Models

3EWC0.80(T)

4EWC1.00(T)

4EWC1.25(T)

5EWC1.55(T)

EMPIRE

OIL-FIRED CAST IRON

HOT WATER

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

Maximum Allowable

Working Pressure 50 psi.

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 325 5479 www.ecrinternational.com

PN 240013012 REV. B [12/15/2020]

CONTENTS

Boiler Ratings And Capacities .................

3

Safety Notices

......................................

4

Safe Installation And Operation ..............5

Locating The Boiler

...............................6

Fresh Air For Combustion

.......................8

System Piping

....................................

10

Antifreeze In The System

....................

16

Chimney And Chimney Connections

......

1

6

Typical Chimney Connection

.................

18

Electrical Connections .........................

19

Electrical Wiring .................................

20

Filling The Boiler

...............................

22

Operating The Boiler

.........................

23

Preliminary Burner Settings

.................

24

Checking And Adjusting Controls

..........

26

Maintenance ......................................

27

Oil Boiler / Burner Cleaning Instructions

28

Oil Burner Cleaning .............................

29

Service Hints .....................................

30

Pump Curves .....................................

31

INTRODUCTION

Empire Water boiler is a natural draft oil fired hot water boiler comprised of cast iron sections. Empire Water boiler is available with 3, 4, or 5 cast iron sections. These sections are held together by cast iron push nipples.

Empire Water boiler is capable of firing #2 fuel oil from

0.80 gph up to 1.55 gph. All packaged boilers include a swing door, Hydrolevel limit control with built-in low water cutoff, temperature and pressure gauge, safety relief valve, drain valve, flue brush, and extra boiler tap for expansion tank or air elimination.

These low pressure oil fired hot water boilers are constructed and hydrostatically tested for maximum working pressure of 50 psig (pounds per square inch) 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.

Heating Capacity indicates amount of heat available after subtracting losses up the stack. Most of this remaining heat is available to heat water. A small portion is heat from the jacket and boiler surface and it is assumed that this heat stays in the structure. Net AHRI Rating represents portion of remaining heat that can be applied to heat radiation or terminal units ( 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 the system and off-setting heat losses from system piping. Net AHRI Rating of the boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by the boiler and associated hot water heating systems. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements.

Save this manual for reference.

2

PN 240013012, Rev. B [12/15/2020]

Figure 1 - Dimensions

BOILER RATINGS AND CAPACITIES

BOILER RATINGS AND CAPACITIES

BOILER

MODEL NO.

Without

Tankless Coil

INPUT

+gph *Mbh

**HEATING

CAPACITY

*Mbh

‡NET

AHRI

RATING

WATER

*Mbh

A.F.U.E.

++

NO.

SEC.

MINIMUM

CHIMNEY

SIZE/

HEIGHT

DIMENSIONS

(inches)

A B C

3EWC0.80(T) 0.80

4EWC1.00(T) 1.00

4EWC1.25(T) 1.25

112

140

175

98

122

152

85

106

132

86.0

86.2

86.0

3

4

4

8” X 8” X 15” 14 ½ 6

8” X 8” X 15” 17¾ 6 9

8

8” X 8” X 15” 17¾ 6 9

5⁄8

5⁄8

5EWC1.55(T) 1.55

217 189 164 86.0

5 8” X 8” X 15” 21 6 11 ½

* Mbh = 1,000 BTU per hour [BTU = British Thermal Unit]

**Heating Capacity based on 13.1% CO

2

with a -0.02” w.c. draft over fire, and a #1 smoke or less. Testing was done in accordance with the D.O.E. (Department of Energy) test procedure.

+ gph = Gallons per hour oil at 140,000 BTU per gallon

++A.F.U.E. = Annual Fuel Utilization Efficiency based upon D.O.E. test procedure.

‡ Net AHRI Water Ratings based on piping and pickup allowance of 1.15. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

3

PN 240013012, Rev. B [12/15/2020]

SAFETY NOTICES

Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

!

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

!

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

!

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Used to address practices not related to personal injury.

Boiler installation shall be completed by qualified agency.

!

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

!

WARNING

Do not tamper with or use this boiler for any purpose other than its intended use. Failure to follow these instructions could result in death or serious injury. Use only manufacturer recommended parts and accessories.

!

WARNING

Fire, Explosion, Asphyxiation, Electrical shock hazard! Flooding will result in damages such as electrical problems, corrosion, inoperative parts, mold and other unforeseen issues which can occur over time. Any equipment determined by a professional as damaged by a flood, defined as excess of water or other liquid, shall be replaced.

Failure to follow these directions will result in a

Hazardous Situation.

!

CAUTION

Laceration, burn hazard. Metal edges and parts may have sharp edges and/or may be hot. Use appropriate personal protection equipment to include safety glasses and gloves when installing or servicing this boiler. Failure to follow these instructions could result in minor or moderate injury.

4

FOR YOUR SAFETY READ BEFORE OPERATING

!

DANGER

Hot Water Can Scald !

Water heated to temperature for clothes washing, dish washing and other sanitizing needs can scald and cause permanent injury.

Children, elderly, and infirm or physically handicapped persons are more likely to be permanently injured by hot water. Never leave them unattended in bathtub or shower. Never allow small children to use a hot water tap or draw their own bath.

If anyone using hot water in the building fits the above description, or if state laws or local codes require certain water temperatures at hot water taps, you must take special precautions:

• Use lowest possible temperature setting.

• Install some type of tempering device, such as an automatic mixing valve, at hot water tap or water heater. Automatic mixing valve must be selected and installed according to manufacturer's recommendations and instructions.

• Water passing out of drain valves may be extremely hot. To avoid injury:

• Make sure all connections are tight.

• Direct water flow away from any person.

Water

Temperature

Setting

120° F

130° F

140° F

150° F

160° F

1st Degree Burn

Exposure Time For

An Adult

1 minute

5 seconds

2 seconds

1 second

Instantaneous

2nd and 3rd Degree Burn

Exposure Time For An

Adult

5 minutes

30 seconds

5 seconds

1.5 seconds

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.

