UTICA BOILERS STARFIRE 3 STEAM, Installation Manual And Operating Instructions

Page 1: ...AL AND OPERA AND OPERA AND OPERA AND OPERA AND OPERATING INSTR TING INSTR TING INSTR TING INSTR TING INSTRUCTIONS UCTIONS UCTIONS UCTIONS UCTIONS ST ST ST ST STARFIRE 3 ARFIRE 3 ARFIRE 3 ARFIRE 3 ARFIRE 3 W W W W WA A A A ATER TER TER TER TER OIL FIRED CAST IRON BOILER Utica Boilers P O Box 4729 Utica NY 13504 ...

Page 2: ...PECTION INSTALLATION PAGE 12 OIL TANK PIPING PAGE 13 ELECTRICAL WIRING PAGES 14 THERMOSTATINSTALLATION PAGE 15 NORMAL SEQUENCE OF OPERATION PAGE 15 OPERATING INSTRUCTIONS PAGES 16 19 SERVICE CHECK LIST PAGE 20 REPLACEMENT PARTS LIST PAGES 21 28 RATINGS DATA AND DIMENSIONS PAGE 29 30 KEEP THIS MANUAL NEAR BOILER RETAIN FOR FUTURE REFERENCE SERIES SFH 3 CAST IRON OIL FIRED BOILER INSTALLATION MANUAL...

Page 3: ...D EXPERT AND IN SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS MANUAL ACCORDANCE WITH THE APPRO...

Page 4: ...with respect to the heat distribution system as practical WARNING WARNING WARNING WARNING WARNING BOILER MAY NOT BE INSTALLED ON COMBUSTIBLE FLOORING Allow 24 inches in the front and top 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 appl...

Page 5: ...th Confined area A space whose volume is 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 1 Ventilation of boiler room must be adequate enough to provide sufficient air to properly support combustion 2 When a boiler is located in an unconfined space in a building of conventional construction frame masonry or metal i...

Page 6: ...rovided with two permanent openings one commencing within 12inchesfromthetopandonecommencing12inchesfromthebottomoftheenclosure The openingsshallcommunicatedirectly orbyducts withtheoutdoorsorspaces crawlorattic that freely communicate with the outdoors One of the following methods must be used to provide adequate air for ventilation and combustion A When directly communicating with the outdoors e...

Page 7: ...own it should be used in calculating the size opening required to provide the free area specified 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 fixed in the open position or interlocked with the boiler so that they are opened automatically during boiler operat...

Page 8: ...heatingboiler 2 During the heating cycle open valves A and B close valves C and D 3 During heating cooling cycle open valves C and D close valves A and B A Maintain a minimum clearance of one inch to hot water pipes In air handling units where they may be exposed to refrigerated air circulation the boiler piping system MUST be supplied with flow control valves or other automatic means to prevent g...

Page 9: ...erallynoticedinlargeconvertedgravitysystemsorotherlargewatervolume systems See figure 6 below B These methods are used to protect systems using radiant panels and the material theyareencasedinfromhightemperaturesupplywaterfromtheboilerandprotecttheboiler from condensation See figures 7 and 8 on page 8 C This method is used to protect boilers from condensate forming as well as protecting the heatin...

Page 10: ...FIGURE 8 FIGURE 7 PAGE8 MIXING VALVE PIPING PRIMARY SECONDARY PIPING WITH BYPASS ...

Page 11: ... 9 9 Typical installation using circulators is shown in figure 9 below 10 Typical installation using zone valves is shown in figure 10 below 11 For further piping information refer to the I B R installation and piping guide ...

Page 12: ... TER TER TER TER DANGER DANGER DANGER DANGER DANGER 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...

