UTICA BOILERS BC3D, BC3, BC4D, BC4 Installation, Operation & Maintenance Manual

BC Series

OIL-FIRED CAST IRON BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Utica Boilers
2210 Dwyer Aven ue, Utica NY 13 504-4729

Phone: [phone] • Fax: [phone]

e-mail: [e-mail]
web site : www . ecrinternationa l . com

P/N 2761101, Rev. A [02/2011]

H

SAFETY INFORMATION

TABLE OF CONTENTS

Ratings, Data, And Dimensions ...........................3

Installation Procedure .......................................4

Ventilation And Combustion Air ..........................5

Connecting Supply And Return Piping ..................7

Venting System Inspection & Installation ...........11

Oil Tank And Piping .........................................11

Electrical Wiring .............................................12

Thermostat Installation ...................................12

Oil Tank And Piping .........................................13

Normal Sequence Of Operation .........................15

Operating Instructions .....................................15

Maintenance Procedures ..................................17

Service Checklist ............................................18

Replacement Parts ..........................................19

Service Record ...............................................23

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

SAFETY SYMBOLS

The following dened symbols are used throughout

this manual to notify the reader of potential hazards
of varying risk levels.

IMPORTANT: Read the following instructions
COMPLETELY before installing!!

WARNING

1. Keep boiler area clear and free from
combustible materials, gasoline and

other ammable vapors and liquids.

2. DO NOT obstruct air openings
to the boiler room.

3. Modication, substitution or

elimination of factory equipped,

supplied or specied components

may result in property damage,

!

personal injury or the loss of life.

TO ThE OWNER - Installation

4.
and service of this boiler must be

performed by a qualied installer.

TO ThE INSTALLER - Leave

5.
all instructions with the boiler
for future reference.

6. When this product is installed in the

Commonwealth of Massachusetts the
installation must be performed by a

Licensed Plumber or Licensed Gas Fitter.

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, may result in minor or moderate
injury.

NOTICE

Indicates information which should be
followed to ensure proper installation and
operation.

WARNING

All installations of boilers and venting

should be done only by a qualied expert

and in accordance with this manual.

!

Installing or venting a boiler or any other
gas appliance with improper methods or
materials may result in serious injury or

death due to re or to asphyxiation from
poisonous gases such as carbon monoxide

which is odorless and invisible.

Tested For 15 psi.

ASME

Working Pressure

2

RATINGS, DATA, AND DIMENSIONS

Min. Natural Draft

Chimney Size

Round Square

Pump Pressure

PSI

Nozzle Furnished

140PSIG

(5)

Boiler Model

Number

(1)

I=B=R Oil Burner

(2)

Input

G.P.h. MBh

(4)

heating

Capacity

(4)

MBh

I=B=R Net
Ratings

(3)(5)

Water MBh

A.F.U.E.

Rating

BC3D 0.77 107 93 75 86.0 6 8x8x15 140 .65 80B

BC3 1.00 140 118 103 80.0 6 8x8x15 140 .85 80B

BC4D 1.00 140 120 104 86.0 6 8x8x15 140 .85 80B

BC4 1.40 196 165 143 81.0 6 8x8x15 140 1.25 80B

NOTES:

1. Add sufx "T" to denote boiler with tankless heater.

2. I=B=R burner capacity is based on an oil heating value of 140,000 Btu/gal. and with 13% CO

3. Net ratings based on 170°F temperature in radiators and include 15% allowance for normal piping and pick-up load. Consult manufacturer for unusual piping and pick-up
temperatures.

4. Nozzle listed for use with Beckett Burner. When alternate burner is used, consult burner manufacturer's recommendations

5. For equivalent square feet of radiation, divide I=B=R output by 150.

6. MEA number for this series is 47-76E.

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.

TANK-LESS WATER HEATER CAPACITIES

Boiler
Model

Number

Firing

Rate

G.P.H.

Tankless

Heater

Number

Tankless Heater

Capacity Intermittent

Draw G.P.M.

Boiler
Water

Content

(Gallons)

BC3D 0.65 L-24 Available on request 6.7

BC3 1.00 L-24 3.25 6.7

.

2

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", Return Tapping-1.1/2", High Limit and Circulator Control,
Primary Control. For Tankless Heater Units-add Tanlkess Hot Water Coil,
Flow Restrictor and Triple Aquastat Relay.

