Utica boilers SFH-6175, SFH-5185, SFH-5160, SFH-4100, SFH-4145 User Manual

...
Models
SFH-3085
SFH-3100 SFH-4100 SFH-4125 SFH-4145 SFH-5160 SFH-5185 SFH-6175 SFH-6210
STARFIRE IV SERIES 4
WATER
OIL FIRED
CAST IRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
Tested For 75 psi
ASME
Working Pressure
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N 240009735, Rev. F [12/2014]
TABLE OF CONTENTS
Dimensions ................................................................................................................... 3
Boiler Ratings & Capacities............................................................................................ 4
Introduction .................................................................................................................. 5
Ventilation & Combustion Air ........................................................................................ 6
Connecting Supply And Return Piping ........................................................................... 9
System Piping ............................................................................................................. 13
Venting System Inspection & Installation.....................................................................16
Oil Tank And Piping ..................................................................................................... 17
Electrical Wiring .......................................................................................................... 18
Operating Instructions ................................................................................................ 23
Keep this manual near boiler and
Retain for future reference
Boiler installation shall be completed by qualied agency.
Become familiar with symbols identifying potential hazards.
This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.
!
DANGER
Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury
!
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
Used to address practices not related to personal
injury.
!
WARNING
All boiler and venting installations shall be done by qualied agency and in accordance with
appropriate Manufacturer’s Installation, Operation
and Maintenance Manual. Installing or venting boiler
or any other appliance with improper methods or materials could result in serious injury or death due
to re or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.
!
WARNING
Modication, substitution or elimination of factory equipped, supplied or specied components could result in death or serious injury.
Keep boiler area clear and free from combustible
materials, gasoline and other ammable vapors and liquids.
DO NOT obstruct air openings to boiler room.
To the owner: Installation and service of this boiler must
be performed by qualied installer.
To the installer: Leave all instructions with boiler for
future reference.
Installation in Commonwealth of Massachusetts must be
performed by Licensed Plumber or Licensed Gas Fitter.
2
DIMENSIONAL DATA
DIMENSIONS
A
BOILER
SECTION
3 17 ⅞" 11 ¼" 6"
4 21 ½" 12 ⅝" 6"
5 25 ⅛" 14 ¼" 7"
6 29¼ 15 ¹⁵/16” 8”
DEPTH
OF
FLUSH
JACKET
TO CENTER LINE
FLUE OUTLET
B
FRONT OF
CASING
OF
C
DIA.
OF
FLUE
OUTLET
3
BOILER RATINGS & CAPACITIES
BOILER RATINGS
(2)
NET
RATINGS
WATER
(3)
A.F.U.E.
CHIMNEY
BOILER
MODEL
NUMBER
(1)
OIL BURNER
INPUT
(3)
HEATING
CAPACITY
gph *Mbh *Mbh *Mbh
SFH-3085W SFH-3085WT 0.85 119 103 90 85.0% 8X8X15
SFH-3100W SFH-3100WT 1.00 140 119 103 84.0% 8X8X15
SFH-4100W SFH-4100WT 1.00 140 122 106 86.0% 8X8X15
SFH-4125W SFH-4125WT 1.25 175 151 131 85.0% 8X8X15
SFH-4145W SFH-4145WT 1.45 203 173 150 84.0% 8X8X15
SFH-5160W SFH-5160WT 1.60 224 193 168 85.0% 8X8X15
SFH-5185W SFH-5185WT 1.85 259 221 192 84.0% 8X8X15
SFH-6175W SFH-6175WT 1.75 245 212 184 85.0% 8X8X15
SFH-6210W SFH-6210WT 2.10 294 252 219 84.0% 8X8X15
*
Mbh = 1,000 Btu per hour [Btu = British Thermal Unit]
1
Oil burner input based on 140,000 Btu per gallon.
2
Net AHRI water ratings shown are based on a piping and pickup allowance of 1.15. Consult manufacturer before selecting a boiler for installation having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.
