UTICA BOILERS SFM6225W User manual

installation, operation and maintenance manUal
R
P/N 27513401, Rev. A [01/09]
UTICA BOILERS
P.O. Box 4729
Utica, NY 13504-4729
www.uticaboilers.com
sFm constellation series
modUlar oil Fired cast iron Boilers
An ISO 9001-2000 Certied Company

3
TABLE OF CONTENTS
Safety Symbols ................................................ 2
Dimensions ..................................................... 4
Boiler Ratings & Capacities ............................ 5
Introduction ...................................................... 6
Connecting Supply & Return Piping............... 11
Primary Secondary Piping .......................... 9-11
Ventilation & Combustion Air.........................7-8
Venting System Inspection & Installation ...... 12
Oil Tank Installation & Piping ....................12-13
Thermostat Installation................................... 13
Operating Instructions.................................... 14
Control System .........................................16-17
Service Check List ......................................... 17
REPLACEMENT PARTS LISTS
Swing Door & Mounting Door Components...28
Jacket............................................................. 28
Hardware ....................................................... 28
Controls & Hardware...................................... 28
SFM SERIES MODULAR OIL FIRED CAST IRON BOILERS
SAFETY SYMBOLS
The following dened symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels.
Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or
serious injury.
Indicates a potentially hazardous situation
which, if not avoided, COULD result in death
or serious injury.
1. Keep boiler area clear and free from combus-
tible materials, gasoline and other ammable
vapors and liquids.
2. DO NOT obstruct air openings to the boiler
room.
3. Modication, substitution or elimination of fac-
tory equipped, supplied or specied compo-
nents 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 qualied
installer.
5. TO THE INSTALLER: Leave all instructions
with the boiler for future reference.
6. When this product is installed in the Com-
monwealth of Massachusetts the instal-
lation must be performed by a Licensed
Plumber or Licensed Gas Fitter.
IMPORTANT: Read the following instructions
COMPLETELY before installing!
Indicates a potential hazardous situation which,
if not avoided, MAY result in minor or moder-
ate injury. It may also be used to alert against
unsafe practices.
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
Tested for 75 PSI ASME
Working Pressure
WARNING
CAUTION
DANGER
WARNING
KEEP THIS MANUAL NEAR BOILER AND
RETAIN FOR FUTURE REFERENCE.

4
MODEL NO. A B C D
SFM6225W * 29 ¼” 13 ⅝” 8” ———
SFM7275W * 32 ⅞” 13 ⅝” 8” ———
SFM24150W 21 ½” 12 ⅝” 6” 53 13⁄16”
SFM25175W 25 ⅛” 14 ¼” 7” 53 13⁄16”
SFM25200W 25 ¼” 14 ¼” 7” 53 13⁄16”
SFM26225W 29 ¼” 13 ⅝” 8” 53 13⁄16”
SFM27275W 32 ⅞” 13 ⅝” 8” 53 13⁄16”
SFM36225W 29 ¼” 13 ⅝” 8” 85 7⁄16”
SFM37275W 32 ⅞” 13 ⅝” 8” 85 7⁄16”
SFM47275W 32 ⅞” 13 ⅝” 8” 87 13⁄16”
SFM57275W 32 ⅞” 13 ⅝” 8” 149 1⁄16”
SFM67275W 32 ⅞” 13 ⅝” 8” 181 13⁄16”
SFM77275W 32 ⅞” 13 ⅝” 8” 212 11⁄16”
SFM87275W 32 ⅞” 13 ⅝” 8” 245 ⅝”
* SFM6225W & SFM7275W are Single Module Units
MODEL # CODE
SF M 2 6 225 W
SERIES
MODULAR DESIGN
NO. OF PACKED BOILERS
SECTIONS PER BOILER
G.P.H. INPUT EACH FOR BOILER
TYPE OF UNIT
MULTIPLE BOILER DIMENSIONAL DATA
DIMENSIONS