(NOTE: For Tankless Heater units, add Tankless hot water coil, Flow Restrictor and
Triple Aquastat Relay.)

BC4D 1.00 L-24 3.25 8.2

BC4 1.40 L-24 4.00 8.2

Boiler No.

BC3 19" 9 ¾" 6.0" 8⅞
BC4 23" 11¾" 6.0" 12¾

DIMENSIONS

Length

of Flush

Jacket

Front of Jacket

to Center Line

of Flue Outlet

Flue

Outlet

Diameter

Coil to Back

-A- -B- -C- -D-

3

Tankless

of Jacket

INSTALLATION PROCEDURE

WARNING

!

Improper installation, adjustment,

The boiler shall be installed such that the oil ignition sys­tem components are protected from water (dripping, spray­ing, rain etc.) during appliance operation and service.

alteration, service or maintenance can
cause injury or property damage.

All installations must conform to the requirements of the
authority having jurisdiction. Such applicable requirements
take precedence over the general instructions of this
manual.

Where required by the authority having jurisdiction, the
installation must conform to the American Society of
Mechanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME No.

CSD-1.

Locate boiler in front of nal 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

ooring.

Allow 24 inches in the front, top and right hand side for
servicing and cleaning, or removing tankless water heating

coil.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY

- The boiler must not be installed on carpeting or vinyl

ooring. Minimum clearances to combustible construction

are:

NOTE: Clearance for access should exceed fire protection

clearance.

Remove crate and plastic protective wrapper, inspect for
damage. All equipment is carefully manufactured, inspected

and packaged by experienced workers. Our responsibility

ceases upon delivery of the crated boiler to carrier in good
condition. Any claims for damage or shortage in shipment

must be led immediately against the carrier by consignee.

Move boiler to permanent position by sliding or walking.

TOP 24 IN.

FRONT 24 IN.

FLUE CONNECTOR 9 IN.

REAR 6 IN.

LEFT SIDE 6 IN.

RIGhT SIDE 24 IN.

When installed in a utility room, the door should be wide
enough to allow the largest boiler part to enter, or to permit

replacement of another appliance such as a water heater.

4

VENTS

CHIMNEY

OR

L TYPE VENT PIPE

VENT PIPE

BASEBOARD

12"

12"

VENTILATION AND COMBUSTION AIR

WARNING

!

Air openings to combustion area must not be obstructed. By following the instructions below,
adequate combustion air can be maintained.

COMBUSTION AIR REQUIREMENTS

(Minimum Opening Requirement)

Unconned Area* Conned Area**

Outside Inside Outside Combustion Air

BTU/hr

Input

Combustion Air 1 Sq.

In./5000 BTU/hr

(Step 4)

107,800 22 108 27 54
140,000 28 140 35 70
196,000 40 196 49 98

* A space whose volume is not less than 50 cubic feet per 1000 BTU/Hour of all appliances installed in that space (cubic feet of space = height x width x length)

** A space whose volume is less than 50 cubic feet per 1000 BTU/Hour of all appliances installed in that space (cubic feet of space = height x width x length)

Ventilation of boiler room must be adequate enough to

1.

provide sufcient air to properly support combustion

and venting.

When the boiler is located in an unconned space in a

2.

building of conventional construction frame, masonry

or metal, inltration normally is adequate to provide

air for combustion and ventilation. however, in any
building which has been altered to conserve energy

or to minimize inltration, the boiler area should
be considered as a conned space. If there is any

doubt, install air supply provisions for combustion
and ventilation in accordance with section 5.3, Air

for Combustion and Ventilation, of the NFPA 54 1988

code, the recommendations that follow, or applicable
provisions of the local building codes.

When the boiler is installed in an unconned space,

3.

in a building of unusually tight construction, air for
combustion and room ventilation must be obtained
from outdoors or from spaces freely communicating
with the outdoors. A permanent opening or openings
having a total free area of not less than 1 square inch
per 5,000 BTU per hour of total input rating of all
appliances shall be provided. Ducts may be used to
convey make-up air from the outdoors and shall have
the same cross-sectional area of the openings to which
they are connected.

