Utica Boilers SW Series II Operation and Installation Manual
Contents
1. 6 IN LEFT SIDE a i ms 0 IN RIGHT nes tarde OIN FOR ALCOVE INSTALLATI ON Recommended clearance for service access should exceed fire protection clearance TOP HP 24 IN FRONT 24 IN FLUE 9 IN REAR tute pM EXE RA DERI DARE 6 IN LEFT SIDE nerit rina 10 IN RIGHT Sl DE Lien rere hen han hee nig 6 IN Remove crate and plastic protective wrapper and inspect for damage Our responsibility ceases upon delivery of the crated boiler to the carrier in good condition Any claims for damage or shortage in shipment must be filed immediately against carrier by consignee Move boiler to permanent position by sliding or walking CONNECTING SUPPLY AND RETURN PIPING Circulators in following illustrations are mounted on system supply side mounting on system return side is also acceptable practice Figure 1 Typical Installation Using Circulators GATE VALVE SYSTEM TANK CIR CIRCULATOR REDUCED PRESSURE TI BACKFLOW PREVENTER FLOW CONTROL OR CHECK VALV hens HOT WATER LU i L IL 4 E 1 ce H f LA COLD WATER OUTLET INLET LL V H PRESSURE REDUCING VALVE FEED WATER Wy SYSTEM o RETURN p Qe re m THERMAL RELIEF VALVE TRAP WIRING FOR DR2. Figure 15 PRESSURE TOP JACKET RELIEF VALVE PANEL HIGH LIMIT km 174 SLOT CONTROL AH BURNER ELECTRICAL DISCONNECT LOWER FRONTA JACKET PANEL OUNTING SCREWS CBOTH SIDES 17 RATINGS AND DATA AMD CERTIFIED RATI NGS AND DATA www ahridirectory org HEATI NG AHRI NET BOILER aa MODEL NUMBER WATER MBH MBH RATING sw3065 65 tT SW4100 140 120 104 SW5125 175 150 130 NOTES 1 AHRI burner input is based on an oil heating value of 140 000 Btu gal 2 Net AHRI Water Ratings shown are based on a 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 3 120 Volts 15 Amps amp 60 Hz required to operate this boiler STANDARD EQUIPMENT Crated Boiler Flush Jacket Oil Burner Target Wall Liner Circulator 1 1 4 Safety Relief Valve Temperature Pressure Gauge Drain Valve Wiring Harness Burner Electrical Disconnect Plastic Cover Supply Tapping 2 Return Tapping 1 High Limit and Circulator Control Primary Control For Tankless Heater Units add Tankless Hot Water Coil Flow Restrictor and Combination High Limit Low Limit and Circulator Control TANKLESS WATER HEATER CAPACITI ES TANKLESS BOILER BOILER TANKLESS HEATER CAPACITY WATER MODEL HEATER aa DRAW CONTENT NUMBER NUMBER GALS CAPACITY AVAILABLE ON REQUEST 18 SERVICE C
3. BECKETT 7505 CAINE PRIMARY CONTROL INSTALLATION CONTROLE PRIMAIRE IGNITER BLU WHT i L2 WHT MOTOR ORG L2 WHT BLK GRN PNK L1 BLK 120V 60 HZ WHT LIMIT RED SUPPLY BY INSTALLER L2 WHT APPROVISIONNEMENT PAR LE PROGRAMME INSTALLATION VALVE VI L2 WHT CAD CELL YEL RED CIRCULATOR CAD CELL YEL CIRCULATEUR NOTES IF ANY OF THE ORIGINAL WIRING SUPPLIED WITH THE BOILER IS REPLACE IT MUST BE REPLACED WITH LIKE WIRE SIZE AND TYPE OF INSULATION OR EQUIVALENT SI DES FILS ORIGINALEMENT FOURNIS AVEC LA CHAUDIERE SONT REMPLACES ILS DOIVENT ETRE REMPLACES PAR DES FILS DE MEME GROSSEUR ET DE MEME TYPE D ISOLANT OU L QUIVALENT 12 ELECTRICAL WIRING Figure 13 Wiring Diagram For Oil Fired Boilers With Tankless Heater And Beckett Burner 120V 60 HZ SUPPLY BY INSTALLER APPROVISIONNEMENT PAR LE PROGRAMME THERMOSTAT BURNER CONTROL INSTALLATION 24 VOLT A m BY INSTALLER BRULEUR CUONTRALE PAR LE PROGRAMME BECKETT 79505 PRIMARY CONTR CONTROLE PRIMAIRE IGNITER BLU WHT L2 WHT MOTOR ORG HT GRN 1 9 PNK z BLK ZA L1 BLK 2 WHT LIMIT RED lt L2 WHT 2 VALVE VI L2 WHT L CIRCULATOR CAD CELL YEL RED CIRCULATEUR CAD CELL YEL NOTES IF ANY OF THE ORIGINAL WIRING SUPPLIED WITH THE BOILER IS REPLACED IT MUST BE REPLACED WITH LIKE WIRE SIZE AND TYPE OF INSULATION OR EQUIVALENT SI DES FILS ORIGINALEMENT F
4. systems Figure 3 TEMPERATURE Method used to protect systems using radiant panels and material they are encased in from high temperature supply water from boiler See Figure 3 Method used to protect boilers from condensate forming due to low temperature return water Generally noticed in large converted gravity systems or other large water volume systems See Figure 4 Method used to protect boilers from condensate forming as well as protecting heating system from high water temperature See Figure 5 When using bypass piping adjust valves A and B until desired system temperature is obtained Bypass loop piping must be same size piping for supply and return Connect supply and return piping as suggested in Figure 6 when boiler is used in connection with refrigerated systems SYSTEM GAUGE SUPPLY 4 WAY MIXING VALVE from floor or allowable safe point of discharge CONNECTING SUPPLY AND RETURN PIPING Figure 4 SUPPLY SYSTEM TEMPERATURE GAUGE EXPANSION TANK from floor or allowable safe point of discharge Figure 5 RETURN SYSTEM SYSTEM CIRCULATOR TEMPERATURE GAUGE le PRIMARY CIRCULATOR EXPANSION from floor or allowable safe point of discharge CONNECTING SUPPLY AND RETURN PIPING A Chilled medium must be in parallel with the boiler B Use appropriate valves to prevent chilled medium Burn and scald hazard Safety relief valve could rona entering heat
