Utica boilers SFE-3090S, SFE-4125S, SFE-6210ST, SFE-4125ST, SFE-5185S, SFE-6210S, SFE-3090ST, SFE-5185ST User Manual

Loading...

MODELS

SFE-3090S SFE-3090ST SFE-4125S SFE-4125ST SFE-5185S SFE-5185ST SFE-6210S SFE-6210ST

An ISO 9001-2008 Certified Company

STARFIRE IV STEAM Series 4

OIL-FIRED

CAST IRON BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

PATENT 7,823,544

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com

P/N 240009806, Rev. B [03/2014]

DIMENSIONS

Figure #1

DIMENSIONS

 

Length of Flush

Front of Jacket

Flue Outlet Diameter

Boiler No.

Jacket

to Center Line of

Flue Outlet

 

 

 

 

 

-A-

-B-

-C-

SFE-3090

16⅜"

6½"

6"

SFE-4125

20¼"

8½"

6"

SFE-5185

23⅝"

10¼"

7"

SFE-6210

27½"

85/"

8"

STANDARD EQUIPMENT: Crated boiler, flush jacket, oil burner, target wall/liner, safety valve, steam water level gauge, steam pressure gauge, steam pressure control, low water cut-off, drain valve, wiring harness, burner electric disconnect, plastic cover, 2" supply tapping, 1½" return tapping, skim port, and primary control.

(NOTE: For tankless heater units, add tankless hot water coil, and low limit control.)

2

RATINGS, DATA

 

 

 

 

RATINGS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Boiler Model

Oil Burner Input(1)

 

 

Net AHRI Ratings(3)

Min. Natural Draft

 

Number

Heating

 

Chimney Size

 

 

 

 

 

 

A.F.U.E.

 

 

 

 

Capacity

 

 

 

 

 

WITHOUT

WITH TANK-

 

 

 

Steam

Sq. Ft.

 

 

Rating(4)

G.P.H.

MBH(2)

MBH(4)

 

Round

Square

 

 

TANKLESS

LESS

 

 

 

 

MBH

Steam

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SFE-3090S

SFE-3090ST

0.90

126

106

 

80

333

6

8"x8"x15'

82.0

 

 

 

 

 

 

 

 

 

 

 

SFE-4125S

SFE-4125ST

1.25

175

147

 

110

458

6

8"x8"x15'

82.0

 

 

 

 

 

 

 

 

 

 

 

SFE-5185S

SFE-5185ST

1.85

259

216

 

162

675

8

8"x8"x15'

82.0

 

 

 

 

 

 

 

 

 

 

 

SFE-6210S

SFE-6210ST

2.10

294

247

 

185

771

8

8"x8"x15'

82.0

 

 

 

 

 

 

 

 

 

 

 

NOTES:

(1)Burner input is based on an oil heating value of 140,000 Btu/gal.

(2)MBH = 1000 Btu per hour [Btu =British Thermal Unit].

(3)Net AHRI Steam Ratings based on piping and pick-up allowance of 1.333. Consult manufacturer before selecting boiler for installations having unusual piping and pick-up requirements, such as intermittent system operation, extensive piping, etc.

(4)Heating Capacity and AFUE based on 13.0% CO2 with 0.02" W.C. draft over fire and #1 smoke or less. Tested in accordance with U.S. Department of Energy test procedures.

 

TANKLESS WATER HEATER CAPACITIES

 

 

 

 

 

 

Tankless

Boiler

Water

Boiler Model

Input

Tankless

Content

Heater Capacity

(Gallons)

Number

Rate

Heater

Intermittent Draw

 

 

 

 

 

To

 

G.P.H.

Number

G.P.M.

To Water

 

 

 

 

Line

LWCO

 

 

 

 

 

 

Line

SFE-3090ST

0.90

L-24

2

11

 

8

 

 

 

 

 

 

 

SFE-4125ST

1.25

L-24

13

 

9

SFE-5185ST

1.85

L-24

15

 

10

SFE-6210ST

2.10

L-24

17

 

11

3

TABLE OF CONTENTS

Dimensions........................................................

