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

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	4½	13		9
SFE-5185ST	1.85	L-24	4½	15		10
SFE-6210ST	2.10	L-24	4½	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