UTICA BOILERS BC3D Instruction manual

P/N 2761101, Rev. A [02/2011]
BC Series
OIL-FIRED CAST IRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Utica Boilers
2210 Dwyer Avenue, Utica NY 13504-4729
Phone: [phone] • Fax: [phone]
e-mail: [e-mail]
web site: www.ecrinternational.com
An ISO 9001-2008 Certified Company

2
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SAFETY SYMBOLS
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
TABLE OF CONTENTS
H
Tested For 15 psi.
ASME
Working Pressure
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 ...........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
!
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or serious
injury.
NOTICE
Indicates information which should be
followed to ensure proper installation and
operation.
!
CAUTION
Indicates a hazardous situation which, if not
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 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.
4. TO THE OWNER - Installation
and service of this boiler must be
performed by a qualied installer.
5. TO THE INSTALLER - Leave
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.
!
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.
SAFETY INFORMATION

3
Boiler Model
Number(1)
I=B=R Oil Burner
Input(2) Heating
Capacity
MBH(4)
I=B=R Net
Ratings(3)(5) A.F.U.E.
Rating
Min. Natural Draft
Chimney Size Pump Pressure
PSI Nozzle Furnished 140PSIG(5)
G.P.H. MBH(4) Water MBH Round Square
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% CO2.
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.
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.)
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" 6.0" 8⅞
BC4 23" 11¾" 6.0" 12¾
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
BC4D 1.00 L-24 3.25 8.2
BC4 1.40 L-24 4.00 8.2
RATINGS, DATA, AND DIMENSIONS

4
The boiler shall be installed such that the oil ignition sys-
tem components are protected from water (dripping, spray-
ing, rain etc.) during appliance operation and service.
FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY
- The boiler must not be installed on carpeting or vinyl
ooring. Minimum clearances to combustible construction
are:
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.
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
Boilermaynot beinstalledoncombustible
ooring.
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 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.
!
WARNING
Improper installation, adjustment,
alteration, service or maintenance can
cause injury or property damage.
INSTALLATION PROCEDURE
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.

5
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)
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.
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 meansB. 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. (Figure #5)
COMBUSTION AIR REQUIREMENTS
(Minimum Opening Requirement)
BTU/Hr
Input
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)
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)
VENTS
CHIMNEY
OR
L TYPE VENT PIPE
VENT PIPE
BASEBOARD
12"
12"
!
WARNING
Air openings to combustion area must not be obstructed. By following the instructions below,
adequate combustion air can be maintained.
Figure #3
VENTILATION AND COMBUSTION AIR

6
If horizontal ducts are used, each opening shallC. 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 sameD. 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
VENTILATION AND COMBUSTION AIR

7
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.
Connect supply and return piping as suggested
1.
in Figure # 5, below. When the boiler is used in
connection with refrigerated systems:
Chilled mediumA. MUST BE IN PARALLEL with
boiler.
Figure #5
Figure #6
Use appropriate valves to prevent chilled mediumB. from entering heating boiler.
During the heating cycle open valves 2. Aand B, close
valves Cand D.

8
During heating cooling cycle open valves 3. Cand D, close
valves Aand 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 usingA. radiant panels and the material they are encased
in from high temperature supply water from the
boiler. See gure 6 above.
CONNECTING SUPPLY AND RETURN PIPING
This method is used to protect boilers fromB. 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 fromC. condensate forming as well as protecting the
heating system from high water temperature. See
Figure #8.
Note: 7. When using bypass piping, adjust valves Aand
Buntil 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. Figure
#9.
Typical installation using zone valves is shown in 10.
Figure #10.
See 11. Figure #11 for typical piping for domestic hot
water heater.
For further piping information refer to the I=B=R 12.
installation and piping guide.
Figure #7

9
CONNECTING SUPPLY AND RETURN PIPING
Figure #8
Figure #9

10
CONNECTING SUPPLY AND RETURN PIPING
Figure #10
Figure #11

11
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
at a time, favoring the water heater.
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.
!
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.
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 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
MODEL NUMBER ROUND
INCHES SQUARE INCHES HEIGHT (FT)
MIN MAX MIN MAX MIN MAX
BC3 6 8 8x8 8x10 15 40
BC4 6 8 8x8 8x10 15 40
Figure #12
VENTING SYSTEM INSPECTION & INSTALLATION
OIL TANK AND PIPING

12
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.
TYPICAL INSTALLATION
SINGLE PIPE OIL SYSTEM
TYPICAL INSTALLATION
TWO PIPE OIL SYSTEM
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.
Thermostat should be installed on an inside wall about 1.
four feet above the oor.
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 xtures,
television, replaces, or chimneys.
Check thermostat operation by raising and lowering
4.
thermostat as required to start and stop the burner.
Instructions for the nal adjustment of the thermostat 5.
are packaged with the thermostat (adjusting heating
anticipator, calibration, etc.).
Figure #13 Figure #14
OIL TANK AND PIPING
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

13
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
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 By Installer
OIL TANK AND PIPING
Figure #15

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

15
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.
!
WARNING
Water will be boiling hot.
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.
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.
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, CO2indicator, and draft gauge.
NOTE: Bacharach or Dwyer test kits include
these instruments.
Check oil burner nozzle to make certain it is tight inA. adapter. Burner mounting bolts should be tight.
Check electrode setting, as they may have beenB. jarred out of position during transportation.
Lubricate burner motor if necessary.C.
Figure #17
NORMAL SEQUENCE OF OPERATION
OPERATING INSTRUCTIONS
!
WARNING
Water will be boiling hot.

16
Set room thermostat to call for heat, or jumpD. 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 soonG. 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 Boiler-
Burner 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, CO2, smoke
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 CO2 approximately one
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.
Boiler
Model
No. End Cone Static
Disc Air Band Settings Air Shutter Settings Nozzle Furnished
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
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 burner
adjustments have been made for satisfactory performance.
High limit control: remove cover and noteA. 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.
To Check:
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.
OPERATING INSTRUCTIONS

17
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.
!
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 three (3) 1/2" nuts from burner ange. 3.
Close oil valve. See 4. Figures #13 and #14.
Disconnect oil line from burner. 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
Reconnect oil line. 1.
Open oil valve. See 2. Figures #13 and #14.
Install and tighten three (3) 1/2" nuts on the burner 3.
ange.
Turn on power to boiler. 4.

18
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 ]
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-Overre/In Flue [ * ]
CO2or O2 [ * ]
Flue Gas Temperature [ * ]
* Measure with instruments and record results below.
SERVICE CHECKLIST

19
JACKET AND FLUE COLLECTOR ASSEMBLY
REPLACEMENT PARTS
Item
Number Part Number Description QTY
1
2162801 Pnl Jkt Wrapper Assy. BC 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

20
REPLACEMENT PARTS
Item
Number Part Number Description QTY
1
1330002 Nut 1/4-20 Hex Stl ZP 2
2 HW-008.01 Wash - 5/16 Flat Stl ZP 4
3
HW-011.02 Tie Rod 1/4-20x13x3 IH WH BC3 2
HW-011.04 Tie Rod 1/4-20x17x3 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 ASSEMBLY