automatically
! DANGER Fired Boilers, ANSI/ASME CSD-1.

Indicates a hazardous situation which, if not avoided, Additional manual reset low water cutoff and manual reset
high limit may be required.
WILL result in death or serious injury

! WARNING 2.6 Requirements for Commonwealth of

Indicates a hazardous situation which, if not avoided, Massachusetts:
could result in death or serious injury. Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
! CAUTION limited to:
Indicates a hazardous situation which, if not avoided, • Installation by licensed plumber or gas fitter.
could result in minor or moderate injury.
NOTICE
Used to address practices not related to personal
injury.
6 P/N 240009350 Rev. J [09/01/2017]
 3 - BEFORE YOU START

3.1 Installation and Operation 3.2 Prior To Installing The Boiler

1. Do not operate unit if any control, switch, components • Verify you have selected right size boiler with proper
or devices have been underwater or subject to water capacity. AHRI rating of boiler selected should be greater
damage. than or equal to calculated peak heating load (heat loss)
2. Before servicing, allow boiler to cool. Always shut off any for building or area(s) served by boiler and associated
electricity and oil supply to boiler when working on it. hot water heating systems. Use heat loss calculations
based on approved methods. See Table 1, Page 8.
3. Inspect oil line and connections for leaks.
• Boiler must be supplied with proper oil supply and oil
4. Verify oil burner nozzle is proper size. Over-firing will piping, sufficient fresh combustion air, and suitable
result in early failure of boiler sections, and result in a electrical supply.
potentially dangerous situation.
• Connect boiler to suitable venting and piping systems
5. Never vent boiler into enclosed space. Always vent to adequate to distribute heating load.
the outside. Never vent to another room or inside a
• Installation is not complete unless pressure relief valve
building.
is installed in 3/4” tapping located in supply piping.
6. Verify adequate air supply for complete combustion. • Thermostat must be properly located and installed
7. Relief valve automatically lifts open when system • Failure to pipe boiler correctly may result in excessive
pressure exceeds 30 psi. Before installing relief valve noise or other related problems.
read manufacturer’s instructions. Pipe relief valve to a
safe location. Check with authorities having jurisdiction.
8. Consider system total water volume, temperature, Existing Water System Evaluation
initial fill pressure and arrangement when sizing and A good system will prevent oxygen contamination of boiler
installing expansion tank. Improperly installed and water.
sized expansion tank may result in frequent lifting of
1. Causes of oxygen contamination may be:
relief valve or other heating system problems. Follow
expansion tank manufacturer guidelines for installation, A. Addition of excessive make up water as a result of
and sizing. leaks.
9. Boiler manufacturer recommends initial fill pressure of B. Absorption through open tanks and fittings.
10-12 psi. For higher fill pressures increase expansion C. Oxygen permeable materials in the distribution
tank’s air charge to match fill pressure. system.
10. Purging heating system of air and gases is critical for 2. To insure long product life, oxygen sources must be
proper circulation and quiet performance. Once the air eliminated.
is purged, for boiler installations using float type vents,
Take the following measures:
air vents should be closed for normal operation. If air
is heard or noticed by loss of heat, purge system and A. Repair system leaks.
open vents for short period of time. B. Eliminate open tanks from the system.
C. Eliminate and/or repair fittings which allow oxygen
absorption.
D. Use non-permeable materials in the heating system.

7 P/N 240009350 Rev. J [09/01/2017]

 4 - RATINGS & CAPACITIES
Table 1 - RATINGS & CAPACITIES
OIL-FIRED HOT WATER BOILERS

Min. Chimney Chimney

Net Max.
Number Firing Heating *MAWP relief Liner Liner Flue
Input AHRI AFUE Water
of Rate Capacity Water Valve Size Size Size
[Mbh] Rating [%] Temp
Sections [GPH] [Mbh] [psi] Capacity Round Square [Inches]
[Mbh] [°F]
[Mbh] [Inches] [Inches]
4 0.75 105 92 80 65 87.0 92 250 6 6¾ 5
4 0.95 133 114 99 65 85.0 115 250 6 6¾ 5
4 1.10 154 132 115 65 84.0 132 250 6 6¾ 5
5 1.00 140 123 107 65 87.0 123 250 6 6¾ 5
5 1.15 161 139 121 65 85.0 139 250 6 6¾ 5
5 1.35 189 161 140 65 84.0 161 250 7 6¾ 5
6 1.30 182 160 139 65 87.0 160 250 6 6¾ 5
6 1.45 203 176 153 65 85.0 176 250 7 6¾ 5
6 1.65 231 198 172 65 84.0 198 250 7 6¾ 5
7 1.65 231 202 176 65 87.0 202 250 7 6¾ 6
7 1.80 252 217 189 65 85.0 217 250 7 6¾ 5
7 1.90 266 228 198 65 84.0 227 250 8 6¾ 5

GPH = U.S. Gallons per Hour

Mbh = 1000 Btu (British thermal units) per hour.
psi = Pounds per square inch

*MAWP = Maximum allowable working pressure. This low pressure oil fired hot water boiler is constructed and
hydrostatically tested for maximum working pressure of 65 psi in accordance with the latest revision of the A.S.M.E.
(American Society of Mechanical Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.

AFUE= Annual Fuel Utilization Efficiency

Heating Capacity and AFUE based on 13.1% CO2 (13.5% CO2 at 0.95 GPH and 1.10 GPH, 13.2% CO2 on 7 section at
1.65 GPH), -0.02” w.c. draft in breech, and # 1 smoke or less. Testing is done in accordance with U.S. DOE (Department
of Energy) test procedure.

Heating Capacity indicates amount of heat available after subtracting losses up the stack. Remaining heat is available
to heat water. Small portion is heat from jacket and surfaces of boiler and this heat stays in structure. Net AHRI rating
represents portion of remaining heat applied to heat radiation or terminal units (i.e. finned tube baseboard, cast iron
radiators, radiant floor, etc.). Difference between Heating Capacity and Net AHRI Rating, called piping and pickup
allowance, establishes reserve for heating volume of water in system and offsetting heat losses from system piping. Net
AHRI ratings shown are based on piping and pickup factor of 15% in accordance with AHRI Standard as published by
Hydronics Institute.

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

8 P/N 240009350 Rev. J [09/01/2017]

 5 - LOCATING THE BOILER

! WARNING 7. Fresh air for combustion and ventilation must be

available at boiler. Ventilating and combustion air must
Fire hazard. Do not be install on carpeting. Failure enter boiler room without restrictions.
to follow these instructions could result in death or 8. Installation shall conform to requirements of authority
serious injury. having jurisdiction or in absence of such requirements
in United States, follow NFPA 31 Installation of Oil
1. Boiler is suitable for installation on combustible Burning Equipment.
flooring. Do not install boiler on carpeting.
9. Clearance to venting is for single wall flue pipe. If Type
2. Locate boiler in front of final position before removing L vent is used, clearance may be reduced to minimum
crate.
required by vent pipe manufacturer.
3. Locate unit so vent pipe connection to chimney will be
short and direct.
4. For basement installation, provide solid elevated base,
such as concrete, if floor is not level, or if water may be
encountered on floor around boiler.
Table 2 - BOILER CLEARANCES
5. Provide recommended service clearance, if applicable,
as follows: Accessibility,
Combustible
• Clearance from Jacket Front Panel Unit Cleaning,
Clearance
24” for servicing burner and Servicing
• Clearance from Jacket Side Panels Top 12” (32 cm) 24” (61 cm)
24” for burner swing door, if opened fully with burner Right Side 2” (5 cm) 24” (61 cm)
mounted, otherwise 2” with burner removed. Left Side 2” (5 cm) 24” (61 cm)
• Clearance From Jacket Rear Panel Floor Combustible No Requirement
24” minimum for rear smoke box cleaning. (Note: Front 17” (43 cm) 24” (61 cm)
this dimension will also be controlled by horizontal to
Back 9” (23 cm) 24” (61 cm)
vertical to horizontal smoke pipe arrangement. See
Flue 9” (23 cm) 9” (23 cm)
Figure 1.
All distances measured from the boiler jacket or flue.
6. Minimum clearances to combustible material see
Figure 1 and Table 2.

Figure 1 - Clearances to Combustible Construction

15”

9 P/N 240009350 Rev. J [09/01/2017]

 6 - INSTALLATION REQUIREMENTS

Figure 2 - General Requirements For A Typical Installation

RELIEF
VALVE

CHECK LOCAL CODES FOR

MAXIMUM DISTANCE FROM
FLOOR, OR OTHER ALLOWABLE
SAFE POINT OF DISCHARGE.
NOTICE
Shut off manual fuel supply valve if burner is shut
down for extended period of time.

10 P/N 240009350 Rev. J [09/01/2017]

 7 - FRESH AIR FOR COMBUSTION

! WARNING Alternate method for boiler located within

confined space: Use indoor air if two permanent
Asphyxiation, fire hazard. Do not obstruct air openings communicate directly with additional space(s)
openings to combustion area. Follow instructions of sufficient volume such that the combined volume of
below, to maintain adequate combustion air. all spaces meet criteria for unconfined space. Size each
opening for minimum free area of 1 square inch per
1,000 BTU per hour input of all equipment in spaces,
NOTICE but not less than 100 square inches.
Install outside air intake if used with a fireplace or 6. Louvers and Grilles of Ventilation Ducts
kitchen or bathroom exhaust fan. These devices rob
boiler and water heater of combustion air. A. All outside openings should be screened and
louvered. Screens used should not be smaller than
1. Determine volume of space (boiler room). Rooms 1/4 inch mesh. Louvers will prevent the entrance of
communicating directly with the space in which rain and snow.
appliances are installed, through openings not furnished
B. Free area requirements need to consider the
with doors, are considered a part of the space.
Volume (ft3) = Length (ft.) x Width (ft.) x Height (ft.) blocking effect of louvers, grilles or screens
protecting the openings. If the free area of the
2. Determine total input of all appliances in the space.
louver or grille is not known, assume wood louvers
Add inputs of all appliances in the space and round the
result to the nearest 1000 BTU/hr. have 20-25% free area and metal louvers and grilles
have 60-75% free area.
3. Determine type of space. Divide Volume by total input
of all appliances in space. If the result is greater than C. Louvers and grilles must be fixed in the open
or equal to 50 ft3/1000 BTU/hr, then it is considered position, or interlocked with the equipment to open
an unconfined space. If the result is less than 50 automatically during equipment operation.
ft3/1000 BTU/hr, then the space is considered a
confined space.
4. When a boiler is located in an unconfined space of a
conventionally constructed building, fresh air infiltration
through cracks around windows and doors normally
provides adequate air for combustion and ventilation.
5. Provide outdoor air for boiler located in a confined
space or an unconfined space in a building of unusually
tight construction. Outdoor air may be provided with
the use of two permanent openings which communicate Figure 3 - Air Openings For Boiler Located In
directly or by duct with the outdoors or spaces Confined Space (Utility Room)
(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.

