UTICA BOILERS TRB4075, Installation, Operation & Maintenance Manual

Page 1: ...ON OPERATION MAINTENANCE MANUAL Models TRB4075 TRB4090 TRB5100 TRB5120 TRB6130 TRB6145 TRB7165 TRB7180 FOR US AND CANADIAN SALES Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com PN 240013415 REV A 08 15 2021 ...

Page 2: ... the right to discontinue change specifications or system design at any time without notice and without incurring any obligation whatsoever PN 240013415 REV A 08 15 2021 TRIFIRE TRIFIRE OIL FIRED CAST IRON HOT WATER BOILER OIL FIRED CAST IRON HOT WATER BOILER Models TRB4075 TRB5100 TRB6130 TRB7165 For Parts lists see manual 240013417 included with your boiler literature package Energy Star Listed ...

Page 3: ...ctions Flue Size Inches cm Dimension A Inches cm Dimension B Inches cm Chimney Vent Direct Vent 4 5 13 18 46 6 1 32 19 5 5 13 21 54 8 1 32 19 6 5 13 24 63 1 1 32 19 7 6 15 28 71 3 19 N A DIMENSIONS PN 240013415 REV A 08 15 2021 ...

Page 4: ...OILER SYSTEM PIPING 20 10 HYDRONIC PIPING 21 11 FUEL SUPPLY PIPING 34 12 ANTIFREEZE IN THE SYSTEM 35 13 ELECTRICAL CONNECTIONS 36 14 CHIMNEY AND VENTING CONNECTIONS 37 15 FILLING BOILER 40 16 OPERATING THE BOILER SYSTEM START UP 41 17 OIL BURNER NOZZLE AIR SETTINGS 48 18 MAINTENANCE 55 19 OIL BOILER BURNER CLEANING INSTRUCTIONS 57 20 TROUBLESHOOTING 59 21 EQUIPMENT AND ACCESSORIES 61 PN 240013415 ...

Page 5: ... 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 80 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 WAR...

Page 6: ...ol Symbol alerts you to potential personal injury hazards Obey all safety messages potential personal injury hazards Obey all safety messages following this symbol to avoid possible injury or death following this symbol to avoid possible injury or death 2 1 Become Familiar With Symbols Identifying Potential Hazards NOTICE Used to address practices not related to personal injury 2 SAFETY INFORMATIO...

Page 7: ... 3rd Degree Burn Exposure Time For An Adult 120 F 1 minute 5 minutes 130 F 5 seconds 30 seconds 140 F 2 seconds 5 seconds 150 F 1 second 1 5 seconds 160 F Instantaneous 0 5 seconds Note Warning for Infants Children and Elderly Great care must be taken when exposing the aforementioned groups to warm or hot water as they can be badly burned in exposure times less than half of the time for an adult 2...

Page 8: ...ntrols and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Additional manual reset low water cutoff and manual reset high limit may be required 2 6 Requirements for Commonwealth of Massachusetts Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to Installation by licensed plumber or gas fitter NOTICE Surface rust on cast...

Page 9: ...e air is purged for boiler installations using float type vents air vents should be closed for normal operation If air is heard or noticed by loss of heat purge system and open vents for short period of time 3 2 Prior To Installing The Boiler Verify you have selected right size boiler with proper capacity AHRI rating of boiler selected should be greater than or equal to calculated peak heating loa...

Page 10: ...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 build...

Page 11: ...re 1 and Table 2 Table 2 BOILER CLEARANCES Unit Combustible Clearance Accessibility Cleaning and Servicing Top 12 32 cm 24 61 cm Right Side 2 5 cm 24 61 cm Left Side 2 5 cm 24 61 cm Floor Combustible No Requirement Front 17 43 cm 24 61 cm Back 9 23 cm 24 61 cm Flue 9 23 cm 9 23 cm All distances measured from the boiler jacket or flue 7 Fresh air for r combustion and ventilation must be available a...

Page 12: ...shut down for extended period of time 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 6 INSTALLATION REQUIREMENTS PN 240013415 REV A 08 15 2021 ...