When air for combustion and room ventilation is from

4.

inside buildings, the conned space shall be provided

with two permanent openings, one starting 12 inches
from the top and one 12 inches from the bottom of the
enclosed space. Each opening shall have a minimum
free area of 1 square inch per 1,000 BTU per hour of
the total input rating of all appliances in the enclosed
space, but must not be less than 100 square inches.
These openings must freely communicate with the

interior areas having adequate inltration from the

outside. (Figure #3)

Combustion Air 1 Sq.

In./1000 BTU/hr

(Min. 100 Sq. In.)

When the boiler is installed in a conned space and

5.

all air is provided from the outdoors, the conned

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, with the outdoors or spaces (crawl or attic)
that freely communicate with the outdoors. One of the
following methods must be used to provide adequate

air for ventilation and combustion.

Figure #3

Vertical Ducts 1 Sq.

In./4000 BTU/hr

(Figures 2 & 3)

horizontal Ducts 1 Sq.

In./2000 BTU/hr

(Figure 4)

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

#4)

When communicating with the outdoors by means B.
of vertical ducts, each opening shall have a mini­mum free area 1 square inch per 4,000 BTU per
hour of total input rating of all appliances in the

enclosed space. (Figure #5)

5

VENTILATION AND COMBUSTION AIR

If horizontal ducts are used, each opening shall C.
have a minimum free area 1 square inch per 2,000
BTU per hour total input rating of all appliances in
the enclosed space. (Figure #6)

When ducts are used, they shall be of the same D.
cross sectional area as the free area of the area of
the openings to which they connect. The minimum
dimension of rectangular air ducts shall not be less

than 3 inches.

In calculating free area using louvers, grills or screens

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

specied. If the design and free area is not known, it

may be assumed that wood louvers will have 20-25%

free area and metal louvers and grills will have 60-75%
free area. Louvers and grills shall be xed in the open

position or interlocked with the boiler so that they are
opened automatically during boiler operation.

Figure #2

Figure #3

Figure #4

6

CONNECTING SUPPLY AND RETURN PIPING

Important: circulators in the following illustrations are
mounted on the system supply side, but mounting on the
system return side is also acceptable practice.

Figure #5

Figure #6

1.

Connect supply and return piping as suggested
in Figure # 5, below. When the boiler is used in

connection with refrigerated systems:

Chilled medium A. MUST BE IN PARALLEL with
boiler.

Use appropriate valves to prevent chilled medium B.
from entering heating boiler.

During the heating cycle open valves

2.

valves C and D.

7

A and B, close

CONNECTING SUPPLY AND RETURN PIPING

During heating cooling cycle open valves

3.

valves A and B.

Maintain a minimum clearance of one (1") inch to A.
hot water pipes. In air handling units where they

may be exposed to refrigerated air circulation, the
boiler piping system MUST be supplied with ow

control valves or other automatic means to prevent
gravity circulation of the boiler water during the
cooling cycle.

hot water boilers installed above radiation level must

4.

be provided with a low water device either as part of
the boiler or at the time of boiler installation.

When a boiler is connected to a heating system that

5.

utilizes multiple zoned circulators, each circulator must

be supplied with a ow control valve to prevent gravity

circulation.

* Reduced pressure back ow preventer must be

present under provisions required by the Environmental
Protection Agency, (EPA).

Bypass piping is an option which gives the ability to

6.

adjust the supply boiler water temperature to t 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 gure 6 above.

C and D, close

This method is used to protect boilers from B.
condensate forming due to low temperature return
water. Generally noticed in large converted gravity
systems or other large water volume systems. See
Figure #7.

This method is used to protect boilers from C.
condensate forming as well as protecting the
heating system from high water temperature. See

Figure #8.

Note:

7.

B until desired system temperature is obtained.
Bypass loop piping must be the same size piping for the

8.

supply and return.
Typical installation using circulators is shown in

9.

#9.
Typical installation using zone valves is shown in

10.

Figure #10.
See

11.

water heater.

For further piping information refer to the I=B=R

12.

installation and piping guide.

When using bypass piping, adjust valves A and

Figure

Figure #11 for typical piping for domestic hot

Figure #7

8

Figure #8

CONNECTING SUPPLY AND RETURN PIPING

Figure #9

9

Figure #10

CONNECTING SUPPLY AND RETURN PIPING

Figure #11

10

VENTING SYSTEM INSPECTION & INSTALLATION

WARNING

Boiler is to be vented by natural draft

!

and shall not be connected into any
portion of a mechanical draft operating
system under a positive pressure.