11 P/N 240009350 Rev. J [09/01/2017]

 7 - FRESH AIR FOR COMBUSTION

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

Table 3 - FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS
¼” Mesh Wood Metal
Fresh Air Screen Louvers Louvers
Duct Size
(Btuh)* (Btuh)* (Btuh)*
3 ½” x 12” 144,000 36,000 108,000
8” x 8” 256,000 64,000 192,000
8” x 12” 384,000 96,000 288,000
8” x 16” 512,000 128,000 384,000
*Btuh = British Thermal Units per hour based
on opening covered by ¼” mesh screen , wood
louvers, or metal louvers.

Figure 4 - Fresh Air Openings

12 P/N 240009350 Rev. J [09/01/2017]

 8 - BOILER ASSEMBLY
1. Remove Crate Figure 5 - Reversible Hinge
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. EYEBOLT & NUT
AS HINGE
4. Do not drop boiler. Do not bump boiler jacket
against floor. 5/8 BOLT
5. Open burner swing door. (BOLT INTO FRONT SECTION)

A. Loosen and remove non-hinged side latching

EYEBOLT & NUT
hardware. AS HINGE
B. Remove hinged side latching hardware.
C. Door can be swung to full open position
approximately 90 to 120 degrees with the burner
mounted providing there is 22” of clearance to the NOTICE
adjacent wall.
For purpose of these instructions, all pipe
NOTICE connections shall use pipe dope or Teflon tape to
Burner door may come off hinges if lifted when assure water tight connections unless otherwise
opened. instructed. Steps 6 thru 16, Figure 10, Page 15.

If reduced clearance prevents door from opening fully, one

of the following can provide full access: 7. Open accessory carton and remove contents. Identify
• Burner can be removed to allow full rotation of door. components using illustrations throughout this section
Door with burner mounted can be lifted off hinges and applicable to your installation.
set aside during servicing. 8. Locate 1-1/4" x 6" pipe nipple. Thread thru insulation
• Door mounting hardware is reversible from left side slot into supply port in rear of boiler. Locate 1 1/4 x
hinge (as shipped) to right side hinge. To reverse hinge 3/4 x 1 1/4 elbow and assemble onto nipple. Verify
arrangement. See Figure 5. connections are tight with outlet facing directly up. See
• Lift door off mounting eye bolts and set aside. Remove Figure 6.
mounting eye bolts from left side. Move door mounting 9. Locate shorter of two 1 1/4” adapters. Thread thru
eye bolts to right side. Tighten both sets of hardware. insulation slot into supply port in rear of boiler. Locate
Lift door and place integral cast hinge pins on door into 1 1/4 x 3/4 x 1 1/4 elbow and assemble onto adapter.
slotted mounting bracket holes. Verify connections are tight with outlet facing directly
Recommend hinges be on same side as flexible oil line in up. See Figure 6.
order to swing door open. 10. Locate longer of the two 1 1/4” adapters. Assemble
onto elbow.
6. Inspect Swing door insulation and rope gasket.
A. Inspect fiber rope located on swing door. Evenly Figure 6 - Adapter Assembled Onto Elbow
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. 1-1/4" X 6” NIPPLE
B. Inspect burner swing door insulation for damage.
C. Combustion chamber and raised portion between
2nd and 3rd pass flue ways make an impression
in door insulation as designed.
D. Do not close and secure door at this time.
1-1/4 x 3/4 x 1-1/4 ELBOW RELIEF VALVE

13 P/N 240009350 Rev. J [09/01/2017]

 8 - BOILER ASSEMBLY

NOTICE Figure 8 - Grommet

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 SENSOR IN WELL
to secure control. See Figure 7. WITH GROMMET
B. Confirm thermal limit/LWCO sensor bulb is fully
inserted to bottom of control well in top of rear
boiler section and secured with grommet. See Figure 9 - Relief Valve
Figure 8.
C. Route thermal limit/LWCO sensor wire to control
and connect. See Figure 10, Page 15 and Figure 15,
Page 17.

Figure 7 - Control On Mounting Plug w/Screw

MOUNTING
PLUG
15. Check installation of liners and baffles (Not all
models). See Table 4, Page 16.
A. Check oval (4 section) or V-shaped (6 and 7 section)
liner. See Figures 9 & 10. Liner should be flush with
front edge of heat exchanger fins.
B. Flue way baffles (4, 5, 6 section only) are factory
installed in 3rd pass. Insure baffles are inserted
! WARNING in flue way such that position tab touches casting
between 2nd and 3rd Pass flue way. See Figure 11,
Burn and scald hazard. Relief valve could Page 14.
discharge steam or hot water during operation.
Check local codes for maximum distance from floor
Efficiency of boiler is based on insertion of flue way baffles
or allowable safe point of discharge. Installation of in 4, 5 and 6 section units. Baffles will generate lower
relief valve shall be consistent with ANSI/ASME Boiler gross stack temperatures entering chimney. This has the
and Pressure Vessel Code, Section IV. potential under certain operating conditions to cool flue
gases below dew point, creating condensation on interior
chimney and chimney connector surfaces. Remove baffles
14. Install Relief Valve. See Figure 9.
to increase stack temperature if there are any signs of
A. DO NOT pipe in area where freezing can occur. DO
condensation in chimney or chimney connector. Removing
NOT install shutoff valves, plugs or caps.
baffles alone may not address condensation depending on
B. Locate 3/4”NPT x 90° street elbow. Install elbow other boiler and heating system operating conditions.
using 3/4” NPT tapping in supply piping. Install
elbow with outlet facing directly up. Install relief NOTICE
valve with outlet facing horizontally. Flue gas condensate is corrosive, which requires
C. Pipe discharge of relief valve. Installation of relief special consideration and must be addressed
valve must be consistent with ANSI/ASME Boiler and immediately.
Pressure Vessel Code, Section IV.

14 P/N 240009350 Rev. J [09/01/2017]

 8 - BOILER ASSEMBLY

Figure 10 - Supply Piping and Control Assembly

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

LIMIT CONTROL
WITH INTEGRAL
LOW WATER
CUT OFF

THERMAL/ LWCO
WIRE

BURNER WIRING
RELIEF VALVE

BACK OF BOILER

15 P/N 240009350 Rev. J [09/01/2017]

 8 - BOILER ASSEMBLY

Figure 11 - Oval Liner

16. Connect Field Wiring. See “13 - Electrical
Connections” on page 34.
A. Route wire harness from burner to Limit control
through rear jacket panel. See Figure 15, Page 17.
Connect molex plug on burner wire harness to its
receptacle on limit control.
B. If optional manual reset high temperature limit is
not used, ensure supplied jumper is installed.
C. Connect the wiring harness from limit control to
circulator. See Figure 15, Page 17.
D. 120 volt power supply field wiring connects to limit
control. Provide appropriate overcurrent protection
and service disconnect switch.
E. Wire power supply. See Figure 15, Page 17.
Connect green wire to grounding lug. When
installing wiring through hole in Limit, use anti-
abrasion cable clamp. Connect black “hot” wire to L1
Figure 12 - V-Shaped Liner 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
Figure 13 - 3rd Pass Baffles pressure directly to door while re-installing securing
hardware with your opposite hand. Always install
non-hinged side latching hardware first, then install
hinged side hardware. Apply additional pressure
while hand tightening hardware as far as possible,
then release pressure.

Table 4 - BAFFLES & LINERS

Liner
Model Liner Baffles
Length
4 Oval 4” 9”
5** NONE NA 12”
6 V SHAPE 12” 15”
7 V SHAPE 14” NONE
** 9” V liner used only on Models 5115 and 5135 and
only with Beckett NX burner. All other 5 section models
and burner combinations use no liner.
16 P/N 240009350 Rev. J [09/01/2017]
 8 - BOILER ASSEMBLY

Figure 14 - Circulator Wiring B. Use hand wrench to tighten door hardware and start
with non-hinged side. Use alternating tightening
method from non-hinged side to hinged side to
tighten door equally until sealed without applying
excessive torque. Never tighten hinged side flange
bolt first or tighten either piece of hardware 100%
without using alternating tightening method described
above.

GREEN TO NOTICE
GROUND
BLACK When securing burner swing door, make sure door is
SCREW
TO drawn-in equally on both sides.
YELLOW
WHITE
Failure to follow the prescribed procedure could
TO cause thread damage to casting or a leak in the
WHITE door seal. If hinged side is tightened before the
unhinged side, the hinged side of door cannot
NOTICE be drawn to provide an air-tight seal. Applying
Ensure all conduit is secured to prevent contact with excessive torque will only cause thread damage.
flue pipe

Figure 15 - Limit Control Wiring

20. Install oil burner
THERMAL/ • Check oil nozzle in burner for size, angle and type,
LWCO WIRE
PIN inspect electrode settings, check head setting, check air
band and air shutter settings. See “Oil Burner, Nozzle,
& Air Settings” on page 49.
• DO NOT install burner without gasket. Place oil burner
gasket on face of burner swing door with 4 burner
flange bolts installed part way.
RED
WIRE
• Align round part of key hole slots of burner flange with
TO B1 burner door bolts. Turn burner to lock in place.
• Tighten all 4 hex nuts using diagonal sequence.
• Plug burner power cord into burner harness.
• Attach flexible oil hose included in parts box.
BLACK
WIRE TO
C1, C2 WHITE
L1
CIRCULATOR WIRE TO
WIRING B2

Figure 16 - Drain Valve

DRAIN
VALVE

17 P/N 240009350 Rev. J [09/01/2017]

 9 - BOILER SYSTEM PIPING

9.1 Connect System Supply And Return Piping 9.2 Bypass Piping
To Boiler See Piping Diagrams for illustrations for this section.
Connect system supply and return piping to correct boiler Bypass piping may be required for applications listed
fittings. below. Failure to do so may cause damage due to thermal
Size system circulator to supply sufficient flow (GPM) to shock and sustained condensation within the boiler.
allow 20°F temperature differential in system. Connect Protect boiler from sustained operation of return water
circulator harness to circulator per Figure 12 and furnished temperatures lower than 130°F (54C). Occasionally,
wiring diagram. temperatures as low as 70°F (21C) may return back to
When sizing system circulator, use single most restrictive boiler when a zone that has not been activated for some
zone to determine maximum pressure drop. time is opened. However, most residential systems with
finned-tube (aluminum-copper) baseboard radiation
1. Boiler used in connection with refrigeration systems, contain low volume of water and will not adversely affect
install boiler so chilled medium is piped in parallel with
boiler. Systems with finned-tube baseboard radiation
heating boiler using appropriate valves to prevent
typically do not require bypass.
chilled medium from entering boiler. See Figure 28,
Page 19. Bypass piping details shown in piping diagrams must be
2. If boiler is connected to heating coils located in air used for any one of following conditions:
handling units exposed to refrigerated air, equip boiler • All large water content systems, including cast iron
piping with flow control valves to prevent gravity standing radiators, cast iron baseboard, converted
circulation of boiler water during operation of cooling two-pipe steam systems, converted gravity circulation
system. systems and other similar systems.
3. Limit control includes low water cutoff function, sensing
water level at control well in top of the rear boiler • Any system, including finned-tube baseboard, with
section. Periodic inspection and testing is necessary priority domestic hot water zone.
per instructions provided with limit control. Install ¾ inch bypass line as shown in piping diagrams for
4. When installation of boiler is for new heating system, systems identified above.
install all radiation units (panels, radiators, baseboard, Bypass valve cannot protect boiler from sustained
or tubing) and supply and return mains. After heating condensing operation for low temperature applications such
system piping and components have been installed, as radiant floor heating. These types of system require
make final connection of system piping to boiler. active controls that prevent return of cold return water to
Recommend mount circulating pump on supply side boiler.
piping, such that it pumps away from expansion tank. Refer to Radiant Professional’s Alliance (RPA)
5. Hot water boiler installed above radiation level must www.radiantprofessionalsalliance.org for piping
be equipped with low water cut off device. This boiler recommendations for non-condensing boiler applications.
is factory equipped with low water cutoff. Periodic
inspection is necessary, per manufacturer’s specific
instructions.
6. When connecting cold water supply to pressure
reducing valve, make sure clean water supply is
available. When water supply is from well or pump,
install sand strainer at pump.