2

Ratings, Data.....................................................

3

Safety Symbols...................................................

4

Locating The Boiler..............................................

5

Ventilation And Combustion Air.............................

6

Supply And Return Piping.....................................

8

Venting System Inspection & Installation..............

12

Oil Tank And Piping............................................

13

Electrical Wiring................................................

14

Operating Instructions.......................................

16

Maintenance Procedures.....................................

19

Service Checklist...............................................

21

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

SAFETY SYMBOLS

The following defined symbols are used throughout this manual to notify reader of potential hazards of varying risk levels.

!DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

IMPORTANT: Read and understand the following instructions COMPLETELY before installing.

! WARNING

Installations of boilers and venting shall be done only by qualified expert and in accordance with this manual. Installing or venting a boiler or any other gas appliance with improper methods or materials could result in serious injury or death due to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

! WARNING

Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

Do not obstruct air openings to boiler room.

Modification, substitution or elimination of factory equipped, supplied or specified components could result in personal injury or the loss of life.

Owner - Installation and service of this boiler must be performed by a qualified installer.

Installer - Leave all instructions with the boiler for future reference.

When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter.

! WARNING

 

Indicates a hazardous situation which, if not avoided,

 

could result in death or serious injury.

 

! CAUTION

 

Indicates a hazardous situation which, if not

 

avoided, could result in minor or moderate injury.

 

NOTICE

PATENT 7,823,544

Indicates information which should be followed to

 

ensure proper installation and operation.

 

4

LOCATING THE BOILER

Installations shall conform to the requirements of the authority having jurisdiction. Such applicable requirements take precedence over the general instructions of this manual.

Where required by the authority having jurisdiction, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME No. CSD-1.

! WARNING

Fire hazard. Do not install boiler on combustible flooring or carpeting. Failure to follow these instructions could result in death or serious injury.

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY Boiler must not be installed on carpeting or vinyl flooring. Minimum clearances to combustible construction are:

Locate boiler in front of final position before removing crate.

Provide level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical.

Allow 24 inches in front, top and right hand side for servicing and cleaning, or removing tankless water heating coil.

Recommend 24 inches be allowed in back of boiler for convenience when skimming hole is used.

When installed in a utility room, the door should be wide enough to allow largest boiler part to enter, or to permit replacement of another appliance such as water heater.

Install boiler such that oil ignition system components are protected from water (dripping, spraying, rain etc.) during appliance operation and service.

TOP

24 IN.

FRONT

24 IN.

FLUE CONNECTOR

9 IN.

REAR

24 IN.

LEFT SIDE

6 IN.

RIGHT SIDE

24IN.

NOTE: Clearance for access should exceed fire protection clearance.

Figure #2 - Minimum Clearances To Combustible Construction (as seen from above)

BACK

24"

6" BOILER

24"

24"

FRONT

5

VENTILATION AND COMBUSTION AIR

! WARNING

Asphyxiation, fire hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air.

COMBUSTION AIR REQUIREMENTS

(Minimum Opening Requirement)

 

Unconfined Area*

Confined Area**

 

Outside

Inside

Outside Combustion Air

Input (Mbh)

Combustion Air

Combustion Air

Vertical Ducts

Horizontal Ducts

 

1 Sq.In./5000 BTU/Hr

1 Sq. In./1000 BTU/

1 Sq. In./4000 BTU/Hr

1 Sq. In./2000 BTU/Hr

 

Hr (Min. 100 Sq. In.)