5
NOTES:
1. Add sufx “T” to denote boiler with tankless heater.
2. I=B=R burner capacity is based on an oil heating value of 140,000 Btu/gal. and with 13% CO2.
3. For equivalent square feet of radiation, divide I=B=R output by 150.
4. Net ratings based on 170 0 F temperature in radiators and include 15% allowance for normal pip-
ing and pick-up load. Consult manufacturers for unusual piping and pick-up requirements.
5. Nozzle listed is for use with Beckett burner. When alternate burner is used, consult burner manu-
facturer’s recommendations.
6. Electrical service to be 120 Volts, 15 Amps, 60 Hz. (Each Boiler).
7. The MEA number for the SFM series is 182-86E.
8. The MEA number for the AFG burner is 213-83-E.
STANDARD EQUIPMENT: Crated Boiler, Flush Jacket, Oil Burner, Target Wall/Liner, ASME Re-
lief Valve, Theralitimeter Gauge, Drain Cock, Wiring Harness, Burner Electrical Disconnect, Plastic
Cover, Supply Tapping - 2”, Return Tapping - 1 ¼”, High Limit and Circulator Control, Primary Con-
trol. For Tankless Heater Units-add Tankless Hot Water Coil.
MODEL NO.
FIRING
RATE
G.P.H.
INPUT
M.B.H.
DOE
OUTPUT
M.B.H.
IBR
OUTPUT
M.B.H.
MODEL NO.
OF MODULES
NO. OF
MODULES
TOTAL
BOILER
WATER
VOLUME
GAL
BOILER
WEIGHT
LBS.
PUMP
PRESSURE
P.S.I
NOZZLE
FURNISHED
SFH6225W 2.25 315 254 221 SFM6225W 1 19.5 915 140 2.00 45B
SFH7275W 2.75 385 307 267.1 SFM7275W 1 22.5 1058 140 2.25 45B
SFM24150W 3.00 420 350 304 SFM4150W 2 27.0 1251 140 1.25 80B
SFM25175W 3.50 490 412 358 SFM5175W 2 33.0 1546 140 1.50 80B
SFM25200W 4.00 560 462 402 SFM5200W 2 33.0 1546 140 1.75 80B
SFM26225W 4.50 630 508 442 SFM6225W 2 39.0 1831 140 2.00 45B
SFM27275W 5.50 770 614 534.2 SFM7275W 2 45.0 2116 140 2.25 45B
SFM36225W 6.75 945 762 663 SFM6225W 3 58.5 2745 140 2.25 45B
SFM37275W 8.25 1155 921 801.3 SFM7275W 3 67.5 3174 140 2.25 45B
SFM47275W 11.00 1540 1228 1068.4 SFM7275W 4 90.0 4232 140 2.25 45B
SFM57275W 13.75 1925 1535 1335.5 SFM7275W 5 112.5 5290 140 2.25 45B
SFM67275W 16.50 2310 1842 1602.6 SFM7275W 6 135.0 6347 140 2.25 45B
SFM77275W 19.25 2695 2149 1869.7 SFM7275W 7 157.5 7905 140 2.25 45B
SFM87275W 22.00 3080 2456 2136.8 SFM7275W 8 180.0 8464 140 2.25 45B
BOILER RATINGS, CAPACITIES & DIMENSIONS

6
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 jurisdic-
tion, the installation must conform to theAmerican
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 a level solid base as near
the chimney as possible, and centrally located
with respect to the heat distribution system as
practical.
BOILER MAY NOT BE INSTALLED ON
COMBUSTIBLE FLOORING.
Allow 24 inches in the front and top for servicing and
cleaning, or removing tankless water heating coil.
When installed in a utility room, the door should
be wide enough to allow the largest boiler part to
INTRODUCTION
enter, or to permit replacement of another appli-
ance such as a water heater.
FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY. The 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 .........................................12 IN.
NOTE: Clearance for access should exceed
fore protection clearance.
REMOVE CRATE and plastic protective wrapper
and inspect for damage. All equipment is carefully
manufactured, inspected and packaged by expe-
rienced workers. Our responsibility ceases upon
delivery of the crated boiler to the carrier in good
condition. Any claims for damage or shortage in
shipment must be led immediately against the
carrier by the cosigner. Move boiler to permanent
position by sliding or walking.
WARNING

7
The recommended method of connecting the supply and return piping can be seen in
Figure #1 below.
(For detailed piping recommendations refer to the engineering manual)
MODULAR BOILER HOOK-UP
RECOMMENDED PARALLEL PIPING
RETURN
SUPPLY
CIRCULATOR
REAR OF BOILER
FRONT OF BOILER BRANCH
BRANCH
MAIN
Figure #1
CONNECTING SUPPLY AND RETURN PIPING