Page 13: ...1 square inch per 4 000 BTU per hour input of all equipment in space Duct cross sectional area shall be same as opening free area C Horizontal Ducts Minimum free area of 1 square inch per 2 000 BTU per hour input of all equipment in space Duct cross sectional area shall be same as opening free area Alternate method for boiler located within confined space Use indoor air if two permanent openings c...

Page 14: ...ze Mesh Screen Wood Louvers Metal Louvers Btuh Btuh Btuh 3 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 mesh screen wood louvers or metal louvers Figure 4 Fresh Air Openings 7 FRESH AIR FOR COMBUSTION PN 240013415 REV A 08 15 2021 ...

Page 15: ...ge pins on door into slotted mounting bracket holes Recommend hinges be on same side as flexible oil line in order to swing door open 6 Inspect Swing door insulation and rope gasket A Inspect fiber rope located on swing door Evenly distribute rope around perimeter of door groove do not bunch or overhang There must not be a gap where two ends of rope meet Repair or replace if rope is damaged or if ...

Page 16: ...is water tight 11 Install Limit control mounting plug in upper 3 4 NPT port facing front See Figure 7 12 Install Limit control harness assembly Loosen mounting screw on bottom of limit control A Mount control on mounting plug and tighten screw to secure control See Figure 7 B Confirm thermal limit LWCO sensor bulb is fully inserted to bottom of control well in top of rear boiler section and secure...

Page 17: ...ping and Control Assembly LIMIT CONTROL WITH INTEGRAL LOW WATER CUT OFF THERMAL LWCO WIRE BURNER WIRING RELIEF VALVE BACK OF BOILER NOTICE Do not install valve between boiler and controls manifold or relief valve PN 240013415 REV A 08 15 2021 ...

Page 18: ...e to grounding lug When installing wiring through hole in Limit use anti abrasion cable clamp Connect black hot wire to L1 of terminal block white N wire to L2 of terminal block 16 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 17 Install drain valve Install drain valve with hose conn...

Page 19: ...ge bolt first or tighten either piece of hardware 100 without using alternating tightening method described above 19 Install oil burner Check oil nozzle in burner for size angle and type inspect electrode settings check head setting check air band and air shutter settings See Oil Burner Nozzle Air Settings DO NOT install burner without gasket Place oil burner gasket on face of burner swing door wi...

Page 20: ... is necessary per manufacturer s specific instructions 6 When connecting cold water supply to pressure reducing valve make sure clean water supply is available When water supply is from well or pump install sand strainer at pump 9 2 Bypass Piping See Piping Diagrams for illustrations for this section Bypass piping may be required for applications listed below Failure to do so may cause damage due ...

Page 21: ...21 Figure 17 Standard Near Boiler Piping Piping Diagram Legend 10 HYDRONIC PIPING PN 240013415 REV A 08 15 2021 ...

Page 22: ...22 10 HYDRONIC PIPING DHW Heater Figure 18 Piping And Wiring Single Zone System With Domestic Hot Water DHW Priority PN 240013415 REV A 08 15 2021 ...

Page 23: ... X CONTACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY Figure 19 Multi Zone Piping and Wiring With Zone Valves And Domestic Hot Water Priority With Zone Valve SEE FIGURE 20 PN 240013415 REV A 08 15 2021 ...

Page 24: ...ACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY Figure 20 Piping And Wiring Multizone System With Zone Valves And Domestic Hot Water Priority With Circulator PN 240013415 REV A 08 15 2021 ...

Page 25: ...25 10 HYDRONIC PIPING Figure 21 Piping and Wiring Multi Zone System With Circulators And Domestic Hot Water Priority PN 240013415 REV A 08 15 2021 ...

Page 26: ...Figure 22 Primary Secondary Piping And Wiring With Circulators And Domestic Hot Water MAX 4 X DIAMETER CLOSELY SPACED TEES BOILER PUMP 26 10 HYDRONIC PIPING PN 240013415 REV A 08 15 2021 ...

Page 27: ...27 10 HYDRONIC PIPING PN 240013415 REV A 08 15 2021 ...