5. AIN COCK THERMDSTAT Check local codes 3 PUMP CONTROL for maximum from floor or allowable safe point of discharge Figure 2 Typical I nstallation Using Zone Valves GATE VALVE SYSTEM ZONE VALVE COLD WATER SYSTEM INLET REDUCED PRESSURE RETURN BACKFLOW PREVENTER TANK ZONE n VALVE LI HOT WATER A AA ey HAm ID An OUTLET r1 14 T Ee CIR PRESSURE REDUCING VALVE FEED d WATER A ed VIN TERMAL TRAP Z5 RELIEF VALVE MERNSSTAT H M 4 g Check local codes for 9 PUMP CONTROL maximum from floor DRAIN COCK or allowable safe point of discharge CONNECTING SUPPLY AND RETURN PIPING Typical installation using circulators shown in Figure 1 Typical installation using zone valves shown in Figure 2 Hot water boilers installed above radiation level must be provided with low water device either as part of boiler or at time of boiler installation When boiler is connected to heating system utilizing multiple zoned circulators each circulator must be supplied with flow control valve to prevent gravity circulation Reduced pressure back flow preventer must be present under provisions required by Environmental Protection Agency EPA Bypass piping is an option which gives ability to adjust supply boiler water temperature to fit system or condition of installation This method of piping is not typically required for baseboard heating
6. HECK LIST Pump Pressure Vacuum Inspect Chimney and Flue pipe Line Voltage Motor Amps Inspect and Clean Appliance Smoke Test Inspect Oil Line Size Leaks Draft Over fire ln Flue Inspect Electrical Connections CO or O Install New Filter Flue Gas Temperature Room Make up Air Proper Light Off Hot amp Cold Electrode setting Controls and Safety Devices Nozzle Size Angle Type Measure with Instruments and Record results on chart provided below Pump Flue Date Nozzle Pressure Smoke Draft CO or O Temperature 19 UTICA BOILERS OIL FIRED DIRECT EXHAUST CAST IRON BOILER innovative living
7. OURNIS AVEC LA CHAUDI RE SONT REMPLAC S ILS DOIVENT ETRE REMPLAC S PAR DES FILS DE MEME GROSSEUR ET DE MEME TYPE D ISOLANT OU L QUIVALENT 13 ELECTRICAL WIRING Thermostat Installation 1 Install thermostat on inside wall about four feet above floor Never install thermostat on outside wall Do not install thermostat where it will be affected by A Drafts Hot or cold pipes Sun light Lighting fixtures Television sets A fireplace or chimney oO oO Ug 4 Check thermostat operation by raising and lowering 5 thermostat as required to start and stop burner Instructions for final adjustment of thermostat are packaged with thermostat adjusting heating anticipator calibration ect SEQUENCE OF OPERATI ON Sequence of Operation Non Tankless 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 See limit literature for additional information Burner and circulator operation continues until thermostat stops call for heat Sequence of Operation Tankless 14 Thermostat will activate completing circuit to limit control Circulator motor starts and power is switched to limit If limit circuit is closed burner motor circuit is energized Burner motor starts prepurge and approximately 15 seconds after so
8. SW SERIES 2 OIL FIRED DIRECT EXHAUST CAST IRON BOILER INSTALLATION OPERATION amp MAINTENANCE MANUAL Zu we d CERTIFIED Tested For 75 psig ASME Working Pressure e Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 An 150 9001 2008 Certified Company web site www ecrinternational com P N 240009678 Rev B 02 2013 innovative living DIMENSIONS 21 13 16 B C A LENGTH OF FLUSH FRONT OF CASTING BOILER J ACKET TO CENTER LINE OF DIAMETER OF FLUE FLUE OUTLET OUTLET NO TABLE OF CONTENTS Blei MEI UU Tc 2 cias T 3 Installation 4 Connecting Supply And Return Piping ppp 5 Recommended Piping For Boilers Equipped With A Or 4 Tankless Heater ppp 9 Options Utilizing 3 4 Tapping pp 10 Oil Tank And RR E D ede ante ade 11 Electrical WIRING mn 12 Sequence Of Operation pp 14 91 15 Instructions To Obtain Proper Operation Of The Boiler Burner Unit pp 16 Preventive Maintenance 2s d e DE Olen RO DL REV tubers 17 Instructions For Opening And Closing Burner Swing DOOF ppp 17 Ratings and DEUDA 18 Service Check dii M cT 19 KEEP THI S MANUAL NEAR BOILER RETAI N FOR FUTURE REFERENCE IMPORTANT Read the following
