UTICA BOILERS SW3 Instruction manual

SW
OIL FIRED DIRECT EXHAUST
CAST IRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
P/N# 27515401, Rev. A [03/2011]
An ISO 9001-2008 Certified Company
Utica Boilers
2210 Dwyer Avenue, Utica NY 13504-4729
Phone: [phone] • Fax: [phone]
e-mail: [email protected]
web site: www.ecrinternational.com

2
Tested For 75 psig.
ASME Working Pressure
tABLE OF CONtENtS
Safety Symbols........................................................................................................................... 3
Installation ................................................................................................................................ 4
Connecting Supply And Return Piping............................................................................................. 5
Recommended Piping For Boilers Equipped With A P3 Or T4 Tankless Heater........................................ 9
Options Utilizing 3/4" Tapping ......................................................................................................10
Oil Tank And Piping.....................................................................................................................11
Electrical Wiring .........................................................................................................................12
Thermostat Installation ...............................................................................................................13
Normal Sequence Of Operation.....................................................................................................14
Operating Instructions.................................................................................................................14
Instructions To Obtain Proper Operation Of The Boiler-Burner Unit ....................................................15
Preventive Maintenance...............................................................................................................16
Instructions For Opening And Closing Burner Swing Door.................................................................16
Service Check List ......................................................................................................................17
Sw Series Replacement Parts .......................................................................................................18
Dimensions................................................................................................................................26
Read All Instructions Before Installing.

3
Safety Symbols
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
SAFEty SymBOLS
!
WARNING
Keep boiler area clear and free from• combustible materials, gasoline and other
ammable vapors and liquids.
DO NOT obstruct air openings to boiler
• room.
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.
!
WARNING
Boiler and venting installations should be done
only by a qualied expert and in accordance
with the appropriate Utica Boilers Installation,
Operation and Maintenance 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.
!
DANGER
Indicates a hazardous situation which, if
not avoided, WILL result in death or serious
injury.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, may result in minor or moderate
injury.
!
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.
NOTICE
To the owner: Installation and service of•
this boiler must be performed by a qualied
installer.
To the installer: Leave all instructions with
• the boiler for future reference.
When this product is installed in the
• Commonwealth of Massachusetts installation
must be performed by a Licensed Plumber
or Licensed Gas Fitter.

4
Installation
Installation must conform to American Society of
Mechanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
In Canada installations must be in accordance with CSA
B139. In absence of such codes, installation must conform
to the requirements of authority having jurisdiction. Such
applicable requirements take precedence over general
instructions of this manual.
Locate boiler in front of nal 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.
Installation on Combustible Floors
Boiler shall not be installed directly on carpeting, tile or
other combustible material other than wood ooring. Boiler
must not be installed on carpeting or vinyl ooring.
INStALLAtION
!
WARNING
Improper installation, adjustment, alteration,
service or maintenance could result in
personal injury or loss of life.
Minimum clearances to combustible construction are:
TOP..............................................0.0 IN.
FRONT ..................................... 24.0 IN.*
FLUE CONNECTOR ..........................2.0 IN.
REAR ............................................0.0 IN.
LEFT SIDE .....................................0.0 IN.
RIGHT SIDE...................................0.0 IN.
* "FOR ALCOVE INSTALLATION"
Recommended clearance for service access should exceed
re protection clearance.
TOP ...............................................24 IN.
FRONT ...........................................24 IN.
FLUE CONNECTOR .............................9 IN.
REAR ...............................................6 IN.
LEFT SIDE ......................................10 IN.
RIGHT SIDE......................................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 led immediately against
carrier by consignee. Move boiler to permanent position by
sliding or walking.

5
CONNECtINg SuppLy ANd REtuRN pIpINg
NOTICE
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
Figure 2 - Typical Installation Using Zone Valves

6
Typical installation using circulators shown in 1. Figure
1 .
Typical installation using zone valves shown in 2. Figure
2 .
Hot water boilers installed above radiation level must 3.
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 4.
multiple zoned circulators, each circulator must be
supplied with ow control valve to prevent gravity
circulation.
Reduced pressure back ow preventer must be • present under provisions required by Environmental
Protection Agency, (EPA).
Bypass piping is an option which gives ability to adjust 5.
supply boiler water temperature to t system or
condition of installation. This method of piping is not
typically required for baseboard heating systems.
CONNECtINg SuppLy ANd REtuRN pIpINg
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 6.
desired system temperature is obtained.
Bypass loop piping must be same size piping for supply 7.
and return.
WITHIN 6"
Figure 3

