UTICA BOILERS STARFIRE 3 STEAM Installation Manual And Operating Instructions

STST

OIL FIRED CAST IRON BOILER

ARFIRE 3ARFIRE 3

ARFIRE 3

ARFIRE 3ARFIRE 3

STEAMSTEAM

STEAM

STEAMSTEAM

UCTIONSUCTIONS

UCTIONS

TING INSTRTING INSTR

TING INSTR

Utica Boilers • P.O. Box 4729 • Utica, NY 13504

AND OPERAAND OPERA

AND OPERA

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TION MANUTION MANU

TION MANU

ALLAALLA

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ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

ABLE OF CONTENTSABLE OF CONTENTS

SAFETY SYMBOLS & WARNINGS ......................................................... PAGE 1

INSTALLATION PROCEDURE ................................................................ PAGE 2

VENTILATION AND COMBUSTION AIR ................................................. PAGES 3 - 5

CONNECTING SUPPLY AND RETURN PIPING STEAM ....................... PAGE 6 - 7

VENTING SYSTEM INSPECTION AND INSTALLATION ....................... PAGE 8

OIL TANK AND PIPING ........................................................................... PAGE 9

ELECTRICAL WIRING ............................................................................. PAGE 10

THERMOSTAT INSTALLATION .............................................................. PAGE 11

NORMAL SEQUENCE OF OPERATION ................................................. PAGE 11

OPERATING INSTRUCTIONS ................................................................ PAGES 12 - 14

ANNUAL MAINTENANCE PROCEDURE ................................................ PAGES 15 - 16

SERVICE CHECK LIST ........................................................................... PAGE 17

REPLACEMENT PARTS LIST ................................................................. PAGES 18- 19

GENERAL ASSEMBLY ............................................................................ PAGES 20 - 25

RATINGS, DATA AND DIMENSIONS ..................................................... PAGES 25 - 26

KEEP THIS MANUAL NEAR BOILER. RETAIN FOR FUTURE REFERENCE

SERIES SFH-S CAST IRON OIL FIRED BOILER INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

PUBLISHED APRIL 1994 APRIL 1994 - UTICA BOILERS PRINTED IN USA MADE IN USA

TESTED FOR 15 LBS.

ASME WORKING

PRESSURE

Safety SymbolsSafety Symbols

Safety Symbols

Safety SymbolsSafety Symbols

The following defined symbols are used throughout this manual to notify the

reader of potential hazards of varying risk levels.

DANGERDANGER

DANGER

DANGERDANGER

DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL

result in death or serious injury.

ARNINGARNING

ARNING

ARNINGARNING

WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD

result in death or serious injury

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

CAUTION - Indicates a potentially hazardous situation which, if not avoided, MAY

result in minor or moderate injury. It may also be used to alert against unsafe practices.

IMPORIMPOR

IMPOR

IMPORIMPOR

1. Keep boiler area clear and free from combustible materials, gasoline and other

flammable vapors and liquids.

2. DO NOT obstruct air openings to the boiler room.

3. Modification, substitution or elimination of factory equipped, supplied or specified

components may result in property damage, personal injury or the loss of life.

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

installer.

5. To the installer: Leave all instructions with the boiler for future reference.

6. When this product is installed in the Commonwealth of Massachusetts the installation

must be performed by a Licensed Plumber or Licensed Gas Fitter.

SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND INSHOULD 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 INSHOULD 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 APPROPRIATE UTICA BOILERS MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCEINSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE

INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE

INSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCEINSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUSWITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS

WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS

WITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUSWITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROMINJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM

INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM

INJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROMINJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH ISPOISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS

POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS

POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH ISPOISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS ODORLESS AND INVISIBLE.ODORLESS AND INVISIBLE.

ODORLESS AND INVISIBLE.

ODORLESS AND INVISIBLE.ODORLESS AND INVISIBLE.

ANT!ANT!

ANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.

ANT!ANT!

ARNING:ARNING:

ARNING:

ARNING:ARNING:

ARNING:

ARNING:ARNING:

ALL INSTALLATIONS OF BOILERS AND VENTINGALL INSTALLATIONS OF BOILERS AND VENTING

ALL INSTALLATIONS OF BOILERS AND VENTING

ALL INSTALLATIONS OF BOILERS AND VENTINGALL INSTALLATIONS OF BOILERS AND VENTING

PAGE 1

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WARNING:WARNING:

WARNING: Improper installation, adjustment, alteration, service or

WARNING:WARNING:

maintenance can cause property damage, personal injury or loss of life.