9. e RECOMMENDED PIPING FOR BOILERS EQUIPPED WITH A P3 OR T4 TANKLESS HEATER 44 DANGER Burn scald hazard Water temperatures exceeding 1252 F will cause severe burns instantly or death by scalding An automatic mixing valve must be installed on the outlet of the domestic coil Installation must comply with the valve manufacture s recommendations and instructions Do not remove the bolts or limit at the time of installation Pipe in accordance with the installation manual Due to varying water conditions an adjustable flow restrictor must be installed in the cold water inlet of this coil Figure 7 Recommended Piping For Boilers Equipped With A P3 Or T4 Tankless Heater ADJUSTABLE PRESSURE GAUGE OPTIONAL FLOW RESTRICTOR WATTS N P3 OR EQUIV WATER SUPPLY CONTROL TEMPERED DOMESTIC WATER OPTIONS UTILIZING 3 4 TAPPING Figure 8 Optional Location For Air Vent SUPPLY AIR VENT ATTACHED 2 SUPPLY TO 3 4 TAPPING TAPPING RETURN Figure 9 Optional Location For Expansion Tank Non Diaphragm Type EXPANSION TANK SUPPLY 2 SUPPLY TAPPING TAPPING RETURN OIL TANK AND PIPING Install Oil tank and piping in accordance with the National Board of Fire Underwriters and in absence of such regulations in accordance with authority having jurisdiction Oil storage tank vent fill pipe and caps should be in accordance wit
10. g at trace point Check draft over fire and in vent normal readings will be positive 01 Over fire amp 02 In Vent W C Table page 17 is provided as guideline for initial start up Final adjustments MUST be made using combustion instruments as previously mentioned INSTRUCTIONS TO OBTAIN PROPER OPERATION OF THE BOILER BURNER UNIT Check Safety Control Circuit after burner adjustments have been made for satisfactory performance BECKETT SETTINGS Boiler Burner Air Pin No No Damp Pump Nozzle SW3065 AFII 100 140 PSI HLX 6 60 45B 51 4100 AFII 100 140 PSI HLX 6 85 45 51 5125 AFI 150 50 140PSI HLX 6 1 10 45B A HIGH LIMIT CONTROL remove cover and note temperature setting See figure 15 on page 15 With burner operating decrease this setting to minimum B PRIMARY CONTROL AND FLAME SENSOR To Check point When boiler water temperature exceeds this set point high limit switch will open shutting off power to oil burner and starting post purge cycle for approximately 2 minutes Return setting to desired high limit point Burner should restart Flame failure simulate by shutting off oil supply with hand valve while burner is on 15 seconds after flameout safety switch locks out ignition stops motor stops and oil valve closes To restart open oil supply valve and reset safety switch Ignition failure with burner off unplug electrical disconnect on burner harness Disconnect one wire from tra
11. h the authority having jurisdiction A In no case should vent pipe be smaller than 1 1 4 P S B Fill pipe should not be less than 2 I P S Suction line from tank to burner should be one continuous piece of tubing to prevent air entering line Suction line must be 3 8 O D copper tubing for runs of 50 feet or less and 1 2 O D for longer runs Oil return line same size as suction line must be used on any installation where bottom of tank is below fuel unit of burner Oil lines should be buried or otherwise protected from mechanical injury Flare fittings on all oil lines are recommended Compression fittings on suction line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle Figure 10 Typical I nstallation Single Pipe Oil System APPROVED FITTINGS 4 SWING JOINTS VENT PIPE REF TO NATION BOARD OF IRE UNDERWRITERS 2 RN lt f DIL GAUGE BOILER DIL BURNER oto d SHUT DFF VALVE DIL FILTER OIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM DAMAGE MINIMUM 378 IPS DR 3 8 O D COPPER TUBING Do not run overhead fuel lines from tank to oil burner Fuel pump connections and by pass should be made according to instructions attached to fuel pump If tank is more than 20 from the boiler a two stage fuel unit should be installed in place of single stage pump supplied as standard equipment with burner Make certain ro