PN 240013012, Rev. B [12/15/2020]

SAFE INSTALLATION AND OPERATION

!

WARNING

Fire, Explosion, burn, scald hazard. Use only number

2 fuel oil. Do not use gasoline, kerosene, crankcase oil or any oil containing gasoline. Failure to follow these instructions could result in death or serious injury.

!

WARNING

Combustion chamber insulation in this product contains ceramic fiber material. Ceramic fibers can be converted to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans

(Group1). Avoid breathing dust and contact with skin and eyes. Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website https:// www.cdc.gov/niosh/topics/silica/.

approved respirators, manufacturers, and phone numbers are also listed on this website. Wear long-sleeved, loose fitting clothing, gloves, and eye protection. Apply enough water to the combustion chamber lining to prevent dust. Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid. Eye: Irrigate immediately.

Breathing: Fresh air.

NOTICE

This boiler has been designed for residential installations. If used for commercial applications, all jurisdictional requirements must be met. This may require wiring and/or piping modifications.

Manufacturer is not responsible for any changes to the original design.

1.

Check your local codes and utility requirements before installation. Installation must be in accordance with their directives, or follow NFPA 31 Standard for the

Installation of Oil Burning Equipment, latest revision.

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

3.

Inspect oil line and connections for leaks.

5

4.

Be certain oil burner nozzle is the size required. Overfiring will result in early failure of the boiler sections.

This will cause dangerous operation.

5.

Do not vent this boiler into enclosed space. Always vent to outside. Do not vent to another room or inside a building.

6.

Be sure there is adequate air supply for complete combustion.

7.

Follow regular service and maintenance schedule for efficient and safe operation.

8.

Keep boiler area clean and free of combustible material, gasoline and other flammable vapors and liquids.

9.

Oil burners are not do-it-yourself items. This boiler must be installed and serviced by qualified professionals using combustion test instruments.

!

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

Install discharge piping per these instructions.

10.

Be aware when piping the safety relief valve if system pressure exceeds safe limit of 30 pounds per square inch, the safety relief valve will automatically lift open. Lifting of the safety relief valve can discharge large quantities of steam and hot water, which may damage the surroundings. Before installing the safety relief valve read the manufacturer’s instructions and maintenance section of the manual on safety relief valves.

11.

Installation and sizing of the expansion tank must consider heating systems total water volume, temperature, boiler initial fill pressure, and system arrangement. Improperly installed and sized expansion tank may result in frequent lifting of the safety relief valve or other heating system problems. For proper installation, sizing, and maintenance of the expansion tank follow guidelines established by tank manufacturer.

12.

Expansion tank performance and life expectancy can be hindered by overfilling the boiler. Recommend initial fill pressure of 10-12 psig. For higher fill pressures expansion tank’s air charge will need to be increased to match fill pressure. Consult manufacturer’s guidelines for sizing and selection.

13.

Purging the heating system of air and gases when first putting boiler into service is critical for proper circulation and quiet performance. Once air and gases are 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.

PN 240013012, Rev. B [12/15/2020]

LOCATING THE BOILER

Complete Prior To Installing Boiler.

A. Verify you have selected the right size boiler with proper capacity. AHRI rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. See boiler rating and capacity table previously listed in this manual. Any heat loss calculations used should be based on approved methods.

1.

Place boiler in location centralized with the piping system and as close to chimney as possible.

2.

3.

Boiler must be level. If necessary use metal shims beneath boiler’s feet.

Use raised base if floor can become wet or damp.

B. Boiler must be supplied with proper oil supply and oil piping, sufficient fresh combustion air, and suitable electrical supply.

C. Boiler must be connected to suitable venting system and piping system adequate to distribute heating load.

D. Properly locate and install thermostat for heating system control.

4.

Maintain clearances for fire safety as well as servicing.

18” clearance must be maintained at side where passage is required for access to another side for cleaning, servicing, inspection or replacement of any parts that may normally require attention. Install boilers at least 6” from combustible material on left side, rear, and above, and at least 24” on right side and front. Allow at least 24” accessibility clearance above for servicing.

5.

Fresh air for combustion must be available at front of the boiler. Fresh air for ventilation must be available to front and rear of boiler. Air passages must be free of obstructions at all times. Ventilating and combustion air must enter boiler room without restrictions.

Any doubts as to requirements, check with local authorities and obtain professional help where needed. OPERATING

INSTRUCTIONS, FINAL CHECKS AND ADJUSTMENTS, and

MAINTENANCE sections in this manual are vital to the proper and safe operation of the heating system.

!

WARNING

Fire hazard. Do not install boiler directly on combustible flooring or carpeting. Failure to follow these instructions could result in death or serious injury.

Figure 2 - Clearances

6”

Min.

Front

(Burner

Side)

6”

Min.

24” Min.

24” Min.

6

6.

Floor supporting boiler shall be noncombustible and stable. Boiler is permitted to be placed over combustible floor provided the floor is protected in accordance with the requirements of accepted building code practice and approved by the Authority Having

Jurisdiction . In absence of local codes, follow NFPA-31

S tandard for the Installation of Oil-Burning Equipment .

7.

Installation shall be in accordance with the requirements of the authority having jurisdiction.

Compliance with these regulations is required. In the absence of local codes, follow NFPA 31 Installation of

Oil Burning Equipment , latest revision.

MINIMUM CLEARANCE DIMENSIONS

BOILER CLEARANCES

Unit

Combustible

Clearance

Accessibility,

Cleaning, and

Servicing

Flue to

Combustible

Clearance

Top

Left Side

Right Side

6”

6”

24”

24”

6”

24”

24”

6”

24”

6”

9”

Base non-combustible non-combustible

Front

Back

All distances measured from the cabinet of the boiler.

PN 240013012, Rev. B [12/15/2020]

Figure 3 - Boiler With Piping System

LOCATING THE BOILER

C H I M N E Y

VENT PIPE

PUMP IN RE

7

PN 240013012, Rev. B [12/15/2020]

FRESH AIR FOR COMBUSTION

!