If an oil red water heater is vented into the same ue

as the boiler, provide a separate hole into the chimney
whenever possible. When this isn’t possible, use a “Y”

connection in the ue pipe, using a separate draft regulator

for each unit. When a chimney will not provide adequate
draft to handle the input from the water heater and boiler
simultaneously, wire the units so that only one will operate

Inspect chimney to make certain it is constructed according

to the latest revision of the NFPA 211. Local regulations

at a time, favoring the water heater.

Figure #12

may differ from this code and should be checked. Where

there is a conict, the local code will prevail.

The boiler must be installed into a chimney which has a
masonry or metallic chimney liner.

An unlined chimney will have leaks that will cause poor
chimney performance (no draft), and could result in a
positive pressure in the combustion chamber.

horizontal portions of the venting system should not

exceed 10 feet in length. Horizontal lengths over 10 ft. will

have a negative effect on the chimney performance.

The chimney should extend at least 2 ft. above any portion

of the building within 10 ft. (Figure #12) It should

produce a -.06 to -.08 inch W.C. draft, as measured with a

draft gauge between the boiler and barometric draft control
while maintaining an .02 inch W.C. negative draft in the
combustion chamber. in the combustion chamber. See

"Chimney or Vent Sizes" chart for recommended minimum
and maximum chimney or vent sizes.

Inadequate draft will cause improper combustion, resulting

in dirty ue ways and high fuel bills.

Connect ue pipe same size as boiler outlet to chimney,

sloping upward continuously toward the chimney

approximately ¼" per foot. Bolt or screw joints together to

avoid sag.

CHIMNEY OR VENT SIZES

ROUND

MODEL NUMBER

BC3 6 8 8x8 8x10 15 40

BC4 6 8 8x8 8x10 15 40

INCHES

MIN MAX MIN MAX MIN MAX

SQUARE

INCHES

HEIGHT (FT)

OIL TANK AND PIPING

Oil tank and piping should be installed in accordance

with the National Board of Fire Underwriters and local
regulations. Oil storage tank, vent, ll pipe and caps should

be as prescribed by local codes. In no case should the vent

pipe be smaller than 1¼" I.P.S. The ll pipe should not be
less than 2" I.P.S.

The suction line from the tank to the burner should be one
continuous piece of tubing to prevent air entering the line.

The suction line, must be ⅜" O.D. copper tubing for runs of
50 feet or less, and ½" O.D. for longer runs. An oil return

line, same size as the suction line, must be used on any
installation where the bottom of the tank is below the fuel
unit of the burner. Oil lines should be buried or otherwise

protected from mechanical injury. Flare ttings on all
oil lines are recommended. Compression ttings on the

suction line often allow air to be drawn into the fuel pump,

making it difcult to maintain oil pressure at the nozzle. Do

not run overhead fuel lines from tank to oil burner.

11

OIL TANK AND PIPING

Fuel pump connections and by-pass should be made

according to instructions attached to the fuel pump. If
tank is more than 20' from the boiler, a two stage fuel
unit should be installed in place of the single stage pump
supplied as standard equipment with the burner. Make
certain the rotation and speed are the same and the pump
is suitable for the burner horsepower rating.

Figure #13 Figure #14

An oil line lter and shut-off valve should be installed in

the suction line. Shut-off valves should be installed in both
the suction and return lines at the burner for convenience

in servicing burner. Allow extra tubing at burner so

burner may be removed from boiler for cleaning without
disconnecting tubing. (Figures #13 - #14) An optional

exible oil line is available.

TYPICAL INSTALLATION

SINGLE PIPE OIL SYSTEM

TYPICAL INSTALLATION

TWO PIPE OIL SYSTEM

ELECTRICAL WIRING

ELECTRICAL WIRING should conform with the latest edition

of National Electrical Code ANSI/NFPA No. 70 and/or local

authority having jurisdiction.
A separate electrical circuit should be run from the entry

box with a fused disconnect switch in this circuit. See

wiring diagram’s in Figures #15, & #16, for suggested

circuitry and eld wiring.

Wiring for zone valve installations are furnished with zone
valve packages.

THERMOSTAT INSTALLATION

Thermostat should be installed on an inside wall about

1.

4.

four feet above the oor.

NEVER

2.