7
CONNECtINg SuppLy ANd REtuRN pIpINg
Figure 4
Figure 5

8
CONNECtINg SuppLy ANd REtuRN pIpINg
Connect supply and return piping as suggested in 8. Figure 6
, when boiler is used in connection with
refrigerated systems:
Chilled medium must be in parallel with the boiler.A.
Use appropriate valves to prevent chilled mediumB. from entering heating boiler.
During heating cycle open valves A and B, close valves 9.
C and D.
During heating cooling cycle open valves C and D, close 10.
valves A and B.
Maintain minimum clearance of one inch to hotA. water pipes.
In air handling units where they may be exposed to
refrigerated air circulation, boiler piping system MUST be
supplied with ow control valves or other automatic means
to prevent gravity circulation of boiler water during cooling
cycle.
For further piping information refer to the I=B=R 11.
installation and piping guide.
Figure 6

9
RECOmmENdEd pIpINg FOR BOILERS EquIppEd WIth A p3 OR t4 tANkLESS hEAtER
!
DANGER
Burn, scald hazard. Water temperatures
exceeding 125º 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 aquastat at the time of
• installation.
Pipe in accordance with the installation manual.
•
Due to varying water conditions, an adjustable ow • 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

10
OptIONS utILIzINg 3/4" tAppINg
Figure 8 - Optional Location For Air Vent
Figure 9 - Optional Location For Expansion Tank (Non-Diaphragm Type)

11
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, ll pipe and caps should be in
accordance with the authority having jurisdiction.
In no case should vent pipe be smaller than 1-1/4"A. I.P.S.
Fill pipe should not be less than 2" I.P.S.B.
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 ttings on all oil lines are recommended. •
Compression ttings on suction line often allow air to •
be drawn into fuel pump, making it difcult to maintain
oil pressure at nozzle.
OIL tANk ANd pIpINg
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 rotation and speed are same and pump is
suitable for burner horsepower rating.
Oil line lter 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 & 11 ).
A UL approved exible oil line may be used.•
Figure 10 - Typical Installation Single Pipe Oil
System
Figure 11 - Typical Installation Two Pipe Oil
System

12
Electrical wiring must conform with National Electrical
Code ANSI/NFPA No. 70 in United States and CSA C22.1
Canadian Electrical Code in Canada and/or the local
authority having jurisdiction.
Separate electrical circuit should be run from entry•
box with fused disconnect switch in this circuit.
See wiring diagrams in• Figures 12 & 13 , for
suggested circuitry and eld wiring see Normal
Sequence of Operation in this manual.
Wiring for zone valve installations are furnished with• zone valve packages.
Wiring Code
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
* Not all components listed are used in all control
systems.
Component Coding
TH-1 ermostat (millivolt)
TH-2 Thermostat (24 Volt)
TH-3 Thermostat (Line Voltage)
TR-1 Transformer (120V/24V 40VA)
TR-2 Transformer (120V/24V 50VA)
LGV 24 Volt Gas Valve
PS Pressure Switch
MR-PS Manual Reset Pressure Sw.
Control Terminal
1K Relay Coil
1K1 Relay Contacts
1K2 Relay Contacts
LS Limit Switch
MS Manual Switch
CIR Circulator
ECO Energy Cut-Off
PSC Pilot Safety Coil
Wire Connection
LWCO Low Water Cut Off
EWF Electric Water Feeder
PG Power Generator
ELECtRICAL WIRINg
Figure 12 - Wiring Diagram For Oil Fired Boilers Less Tankless Heater

13
Install thermostat on inside wall about four feet above 1.
oor.
Never install thermostat on outside wall. 2.
Do not install thermostat where it will be affected by: 3.
DraftsA.
Hot or cold pipesB.
Sun lightC.
Lighting xturesD.
Television setsE.
A replace or chimneyF.
thERmOStAt INStALLAtION
ELECtRICAL WIRINg
Check thermostat operation by raising and lowering 4.
thermostat as required to start and stop burner.
Instructions for nal adjustment of thermostat 5.
are packaged with thermostat ( adjusting heating
anticipator, calibration, ect.).
Figure 13 - Wiring Diagram For Oil Fired Boilers With A Circulator Zoned System And A Tankless
Heater