WARNING

Asphyxiation, fire hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air.

NOTICE

Install outside air intake if you use fireplace or kitchen or bathroom exhaust fan. These devices rob boiler and water heater of combustion air.

Installation shall comply with NFPA-31 Standard for the

Installation of Oil Burning Equipment (latest edition), and applicable provisions of local building codes to provide combustion and ventilation air.

Provide enough fresh air to assure proper combustion.

Fire in the boiler uses oxygen. It must have continuous supply. Air in the house contains only enough oxygen to supply burner for short time. Outside air must enter the house to replace air used by the burner. Study the following examples 1 and 2 to determine your fresh air requirements.

EXAMPLE 2: Boiler Located in Confined Space

A.

All Air from Inside the Building: Confined space shall be provided with two permanent openings communicating directly with additional room(s) of sufficient volume so the combined volume of all spaces meets the criteria for unconfined space. Total input of all combustion equipment installed in combined space shall be considered in making this determination. Each opening shall have minimum free area of one square inch per 1,000 Btu per hour of total input rating of all combustion equipment in the confined space, but not less than 100 square inches. One opening shall be within 12 inches of top and one within 12 inches of bottom of the enclosure.

Example: Your boiler is rated at 100,000 Btu per hour.

Water heater is rated at 30,000 Btu per hour. Total is

130,000 Btu per hour. You need two grilles, each with 130 square inches of FREE opening. Metal grilles have about

60% FREE opening. To find louvered area needed, multiply free opening required by 1.7 (130 x 1.7 = 221.0 sq. in. louvered area). In this example, two grilles each having 8” x 30” (240 sq. in.) louvered area would be used.

EXAMPLE 1: Boiler Located in Unconfined Space

If your boiler is in an open area (un-partitioned basement) in conventional house, air that leaks through cracks around doors and windows will usually be adequate to provide air for combustion. Doors should not fit tightly. Do not caulk cracks around windows.

An unconfined space is defined as space whose volume is not less than 50 cubic feet per 1,000 Btu per hour of total input rating of all appliances installed in that space.

Figure 4 - Air Openings For Boiler Located In

Confined Space (Utility Room )

8

PN 240013012, Rev. B [12/15/2020]

FRESH AIR FOR COMBUSTION

B. All Air from Outdoors: Confined space shall be provided with two permanent openings, one commencing within 12 inches of top and one commencing within 12 inches of bottom of enclosure.

Openings shall communicate directly, or by ducts, with outdoors or spaces (crawl or attic) that freely communicate with outdoors.

1. When directly communicating with outdoors, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

2. When communicating with outdoors through vertical ducts, each opening shall have minimum free area of one square inch per 4,000 Btu per hour of total input rating of all equipment in the enclosure.

3. When communicating with outdoors through horizontal ducts, each opening shall have minimum free area of one square inch per 2,000

Btu per hour of total input rating of all equipment in the enclosure.

4. When ducts are used, they shall be of same cross sectional area as free area of openings to which they connect. Minimum dimension of rectangular air ducts shall be not less than three inches.

Figure 5 - Fresh Air Duct Capacities For Ducts Supplying Fresh Air To Boiler In

Tightly Constructed Houses

FRESH AIR DUCT CAPACITIES

THROUGH LOUVERS

Fresh Air

Duct Size

¼” Mesh

Screen

Wood

Louvers

Metal

Louvers

3 ½” x 12”

8” x 8”

8” x 12”

8” x 16”

(Btuh)*

144,000

256,000

384,000

512,000

(Btuh)* (Btuh)*

36,000 108,000

64,000

96,000

128,000

192,000

288,000

384,000

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

9

PN 240013012, Rev. B [12/15/2020]

SYSTEM PIPING

1.

Installation of boiler for new heating system,

Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains first. After all heating system piping and components have been installed, make final connection of system piping to boiler. It is recommended to mount circulating pump on supply side piping, such that it pumps away from expansion tank. Refer to figures on next pages.

2.

Equip hot water boiler installed above radiation level with low water cut off device. Periodic inspection is necessary, as is flushing of float type devices, per low water cut off manufacturer’s specific instructions.

Figure 6a - Safety Relief Valve Installation

3.

Packaged boiler is set up with 1¼” NPT supply and return piping from front of boiler. Boiler supply and return piping can be moved to rear of boiler. Boiler should not be piped return line to front, supply line to rear, or vice versa, will cause boiler water to short circuit heat exchanger. Piping connections may require additional fittings and parts.

4.

Install drain valve provided with boiler in return tee.

Follow Instructions to install discharge piping from safety relief valve to drain.

5.

Install Safety Relief valve in rear section using

¾” nipple and street elbow provided with boiler. See

Figures 6a and 6b.

A. Install safety relief valve with spindle in vertical position.

B. Do not install shutoff valve between boiler and safety relief valve.

C. Install discharge piping from safety relief valve.

• Use ¾” or larger pipe.

• Use pipe suitable for temperatures of 375°F

(191°C) or greater.

• Individual boiler discharge piping shall be independent of other discharge piping.

• Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

• Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

• Install union, if used, close to safety relief valve outlet.

• Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

• Terminate pipe with plain end (not threaded).

Figure 6b - Discharge Piping From Safety Relief

Valve

SAFETY RELIEF VALVE

DISCHARGE

LINE

Check local codes for maximum distance from floor or allowable safe point of discharge .

6.

Verify clean cold water supply is available when connecting to pressure reducing valve. When water supply is from well or pump, a sand strainer should be installed at the pump.

10

PN 240013012, Rev. B [12/15/2020]

SYSTEM PIPING

Figure 7 - Bypass Piping Arrangement Diagram

Low Design Water Temperature Systems (Below 140°

F) And Large Water Content Systems

> LOW DESIGN WATER TEMPERATURE

SYSTEMS

> LARGE WATER CONTENT SYSTEMS

> PIPING ARRANGED FOR “POWER

PURGING” AIR OUT OF THE SYSTEM

PIPING, REFER TO THIS MANUAL’S

SECTION ON “FILLING THE SYSTEM

WITH WATER” OPTION #1

• Significant condensation may form in this boiler and/ or venting system if boiler is operated with return temperatures of less than 120°F.