Do not install a thermostat where it will be affected

3.

install a thermostat on an outside wall.

5.

by drafts, hot or cold pipes, sunlight, lighting xtures,
television, replaces, or chimneys.

Check thermostat operation by raising and lowering
thermostat as required to start and stop the burner.

Instructions for the nal adjustment of the thermostat
are packaged with the thermostat (adjusting heating

anticipator, calibration, etc.).

12

Figure #15

OIL TANK AND PIPING

COMPONENT CODING

TH-1 Thermostat (Millivolt) MR-PS Manual Reset Pressure Switch CIR Circulator
TH-2 Thermostat (24 Volt) Control Terminal ECO Energy Cut-Off
TH-3 Thermostat (Line Voltage) 1K Relay Coil PSC Pilot Safety Coil
TR-1 Transformer (120V/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

WIRING CODE

Line Voltage By Factory

Low Voltage By Factory
Line Voltage By Installer
Low Voltage By Installer

NOTE: Not all components listed are used in all control systems.

13

Figure #16

OIL TANK AND PIPING

WIRING CODE

Line Voltage By Factory

Low Voltage By Factory
Line Voltage By Installer
Low Voltage By Installer

14

NORMAL SEQUENCE OF OPERATION

On a call for heat, the thermostat will actuate, completing
the circuit to the aquastat. In turn, the circulator and
ignition systems are activated and ignition will begin.

In the event the boiler water temperature exceeds the high

limit setting on the boiler mounted aquastat, power will be
interrupted between the aquastat and the ignition system.

The power will remain off until the boiler water temperature
drops below the high limit setting. The circulator will
continue to operate under this condition until the

thermostat is satised.

OPERATING INSTRUCTIONS

The venting system should be inspected at the start of each
heating season. Check the vent pipe from the boiler to the
chimney for signs of deterioration by rust or sagging joints.
Repair if necessary.

Remove the vent pipe at the base of the chimney or

ue and, using a mirror, check for obstruction and verify
compliance to the latest revision of the NFPA 211.

Figure #17

The lever of the pressure relief valve, shown in Figure
#17, on the boiler should be operated periodically to make

sure that it is functioning properly. The pressure relief

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.

!

WARNING

Water will be boiling hot.

!

WARNING

Water will be boiling hot.

START-UP AND ADJUSTMENT OF OIL BURNER

(See oil burner instructions for nozzle and electrode setting)

CAUTION

DO NOT SET FIRE VISUALLY.

Instruments are the only reliable method
to determine proper air adjustments.
An improperly adjusted burner causes
soot and high fuel bills because of
incomplete combustion of the fuel oil.

This in turn may require excessive

!

boiler maintenance, service costs, and
in some instances, house cleaning or
redecorating. A competent service
mechanic should be consulted to make
the proper adjustments with a smoke
tester, CO

indicator, and draft gauge.

2

NOTE: Bacharach or Dwyer test kits include

these instruments.

Check oil burner nozzle to make certain it is tight in A.
adapter. Burner mounting bolts should be tight.

Check electrode setting, as they may have been B.
jarred out of position during transportation.

Lubricate burner motor if necessary.C.

15

OPERATING INSTRUCTIONS

Set room thermostat to call for heat, or jump D.

thermostat contacts on the boiler control.

Open all oil line valves.E.
Turn service switch on. Burner should start.F.
On one pipe fuel systems only, bleed pump as soon G.

as burner starts. Allow oil to run until all traces of
air in the suction line disappear.

Turn “OFF” burner and install pressure gauge port h.
on pump.

Start burner again and check oil pressure for 140 lbs. I.
Adjust if necessary.

Instructions To Obtain Proper Operation Of Boiler­Burner Unit. A ¼" diameter slot is provided in the

inspection cover plate to take draft readings in the
combustion chamber. (Figure #17) A ¼" diameter hole

will be required in the ue pipe between the boiler and

barometric damper (if used) to take draft, CO
and temperature readings. Adjust air shutter on oil burner
to obtain a “trace” of smoke. Measure CO2 at this point.
Increase air adjustment to lower CO
percent. Check to insure minimum negative .02 w.c.,

(water column), “overre” draft and zero smoke. If -.02
w.c. “overre” draft can not be maintained, changes and/or
modications may be required in venting or chimney.

