Utica boilers SFH-6175, SFH-5185, SFH-5160, SFH-4100, SFH-4145, SFH-3085, SFH-6210, SFH-4125, SFH-3100 User Manual

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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

Tested For 75 psi

ASME

Working Pressure

An ISO 9001-2008 Certified Company

Manufactured by:

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 qualified 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.

! WARNING

All boiler and venting installations shall be done by qualified 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 fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible.

!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

Modification, substitution or elimination of factory equipped, supplied or specified components could result in death or serious injury.

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

DO NOT obstruct air openings to boiler room.

To the owner: Installation and service of this boiler must be performed by qualified 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

DIMENSIONS

DIMENSIONAL DATA

 

A

B

C

 

FRONT OF

 

DEPTH

DIA.

BOILER

CASING

OF

OF

SECTION

TO CENTER LINE

FLUSH

FLUE

 

OF

 

JACKET

OUTLET

 

FLUE OUTLET

 

 

 

3

17 ⅞"

11 ¼"

6"

4

21 ½"

12 ⅝"

6"

5

25 ⅛"

14 ¼"

7"

6

29¼

15 ¹ /16

8”

3

BOILER RATINGS & CAPACITIES

BOILER RATINGS

 

 

 

(1)

(3)

(2)

 

 

 

 

 

NET

(3)

 

BOILER

OIL BURNER

HEATING

CHIMNEY

 

RATINGS

A.F.U.E.

MODEL

INPUT

CAPACITY

 

NUMBER

 

 

 

 

WATER

 

 

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]

1Oil burner input based on 140,000 Btu per gallon.

2Net 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.

3Heating 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.

T= Tankless

STANDARD EQUIPMENT: Crated Boiler, Flush Jacket, Oil Burner, Target Wall/Liner, Circulator1¼”, 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

INPUT

TANKLESS

TANKLESS

BOILER

HEATER CAPACITY

MODEL

RATE

HEATER

WATER CONTENT

INTERMITTENT DRAW

NUMBER

G.P.H.

NUMBER

GALS.

G.P.M.

 

 

 

 

 

 

 

 

 

SFH-3085WT

0.85

T3

3

10.5

SFH-3100WT

1.00

T3

10.5

SFH-4100WT

1.00

T4

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

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 final 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 flooring or carpeting. Failure to follow these instructions could result in death or serious injury.

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 protective wrapper, inspect for damage.

Move boiler to permanent position by sliding or walking.

5

VENTILATION & 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 IN SQUARE INCHES)

 

*UNCONFINED AREA

**CONFINED AREA

 

 

 

 

 

 

OUTSIDE

INSIDE

OUTSIDE

INPUT

COMBUSTION AIR

COMBUSTION AIR

COMBUSTION AIR

1 IN2/5000Btu/HR

1 IN2/1000 Btu/HR

1 IN2/4000 Btu/HR

1 IN2/2000 Btu/HR

(Mbh)

(MIN 100IN2) (Figure

 

(PARAGRAPH 4)

1)

(Figures 2&3)

(Figure 4)

 

 

 

 

 

 

 

 

 

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

* 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 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 boiler is located in an unconfined space in a building of conventional construction frame, masonry or metal, infiltration normally is adequate to provide air for combustion and ventilation. However, in any building which has been altered to conserve energy or to minimize infiltration, 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 unconfined 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, confined 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 infiltration from the outside. See Figure #1.

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. See

Figure #2.

Figure #1

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 specified. 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 fixed 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.

7

VENTILATION & COMBUSTION AIR

Figure #2

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 flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

Figure #5 Typical Piping Configuration

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 flow control valve to prevent gravity circulation.

*Reduced pressure back flow 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 fit system or condition of installation. Although, this method of piping is not typically required for baseboard heating systems.

9

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