Page 13: ...OCA OCA OCA OCA OCATION FOR TION FOR TION FOR TION FOR TION FOR AIR AIR AIR AIR AIR VENT VENT VENT VENT VENT OPTION OPTION OPTION OPTION OPTIONAL L AL L AL L AL L AL LOCA OCA OCA OCA OCATION FOR EXP TION FOR EXP TION FOR EXP TION FOR EXP TION FOR EXPANSION ANSION ANSION ANSION ANSION T T T T TANK ANK ANK ANK ANK NON DIAPHRAM TYPE NON DIAPHRAM TYPE NON DIAPHRAM TYPE NON DIAPHRAM TYPE NON DIAPHRAM T...

Page 14: ... 2 feet above any portion of the building within 10 feet See figure 14 below It should produce a negative draft of 06 to 08 inches of water column W C 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 See chart below for recommended chimney or vent sizes Inadequatedraftwillcauseimpropercombustion...

Page 15: ... lines are recommended Compression fittings on the suction line often allow air to be drawn into the fuel pump making it difficult to maintain oil pressure at the 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 the fuel pump If tank is more than 20 from the boiler a two stage fuel unit should be in...

Page 16: ...alled in the United states the CSA C22 1 Canadian Electrical Code Part 1 when installed in Canada and or the local authority having jurisdiction WARNING WARNING WARNING WARNING WARNING 1 When an external electrical source is utilized the boiler when installed MUST BE MUST BE MUST BE MUST BE MUST BE electrically grounded in accordance with these requirements 2 Install a fused disconnect switch betw...

Page 17: ...ing The circulator will continue to operate under this condition until the thermostat is satisfied THERMOST THERMOST THERMOST THERMOST THERMOSTA A A A AT INST T INST T INST T INST T INSTALLA ALLA ALLA ALLA ALLATION TION TION TION TION 1 Thermostat should be installed on an inside wall about four feet above the floor 2 NEVER install a thermostat on an outside wall 3 Do not install a thermostat wher...

Page 18: ...valves F Turn service switch on Burner should start G On one pipe fuel systems only vent pump as soon as burner starts Allow oil to run until all traces of air in the suction line disappear H Turn OFF burner and install pressure gauge port on pump I Start burner again and check oil pressure for 140 lbs Adjust if necessary CAUTION CAUTION CAUTION CAUTION CAUTION DO NOT SET FIRE VISUALLY Instruments...

Page 19: ...h burner off close oil supply valve and run through start up procedure The safety switch should lock out as in flame failure 3 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 PREVENTIVE MAINTENANCE of an oil fired boiler reduces operating costs The b...

Page 20: ... 150 PSI 1 10 1 25 1 10 70B SFH4150 EZ 1 1 25 1 35 150 PSI 1 10 1 25 1 25 70B SFH5175 EZ 2 1 65 150 PSI 1 65 1 75 1 75 70B SFH5200 EZ 2 1 75 150 PSI 1 65 1 75 1 50 70B BECKETT SETTINGS BOILER BURNER AIR AIR PUMP STATIC END NOZZLE NO NO BAND SHUT PRESS DISC CONE FURNISHED SFH365 AFG 0 7 140 PSI 2 3 4 F0 60 80B SFH3100 AFG 1 5 140 PSI 3 3 8U F3 85 80B SFH4100 AFG 1 5 140 PSI 3 3 8U F3 85 80B SFH3125...

Page 21: ... CAUTION CAUTION CAUTION USECAUTIONWHENVACUUMINGINTHECHAMBERAREA DAMAGE TO CHAMBER COULD RESULT 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 f...

Page 22: ...desetting Nozzle Size Angle Type SERVICE CHECK LIST x PumpPressure Vacuum LineVoltage MotorAmps SmokeTest Draft Overfire In Flue CO2 or O2 FlueGasTemperature Proper Light Off Hot Cold Controls and Safety Devices x Measure with Instruments and Record results on chart provided below Pump Flue Date Nozzle Pressure Smoke Draft CO2 or O2 Temperature Size Angle Type PSI NO O F INF o F ...