The following table IS provided as a guideline for

initial start-up. Final adjustments MUST be made using

combustion instruments as previously mentioned.

approximately one

2

, smoke

2

IMPORTANT: Check safety control circuit after burner
adjustments have been made for satisfactory performance.

To Check:

high limit control: remove cover and note A.
temperature setting. See Figure #17. With the
burner operating, decrease this setting to the
minimum point. When boiler water temperature

exceeds this set point, the high limit switch will

open, shutting off the power to the oil burner.
Return setting to desired high limit point. Burner

should re-start.

WARNING

!

WATER WILL BE BOILING HOT.

Primary Control and Flame Sensor -B.

Flame Failure• - simulate by shutting off oil supply

with hand valve while burner is on. Sixty seconds after
ameout, the safety switch locks out, ignition stops,

motor stops and oil valve - when used - closes. To
restart, open oil supply valve and reset safety switch.

Ignition Failure• - With burner off, close oil sup-

ply valve and run through start-up procedure, The

safety switch should lock out as in ame failure.

Power Failure• - Turn off main power supply switch
while burner is operating. When burner stops, restore
power and burner should start. If operation is not as

described as above, check wiring and controls.

Boiler
Model

No.

BC3D F-0 2¾ 0 8 .65x80B

BC3 F-3 2¾ 1 8 .85X80B

BC4D F-3 2¾ 1 8 .85X80B

BC4 F-6 2¾ 3 10 1.25X80B

End Cone

Static

Disc

Air Band

Settings

Air Shutter

Settings

Nozzle Furnished

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.

16

MAINTENANCE PROCEDURES

Preventive Maintenance of an oil red boiler reduces

operating costs.
The boiler, vent and vent pipe should be inspected for

accumulation of soot or scale deposits periodically but
at least once every year before the start of each heating
season. When soot is present on the section walls and

ueways, improper combustion will result, causing
additional sooting and scaling until ueways are completely

closed.

To remove soot and scale from the ueways, remove

top jacket panel, top clean-out plate and burner. See
instructions on page 15 for instructions on removal of the
oil burner. Using a wire brush, brush the soot and scale into
the combustion chamber where it can be removed through
the burner opening.

Carefully vacuum debris from the combustion chamber.
Inspect combustion chamber for signs of damage, i.e.
cracks.

In the event the combustion chamber is damaged, replace

it immediately. Failure to do so will cause pre mature failure

of the unit, and may result in personal injury. See Figure
#17.

Instructions For Removing Oil Burner

1.

2.

3.

4.

5.

It is recommended to replace the nozzle at the start of
each heating season. Lubricate the burner motor and
circulator motor - if required - with a few drops of a good
grade of light motor oil. Do not over oil. have a competent
service person service the burner and check the controls
and check the electrodes for carbon or cracks in the
insulators. Burners should be adjusted to produce the
conditions shown in Start-up and Adjustment of Oil Burner
procedure.

Instructions For Replacing Oil Burner

1.

CAUTION

Use caution when vacuuming in the

!

2.

3.

chamber area. Damage to chamber could
result.

4.

Turn off power to boiler.
Allow boiler to cool down.

Remove three (3) 1/2" nuts from burner ange.

Close oil valve. See
Disconnect oil line from burner.

Reconnect oil line.
Open oil valve. See

Install and tighten three (3) 1/2" nuts on the burner
ange.

Turn on power to boiler.

Figures #13 and #14.

Figures #13 and #14.

PERIODIC INSPECTION and tightening of the tankless

heater/cover plate bolts will reduce the risk of leaks. CAU­TION: Do not overtighten bolts.

17

SERVICE CHECKLIST

Inspect Chimney and Flue Pipe [ X ]
Inspect and Clean Appliance [ X ]
Inspect Oil Line - Size/Leaks [ X ]
Inspect Electrical Connections [ X ]
Install New Filter [ X ]
Room Make-up Air [ X ]
Electrode Setting [ X ]
Proper Light-Off (Hot & Cold) [ X ]

* Measure with instruments and record results below.