Page 28: ...UM TANK PERFORMANCE CONSIDER USING ZONE CIRCULATOR BOILER PUMP MAX 4 X DIAMETER CLOSLEY SPACED TEES CONSULTER LA FIGURE 24 Figure 23 Piping And Wiring Primary Secondary Multi Zone System Piping With Zone Valves And Domestic Hot water With Zone Valve PN 240013415 REV A 08 15 2021 ...

Page 29: ...ILER 120 VAC TO XFRM 24 VAC X X CONTACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY 10 HYDRONIC PIPING PN 240013415 REV A 08 15 2021 ...

Page 30: ...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 PN 240013415 REV A 08 15 2021 ...

Page 31: ...IORITY PUMP FROM BOILER 120 VAC TO XFRM 24 VAC X X CONTACT ZR ON PRIORITY PUMP PRIMARY PUMP PRIORITY ON STATUS OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY OPTION SWITCHES ZONE VALVE PUMP ZR ZC DPM 2 PRIORITY PN 240013415 REV A 08 15 2021 ...

Page 32: ...EPARATOR ZONE VALVE EXPANSION TANK WATER INLET SYSTEM CIRCULATOR Figure 25 Bypass Piping Fixed Low Temperature Only Adjust two throttling valves to maintain at least 130 F 140 F in boiler return BOILER WATER INLET ALTERNATE CIRCULATOR LOCATION TO SYSTEM FROM SYSTEM PRESSURE EXPANSION TANK Figure 26 Bypass Piping Automatic Mixing Valve PN 240013415 REV A 08 15 2021 ...

Page 33: ...LVE 4 WAY MIXING VALVE EXPANSION TANK Figure 27 Bypass Piping 4 Way Valve Option with Circulator On Supply Side SHUT OFF VALVES SHUT OFF VALVES BOILER SUPPLY MAIN TO COMBINED HEATING COOLING SYSTEM RETURN MAIN FROM COMBINED HEATING COOLING SYSTEM CIRCULATOR WATER CHILLER AIR CUSHION TANK Figure 28 Recommended Piping For Combination Heating and Colling Refrigeration System PN 240013415 REV A 08 15 ...

Page 34: ... 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 p...

Page 35: ... or more and increase fuel consumption See Table 6 and 7 Table 6 BOILER WATER VOLUMES Number of Boiler Section Total Volume Gallons 4 3 6 5 4 3 6 5 1 7 5 9 Table 7 PIPING WATER VOLUMES PIPE SIZE COPPER PIPE FACTOR STEEL PIPE FACTOR 82 5 63 5 40 0 36 0 1 23 3 22 2 1 15 3 12 8 1 10 8 9 5 2 6 2 5 8 Divide total length of piping in feet by appropriate factor in table to determine volume in gallons 12 ...

Page 36: ...e electrical circuit from entry box with fused disconnect switch in this circuit Never jump out or make inoperative any safety or operating controls WARNING Electrical shock hazard Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury SEE APPROPRIATE ADDENDUM FOR WIRING DIAGRAMS 13 ELECTRICAL CONNECTIONS PN 2...

Page 37: ...d into fireclay tile lined masonry chimney or type L vent or factory built chimney that complies with type HT requirements of UL103 See Figure 32 3 Chimney Inspection Prior to installation of any new or replacement fuel burning equipment chimney shall be inspected by qualified service agency A De rating may cause condensation on interior walls of chimney and boiler Loose mortar can be indication o...

Page 38: ... height temperature of flue gases cross section area of chimney chimney wall insulation value dilution air and total volume of flue gases Operate boiler for at least 5 minutes before measuring draft Minimum Draft at Breech Draft induced by the chimney must create at least a neutral pressure of 0 zero inches water column INWC at breech Slightly negative i e suction pressure is preferred Pressure at...

Page 39: ...ghest part of passage through roof Must be at least 2 FT higher than any neighboring object within 10 Ft Must have unobstructed top opening Must be at least 4 inches thick and be tight Must slope up at least 1 4 inch per foot of horizontal run Tight smooth correctly sized Sealed in thimble Tight clean out door Balanced Weight Crimped End Draft Regulator Vane 14 CHIMNEY AND VENTING CONNECTIONS PN 2...

Page 40: ...ing 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 s...