3
Heating Capacity and AFUE based on 13.0% CO2 with -0.02” W. C. draft over re and #1 smoke or less. Tested in accordance with U.S. Department of Energy test procedures.
T= Tankless
STANDARD EQUIPMENT: Crated Boiler, Flush Jacket, Oil Burner, Target Wall/Liner, Circulator- 1¼”, Safety
Relief Valve, Temperature Pressure Gauge, Drain Valve, Wiring Harness, Burner Electrical Disconnect, Plastic Cover, Supply Tapping-2”, Return Tapping-1 1/2”, High Limit and Circulator Control, Primary Control. For Tankless Heater Units add Tankless Hot Water Coil and Triple Combination High Limit/Low Limit/Circulator Control.
TANKLESS WATER HEATER CAPACITIES
BOILER
MODEL
NUMBER
INPUT
RATE
G.P.H.
TANKLESS
HEATER
NUMBER
INTERMITTENT DRAW
SFH-3085WT 0.85 T3 3 10.5
SFH-3100WT 1.00 T3 3¼ 10.5
SFH-4100WT 1.00 T4 3¼ 13.5
SFH-4125WT 1.25 T4 13.5
SFH-4145WT 1.45 T4 4 13.5
SFH-5160WT 1.60 T4 4 16.5
SFH-5185WT 1.85 T4 16.5
SFH-6175WT 1.75 T4 19.5
SFH-6210WT 2.10 T4 19.5
TANKLESS
HEATER CAPACITY
G.P.M.
BOILER
WATER CONTENT
GALS.
4
INTRODUCTION
!
WARNING
Improper installation, adjustment, alteration, service or maintenance could result in death or serious
injury.
• Installation must conform to requirements of the
authority having jurisdiction. Such applicable requirements take precedence over the general instructions of this manual.
• Install boiler in accordance with requirements of
authority having jurisdiction, or in the absence of such
requirements, CSA B139: Installation Code for Oil
Burning Equipment.
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.
LOCATE BOILERS in front of nal position before removing crate. Provide level solid base as near the
chimney as possible, and centrally located with respect
to heat distribution system as practical.
Allow 24 inches in the front and top for servicing and cleaning, or removing tankless water heating coil.
• When installed in utility room, door should be wide
enough to allow largest boiler part to enter, or to permit replacement of another appliance such as water heater.
!
WARNING
Fire hazard. Do not install boiler on combustible ooring or carpeting. Failure to follow these instructions could result in death or serious injury.
Boiler must not be installed on carpeting or vinyl ooring.
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 re protection clearance.
REMOVE CRATE and plastic protective wrapper, inspect for
damage. Move boiler to permanent position by sliding or walking.
5
VENTILATION & COMBUSTION AIR
!
WARNING
Asphyxiation, re hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air.
COMBUSTION AIR REQUIREMENTS
(MINIMUM OPENING IN SQUARE INCHES)
*UNCONFINED AREA **CONFINED AREA
OUTSIDE
INSIDE
OUTSIDE
INPUT (Mbh)
119 24 119 30 60
140 28 140 35 70
175 35 175 44 88
203 41 203 51 102
224 45 224 56 112
245 49 245 62 123
259 52 259 65 130
294 59 297 74 147
* Unconned 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).
** Conned 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).
COMBUSTION AIR
1 IN2/5000Btu/HR
(PARAGRAPH 4)
COMBUSTION AIR
1 IN2/1000 Btu/HR
(MIN 100IN2) (Figure
1)
COMBUSTION AIR
1 IN2/4000 Btu/HR
(Figures 2&3)
1 IN2/2000 Btu/HR
(Figure 4)
1.
Ventilation of boiler room must be adequate enough to provide sufcient air to properly support combustion.
2.