• Condensation is corrosive and can eventually cause damage to boiler and venting system. Minimum design return water temperature to prevent this condensation in boiler and venting is 120°F.

• Boiler used in heating system where design water temperatures below 140°F are desired (e.g. radiant floor heating), a 3-way or 4-way mixing valve or suitable alternative (e.g. Bypass Piping Arrangement shown in

Figure 7 ) is required to prevent low temperature (below return 120°F) return water from entering boiler. When using mixing valve, follow manufacturer’s installation instructions.

• Boiler connected to system having large water content

(such as former gravity system), use of Bypass Piping

Arrangement shown in diagram on following page is suggested.

11

PN 240013012, Rev. B [12/15/2020]

SYSTEM PIPING

Figure 8 - System Piping Arrangement Zoning With Zone Valves

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

NOTE: CIRCULATOR CAN ALSO BE

INSTALLED ON RETURN PIPING.

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO

THIS MANUAL’S SECTION ON “FILLING THE

SYSTEM WITH WATER” OPTION #1

12

PN 240013012, Rev. B [12/15/2020]

SYSTEM PIPING

Figure 9 - System Piping Arrangement Zoning With Circulators

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PIPING ARRANGED FOR “POWER PURGING”

AIR OUT OF SYSTEM PIPING, REFER TO

THIS MANUAL’S SECTION ON “FILLING

THE SYSTEM WITH WATER” OPTION #1

13

PN 240013012, Rev. B [12/15/2020]

SYSTEM PIPING

Figure 10 - System Piping Arrangement Alternate Near Boiler Piping

> DIAPHRAGM EXPANSION TANK MOUNTED

OFF THE BOILER

> CIRCULATOR ON SUPPLY PIPING PUMPS

AWAY FROM EXPANSION TANK

> PER THIS MANUAL, USE OPTION #2 IN

“FILLING THE SYSTEM WITH WATER”

> THIS PIPING ARRANGEMENT CAN BE USED

WITH ZONE VALVES OR ZONE

CIRCULATORS

14

PN 240013012, Rev. B [12/15/2020]

SYSTEM PIPING

Tankless Coil Piping Arrangement

!

DANGER

Scald, Burn Hazard! Temperatures exceeding 120°F will cause severe burns or death. Use of water tempering device or mixing valve may be required by the Authority having jurisdiction, follow all codes as required before leaving installation.

Boilers may be factory packaged with tankless heater coil see figure below. Coil provides instantaneous heating of water for domestic use if proper burner and water supply line controls are used. Tankless coils are meant to provide domestic hot water for intermittent draws, not continuous flow.

NOTICE

Do not use tankless coil if your water is excessively hard with lime or other deposits which will accumulate inside the coil.

Boiler

Model

3EWC0.80T

4EWC1.00T

4EWC1.25T

5EWC1.55T

Burner

Input

Rate (gph)

0.80

1.00

1.25

1.55

Input

(MBH)

112

140

175

217

Tankless

Rating

(gpm)‡

3.05

3.25

3.50

3.80

‡ Gallons of water per minute heated from 40°F to 140°F with

200°F boiler water temperature, intermittent draw

When using tankless coil, the Hydrolevel control is mounted on control well in tankless heater.

Tempering valve (mixing valve) is recommended as shown below. Flow restrictor may be required on tankless coil inlet piping so that flow rates are matched to boiler heat input

(see table).

Figure 11 -Tankless Coil Piping Arrangement

15

PN 240013012, Rev. B [12/15/2020]

ANTIFREEZE IN THE SYSTEM

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. Tankless coil performance will fall as concentration of antifreeze is increased. Refer to boiler and piping water volumes tables.

PIPING WATER VOLUMES

PIPE SIZE

COPPER PIPE

FACTOR

STEEL PIPE

FACTOR

½”

¾”

1”

1 ¼”

82.5

40.0

23.3

15.3

63.5

36.0

22.2

12.8

1 ½”

2”

10.8

6.2

9.5

5.8

Divide total length of piping in feet by appropriate factor in table to determine volume in gallons.

BOILER WATER VOLUMES

Number of

Boiler Section

Total Volume

(Gallons)

3

4

5

9.6

11.6

13.7

CHIMNEY AND CHIMNEY CONNECTIONS

For oil fired boilers for connections to vents or chimneys, vent installations shall be in accordance with applicable provisions of NFPA-31 Standard for the installation of

Oil-Burning Equipment (latest edition) and applicable provisions of local building codes.

NOTICE

Fresh air (ventilation) is important to proper venting. Ventilation and venting are two parts of the same system. Inadequate ventilation will result in inadequate venting. Always be sure to have enough ventilation to support proper venting.

For additional chimney design and sizing information, consult the National Standard for Chimneys, Fireplaces,

Vents and Solid Fuel Burning Appliances, ANSI/NFPA 211.

Check your chimney to make certain that it is right size, properly constructed and in good condition.

See Table “Recommended Minimum Chimney Sizes”.

FIRING RATE

(gph)

0.60 1.30

1.31 1.80

RECOMMENDED MINIMUM CHIMNEY SIZES

CHIMNEY

HEIGHT (ft)

15

15

NOMINAL

CHIMNEY

8” x 8”

8” x 8”

ROUND

LINER INSIDE

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

6”

7”

SQUARE

LINER INSIDE

6 ¾” x 6 ¾”

6 ¾” x 6 ¾”

Sidewall Venting With Listed Power Venter

— This boiler is not approved for direct sidewall horizontal venting.

— In the U.S. : Per section E.11 of NFPA 31-2020 Standard for the Installation of Oil Burning Equipment, a listed

power venter providing mechanical draft may be used when approved by the Authority having jurisdiction. Select

the listed power venter to match the BTU per hour input of the boiler being vented. Follow all manufacturer’s

installation and operating instructions for venting and termination included with the power venter.