14
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 pressure relief valve, shown in Figure 14, on• page 15, on boiler should be operated periodically to
make sure it is functioning properly. Pressure relief
valve should open before water pressure exceeds 30 lb.
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.
!
WARNING
Water will be boiling hot.
Start-up and adjustment of oil burner (See oil burner
instructions for nozzle and electrode setting).
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 and circulator motor ifC. required. Some circulators are water lubricated and
do not require oiling.
Set room thermostat to call for heat.D. Open all oil line valves.E. Turn service switch on. Burner should start.F. On one pipe fuel systems only, vent pump as soonG. as burner starts. Allow oil to run until all traces of
air in the suction line disappear.
Thermostat will activate, completing circuit to aquastat.
•
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 solenoid valve opens and ignition system
is activated, ignition will begin.
In event boiler water temperature exceeds high limit
• setting on boiler mounted aquastat; Power will be
interrupted between aquastat 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
satised.
NORmAL SEquENCE OF OpERAtION
OpERAtINg INStRuCtIONS
When thermostat is satised power is interrupted to • boiler mounted aquastat and burner will run in post
purge mode for 2 minutes.
Turn “OFF” burner and install pressure gauge in
H. port on pump.
Start burner again and check oil pressure for 140I. lbs. Adjust if necessary.
!
CAUTION
Do not set re visually.
Instruments are only reliable method to determine proper
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, CO2indicator 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, CO2, smoke, and temperature readings.
Adjust air dial on oil burner to obtain trace of smoke.• Measure CO2at this point and increase air setting until
CO2= 1-1.5% lower than reading at trace point.
Check draft over re and in vent, normal readings will
•
be positive (+.01 Over-re & +.02 In Vent) W.C.

15
Table below 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
REILLO SETTINGS
Boiler
No. Burner No. Air Damp Turb. Setting Pump Pressure Head Nozzle Furnished
SW3 BF3 4.00 2 150 PSI 6 SLOT .60 80 W
SW4 BF5 4.25 3 150 PSI 9 SLOT .85 80 W
SW5 BF5 5.50 4 150 PSI 9 SLOT 1.10 60 B
BECKETT SETTINGS
Boiler
No. Burner No. Air Damp Pin Pump Pressure Head Nozzle Furnished
SW3 AFII 100 3.25 3 140 PSI HLX 6 .60 45B
SW4 AFII 100 7.50 5 140 PSI HLX 6 .85 45B
SW5 AF 11 150 5.00 8 140 PSI HLX 6 1.10 45B
!
WARNING
Use only number 2 fuel oil.•
Do not use gasoline, crankcase drainings or• any oil containing gasoline.
Do not attempt to start the burner when•
excess oil has accumulated, when the unit
is full of vapor or when the combustion
chamber is very hot.
Check Safety Control Circuit after burner adjustments
have been made for satisfactory performance.
HIGH LIMIT CONTROL:A. remove cover and note
temperature setting. See gure 15 on page 15. With
burner operating, decrease this setting to minimum
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.
PRIMARY CONTROL AND FLAME SENSOR:B.
To Check:
Flame failure - simulate by shutting off oil supply• with hand valve while burner is on. 15 seconds after
ameout, 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 transformer and put wire nut on disconnected
wires . Restore power and run through start-up
procedure, safety switch should lockout as ame
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
Instructions for Opening Burner Swing Door
Turn off power to boiler. 1.
Allow boiler to cool down. 2.
Disconnect power cable at factory supplied burner 3.
electrical disconnect. See Figure 15 .
Loosen screws on sides of lower front jacket panel. See 4.
Figure 15 .
Pull bottom part of lower front panel forward. 5.
Lift lower front panel up and off boiler. See 6. Figure 15 .
Close oil valve. See 7. Figures 10, and 11 .
Disconnect oil line from burner. 8.
NOTICE
Do not try to swing door with oil line attached
Disconnect inlet air pipe from side of burner. 9.
Remove nut from swing door stud on right hand side of 10.
door.
Swing open burner and door to left. 11.
Using ue brush, brush soot and scale into combustion 12.
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
Swing burner and door to right until insulation is 1.
slightly compressed and stud is exposed.
Attach nut to stud and tighten it until built in stop 2.
contacts mounting door.
Replace oil line to burner. 3.
pREvENtIvE mAINtENANCE
Preventive Maintenance of oil red 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 ueways, im-
proper combustion will result, causing additional sooting
and scaling until ueways are completely closed. To remove
soot and scale from ueways, remove top jacket panel, top
clean-out plate, and open burner swing door. ( Figure 14 ).
INStRuCtIONS FOR OpENINg ANd CLOSINg BuRNER SWINg dOOR
Periodic Inspection and tightening of tankless heater/
cover plate bolts will reduce risk of leaks. See Figure 17 .
Replace inlet air pipe.
4.
Replace lower jacket panel, and tighten screws. 5.
Connect power cable at factory supplied burner 6.
electrical disconnect.
Turn on power to boiler. 7.
Bleed oil line. 8.
Figure 14
Figure 15

