UTICA BOILERS STARFIRE 3 WATER, Installation, Operation & Maintenance Manual

Page 1: ...RED CAST IRON BOILER INSTALLATION OPERATION MAINTENANCE MANUAL An ISO 9001 2008 Certified Company Utica Boilers 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ecrinternational com web site www ecrinternational com ...

Page 2: ...s to the boiler room Modification substitution or elimination of factory equipped supplied or specified components may result in property damage personal injury or the loss of life To the owner Installation and service of this boiler must be performed by a qualified installer To the installer Leave all instructions with the boiler for future reference When this product is installed in the Commonwe...

Page 3: ...2 000 ft ratings may be reduced at rate of 4 for every 1 000 ft above sea level BOILER SEC TION A LENGTH OF FLUSH JACKET B FRONT OF CASTING TO CENTER LINE OF FLUE OUTLET C DIA OF FLUE OUTLET 3 17 11 6 4 21 12 6 5 25 14 7 6 29 15 15 16 8 7 32 17 15 16 8 DIMENSIONAL DATA WARNING All installations of boilers and venting should be done only by qualified expert and in accordance with the appropriate Ma...

Page 4: ...3 4 I B R NET RATINGS WATER A F U E MINIMUM NATURAL DRAFT CHIMNEY SIZE PUMP PRES SURE G P H MBH MBH MBH RATING ROUND SQUARE PSI 365 65 91 79 68 7 86 0 6 8X8X15 140 3100 1 00 140 117 102 81 0 6 8X8X15 140 3125 1 25 175 144 125 80 0 7 8X8X15 140 4100 1 00 140 120 104 86 0 6 8X8X15 140 4125 1 25 175 149 130 82 5 7 8X8X15 140 5125 1 25 175 151 131 86 0 7 8X8X15 140 4150 1 50 210 175 152 81 0 7 8X8X15 ...

Page 5: ...m door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater Boiler must not be installed on carpeting or vinyl flooring Minimum clearances to combustible construction are TOP 24 IN FRONT 24 IN FLUE CONNECTOR 9 IN REAR 6 IN SIDES 6 IN NOTICE Clearance for access should exceed fire protection clearance REMOVE CRATE and plastic...

Page 6: ...e 4 91 000 19 100 23 46 140 000 28 140 35 70 175 000 35 175 44 88 210 000 42 210 53 106 245 000 49 245 61 122 280 000 56 280 61 140 Unconfined area A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all appliances installed in that space cubic feet of space height x width x length Confined area A space whose volume is less than 50 cubic feet per 1000 BTU per hour of all a...

Page 7: ...ea of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 inches VENTILATION COMBUSTION AIR 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 inch mesh If the free area through a design of louver or grill is known it should be us...

Page 8: ...8 VENTILATION COMBUSTION AIR Figure 2 Figure 3 Figure 4 ...

Page 9: ...ther automatic means to prevent gravity circulation of boiler water during cooling cycle Hot water boilers installed above radiation level must 4 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 5 multiple zoned circulators each circulator must be supplied with flow control valve to prevent gravity cir...

Page 10: ...in from high temperature supply water from boiler and protect boiler from condensation See figures 7 and 8 following page This method is used to protect boilers from C condensate forming as well as protecting heating system from high water temperature See figure 8 following page Note When using bypass piping adjust valves A and B until desired system temperature is obtained Bypass loop piping must...

Page 11: ...11 CONNECTING SUPPLY AND RETURN PIPING Figure 7 Mixing Valve Piping Figure 8 Primary Secondary Piping With Bypass ...

Page 12: ...irculators is shown in 8 Figure 9 Typical installation using zone valves is shown in 9 Figure 10 For further piping information refer to I B R 10 installation and piping guide Figure 9 Primary Secondary Piping With Bypass Figure 10 Primary Secondary Piping With Bypass ...

Page 13: ...tion Pipe in accordance with boiler s Installation Operation and Maintenance Manual Due to varying water conditions adjustable flow restrictor must be installed in cold water inlet of this coil DANGER Water temperatures exceeding 125 F will cause severe burns instantly or death by scalding CONNECTING SUPPLY AND RETURN PIPING Figure 11 Recommended Piping For Boilers Equipped With T3 Or T4 Tank Less...

Page 14: ...14 CONNECTING SUPPLY AND RETURN PIPING Figure 12 Optional Location For Air Vent OPTIONS UTILIZING 3 4 TAPPING Figure 13 Optional Location For Expansion Tank Non Diaphragm Type ...

