UTICA BOILERS BC3, Installation, Operation & Maintenance Manual

Page 1: ...CAST IRON BOILER INSTALLATION OPERATION MAINTENANCE MANUAL Utica Boilers 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ecrinternational com web site www ecrinternational com An ISO 9001 2008 Certified Company ...

Page 2: ...ot avoided may result in minor or moderate injury DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury WARNING 1 Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 DO NOT obstruct air openings to the boiler room 3 Modification substitution or elimination of factory equipped supplied or specified...

Page 3: ... 76E 7 MEA number for R W Beckett Burner used in this boiler series are AF 156 77 E AFG 213 83 E AFII 85 24 92 E AFII 150 456 90 E 8 Electrical service to be 120 Volts 15 Amps 60 Hz STANDARD EQUIPMENT Crated Boiler Flush Jacket Oil Burner Target Wall Liner Circulator 1 1 4 ASME Relief Valve Theralitimeter Gauge Drain Cock Wiring Harness Burner Electrical Disconnect Plastic Cover Supply Tapping 2 R...

Page 4: ... Locate boiler in front of final position before removing crate Provide a solid level base as near chimney as possible and centrally located with respect to the heat distribution system as practical WARNING Boiler may not be installed on combustible flooring Allow 24 inches in the front top and right hand side for servicing and cleaning or removing tankless water heating coil When installed in a u...

Page 5: ...cate with the interior areas having adequate infiltration from the outside Figure 3 When the boiler is installed in a confined space and 5 all air is provided from the outdoors the confined space shall be provided with two permanent openings one commencing within 12 inches from the top and one commencing 12 inches from the bottom of the enclosure The openings shall communicate directly or by ducts...

Page 6: ...creens 6 for the above consideration shall be given to their blocking effect Screens used shall not be smaller than 1 4 inch mesh If the free area through a design of louver or grill is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 free area and metal l...

Page 7: ...s also acceptable practice Connect supply and return piping as suggested 1 in Figure 5 below When the boiler is used in connection with refrigerated systems Chilled medium A MUST BE IN PARALLEL with boiler Figure 5 Figure 6 Use appropriate valves to prevent chilled medium B from entering heating boiler During the heating cycle open valves 2 A and B close valves C and D ...

Page 8: ...o fit the system or condition of the installation Although this method of piping is not typically required for baseboard heating systems This method is used to protect systems using A radiant panels and the material they are encased in from high temperature supply water from the boiler See figure 6 above Connecting Supply And Return Piping This method is used to protect boilers from B condensate f...

Page 9: ...9 Connecting Supply And Return Piping Figure 8 Figure 9 ...

Page 10: ...10 Connecting Supply And Return Piping Figure 10 Figure 11 ...

Page 11: ...o be vented by natural draft and shall not be connected into any portion of a mechanical draft operating system under a positive pressure Inspect chimney to make certain it is constructed according to the latest revision of the NFPA 211 Local regulations may differ from this code and should be checked Where there is a conflict the local code will prevail The boiler must be installed into a chimney...

Page 12: ...available Thermostat should be installed on an inside wall about 1 four feet above the floor NEVER 2 install a thermostat on an outside wall Do not install a thermostat where it will be affected 3 by drafts hot or cold pipes sunlight lighting fixtures television fireplaces or chimneys Check thermostat operation by raising and lowering 4 thermostat as required to start and stop the burner Instructi...

Page 13: ...20V 24V 40VA 1K1 Relay Contacts Wire Connection TR 2 Transformer 120V 24V 50VA 1K2 Relay Contacts LWCO Low Water Cut Off LGV24 Volt Gas Valve LS Limit Switch EWF Electric Water Feeder PS Pressure Switch MS Manual Switch PG Power Generator NOTE Not all components listed are used in all control systems WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage B...

Page 14: ...14 WIRING CODE Line Voltage By Factory Low Voltage By Factory Line Voltage By Installer Low Voltage By Installer Oil Tank And Piping Figure 16 ...

Page 15: ...ef valve should open before the water pressure exceeds the 30 lb reading on the gauge If this pressure is exceeded and the pressure relief valve leaks water when the boiler is operating at normal pressures it should be immediately replaced Corrosion can build up rapidly at the valve seat and prevent its functioning as a safety device START UP AND ADJUSTMENT OF OIL BURNER See oil burner instruction...