8
ZONE 1 ZONE2
ZONE 3
REAR OF
BOILER
BRANCH
BRANCH
12"
MAX
FRONT OF
BOILER
AIR ELIMINATOR &
EXPANSION
TANK
PRIMARY
PUMP
PRIMARY
LOOP
SECONDARY
PUMP
LOAD
PUMPS
TO
EXPANSION
TANK & SYSTEM
FILL
An alternate method of connecting the supply and return piping can be seen in Figure #2
below.
(Refer to the engineering manual for detailed piping recommendations.)
Note: The tapping sizes for the supply and return piping are 2” and 1 ½” respectively.
It is recommended that the main piping be 3” and the branches 1 ½”.
PRIMARY SECONDARY PIPING
Figure #2
PRIMARY SECONDARY PIPING

9
AIR OPENINGS TO COMBUSTIONAREAMUST NOT BE OBSTRUCTED. FOLLOW THE CHART
BELOW TO OBTAIN AND MAINTAIN ADEQUATE COMBUSTION AIR.
WARNING
1. When a 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. If
there is any doubt, install air supply provisions
for combustion and ventilation in accordance
with section 5.3,Air for Combustion and Ventila-
VENTILATION & COMBUSTION AIR
COMBUSTION AIR REQUIRMENTS
(MINIMUM OPENING IN SQUARE INCHES)
*UNCONFINED AREA **CONFINED AREA
OUTSIDE
COMBUSTION AIR
INSIDE
COMBUSTION AIR
OUTSIDE
COMBUSTION AIR
1 IN2/5000BTU
(PARAGRAPH 2)(SQ IN)
1 IN2/1000 BTU
(MIN 100IN2) (FIG 4) (SQ IN)
1 IN2/4000 BTU
(FIG 3)(SQ IN)
1 IN2/2000 BTU
(FIG 3)(SQ IN)
BTU/HR INPUT
315,000 63 315 78.75 158
385,000 77 385 96.25 193
420,000 84 420 105 210
490,000 98 490 123 245
560,000 112 560 140 280
630,000 126 630 158 315
770,000 154 770 193 385
945,000 189 945 237 473
1,155,000 231 1155 289 578
1,540,000 308 1540 385 770
1,925,000 385 1925 482 963
2,310,000 462 2310 578 1155
2,695,000 539 2695 675 1348
3,080,000 616 3080 770 1540
* Unconned area: A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all appliances in-
stalled 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).
tion, of the latest revision of the NFPA 54 code,
the recommendations that follow, or applicable
provisions of the local building codes.
2. 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.Apermanent
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

10
VENTILATION & COMBUSTION AIR
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.
3. When air for combustion and room ventilation
is from inside buildings, the 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 #4.
4. 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 out-
doors. One of the following methods must be
used to provide adequate air for ventilation and
combustion.
A. When directly communicating with the out-
doors, 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.
COMBUSTION AIR SUPPLIED
FROM OUTSIDE THE BUILDING
Figure #3

11
OIL LINE MUST BE BURIED OR OTHERWISE
PROTECTED FROM DAMAGE. MINIMUM
OIL FILTER
SHUT OFF VALVE
SWING JOINTS
APPROVED FITTINGS
OIL GAUGE
FILLER PIPE
VENT PIPE
.5" IPS OR 1/2" O.D. COPPER TUBING
REFER TO NATIONAL BOARD OF
FIRE UNDERWRITERS
MINIMUM
OIL TANK
TYPICAL INSTALLATION SINGLE PIPE OIL SYSTEM WITH 2 OR MORE UNITS
TEES
CLOSE
NIPPLES
VENTILATION & COMBUSTION AIR
VENTING SYSTEM INSPECTION & INSTALLATION
COMBUSTION AIR SUPPLIED
FROM INSIDE THE BUILDING
Figure #4
INSPECT CHIMNEY to make certain it is
constructed according to the latest revision of
NFPA211. Local codes may differ from this code
and should be checked. Where there is a conict,
the local code will prevail.
This boiler must be installed into a chimney which
has a masonry or metallic chimney liner.
BOILER IS TO BE VENTED BY NATURAL
DRAFT AND SHALL NOT BE CONNECTED
INTO ANY PORTION OF A MECHANICAL
DRAFT SYSTEM OPERATING UNDER A
POSITIVE PRESSURE.
WARNING
MORE THAN 10'(3.1 M)
10' (3.1 M)
2' (.61 M)
HEIGHT ABOVE ANY
ROOF SURFACE WITHIN
10' (3.1 M)
HORIZONTALLY
CHIMNEY 3'
RIDGE
MIN. (.92 M) MIN.
GAS VENT OR
TYPE L VENT 2'
(.61 M) MIN.
Figure #5