When boiler is located in an unconned space in a building of conventional construction frame, masonry or metal, inltration normally is adequate to provide air for combustion and ventilation. However, in any building which has been altered to conserve energy or to minimize inltration, the boiler area should be considered as a CONFINED SPACE. Provide combustion
air and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of NFPA 31:
Standard for the Installation of Oil-Burning Equipment.
3.
When a boiler is installed in an unconned space, in a building of unusually tight construction, air for
combustion and room ventilation must be obtained
from outdoors or from spaces freely communicating 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 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 they are connected.
6
VENTILATION & COMBUSTION AIR
4.
When air for combustion and room ventilation is from
inside buildings, conned space shall be provided with two permanent openings, one starting 12 inches from
the top and one 12 inches from the bottom of the
enclosed space. Each opening shall have a minimum
free area of 1 square inch per one thousand (1,000)
Btu per hour of the total input rating of all appliances
in the enclosed space, but must not be less than one
hundred (100) square inches. These openings must freely communicate with the interior areas having adequate inltration from the outside. See Figure #1.
5.
When the boiler is installed in a conned space and all air is provided from the outdoors, the conned 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. See Figure #2.
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. See Figure #3.
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. See Figure #4.
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 ¼ 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 specied. If the design and free area is not known, it may be assumed that wood louvers will have 20­25% free area and metal louvers and grills will have 60-75% free area. Louvers and grills shall be xed in the open position or interlocked with the boiler so that they are opened automatically during boiler operation.
Refer to the Combustion Air Requirements chart on
previous page for combustion air minimum opening requirements.
Figure #1
7
Figure #2
VENTILATION & COMBUSTION AIR
Figure #3 Figure #4
8
CONNECTING SUPPLY AND RETURN PIPING
1.
Connect supply and return piping as suggested in Figure #5, below. When boiler is used in connection with refrigerated systems:
A. Chilled medium MUST BE IN PARALLEL with boiler.
B. Use appropriate valves to prevent chilled medium
from entering heating boiler.
2.
During 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 minimum clearance of one inch to hot
water pipes.
In air handling units where they may be exposed to refrigerated air circulation, boiler piping system MUST be supplied with ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.
4.
Hot water boilers installed above radiation level must be provided with low water device either as part of
boiler or at time of boiler installation.
5.
When boiler is connected to heating system utilizing
multiple zoned circulators, each circulator must be
supplied with ow control valve to prevent gravity circulation.
* Reduced pressure back ow preventer must be used
under provisions required by the Environmental Protection Agency, (EPA).
6.
Bypass piping is an option which gives ability to adjust supply boiler water temperature to t system or condition of installation. Although, this method of piping is not typically required for baseboard heating systems.
Figure #5 Typical Piping Conguration
9
CONNECTING SUPPLY AND RETURN PIPING
A. This method is 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 #6.
B. These methods are used to protect systems using
radiant panels and material they are encased in
from high temperature supply water from boiler and protect boiler from condensation. See Figures #7 and #8 following page.
C. This method is used to protect boilers from
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.
7.
Bypass loop piping must be same size piping for supply and return.
Figure #6 Bypass Piping
10
CONNECTING SUPPLY AND RETURN PIPING
Figure #7 - Mixing Valve Piping
Figure #8 - Primary Secondary Piping With Bypass
11
DRAIN VALVE
DRAIN VALVE
CONNECTING SUPPLY AND RETURN PIPING
8.
Typical indirect water heater installation using circulators is shown in Figure #9.
9.
Typical indirect water heater installation using zone valves is shown in Figure #10.
Figure #9 - Indirect Water Heater Piping with Circulator
Figure #10 - Indirect Water Heater Piping with Zone Valve
12
SYSTEM PIPING
!
WARNING
Burn or Scald Hazard. Discharge line shall be installed to relief 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 oor 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.
10.
Install discharge piping from safety relief valve.
Use ¾” or larger pipe. See Figure #11.
Individual boiler discharge piping shall be
independent of other discharge piping.
Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity
below minimum relief valve capacity stated on
rating plate.
• Install union, if used, close to safety relief valve
outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
Figure #11 - Discharge Piping From Safety Relief Valve
SAFETY RELIEF VALVE
DISCHARGE
Check local
codes for
maximum
distance
from oor
or allowable safe point of
discharge.
PIPING
13
CONNECTING SUPPLY AND RETURN PIPING
Figure #12 - Recommended Piping For Boilers Equipped With T3 Or T4 Tankless Heater
!
DANGER
Water temperatures exceeding 125°F will cause severe burns instantly or death by scalding.
Automatic mixing valve must be installed on outlet of domestic coil. Installation must comply with valve manufacturer’s recommendations, and instructions.
Do not remove bolts or limit at time of installation.
• Pipe in accordance with boiler’s Installation, Operation
and Maintenance Manual.
Due to varying water conditions, adjustable ow restricter must be installed in cold water inlet of this
coil.
14
CONNECTING SUPPLY AND RETURN PIPING
OPTIONS UTILIZING 3/4” TAPPING
Figure #13 - Optional Location For Air Vent
Figure #14 - Optional Location For Expansion Tank (Non-Diaphragm Type)
15
VENTING SYSTEM INSPECTION & INSTALLATION
INSPECT CHIMNEY to verify it is constructed according to latest revision of the NFPA 211. Local codes may differ from this code and should be checked. Where there is a conict, local code will prevail.
• Boiler must be installed into chimney which has
masonry or metallic chimney liner.
Unlined chimney will have leaks that will cause poor chimney performance (NO DRAFT), and could result in
positive pressure in combustion chamber.
Horizontal portions of venting system should not exceed 10 feet in length. Horizontal lengths over 10 feet will have negative effect on chimney performance.
Chimney should extend at least 2 feet above any portion of building within 10 feet. See Figure #15. It should produce negative draft of .06 to .08 inches of water column, (W.C.), as measured with draft gauge
between boiler and barometric draft 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 ue ways and high fuel bills.
Figure #15
CONNECT FLUE PIPE same size as boiler outlet to
chimney, sloping upward continuously toward chimney approximately ¼” per foot. Bolt or screw joints together to avoid sag.
If oil red water heater is vented into same ue as
boiler, provide separate hole into chimney whenever
possible. When not possible, use “Y” connection in ue pipe, using separate draft regulator for each unit.
When chimney will not provide adequate draft to handle input from water heater and boiler simultaneously, wire units so that only one will
operate at a time, favoring water heater.
16
OIL TANK AND PIPING
Install burner per instructions provided with burner-in­a-box kit.
Install oil tank and piping in accordance with the National Board of Fire Underwriters and local
regulations.
Oil storage tank, vent, ll pipe and caps should be as prescribed by local codes.
In no case should vent pipe be smaller than 1¼” I.P.S. Fill pipe should not be less than 2” I.P.S.
Suction line from tank to burner should be one continuous piece of tubing to prevent air entering line.
Suction line, must be ⅜” O.D. copper tubing for runs of 50 feet or less, and ½” O.D. for longer runs. Oil return
line, same size as suction line, must be used on any
installation where bottom of tank is below fuel unit of burner.
• Oil lines should be buried or otherwise protected from
mechanical injury.
Flare ttings on all oil lines are recommended. Compression ttings on suction line often allow air to be drawn into fuel pump, making it difcult 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
certain rotation and speed are same and pump is
suitable for burner horsepower rating.
Oil line lter and shut-off valve should be installed in suction line. Shut-off valves should be installed in both
suction and return lines at burner for convenience in
servicing burner.
Allow extra tubing at burner so burner may be removed from boiler for cleaning without disconnecting tubing.
(See Figures #16 & #17, below).
Optional exible oil line is available.
Figure #16 - Typical Installation Single Pipe Oil System
Figure #17 - Typical Installation Two Pipe Oil System
17
ELECTRICAL WIRING
!