Page 16: ...ir Band Settings Air Shutter Settings Nozzle Furnished BC3D F 0 2 0 8 65x80B BC3 F 3 2 1 8 85X80B BC4D F 3 2 1 8 85X80B BC4 F 6 2 3 10 1 25X80B NOTES Information in above table uses Beckett model AF burner for both model numbers BC 3 and BC 4 BC3D and BC4D are derated boilers which require derate kits part numbers 5612501 for BC3D and 5612202 for BC4D IMPORTANT Check safety control circuit after b...

Page 17: ...t and may result in personal injury See Figure 17 CAUTION Use caution when vacuuming in the chamber area Damage to chamber could result PERIODIC INSPECTION and tightening of the tankless heater cover plate bolts will reduce the risk of leaks CAU TION Do not overtighten bolts MAINTENANCE PROCEDURES Instructions For Removing Oil Burner Turn off power to boiler 1 Allow boiler to cool down 2 Remove th...

Page 18: ...ode Setting X Proper Light Off Hot Cold X Service Record Date Nozzle Pump Pressure PSI Smoke Draft CO2 or O2 Flue Temp F Size Angle Type O F INF Controls and Safety Devices X Nozzle Size Angle Type Pump Pressure Vacuum Line Voltage Motor Amps Smoke Test Draft Overfire In Flue CO2 or O2 Flue Gas Temperature Measure with instruments and record results below Service Checklist ...

Page 19: ... 3 1 2162802 Pnl Jkt Wrapper Assy BC 4 1 2 2462101 Flue Collector Assy BC 3 1 2462102 Flue Collector Assy BC 4 1 3 2162701 Pnl Jkt Top ASsy BC 1 2162702 Pnl Jkt Top ASsy BC 4 1 4 HW 009 01 Scr 8 18x1 2 Stl Hx Wash Hd 16 5 HW09501 Scr 5 16 18x1 5 Type F SLHX 2 6 2162501 Pnl Jkt Top Frt Assy BC 1 7 2162601 Pnl Jkt Low Frt Assy BC 1 ...

Page 20: ...17x3 IH WH BC4 2 4 100 2 3 01 Right Section B 1 5 43300976 Nipple 2 Mach BC3 4 BC4 6 6 100 2 1 01 Center Section B BC3 1 BC4 2 7 100 2 4 01 Tankless Section B 1 8 HW06901 Nut 5 16 18 Wislock 4 9 HW 012 02 Bolt 7 16 14x1 1 2 Sq Hd 8 10 252 2 2 00 Gasket B tankless 1 11 252 3 1 02 Tankless Coil L 24 1 12 HW 013 01 Nut 7 16 14 Sq Stl 8 13 202 2 1 00 Cover plate B SF S Tankless 1 HEAT EXCHANGER ASSEMB...

Page 21: ...2262101 Base Assy BC 3 1 2262102 Base Assy BC 4 1 2 252 2 3 01 Combustion Chamber BC 3 1 252 2 3 02 Combustion Chamber BC 4 1 3 2261201 Base Burner Mtg pl Assy BC 3 4 1 4 HW 005 01 Scr 1 4 20x1 2 Self Tap 7 5 HW09501 Scr 5 16 18x1 5 Type F SLHX 2 6 10011701 Cast Iron Obsv Door 1 ...

Page 22: ...rn Ctrl Burn BC 1 9 BN08301 Burner Oil AF BC 3 1 BN08302 Burner Oil AF BC 4 1 10 HW06901 Nut 5 16 18 Wislock 3 11 GA 001 00 Gauge Theraltimeter Water 1 Burner Replacement Parts BN08101 Burner Static Disc 3383 2 3 4 1 BN08501 Burner Blast Tube 580501 BC 1 BN07103 Burner Drawer Assembly NL65XN 1 BN08001 Burner oil Flange Gasket 3616 1 RP 015 00 Oil Burner Motor PSC 21805U 1 RP 019 01 Oil Burner Tran...

Page 23: ...23 Date Service Performed Company Name Tech Initials Company Address Phone Service Record ...

Page 24: ...Utica BOILERS 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ecrinternational com web site www ecrinternational com ...