Page 41: ...rsely if boiler provides adequate heat added fuel savings can be achieved by selecting higher setting example 4 or 5 If heating and indirect water heater signals were not separated when wiring the control Economy feature should be turned off to ensure the boiler supplies adequate temperature to heat indirect tank 16 5 Setting Zone Indirect Switch When installing with indirect water heater zone ind...

Page 42: ...on 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 f...

Page 43: ...argeting 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 16 8 page 42 16 OPERATING THE BOILER SYSTEM START UP 6 ECONOMY TARGET Economy feature is active limit control continually sets target temperatures below high limit setting to maximize fuel efficiency When boiler water reac...

Page 44: ... Fire burn asphyxiation hazard Do not attempt to start burner when oil has accumulated in combustion chamber or unit is full of vapor or hot Check operation of all boiler controls before installation of boiler is completed Failure to follow these instructions could result in death or serious injury 16 OPERATING THE BOILER SYSTEM START UP 3 Preliminary Oil Burner Adjustments A Adjust Draft Regulato...

Page 45: ...reliminary steps I Check wiring connections and power supply II Verify power is on to controls III Verify limit control is closed IV Check contacts between igniter and electrodes V Check piping to oil tank B Safe Start Check I Place jumper across cad cell terminals II Initiate call for heat III Burner must not start Verify green light is on continuously and control remains in standby IV End call f...

Page 46: ...ve is turned off and control delays turning motor off for set motor off delay time before control returns to standby I Pump Prime Igniter and motor are on with solenoid valve energized for 4 minutes During Pump Prime mode cad cell is disregarded allowing technician to prime pump without having to jumper cad cell 7 Genisys Control Reset Button Operation See Table 11 for action control takes when re...

Page 47: ...mperature Table 12 Thermostat locations to Avoid DEAD SPOTS HOT SPOTS COLD SPOTS Behind doors Concealed pipes Concealed pipes or ducts Fireplace TV sets Stairwell drafts Corners alcoves Radios Door drafts Lamps Unheated room on other side of wall Direct sunlight Kitchens C Verify room temperature reaches selected temperature setting thermostat should turn boiler s burner off and once room temperat...

Page 48: ...l connector tube 2 Recheck Z dimension periodically when servicing to ensure escutcheon plate has not been moved Reset Z dimension if you replace air tube or nozzle line assembly AFG Burner with V1 Heads See Figures 40 and 42 The important Z dimension is distance from leading edge of head to end of air tube This distance for V1 heads is 1 Z dimension is factory set for burners shipped with air tub...

Page 49: ...RKER 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 17 OIL BURNER NOZZLE AIR SETTINGS Figure 45 Carlin Electrode Setting PN 240013415 REV A 08 15 2021 ...

Page 50: ...V1 2 75M 2 625 1 65 V7 Hago 1 25 x 45B 175 2 4 10 87 0 7180 V1 2 75M 2 625 1 80 V7 Hago 1 35 x 45B 175 3 3 10 86 0 Timings Pre purge 15 seconds Post purge 15 seconds Table 13 Beckett Chimney Vent Preliminary Burner Settings Burner settings provided are for initial startup only Final adjustments must be made using combustion test instruments TABLE 13B BECKETT ECR PART NUMBERS Boiler Model Beckett O...

Page 51: ... 4 0 0 85 WC 6130 6 Slot 2 5 1 30 V6 Delavan 1 00x45B 175 2 0 0 65 WC Timings Pre purge 15 seconds Post purge 30 seconds Table 14 Beckett NX Direct Vent Preliminary Burner Settings TABLE14b BECKETT ECR PART NUMBERS Boiler Model Beckett Oil Burner ECR Oil Burner Part Number 4075 NX70LC 550004238 5100 NX70LC 240007532 6130 NX70LD 240007533 Burner settings provided are for initial startup only Final ...

Page 52: ...87 0 4090 Reverse 2 75 0 90 Oval Delavan 0 75 x 90B 140 2 3 5 86 0 5100 Standard 2 75 1 00 None Delavan 0 80 x 90B 180 0 2 75 87 0 5120 Standard 2 75 1 20 None Delavan 1 00 x 90B 190 0 5 9 86 0 6130 Standard 2 75 1 30 V6 Delavan 1 10 x 80B 170 1 5 5 87 0 6145 Standard 2 75 1 45 V6 Delavan 1 20 x 80B 185 3 3 9 86 0 7165 Standard 2 75 1 65 V7 Delavan 1 35 x 45B 190 1 4 2 87 0 7180 Standard 2 75 1 80...