Date

Nozzle

Pump Pressure

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-Overre/In Flue [ * ]

CO2 or O
Flue Gas Temperature [ * ]

SERVICE RECORD

PSI

Smoke#

2

Draft

CO

or O

2

2

[ * ]

Flue

Temp °F

18

REPLACEMENT PARTS

JACKET AND FLUE COLLECTOR ASSEMBLY

Item

Number

1

2

3
4

5

6

7

Part Number Description QTY

2162801 Pnl Jkt Wrapper Assy. BC 3

2162802 Pnl Jkt Wrapper Assy. BC 4

2462101 Flue Collector Assy. BC 3

2462102 Flue Collector Assy. BC 4

2162701 Pnl Jkt Top ASsy. BC

2162702 Pnl Jkt Top ASsy. BC 4

hW-009.01 Scr 8-18x1/2 Stl Hx Wash Hd

hW09501 Scr 5/16-18x1.5 Type F SLHX

2162501 Pnl Jkt Top Frt Assy. BC

2162601 Pnl Jkt Low Frt Assy. BC

1
1
1
1
1
1

16

2
1
1

19

HEAT EXCHANGER ASSEMBLY

REPLACEMENT PARTS

Item

Number

1
2

3

4
5

6

7

8

9
10
11
12
13

Part Number Description QTY

1330002 Nut 1/4-20 Hex Stl ZP

HW-008.01 Wash - 5/16 Flat Stl ZP

hW-011.02 Tie Rod 1/4-20x13x3 IH WH BC3
hW-011.04 Tie Rod 1/4-20x17x3 IH WH BC4

100-2-3.01 Right Section B

43300976 Nipple 2" Mach.

100-2-1.01 Center Section B

100-2-4.01 Tankless Section B

HW06901 Nut 5/16-18 Wislock

hW-012.02 Bolt 7/16-14x1-1/2 Sq Hd
252-2-2.00 Gasket B tankless
252-3-1.02 Tankless Coil L-24

hW-013.01 Nut 7/16-14 Sq Stl
202-2-1.00 Cover plate B/SF S Tankless

2
4

2
2

1

BC3(4)

BC4(6)

BC3(1)
BC4(2)

1
4

8

1
1

8

1

20

BASE ASSEMBLY

REPLACEMENT PARTS

Item

Number

1

2
3

4
5

6

Part Number Description QTY

2262101 Base Assy BC 3
2262102 Base Assy BC 4

252-2-3.01 Combustion Chamber BC 3
252-2-3.02 Combustion Chamber BC 4

2261201 Base Burner Mtg pl Assy, BC 3, 4

hW-005.01 Scr-1/4-20x1/2 Self Tap

hW09501 Scr 5/16-18x1.5 Type F SLHX

10011701 Cast Iron Obsv Door

1
1
1
1
1
7
2
1

21

REPLACEMENT PARTS

BURNER, CONTROLS AND MISC. PARTS

Item

Number

1
2

3
4
5

6

7

8

9

10
11

Part Number Description QTY

HW-016.02 Drain Long 31-608-04

PF-005.11 Pipe Fit Npl 3/4x4 NPT

PF-002.04 Pipe Fit Elb 3/4 NPT 90 Deg

VR-001.01 R/V-30 # 3/4 10-407-05
AQ-020.01 Well 123871A-3/4x3 HW
AQ-010.00 Control-L8124A-1130 HW

37519501 Harness Circulator 72"

2861401 Wire harn Ctrl/Burn BC

BN08301 Burner Oil AF BC 3

BN08302 Burner Oil AF BC 4

HW06901 Nut-5/16-18 Wislock

GA-001.00 Gauge Theraltimeter Water

Burner Replacement Parts

BN08101 Burner Static Disc 3383 - 2.3/4

BN08501 Burner Blast Tube 580501 BC
BN07103 Burner Drawer Assembly NL65XN

BN08001 Burner-oil Flange Gasket 3616

RP-015.00 Oil Burner Motor PSC #21805U
RP-019.01 Oil Burner Transformer 5878U

RP03701 Pump - 140 PSI 1 Stage

RY-001.02 Control R4184D1027

CD-001.01 C554A Cad Cell - Oil

1050002 F-3 Burner Head BC3
1050004 F-6 Burner Head BC4

1
1

1
1

1
1

1
1
1
1

3
1

1
1
1
1
1
1
1
1
1
1
1

22

SERVICE RECORD

Date Service Performed Company Name & Tech Initials Company Address & Phone #

23

UTICA BOILERS

2210 Dwyer Avenue, Utica NY 13504-4729

Phone: [phone] • Fax: [phone]

e-mail: [e-mail]

web site: www.ecrinternational.com