18 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

Figure 17 - Standard Near Boiler Piping

Piping Diagram Legend

19 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

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

DHW Heater

FIGURE 18
INDIRECT WATER TANK
HEATER, AQUASTAT
CONTROL
OR THERMOSTAT

T-STAT

THERMOSTAT
PRIORITY
ZONE ZONE 2
COMMON
DATA PORT +
ELECTRONIC T 1 T
W R T 2 T
W R
FUSE 24 VAC @ 1 VA

HYDROSTAT
ZONE 1 ZONE 2

TORQUE TERMINAL SCREWS

MODEL 3250 + + +
CT

6 TO 7 INCH LBS
PRIORITY ON TO EXTRA
ZONE MODULE

X-X
PRIORITY ON

ARM-2P
CONTROL
WITH
PRIORITY X1 X1 X2 X2 L 1 N L 2 N L N
ISOLATED ISOLATED PRIORITY ZONE 2
SWITCH SWITCH 120VAC CIRCULATORS
120 VAC

CIRC
DHW
TO OIL
CIRC
BURNER

L
120 VAC
N

20 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

Figure 19 - M
 ulti-Zone Piping and Wiring With Zone Valves And Domestic Hot Water Priority
(With Zone Valve)

SEE FIGURE
(CONSULTER 20
LA FIGURE 20)

ON

ZONE VALVE / PUMP

FIGURE 19 INDIRECT WATER
PRIORITY
HEATER, AQUASTAT
ZR-ZC
OR THERMOSTAT DPM-2

TANK T-STAT OPTION SWITCHES

CONTROL
KEY
T-STAT T-STAT
ON
24VAC FROM OFF
TRANSFORMER
C T T T T T T T T
24 VAC
R
TO DPM-2
X X
Z1 Z2 Z3 Z4
STATUS
HYDROSTAT PRIORITY ON
PRIMARY PUMP
MODEL 3250 PRIORITY PUMP
X-X CONTACT
ZR ON
ZONE VALVE / PUMP
120VAC TO PRIORITY
ZR-ZC
TRANSFORMER DPM-2
ZC ON
L OPTION SWITCHES
120 VAC
TO XFRM
N

120VAC PRIMARY PRIORITY FROM BOILER

PUMP PUMP
N L L N L N ZR ZC

AZ-4CP
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
PRI ZONE 1 ZONE 2 ZONE 3 ZONE 4

CIRC ZONE ZONE

VALVE VALVE
RELAY
24VAC COIL
120VAC CONTACTS ZONE
DHW ZONE
TO OIL VALVE VALVE
BURNER

L
120 VAC
N

21 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

Figure 20 - Piping And Wiring Multizone System With Zone Valves And Domestic Hot Water
Priority (With Circulator)

ON

ZONE VALVE / PUMP

FIGURE 20 INDIRECT WATER PRIORITY
HEATER, AQUASTAT ZR-ZC
OR THERMOSTAT DPM-2

TANK OPTION SWITCHES

T-STAT
CONTROL
KEY
T-STAT T-STAT
ON
24VAC FROM
OFF
TRANSFORMER
C T T T T T T T T
24 VAC
R
TO DPM-2
X X
Z1 Z2 Z3 Z4
STATUS
HYDROSTAT PRIORITY ON
PRIMARY PUMP
MODEL 3250 PRIORITY PUMP
X-X CONTACT
ZR ON
ZONE VALVE / PUMP
120VAC TO PRIORITY
ZR-ZC
TRANSFORMER DPM-2
ZC ON
L OPTION SWITCHES
120 VAC
TO XFRM
N

120VAC PRIMARY PRIORITY FROM BOILER

PUMP PUMP
N L L N L N ZR ZC

AZ-4CP
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
PRI ZONE 1 ZONE 2 ZONE 3 ZONE 4

CIRC ZONE
VALVE

ZONE ZONE
TO OIL VALVE VALVE
BURNER DHW
CIRC
L
120 VAC
N

22 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

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

FIGURE 21 INDIRECT WATER TANK

HEATER, AQUASTAT
CONTROL
OR THERMOSTAT T-STAT

T-STAT T-STAT

THERMOSTATS
DATA PORT PRIORITY
ZONE ZONE 2 ZONE 3 ZONE 4 COMMON
+

ELECTRONIC
FUSE
Z TW 1 T R TW 2 T R TW 3 T R TW 4 T R 24 VAC
@ 1VA

+
+

24AC

PRIORITY ON
HYDROSTAT
MODEL 3250 30 VA TO EXTRA
ZONE MODULE

COMMON
X-X
ZR-ZC

PRIORITY ON
+

ZONE 1 ZONE 2 ZONE 3 ZONE 4

ARM-4P
CONTROL WITH
PRIORITY
X X L 1 N L 2 N L 3 N L 4 N L N
ISOLATED
SWITCH ZC ZR PRIORITY ZONE 2 ZONE 3 ZONE 4
120 VAC

CIRC CIRC
TO OIL DHW
BURNER CIRC
CIRC

L
120 VAC
N

23 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

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

MAX = 4 X DIAMETER
CLOSELY - SPACED TEES

BOILER
PUMP

24 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

FIGURE 22 INDIRECT WATER TANK

HEATER, AQUASTAT
CONTROL
OR THERMOSTAT T-STAT

T-STAT T-STAT

THERMOSTATS
DATA PORT PRIORITY
ZONE ZONE 2 ZONE 3 ZONE 4 COMMON

+
ELECTRONIC
FUSE
Z TW 1 TR TW 2 T R TW 3 TR TW 4 TR
24 VAC
@ 1VA

+
24AC

PRIORITY ON
HYDROSTAT
MODEL 3250 30 VA TO EXTRA
ZONE MODULE

COMMON
X-X
ZR-ZC

PRIORITY ON

+
ZONE 1 ZONE 2 ZONE 3 ZONE 4

ARM-4P
CONTROL WITH
PRIORITY
X X L 1 N L 2 N L 3 N L 4 N L N
ISOLATED
SWITCH ZC ZR PRIORITY ZONE 2 ZONE 3 ZONE 4
120 VAC

CIRC CIRC

CIRC
TO OIL
BURNER RELAY
120VAC COIL
120VAC CONTACTS
DHW
CIRC
BLR
CIRC

L
120 VAC
N

25 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

Figure 23 - Piping And Wiring Primary/Secondary Multi Zone System Piping With Zone Valves
And Domestic Hot water (With Zone Valve)

* ZONE 1 (PRIORITY ZONE)*

* USE FULL PORT ZONE

VALVE.
FOR OPTIMUM TANK
PERFORMANCE, CONSULTER LA FIGURE 24.
CONSIDER USING ZONE
CIRCULATOR.
MAX = 4 X DIAMETER
CLOSLEY - SPACED
TEES

BOILER
PUMP

26 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

ON

ZONE VALVE / PUMP

FIGURE 23 INDIRECT WATER PRIORITY
HEATER, AQUASTAT ZR-ZC
OR THERMOSTAT DPM-2

TANK OPTION SWITCHES

T-STAT
CONTROL
KEY
T-STAT T-STAT
ON
24VAC FROM
OFF
TRANSFORMER
C T T T T T T T T
24 VAC
R
TO DPM-2
X X
Z1 Z2 Z3 Z4
STATUS
HYDROSTAT PRIORITY ON
PRIMARY PUMP
MODEL 3250 PRIORITY PUMP
X-X CONTACT
ZR ON
ZONE VALVE / PUMP
120VAC TO PRIORITY
ZR-ZC
TRANSFORMER DPM-2
ZC ON
L OPTION SWITCHES
120 VAC
TO XFRM
N

120VAC PRIMARY PRIORITY FROM BOILER

PUMP PUMP
N L L N L N ZR ZC

AZ-4CP
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
PRI ZONE 1 ZONE 2 ZONE 3 ZONE 4

CIRC ZONE ZONE

VALVE VALVE
RELAY
24VAC COIL
120VAC CONTACTS ZONE
DHW ZONE
VALVE VALVE
TO OIL
BURNER

BLR
CIRC
L
120 VAC
N

27 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

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

28 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

ON

ZONE VALVE / PUMP

FIGURE 24 INDIRECT WATER PRIORITY
HEATER, AQUASTAT ZR-ZC
OR THERMOSTAT DPM-2

TANK OPTION SWITCHES

T-STAT
CONTROL
KEY
T-STAT T-STAT
ON
24VAC FROM
OFF
TRANSFORMER
C T T T T T T T T
24 VAC
R
TO DPM-2
X X
Z1 Z2 Z3 Z4
STATUS
HYDROSTAT PRIORITY ON
PRIMARY PUMP
MODEL 3250 PRIORITY PUMP
X-X CONTACT
ZR ON
ZONE VALVE / PUMP
120VAC TO PRIORITY
ZR-ZC
TRANSFORMER DPM-2
ZC ON
L OPTION SWITCHES
120 VAC
TO XFRM
N

120VAC PRIMARY PRIORITY FROM BOILER

PUMP PUMP
N L L N L N ZR ZC

AZ-4CP
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
PRI ZONE 1 ZONE 2 ZONE 3 ZONE 4

CIRC ZONE
VALVE

ZONE ZONE
VALVE VALVE
TO OIL RELAY DHW
24VAC COIL
BURNER 120VAC CONTACTS CIRC

BLR
CIRC
L
120 VAC
N

29 P/N 240009350 Rev. J [09/01/2017]

 10 - HYDRONIC PIPING

Figure 25 Bypass Piping (Fixed Low Temperature Only)

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

FROM SYSTEM
TO SYSTEM

V1 V2
SYSTEM
CIRCULATOR

WATER INLET

EXPANSION
TANK BOILER ALTERNATE
CIRCULATOR
LOCATION

Figure 26 - Bypass Piping Automatic Mixing Valve

PRESSURE BALL VALVE AIR SEPARATOR
CIRCULATOR
REDUCER VALVE

TO SYSTEM SHUT-OFF ZONE VALVE FROM SYSTEM

CHECK VALVE
VALVE

WATER INLET

EXPANSION
TANK

BOILER ALTERNATE
CIRCULATOR
LOCATION

30 P/N 240009350 Rev. J [09/01/2017]

PRESSURE
 10 - HYDRONIC PIPING

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

TO SYSTEM

FROM SYSTEM

WATER INLET

EXPANSION
TANK

BOILER ALTERNATE
CIRCULATOR
LOCATION

Figure 28 Recommended Piping For Combination Heating and Colling (Refrigeration) System