Page 15: ...ft control while maintaining 02 inch W C negative draft in combustion chamber See chart Chimney or Vent Sizes for recommended chimney or vent sizes Inadequate draft will cause improper combustion resulting in dirty flue ways and high fuel bills CONNECT FLUE PIPE same size as boiler outlet to chimney sloping upward continuously toward chimney approximately per foot Bolt or screw joints together to ...

Page 16: ...allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle 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 boiler a two stage fuel unit should be installed in place of single stage pump supplied as standard equipment with burner Make ...

Page 17: ... Safety Standard for Electrical Installations See Wiring Addendum For Wiring Diagrams And Component Coding Install fused disconnect switch between boiler and meter at convenient location On call for heat thermostat will actuate completing circuit to aquastat In turn circulator and ignition systems are activated and ignition will begin In event boiler water temperature exceeds high limit setting on...

Page 18: ...e for 140 I lbs Adjust if necessary CAUTION Do not set fire 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 and in some instances house cleaning or redecorating A competent service mechanic shou...

Page 19: ...hanger section 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 19 Loosen screws on the sides of lower front jacket panel 4 See figure 19 Pull bottom part of lower front panel forward 5 Lift lower front panel up and off boiler See 6 figure 19 Close oil valve See 7 f...

Page 20: ...I 1 10 1 25 1 10 70B 4150 EZ 1 1 25 1 35 150 PSI 1 10 1 25 1 25 70B 5175 EZ 2 1 65 150 PSI 1 65 1 75 1 75 70B 5200 EZ 2 1 75 150 PSI 1 65 1 75 1 50 70B BECKETT SETTINGS BOILER NO BURNER NO AIR BAND AIR SHUT PUMP PRESS STATIC DISC END CONE NOZZLE FURNISHED 365 AFG 0 7 140 PSI 2 3 4 F0 60 80B 3100 AFG 1 5 140 PSI 3 3 8U F3 85 80B 4100 AFG 1 5 140 PSI 3 3 8U F3 85 80B 3125 AFII N A 6 140 PSI N A N A ...

Page 21: ...d is exposed Attach nut to the stud and tighten it until the built in 2 stop contacts the mounting door Replace oil line to burner 3 Replace lower jacket panel and tighten screws 4 Connect power cable at factory supplied burner 5 electrical disconnect Turn on power to boiler 6 Bleed oil line 7 OPERATING INSTRUCTIONS Figure 19 ...

Page 22: ...le Type Pump Pressure Vacuum Line Voltage Motor Amps Smoke Test Draft Over fire In Flue CO2 or O2 Flue Gas Temperature Proper Light Off Hot Cold Controls and Safety Devices Service Record Chart Date Nozzle Pump Pressure psi Smoke Draft CO2 or O2 Flue Temperature F Size Angle Type O F NF SERVICE CHECK LIST AND RECORD CHART Measure with Instruments and Record results on chart provided below ...

Page 23: ... 6 SEC HW 025 05 TIE ROD X 9 3 SEC HW 025 09 TIE ROD X 23 7 SEC 9 100 1 5 01 22 PUSH NIPPLE 3 SECTION 2 4 SECTION 3 5 SECTION 4 6 SECTION 5 7 SECTION 6 10 MS 006 00 ROPE MED DENSITY 3 SECTION 13 1 4 SECTION 19 5 5 SECTION 26 6 SECTION 32 5 7 SECTION 39 11 HW 008 03 WASHER 1 2 ID FLAT 3 12 HW 003 05 NUT 1 2 13 HEX HEAD 3 HEAT EXCHANGER FULLY ASSEMBLED HEAT EXCHANGERS 10023101 3 SECT TNKLS W O COIL ...

Page 24: ... CARLIN BUNERS ONLY 8 1263013 HARNESS BURNER FOR BECKETT BURNERS ONLY 1 1263011 HARNESS BURNER FOR RIELLO BURNERS ONLY 28511901 HARNESS BURNER FOR CARLIN BURNERS ONLY 1 9 5612001 TANKLESS COIL KIT P3 FOR 3 SECTION BOILERS 5612002 TANKLESS COIL KIT T4 4 5 6 7 SECT BOILERS ABOVE KITS INCLUDE ITEM NOs 2 4 AND THE APPROPRIATE COIL 10 27511401 TANKLESS COVER KIT 1 KIT INCLUDES ITEM NOs 2 4 AND COVER PL...