16

PN 240013012, Rev. B [12/15/2020]

CHIMNEY AND CHIMNEY CONNECTIONS

!

WARNING

Fire Hazard! Maintain minimum vent pipe clearance of 9” from surface of vent to wood and other combustible materials. Failure to comply could result in death or serious injury.

Chimney Connector And Draft Regulator

• Venting the boiler requires 6” diameter chimney connector pipe and use of manufacturer provided draft regulator.

• Regulator, when properly installed, automatically controls the draft.

• Install in horizontal section of pipe, may also be installed in angled or vertical section of pipe.

• Verify “top” of regulator is at the top and short pipe section which holds the vane is horizontal.

• Even though locating draft regulator close to chimney reduces noise, install draft regulator as close as practicable to the boiler.

• Install chimney connector, start at boiler with vertical pipe, elbow, then install draft regulator horizontally.

• When regulator is in place, start at chimney and work back to the regulator.

• Join the two sections with draw-band.

• Horizontal pipe must slope up toward the chimney at least 1/4 inch per linear foot of venting.

• Chimney connector must not leak and must be firmly supported.

• Join each section with at least two sheet metal screws.

Support every second section with a stovepipe wire.

17

PN 240013012, Rev. B [12/15/2020]

TYPICAL CHIMNEY CONNECTION

Figure 12 -Typical Chimney Connection

MINIMUM HEIGHT:

MUST BE AT LEAST 3 FT (.9m)

HIGHER THAN HIGHEST PART OF

PASSAGE THROUGH ROOF. MUST BE

AT LEAST 2 FT HIGHER THAN ANY

NEIGHBORING OBJECT WITHIN 10 FT.

TOP OPENING.

18

PN 240013012, Rev. B [12/15/2020]

ELECTRICAL CONNECTIONS

!

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.

Thermostat

Install 24 V olt thermostat (not provided) in proper location.

Location of thermostat has effect on boiler system operation.

Follow instructions included with thermostat.

Electric Power Supply

Installation must comply with the latest revision of the

National Electrical Code , any other national, state, or local codes or regulations.

Connect 120 volt electrical supply to L1 and L2 terminals and two thermostat wires to T and T terminals on

Hydrolevel limit control.

Run separate circuit from separate over current protection device in your electrical service entrance panel. Minimum

15 ampere circuit. Locate shutoff switch at boiler. Turn off during any maintenance. Solder and tape or securely fasten connections with wire nuts.

Grounding

Permanently ground boiler according to local codes and latest revision of the National Electrical Code. Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

Oil Burner Wiring

For boilers packaged with oil burners, burners are wired at the factory. For boilers shipped without a burner, wiring connections are shown in the electrical wiring diagrams of this manual.

19

PN 240013012, Rev. B [12/15/2020]

ELECTRICAL WIRING

Figure 13 -Hydrolevel 3250 Control with Beckett or Carlin Burner

20

PN 240013012, Rev. B [12/15/2020]

ELECTRICAL WIRING

Figure 14 - Hydrolevel 3250 Control with Riello Burner

21

PN 240013012, Rev. B [12/15/2020]

How A Hot Water System Operates

Entire heating system (boiler, piping, and radiation units) is filled with water. As water in the boiler is heated, it is circulated from top of boiler through supply main to radiation units. Cooler water in radiation units flows back through return piping through return main into the boiler.

This arrangement provides positive and rapid response to the thermostat.

Filling The System With Water

FILLING THE BOILER

OPTION #1 This method utilizes boiler piping as shown in figures 7, 8 and 9.

OPTION #2

• Close air vents on all radiation units.

• Open valves to radiation units. Verify boiler drain valve, expansion tank drain cock, and air bleed screw on expansion tank drain fitting are closed.

• Open fill valve on piping to expansion tank.

• Open water inlet to boiler and leave it open.

• Open air vent on lowest radiation unit.

• When all air has escaped and water starts to flow from vent, close it.

• Go to next radiation unit, and repeat this process until finishing with highest radiation unit.

• If heating system has automatic vents, this manual venting is unnecessary but it will speed up proper filling of the system.

A. Close main shutoff valve, isolation valves, and zone valves (if applicable). If bypass piping is installed, also close two throttling valves. Leave boiler service shutoff valve (if installed) and balancing valves to each heating zone fully open.

B. Open following valves in order: drain valve for power purging, isolating valves before and after boiler circulator (if applicable), both throttling valves (if applicable), and then open fill line shutoff valve. Water will fill bypass piping and push air through piping and out power purging drain valve. When power purging drain valve runs air free, close bypass piping throttling valve (leaving throttling valve to supply piping fully open).

If system is a closed expansion tank system, automatic fill valve is needed. Leave automatic fill valve open to refill system automatically as needed.

Note initial fill pressure on boiler’s temperature / pressure gauge, which should be 10-15 psig. Any lowering of pressure from its initial fill pressure indicates loss of water due to leakage. Automatic fill valve should then compensate for this water pressure loss. If it does not, manually open this valve to refill system until needle is again pointing to same pressure reading. Instructions are packaged with valve.

C. Next, open isolation valve (or zone valve) to first zone. Water will fill piping and push any air out power purging drain valve. When power purging drain valve runs air free, close isolation valve or zone valve).

Repeat this procedure for remaining heating zones.

D. Once all zones are filled with water and purged of air, close power purging drain valve and fill line shut off valve, open main shutoff valve, and adjust throttling valves and balancing valves as required.

22

PN 240013012, Rev. B [12/15/2020]

OPERATING THE BOILER

Start: Fill entire system with water. Vent all air from system following section for Filling The Boiler.

Fuel Units And Oil Lines:

• Install oil line(s) to oil burner.

• Recommend using heavy wall copper tubing and flared fittings, not compression fittings.

• All connections and joints must be absolutely airtight.

Use an appropriate non-hardening thread sealing compound on the threaded connections, not Teflon tape.

• See fuel unit data sheet furnished with the burner for sizing, lift, and length of tubing recommendations.