12
VENTING SYSTEM INSPECTION & INSTALLATION
An unlined chimney will have leaks that will cause
poor chimney performance (NO DRAFT), and could
result in poor positive pressure in the combustion
chamber.
Horizontal portions of the venting system should
not exceed 10 feet in length. Horizontal lengths
over 10 feet will have a negative effect on the
chimney performance.
The chimney should extend at least 2 feet above
any portion of the building within 10 feet. See
gure 5 at right. It should produce a negative draft
of .06 to .08 inches of water column, (W.C.), as
measured with a draft gauge between the boiler
and barometric draft control while maintaining an
.02 inch W.C. negative draft in the combustion
chamber. See chart below for recommended
chimney or vent sizes.
Inadequate draft will cause improper combustion,
resulting in dirty ue ways and high fuel bills.
When installing a single boiler, connect the ue
pipe with the same size
as the boiler outlet to the
chimney, sloping upward
continuously toward the
chimney approximately ¼”
per foot. Bolt or screw joints
together to avoid sag.
If an oil red water heater
is vented into the same
ue as the boiler, provide
a separate hole into the
chimney whenever pos-
sible. When this isn’t pos-
sible, use a “Y” connection
in the ue pipe, using a
separate draft regulator for
each unit. When a chimney
will not provide adequate
draft to handle the input
from the water heater and
boiler simultaneously, wire
the units so that only one will operate at a time,
favoring the water heater.
CHIMNEY OR VENT SIZES
MODEL NO.
DIA. OF
CHIMNEY
OPENING
(BREECHING)
CHIMNEY SIZE
(IN. X IN. X FT.)
FLUE
OUTLET
SIZE
SFM6225W 8 8X8X15 8”
SFM7275W 9 8X12X15 8”
SFM24150W 9 8X12X15 6”
SFM25175W 9 8X12X20 7”
SFM25200W 9 8X12X20 7”
SFM26225W 9 8X12X20 8”
SFM27275W 10 12X16X15 8”
SFM36225W 12 12X16X15 8”
SFM37275W 14 12X16X20 8”
SFM47275W 14 12X16X15 8”
SFM57275W 18 16X20X20 8”
SFM67275W 18 20X20X15 8”
SFM77275W 22 20X24X15 8”
SFM87275W 22 20X24X20 8”
TYPICAL VENTING OF 2 OR MORE UNITS
Figure #6

13
OIL TANK AND PIPING
Oil tank and piping should be installed in accor-
dance 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 the vent pipe be smaller
than 1 ¼” I.P.S. The ll pipe should not be less
than 2” I.P.S.
The suction line from the tank to the burner should
be one continuous piece of tubing to prevent air
entering the line. The suction line, must be ⅜” O.D.
copper tubing for runs of 50 feet or less, and ½”
O.D. for longer runs. An oil return line, same size
as the suction line, must be used on any instal-
lation where the bottom of the tank is below the
fuel unit of the burner. Oil lines should be buried or
otherwise protected from mechanical injury. Flare
ttings on all oil lines are recommended. Compres-
sion ttings on the suction line often allow air to
be drawn into the fuel pump, making it difcult to
maintain oil pressure at the 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 the fuel
pump. If tank is more than 20’ from the boiler, a
two stage fuel unit should be installed in place of
the single stage pump supplied as standard equip-
ment with the burner. Make certain the rotation and
speed are the same and the pump is suitable for
the burner horsepower rating.
An oil line lter and shut-off valve should be in-
stalled in the suction line. Shut-off valves should be
installed in both the suction and return lines at the
burner for convenience in servicing burner. Allow
extra tubing at burner so burner may be removed
from boiler for cleaning without disconnecting tub-
ing. (See Figures #7 & #8). An optional exible
oil line is available.
OIL LINE MUST BE BURIED OR OTHERWISE
PROTECTED FROM DAMAGE. MINIMUM
OIL FILTER
SHUT OFF VALVE
SWING JOINTS
APPROVED FITTINGS
OIL GAUGE
FILLER PIPE
VENT PIPE
.5" IPS OR 1/2" O.D. COPPER TUBING
REFER TO NATIONAL BOARD OF
FIRE UNDERWRITERS
MINIMUM
OIL TANK
TYPICAL INSTALLATION SINGLE PIPE OIL SYSTEM WITH 2 OR MORE UNITS
TEES
CLOSE
NIPPLES
COMBUSTION AIR SUPPLIED FROM INSIDE THE BUILDING
Figure #7

