ECR UTICA STARFIRE 3 STEAM Instruction manual
P/N 240007512, Rev. E [01/2011]
STARFIRE 3 STEAM
OIL-FIRED CAST IRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Utica Boilers
2201 Dwyer Ave
Utica, NY 13501
www.ecrinternational.com
An ISO 9001-2008 Certified Company
MODEL NUMBERS:
SFE0365, SFE3100,
SFE4100, SFE4125,
SFE4150, SFE5175,
SFE5200, SFE6225,
SFE7275
2
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
SAFETY SYMBOLS
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
TABLE OF CONTENTS
H
Tested For 15 psi.
ASME
Working Pressure
risk levels.
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
........................ 3
....................................... 4
........................ 5
............. 7
.......... 8
..........................................8
................................................ 9
.....................................9
..................... 13
....................................13
................................ 15
............................................17
.........................................18
!
WARNING
NOTICE
!
CAUTION
!
DANGER
!
WARNING
life.
4. TO THE OWNER -
5.
Fitter.
!
WARNING
3
Boiler Model
(1)
I=B=R Oil Burner
Input(2)
MBH(4)
(3)(4)
Pressure
PSI
Furnished
(5)
A.F.U.E.
MBH(4)
MBH
Round
365S 0.65 91 79 59 246 6 8x8x15 140 .60 80B 85
3100S 1.00 140 116 87 363 6 8x8x15 140 .85 80B 81.5
4100S 1.00 140 120 91 377 7 8x8x15 140 .85 80B 85
4125S 1.25 175 145 109 454 7 8x8x15 140 1.10 60B 82.5
4150S 1.50 210 170 128 533 7 8x8x15 140 1.25 80B 81
5175S 1.75 245 202 152 633 8 8x8x15 140 1.50 80B H 83
5200S 2.00 280 227 170 708 8 8x8x15 140 1.75 70B H 82
6225S 2.25 315 251 188 783 8 8x12x15 140 2.00 45B -
7275S 2.75 385 307 230 958 8 8x12x15 140 2.25 60B -
NOTES:
2.
RATINGS, DATA, AND DIMENSIONS
STANDARD EQUIPMENT:
(NOTE: For tankless heater units, add tankless hot water coil, and 4006
limit control.)
DIMENSIONS (See Figure A)
Boiler No. Length of Flush
Jacket
Front of Jacket to
Center Line of Flue
Outlet
Flue Outlet Diam-
eter
-A- -B- -C-
3S
4S
5S
6S
7S
TANKLESS WATER HEATER CAPACITIES
Boiler Model
Number
Firing
Rate
G.P.H.
Tankless
Heater
Number
Tankless Heater Capac-
ity Intermittent Draw
G.P.M.
Boiler Water Content
(Gallons)
To Water
Line To LWCO
Line
365S 0.65 11 8
3100S 1.00 4.5 11 8
4100S 1.00 4.5 13 9
4125S 1.25 4.5 13 9
4150S 1.50 4.5 13 9
5175S 1.75 5.0 15 10
5200S 2.00 5.0 15 10
6225S 2.25 5.0 17 11
7275S 2.75 5.0 19 12
Figure #1
4
INSTALLATION PROCEDURE
-
TOP 24 IN.
FRONT 24 IN.
9 IN.
REAR 24 IN.
6 IN.
24IN.
NOTE:-
-
-
-
!
WARNING
Minimum clearances to combustible
construction (as seen from above)
BOILER
!
WARNING
-
Figure #2
5
VENTILATION AND COMBUSTION AIR
1.
2.
-
-
-
3.
-
4.
-
(Figure #3)
5.
COMBUSTION AIR REQUIREMENTS
(Minimum Opening Requirement)
BTU/Hr Input
Unconned Area* Conned Area**
Outside Inside Outside Combustion Air
Combustion Air 1 Sq.
In./5000 BTU/Hr
(Step 4)
Combustion Air 1 Sq.
In./1000 BTU/Hr
(Min. 100 Sq. In.) (Figure #1)
Vertical Ducts 1 Sq. In./4000 BTU/
Hr (Figures # 2 & #3)
Horizontal Ducts 1 Sq. In./2000
BTU/Hr (Figure # 4)
91,000 19 100 23 46
140,000 28 140 35 70
175,000 35 175 44 88
210,000 42 210 53 106
245,000 49 245 61 122
280,000 56 280 61 140
VENTS
CHIMNEY
OR
L TYPE VENT PIPE
VENT PIPE
BASEBOARD
12"
12"
!
WARNING
Figure #3
6
(Figure #5)
(Figure #6)
6.
A.
(Figure #4)
B.
VENTILATION AND COMBUSTION AIR
Figure #4
Figure #5
Figure #6
7
CONNECTING SUPPLY AND RETURN PIPING
1.
seen in Figure #7
-
2.
See
3.
Figure #8
See
4.
