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ECR International UTICA BOILERS TRB4075, Installation, Operation & Maintenance Manual

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ECR International UTICA BOILERS TRB4075 Installation, Operation & Maintenance Manual Download Page 31

31

10 - HYDRONIC PIPING

BOILER

ALTERNATE

CIRCULATOR

LOCATION

TO SYSTEM

FROM SYSTEM

V2

V1

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE

AIR SEPARATOR

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

CIRCULATOR

SHUT-OFF

VALVE

PRESSURE

REDUCER VALVE

CHECK VALVE

BALL VALVE

3 WAY MIXING

VALVE

AIR SEPARATOR

HOSE BIB

EXPANSION

TANK

Figure 26  - Bypass Piping Automatic Mixing Valve

 PN 240013278, Rev. A [12/31/2020]

Summary of Contents for UTICA BOILERS TRB4075

Page 1: ...iler INSTALLATION OPERATION MAINTENANCE MANUAL Models TRB4075 TRB4090 TRB5100 TRB6130 TRB7165 FOR US SALES ONLY Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479...

Page 2: ...ly 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 chan...

Page 3: ...tions 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...

Page 4: ...ILER SYSTEM PIPING 19 10 HYDRONIC PIPING 20 11 FUEL SUPPLY PIPING 33 12 ANTIFREEZE IN THE SYSTEM 34 13 ELECTRICAL CONNECTIONS 35 14 CHIMNEY AND VENTING CONNECTIONS 36 15 FILLING BOILER 39 16 OPERATING...

Page 5: ...pplemental 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...

Page 6: ...not related to personal injury 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...

Page 7: ...nitizing 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...

Page 8: ...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 o...

Page 9: ...seboard 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 o...

Page 10: ...e material see Figure 1 and Table 2 Table 2 BOILER CLEARANCES Unit Combustible Clearance Accessibility Cleaning and Servicing Top 12 32 cm 24 61 cm Right Side 2 5 cm 24 61 cm Left Side 2 5 cm 24 61 cm...

Page 11: ...hut 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...

Page 12: ...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...

Page 13: ...e 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 Uni...

Page 14: ...nge 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 r...

Page 15: ...nt 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 Mo...

Page 16: ...ing 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 r...

Page 17: ...wire to grounding lug When installing wiring through hole in Limit use anti abrasion cable clamp Connect black hot wire to L1 of terminal block white N wire to L2 of terminal block 16 Install top pane...

Page 18: ...e 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 electr...

Page 19: ...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 in...

Page 20: ...20 Figure 17 Standard Near Boiler Piping Piping Diagram Legend 10 HYDRONIC PIPING PN 240013278 Rev A 12 31 2020...

Page 21: ...ARM 2P ISOLATED SWITCH X1 X1 ISOLATED SWITCH X2 PRIORITY 120VAC CIRCULATORS X2 L 1 ZONE 2 L N N 2 CT WITH X X PRIORITY ON ZONE 1 FUSE ELECTRONIC DATA PORT T T W 1 R TW PRIORITY ZONE 120 VAC L N PRIORI...

Page 22: ...3 4 OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY Z1 Z2 Z3 Z4 T T T T T T T T AZ 4CP 120VAC TO TRANSFORMER 24VAC FROM TRANSFORMER ZONE VALVE ZONE VALVE T STAT T STAT T STAT CONTROL TANK OR THE...

Page 23: ...4 OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY Z1 Z2 Z3 Z4 T T T T T T T T AZ 4CP 120VAC TO TRANSFORMER 24VAC FROM TRANSFORMER ZONE VALVE ZONE VALVE ZONE VALVE T STAT T STAT T STAT CONTROL TAN...

Page 24: ...RIORITY ON X X ZR ZC ZONE 2 Z DATA PORT 120 VAC N 4 L N L N ZONE MODULE TO EXTRA PRIORITY ON ZONE 4 COMMON 1 3 2 4 ZONE 4 ZONE 3 ZONE 2 ZONE PRIORITY THERMOSTATS 24 VAC 1VA ZONE 4 ZONE 3 ZONE 2 PRIORI...