14
1. Thermostat should be installed on an inside
wall about four feet above the oor.
2. NEVER install a thermostat on an outside
wall.
3. Do not install a thermostat where it will be af-
fected by:
A. Drafts
B. Hot or cold pipes
C. Sun light
D. Lighting xtures
E. Television sets
F. A replace or chimney
TYPICAL INSTALLATION BURRIED TANK OIL SYSTEM WITH 2 OR MORE UNITS
OIL LINE MUST BE BURIED OR OTHERWISE
PROTECTED FROM DAMAGE. MINIMUM
OIL FILTER
SHUT OFF VALVE
APPROVED
FITTINGS
SUCTION
FILL
PIPE
.5" IPS OR 1/2" O.D. COPPER TUBING
OIL
JOINTS
SWING
RETURN LINE
REFER TO LOCAL
CODE
LINE
TANK
SUPPLY LINE
*
APPROVED DAY TANK OR
AUX. TANK WITH BOOST PUMP
4"
3"
MANIFOLD .5"
Figure #8
OIL TANK AND PIPING
THERMOSTAT INSTALLATION
4. Check thermostat operation by raising and
lowering thermostat as required to start and
stop the burner.
5. Instructions for the nal adjustment of the ther-
mostat are packaged with the thermostat ( ad-
justing heating anticipator, calibration, ect.).

15
OPERATING INSTRUCTIONS
CAUTION
WATER WILL BE BOILING HOT.
The venting system should be inspected at the start
of each heating season. Check the vent pipe from
the boiler to the chimney for signs of deterioration
by rust or sagging joints. Repair if necessary.
Remove the vent pipe at the base of the chimney or
ue and, using a mirror, check for obstruction.
The lever of the pressure relief valve, shown in
Figure #9, on the boiler should be operated peri-
odically to make sure that it is functioning properly.
The pressure relief valve should open before the
water pressure exceeds the 30 lb. reading on
the gauge. If this pressure is exceeded and the
pressure relief valve leaks water when the boiler
is operating at normal pressures, it should be im-
mediately replaced. Corrosion can build up rapidly
at the valve seat and prevent its functioning as a
safety device.
START-UP AND ADJUSTMENT OF OIL BURNER
(See oil burner instructions for nozzle and electrode setting)
A. Check oil burner nozzle to make certain it is
tight in adapter. Burner mounting bolts should
be tight.
B. Check electrode setting, as they may have been
jarred out of position during transportation.
C. Lubricate burner motor and circulator motor if
required. Some circulators are water lubricated
and do not require oiling.
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 for
140 lbs. Adjust if necessary.
CAUTION
DO NOT SET FIRE VISUALLY.
Instruments are the only reliable method to de-
termine 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 main-
tenance, 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, CO2
indicator and draft gauge. Bacharach or Dwyer
test kits include these instruments.
INSTRUCTIONS FOR PROPER OPERATION
OF THE BOILER-BURNER UNIT
A ¼” diameter slot is provided in the inspection
cover plate to take draft readings in the combus-
tion chamber. See Figure #9. A ¼” diameter
hole will be required in the ue pipe between the
boiler and barometric damper (if used) to take
draft, CO2, smoke and temperature readings.
Adjust air shutter on oil burner to obtain a “trace”
of smoke. Measure CO2at this point. Increase
air adjustment to lower CO2approximately 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 the venting or the chimney.
The following table (on next page) is provided as
a guideline for initial start-up. Final adjustments
MUST be made using combustion instruments as
previously mentioned.