WARNING
Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.
Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to:
USA- National Electrical Code, ANSI/NFPA 70.
Install fused disconnect switch between boiler and meter at
convenient location.
Thermostat Installation
1.
Thermostat should be installed on inside wall about
four feet above the oor.
2.
NEVER install thermostat on outside wall.
3.
Do not install thermostat where it will be affected by:
• Drafts
• Hot or cold pipes
Sun light
Lighting xtures
• Television sets
• Fireplace or chimney
Sequence Of Operations
On call for heat, thermostat will actuate, completing circuit to limit. In turn, circulator and ignition systems are activated and ignition will begin.
In event boiler water temperature exceeds high limit setting on boiler mounted limit, power will be interrupted between limit and ignition system. Power will remain off until boiler water temperature drops below high limit setting. Circulator will continue to operate under this condition until thermostat is satised.
4.
Check thermostat operation by raising and lowering thermostat as required to start and stop burner.
5.
Instructions for nal adjustment of thermostat are packaged with thermostat ( adjusting heating anticipator, calibration, ect.).
18
ELECTRICAL WIRING
ZR
Figure #18 - Wiring Diagram Beckett AFG without Tankless Heater
Figure #19 Wiring Diagram Beckett AFG wth Tankless Heater
19
ELECTRICAL WIRING
Figure #20 Wiring Diagram Riello 40F5 without Tankless Heater
Figure #21 Wiring Diagram Riello 40F5 with Tankless Heater
20
ELECTRICAL WIRING
Figure #22 Wiring Diagram Riello 40F10 without Tankless Heater
Figure #23 Wiring Diagram Riello 40F10 with Tankless Heater
21
ELECTRICAL WIRING
Figure #24 Wiring Diagram Carlin EZ-1/2 without Tankless Heater
Figure #25 Wiring Diagram Carlin EZ-1/2 with Tankless Heater
22
OPERATING INSTRUCTIONS
Operating Instructions
1.
Inspect venting system at start of each heating season.
2.
Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints. Repair if necessary.
3.
Remove vent pipe at base of chimney or ue and, using mirror, check for obstruction.
Safety Relief Valve
!
WARNING
Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.
• Operate lever of safety relief valve, on boiler
periodically to make sure it is functioning properly.
• Safety relief valve should open before water pressure
exceeds 30 psi reading on gauge.
If this pressure is exceeded and safety relief valve starts leaking water when boiler is operating at normal pressures, it should be immediately replaced.
• Corrosion can build up rapidly at valve seat and
prevent its functioning as safety device. See Figure #11, page 13.
Start-Up And Adjustment Of Oil Burner
(See oil burner instructions for nozzle and electrode
setting)
A. Check oil burner nozzle to verify it is tight in the
adapter.
B. Check electrode setting, may have been jarred out
of position during transportation.
C. Burner mounting bolts should be tight.
D. Set room thermostat to call for heat, or jump
thermostat contacts on the boiler control.
E. Open all oil line 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 per setup
charts on page 24. Adjust if necessary.
Do not set re visually. 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 should be consulted to make proper adjustments with smoke tester, CO2 indicator and draft gauge.
Instructions For Proper Operation Of Boiler Burner Unit
A ¼” diameter slot is provided in inspection cover plate to
take draft readings in combustion chamber. See Figure #26. A ¼” diameter hole will be required in ue pipe
between boiler and barometric damper (if used) to take
draft, CO2, smoke and temperature readings. Adjust air
shutter on oil burner to obtain “trace” of smoke. Measure
CO2 at this point. Increase air adjustment to lower CO
approximately one (1) percent. Check to insure minimum negative .02” w.c., (water column), “overre” draft and zero (0) smoke. If - .02”w.c. “overre” draft can not be maintained, changes and/or modications may be required in venting or chimney.