All installations must 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.

LOCATE Starfire 3 in front of final position before removing crate. Provide a level solid base as near chimney as possible and centrally located with respect to the heat distribution system as practical.

WARNING:WARNING:

WARNING: BOILER MAY NOT BE INSTALLED ON COMBUSTIBLE

WARNING:WARNING:

FLOORING.

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

It is recommended that 24 IN. 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 the largest boiler part to enter, or to permit replacement of another appliance such as a water heater.

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

FOR INSTALLATION ON NON-COMBUSTIBLE FLOORS ONLY. The 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 ................................................................24 IN.

LEFT SIDE ........................................................ 6 IN.

RIGHT SIDE ......................................................24IN.

ALLAALLA

ALLA

ALLAALLA

TION PRTION PR

TION PR

TION PRTION PR

OCEDUREOCEDURE

OCEDURE

OCEDUREOCEDURE

NOTE: CLEARANCE FOR ACCESS SHOULD EXCEED FIRE PROTECTION CLEARANCE.

PAGE 2

VENTILAVENTILA

VENTILA

VENTILAVENTILA

ARNING:ARNING:

ARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT

ARNING:ARNING:

BE OBSTRUCTED. BY FOLLOWING THE CHART BELOW, ADEQUATE COMBUSTION AIR CAN BE MAINTAINED.

TION & COMBTION & COMB

TION & COMB

TION & COMBTION & COMB

COMBUSTION AIR REQUIREMENTS

(Minimum Opening Requirements)

USTION USTION

USTION

USTION USTION

AIRAIR

AIR

AIRAIR

*UNCONFINED AREA **CONFINED AREA

Outside Inside Outside Combustion Air

Combustion Combustion VERTICAL HORIZONTAL

BTU/HR Air 1 IN.

INPUT /5000 BTU/HR /1000 BTU/HR 1 IN.

(Paragraph 4) (See Fig 1) /4000 BTU/HR /2000 BTU/HR

91,000 19 100 23 46

140,000 28 140 35 70

175,000 35 175 44 88

Air 1 IN.

(MIN. 100 IN2) (See Fig 2 & 3) (See Fig 4)

DUCTS DUCTS

1 IN.

210,000 42 210 53 106

245,000 49 245 61 122

280,000 56 280 61 140

*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 and venting.

2. When a Starfire 3 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. If there is any doubt, install air supply provisions for combustion and ventilation in accordance with section 5.3, Air for Combustion and Ventilation, of the NFPA 54 1988 code, the recommendations that follow, or applicable provisions of the local building codes.

3. When a Starfire 3 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

PAGE 3

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.

4. When air for combustion and room ventilation is from inside buildings, the 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 below.

FIGURE 1 FIGURE 2

5. When the Starfire 3 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 above.

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 on page 5.

PAGE 4

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 below.

FIGURE 3 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 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. See chart on page 3 for combustion air minimum opening requirements.

PAGE 5

CONNECTING SUPPLCONNECTING SUPPL

CONNECTING SUPPL

CONNECTING SUPPLCONNECTING SUPPL

1. Suggested piping for steam heating system can be seen in figure 6 below. Actual piping

may vary based on system design and local conditions.

2. For further piping information refer to the I=B=R installation piping guide.

3. See figure 5 below for typical piping for domestic hot water heater.

4. See figures 7 & 8 on page 7 for the suggested piping for a modular steam boiler.

PIPING FOR BUILT IN DOMESTIC HOT WATER HEATER

Y Y

AND RETURN PIPINGAND RETURN PIPING

AND RETURN PIPING

Y Y

AND RETURN PIPINGAND RETURN PIPING

FIGURE 5

FIGURE 6

PAGE 6

SUGGESTED PIPING FOR MODULAR STEAM BOILER

PUMPED RETURN

FIGURE 7

GRAVITY RETURN

FIGURE 8

PAGE 7

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UTICA BOILERS STARFIRE 3 STEAM Installation Manual And Operating Instructions

Specifications and Main Features

Frequently Asked Questions

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