UTICA BOILERS BC3095 Gebrauchsanweisung

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

BC Series II

OIL-FIRED CAST IRON BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certied Company

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

Models

BC3095

BC4100

BC4115

Maximum Allowable

Working Pressure 30

psi.

IMPORTANT: Read the following instructions

COMPLETELY before installing!!

SAFETY INFORMATION

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

NOTICE

Used to address practices not related to personal

injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not

avoided, WILL result in death or serious injury.

Safety Symbols & Warnings

The following dened symbols are used throughout this

manual to notify the reader of potential hazards of varying

risk levels.

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

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.

WARNING

All boiler and venting installations shall be done

by qualied agency and in accordance with

appropriate Manufacturer’s Installation, Operation

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.

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.

DIMENSIONS

Table 1 DIMENSIONS

Boiler No.

Length

of Flush

Jacket

Front of Jacket

to Center Line

of Flue Outlet

Flue

Outlet

Diameter

Tankless

Coil to Back

of Jacket

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

BC3 19" 9 ¾" 6" 8⅞

BC4 23" 11¾" 6" 12¾

Figure 1 - Dimensions

Table 2 RATINGS & DATA

Boiler Model

Number(1)

AHRI Oil Burner

Input(1) Heating

Capacity

MBH(4)

AHRI Net

Ratings(2)(4) A.F.U.E.

Rating

Min. Natural Draft

Chimney Size

G.P.H. MBH(4) Water MBH Round Square

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

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.

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.

Table 3 TANK-LESS WATER HEATER CAPACITIES

Boiler

Model

Number

Input

Rate

G.P.H.

Tankless

Heater

Number

Tankless Heater

Capacity Intermittent

Draw G.P.M.

Boiler

Water

Content

(Gallons)

BC3095 0.95 L-24 3.25 6.7

BC4100 1.00 L-24 3.25 8.2

BC4115 1.15 L-24 4.00 8.2

RATINGS, DATA, AND DIMENSIONS

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.

NOTE: Clearance for access should exceed fire protection

clearance.

• 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.

INSTALLATION PROCEDURE

WARNING

Improper installation, adjustment, alteration, service

or maintenance could result in death or serious

injury.

DANGER

Fire hazard. Do not install boiler on combustible

ooring or carpeting. Failure to follow these

instructions WILL result in death or serious injury.

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.

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

interior areas having adequate inltration from the

outside. See Figure 2.

Table 5 COMBUSTION AIR REQUIREMENTS

(Minimum Opening Requirement)

BTU/Hr

Input

(Mbh)

Unconned Area* Conned Area**

Outside Inside Outside Combustion Air

Combustion Air 1 Sq.

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)

VENTS

CHIMNEY

L TYPE VENT PIPE

VENT PIPE

BASEBOARD

12"

VENTILATION AND COMBUSTION AIR

Figure 2 Combustion and Room Air From Inside

Buildings

WARNING

Asphyxiation, re hazard. Do not obstruct air

openings to combustion area. Follow instructions

below, to maintain adequate combustion air.

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.

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

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.

A. When directly communicating with the outdoors,

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. See

Figure 3.

B. When communicating with the outdoors by means

of vertical ducts, each opening shall have a mini-

mum free area 1 square inch per 4,000 BTU per

hour of total input rating of all appliances in the

enclosed space. See Figure 4.

C. If horizontal ducts are used, each opening shall

have a minimum free area 1 square inch per 2,000

BTU per hour total input rating of all appliances in

the enclosed space. See Figure 5.

D. When ducts are used, they shall be of the same

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

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.

VENTILATION AND COMBUSTION AIR

Figure 3 Boiler Installed In Conned Space - Air

From Outdoors

Figure 4 Vertical Ducts

Figure 5 Horizontal Ducts

CONNECTING SUPPLY AND RETURN PIPING

Circulators in the following illustrations are mounted on

system supply side, mounting on system return side is also

acceptable practice.

Connect supply and return piping as suggested in

Figure 6. When the boiler is used in connection with

refrigerated systems:

A. Chilled medium MUST BE IN PARALLEL with

boiler.

B. Use appropriate valves to prevent chilled medium

from entering heating boiler.

During the heating cycle open valves Aand B, close

valves Cand D.

Figure 6 Boiler Used In Connection With Refrigerated System

Figure 7 Bypass Piping Typically Used With Baseboard Heating

During heating cooling cycle open valves Cand D, close

valves Aand B.

A. Maintain a minimum clearance of one (1") inch to

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

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

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

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.

A. This method is used to protect systems using

radiant panels and the material they are encased

in from high temperature supply water from the

boiler. See Figure 7, page 7.

CONNECTING SUPPLY AND RETURN PIPING

B. This method is 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 8.

C. This method is used to protect boilers from

condensate forming as well as protecting the

heating system from high water temperature. See

Figure 9, page 9.

Note: When using bypass piping, adjust valves Aand

Buntil desired system temperature is obtained.

Bypass loop piping must be same size piping for supply

and return.

Typical installation using circulators is shown in

Figure 10, page 9.

10.

Typical installation using zone valves is shown in

Figure 11, page 10.

11.

See Figure 12, page 10 for typical piping for domestic

hot water heater.

Figure 8 Bypass Piping Option For Converted Large Volume Systems

CONNECTING SUPPLY AND RETURN PIPING

Figure 9 Bypass Piping Option Used to Protect From Converted Systems With High Water

Temperature

Figure 10 Typical Installation With Circulators

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