12. icensed Gas Fitter INSTALLATION Improper installation adjustment alteration service or maintenance could result in death or serious injury Installation Installation shall conform to requirements of authority having jurisdiction or in the absence of such requirements NFPA 31 Installation Code for Oil Burning Equipment 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 final position before removing crate Provide level solid base as near to vent outlet as possible and centrally located with respect to heat distribution system as practical Allow 24 inches in front and top 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 permit replacement of another appliance such as water heater Fire hazard Do not install boiler on combustible flooring or carpeting Failure to follow these instructions could result in death or serious injury FOR INSTALLATI ON ON NON COMBUSTIBLE FLOORS ONLY The boiler must not be installed on carpeting or vinyl flooring Minimum clearances to combustible construction are Minimum clearances to combustible construction are TOP ER OIN 24 IN FLUE 21N
13. ing boiler discharge steam or hot water during operation 9 During heating cycle open valves A and B close valves Cand D Install discharge piping from safety relief valve Use 3 4 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 10 During heating cooling cycle open valves C and D close valves A and B A Maintain minimum clearance of one inch to hot water pipes In air handling units where they may be exposed to i refrigerated air circulation boiler piping system MUST be supplied with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle Figure 6 CIRCULATOR SUPPLY PIPING TO HEATING AND COOLING ELEMENT WATER CHILLER EXPANSION TANK RETURN PIPING FROM HEATING AND COOLING ELEMENT from floor or allowable safe point of discharg
14. instructions COMPLETELY before installing Safety Symbols amp Warnings The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels A DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury 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 Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids DO NOT obstruct air openings to the boiler room Modification substitution or elimination of factory equipped supplied or specified components may result in personal injury or loss of life TO THE OWNER Installation and service of this boiler must be performed by a qualified installer TO THE INSTALLER Leave all instructions with boiler for future reference 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 NOTI CE When this product is installed in the Commonwealth of Massachusetts installation must be performed by a Licensed Plumber or L
15. lenoid valve opens and ignition system is activated ignition will begin In event boiler water temperature exceeds high limit setting on boiler mounted limit control Power will be interrupted between limit control and ignition system Burner motor will continue to run in post purge mode for approximately 2 min or until water temperature drops below high limit setting Circulator will continue to operate under this condition until thermostat is satisfied When thermostat is satisfied power is interrupted to boiler mounted limit control and burner will run in post purge mode for 2 minutes OPERATING INSTRUCTIONS Venting system should be inspected at start of each heating season Check vent pipe from boiler to termination cap for signs of deterioration by rust or cracked silicone joints Repair if necessary Lever of safety relief valve shown in Figure 17 on page 18 on boiler should be operated periodically to make sure it is functioning properly Pressure relief valve should open before water pressure exceeds 30 psi reading on gauge If pressure is exceeded and pressure relief valve leaks water when boiler is operating at normal pressures immediately replace Corrosion can build up rapidly at valve seat preventing it functioning as safety device Start up and adjustment of oil burner See oil burner instructions for nozzle and electrode setting A Check oil burner nozzle to make certain it is tight in adapter Burne
16. nsformer and put wire nut on disconnected wires Restore power and run through start up procedure safety switch should lockout as flame failure Reconnect wires after this procedure is complete 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 16 PREVENTIVE MAINTENANCE Preventive Maintenance of oil fired boiler reduces op erating costs Boiler and vent pipe should be inspected for accumulation of soot or scale deposits periodically but at least once every year before start of each heating season When soot is present on section walls and flueways im proper combustion will result causing additional sooting and scaling until flueways are completely closed To remove soot and scale from flueways remove top jacket panel top clean out plate and open burner swing door Figure 14 Periodic Inspection and tightening of tankless heater cover plate bolts will reduce risk of leaks INSTRUCTIONS FOR OPENING AND CLOSING BURNER SWING DOOR Instructions for Opening Burner Swing Door 1 Turn off power to boiler 2 Allow boiler to cool down 3 Disconnect power cable at factory supplied burner electrical disconnect See Figure 15 4 Loosen screws on sides of lower front jacket panel See Figure 15 Pull bottom part of lower front panel forward Lift lower front panel u
