ECR Utica Keystone UH3KWC0.80 Installation, Operation & Maintenance Manual Download

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OIL-FIRED CAST IRON

HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Model

UH3KWC0.80(T)
UH4KWC1.00(T)
UH4KWC1.25(T)
UH5KWC1.55(T)

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 325 5479

www.ecrinternational.com

PN 240013023 REV. B [12/31/2020]

Summary of Contents for Utica Keystone UH3KWC0.80

Page 1: ...STALLATION OPERATION MAINTENANCE MANUAL Model UH3KWC0 80 T UH4KWC1 00 T UH4KWC1 25 T UH5KWC1 55 T Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com PN 240013023 REV B 12 31 2020 ...

Page 2: ...se low pressure oil fired hot water boilers are constructed and hydrostatically tested for maximum working pressure of 50 psig pounds per square inch in accordance with the latest revision of the A S M E American Society of Mechanical Engineers Boiler and Pressure Vessel Code Section IV Standards for heating boilers Heating Capacity indicates amount of heat available after subtracting losses up th...

Page 3: ... 132 8 x8 x15 86 0 17 3 4 6 9 5 8 UH5KWC1 55 T 5 1 55 217 189 164 8 x8 x15 86 0 21 6 11 1 2 MBH 1 000 Btu Per Hour BTU British Thermal Unit Heating capacity based on 13 1 CO2 with 0 02 W C draft over fire and 1 smoke or less Testing was done in accordance with D O E Department Of Energy test procedure GPH Gallons Per Hour Of Oil At 140 000 Btu Per Gallon A F U E Annual fuel utilization efficiency ...

Page 4: ...anent injury Children elderly and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never leave them unattended in bathtub or shower Never allow small children to use a hot water tap or draw their own bath If anyone using hot water in the building fits the above description or if state laws or local codes require certain water temperatures at hot water...

Page 5: ...g the boiler Boiler manufacturer recommends initial fill pressure of 10 12 psig For higher fill pressures expansion tank s air charge will need to be increased to match fill pressure Consult manufacturer s guidelines for sizing and selection 13 Purging heating system of air and gases when first placing boiler into service is critical for proper circulation and quiet performance Once air and gases ...

Page 6: ...such attention Boilers must be installed at least 6 from combustible material on left side rear and above and at least 24 on right side and front Allow 24 accessibility clearance above for servicing 5 Fresh air for combustion must be available at front of the boiler Fresh air for ventilation must be available to front and rear of boiler Air passages must be free of obstructions at all times Ventil...

Page 7: ...N TANK AUTOMATIC FILL VALVE AND SHUTOFF RELIEF VALVE TO RADIATION FROM RADIATION CIRCULATING PUMP IN RETURN LINE OR AFTER THE EXPANSION TANK SHUT OFF VALVE OIL FILTER OIL LINES FOUNDATIONS TO OUTSIDE LINES TO OTHER APPLIANCES SERVICE LINE OVERCURRENT PROTECTED SAFETY SWITCH 2 FILL PIPE MIN 2 I D VENT PIPE ENTRANCE SWITCH OIL BURNER GENERAL PRINCIPAL REQUIREMENTS FOR A TYPICAL INSTALLATION within 6...

Page 8: ...with additional room s of sufficient volume so that combined volume of all spaces meets criteria for unconfined space Total input of all combustion equipment installed in combined space shall be considered in making this determination Each opening shall have minimum free area of one square inch per 1 000 Btu per hour of total input rating of all combustion equipment in confined space but not less ...

Page 9: ...osure 3 When communicating with outdoors through horizontal ducts each opening shall have minimum free area of one square inch per 2 000 Btu per hour of total input rating of all equipment in the enclosure 4 When ducts are used they shall be of same cross sectional area as free area of openings to which they connect Minimum dimension of rectangular air ducts shall be not less than three inches FRE...

Page 10: ...ler See figures 6a and 6b A Install safety relief valve with spindle in vertical position B Do not install shutoff valve between boiler and safety relief valve C Install discharge piping from safety relief valve Use 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...

Page 11: ...lly cause damage to boiler and venting system Minimum design return water temperature to prevent this condensation in boiler and venting is 120 F Boiler used in heating system where design water temperatures below 140 F are desired e g radiant floor heating a 3 way or 4 way mixing valve or suitable alternative e g Bypass Piping Arrangement as shown in Figure 7 is required to prevent low temperatur...

Page 12: ...OR MAY ALSO BE INSTALLED ON RETURN PIPING PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 SYSTEM PIPING Figure 8 System Piping Arrangement Zoning With Zone Valves PN 240013023 Rev B 12 31 2020 ...

Page 13: ...OR CAN ALSO BE INSTALLED ON RETURN PIPING PIPING ARRANGED FOR POWER PURGING AIR OUT OF SYSTEM PIPING REFER TO THIS MANUAL S SECTION ON FILLING THE SYSTEM WITH WATER OPTION 1 SYSTEM PIPING Figure 9 System Piping Arrangement Zoning With Circulators PN 240013023 Rev B 12 31 2020 ...