Page 25: ...Figure 22 Primary Secondary Piping And Wiring With Circulators And Domestic Hot Water MAX 4 X DIAMETER CLOSELY SPACED TEES BOILER PUMP 25 10 HYDRONIC PIPING PN 240013278 Rev A 12 31 2020...

Page 26: ...ZR L 2 N 1 L N L ZONE 1 PRIORITY ON X X ZR ZC ZONE 2 Z DATA PORT 120 VAC N 4 L N L N ZONE MODULE TO EXTRA PRIORITY ON ZONE 4 COMMON 1 3 2 4 ZONE 4 ZONE 3 ZONE 2 ZONE PRIORITY THERMOSTATS 24 VAC 1VA Z...

Page 27: ...M 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 Zo...

Page 28: ...2 3 4 2 1 3 4 OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY Z1 Z2 Z3 Z4 T T T T T T T T AZ 4CP 120VAC TO TRANSFORMER 24VAC FROM TRANSFORMER ZONE VALVE ZONE VALVE T STAT T STAT T STAT CONTROL TA...

Page 29: ...0 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 240013278 Rev A 12 31...

Page 30: ...3 ZONE 2 2 4 ZONE 3 1 2 3 4 2 1 3 4 OPTION SWITCHES ZR ZC DPM 2 ZONE VALVE PUMP PRIORITY Z1 Z2 Z3 Z4 T T T T T T T T AZ 4CP 120VAC TO TRANSFORMER 24VAC FROM TRANSFORMER ZONE VALVE ZONE VALVE ZONE VALV...

Page 31: ...PARATOR 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...

Page 32: ...VE 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 RET...

Page 33: ...n 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 conne...

Page 34: ...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...

Page 35: ...ith 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...

Page 36: ...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 o...

Page 37: ...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 inche...

Page 38: ...hest 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...

Page 39: ...ng 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...

Page 40: ...sely 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 cont...

Page 41: ...n 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...

Page 42: ...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 thi...

Page 43: ...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 o...

Page 44: ...eliminary 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...

Page 45: ...e 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 Du...

Page 46: ...perature 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 dra...

Page 47: ...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 Hea...

Page 48: ...KER 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 som...

Page 49: ...1 10 87 0 7165 V1 2 75M 2 625 1 65 V7 Delavan 1 25x45B 175 3 4 10 87 0 Timings Pre purge 15 seconds Post purge 15 seconds Table 13 Beckett Chimney Vent Preliminary Burner Settings Burner settings pro...

Page 50: ...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 P...

Page 51: ...tting Air Setting Rated AFUE Efficiency 4075 Reverse 2 75 0 75 Oval Delavan 0 65x60W 150 1 3 6 87 0 4090 Reverse 2 75 0 90 Oval Delavan 0 75x90B 140 2 3 5 86 0 5100 Standard 2 75 1 00 None Delavan 0 7...

Page 52: ...ing 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...

Page 53: ...zle Mfr Nozzle Type Pump Pressure PSI Head Bar Setting Air Band Setting Rated AFUE Efficiency 4075 4 56 0 75 OVAL DELAVAN 0 60x60B 160 1 22 87 0 4090 4 56 0 90 OVAL DELAVAN 0 75x70A 145 2 28 86 0 5100...

Page 54: ...ring 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...

Page 55: ...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 h...

Page 56: ...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...

Page 57: ...UM 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 240013278 Rev A 12 3...

Page 58: ...ot 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 fo...

Page 59: ...low 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 CO...

Page 60: ...ed 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 A...

Page 61: ...US GPM 5 10 15 20 m h 3 Head feet Model Watts Volts Amps Capacitor UP 15 42F 85 115 0 74 10 F 180 V Fourni avec la pompe Figure 47 Grundfos Pump Curve Figure 48 Taco 007e Pump Curve 21 EQUIPMENT AND A...

Page 62: ...62 NOTES PN 240013278 Rev A 12 31 2020...

Page 63: ..._________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner maintenance person Installation booklet affixed o...

Page 64: ...ll specifications subject to change without notice 2020 ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com BDR THERMEA GROUP PN 240013278 Rev A 12 31 2020...

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