 

(Step 4)

(Figure #1)

(Figures # 2 & #3)

(Figure # 4)

126

26

126

32

63

175

35

175

44

88

259

52

259

65

130

294

59

294

74

147

* A space whose volume is not less than 50 cubic feet per 1000 BTU/Hour of all appliances installed in that space (cubic feet of space = height x width x length)

** A space whose volume is less than 50 cubic feet per 1000 BTU/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

4. When air for combustion and room ventilation is from

provide sufficient air to properly support combustion,

inside buildings, the confined space shall be provided

venting and maintain safe ambient temperatures under

with two permanent openings, one starting 12 inches

normal operating conditions.

from the top and one 12 inches from the bottom of the

2. When the boiler is located in an unconfined space in a

enclosed space. Each opening shall have a minimum

building of conventional construction frame, masonry

free area of 1 square inch per 1,000 BTU per hour of

or metal, infiltration normally is adequate to provide

the total input rating of all appliances in the enclosed

air for combustion and ventilation. However, in any

space, but must not be less than 100 square inches.

building which has been altered to conserve energy

These openings must freely communicate with the

or to minimize infiltration, the boiler area should

interior areas having adequate infiltration from the

be considered as a confined space. If there is any

outside. See Figure #3.

doubt, install air supply provisions for combustion

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and ventilation in accordance with Chapter 5, Air for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure #3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Combustion and Ventilation, of NFPA 31, Standard

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

for the Installation of Oil Burning Equipment. The

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

recommendations that follow, or applicable provisions

 

 

 

 

CHIMNEY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of the local building codes.

 

 

 

 

 

OR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. When the boiler is installed in an unconfined space,

 

 

 

L TYPE VENT PIPE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

in a building of unusually tight construction, air for

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

combustion and room ventilation must be obtained

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

from outdoors or from spaces freely communicating

 

 

 

BASEBOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

with the outdoors. A permanent opening or openings

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

having a total free area of not less than 1 square inch

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

per 5,000 BTU per hour of total input rating of all

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VENT PIPE

12"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

appliances shall be provided. Ducts may be used to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

convey make-up air from the outdoors and shall have

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the same cross-sectional area of the openings to which

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VENTS

they are connected.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

VENTILATION AND COMBUSTION AIR

5.When the boiler is installed in a confined space and all air is provided from the outdoors, the confined space shall be provided with two permanent openings, one commencing within 12 inches from the top and one commencing 12 inches from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) 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, each opening shall have a minimum free area of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure. (Figure #4)

B.When communicating with the outdoors by means of vertical ducts, each opening shall have a minimum free area 1 square inch per 4,000 BTU per hour of total input rating of all appliances in the enclosed space. (Figure #5)

C.If horizontal ducts are used, each opening shall have a minimum free area 1 square inch per 2,000 BTU per hour total input rating of all appliances in the enclosed space. (Figure #6)

D.When ducts are used, they shall be of the same cross sectional area as the free area of the area of the openings to which they connect. The minimum dimension of rectangular air ducts shall not be less than 3 inches.

6.In calculating free area using louvers, grills or screens for the above, consideration shall be given to their blocking effect. Screens used shall not be smaller than 1/4 inch mesh. If the free area through a design of louver or grill is known, 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 operation.

Figure #4

Figure #5

Figure #6

7

SUPPLY AND RETURN PIPING

! WARNING

Burn or Scald Hazard. Discharge line shall be installed to safety valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation.

Discharge line shall:

Connect to safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum distance from floor or allowable safe point of discharge.

Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.

Have no intervening shutoff valve between safety valve and discharge to atmosphere. Do not plug or place any obstruction in discharge line.

Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing.

Allow complete drainage of valve and discharge line.

Install safety valve with spindle in vertical position.

Do not install shutoff valve between boiler and safety valve.

Support safety valve discharge piping.

Be short and straight as possible.

Terminate with plain end, not threaded.

Constructed of material suitable for exposure to temperatures of 375° F (191°C); or greater.

Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements.

Figure 4 - Safety Valve

SAFETY VALVE

DISCHARGE

PIPING

Check local codes for maximum distance from floor or other allowable safe point of discharge

6" Above Floor

8

+ 16 hidden pages