Page 14: ...NG PUMPS AWAY FROM EXPANSION TANK PER THIS MANUAL USE OPTION 2 IN FILLING THE SYSTEM WITH WATER THIS PIPING ARRANGEMENT CAN BE USED WITH ZONE VALVES OR ZONE CIRCULATORS Figure 10 System Piping Arrangement Alternate Near Boiler Piping SYSTEM PIPING PN 240013023 Rev B 12 31 2020 ...

Page 15: ...s also recommended as shown in figure below Flow restrictor may be required on tankless coil inlet piping so flow rates are matched to boiler heat input see table SYSTEM PIPING Tankless Coil Piping Arrangement Figure 11 Tankless Coil Piping Arrangement DANGER Scald Burn Hazard Temperatures exceeding 120 F will cause severe burns or death Use of water tempering device or mixing valve may be require...

Page 16: ... SIZES FIRING RATE gph CHIMNEY HEIGHT ft NOMINAL CHIMNEY ROUND LINER INSIDE SQUARE LINER INSIDE 0 60 1 30 15 8 x 8 6 6 x 6 1 35 1 80 15 8 x 8 7 6 x 6 For elevations above 2 000 feet above sea level add 3 feet to the chimney heights For oil fired boilers for connections to vents or chimneys vent installations shall be in accordance with applicable provisions of NFPA 31 Standard for the installation...

Page 17: ...r requires 6 diameter chimney connector pipe and use of manufacturer provided draft regulator Regulator when properly installed automatically controls the draft Install in horizontal section of pipe may also be installed in angled or vertical section of pipe Verify top of regulator is at the top and short pipe section which holds the vane is horizontal Even though locating draft regulator close to...

Page 18: ...r national state or local codes or regulations Connect 120 volt electrical supply to L1 and L2 terminals and two thermostat wires to T and T terminals on Hydrolevel limit control Run separate circuit from separate over current protection device in your electrical service entrance panel Minimum 15 ampere circuit Locate shutoff switch at boiler Turn off during any maintenance Solder and tape or secu...

Page 19: ...19 ELECTRICAL WIRING Figure 13 Boiler With Hydrolevel 3250 Control PN 240013023 Rev B 12 31 2020 ...

Page 20: ...r purging drain valve runs air free close isolation valve or zone valve Repeat this procedure for remaining heating zones D Once all zones are filled with water and purged of air close power purging drain valve and fill line shut off valve open main shutoff valve and adjust throttling valves and balancing valves as required OPTION 2 Close air vents on all radiation units Open valves to radiation u...

Page 21: ...air burner flame will be dark orange and formation of soot will occur in heating unit In buildings of conventional frame brick or stone construction that do not have utility rooms basement windows or stair doors air infiltration is normally adequate to provide enough air for combustion and for operation of barometric draft control Room used for supplying combustion air should be isolated from any ...

Page 22: ...le V1 Head Adjustments and Settings BECKETT AFG BOILER MODEL BURNER MODEL INPUT RATE gph INSERTION DEPTH DELAVAN OIL NOZZLE PUMP PRESSURE psi LOW FIRE BAFFLE BURNER HEAD HEAD SETTING AIR SHUTTER BAND STATIC PLATE UH3KWC0 80 T AFG50MBAS 0 80 2 1 4 0 65 70 W 150 YES L1 N A 10 1 3 3 8 UH4KWC1 00 T AFG50MDASN 1 00 2 1 2 0 85 60 A 140 NO V1 0 6 1 2 3 4 UH4KWC1 25 T AFG50MDASN 1 25 2 1 2 1 00 60 W 155 N...

Page 23: ...n chamber is very hot Adjust Thermostat Heat Anticipator or Thermostat Cycle Rate According to Instructions Included With The Thermostat Check Thermostat Operation Follow instructions included with your thermostat Locate thermostat five feet above the floor on inside wall Locate thermostat to sense average room temperature avoid the following THERMOSTAT LOCATIONS TO AVOID DEAD SPOTS HOT SPOTS COLD...

Page 24: ... will rise to normal height in tank if system has automatic fill valve otherwise manually refill system Diaphragm Expansion Tank Tank may become water logged Frequent automatic opening of safety relief valve indicates water logging High boiler temperature accompanied by unusually low radiation unit temperature and knocking noises indicates excess air in the tank To correct this condition replace d...

Page 25: ...When brushing take care not to damage target wall with flue brush See figure 16 6 Carefully vacuum soot accumulations from combustion chamber area be careful not to damage any refractory or blanket insulation To gain access to combustion chamber first double check the shut off valve on fuel oil line is closed and disconnect fuel oil line Remove oil burner from fire door Remove fire door 7 Inspect ...

Page 26: ...ner being used has damaged head replace head with same head recommended for use on this boiler 6 Inspect and clean oil burner blower wheel 7 Remove oil pump cover and clean replace pump screen Carefully reassemble ensuring pump cover makes proper seal 8 Securely fasten oil burner to fire door 9 Replace fuel filter if applicable 10 Reconnect electrical and fuel supplies 11 Fire burner checking for ...

Page 27: ... be in closed position Circulating pump not running Check over current protection Check relay operation Poor electrical contact Check all control terminals and wire joints Chimney flue is blocked Have the chimney professionally cleaned Circulator running when boiler water temperature is below low limit set point tankless coil boilers only Honeywell L7248L control confirm ELL parameter on L7248L co...

Page 28: ... decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not use...

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