Draft Regulators: Barometric draft regulator is required for controlling draft through boiler. Mount barometric draft regulator in chimney connector. Refer back to section on

“Chimney And Chimney Connections”. Once draft regulator is installed, use draft gauge to adjust to proper opening:

A. Combustion chamber over fire draft shall be -0.01”

WC to -0.02” WC.

B. Stack draft will be approximately -0.02” WC. to

-0.04” WC.

C. Larger installation, greater draft will be required in stack to obtain desired over fire draft.

Oil burner is equipped with single stage fuel unit for single pipe installation. Satisfactory where fuel supply is on same level as or above burner permitting gravity flow of oil. Per

NFPA 31 requirements, never exceed 3 psig pressure to inlet side of fuel unit.

When necessary to lift oil to burner, two pipe installation is required. Run return line between fuel unit and oil supply. Refer to fuel unit instructions furnished with burner for specific instructions on two pipe installations. Do not exceed fuel unit manufacturer’s recommendations for running vacuum.

NOTICE

If lift exceeds 14 feet for Beckett or Carlin burners or 11 feet for Riello burners, two stage fuel unit is required with return line.

Install oil filter of adequate size inside building between tank shutoff valve and oil burner. For ease of servicing, locate shutoff valve and filter near oil burner.

Air Supply For Combustion:

• Do not install boiler in rooms with insufficient air, unless corrective steps are taken.

• It may be necessary to install windows or cut holes in a door to rooms used for supply air to obtain sufficient combustion air and prevent less than atmospheric air pressure in that room.

• If there is a lack of combustion air, burner flame will be dark orange and formation of soot will occur in heating unit.

• In buildings of conventional frame, brick, or stone construction that do not have utility rooms, basement windows, or stair doors, air infiltration is normally adequate to provide enough air for combustion and for operation of barometric draft control.

• Room used for supplying combustion air should be isolated from any area served by exhaust fans.

• Refer to the section " Fresh Air For Combustion " for additional sizing guidelines.

23

Nozzles And Electrodes : Use proper size, spray angle, and spray pattern nozzle.

To install nozzle, remove nozzle line electrode assembly, if necessary remove retention ring assembly, and install and tighten nozzle. Take care not to damage electrode insulators or bend electrode tips.

After installing nozzle, reassemble nozzle line electrode assembly and set electrode tip spacing.

Depending on burner type, electrode tip spacing may need to be set prior to reassembling nozzle line electrode assembly.

Refer to following pages for setting electrode tip spacing.

Final Burner Adjustments: Final burner adjustments must be made using combustion test instruments. Refer to preliminary burner settings charts for initial startup. Set burner accordingly.

• Check draft over fire to verify it is between -0.01” WC and -0.02” WC, adjust draft as necessary.

• After operating 10 minutes to warm up boiler, use combustion test equipment to take smoke reading in flue pipe between boiler and draft regulator.

• Smoke reading should be zero to trace (Shell Bacharach

Scale).

• A new boiler requires more than 10 minutes to burn clean due to oil film on new heat exchanger.

• If smoke reading is zero, gradually close burner’s air adjustment to obtain smoke reading showing trace smoke reading. Once smoke reading is trace, measure

CO

2

and as insurance margin increase air to sufficiently reduce CO

2

by ½% to 1%.

If clean fire cannot be obtained, it is necessary to verify burner head and electrode alignment. Proper electrode alignment figures are presented on following pages. If fire continues to be smoky, replace nozzle with correct replacement.

Once burner is completely adjusted, start and stop burner several times to assure good operation with no fluttering or rumbling. Verify there are no oil leaks. Record nozzle size, oil pressure, combustion readings, and air settings on tag or label attached to burner or, boiler.

PN 240013012, Rev. B [12/15/2020]

PRELIMINARY BURNER SETTINGS

BECKETT AFG

BOILER MODEL

BURNER

MODEL

INPUT

RATE

[gph]

INSERTION

DEPTH

DELAVAN OIL

NOZZLE

3EWC0.80(T) AFG50MBAS 0.80

2-1/4" 0.65-70°W

4EWC1.00(T) AFG50MDASN 1.00

2-1/2" 0.85-60°A

4EWC1.25(T) AFG50MDASN 1.25

2-1/2" 1.00-60°W

5EWC1.55(T) AFG50MDASN 1.55

2-1/2" 1.25-60°B

PUMP

PRESSURE

[psi]

150

140

155

155

LOW

FIRE BAFFLE

YES

NO

NO

NO

BURNER

HEAD

HEAD

SETTING

L1

V1

V1

V1

N/A

0

0

2

AIR

SHUTTER/

BAND

STATIC

PLATE

10/1 3-3/8"

6/1 2-3/4"

10/1 2-3/4"

10/2 2-3/4"

BOILER MODEL

3EWC0.80(T)

4EWC1.00(T)

4EWC1.25(T)

5EWC1.55(T)

BURNER

MODEL

EZ-1HP

EZ-1HP

EZ-1HP

EZ-1HP

CARLIN EZ-1HP

INPUT

RATE

[gph]

INSERTION

DEPTH

DELAVAN OIL

NOZZLE

0.80

2-1/4" 0.65-60°W

1.00

2-1/4" 0.85-60°B

1.25

2-1/4" 1.00-60°B

1.55

2-1/4" 1.25-60°B

PUMP

PRESSURE

[psi]

150

150

155

155

HEAD BAR

AIR

SETTING

0.60/0.65

50%

0.85/1.00

60%

0.85/1.00

75%

1.10/1.25

90%

BOILER MODEL

3EWC0.80(T)

4EWC1.00(T)

4EWC1.25(T)

5EWC1.55(T)

BURNER

MODEL

40F5

40F5

40F5

40F5

INPUT

RATE

[gph]

0.80

1.00

1.25

1.55

RIELLO 40F5

INSERTION

DEPTH

2-1/4"

2-1/4"

2-1/4"

2-1/4"

DELAVAN OIL

NOZZLE

0.70-90°B

0.85-60°B

1.10-60°B

1.25-60°B

PUMP

PRESSURE

[psi]

130

140

130

150

TURBULATOR

SETTING

0

0

2

4

AIR

SHUTTER

SETTING

1.70

2.25

3.00

3.25

Note: All burners fire at an overfire draft of -0.02 inches w.c. The burner settings provided are for initial startup only.