17
Inspect Chimney and Flue pipe
Inspect and Clean Appliance
Inspect Oil Line - Size/Leaks
Inspect Electrical Connections
Install New Filter
Room Make-up Air
Electrode setting
Nozzle-Size, Angle, Type
Pump Pressure/Vacuum
Line Voltage/Motor Amps
Smoke Test
Draft Over-re/In Flue
CO2or O2
Flue Gas Temperature
Proper Light-Off (Hot & Cold)
Controls and Safety Devices
Measure with Instruments and Record results on chart provided below.
Pump Flue
Date Nozzle Pressure Smoke Dra CO2or O2Temperature
Size Angle Type PSI NO. O.F. INF oF
SERvICE ChECk LISt

18
SW SERIES REpLACEmENt pARtS
ITEM # PART # DESCRIPTION QTY
110051701 REAR SECTION 1
2 100-1-8.01 #60 PUSH NIPPLE 3 Section 2 4 Section 3
5 Section 4
3 10051101 CENTER SECTION
3 Section 1
4 Section 2
5 Section 3
410051201 FRONT SECT. CASTOVER 1
10051301 FRONT SECT. TANKLESS COIL 1
5HW02510 TIE ROD 1/2X10.5/8 (3 SEC) 2
HW02511 TIE ROD 1/2X14.1/4 (4 SEC) 2
6 5611508 KIT - TARGET WALL & INSULATION BLANKET 1
7 N/A N/A N/A
8HW-025.01 TIE ROD 1/2X12.1/2 (3 SEC) 1
HW-025.01 TIE ROD 1/2X12.1/2 (4 SEC) 1
9 100-1-5.01 #22 PUSH NIPPLE
3 Section 2
4 Section 3
5 Section 4
10 MS-006.00 ROPE MED DENSITY 3 Section 13'
4 Section 19.5'
5 Section 26'
11 HW-008.03 WASHER 1/2 ID FLAT 3
12 HW-003.05 NUT 1/2-13 HEX HEAD 3
FULLY ASSEMBLED HEAT EXCHANGERS
PART # DESCRIPTION
10023701 3 SECT. WITH
TANKLESS COIL
10023702 4 SECT. WITH
TANKLESS COIL
10023703 5 SECT. WITH
TANKLESS COIL
10023601 3 SEC. WITH
CAST OVER
10023602 4 SEC. WITH
CAST OVER
10023603 5 SEC. WITH
CAST OVER
Figure 16 - Heat Exchanger

19
SW SERIES REpLACEmENt pARtS
ITEM # PART # DESCRIPTION QTY
1 GA-001.00 GAUGE THERALTIMETER, WATER 1
22551401 GASKET - SILICON/DURO 70 1
3 37519501 HARNESS CIRCULATOR 1
4 HW08001 BOLT 5/16" X 3/4" 6
51010001 CONTROL L8148A (FOR BOILERS WITHOUT A TANKLESS COIL) 1
AQ-010.00 CONTROL L8124A (FOR BOILERS WITH A TANKLESS COIL) 1
6 AQ-020.01 WELL 1
7 28512201 HARNESS, AQUASTAT 1
828512301 HARNESS, BURNER (BECKETT) 1
1263011 HARNESS, BURNER (RIELLO) 1
95612001 TANKLESS COIL KIT P3 (FOR 3 SECTION BOILERS) 1
5612002 TANKLESS COIL KIT T4 (FOR 4 & 5 SECTION BOILERS) 1
10 27511401 TANKLESS - COVER KIT 1
11 PF-002.04 PIPE FIT ELBOW 3/4" NPT 1
12 PF-005.11 PIPE FIT - NPL 3/4" X 4" NPT 1
13 VR-001.01 RELIEF VALVE 30# 1
Figure 17 - COIL

20
SW SERIES REpLACEmENt pARtS
ITEM # PART # DESCRIPTION QTY
1 2552901 MOUNTING DOOR INSULATION & PLUG 1
2 HW-005.01 SCREW 1/4-20X1/2 SELF TAPPING 2
3 10011701 OBSERVATION DOOR 1
425511101 OBSERVATION DOOR GASKET
1
5 HW06801 1/4X1.3/4 DRIVE LOCK PIN 2
6 10011501 SWING DOOR 1
7 HW06701 5/16X18X2.3/8 STUD 1
82553301 INSULATION-SWING DOOR (FOR BOILERS WITH RIELLO BURNERS ONLY)
1
2553303 INSULATION-SWING DOOR (FOR BOILERS WITH BECKET BURNERS ONLY) 1
9 10011301 MOUNTING DOOR 1
Figure 18 - Swing Door And Mounting Door Components