Utica Boilers BC Series II Operation and Installation Manual

Models

BC3095

BC4100 BC4115

BC Series II

OIL-FIRED CAST IRON BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certied Company

Maximum Allowable

Working Pressure 30

psi.

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N 240009511, Rev. B [12/2014]

SAFETY INFORMATION

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

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

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

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

Venting System Inspection & Installation...............................................................12

Electrical Wiring ................................................................................................ 14

Wiring Diagrams ................................................................................................ 15

Operating Instructions ....................................................................................... 16

Maintenance Procedures ..................................................................................... 18

Service Checklist ............................................................................................... 19

WARNING

All boiler and venting installations shall be done

by qualied agency and in accordance with

appropriate Manufacturer’s Installation, Operation

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

and Maintenance Manual. Installing or venting boiler or any other appliance with improper methods or materials could result in serious injury or death due

to re or to asphyxiation from poisonous gases such

as carbon monoxide which is odorless and invisible.

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

Safety Symbols & Warnings

The following dened symbols are used throughout this

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

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.

WARNING

Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors

and liquids.

DO NOT obstruct air openings to the boiler room.

Modication, substitution or elimination of factory equipped, supplied or specied components may

result in personal injury or loss of life.

TO THE OWNER - Installation and service of this

boiler must be performed by a qualied installer.

TO THE INSTALLER - Leave all instructions with boiler for future reference.

Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors and

liquids.

DO NOT obstruct air openings to boiler room.

To the owner: Installation and service of this boiler must

be performed by qualied installer.

To the installer: Leave all instructions with boiler for future reference.

Installation in Commonwealth of Massachusetts must be performed by Licensed Plumber or Licensed Gas Fitter.

Figure 1 - Dimensions

DIMENSIONS

Table 1 DIMENSIONS

Length

Boiler No.

BC3 19" 9 ¾" 6" 8⅞ BC4 23" 11¾" 6" 12¾

of Flush

Jacket

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

Front of Jacket

to Center Line

of Flue Outlet

Flue

Outlet

Diameter

Coil to Back

Tankless

of Jacket

RATINGS, DATA, AND DIMENSIONS

Table 2 RATINGS & DATA

AHRI Oil Burner

(1)

Input

Boiler Model

(1)

Number

BC3095 0.95 133 114 99 84.0 6 8x8x15

BC4100 1.00 140 121 105 85.0 6 8x8x15

BC4115 1.15 161 137 119 84.0 6 8x8x15

G.P.H. MBH

(4)

Heating

Capacity

(4)

MBH

AHRI Net

Ratings

Water MBH Round Square

(2)(4)

A.F.U.E.

Rating

Min. Natural Draft

Chimney Size

NOTES:

1. AHRI burner capacity is based on an oil heating value of 140,000 Btu/gal and with 13% CO2.

2. Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15.

3. Consult manufacturer before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping.

4. For forced hot water heating systems where boiler and all piping are within the area to be heated, select boiler on basis of its Heating Capacity.

5. Nozzle listed for use with Beckett Burner.

6. Electrical service to be 120 Volts, 15 Amps, & 60 Hz.

Table 3 TANK-LESS WATER HEATER CAPACITIES

Boiler Model

Number

BC3095

BC4100

BC4115

Input

Rate

G.P.H.

Tankless

Heater

Number

Tankless Heater

Capacity Intermittent

Draw G.P.M.

0.95 L-24 3.25 6.7

1.00 L-24 3.25 8.2

1.15 L-24 4.00 8.2

Boiler Water

Content

(Gallons)

STANDARD EQUIPMENT: Crated Boiler, Flush Jacket, Oil Burner, Target Wall/Liner, Circulator-1¼", Safety Relief Valve, Temperature Pressure Gauge, Drain Valve, Wiring Harness, Supply Tapping 1¼", Return Tapping 1¼", High Limit and Circulator Control, Primary Control. For Tankless Heater Units-add Low Limit.

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury.

• Installation shall conform to requirements of the authority having jurisdiction and shall take precedence over the general instructions of this manual.

• Where required by authority having jurisdiction, installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1.

• Locate boiler in front of nal position before removing crate. Provide solid level base as near chimney as possible and centrally located with respect to the heat distribution system as practical.

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

• When installed in utility room, door should be wide enough to allow largest boiler part to enter, or to permit replacement of another appliance such as water heater.

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

• Remove crate and plastic protective wrapper, inspect for damage.

• Move boiler to permanent position by sliding or walking.

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions WILL result in death or serious injury.

NOTE: Clearance for access should exceed fire protection clearance.

DANGER

Table 4 Clearance To Combustibles

TOP 24 IN.

FRONT 24 IN.

FLUE CONNECTOR 9 IN.

REAR 6 IN.

LEFT SIDE 6 IN.

RIGHT SIDE 24 IN.

VENTILATION AND COMBUSTION AIR

Table 5 COMBUSTION AIR REQUIREMENTS

(Minimum Opening Requirement)

Unconned Area* Conned Area**

BTU/Hr

Input

(Mbh)

Combustion Air 1 Sq.

Outside Inside Outside Combustion Air

In./5000 BTU/Hr

(Step 4)

Combustion Air 1 Sq.

In./1000 BTU/Hr

(Min. 100 Sq. In.)

Vertical Ducts 1 Sq.

In./4000 BTU/Hr

(Figures 2 & 3)

Horizontal Ducts 1 Sq.

In./2000 BTU/Hr

(Figure 4)

133 27 133 33 67 140 28 140 35 70

161 32 161 40 81

* 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 Mbh of all appliances installed in that space (cubic feet of space = height x width x

length)

WARNING

Asphyxiation, re hazard. Air openings to combustion

area SHALL not be obstructed. Provide adequate supply of combustion air in accordance with Installation Code for Oil Burning Appliances, CSA

139.

WARNING

When air for combustion and room ventilation is from

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

Asphyxiation, re hazard. Do not obstruct air

openings to combustion area. Follow instructions

interior areas having adequate inltration from the

outside. See Figure 2.

below, to maintain adequate combustion air.

Ventilation of boiler room must be adequate enough to

provide sufcient air to properly support combustion

and venting.

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

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 requirements of authority having juridiction, or in absence of such requirements, Air for Combustion and Ventilation of the NFPA 31.

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

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.

Figure 2 Combustion and Room Air From Inside

Buildings

CHIMNEY

L TYPE VENT PIPE

BASEBOARD

VENT PIPE

12"

VENTS

12"

+ 14 hidden pages