Following tables (page 25) are provided as guideline for initial start-up. Final adjustments MUST be made using combustion instruments as previously mentioned.
Check Safety Control Circuit - for satisfactory
performance after burner adjustments have been made.
1.
High limit control: remove cover and note temperature setting. See Figure #26. With burner operating, decrease setting to minimum point. When boiler water
temperature exceeds this set point, high limit switch will open, shutting off power to oil burner. Return setting to desired high limit point. Burner should restart. Refer to instructions included with limit.
2.
Primary control and ame sensor check following: A. Flame failure - simulate by shutting off oil supply
with hand valve while burner is on. After ame extinguishes, control goes through recycle period and attempts another ignition then locks out.
To restart, open oil supply valve and reset safety
switch. Refer to instructions included with burner.
B. Ignition failure - with burner off, close oil supply
valve and run through start-up procedure, The safety switch should lock out as in ame failure.
C. 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.
Instruments are only reliable
2
23
OPERATING INSTRUCTIONS
Preventive Maintenance - of oil red 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 ueways, improper combustion will result, causing additional sooting and scaling until ueways are completely closed. To remove soot and scale from ueways, remove top jacket panel, top clean-out plate, open burner swing door. See Figure #26.
Periodic Inspection - and tightening of tankless heater/ cover plate bolts will reduce risk of leaks. See Replacement Parts “Heat Exchanger” section.
Instructions For Opening Burner Swing Door
1.
Turn off power to boiler.
2.
Allow boiler to cool down.
3.
Disconnect power cable at factory supplied burner electrical disconnect. See Figure #26.
4.
Loosen screws on the sides of lower front jacket panel. See Figure #24.
5.
Pull bottom part of lower front panel forward.
6.
Lift lower front panel up and off boiler. See Figure #26.
7.
Close oil valve. See Figures #16 & #17.
8.
Disconnect oil line from burner.
9.
Do not try to swing door with oil line attached.
10.
Remove nut from swing door stud on right hand side of door.
11.
Swing open burner and door to the left.
Brush, using ue brush, soot and scale into combustion space where it can be removed through swing door opening.
• It is recommended to replace nozzle at start of each
heating season.
Lubricate burner motor and circulator motor - if required - with few drops of good grade light motor oil. Do not over oil.
Have service agent service burner, check controls and check electrodes for carbon or cracks in insulators.
• Burners should be adjusted to produce conditions
shown in Start-up and Adjustment of Oil Burner procedure covered earlier in this section.
Use caution when vacuuming in the chamber area. Damage to chamber could result.
WARNING
!
Burn, scald hazard. Do not attempt to start burner when excess oil has accumulated, when unit is full of vapor, or when combustion chamber is very hot.
NOTICE
Use only number 2 fuel oil. Do not use gasoline, crankcase drainings or any oil containing gasoline.
