ECR International Utica Boilers SFH IV Instruction manual
SFH IV
WATER
OIL FIRED CAST IRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Models
SFH-3085
SFH-3100
SFH-4100
SFH-4125
SFH-4145
SFH-5160
SFH-5185
SFH-6185
SFH-6210
Tested For 75 psi
ASME
Working Pressure
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com
PN 240012628 REV. A [09/30/2019]
2
1 - TABLE OF CONTENTS
CONTENTS
2 - DIMENSIONS �����������������������������������������������������������������������������������������������������������3
3 - SAFETY INFORMATION����������������������������������������������������������������������������������������������4
4 - BEFORE YOU START��������������������������������������������������������������������������������������������������6
5 - LOCATING THE BOILER���������������������������������������������������������������������������������������������7
6 - VENTILATION & COMBUSTION AIR ����������������������������������������������������������������������������8
7 - CONNECTING SUPPLY AND RETURN PIPING���������������������������������������������������������������11
8 - SYSTEM PIPING ����������������������������������������������������������������������������������������������������� 17
9 - VENTING SYSTEM INSPECTION & INSTALLATION��������������������������������������������������������18
10 - OIL TANK AND PIPING ������������������������������������������������������������������������������������������ 19
11 - FIELD ASSEMBLY�������������������������������������������������������������������������������������������������� 20
12 - ELECTRICAL WIRING �������������������������������������������������������������������������������������������� 21
13 - ELECTRICAL WIRING DIAGRAMS ��������������������������������������������������������������������������� 22
14 - OPERATING INSTRUCTIONS���������������������������������������������������������������������������������� 24
15 - BURNER SETTINGS����������������������������������������������������������������������������������������������� 26
16 - BOILER RATINGS & CAPACITIES���������������������������������������������������������������������������� 27
Information and specications outlined in this manual were in eect at the
time of printing of this manual. reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
PN 240012628, Rev. A [09/30/2019]
3
4”
C
1
1
/
2
” NPT
C
2” NPT Supply Tapping
35”
Table - 1
BOILER
SECTION
A
DEPTH
OF
FLUSH
JACKET
B
FRONT OF
CASING
TO CENTER LINE
OF
FLUE OUTLET
C
DIAMETER
OF
FLUE
OUTLET
3
4
5
6 29 ¼” 15
/”
8”
Figure #1 - Dimensional Data
2 - DIMENSIONS
PN 240012628, Rev. A [09/30/2019]
4
NOTICE
Used to address practices not related to personal
injury�
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury�
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury�
!
DANGER
Indicates a hazardous situation which, if not
avoided, WILL result in death or serious injury
!
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�
Become familiar with symbols identifying potential
hazards.
WARNING
result in death or serious injury�
!
3.1 - General
WARNING
Fire, explosion, asphyxiation and electrical shock
hazard� Improper installation could result in death
or serious injury� Read this manual and understand
all requirements before beginning installation�
!
WARNING
Installation or venting a boiler or any other oil
appliance with improper methods or materials may
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible�
!3.2 - Installation shall conform to requirements of
authority having jurisdiction or in absence of such
requirements to ANSI/NFPA 31, “Installation of Oil
Burning Equipment”. In Canada, Current Edition
of Canadian Standards Association CSA B139,
Installation Code for Oil Burning Equipment” for
recommended installation practices.
Such applicable
requirements take precedence over general
instructions of this manual.
3.3 - Current Edition of American National
Standard ANSI/NFPA 211 “Chimneys, Fireplaces,
Vents and Solid Fuel Burning Appliances” for
venting.
3.4 - Where required by authority having
jurisdiction, installation shall conform to
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
high limit may be required�
3.5 - Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
3 - SAFETY INFORMATION
WARNING
Construction materials of appliance and products
of combustion and fuel contain alumina, silica,
heavy metals, carbon monoxide, nitrogen
oxides, aldehydes and /or other toxic or harmful
substances which can cause death or serious injury
and which are known to the State of California to
cause cancer, birth defects and other reproductive
harm� Always use proper safety clothing,
respirators and equipment when servicing or
working nearby the appliance�
!
PN 240012628, Rev. A [09/30/2019]
5
3 - SAFETY INFORMATION
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!