Page 25: ...APPING 2 3 10011701 OBSERVATION DOOR 1 4 25511101 OBS 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 8 2553301 INSULATION SWING DOOR FOR BOILERS WITH RIELLO BURNERS ONLY 1 2553303 INSULATION SWING DOOR FOR BOILERS WITH BECKET OR CARLIN BURNERS 9 10011301 MOUNTING DOOR 1 REPLACEMENT PARTS ...

Page 26: ...DE PANEL 6 SECTION 21521806 SIDE PANEL 7 SECTION 2 21522401 TOP FRONT PANEL C O 1 21522402 TOP FRONT PANEL TNKLS COIL SHOWN 3 21521901 LOWER COWL 1 4 21521501 REAR PANEL 1 5 215 1 3 02 TOP PANEL 3 SECTION 1 215 1 3 03 TOP PANEL 4 SECTION 215 1 3 04 TOP PANEL 5 SECTION 2151307 TOP PANEL 6 SECTION 2151308 TOP PANEL 7 SECTION REPLACEMENT PARTS ...

Page 27: ...ECT 2452906 FLUE COLLECTOR ASSY 3 SECT 2452907 FLUE COLLECTOR ASSY 6 SECT 2452908 FLUE COLLECTOR ASSY 7 SECT 3 HW06701 STUD 5 16 18 X 2 3 8 4 4 2252501 SUPPORT JACKET BRACKET 1 5 HW06901 NUT 5 16 18 WISLOCK 8 6 HW07001 STUD 5 16 18 X 1 1 8 3 7 HW 016 02 DRAIN LONG 1 8 1060003 PIPE FIT BUSHING 1 1 4 X 3 4 9 HW06401 NUT ACORN 1 2 13 UNC YELLOW 2 REPLACEMENT PARTS HARDWARE ...

Page 28: ...LIN BURNERS ONLY 1 RY 001 02 CONTROL R4184D TANKLESS COIL CONTROL FOR BOILERS WITH CARLIN BURNERS ONLY RY00701 CONTROL R7184B 1032 7456U FOR BOILERS WITH BECKETT BURNERS ONLY 5 1320003 NOZZLE 60 80B 365 BECKETT 1 1320004 NOZZLE 85 80B 3100 4100 BECKETT NZ 002 08 NOZZLE 1 10 80B 4125 5125 BECKETT NZ 002 10 NOZZLE 1 25 80B 4150 BECKETT NZ 002 12 NOZZLE 1 50 80B 5175 BECKETT NZ00206 NOZZLE 1 75 80B 5...

Page 29: ...NER GASKET 5 RP 015 00 MOTOR 6 1050007 TRANSFORMER BECKETT AFII BURNER PARTS USED ON MODEL 3125 ONLY ITEM PART DESCRIPTION 1 RP03802 BLAST TUBE AF2 2 RP03901 FUEL PUMP AF2 DANFOSS 3 RP04001 7 DRAWER ASSY AF2 4 RP04101 OIL BRN TRANSFORMER AF2 5 RP04201 OIL BRN MOTOR AF2 BECKETT CF375 BURNER PARTS USED ON MODELS 6225 7275 ITEM PART DESCRIPTION 1 RP04501 FUEL PUMP CLEANCUT 21844U 2 RP 015 00 MOTOR PS...

Page 30: ...IELLO BURNER PARTS ITEM PART DESCRIPTION 1 30A064701 BRN PUMP DRIVE KEY RIELLO 2 30A064801 BRN PRIMARY CTRL 53OSE RIELLO 3 30A064901 BRN COIL RIELLO 4 30A065101 BRN MOTOR RIELLO 5 30A065201 BRN CAPACITOR 12 5uF RIELLO 6 30A065301 BRN ELECTRODE PORCELAIN RIELLO 7 30A065401 BRN PUMP RIELLO 8 30A065501 BRN HYDRAULIC JACK RIELLO 9 30A065601 BRN O RING PUMP PRESS RIELLO 10 30A065701 BRN PHOTO CELL RIEL...

Page 31: ...31 Date Service Performed Company Name Tech Initials Company Address Phone Service Record ...

Page 32: ...Utica BOILERS 2210 Dwyer Avenue Utica NY 13504 4729 Phone 315 797 1310 Fax 866 432 7329 e mail info ecrinternational com web site www ecrinternational com ...