CIRCULATOR PRESSURE BALL VALVE AIR SEPARATOR

REDUCER VALVE

4-WAY MIXING
WATER CHILLER
SHUT-OFF FLOW CONTROL
CHECK VALVE VALVE HOSE BIB
VALVE VALVE

BOILER
SHUT OFF SHUT OFF
VALVES VALVES

AIR CUSHION
TANK

CIRCULATOR

SUPPLY MAIN TO RETURN MAIN FROM

COMBINED HEATING COMBINED HEATING
& COOLING SYSTEM & COOLING SYSTEM

31 P/N 240009350 Rev. J [09/01/2017]

 11 - FUEL SUPPLY PIPING

11.1 Installation of oil tank and piping shall conform

to requirements of authority having jurisdiction or Figure 30 - Double Pipe Oil Line
in absence of such requirements National Board
of Fire Underwriters. In addition, refer to NFPA 31
(U.S.). Installation of oil storage tank, vent, fill pipe
and caps shall conform to requirements of authority
having jurisdiction.
• In no case should vent pipe be smaller than 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 fittings on all oil lines are required. Compression
fittings on suction line often allow air to be drawn into
fuel pump, making it difficult to maintain oil pressure at
nozzle.
• Do not run overhead fuel lines from tank to oil burner.
• Follow instructions, attached to fuel pump, for fuel pump
and by-pass 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 Table 5 - TWO STAGE UNITS,
rating.
• Install oil line filter and shut-off valve in suction line. TWO PIPE SYSTEMS (SEE FIGURE 20)
• Install Shut-off valves in both suction and return lines at Maximum Length of Tubing “R”
burner for convenience in servicing burner. LIFT
• Allow extra tubing at burner so burner may be removed “H” 3/8” O.D. 1/2” O.D.
from boiler for cleaning without disconnecting tubing. Tubing (3 GPH) Tubing (3 GPH)
See Figure 29 and 30.
• Use flexible oil lines so burner swing door can be opened 0 93 FT. 100 FT.
without disconnecting oil supply piping. 2 85 FT. 100 FT.
4 77 FT. 100 FT.
6 69 FT. 100 FT.
Figure 29 - Single Pipe Oil Line
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.

32 P/N 240009350 Rev. J [09/01/2017]

 12 - ANTIFREEZE IN THE SYSTEM
12.1 Antifreeze added to boilers must be nontoxic,
and must be of type specifically intended for use in closed
hydronic heating systems. Under no circumstances should
automotive antifreeze be used. Antifreeze used in any
boiler may reduce capacity by 10% or more and increase
fuel consumption. See Table 6 and 7.

Table 6 - BOILER WATER VOLUMES Table 7 - PIPING WATER VOLUMES

COPPER
Number of Total Volume STEEL PIPE
PIPE SIZE PIPE
Boiler Section (Gallons) FACTOR
FACTOR
4 3.6 ½” 82.5 63.5
5 4.3 ¾” 40.0 36.0
6 5.1 1” 23.3 22.2
7 5.9 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.

33 P/N 240009350 Rev. J [09/01/2017]

 13 - ELECTRICAL CONNECTIONS

! WARNING 13.1 Electrical wiring shall conform to requirements

of authority having jurisdiction or in absence of such
Electrical shock hazard. Turn OFF electrical power requirements ANSI/NFPA No. 70.
supply at service panel before making electrical
connections. Failure to do so could result in death Run separate electrical circuit from entry box with
or serious injury. fused disconnect switch in this circuit.

Never “jump out” or make inoperative any safety or

operating controls.

SEE APPROPRIATE ADDENDUM FOR WIRING

DIAGRAMS

34 P/N 240009350 Rev. J [09/01/2017]

 14 - CHIMNEY AND VENTING CONNECTIONS

14.1 Chimney Venting 3. Chimney Inspection – Prior to installation of any new or

Oil fired boilers with connections to vents or replacement fuel burning equipment chimney shall be
chimneys, vent installation shall conform to inspected by qualified service agency.
requirements of authority having jurisdiction or in A. De-rating may cause condensation on interior
absence of such requirements NFPA 31 Installation walls of chimney and boiler. Loose mortar can be
Of Oil Burning Equipment (U.S.) or CSA B139 indication of history of condensing flue gases upon
(Canada) and applicable provisions of local building inside walls of chimney. Do not install chimney until
codes. it meets requirements of NFPA 211 or CSA B139.
Installation shall conform to requirements of B. Unlined Chimney – Do not install boiler if chimney
NFPA31 – Standard for the Installation of Oil-Burning is constructed of brick only. Only approved clay
Equipment and NFPA 211 – Standard for Chimneys, liners or listed chimney lining systems shall be used
Fireplaces, Vents, and Solid Fuel-Burning Appliances as specified in NFPA 31 or CSA B139.
(Installations in U.S.) or CSA B139 – Installation C. Abandoned Openings – Seal Openings through
Code for Oil-burning Equipment. (Installations in chimney wall that are no longer used in accordance
Canada). to NFPA 211.
1. Ensure sufficient draft during heating season to allow D. Clean Chimney – Chimney shall be free of all loose
for safe evacuation of flue gasses. debris.
2. Boiler can be vented into fireclay tile-lined masonry 4. Install draft regulator at least 18” above breech; 18”
chimney or type L vent or factory built chimney that of straight run up-stream of regulator ensures proper
complies with type HT requirements of UL103. See operation.
Figure 32, Page 37. 5. Draft Regulator – Use supplied draft regulator with this
appliance. Do not use any other draft regulator. See
Figure 31, Page 37.

Table 8 - Recommended Minimum Chimney Sizes

SQUARE
FIRING RATE CHIMNEY NOMINAL ROUND
LINER
(gph) HEIGHT (ft) CHIMNEY LINER INSIDE
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.

35 P/N 240009350 Rev. J [09/01/2017]

 14 - CHIMNEY AND VENTING CONNECTIONS

14.2 Chimney and Chimney Connector • Over-fire Draft - Measure pressure at 1/4” NPT test port.
Three pass boilers have higher pressure drop than single
1. Chimney connector should be kept as short as possible.
pass. Table 9 shows expected pressure drop between
Horizontal length of chimney connector should not be
over-fire and breech. Total pressure drop is difference
greater than 10 feet.
between over-fire draft and breech draft. For example,
2. Type L Vent pipe or other suitable material may be if over-fire draft = 0.05 INWC and breech draft = - 0.05,
used for chimney connector if flue temperature is less total pressure drop = 0.05 - (-0.05) = 0.10 INWC. See
than 570° F. Figure 33, Page 37.
3. 4,5 & 6 section boilers are equipped with a sheet metal
flue collar for attaching 5" diameter chimney connector.
Attach chimney connector to flue collar with 3 standard Table 9 - Pressure Drop Between
sheet metal screws (field supplied). Over-Fire & Breech
4. 7 section boilers are equipped with a cast iron flue Sections Inches WC
collar for attaching 6" diameter chimney connector.
Attach chimney connector to flue collar using furnished 4 0.03-0.05
drill bit to drill holes for furnished screws. Vent 5 0.05-0.08
Connection Kit (drill bit and screws) furnished in
6 0.09-0.16
accessory carton. Predrill to avoid cracking cast iron
flue collar. 7 0.07-0.16
5. 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. 14.4 Stack Temperature

6. Inspect base of chimney for any signs of seepage. 1. Higher stack temperature, greater amount of draft
generated. Lower stack temperature not only reduces
Discoloration may be a sign of chimney damage. Have
amount of draft created but also increases possibility
repaired immediately.
flue gases could condense in chimney connector or
7. Contact qualified service agent immediately to examine stack.
damage and correct. Operation of damaged chimney 2. Consult NFPA 31 and CSA B139 for information for
may cause venting failure and force flue gases into appropriate choice of venting materials. Chimney may
living space. have to be lined to create sufficient draft, or chimney
8. If chimney is to be re-lined, use recommendations in may have to be lined to prevent corrosion of masonry
NFPA31, Appendix E or CSA B139. chimney. Consult qualified service agency for chimney
requirements in your area.
3. Baffles – Efficiency of boiler is based on insertion of
flue baffles supplied with 4,5 & 6 section units. Baffles
14.3 Draft are installed in 3rd pass (two inner flueways). Refer to
“8 - Boiler Assembly” on page 13 for baffle installation.
• Natural draft generated through chimney is dependent
Remove baffles to increase stack temperature.
on several factors including, chimney height,
temperature of flue gases, cross section area of 4. Remove baffles if any signs of condensation in chimney
chimney, chimney wall insulation value, dilution air and or chimney connector. Removing baffles may not
total volume of flue gases. Operate boiler for at least 5 address condensation.
minutes before measuring draft.

• Minimum Draft at Breech – Draft induced by the

chimney must create at least a neutral pressure of 0
(zero) inches water column (INWC) at breech. Slightly
negative (i.e. suction) pressure is preferred. Pressure
at breech cannot be positive since this could create
condition that allows flue gas by-products to escape
from draft regulator. Draft is to be measured up stream
of draft regulator. See Burner Specifications.

36 P/N 240009350 Rev. J [09/01/2017]

 14 - CHIMNEY AND VENTING CONNECTIONS

Figure 31 - Proper Draft Regulator Locations

Figure 33 - Pressure Tapping for Checking

Figure 32 - Typical Chimney Locations Draft

Minimum height must be

at least 3 Ft higher than
highest part of passage
through roof. Must be
1/4”NPT TEST PORT
at least 2 FT higher
than any neighboring FOR OVER-FIRE
object within 10 Ft. Must MEASUREMENT
have unobstructed top
opening.
Must be at least
4 inches thick -
and be tight.

Tight, smooth,
Must slope up correctly sized
at least 1/4
inch per foot of
Sealed in Draft Regulator
horizontal run Vane
thimble

Tight clean-out
door

Balanced Crimped
Weight End

37 P/N 240009350 Rev. J [09/01/2017]

 15 - FILLING BOILER

! WARNING NOTICE
Fire, burn, asphyxiation hazard. Turn off service Boiler maximum operating pressure is posted on
switch to boiler to prevent accidental firing of ASME data label located on front lower leg of boiler.
burner outside combustion chamber. Disconnect Never exceed this pressure. Do not plug relief
burner power cord from wire harness in front jacket. valve.
Tighten swing door fastener completely when
L. It may be necessary to clean air vent assembly
service is complete. Failure to follow instructions in
after few days of operation.
this manual and understand all requirements could
result in death or serious injury. 3. Check controls, wiring and burner. Verify all
connections are tight and burner is rigid, all electrical
1. Inspect Installation Before Starting Burner. connections have been completed and fuses installed,
and oil tank is filled and oil lines have been tested.
A. Verify venting, water piping, oil piping, and
electrical system are installed properly. Refer to
installation Instructions contained in this manual.
B. Confirm all electrical, water and oil supplies
are turned off at source and vent is clear from
obstructions.
2. Fill Heating System With Water.
A. Failure to clean system can result in clogged air
vents, circulator damage and seized zone valves.