Final adjustment must be made using combustion test instruments.

24

PN 240013012, Rev. B [12/15/2020]

PRELIMINARY BURNER SETTINGS

Figure 15 - Beckett Burner Adjustments and Settings

BECKETT AFG BURNER ELECTRODE ADJUSTMENTS

L1 OR V1 HEADS

BECKETT AFG VARIABLE (V1) HEAD ADJUSTMENT AND

SETTINGS

Figure 16 - Riello Electrode Setting Figure 17 - Riello Turbulator Setting

Figure 18 - Carlin Electrode Setting

25

Turbulator Setting

A. Loosen NUT

MARKER 3

1 turn SCREW 2 until INDEX

is aligned with correct index number 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.

PN 240013012, Rev. B [12/15/2020]

!

CHECKING AND ADJUSTING CONTROLS

WARNING

Burn, scald hazard. Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when the combustion chamber is very hot.

NOTICE

Installer shall follow these instructions carefully.

Adjust Thermostat Heat Anticipator or

Thermostat Cycle Rate According to Instructions

Included With The Thermostat

Check Thermostat Operation:

Follow instructions included with your thermostat.

Locate thermostat five feet above the floor on inside wall.

Locate thermostat to sense average room temperature, avoid the following:

THERMOSTAT LOCATIONS TO AVOID

DEAD

SPOTS

HOT SPOTS COLD SPOTS

This boiler is equipped with the Hydrolevel 3250-Plus temperature limit and operating control.

Consult Hydrolevel literature provided with boiler for detailed information on various features of control and instructions for setting up the control.

High limit is factory set to 190°F.

Behind doors

Concealed pipes Concealed pipes

Fireplace or ducts

TV sets

Radios

Stairwells drafts

Doors drafts

Lamps

Direct sunlight

Kitchens

Unheated room on other side of wall

Low limit is factory set to OFF. This setting is applicable to models without tankless coil so they operate as a cold start boiler.

Corners & alcoves

Low limit is used to maintain temperature in boilers equipped with tankless coils. For models with tankless coil, turn the low limit dial clockwise until the desired temperature is displayed.

When temperature on thermostat is set above indicated thermostat temperature, boiler’s burner should start. Verify that when room temperature reaches selected temperature setting, thermostat should turn boiler’s burner off, and once room temperature falls few degrees boiler starts operating again.

Do not start burner unless all cleanout doors are secured in place.

Limit settings may be varied to meet the requirements of the installation. Low limit set point must be at least 10°F less than high limit set point.

Economy feature is factory set to 1 for single zone system.

Adjust per Hydrolevel instructions.

Low water cut off feature is factory set for automatic mode.

Refer to the Hydrolevel instructions to activate manual reset mode or to disable low water cut off feature.

Sequence of Operation

• Thermostat calls for heat.

• Circulator turns on.

• Limit checks boiler water temperature. Burner ignition delayed until limit determines call for heat cannot be met by residual heat in boiler and heat distribution system.

A. See limit literature for additional information.

B. Burner delay by-passed for tankless heat call for heat. Burner ignition begins immediately.

• Burner and circulator operation continues until thermostat stops call for heat.

26

PN 240013012, Rev. B [12/15/2020]

MAINTENANCE

!

WARNING

Burn, scald hazard. Some maintenance tasks require draining the boiler. Verify boiler is cool and at zero pressure before draining. Verify boiler is appropriately drained before removing relief valve, control well, tankless coil etc. Failure to follow these instructions could result in death or serious injury.

Diaphragm Expansion Tank : Tank may become water logged. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature

(and “knocking” noises) indicates excess air in the tank. To correct this condition, replace diaphragm expansion tank.

Annually : Recommend flue passages, combustion chamber area (target wall, fire door insulation, durablanket), burner adjustment, control operation, and boiler seals (fire door gasket or silicone seal, cast iron sectional seals, flue collector) be checked once each year by trained Service Technician.

Water System: If system is to remain out of service during freezing weather, drain it completely (water left in system may freeze and will crack pipes and/or boiler).

Tankless Coil (Or Cover Plate) Gasket: Gasket should be checked at least twice year for leakage, replace if necessary. If gasket is replaced, make sure that when coil plate (or cover plate) is reattached, ten nuts are torqued in alternating pattern to insure equal force is applied to entire gasket creating good seal. Nuts should be torqued so gasket does not squeeze out from behind the plate.

Before The Start Of Each Heating Season (or when system has been shut down for extended periods of time) recheck whole system for water, oil, and vent piping leaks.

Replace or patch any leaks or faulty seals.

Vent Pipe: Visually inspect entire venting system once a month for any signs of leakage, deterioration, or soot build up. If vent pipe shows any signs of leaking or deterioration, replace it immediately. If it shows any signs of soot build up, clean vent pipe and have burner settings and combustion checked by trained Service Technician.

Control Well: Remove control well every five years and clean any scale or sediment deposits from all parts exposed to boiler water. After cleaning, reinstall well using pipe sealing compound. Teflon tape is not recommended.

Never burn garbage or paper in the unit, never leave combustible material around it.

Safety Relief Valve: Valve should open automatically when system pressure exceeds pressure rating (usually 30 psi) of safety relief valve. Should valve ever fail to open under this condition, shut down the system. Drain system until system pressure is reduced below safety relief valve pressure rating. Contact Service Technician to replace the valve and inspect heating system to determine cause, may indicate equipment malfunction. Safety relief valve should be tested monthly during heating season. Prior to testing, make certain discharge pipe is properly connected to valve outlet and arranged so as to contain and safely dispose of boiler discharge. Hold trip lever fully open for at least five seconds in order to flush free any sediment that may lodge on valve seat. Permit valve to snap shut. Refer to valve manufacturer’s instructions packaged for more details.

