SW SERIES 2 OIL FIRED DIRECT EXHAUST CAST IRON BOILER Model SW3065 SW4100 SW5125 INSTALLATION, OPERATION & MAINTENANCE MANUAL Tested For 75 psig ASME Working Pressure An ISO 9001-2008 Certified Company 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com P/N# 240009678, Rev.
DIMENSIONS A LENGTH OF FLUSH JACKET B FRONT OF CASTING TO CENTER LINE OF FLUE OUTLET DIAMETER OF FLUE OUTLET SW3065 17 7/8" 11 1/4" 4" SW4100 21 1/2" 12 5/8" 4" SW5125 25 1/8" 14 1/4" 4" BOILER NO.
TABLE OF CONTENTS Dimensions................................................................................................................................. 2 Safety Symbols .......................................................................................................................... 3 Installation ................................................................................................................................ 4 Connecting Supply And Return Piping ................................
INSTALLATION ! WARNING ! WARNING Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury. Fire hazard. Do not install boiler on combustible flooring or carpeting. Failure to follow these instructions 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.
CONNECTING SUPPLY AND RETURN PIPING Circulators in following illustrations are mounted on system supply side, mounting on system return side is also acceptable practice.
CONNECTING SUPPLY AND RETURN PIPING 1. Typical installation using circulators shown in Figure • Method used to protect systems using radiant panels and material they are encased in from high temperature supply water from boiler. See Figure 3. 1. 2. Typical installation using zone valves shown in Figure 2. • 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. 3.
CONNECTING SUPPLY AND RETURN PIPING Figure 4 Check local codes for maximum from floor or allowable safe point of discharge Figure 5 Check local codes for maximum from floor or allowable safe point of discharge 7
CONNECTING SUPPLY AND RETURN PIPING A. Chilled medium must be in parallel with the boiler. ! WARNING B. Use appropriate valves to prevent chilled medium from entering heating boiler. Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. 9. During heating cycle open valves A and B, close valves Install discharge piping from safety relief valve. C and D. • Use ¾” or larger pipe. 10.
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 limit at the time of installation. • Pipe in accordance with the installation manual.
OPTIONS UTILIZING 3/4" TAPPING Figure 8 - Optional Location For Air Vent Figure 9 - Optional Location For Expansion Tank (Non-Diaphragm Type) 10
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 with the authority having jurisdiction. A. In no case should vent pipe be smaller than 1-1/4" I.P.S. B. Fill pipe should not be less than 2" I.P.S. • Do not run overhead fuel lines from tank to oil burner.
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 & 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.
ELECTRICAL WIRING Figure 13 - Wiring Diagram For Oil Fired Boilers With Tankless Heater And Beckett Burner 13
ELECTRICAL WIRING Thermostat Installation 1. Install thermostat on inside wall about four feet above floor. 2. Never install thermostat on outside wall. 3. Do not install thermostat where it will be affected by: A. B. C. D. E. F. 4. Check thermostat operation by raising and lowering thermostat as required to start and stop burner. 5. Instructions for final adjustment of thermostat are packaged with thermostat (adjusting heating anticipator, calibration, ect.).
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.
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 No. Burner No. Air Damp Pin Pump Pressure Head Nozzle Furnished SW3065 AFII 100 3.25 3 140 PSI HLX 6 .60 45B SW4100 AFII 100 7.50 5 140 PSI HLX 6 .85 45B SW5125 AFII 150 5.00 8 140 PSI HLX 6 1.10 45B A. HIGH LIMIT CONTROL: remove cover and note temperature setting. See figure 15 on page 15.
PREVENTIVE MAINTENANCE Preventive Maintenance of oil fired boiler reduces operating 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, improper combustion will result, causing additional sooting and scaling until flueways are completely closed.
RATINGS AND DATA RATINGS AND DATA BOILER MODEL NUMBER OIL BURNER INPUT(1) HEATING CAPACITY AHRI NET RATINGS (2) A.F.U.E. G.P.H. MBH MBH* WATER MBH RATING SW3065 .65 91 78 68 85.0 SW4100 1.00 140 120 104 85.0 SW5125 1.25 175 150 130 85.0 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.
SERVICE CHECK 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/In Flue Inspect Electrical Connections CO2 or O2 Install New Filter Flue Gas Temperature Room Make-up Air Proper Light-Off (Hot & Cold) Electrode setting Controls and Safety Devices Nozzle-Size, Angle, Type Measure with Instruments and Record results on chart provided below.
SW OIL FIRED DIRECT EXHAUST CAST IRON BOILER