16
CHECK SAFETY CONTROL CIRCUIT after
burner adjustments have been made for satisfac-
tory performance.
A. High limit control: remove cover and note
temperature setting. See Figure #13. With
the burner operating, decrease this setting
to the minimum point. When boiler water
temperature exceeds this set point, the high
limit switch will open, shutting off the power
to the oil burner. Return setting to desired
high limit point. Burner should restart.
B. Primary control and ame sensor:
Check:
1. Flame failure - simulate by shutting off oil sup-
ply with hand valve while burner is on. Sixty
seconds after ameout, the safety switch locks
out, ignition stops, motor stops and oil valve -
when used - closes. To restart, open oil supply
valve and reset safety switch.
2. Ignition failure - with burner off, close oil sup-
ply valve and run through start-up procedure,
The safety switch should lock out as in ame
failure.
3. 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.
OPERATING INSTRUCTIONS
Model
No.
End
Cone
Static
Disc
Air Band
Setting
Air Shutter
Setting
Head
Setting
Low Firing
Rate Bafe
SFM4150 F-6 2¾ 2 6 ––––– 0
SFM5175 F-12 3U 3 5 ––––– 0
SFM5200 F-12 3U 5 5 ––––– 0
SFM6225 ––––– L1 4 6 1 –––––
SFM7275 ––––– L1 4 6 2 –––––
Information in above table uses Beckett model AFG burner for model numbers SFM4150-5200 and Beckett model
SMG for models 6225 and 7275.
PREVENTIVE MAINTENANCE of an oil red boiler
reduces operating costs. The boiler and vent pipe
should be inspected for accumulation of soot or
scale deposits periodically but at least once ev-
ery year before the start of each heating season.
When soot is present on the section walls and
ueways, improper combustion will result, caus-
ing additional sooting and scaling until ueways
are completely closed. To remove soot and scale
from the ueways, remove top jacket panel, top
clean-out plate, open burner swing door. (See
Figure #9 next page)
PERIODIC INSPECTION and tightening of the
tankless heater/cover plate bolts will reduce the
risk of leaks. See part number 6, in Figure #14,
Replacement Parts “Heat Exchanger” section in
the back of this manual.
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 #9
4. Loosen screws on the sides of the lower front
jacket panel. See Figure #9.
5. Pull the bottom part of the lower front panel
forward.
6. Lift the lower front panel up and off the boiler.
See Figure #9.

17
OPERATING INSTRUCTIONS
7. Close oil valve. See Figures #3 & #4 .
8. Disconnect oil line from burner.
9. Do not try to swing door with oil line at-
tached.
10. Remove nut from swing door stud on right
hand side of door.
11. Swing open burner and door to the left.
Using a ue brush, brush the soot and scale into
the combustion space where it can be removed
through the swing door opening.
It is recommended to replace the nozzle at the
start of each heating season. Lubricate the burner
motor and circulator motor - if required - with a few
drops of a good grade of light motor oil. Do not
over oil. Have a competent service person service
the burner and check the controls and check the
electrodes for carbon or cracks in the insulators.
Burners should be adjusted to produce the con-
ditions 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.
CAUTION
UTICA
BOILERS
LOWER FRONT
JACKET
PANEL
BURNER
ELECTRICAL
DISCONNECT
MOUNTING
SCREWS
(BOTH SIDES)
1/4" SLOT
HIGH LIMIT
CONTROL
TOP JACKET
PANEL
PRESSURE
RELIEF VALVE
HOT
Figure #9
INSTRUCTIONS FOR CLOSING BURNER
SWING DOOR
1. Swing burner and door to the right until insu-
lation is slightly compressed and the stud is
exposed.
2. Attach nut to the stud and tighten it until the built
in stop contacts the mounting door.
3. Replace oil line to burner.
4. Replace lower jacket panel, and tighten the
screws.
5. Connect the power cable at the factory supplied
burner electrical disconnect.
6. Turn on power to boiler.
7. Bleed oil line.