Conventional Expansion Tank : Tank may become water logged or may receive excess air. Frequent automatic opening of safety relief valve indicates water logging. High boiler temperature accompanied by unusually low radiation unit temperature (and “knocking” noises) indicates excess air in the tank. To correct either condition, close valve between boiler and tank. Drain tank until empty. Check all tank plugs and fittings, tighten as necessary. Open valve between boiler and tank. Water will rise to normal height in tank if system has automatic fill valve, otherwise manually refill system.

Oil Burner Maintenance : Perform following preventative maintenance annually, prior to heating season.

1.

2.

3.

4.

5.

6.

7.

Do not oil. lubricated.

Oil burner motors are permanently

Fuel Filter Replace to prevent contaminated fuel from reaching nozzle. Partially blocked fuel filter can cause premature failure of fuel pump.

Fuel Pump Unit Replace pump screen and clean pump unit to maintain fuel delivery to nozzle.

Ignition Electrodes Clean and adjust per manufacturer’s recommendations, to maintain reliable ignition of oil.

Nozzle Replace to maintain safe and reliable combustion efficiency. Replace with nozzle as required in charts located in this manual.

Fan and Blower Housing Must be kept clean, free of dirt, lint and oil to maintain proper amount of air fuel requires to burn.

Check Final Burner Adjustments.

27

If any component parts must be replaced, always use parts recommended by burner manufacturer.

PN 240013012, Rev. B [12/15/2020]

OIL BOILER / BURNER CLEANING INSTRUCTIONS

Oil Boiler Cleaning:

1.

Shut off all electrical power to boiler / burner and shut off fuel oil supply.

2.

3.

Remove vent pipe from top of boiler. Inspect pipe and chimney for signs of corrosion and deterioration. Clean out base of chimney. If vent pipe shows any signs of corrosion or deterioration, replace it immediately. If chimney damage or deterioration is discovered, contact a service technician.

Remove top jacket panel screws (5), brass wing nuts

(2) holding flue collector top, and flue collector top.

Inspect gasket on underside of flue collector and replace as necessary.

6.

7.

8.

Carefully vacuum soot accumulations from combustion chamber area, take care to not damage any of refractory or blanket insulation. To gain access to combustion chamber first check that shut off valve on fuel oil line is closed and disconnect fuel oil line. Open swing door by removing whiz lock nut holding door shut.

Inspect target wall, fire door refractory, and combustion chamber blanket (when included) for cracking and deterioration. If there are signs of cracking or deterioration, replace refractory or blanket before reassembling burner / front plate.

Inspect door’s braided gasket for wear and damage.

Replace when necessary with braided gasket of same material and size.

4.

Before beginning to clean flue passageways, insure combustion chamber blanket is covered. If blanket is not covered prior to cleaning, replace blanket once cleaning is completed.

9.

Inspect and clean oil burner.

5.

With access to flue passageways, remove soot from fireside surfaces by brushing diagonally through flue passages (see drawing below). Brushing can be made easier by cutting end of flue brush off and inserting it into drill. When brushing, take care to not damage target wall with flue brush.

NOTICE

Important operating and maintenance requirements:

• Keep your boiler and the area around it clean

• Never burn refuse or any material other than specified fuel in your boiler

Figure 19 - Brush Diagonally Through Flue

Passages

28

PN 240013012, Rev. B [12/15/2020]

OIL BURNER CLEANING

These are general instructions for cleaning an oil burner. For specifics, consult burner manufacturer’s instructions.

!

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.

1.

Verify all electrical power to boiler / burner and fuel supply to burner are shut off.

2.

With swing door open, clean any soot accumulations from end of burner and if applicable burner head.

3.

Remove burner drawer assembly, clean electrodes and then reset electrode spark gap per manufacturer’s recommendations.

4.

Replace oil nozzle with same size and type recommended for use on this boiler.

5.

Install burner drawer assembly make sure head location (and size if applicable) are per manufacturer’s recommendations. If burner being used has damaged head, replace head with same head recommended for use on this boiler.

6.

Inspect and clean oil burner blower wheel.

7.

Remove oil pump cover and clean / replace pump screen. Carefully reassemble insuring pump cover creates proper seal.

8.

Securely fasten swing door shut.

9.

Replace fuel filter (if applicable).

10.

Connect electrical and fuel supplies.

11.

Fire burner, check for proper combustion using combustion test equipment and making adjustments as necessary.

12.

Insure all safety controls and operating controls are functioning properly.

29

PN 240013012, Rev. B [12/15/2020]

SERVICE HINTS

You may avoid inconvenience and service calls by checking these points before you call for service:

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

C heck flame. If it is yellow, the burner is not getting enough air.

Or, if flame is blue and noisy and seems to lift off the burner, the burner is getting too much air. Contact your service technician.

No electric power to boiler

Controls out of adjustment

Radiators not heating

Check over-current protection. Check to be sure electric power supply circuit is “ON”.

Reset according to instructions.

Open radiator vents to excess air. Check flow control valve (if used). It may be in closed position.

Check over-current protection. Check relay operation.

Check all control terminals and wire joints.

Circulating pump not running

Poor electrical contact

Chimney flue is blocked Have the chimney professionally cleaned.

POSSIBLE CAUSE

Corrosion and/or deposits on seat.

RELIEF VALVE LEAKING . . .

WHAT TO DO

Open valve manually. Allow water to run and clear valve seat.

Water logged expansion tank Drain tank, see instructions.

HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU

ARE UNABLE TO CORRECT.

30

PN 240013012, Rev. B [12/15/2020]

PUMP CURVES

Grundfos UP15-42F Pump Curve

5

15

4

3 10

2

5

1

0

US GPM 5 10 15 20

2 3 4 5

31

PN 240013012, Rev. B [12/15/2020]

IMPORTANT

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

Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases.

This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

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

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating

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

300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 325 5479 www.ecrinternational.com

BDR THERMEA GROUP

All specifications subject to change without notice.

©2020 ECR International, Inc.