24
OPERATING INSTRUCTIONS
TABLE 1 - BECKETT AFG SETTINGS
BOILER
MODEL
SFH-3085W(T) L1 -- 3⅜ 0.75-60°B 140 0 8
SFH-3100W(T) L1 -- 3⅜ 0.85-60°B 140 1 8
SFH-4100W(T) V1 0 0.85-60°B 140 0 6
SFH-4125W(T) V1 0 1.10-60°B 140 1 8
SFH-4145W(T) V1 2 1.25-60°B 140 2 10
SFH-5160W(T) F12 -- 1.35-70°B 140 1 10
SFH-5185W(T) F12 -- 1.50-70°B 150 2 10
SFH-6175W(T) F12 -- -- 1.50-70°B 140 1 8
SFH-6210W(T) F16 -- -- 1.75-70°B 145 2 10
BOILER
MODEL
SFH-3085W(T) 40F5 2.25 0.70x80°W 145 0.0 2.0
HEAD
TYPE
RIELLO
BURNER
MODEL
HEAD
SETTING
TABLE 2 - RIELLO 40F5/40F10 SETTINGS
BURNER
INSERTION
[INCHES]
STATIC
PLATE
NOZZLE
NOZZLE
PUMP
PRESSURE
[PSI]
PUMP
PRESSURE
[PSI]
TURBULATOR
SETTING
AIR
BAND
AIR
SHUTTER
AIR
GATE
SETTING
SFH-3100W(T) 40F5 2.25 0.85x80°W 145 1.0 2.5
SFH-4100W(T) 40F5 2.25 0.85x80°W 145 1.0 2.55
SFH-4125W(T) 40F5 2.25 1.00x80°W 155 2.0 4.0
SFH-4145W(T) 40F5 2.25 1.20x60°W 150 3.5 4.75
SFH-5160W(T) 40F5 2.25 1.35x60°W 145 4.0 5.75
SFH-5160W(T) 40F10 2.25 1.35x60°W 145 1.5 2.5
SFH-5185W(T) 40F10 2.25 1.50x60°B 150 2.0 3.0
SFH-6175W(T) 40F10 4.75 1.50x45°B 140 0.0 3.8
SFH-6210W(T) 40F10 4.75 1.75x45°B 145 2.0 4.75
TABLE 3 - CARLIN EZ-1/2 SETTINGS
BOILER
MODEL
3085 EZ-1HP 0.85 DELAVAN 0.75 x 70 B 130 0.75 45% BLANK
3100 EZ-1HP 1.00 DELAVAN 0.85 x 70 B 140 0.85/1.00 55% BLANK
4100 EZ-1HP 1.00 DELAVAN 0.85 x 70 B 140 0.85/1.00 52% BLANK
4125 EZ-1HP 1.25 DELAVAN 1.00 x 70 B 155 0.85/1.00 70% BLANK
4145 EZ-1HP 1.45 DELAVAN 1.20 x 70 B 145 1.10/1.25 78% BLANK
BURNER
MODEL
FIRING
RATE
NOZZLE
MFR.
NOZZLE
TYPE
PUMP
PRESSURE
[PSI]
HEAD
BAR
AIR
BAND
SETTING
AIR
SHUTTER
5160 EZ-2HP 1.60 DELAVAN 1.35 x 70 B 140 0.85/1.00 20% 3 SLOT
5185 EZ-2HP 1.85 DELAVAN 1.50 x 70 B 155 1.50 30% 3 SLOT
6175 EZ-2HP 1.75 DELAVAN 1.50 x 60 B 140 1.50 35% 3 SLOT
6210 EZ-2HP 2.10 DANFOSS 1.75 x 70 AS 145 1.65/1.75 65% OPEN
Above settings are preliminary settings only. Final adjustments must be made using combustion test instruments as previously outlined in the Operating Instructions
25
SAFETY RELIEF VALVE
Figure #26
OPERATING INSTRUCTIONS
Instructions For Closing Burner Swing Door
1.
Swing burner and door to right until insulation is slightly compressed and stud is exposed.
2.
Attach nut to stud and tighten until built in stop contacts the mounting door.
3.
Replace oil line to burner.
4.
Replace lower jacket panel, and tighten screws.
5.
Connect power cable at factory supplied burner
electrical disconnect.
6.
Turn on power to boiler.
7.
Bleed oil line.
26
SERVICE RECORD
Company Address & Phone #Company Name & Tech InitialsService PerformedDate
27
IMPORTANT
In accordance with Section 325 (f) (3) of the Energy Policy and
Conservation Act, this boiler is equipped with a feature that saves energy
by reducing the boiler water temperature as the heating load decreases.
This feature is equipped with an override which is provided primarily to
permit the use of an external energy management system that serves the
same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE
FOLLOWING CONDITIONS IS TRUE:
An external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.
This boiler is not used for any space heating
This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.
This boiler is equipped with a tankless coil.
UTICA BOILERS
2201 Dwyer Avenue
Utica NY 13501
web site: www.ecrinternational.com
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