18
ELECTRICAL WIRING should conform with the
latest edition of National Electrical Code ANSI/
NFPA No. 70 and/or local authority having juris-
diction. A separate electrical circuit should be run
SFM INDIVIDUAL MODULE WIRING
L4006A J-BOX
CAD CELL
R8284D
BURNER J-BOX
TRANSFORMER
BURNER
MOTOR
BURNER
DISCONNECT
L1
L2
SFM INDIVIDUAL MODULE WIRING
BLACK
BLACK
BLACKBLACK BLACK
GREEN GREEN
WHITE
WHITE WHITEORANGE
BLACK
BLACK
BLACK
WHITE
TO LOW
VOLTAGE
CONTROLLER
CONTROL SYSTEMS
COMPONENT CODING
TH-1 Thermostat (millivolt) 1K2 Relay Contacts
TH-2 Thermostat (24 Volt) LS Limit Switch
TH-3 Thermostat (Line Voltage) MS Manual Switch
TR-1 Transformer (120V/24V 40VA) CIR Circulator
TR-2 Transformer (120V/24V 50VA) ECO Energy Cut-Off
LGV 24 Volt Gas Valve PSC Pilot Safety Coil
PS Pressure Switch Wire Connection
MR-PS Manual Reset Pressure Sw. LWCO Low Water Cut Off
Control Terminal EWF Electric Water Feeder
1K Relay Coil PG Power Generator
1K1 Relay Contacts
SFM INDIVIDUAL MODULE WIRING:
Refer to Figure #10 below for factory module
wiring.
WIRING CODE
Line Voltage by Factory
Low Voltage by Factory
Line Voltage by Installer
Low Voltage by Installer
* Not all components listed are used in all control systems.
Figure #10
from the entry box with a fused disconnect switch
in this circuit. Refer to component coding and
wiring code for the following control systems and
wiring diagrams.

19
OPTIONAL CONTROLS & WIRING
PHASE 2 CONTROLS:
This system consists of multiple outdoor thermo-
stats with settings spaced at increments to actuate
thenumberof modulesnecessaryto matchtheheat
load based on outdoor temperature. The heating
modulesarecycledasa groupbyanindoor-outdoor
reset controller with temperature bulbs connected
by capillary tubes. This system provides low cost
control for small and medium heating systems of
two to ve modules where it is desired to control
the supply water temperature in relation to outdoor
temperature. Ratio and temperature range are
adjustable. Control capillary tube length places
some limitations on this system. Module location
in relation to outside wall is important and should
be checked before selecting this system. See
Figure #12.
OPERATION:
When the outdoor temperature drops below set
point of the main outdoor thermostat, the circulator
is turned on. The indoor-outdoor control regulates
the supply water temperature. Individual outdoor
thermostats turn on more modules as the outdoor
temperature falls below their set points.
PHASE 6 CONTROLS
Consist of a microprocessor control (W7100J)
capable of sequentially step ring up to 6 heating
modules necessary to match the heat load based
on outdoor and/or indoor air temperature. The
C7031G outdoor air sensor and C7170Adischarge
water temperature sensor work in unison to adjust
the system water temperature corresponding to the
heat load demand. This system utilizes lead lag
operation to equalize the on time of each module.
Separate control band, reset ratio, and setpoint
control settings allows customizing of any modular
heating system. See Figure #13.
OPERATION:
When the indoor air temperature drops below the
thermostat setpoint, the system is energized. The
rst module will re and the remaining ones will
follow at one minute increments. Once the setpoint
limits plus the control band setting is reached, the
rst module will cut out. If the system water tem-
perature remains above the control band setting
the remaining modules will begin to cut out. If the
system water temperature drops below the lower
control band setting, the next module in sequence
will re. This process of sequencing will continue
until the heat load is satised.

20
PHASE 2 CONTROL WIRING FOR SPACE HEATING
UTICA BOILERS
UTICA BOILERS
UTICA BOILERS
BLACK BLACK
BLACK WHITE
WHITE
BLACK
TO BURNER
TO LIMIT
T475A
CIR
DISTRIBUTION PANEL
FUSED
DISCONNECT
1
2 3 4 5
H G
120V 60HZ
SERVICE
MM #900 LWCO
(OPTIONAL)
*
MANUAL RESET
HIGH LIMIT
(OPTIONAL)
*
T6031 MASTER
OUTDOOR CONTROL
*
CONTACTOR-RATE FOR BURNER
AND CIRCULATOR LOAD
BOILER
MOUNTED
HIGH LIMITS
T6031 OUTDOOR
THERMOSTATS
LINE VOLTAGE LOW VOLTAGE
* MOUNT IN SUPPLY HEADER
TO
DISTRIBUTION
PANEL
T T F F
TO
MODULE
WR
B
R
B
R
W
B
R
W
B
OPTIONAL CONTROLS & WIRING
Figure #12