Water heated to temperature for clothes
washing, dish washing and other sanitizing
needs can scald and cause permanent injury�
handicapped persons are more likely to be
permanently injured by hot water� Never leave
them unattended in bathtub or shower� Never
allow small children to use a hot water tap or
draw their own bath�
above description, or if state laws or local codes
require certain water temperatures at hot water
taps, you must take special precautions:
• Use lowest possible temperature setting�
• Install some type of tempering device, such
as an automatic mixing valve, at hot water
tap or water heater� Automatic mixing valve
must be selected and installed according
to manufacturer's recommendations and
instructions�
• Water passing out of drain valves may be
extremely hot� To avoid injury:
• Make sure all connections are tight�
•
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note: Warning for Infants, Children, and Elderly:
Great care must be taken when exposing the
aforementioned groups to warm or hot water as they
can be badly burned in exposure times less than half
of the time for an adult�
WARNING
Combustion chamber insulation in this product
be converted to cristobalite in very high temperature
applications� The International Agency for Research
on Cancer (IARC) has concluded, Crystalline silica
inhaled in the form of quartz or cristobalite from
occupational sources is carcinogenic to humans
(Group1)� Avoid breathing dust and contact
respirator (N95)� This type of respirator is based
on the OSHA requirements for cristobalite at the
time this document was written� Other types of
respirators may be needed depending on the job
site conditions� Current NIOSH recommendations
can be found on the NIOSH website
https://
www�cdc�gov/niosh/topics/silica/�
approved
respirators, manufacturers, and phone numbers are
also listed on this website� Wear long-sleeved, loose
enough water to the combustion chamber lining to
prevent dust� Wash potentially contaminated clothes
separately from other clothing� Rinse clothes washer
thoroughly�
NIOSH stated First Aid� Eye: Irrigate immediately�
Breathing: Fresh air�
!
CAUTION
Laceration, burn hazard� Metal edges and parts
may have sharp edges and/or may be hot� Use
appropriate personal protection equipment to
include safety glasses and gloves when installing
or servicing this boiler� Failure to follow these
instructions could result in minor or moderate injury�
!
PN 240012628, Rev. A [09/30/2019]
6
4 - BEFORE YOU START
4.1 Installation and Operation
1.
Do not operate unit if any control, switch, components
or devices have been underwater or subject to water
damage�
2.
electricity and oil supply to boiler when working on it�
3.
Inspect oil line and connections for leaks�
4.
result in early failure of boiler sections, and result in a
potentially dangerous situation�
5.
Never vent boiler into enclosed space� Always vent to
the outside� Never vent to another room or inside a
building�
6.
Verify adequate air supply for complete combustion�
7.
Relief valve automatically lifts open when system
pressure exceeds 30 psi� Before installing relief valve
read manufacturer’s instructions� Pipe relief valve to a
safe location� Check with authorities having jurisdiction�
8.
Consider system total water volume, temperature,
installing expansion tank� Improperly installed and
sized expansion tank may result in frequent lifting of
relief valve or other heating system problems� Follow
expansion tank manufacturer guidelines for installation,
and sizing�
9.
Purge heating system of air and gases is critical for
proper circulation and quiet performance� Once the air
air vents should be closed for normal operation� If air
is heard or noticed by loss of heat, purge system and
open vents for short period of time�
4.2 Prior To Installing The Boiler
• Verify you have selected right size boiler with proper
capacity� AHRI rating of boiler selected should be greater
than or equal to calculated peak heating load (heat loss)
for building or area(s) served by boiler and associated
hot water heating systems� Use heat loss calculations
based on approved methods� See Table 6, page 27�
• Boiler must be supplied with proper oil supply and oil
electrical supply�
• Connect boiler to suitable venting and piping systems
adequate to distribute heating load�
• Installation is not complete unless pressure relief valve
is installed at 3/4” tapping located at front of unit�
• Thermostat must be properly located and installed
• Failure to pipe boiler correctly may result in excessive
noise or other related problems�
4.3 Existing Water System Evaluation
A good system will prevent oxygen contamination of boiler
water�
1.
Causes of oxygen contamination may be:
A� Addition of excessive make up water as a result of
leaks�
B�
C� Oxygen permeable materials in the distribution
system�
2.