Page 53: ...ring Rate GPH Combus tion Liner Nozzle Mfr Nozzle Type Pump Pressure PSI Head Setting Air Setting Pressure Switch Setpoint 4075 Reverse 2 75 0 75 Oval Delavan 0 65x60W 150 3 5 0 0 25 WC 5100 Standard 2 75 1 00 None Delavan 0 75x60B 175 1 5 0 0 80 WC 6130 Standard 2 75 1 30 V6 Delavan 1 10x70B 145 3 8 0 0 90 WC Timings Pre purge 12 seconds Post purge 30 seconds Boiler Model Riello Oil Burner Model ...

Page 54: ...60 x 60B 160 1 22 87 0 4090 4 56 0 90 Oval Delavan 0 75 x 70A 145 2 28 86 0 5100 3 00 1 00 None Delavan 0 75 x 45B 175 0 75 36 87 0 5120 3 00 1 20 None Delavan 1 00 x 60A 165 0 85 1 00 40 86 0 6130 3 00 1 30 V6 Delavan 1 00 x 70A 170 0 85 1 00 50 87 0 6145 3 00 1 45 V6 Delavan 1 10 x 70B 190 1 10 1 25 50 86 0 Timings Pre purge 15 seconds Post purge 15 seconds Boiler Model Carlin Oil Burner Model E...

Page 55: ...uring freezing weather Water left in system will freeze and crack pipes and or boiler 18 7 Oil Burner Maintenance Perform following preventative maintenance annually preferably prior to heating season Fuel Filter Replace to prevent contaminated fuel from reaching nozzle Partially blocked fuel filter can cause premature failure of fuel pump Fuel Pump Unit Replace pump screen and clean pump unit to ...

Page 56: ...t system including radiation Allow boiler water to reach operating temperature if possible Continue to circulate water for few hours Stop firing boiler Drain system in a manner and to a location that hot water can be discharged safely Remove plugs from all available returns and wash water side of boiler as thoroughly as possible using high pressure water stream Refill system with fresh water 3 Add...

Page 57: ... 3rd pass Two inner flue ways B Inspect chimney and clean if necessary C Clean and re attach vent connector onto rear of the boiler with three screws NOTICE When securing burner swing door verify door is drawn in equally on both sides Do not overtighten door bolts Rope gasket will provide sufficient seal when door is snugged into place D Tighten swing door hardware to provide adequate seal to rope...

Page 58: ...UUM HOSE VACUUM HOSE BRISTLE BRUSH FLUE BRUSH FLUE BRUSH FRONT VIEW 3RD PASS COMBUSTION CHAMBER 2ND PASS Figure 46 Cleaning the Boiler 19 OIL BOILER BURNER CLEANING INSTRUCTIONS PN 240013415 REV A 08 15 2021 ...

Page 59: ...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 Section 16 9 for more details III CAD Cell seeing light IV CAD cell is defective B Burner control will light then shut...

Page 60: ...llow water to run and clear valve seat Water logged expansion tank Drain tank follow instructions to provide air buffer HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT LIMIT CONTROL TROUBLESHOOTING GUIDE System Condition Diagnostic Condition Check Action Boiler is cold house is cold Display off 120 VAC system power Turn system power on Display on 24 VAC T T No 24 V replace...

Page 61: ...ted 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 inefficie...

Page 62: ...US GPM 5 10 15 20 m h 3 Head feet Model Watts Volts Amps Capacitor UP 15 42F 85 115 0 74 10 µF 180 V Fourni avec la pompe Figure 47 Grundfos Pump Curve Figure 48 Taco 007e Pump Curve 21 EQUIPMENT AND ACCESSORIES PN 240013415 REV A 08 15 2021 ...

Page 63: ...__________ 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 PN 240013415 REV A 08 15 2021 ...

Page 64: ...All specifications subject to change without notice 2021 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com ...