Figures #9#10
SUGGESTED PIPING FOR MODULAR
STEAM BOILERS - PUMPED RETURN
CHECK
VALVE BLOWOFF
VALVE
SOLENOID
VALVE
(OPTIONAL)
F & T TRAPHIGH
LEVEL"SPILL"
(DO NOT USE WITH
CONDENSATE PUMP)
TO
RECEIVER
TANK
STEAM MAIN
TRAP
PUMPED RETURN
TO
SYSTEM
FROM
RECEIVER
TANK
FROM
RECEIVER
TANK
STOP
VALVE
TO
RECEIVER
TANK
STOP
VALVE
PIPING FOR BUILT-IN
DOMESTIC HOT WATER HEATER
PIPING FOR BUILT-IN
DOMESTIC
HOT WATER HEATER
COLD WATER IN
UNTEMPERED
HOT
FLO W
REGULATOR
TEMPERING VALVE
COLD WATER
DOMESTIC
HOT
WATER
T & P VALVE
UNTEMPERED HOT
WATER TO
AUTOMATIC WASHER
CONTROL
WATER
INSTALLED BELOW CENTER
LINE OF BOILER HOT
CONNECTION
SUGGESTED PIPING FOR MODULAR
STEAM BOILERS - GRAVITY RETURN
RETURN
GRAVITY RETURN
2"
TO
SYSTEM
STOP
VALVE
BLOWOFF
VALVE
STOP
VALVE
CHECK
VALVE
(OPTIONAL)
STEAM MAIN
WATER
LINE
28"
Figure #7
Figure #8
Figure #9
Figure #10
8
VENTING SYSTEM INSPECTION & INSTALLATION
RIDGE 2’ (.61 M) MIN.
MORE THAN 10’(3.1 M)
10’ (3.1 M)
HEIGHTABOVE ANY
ROOF SURFACE WITHIN
10’ (3.1 M)
HORIZONTALLY
CHIMNEY 3’ (.92 M)
GAS VENT OR
TYPE L VENT
2’ (.61 M) MIN.
OIL TANK AND PIPING
!
WARNING
Boiler is to be vented by natural draft
and shall not be connected into any
portion of a mechanical draft operating
system under a positive pressure.
(Figure #11)
CHIMNEY OR VENT SIZES
BTU/HR INPUT ROUND
INCHES SQUARE
INCHES HEIGHT (FT)
MIN MAX MIN MAX MIN MAX
91,000 - 140,000 6 8 8x8 8x8 15 40
175,000 - 210,000 7 8 8x8 8x10 15 40
245,000 - 280,000 8 10 8x8 8x12 15 50
315,000 8 10 8x8 8x12 15 50
385,000 8 10 8x8 8x12 15 50
Figure #11
9
THERMOSTAT INSTALLATION
TYPICAL INSTALLATION
SINGLE PIPE OIL SYSTEM TYPICAL INSTALLATION
TWO PIPE OIL SYSTEM
(Figures #12 - #13)
ELECTRICAL WIRING
1.
MUST BE
OIL TANK AND PIPING
2.
3.
(See "Steam
Wiring" on next page.)
1.
NEVER
2.
3.
4.
5.
Figure #12 Figure #13
10
TH-1 MR-PS
TH-2
TH-3 1K
TR-1 1K1
TR-2 1K2
EWF
PS MS
STEAM WIRING W/BECKETT BURNER
NOTE:
11
STEAM WIRING W/RIELLO BURNER
12
STEAM WIRING W/CARLIN BURNER
13
NORMAL SEQUENCE OF OPERATION
IMPORTANT TO THE INSTALLER - Before putting the
!
WARNING
WATER WILL BE BOILING HOT.
OPERATING INSTRUCTIONS
(Figure #14)on the
MOUNTING
(BOTH SIDES)
LOWER FRONT
JACKET PANEL
PRESSURE RELIEF
VALVE TOP JACKET
PANEL
1/4" SLOT
BURNER
ELECTRICAL
DISCONNECT
28"
WATER
ELECTRONIC LOW
WATER CUT OFF
INSPECTION
COVER
LINE
SCREWS
HOT
START-UPAND ADJUSTMENT OF OIL BURNER
(See oil burner instructions for nozzle and electrode setting)
!
CAUTION
DO NOT SET FIRE VISUALLY.
Instrumentsaretheonlyreliablemethod
to determine proper air adjustments.
An improperly adjusted burner causes
soot and high fuel bills because of
incomplete combustion of the 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
the proper adjustments with a smoke
tester, CO2indicator, and draft gauge.
NOTE:
A.
B.
!
WARNING
Discharge will be boiling hot water and
steam.
Figure #14
14
-
E.
F.
H.
I.
OPERATING INSTRUCTIONS
INSTRUCTIONS TO OBTAIN PROPER OPERATION OF
BOILER-BURNER UNIT
-
(Figure #14)
2-
2
2
-
guideline for ini-
-
IMPORTANT: Check safety control circuit after burner adjustments have been made for satisfactory performance.