To insure long product life, oxygen sources must be
eliminated�
Take the following measures:
A� Repair system leaks�
B� Eliminate open tanks from the system�
C�
absorption�
D� Use non-permeable materials in the heating
system�
PN 240012628, Rev. A [09/30/2019]
7
5 - LOCATING THE BOILER
1.
Boiler shall not be installed on carpeting or vinyl
2.
crate�
3.
Locate unit so vent pipe connection to chimney will be
short and direct�
4.
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
5.
For basement installation, provide solid elevated base,
6.
Minimum clearances to combustible construction are:
TOP ������������������������������������� 24 IN�
FRONT ��������������������������������� 24 IN�
FLUE CONNECTOR �������������������9 IN�
REAR �������������������������������������6 IN�
SIDES������������������������������������6 IN�
7.
Fresh air for combustion and ventilation must be
available at boiler� Ventilating and combustion air must
enter boiler room without restrictions�
8.
Keep boiler area clear and free from combustible
liquids�
9.
DO NOT obstruct air openings to the boiler room�
WARNING
Fire hazard� Do not install on carpeting, or vinyl
result in death or serious injury�
!
NOTICE
clearance�
PN 240012628, Rev. A [09/30/2019]
8
1.
Boiler room ventilation must be adequate enough to
See Table 2�
2.
building of conventional construction frame, masonry
air for combustion and ventilation� However, in any
building which has been altered to conserve energy
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�
Table 2 - COMBUSTION AIR REQUIREMENTS
(MINIMUM OPENING IN SQUARE INCHES)
INPUT
(Mbh)
*UNCONFINED AREA **CONFINED AREA
OUTSIDE
COMBUSTION AIR
INSIDE
COMBUSTION AIR
OUTSIDE
COMBUSTION AIR
1 IN2/5000Btu/HR
(PARAGRAPH 4)
1 IN2/1000 Btu/HR
(MIN 100IN2) (Figure
1)
1 IN2/4000 Btu/HR
(Figures 2&3) 1 IN2/2000 Btu/HR
(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
* Unconned 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).
** Conned 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).
3.
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
WARNING
openings to combustion area� Follow instructions
below, to maintain adequate combustion air�
!
PN 240012628, Rev. A [09/30/2019]
9
4.
When air for combustion and room ventilation is from
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
Figure #2�
5.
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
#3�
6 - VENTILATION & COMBUSTION AIR
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 #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 #5�
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
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
may be assumed that wood louvers will have 20-25%
free area and metal louvers and grills will have 60-75%
position or interlocked with the boiler so that they are
opened automatically during boiler operation� Refer
to Combustion Air Requirements chart on page 7 for
combustion air minimum opening requirements�
Figure #2
PN 240012628, Rev. A [09/30/2019]
10
6 - VENTILATION & COMBUSTION AIR
Figure #3
Figure #4 Figure #5
PN 240012628, Rev. A [09/30/2019]
11
1.
Connect supply and return piping� See Figure #6� 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 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
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
circulation�
* Reduced pressure back ow preventer shall be used under
provisions required by the Environmental Protection Agency,
(EPA).
6.
Bypass piping is an option which gives ability to
or condition of installation� Although, this method of
piping is not typically required for baseboard heating
systems�
7 - CONNECTING SUPPLY AND RETURN PIPING
Figure #6 Typical Piping Conguration
PN 240012628, Rev. A [09/30/2019]
12
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 #7�
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
#8 and #9�
C� This method is used to protect boilers from
condensate forming as well as protecting heating
system from high water temperature� See Figure
#9�
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�
7 - CONNECTING SUPPLY AND RETURN PIPING
Figure #7 Bypass Piping
PN 240012628, Rev. A [09/30/2019]
13
7 - CONNECTING SUPPLY AND RETURN PIPING
Figure #8 - Mixing Valve Piping
Figure #9 - Primary Secondary Piping With Bypass
PN 240012628, Rev. A [09/30/2019]
14
DRAIN VALVE
DRAIN VALVE
7 - CONNECTING SUPPLY AND RETURN PIPING
Figure #10 - Indirect Water Heater Piping with Circulator
Figure #11 - Indirect Water Heater Piping with Zone Valve
PN 240012628, Rev. A [09/30/2019]
15
7 - 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�
!