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

Maintenance” on page 53 for proper cleaning instructions
for water boilers.
Fill entire heating system with water and vent air from
system.
Use following procedure on series loop or multi-zoned
system installed as per piping diagrams, to remove air
from system when filling:
A. Close shut off valve in boiler system piping
between air separator and vertical purge valve.
B. Isolate all zones by closing zone valves or shut-off
valves in supply and return of each zone(s).
C. Attach hose to vertical purge valve in boiler system
supply piping. Terminate hose in five gallon bucket
or suitable floor drain or outdoor area.
D. Starting with one zone at a time, open zone valve
or shut-off valve in boiler supply and return piping.
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 filling system until
pressure gauge reads 12 psi. Close shut-off valve
in cold water supply piping.
I. Open shut off valve in boiler system piping.
J. Remove hose from purge valve.
K. Confirm boiler and system have no water leaks.
38 P/N 240009350 Rev. J [09/01/2017]
 16 - OPERATING THE BOILER - SYSTEM START-UP

16.1 Setting The Limit Control

Figure 34 - Limit
Setting can be verified using TEST/SETTINGS button.
See Page 41.

16.2 Setting High Limit

To adjust, turn HI TEMP dial A until desired setting is
displayed. See Figure 24. 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 D until number
displayed equals number of heating zones.
• Do not include indirect water heaters in number of
heating zones.
• Economy feature conserves fuel by reducing boiler
temperature. If heating system is unable to supply
needed heat to house, ECONOMY dial should be turned
to lower setting. (example: in a three zone house, turn
Figure 35 - Setting Economy Feature
dial to 2 or 1).
• Conversely, if boiler provides adequate heat, added SETTING
fuel savings can be achieved by selecting higher setting Disables economy function. Will allow boiler to
(example: 4 or 5). OFF fire until hi-limit temp is reached and re-fire
• If heating and indirect water heater signals were not with a 10° subtractive differential.
separated when wiring the control, Economy feature Provides lowest level of fuel savings. Use this
should be turned off to ensure the boiler supplies LO setting only if the house does not stay warm at
adequate temperature to heat indirect tank. higher settings.
1 Recommended setting for single zone systems.
16.5 Setting Zone/Indirect Switch 2 Recommended setting for Two zone systems.
When installing with indirect water heater, zone/indirect 3 Recommended setting for Three zone systems.
switch must be set in the I position, calls to ZC-ZR will 4 Recommended setting for Four zone systems.
bypass thermal targeting feature and allow boiler to fire to 5 Recommended setting for Five zone systems.
high limit setting to heat indirect tank.
HI Provides highest level of fuel savings.
Indirect signal must be separate from all heating zone
signals.
If you choose not to separate indirect signal from heating
zones, turn off economy feature to ensure boiler supplies
adequate temperature to indirect tank.

39 P/N 240009350 Rev. J [09/01/2017]

 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
efficiency. When activated, control will purge higher
boiler temperatures down to 135°F at start of any
thermostat call and supply latent energy in boiler to
heating zone calling.
• During purge cycle, display will indicate PUR.
• If heat is not sufficient 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

1. Push and hold TEST/SETTINGS button for 20 seconds.
2. Display will read PURR On.
3. To deactivate feature, push and hold button a second
time for 20 seconds.
4. Display will read PURR OFF.

16.7 Control Action On System Start-Up

At initial start-up, with economy feature active, control
establishes 145°F target temperature. To test high limit
shut-off function, economy dial must be turned to off.
Once tested, restore economy setting.
If heating demand is high, target will increase over time to
satisfy heat load.
To reduce potential for condensing, control will allow boiler
to heat to 125°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.

40 P/N 240009350 Rev. J [09/01/2017]

 16 - OPERATING THE BOILER - SYSTEM START-UP

Figure 36 - LED Legend 6 ECONOMY TARGET Economy feature is active,

limit control continually sets target temperatures below
high limit setting to maximize fuel efficiency. When boiler
water reaches target temperature, LED illuminates and
burner shuts down. Boiler water will continue to circulate
and heat the house as long as thermostat call continues.
LED will stay lit until boiler temperature drops below
differential set point at which point boiler will be allowed to
fire again.
Note: LED illuminates regularly during normal boiler
operation.

7 TEST/SETTINGS Button
To Test Low Water Cut-Off: Press and hold Test/
1 TEMP ACTIVE Indicates Limit Control is powered Settings button for 5 seconds. Display will read LCO.
and temperature function is active. LWCO TEST LCO

2 TEMP HI TEMP Illuminates when boiler water Red Low Water light should illuminate and burner circuit
temperature reaches high limit setting. Remains lit until (B1 and B2) should de-energize. Note: Control must
water temperature falls 10°F. Limit control prevents burner be installed with Electro-Well for low water cut-off
operation while this LED is on. See Differential explanation functionality.
page 27.
To View Current Settings: Press and release Test/
3 LWCO ACTIVE Indicates low water cut-off (LWCO)
Settings button in short intervals to sequentially display the
function of limit control is active. Boiler is factory equipped following settings:
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.
4 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 qualified service Display will return to boiler temperature (default) if Test/
agency prior to resuming operation. Settings button is not pressed for 5 seconds.

5 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.

41 P/N 240009350 Rev. J [09/01/2017]

 16 - OPERATING THE BOILER - SYSTEM START-UP

NOTICE ! WARNING
Instructions are for Beckett AFG with Beckett Fire, burn, asphyxiation hazard. Do not loosen
Genisys primary control. For other burners, refer to or remove any oil line fittings while burner is in
manufacturer’s manual. operation. Failure to follow these instructions could
Nozzle and air settings are given in Table 14 page result in death or serious injury.
50.
! WARNING
For direct vent installation guide, see Direct Vent
Fire, burn, asphyxiation hazard. Do not attempt
Addendum.
to start burner when oil has accumulated in
16.9 Oil Burner combustion chamber or unit is full of vapor, or
hot. Check operation of all boiler controls before
1. Prepare Oil Burner Before Starting.
installation of boiler is completed. Failure to follow
A. Check burner air band, air shutter and head setting
these instructions could result in death or serious
(if equipped), readjust if necessary. See “17 - Oil
Burner, Nozzle, & Air Settings” on page 46.
injury.
B. Open all oil line valves.
3. Preliminary Oil Burner Adjustments
C. Attach a plastic hose to fuel pump vent fitting and
provide a pan to catch the oil. 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
2. Prime Pump and Start Oil Burner running.
A. Open bleed port fitting on fuel pump. B. Use smoke tester and adjust air if necessary for
B. Initiate a call for heat minimum smoke (not to exceed trace) with minimum
I. After burner starts, press and hold reset button for of excess air. Check using suitable instrumentation to
approximately 15 seconds until yellow light turns confirm CO2 of 11 to 13%. If flame appears stringy
on. Indicates button has been pressed long enough. instead of solid fire, try another nozzle of same type.
Flame should be solid and compact.
II. Release reset button. Yellow light turns off and
burner starts up again. C. Turn off burner and remove pressure gauge. Install
gauge port/bleeder plug and tighten. Start burner
III. At burner startup, click reset button while igniter is
still on. This transitions control to dedicated pump again.
priming mode, during which the motor, igniter and 4. Final Burner Adjustments: Final burner
valve are powered for four minutes. Yellow light will adjustments must be made using combustion test
be on. instruments.
C. Bleed pump until all froth and bubbles are purged. A. Check breech draft to verify between 0.00” WC and
I. If desired, terminate call for heat or hold reset -0.05” WC, or otherwise adjust draft to -0.05” WC (or
button for at least one second to exit pump priming less than zero.)
mode and return to standby mode. B. After operating 10 minutes to warm up boiler, use
II. At end of four minutes, yellow light will turn off and combustion test equipment to take smoke reading in
control will automatically return to standby mode. flue pipe between boiler and draft regulator. Smoke
III. If prime is not established during four minute pump reading should be zero to trace (Shell Bacharach
priming mode, return to step 2.B.III. to re-enter Scale).
pump priming mode. Repeat steps 2.C.I. to 2.C.II. C. New boiler may require more than 10 minutes to
until pump is fully primed and oil is free of bubbles. burn clean due to oil film on new heat exchanger.
D. Terminate call for heat. Close bleed port fitting on fuel If smoke reading is zero, gradually close burner’s
pump. air adjustment to obtain smoke reading showing
trace smoke reading. Once smoke reading is trace,
E. Adjust oil pressure.
measure CO2 and as insurance margin increase air to
I. When checking fuel unit’s operating pressure, sufficiently reduce CO2 by 1/2% to 1%.
reliable pressure gauge may be installed in either
bleeder port or nozzle port. D. If clean fire cannot be obtained, it is necessary to
verify burner head alignment. If fire continues to be
II. Initiate call for heat.
smoky, replace nozzle.
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.
42 P/N 240009350 Rev. J [09/01/2017]
 16 - OPERATING THE BOILER - SYSTEM START-UP

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

restart system.
Do not run boiler unattended until following procedure
V. After 15 second lockout time, control will lock out
is completed. Failure to follow these instructions could burner and reset button will flash. Verify burner,
result in minor or moderate injury. motor and igniter are off and burner solenoid
valve (if used) is not energized.

E. Once burner is completely adjusted, start and stop VI. Open hand valve in oil line.
burner several times to assure good operation with no VII. Click reset button and verify red light in reset
fluttering or rumbling. Verify there are no oil leaks, button shuts off and burner lights.
record nozzle size, oil pressure, combustion readings,
and air settings on tag or label attached to burner or, VIII. End call for heat.
boiler.

! WARNING
Figure 37 - CAD Cell Location
Electrical shock hazard. Following safety checks shall
be completed by qualified agency. Failure to do so
could result in death or serious injury.

NOTICE
Control contains no field serviceable parts. Do not
attempt to take it apart. Replace entire control if
operation is not as described.

5. Check Genisys Oil Primary Control

A. Preliminary steps
I. Check wiring connections and power supply.
II. Verify power is on to controls.
III. Verify limit control is closed. D. Cad Cell Check : Cad cell resistance can be checked
IV. Check contacts between igniter and electrodes. with use of Genisys display module or Genisys
V. Check piping to oil tank. contractor tool. If not available, cad cell leads can
be unplugged from control and resistance measured
B. Safe Start Check
in conventional way. Conduct these tests with flame
I. Place jumper across cad cell terminals. present. See Figure 37.
II. Initiate call for heat. Flame Detection Range
III. Burner must not start. Verify green light is on • Normal (0-1600 ohms)
continuously and control remains in standby • Limited (1600 ohms to lockout)
IV. End call for heat and remove cad cell jumper. E. Power Failure Check: After flame is established,
C. Simulate Flame Failure And Ignition Failure turn power off to control / burner. Burner should shut
mode. down safely. When power is restored, normal ignition
sequence should be started.
I. Initiate call for heat.
II. After flame is established and burner igniter turns
off, close hand valve in oil supply line.
III. At flame loss, control will enter recycle mode.
Verify green light is flashing. Control will remain in
recycle for 60 seconds.