17. p and off boiler See Figure 15 Close oil valve See Figures 10 and 11 Disconnect oil line from burner NOTICE Do not try to swing door with oil line attached B 9 Disconnect inlet air pipe from side of burner 10 Remove nut from swing door stud on right hand side of door 11 Swing open burner and door to left 12 Using flue brush brush soot and scale into combustion space where it can be removed through swing door opening NOTICE Use caution when vacuuming in the chamber area Damage to chamber could result Recommend to replace nozzle at start of each heating season Lubricate burner motor and circulator motor if required with few drops of good grade light motor oil Do not over oil Have competent service person service burner check controls and check electrodes for carbon or cracks in insulators Burners should be adjusted to produce conditions shown in Start up and Adjustment of Oil Burner procedure Instructions for Closing Burner Swing Door 1 Swing burner and door to right until insulation is slightly compressed and stud is exposed 2 Attach nut to stud and tighten it until built in stop contacts mounting door Replace oil line to burner Replace inlet air pipe Replace lower jacket panel and tighten screws Connect power cable at factory supplied burner electrical disconnect Turn on power to boiler 8 Bleed oil line qe S Figure 14 PLATE BURNER SWING DOOR
18. r mounting bolts should be tight B Check electrode setting as they may have been jarred out of position during transportation C Lubricate burner motor and circulator motor if required Some circulators are water lubricated and do not require oiling Set room thermostat to call for heat Open all oil line valves Turn service switch on Burner should start On one pipe fuel systems only vent pump as soon as burner starts Allow oil to run until all traces of air in the suction line disappear H Turn OFF burner and install pressure gauge in port on pump Start burner again and check oil pressure for 140 psi Adjust if necessary 15 Instruments only reliable method to determine air adjustments Improperly adjusted burner causes soot and high fuel bills because of incomplete combustion of fuel oil This in turn may require excessive boiler maintenance service costs Consult competent service mechanic to make proper adjustments with smoke tester CO indicator and draft gauge Bacharach or Dwyer test kits include these instruments 1 4 diameter slot is provided in inspection cover plate to take draft reading in combustion chamber 3 8 hole is provided in vent appliance adapter to take draft CO smoke and temperature readings Adjust air dial on oil burner to obtain trace of smoke Measure CO at this point and increase air setting until CO 1 1 5 lower than readin
19. tation and speed are same and pump is suitable for burner horsepower rating Oil line filter and shut off valve should be installed in suction line Shut off valves should be installed in both suction and return lines at burner for convenience in servicing burner Allow extra tubing at burner so burner may be removed from boiler for cleaning without disconnecting tubing See Figures 10 amp 11 AUL approved flexible oil line may be used Figure 11 Typical Installation Two Pipe Oil System of TT Tt it tT I APPROVED FITTINGS FILL PIPE SWING y JOINTS RETURN LINE REFER TO LOCAL SEN DIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM DAMAGE MINIMUM 1 2 IPS OR 1 2 O D COPPER TUBING ELECTRICAL WIRING Install electrical wiring in accordance with requirements of authority having jurisdiction or in the absence of such requirements NFPA 70 Electrical Code Separate electrical circuit should be run from entry box with fused disconnect switch in this circuit See wiring diagrams in Figures 12 amp 13 for suggested circuitry and field wiring see Normal Sequence of Operation in this manual Wiring for zone valve installations are furnished with zone valve packages Figure 12 Wiring Diagram For Oil Fired Boilers Less Tankless Heater And Beckett Burner LIMIT SENSOR BURNER CONTROL THERMOSTAT LIMITER CAPTEUR BROLEUR CUNTRALE 24 VOLT BY INSTALLER
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