Page 23: ...25 02 TIE ROD 1 2X16 1 2 5 SEC HW 025 03 TIE ROD 1 2X20 1 2 6 SEC HW 025 05 TIE ROD 1 2X9 3 SEC HW 025 09 TIE ROD 1 2X23 1 2 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 1 3 SECTION 13 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 FULLYASSEMB...

Page 24: ...RNESS CTRL BOX BECKETT OR RIELLO 1 28511801 HARNESSAQUASTAT FOR 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 9 5612001 TANKLESS COIL KIT P3 FOR 3 SECTION BOILERS 1 5612002 TANKLESS COIL KIT T4 4 5 6 7 SECT BOILERS ABOVE KITS INCLUDE ITEM NOs 2 4 AND THE APPROPRIATE COIL 10 27511...

Page 25: ... 1 4 20X1 2 SELF TAPPING 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 1 FOR BOILERS WITH RIELLO BURNERS ONLY 2553303 INSULATION SWING DOOR FOR BOILERS WITH BECKET OR CARLIN BURNERS 9 10011301 MOUNTING DOOR 1 PAGE 23 FIGURE22 ...

Page 26: ...ECTION 21521805 SIDE 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 PAGE 24 FIGURE23 ...

Page 27: ...OR ASSY 5 SECT 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 PAGE 25 FIGURE24 ...

Page 28: ...OL FOR BOILERS WITHOUT COIL 1 FOR BOILERS WITH CARLIN BURNERS ONLY 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 SFH365 BECKETT 1 1320004 NOZZLE 85 80B SFH3100 SFH4100 BECKETT NZ 002 08 NOZZLE 1 10 80B SFH4125 SFH5125 BECKETT NZ 002 10 NOZZLE 1 25 80B SFH4150 BECKET...

Page 29: ...FG 4 BN08001 BURNER GASKET 5 RP 015 00 MOTOR 6 1050007 TRANSFORMER BECKETT AFII BURNER PARTS USED ON MODEL SFH3125 ONLY ITEM NO PART NO DISCRIPTION 1 RP03802 BLAST TUBE AF2 2 RP03901 FUEL PUMP AF2 DANFOSS 3 RP04001 7 DRAWERASSY AF2 4 RP04101 OIL BRN TRANFORMER AF2 5 RP04201 OIL BRN MOTOR AF2 BECKETT CF375 BURNER PARTS USED ON MODELS SFH6225 SFH7275 ITEM NO PART NO DISCRIPTION 1 RP04501 FUEL PUMP C...

Page 30: ...100 SFH4100 BN08603 BRN HEAD BAR 1 1 1 25 SFH4125 SFH4150 SFH5125 BN08604 BRN HEAD BAR 1 65 1 75 CSFH5175 SFH5200 RIELLO BURNER PARTS ITEM NO PART NO DISCRIPTION 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 PU...

Page 31: ...E G P H MBH MBH MBH ROUND SQUARE PSI RATING SFH 365 65 91 79 68 7 6 8X8X15 140 86 0 SFH 3100 1 00 140 117 102 6 8X8X15 140 81 0 SFH 3125 1 25 175 144 125 7 8X8X15 140 80 0 SFH 4100 1 00 140 120 104 6 8X8X15 140 86 0 SFH 4125 1 25 175 149 130 7 8X8X15 140 82 5 SFH 5125 1 25 175 151 131 7 8X8X15 140 86 0 SFH 4150 1 50 210 175 152 7 8X8X15 140 81 0 SFH 5175 1 75 245 206 179 8 8X8X15 140 81 5 SFH 5200...

Page 32: ...5 Amps 60 Hz required to operate this boiler 6 The MEA number for the SFH W series is 182 86E 7 For altitudes above 2 000 ft ratings may be reduced at the rate of 4 for every 1 000 ft above sea level 7 The MEA number for the Beckett burners used on the SFH W are as follows AF 156 77 E AFG 213 83 E AFII 85 24 92 E AFII 150 456 90 E DIMENSIONS DIMENSIONS DIMENSIONS DIMENSIONS DIMENSIONS A B C BOILER...