43 P/N 240009350 Rev. J [09/01/2017]

 16 - OPERATING THE BOILER - SYSTEM START-UP
E. Ignition Carry-over. Once flame is established,
Figure 38 - Sequence of Operation igniter remains on for 10 additional seconds to ensure
flame stability.
F. Run. Flame is sustained until call for heat is satisfied.
Burner is then sent to Motor-Off Delay, if applicable,
or it is shut down and sent to Standby.
G. Recycle. If flame is lost while burner is firing, control
shuts down burner, enters 60 second recycle delay,
and repeats ignition sequence. Control will continue to
recycle each time flame is lost, until it reaches preset
time allotment. Control will then go into Hard Lockout
instead of recycle. Feature prevents excessive accu-
mulation of oil in the boiler firing chamber.
H. Motor-Off Delay. If applicable, oil solenoid valve is
6. Genisys Control Sequence of Operation turned off and control delays turning motor off for
A. Standby. Burner is idle, waiting for call for heat. set motor-off delay time before control returns to
B. Valve-On Delay. Igniter and motor are on while standby.
control delays turning on oil solenoid valve for pro- I. Pump Prime. Igniter and motor are on with solenoid
grammed time. valve energized for 4 minutes. During Pump Prime
C. Trial for Ignition. Oil solenoid valve is energized. mode, cad cell is disregarded, allowing technician to
Flame should be established within factory set trial for prime pump without having to jumper cad cell.
ignition time (“lockout time”).
D. Lockout. Control has shut down for one of following 7. Genisys Control Reset Button Operation
safety reasons: See Table 11 for action control takes when reset button
I. Trial for ignition (lockout) time expired without is pressed for different lengths of time during various
flame being established. burner operation states.
II. Cad cell detected flame at end of Valve On Delay
State.
To reset from hard lockout, hold reset button 15
seconds until yellow light turns on.

Table 10 - Genisys Control Reset Button Operation

Pushing reset button will:
If burner is in below
state: Button Click Button Hold Button Hold
(press < 1 second) (press > 1 second) (press 15+ seconds)
Reset from Restricted (Hard)
Lockout Reset from Soft Lockout Lockout
Valve-on Delay, Trial for Go to Pump Prime Enables Pump Priming: After
Ignition, Ignition Carry- See Disable Burner: Anytime burner reset button has been held for
over “Priming the Pump” page 44 is running, press and hold reset 15 seconds, button can then
button to disable burner. Burner be clicked during next ignition
Run (Igniter shut off) No Action will remain off as long as button sequence to enter Pump Prime
is held.
Motor-Off Delay, Standby No Action mode.
Pump Prime No Action Exit Pump Prime mode and return to Standby

Table 11 - Genisys Control Status Lights

Light Color On Continuously On Continuously
Red Restricted (Hard) Lockout Soft Lockout
Flame Sensed during normal operation (Possible stray
Green Recycle
light during standby)
Control is in Pump Prime mode or
Yellow N/A
reset button currently held for 15+ seconds.

44 P/N 240009350 Rev. J [09/01/2017]

 16 - OPERATING THE BOILER - SYSTEM START-UP

C. After installing nozzle, reassemble nozzle line

NOTICE electrode assembly and set electrode tip spacing.
Before starting or resetting control from restricted D. Electrode tip spacing may need to be set prior to
lockout state, troubleshoot heating system for root reassembling nozzle line electrode assembly. Refer
cause(s) of lockout. to figures on following pages for setting electrode tip
8. Genisys Control - Resetting From Restricted or spacing on Beckett.
Hard Lockout.
A. Make necessary repairs or adjustment to ensure 16.14 Check Thermostat Operation: Thermostat
safe start condition. location has important effect on operation of boiler system.
B. Ensure appliance is free of oil and oil vapors before A. Follow instructions included with your thermostat.
starting or resetting burner Typically, thermostat is located about five feet above
C. If control continues to lock out without satisfied floor on inside wall.
call for heat, or fails motor relay check, control B. Thermostat should be located to sense average room
enters Hard (restricted) Lockout in order to limit temperature.
accumulation of unburned oil in combustion
chamber. Table 12 - Thermostat locations to Avoid
D. To reset, hold button down for 15 seconds until red DEAD
HOT SPOTS COLD SPOTS
light turns off and yellow light turns on. SPOTS
E. Always verify control functions according to Concealed pipes Concealed pipes
specifications before leaving installation site. Behind
Fireplace or ducts
F. Replace control if it does not operate as specified. doors
TV sets Stairwell drafts
Radios Door drafts
9. Genisys Control - Disable Function Lamps
Anytime burner is running, press and hold reset button Corners & Unheated room
to disable burner. Burner will remain off as long as alcoves Direct sunlight on other side of
button is held. Kitchens wall

C. Verify room temperature reaches selected

! WARNING temperature setting, thermostat should turn boiler’s
Remove jumper after following check. burner off, and once room temperature falls few
degrees boiler starts operating again.
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.

45 P/N 240009350 Rev. J [09/01/2017]

 17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Figure 39 - B
 eckett Electrode Tip Adjustments Figure 40 - B
 eckett Electrode Tip Adjustments Standard
Standard Dimensions (L1, V1) Heads Dimensions (L2) Heads

Figure 41 -B
 eckett Check/Adjustment "Z" Figure 42 Beckett Check/Adjustment "Z"
Dimensions L1 & L2 Heads Dimensions - V1 Heads

L1/L2 Heads V1 Heads

See Figure 39. The important “Z” dimension is distance See Figure 40. The important “Z” dimension is distance
from leading edge of head to end of air tube. This from leading edge of head to end of air tube. This distance
distance for L1 & L2 heads is 1-3/8” if the tube has a for V1 heads is 1-¾”. “Z” dimension is factory set for
straight shroud or 1-3/4” if air tube has conic shroud. “Z” burners shipped with air tube installed. Even if factory set,
dimension is fac-tory set for burners shipped with air tube verify “Z” dimension has not been changed.
installed. Even if factory set, verify “Z” dimension has not
1. Use following procedure to adjust “Z” dimension, if it is
been changed.
not correct:
1. Use following procedure to adjust “Z” dimension, if it is • Turn off power to burner.
not correct:
• Disconnect oil connector tube from nozzle line. Refer
• Turn off power to burner. to figure above. Loosen splined nut from nozzle line.
• Disconnect oil connector tube from nozzle line. Loosen hex head screw securing escutcheon plate to
• Refer to figure above. Loosen splined nut from nozzle burner housing.
line. Loosen hex head screw securing escutcheon • Loosen acorn nut. Move head adjusting plate until
plate to burner housing. “0” lines up with reference indicator on housing, and
• Place end of ruler at leading edge of head and, using tighten hex head screw. Place end of ruler at leading
straight edge across end of airtube, measure distance edge of head and, using straight edge across end of
to end of tube. A Beckett T501 gauge may also be air tube, measure distance to end of tube. A Beckett
used. T501 gauge may also be used.
• Slide nozzle line forward or back until this dimension • Slide the nozzle line forward or back until this
is 1-3/8” for L1 & L2 heads if tube has straight dimension is 1-¾” for V1 heads. Tighten acorn nut.
shroud, or 1-3/4” if air tube has conic shroud. • Tighten hex head screw to secure head adjusting
• Tighten hex head screw to secure escutcheon plate to plate to burner chassis. Then tighten splined nut and
burner chassis. Then tighten splined nut and attach attach oil connector tube.
oil connector tube.
2. Recheck “Z” dimension periodically when servicing to
2. Recheck “Z” dimension periodically when servicing to ensure escutcheon plate has not been moved. Reset
ensure escutcheon plate has not been moved. Reset “Z” dimension if you replace air tube or nozzle line
“Z” dimension if you replace air tube or nozzle line assembly.
assembly.
46 P/N 240009350 Rev. J [09/01/2017]
 17 - OIL BURNER, NOZZLE, & AIR SETTINGS

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

Turbulator Setting
A. Loosen nut (1) turn SCREW (2) until INDEX MARKER
(3) is aligned with correct index number as per
Burner Settings Table.
B. Tighten RETAINING NUT (1).
NOTE: Zero and four are scale indicators only.
From left to right, first line is 4 and last line 0. On some
models, scale indicators are 0 and 3.

Figure 45 - Réglage des électrodes Carlin

47 P/N 240009350 Rev. J [09/01/2017]

 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.

TABLEAU 13a : RÉGLAGES PRÉLIMINAIRES DU BRÛLEUR BECKETT AVEC ÉVACUATION PAR CHEMINÉE

Firing Com- Pump Rated AFUE

Boiler Head Static Insertion Nozzle "Z" Head Air Air
Rate bustion Nozzle Type Pressure Efficiency
Model Type Plate Depth Mftr. Settings Band Shutter
[GPH] Liner [PSI] [%]

4075 L2 3.375U 2.625 0.75 Oval Delavan 0.65x60B 140 N/A 0 7 87.0

4095 L2 3.375U 2.625 0.95 Oval Delavan 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 87.0

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 87.0

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 87.0

Timings
Pre-purge 15 seconds
Post-purge 15 seconds ABLE 13B: BECKETT /ECR PART NUMBERS

ECR Oil ECR Oil

Beckett Oil
Boiler Burner Part Burner Part
Burner
Model Number Number
Model
with Cover 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

48 P/N 240009350 Rev. J [09/01/2017]

 17 - OIL BURNER, NOZZLE, & AIR SETTINGS

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

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

TABLE 14a: BECKETT DIRECT VENT PRELIMINARY BURNER SETTINGS

Pump Pressure Rated AFUE
Boiler Head Insertion Firing Rate Combustion Nozzle Air
Nozzle Type Pressure Switch Efficiency
Model Type Depth [GPH] Liner Mfr. Setting
[PSI] Setpoint [%]

4075 6 Slot 2.5" 0.75 Oval Delavan 0.60x60B 150 1.5 0.65" WC 87.0

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 87.0

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 6 Slot 2.5" 1.30 V6 Danfoss 1.00x45B 175 2.0 0.65" WC 87.0

Timings

Pre-purge 15 seconds

Post-purge 30 seconds

TABLE14b : BECKETT /ECR PART NUMBERS

Boiler Beckett Oil ECR Oil Burner
Model Burner Part Number

4075 Model 240007531

4095 NX70LC 240009393

5100 NX70LC 240007532

5115 NX70LF 240009395

5135 NX70LF 240009396

6130 NX70LD 240007533

49 P/N 240009350 Rev. J [09/01/2017]

 17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 15 - Riello 40F Chimney Vent Preliminary Burner Settings

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

TABLE 15: RIELLO 40F CHIMNEY VENT PRELIMINARY BURNER SETTINGS

Pump Rated
Inser- Firing Com-
Boiler Head Nozzle Nozzle Pres- Head Air AFUE
tion Rate bustion
Model Type Mfr. Type sure Setting Setting Efficiency
Depth [GPH] Liner
[PSI] [%]

4075 Reverse 2.75" 0.75 Oval Delavan 0.65x60W 150 1 3.6 87.0

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 87.0

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 87.0

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 87.0

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

Riello Riello
ECR Oil ECR Oil
Boiler Oil Boiler Oil
Burner Part Burner Part
Model Burner Model Burner
Number Number
Model Model

4075 40F3 240007503 6130 40F5 240007504

4095 40F3 240009399 6145 40F5 240009403

4110 40F5 240009400 6165 40F10 240009404

5100 40F5 240007503 7165 40F5 240007505

5115 40F5 240009401 7180 40F10 240009405

5135 40F5 240009402 7190 40F10 240009406

50 P/N 240009350 Rev. J [09/01/2017]

 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.