RIELLO SETTINGS
Boiler
No. Burner No. Air Damper Pump
Press. Turb. Nozzle Fur-
nished
3100 F-5 3.6 150 PSI 1 .85 80W
4125 F-5 4 150 PSI 3 1.10 60W
4150 F-5 6 150 PSI 4 1.25 60W
5200 F-10 5 150 PSI 0 1.75 80B
CARLIN SETTINGS
Boiler
No. Burner
No. Air
Pump
Press. Head
Bar Nozzle Fur-
nished
3100 EZ-1 0.85 150 PSI .85 - 1.00 .85 70B
4125 EZ-1 1.00 - 1.10 150 PSI 1.10 - 1.25 1.10 70B
4150 EZ-1 1.25 - 1.35 150 PSI 1.10 - 1.25 1.25 70B
5200 EZ-2 1.75 150 PSI 1.65 - 1.75 1.75 70B
BECKETT SETTINGS
Boiler
No. Burner
No. Air
Damper Air
Shut. Pump
Press. Static
Disc End
Cone Nozzle Fur-
nished
3100 1 5 140 PSI F3 .85 80B
4125 1 8 140 PSI F4 1.10 60B
4150 2 6 140 PSI F6 1.25 80B
5200 5 5 140 PSI 3U F12 1.75 70B H
6225 4 6 140 PSI N/A 2.00 45B
7275 4 6 140 PSI N/A 2.25 60B
NOTES:
A.
B.
!
WARNING
WATER WILL BE BOILING HOT.
15
shown in "Startup and Adjustment of Oil Burner."
CLOSING THE BURNER SWING DOOR
1.
2.
3.
4.
5.
6.
MAINTENANCE PROCEDURES
OPERATING INSTRUCTIONS
Figure #14
!
WARNING
Discharge may be boiling hot water.
(Figure
#14)
Flame Failure
1.
-
Ignition Failure
2.
Power Failure
3.
-
-
(Figure #14)
OPENING THE BURNER SWING DOOR
1.
-
2.
(Figure #14)
3.
(Figure 6)
(Figure #14)
4.
(Figures #12 - #13)
IMPORTANT: Do not open swing door with oil line
attached.
5.
door.
6.
opening.
!
CAUTION
Use caution when vacuuming in the
chamber area. Damage to chamber
could result.
16
MAINTENANCE PROCEDURES
(Figure #7)
BLOWING DOWN THE BOILER
!
WARNING
WATER WILL BE BOILING HOT.
USING CLEANING COMPOUND
!
WARNING
Discharge will be boiling hot water and
steam.
(Figure #14)If
Impurities in boiler water
BOILERS SHOULD BE CLEANED BY SKIMMING OR
BLOWING DOWN.
!
CAUTION
Theboiler should not beleftunattended
during the cleaning process.
SKIMMING OFF IMPURITIES
17
MAINTENANCE PROCEDURES
under "Coil and Cover Plate Replacement Parts."
ELECTRONIC LOW WATER CUT-OFF
SERVICE CHECKLIST
[ X ]
SERVICE RECORD
Date Nozzle Pump Pressure
PSI
Motor
2
or O2
Flue
Angle O.F. INF
2or O2 [ * ]
!
WARNING
WATER WILL BE BOILING HOT.
18
CONTROLS AND HARDWARE
REPLACEMENT PARTS
COIL AND COVER PLATE
ITEM PART NO. DESCRIPTION QTY.
1HW-012.02 Bolt -
7
16 -14 x 1½
8
2 252-2-2.00 1
3 202-2-1.00 -
1
4HW-013.01
Nut
7
16
8
5 252-3-1.02 1
6 1635001 Well ¾ x 1½ - 123870A 1
7 275-1-1.00 1
8 AQ-008.00 1
ITEM PART NO.
1 PF-033.02 2
2 14693052 2
3 1
4 240007394 BRASS,SIPHON,OFF
1
5 14693057 1
6 240007412 1
7 240007411 2
8 1
9 240007160
1
10 SS-001.01 1
11 1263012
1
240007185
12 240007187
11263011
240007186
13 240007161 1
14 28511201 1
15 14631316 1
16 240007282 1
17 240007281 1
19
REPLACEMENT PARTS
HARDWARE
ITEM PART NO. DESCRIPTION QTY
1 1570001
1
2 PF-019.02
1
3 PF-005.01
1
4HW06701 Stud
5
16
4
5 2252501
2
6HW07001 Stud
5
16
3
7HW06901 Nut
5
16
8
8HW-016.02
1
9 PF-004.04
1
10
2452906
1
2452902
2452903
2452907
2452908
11
109007327
1
20
REPLACEMENT PARTS
HEAT EXCHANGER
ITEM PART NO. DESCRIPTION QTY
1 100-5-10.01
1
2 100-1-8.01
2
3
4
5
6
3 10051101
1
2
3
4
5
4 10051802
1
5611508
5 2552701
1
6 25511005
1
7
HW-025.05
3
HW-025.01
HW-025.02
HW-025.03
HW-025.09
ITEM PART NO. DESCRIPTION QTY
8
100-1-5.01
2
3
4
5
6
9 MS-006.00
10 HW-008.03
3
11 HW-003.05
3
FULLY ASSEMBLED HEAT EXCHANGERS
550001977
550001978
550001979
550001980
550001981
550001982
550001983
550001984
550001985
550001986
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9
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