8.
Typical indirect water heater installation using
circulators is shown in Figure #10�
9.
Typical indirect water heater installation using zone
valves is shown in Figure #11�
10.
Install automatic mixing valve 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�
•
restricter must be installed in cold water inlet of this
coil� Terminate pipe with plain end (not threaded)�
PN 240012628, Rev. A [09/30/2019]
16
7 - CONNECTING SUPPLY AND RETURN PIPING
Figure #13 - Optional Location For Air Vent
OPTIONS UTILIZING 3/4” TAPPING
Figure #14 - Optional Location For Expansion Tank (Non-Diaphragm Type)
PN 240012628, Rev. A [09/30/2019]
17
1.
with boiler�
2.
Install safety relief valve with spindle in vertical
position�
3.
relief valve�
4.
DO NOT pipe in area where freezing can occur� DO NOT
5.
Install discharge piping from safety relief valve� See
Figure #15�
• Use ¾” or larger pipe�
• Use pipe suitable for temperatures of 375°F (191°C)
or greater�
• 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�
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping�
• 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)�
8 - SYSTEM PIPING
Check local
codes for
maximum
distance
from oor
or allowable
safe point of
discharge.
SAFETY RELIEF VALVE
DISCHARGE
PIPING
Figure #15 - Discharge Piping From Safety
Relief Valve
WARNING
Burn and scald hazard� Safety relief valve could
discharge steam or hot water during operation�
Install discharge piping per these instructions�
!
PN 240012628, Rev. A [09/30/2019]
18
1.
INSPECT CHIMNEY - verify chimney construction
conforms with requirements of authority having
jurisdiction or in absence of such requirements ANSI
Z211�1, NFPA 211�
• Boiler must be installed into chimney which has
masonry or metallic chimney liner�
• An 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
performance�
• Chimney should extend at least 2 feet above any
portion of building within 10 feet� See Figure #16�
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,
2.
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�
as boiler, provide separate hole into chimney
whenever possible� When not possible, use “Y”
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�
9 - VENTING SYSTEM INSPECTION & INSTALLATION
Figure #16
PN 240012628, Rev. A [09/30/2019]
19
1.
Installation of oil tank and piping shall conform to
requirements of authority having jurisdiction or in
absence of such requirements National Board of Fire
Underwriters � In addition, refer to NFPA 31 (U�S�) or
CSA B139 (Canada)
•
shall conform to requirements of authority having
jurisdiction�
• 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
•
50 feet or less, and ½” O�D� for longer runs�
• Use oil return line, same size as the suction line, on
installations where bottom of tank is below fuel unit of
burner�
• Bury oil lines or protect from mechanical injury�
•
nozzle�
• Do not run overhead fuel lines from tank to oil burner�
• Follow instructions, attached to fuel pump, for fuel
pump and by-pass connections�
• Install two stage fuel unit if tank is more than 20’
from boiler in place of single stage pump supplied as
standard equipment with burner� Verify rotation and
speed are identical and pump is suitable for burner
horsepower rating�
•
•
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 #17 and #18�
•
opened without disconnecting oil supply piping�
10 - OIL TANK AND PIPING
Figure #17 - Typical Installation Single Pipe Oil
System
Figure #18 - Typical Installation Two Pipe Oil
System
PN 240012628, Rev. A [09/30/2019]
20
11 - FIELD ASSEMBLY
1. Install oil burner� Follow burner manufacturer
• Check oil nozzle in burner for size, angle and type,
inspect electrode settings, check head setting,
check air band and air shutter settings�
See “Oil
Burner, Nozzle, & Air Settings” �
• DO NOT install burner without gasket� Place oil
burner gasket on face of burner swing door with 4
•
with burner door bolts� Turn burner to lock in place�
• Tighten all 4 cap screws using diagonal sequence�
• Plug burner power cord into burner harness�
•
• Connect burner quick connect to corresponding
High Limit Control harness� See Figure #22�
2.
included with circulator if appropriate�
PN 240012628, Rev. A [09/30/2019]
This manual suits for next models
9
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