Tableau 16 : RIELLO 40F CHIMNEY VENT PRELIMINARY BURNER SETTINGS

Com- Pump
Inser- Firing Head Air Pressure Rated AFUE
Boiler Head bus- Nozzle Nozzle Pres-
tion Rate Set- Set- Switch Efficiency
Model Typer tion Mfr. Type sure
Depth [GPH] ting ting Setpoint [%]
Liner [PSI]

4075 Reverse 2.75 po 0.75 Oval Delavan 0.65x60W 150 3 5.0 0.25" WC 87.0

4095 Standard 1.75 po 0.95 Oval Delavan 0.75x90B 175 1 4.0 0.25" WC 85.0

4110 Standard 1.75 po 1.10 Oval Delavan 1.00x90B 125 2 5.0 0.25" WC 84.0

5100 Standard 2.75 po 1.00 None Delavan 0.75x60B 175 1 5.0 0.80" WC 87.0

5115 Standard 1.75 po 1.15 None Delavan 1.00x80B 130 2 5.8 0.80" WC 85.0

5135 Standard 1.75 po 1.35 None Delavan 1.20x80B 125 4 5.8 0.80" WC 84.0

6130 Standard 2.75 po 1.30 V6 Delavan 1.00x4 B 175 2 8.0 0.90" WC 87.0

Timings
Pre-purge 12 seconds
Post-purge 30 seconds

Riello ECR Oil

Boiler
Oil Burner Burner Part
Model
Model Number

4075 40BF3 240007528

4095 40BF5 240009407

4110 40BF5 240009408

5100 40BF5 240007529

5115 40BF5 240009409

5135 40BF5 240009410

6130 40BF5 240007530

51 P/N 240009350 Rev. J [09/01/2017]

 17 - OIL BURNER, NOZZLE, & AIR SETTINGS

Table 17 - Carlin (CHIMNEY VENT) Preliminary Burner Settings

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

TABLEAU 1 - PARAMÈTRES CARLIN

Rated
Pump
Boiler Insertion Firing Combustion Nozzle Nozzle Air Band AFUE
Pressure Head Bar
Model Depth Rate Liner Mfr. Type Setting Efficiency
[PSI]
[%]

4075 3.00" 0.75 OVAL DANFOSS 0.60x60AS 160 0.60/0.65 25% 87.0
4095 3.00" 0.95 OVAL DELAVAN 0.75x45W 160 0.75 35% 85.0
4110 3.00" 1.10 OVAL DELAVAN 0.85x60A 165 0.75 50% 84.0
5100 3.00" 1.00 NONE HAGO 0.75x60B 175 0.75 35% 87.0
5115 3.00" 1.15 NONE DELAVAN 0.85x45A 180 0.85/1.00 40% 85.0
5135 3.00" 1.35 NONE DANFOSS 1.10x60AB 150 1.10/1.25 45% 84.0
Timings
Pre-purge 15 seconds
Post-purge 15 seconds

ECR Oil
Carlin
Boiler Burner
Burner
Model Part
Model
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

52 P/N 240009350 Rev. J [09/01/2017]

 18 - MAINTENANCE

! DANGER 18.3 Relief Valve

• Test relief valve for proper operation. Refer to valve
Before servicing, turn off electrical power to boiler manufacturer’s instructions packaged with relief valve.
at service switch. Turn off fuel supply to burner
Failure to comply will result in death or serious 18.4 Conventional Expansion Tank
injury. See “Equipment And Accessories” section.

NOTICE 18.5 Diaphragm Expansion Tank

Perform regular service and maintenance by See “ 21 Equipment And Accessories” section, page 59.
qualified service agency at least once every 12
18.6 WATER SYSTEM
months to assure safe, trouble free operation
and maximum efficiency. 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.
NOTICE
Verify proper operation after servicing. 18.7 Oil Burner Maintenance
Perform following preventative maintenance annually,
18.1 Annually preferably prior to heating season.
Recommend qualified Service Agency check at lease once a
• Fuel Filter Replace to prevent contaminated fuel from
year:
reaching nozzle. Partially blocked fuel filter can cause
• Flue passages, premature failure of fuel pump.
• Combustion chamber area (target wall, fire door • Fuel Pump Unit Replace pump screen and clean pump
insulation) unit to maintain fuel delivery to nozzle.
• Burner adjustment, • Ignition Electrodes Clean and adjust as per
• Operation of the controls, manufacturer’s recommendations, so as to maintain
• Boiler seals (fire door gasket or silicone seal, cast iron reliable ignition of oil.
sectional seals, flue collector) • Nozzle Replace so as to maintain safe and reliable
Before start of each heating season (or system has been combustion efficiency. Always replace with exact nozzle
shut down for extended period of time) as required in charts. See “17 - Oil Burner, Nozzle, &
Air Settings” on page 31.
• Recheck whole system for water, oil, and vent piping
• Fan and Blower Housing Keep clean, free of dirt, lint
leaks.
and oil to maintain proper amount of air fuel requires to
• Replace or patch any leaks or seals that are faulty burn.
• Inspect flue ways at least once a year- Preferably at • Check burner settings and adjust as needed.
start of heating season.
• Inside of combustion chamber.
NOTE: If any component parts must be replaced, always
• Clean vent system and boiler flue ways if soot or scale
use parts recommended by burner manufacturer.
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 18.8 Low Water Cut Off Maintenance
immediately. ! WARNING
• Oil Burner and controls.
Burn and scald hazard. Verify boiler is at zero
18.2 Vent Pipe pressure before removing relief valve or control well.
Open safety valve to relieve all internal pressure
Visually inspect entire venting system once a month for any
signs of leakage, deterioration, or soot build up.
prior to proceeding.

If vent pipe shows any signs of leaking or deterioration, Remove control well from top of rear boiler section every
replace it immediately. five years and clean any scale or sediment deposits from all
parts exposed to boiler water.
If it shows any signs of soot build up, clean vent pipe and
have burner settings and combustion checked by qualified
service agency.

53 P/N 240009350 Rev. J [09/01/2017]

 18 - MAINTENANCE

Steps to inspect, clean and/or replace control well: • Continue to circulate water for few hours.
1. Turn off electric service to boiler controls. • Stop firing boiler.
2. Drain boiler water to level below tapping for control • Drain system in a manner and to a location that hot
well. water can be discharged safely.
• Remove plugs from all available returns and wash
3. Remove low water cut-off/limit sensor from control
water side of boiler as thoroughly as possible, using
well.
high-pressure water stream.
4. Unscrew control well from tapping.
• Refill system with fresh water.
5. Inspect portion of control well exposed to water for
scale or sediment buildup.
3. Add appropriate boiler water treatment compounds
as recommended by your qualified water treatment
6. Light deposits may be removed by wiping control well company.
with damp cloth. Wiping probe with cloth soaked in
vinegar will remove more tenacious lime deposits.
4. Testing pH /alkalinity. After boiler and system have
been cleaned and refilled as previously described, test
7. Clean pipe threads of probe to remove old, hardened pH of water in system. Use pH test kit. pH should
pipe dope and other foreign matter. be higher than 7 but lower than 11. Add appropriate
8. Apply moderate amount of good quality pipe dope to water treatment chemicals, if necessary, to bring pH
pipe threads on control well, leaving two end threads within range. Care must be excercised to eliminate all
bare. Do not use PTFE (Teflon) tape. free oxygen in system.
9. Reinstall control well into tapping. 5. Boiler is now ready to be put into service.
10. Reinsert low water cutoff/limit sensor in control well
and secure with grommet.
11. Fill system with water and purge. 18.10 Frequent Water Addition
12. Restore electric service to boiler. Frequent water additions, although unusual for water
13. Fire burner to heat water in boiler 180°F to drive off boilers, are sign a of leaky system. Excessive amounts of
free oxygen. make up water supplied to boiler can significantly shorten
life of boiler. Repair leak and consult with your water
14. Warning – before returning boiler to service: Follow treatment specialist for recommendations.
low water cut-off test procedure in Figure 36, Page 41.

18.11 Attention To Boiler While Not In Operation

18.9 Boiler And System Cleaning Instructions
For Trouble Free Operation NOTICE
1. Boiler and system (other than expansion tank) must Fully drain boiler if not used during winter months
be full of water for satisfactory operation. Add water to prevent freeze damage.
to system until boiler pressure gauge registers 12 psi.
Water should come out of all air vents when opened. 1. Keep manual fuel supply valve shut off if burner is shut
2. Wash Oil and grease which accumulate in new hot down for extended period of time.
water boiler out in following manner: 2. To recondition heating system in fall season after
• Shut off valves that have been installed between boiler prolonged shut down, follow instructions outlined in
return manifold and system, to minimize amount of See “15 - Filling boiler” on page 26.
system draining.
3. Boiler contains controls which may cause boiler to shut
• Drain boiler to level below relief valve tapping. down and not restart without service. If damage due
• Remove relief valve using extreme care to avoid to frozen pipes is a possibility, heating system should
damaging it. not be left unattended in cold weather; or appropriate
• Add appropriate amount of recommended boil out safeguards and alarms should be installed on heating
compound. system to prevent damage if boiler is inoperative.
• Replace relief valve. 4. Keep boiler and area around it clean. Never burn
• Fill entire system with water and purge. refuse or any material other than specified fuel in your
boiler. Have your boiler checked each year by qualified
• Start firing boiler.
service agency.
• Circulate water through entire system.
• Vent system, including radiation.
• Allow boiler water to reach operating temperature, if
possible.

54 P/N 240009350 Rev. J [09/01/2017]

 19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS

! DANGER 2. Clean combustion chamber and baffles. Use wire

or fiber bristle brush to clean surfaces of combustion
Before servicing, turn off electrical power to boiler chamber and baffles. Vacuum all of loose debris in
at service switch. Turn off fuel supply to burner. bottom of combustion chamber. Take care not to
Failure to comply will result in death or serious damage or loosen target wall.
injury. 3. After cleaning: Vacuum all remaining debris as
necessary. Inspect burner swing door insulation, target
! WARNING wall and rope gasket for signs of damage. If damaged,
replace as needed.
Fire, burn, asphyxiation hazard. Turn off service
switch to boiler to prevent accidental firing of 4. Re-assemble boiler.
burner outside combustion chamber. Disconnect A. Insert liner and baffles (if equipped) into correct flue
burner power cord from wire harness in front jacket. way. Baffles are installed in 3rd pass. (Two inner flue
ways)
Tighten swing door fastener completely when
service is complete. Failure to follow instructions in B. Inspect chimney and clean if necessary.
this manual and understand all requirements could C. Clean and re-attach vent connector onto rear of the
result in death or serious injury. boiler with three screws.
NOTICE
19.1 Oil Boiler Cleaning Instructions
When securing burner swing door verify door is
1. Clean flueways. Figure 29, Page 35. drawn-in equally on both sides. Do not overtighten
A. Shut off power to burner. door bolts. Rope gasket will provide sufficient seal
B. Access to combustion chamber, remove swing door when door is snugged into place.
bolts. If boiler is equipped with flexible fuel line(s),
swing door open. D. Tighten swing door hardware to provide adequate
seal to rope gasket around perimeter of door. Use
C. Remove vent connector.
alternating tightening method from non-hinged side to
D. Remove liners & baffles (if equipped) from flue hinged side cap screws to pull door tight equally.
passages. Baffles are installed in 3rd pass (two inner
E. Do not start burner unless burner swing door and vent
flue ways.)
connector are secured in place.
E. Clean 3rd Pass – Insert 2” Dia. x 42” long wire or fiber
bristle brush into each of two 3rd passes. Using long
strokes, push brush all the way through boiler until ! WARNING
brush has exited the smoke box opening. Asphyxiation hazard. A clean and unobstructed
Pull brush all the way forward until it has exited front chimney flue is necessary to allow noxious fumes
of boiler. that could cause injury or loss of life to vent safely.
Continue this operation for entire height of flue way Inspect periodically throughout heating season for
until clean. Repeat operation for other 3rd pass flue any obstructions. Failure to follow instructions in
way. this manual and understand all requirements could
F. Clean 2nd Pass – Insert wire or fiber bristle brush into result in death or serious injury.
each of two 2nd passes. Using long strokes, push
brush all the way through boiler until brush hits back NOTICE
wall of reversing chamber. Pull brush all the way
forward until it has exited front of boiler. Connect boiler to approved chimney in good
Continue operation for entire height of flue way until condition. Property damage could result if boiler is
clean. Repeat operation for other 2nd pass flue way. connected to dirty or inadequate chimney. Inspect
interior of chimney flue and clean before start of
G. Clean passage from combustion chamber to 2nd pass.
heating season.
Take care not to damage or loosen target wall

19.2 Oil Burner Cleaning Instructions

Consult burner manufacturer’s instructions.

55 P/N 240009350 Rev. J [09/01/2017]

 19 - OIL BOILER / BURNER CLEANING INSTRUCTIONS

Figure 46 - Cleaning the Boiler

FLUE BRUSH

3RD PASS VACUUM

HOSE

FLUE BRUSH

BRISTLE
BRUSH

VACUUM
HOSE

FRONT VIEW COMBUSTION CHAMBER & 2ND PASS

56 P/N 240009350 Rev. J [09/01/2017]

 20 - TROUBLESHOOTING

20.1 Combustion C. Control locks out after trial for Ignition.

(TFI)
A. Nozzles - See “17 - Oil Burner, Nozzle, & Air Settings”
on page 46. I. No oil to burner.
B. Fuel leaks - Any fuel leak between pump and nozzle II. Shortened electrodes
is detrimental to good combustion results. Look for III. Clogged nozzles.
wet surfaces in air tube, under ignitor, and around air
IV. Airflow too high.
inlet. Repair any such leaks as they may cause erratic
burning of fuel and in extreme case may become fire V. Ignitor module defective.
hazard. VI. CAD cell defective.
C. Dirt - Fuel filter is required to prevent clogging nozzle VII. Oil valve stuck open or closed.
or nozzle strainer and produce poor spray pattern
from nozzle.
To isolate fuel problems: disconnect fuel system and fire
D. Water - Water in fuel in large amounts will stall fuel
out of auxiliary container of clean, fresh, warm #2 fuel
pump. Water in fuel in smaller amounts will cause
oil from another source. If burner runs successfully when
excessive wear on pump. Water doesn’t burn, it chills
drawing out of container problem is in fuel or fuel lines.
the flame and causes smoke and unburned fuel to
pass out of the combustion chamber and clog flue
ways of the boiler. If flame is not established within 15 seconds of oil valve
E. Cold Oil - If oil temperature approaching fuel pump actuation (known as Trial For Ignition or TFI) soft lockout
is 40°F or cooler, poor combustion or delayed ignition will occur. Soft lockout is indicated by flashing red LED
may result. Outside fuel tank above grade or fuel lines located on oil primary control.
in shallow bury may be the cause.
F. High Altitude Installation - Air openings must be
increased at higher altitudes. Use combustion analyzer
and set to 11.5% for initial setting. NOTICE
G. Start up noise - Late ignition is cause of start up Restricted lockout without retries will occur if flame
noises. If it occurs recheck for electrode settings, is lost three times during one call for heat. this is
flame shape, air or water in fuel lines. indicated by a steady on red LED.
H. Shut-down noise - Post Purge timed 15 seconds
should eliminate shut-down noise.

20.2 Oil Primary Control

A. 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.
B. Burner (control) will light, then shut down after
short time, then restart after one (1) minute.
I. CAD cell is defective.
II. Air leaking into oil line causing flame out.
III. Defective nozzle causing flame to be erratic.
IV. Excessive airflow or draft causing flame to leave
burner head.
V. Excessive back pressure causing erratic flame.

57 P/N 240009350 Rev. J [09/01/2017]

 20 - TROUBLESHOOTING

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

POSSIBLE CAUSE WHAT TO DO
Thermostat is not set correctly Reset thermostat

Burner is not operating properly Adjust burner per instructions.

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

No electric power to boiler cuit is “ON”. There may be as many as 3 safety shut-off switches installed.
Look for a red plate which may be on the service switch.

Controls out of adjustment Reset according to instructions.

Check over-current protection. Check relay operation. Check power to
Circulating pump not running
circulator.
Poor electrical contact Check all control terminals and wire joints.

Chimney flue is blocked Have the chimney professionally cleaned.

RELIEF VALVE LEAKING . . .

POSSIBLE CAUSE WHAT TO DO
Corrosion and/or deposits on
Open valve manually. Allow water to run and clear valve seat.
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, Display off 120 VAC system power Turn system power on
house is cold. Display on 24 VAC T-T No 24 V; replace control
24 V present; disconnect
Boiler starts, check wiring and thermostat
thermostat, short T-T
120 VAC at B1-B2 •  If no, replace
•  If yes, check burner and wiring
Low Water status light • If illuminated, find and repair water
leak(s).
Boiler is hot, Display on 120 VAC at C1-C2 •  120 vac at C1-C2, check wiring to
house is cold. pump
•  Wiring OK, is pump running?
•  If not, replace pump.
•  If pump is running, check for trapped
air or closed zone valves.
Burner will not Display On Burner wired incorrectly. L1
turn off. (black) and Limit (red) are
reversed. See wiring diagram Re-Wire burner.
for installed burner.

58 P/N 240009350 Rev. J [09/01/2017]

 21 - EQUIPMENT AND ACCESSORIES

21.1 Limit Relay Control (provided) 21.6 Conventional Expansion Tank (Not
Water temperature limit control in limit relay is adjustable. Provided)
See Limit instructions for how to set limit temperature. In a properly assembled system, expanding water flows
into an expansion tank.
21.2 Drain Valve (provided)
• Expansion tank should be sized correctly because
Drain valve is manually operated valve, means of draining improperly installed or sized expansion tank may result
all water from boiler and heating system. Installed in in frequent lifting of relief valve or other heating system
casting below burner door. problems.
21.3 Circulator • It is important to install tank higher than top of boiler.
Connecting pipe from boiler to expansion tank shall rise
• Forced hot water systems require circulator.
continuously up to expansion tank so that air can rise
• Separate circulator or zone valve is required for each into expansion tank.
zone, if there are two or more zones. Circulator must
• Expansion tank is partially filled with air. Air compresses
have capacity to provide circulation required by heating
as water expands, thus forming an air pressure
system.
cushion. This “spring-like” cushion serves to maintain
• Circulator should be connected to supply main and correct operating water pressure regardless of water
must be wired into boiler’s electrical system. “9 - Boiler temperature. This assures a “full measure” of water, even
System Piping” on page 16, for piping configurations in highest radiation unit of the system.
with circulator located on supply main piping using zone
• Tank also serves as trap for excess air in the system. Air
circulators or zone valves.
can cause noises in pipes and inefficient circulation in
• When piping is arranged with zone circulators and no radiators if left in piping system.
bypass piping, circulator provided with boiler may be
• It is possible for a tank to become “waterlogged” (filled
used as zone circulator. Both piping arrangements allow
with water). It can also become overfilled with air when
circulator to pump away from expansion tank and show
filling system with new water. Fittings on tank and in line
how piping should be arranged to allow heating system to
to tank are for bleeding off excess air and water.
be easily purged of air.
• Circulator can be installed on return side of boiler, if 21.7 Diaphragm Expansion Tank (Not Provided)
preferred. Diaphragm type expansion tank takes place of conventional
21.4 Main Air Vent: (Not Provided) expansion tank.

Before system is filled with water, there is air in pipes and • Carefully read instructions packed with your tank
radiation units. Some air will be trapped as system is filled. assembly. Expansion tank should be sized and installed
It is possible to eliminate most of this air through air vents correctly. Improperly installed or sized expansion tank
on radiation units. Main air vent will speed and simplify this may result in frequent lifting of relief valve or other
process. Main air vent should be installed on highest point heating system problems.
in supply main. • Tank typically comes with 10-12 psi air charge. Same as
pressure produced in system by automatic fill valve set
21.5 Automatic Fill Valve (Not Provided) to fill boiler to 10-12 psi with fresh water. When system
Hot water system must be filled with water. Adding new is first filled, tank will fill partially with water. As water is
water, when needed can be done manually (by use of hand heated, and system pressure increases, water expands
valve in water supply line). This requires regular attention into tank and compresses air in the tank. This compressed
to system’s needs. Automatic fill valve or pressure reducing air cushion permits water in the system to expand as
valve accomplishes this without attention. Install in supply temperature changes and assures “full measure” of water,
line on hot water boilers only. Valve operates through even in highest radiation unit of system.
water pressure differentials. It does not require electrical • Diaphragm type expansion tank can be mounted on air
connection. purger fitting or at any other convenient place in supply
or return line. It is recommended to locate diaphragm
type expansion tank in supply line with circulator located
after expansion tank. This configuration allows circulator
to “pump away” from expansion tank for improved air
elimination and system performance.
• Air eliminator fitting or air purger is not provided. Air
eliminator fitting or air purger is used to help remove
air from system before it reaches radiators. It should be
installed in supply line. Air left in system can cause noises
in pipes and inefficient circulation in radiators.

59 P/N 240009350 Rev. J [09/01/2017]

 21 - EQUIPMENT AND ACCESSORIES

Figure 47 - Grundfos Pump Curve

5
15
4

3 10

2
Head (feet)

5
m Head

0
US GPM 5 10 15 20

3
m /h 1 2 3 4 5
Model Watts Volts Amps Capacitor
UP 15-42F 85 115 0.74 10 µF/180 V*
*Fourni avec la pompe

Figure 48 - Taco Pump Curve

Model Volts Amps Capacitor

007-F5 115 0.70 Supplied w/pump

60 P/N 240009350 Rev. J [09/01/2017]

NOTES

61 P/N 240009350 Rev. J [09/01/2017]

NOTES

60
 INSTALLATION AND CHECK-OUT CERTIFICATE

Boiler Model Serial # Date Installed___________

Measured BTU/HR input____________

 Installation instructions have been followed

 Checkout procedure and adjustments performed

 Maintenance and Service issues reviewed with owner/ maintenance person

 Installation booklet affixed on or adjacent to boiler

Installer (Company)

Address

Phone

Installer’s Name

Signature
 UTICA BOILERS
2201 Dwyer Avenue
Utica NY 13501
web site: www.ecrinternational.com