UTICA BOILERS STARFIRE 3 STEAM Technical Document

INSTINST INSTINST
INSTALLAALLA
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ALLATION MANUTION MANU
TION MANUTION MANU
TION MANUALAL
ALAL
AL AND OPERAAND OPERA
AND OPERAAND OPERA
AND OPERATING INSTRTING INSTR
TING INSTRTING INSTR
TING INSTRUCTIONSUCTIONS
UCTIONSUCTIONS
UCTIONS
STST
STST
STARFIRE 3ARFIRE 3
ARFIRE 3ARFIRE 3
ARFIRE 3
STEAMSTEAM
STEAMSTEAM
STEAM
OIL FIRED CAST IRON BOILER
Utica Boilers • P.O. Box 4729 • Utica, NY 13504

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TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE OF CONTENTS
ABLE 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

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WARNING:ARNING:
ARNING:ARNING:
ARNING: ALL INSTALLATIONS OF BOILERS AND VENTINGALL INSTALLATIONS OF BOILERS AND VENTING
ALL INSTALLATIONS OF BOILERS AND VENTINGALL INSTALLATIONS OF BOILERS AND VENTING
ALL INSTALLATIONS OF BOILERS AND VENTING
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 INSHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND IN
SHOULD 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 APPLIANCEINSTALLING OR VENTING A BOILER OR ANY OTHER GAS APPLIANCE
INSTALLING 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 SERIOUSWITH IMPROPER METHODS OR MATERIALS MAY RESULT IN SERIOUS
WITH 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 FROMINJURY OR DEATH DUE TO FIRE OR TO ASPHYXIATION FROM
INJURY 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 ISPOISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS
POISONOUS GASES SUCH AS CARBON MONOXIDE WHICH IS
ODORLESS AND INVISIBLE.ODORLESS AND INVISIBLE.
ODORLESS AND INVISIBLE.ODORLESS AND INVISIBLE.
ODORLESS AND INVISIBLE.
Safety SymbolsSafety Symbols
Safety SymbolsSafety Symbols
Safety Symbols
The following defined symbols are used throughout this manual to notify the
reader of potential hazards of varying risk levels.
DANGERDANGER
DANGERDANGER
DANGER
DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
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WARNINGARNING
ARNINGARNING
ARNING
WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
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.
PAGE 1
IMPORIMPOR
IMPORIMPOR
IMPORTT
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TANT!ANT!
ANT!ANT!
ANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.
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WARNING:ARNING:
ARNING:ARNING:
ARNING:
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.

INSTINST
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TION PROCEDUREOCEDURE
OCEDUREOCEDURE
OCEDURE
WARNING:WARNING:
WARNING:WARNING:
WARNING: Improper installation, adjustment, alteration, service or
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:WARNING:
WARNING: BOILER MAY NOT BE INSTALLED ON COMBUSTIBLE
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.
NOTE: CLEARANCE FOR ACCESS SHOULD EXCEED FIRE PROTECTION
CLEARANCE.
PAGE 2

VENTILAVENTILA
VENTILAVENTILA
VENTILATION & COMBTION & COMB
TION & COMBTION & COMB
TION & COMBUSTIONUSTION
USTIONUSTION
USTION AIRAIR
AIRAIR
AIR
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WARNING:ARNING:
ARNING:ARNING:
ARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT
BE OBSTRUCTED. BY FOLLOWING THE CHART BELOW, ADEQUATE
COMBUSTION AIR CAN BE MAINTAINED.
PAGE 3
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
COMBUSTION AIR REQUIREMENTS
(Minimum Opening Requirements)
*UNCONFINED AREA **CONFINED AREA
Outside Inside Outside Combustion Air
Combustion Combustion VERTICAL HORIZONTAL
BTU/HR Air 1 IN.2Air 1 IN.2DUCTS DUCTS
INPUT /5000 BTU/HR /1000 BTU/HR 1 IN.21 IN.2
(Paragraph 4) (See Fig 1) /4000 BTU/HR /2000 BTU/HR
(MIN. 100 IN2) (See Fig 2 & 3) (See Fig 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
*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).

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.
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.
FIGURE 1 FIGURE 2
PAGE 4

PAGE 5
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.
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.
FIGURE 3 FIGURE 4

CONNECTING SUPPLCONNECTING SUPPL
CONNECTING SUPPLCONNECTING SUPPL
CONNECTING SUPPLYY
YY
Y AND RETURN PIPINGAND RETURN PIPING
AND RETURN PIPINGAND RETURN PIPING
AND RETURN PIPING
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.
FIGURE 5
PAGE 6
PIPING FOR BUILT IN DOMESTIC HOT WATER HEATER
FIGURE 6

FIGURE 7
SUGGESTED PIPING FOR MODULAR STEAM BOILER
PAGE 7
PUMPED RETURN
FIGURE 8
GRAVITY RETURN

PAGE 8
CHIMNEY OR VENT SIZES
ROUND SQUARE HEIGHT
MODEL NO. INCHES INCHES FEET
MIN MAX MIN MAX MIN MAX
SFH365,3100
4100 6 8 8X8 8X8 15 40
SFH4125,3125
4150, 5125 7 8 8X8 8X10 15 40
SFH5175,5200 8 10 8X8 8X12 15 50
SFH6225 8 10 8x8 8x12 15 50
SFH7275 8 10 8x8 8x12 15 50
FIGURE 9
VENTING SYVENTING SY
VENTING SYVENTING SY
VENTING SYSTEM INSPECTION & INSTSTEM INSPECTION & INST
STEM INSPECTION & INSTSTEM INSPECTION & INST
STEM INSPECTION & INSTALLAALLA
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TION
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WARNING:ARNING:
ARNING:ARNING:
ARNING: 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.
INSPECT CHIMNEY to make certain it is constructed according to the latest revision of
the NFPA 211. Local regulations may differ from this code and should be checked. Where
there is a conflict, the local code will prevail.
The Starfire 3 must be installed into a chimney which has a masonry or metallic chimney
liner.
An unlined chimney will have leaks that will cause poor chimney performance (NO
DRAFT), and could result in a positive pressure in the combustion chamber.
Horizontal portions of the venting system should not exceed 10 feet in length. Horizontal
lengths over 10 ft. will have a negative effect on the chimney performance.
The chimney should extend at least 2' above any portion of the building within 10'. See
figure 9 below. It should produce a -.02 inch W.C. draft in the combustion chamber. See
chart, below, for recommended chimney or vent sizes.
Inadequate draft will cause improper combustion, resulting in dirty flue ways and high
fuel bills.
CONNECT FLUE PIPE same size as boiler outlet to chimney, sloping upward continuously
toward the chimney approximately 1/4" per foot. Bolt or screw joints together to avoid sag.
If an oil fired water heater is vented into the same flue as the boiler, provide a separate
hole into the chimney whenever possible. When this isn’t possible, use a “Y” connection in
the flue 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.

OILOIL
OILOIL
OIL TT
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TANKANK
ANKANK
ANK AND PIPINGAND PIPING
AND PIPINGAND PIPING
AND PIPING
OIL TANK AND PIPING should be installed in accordance with the National Board of
Fire Underwriters and local regulations. Oil storage tank, vent, fill pipe and caps should be
as prescribed by local codes. In no case should the vent pipe be smaller than 1-1/4" I.P.S.
The fill 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 3/8" O.D. copper tubing for runs
of 50 feet or less, and 1/2" O.D. for longer runs. An oil return line, same size as the suction
line, must be used on any installation 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
fittings on all oil lines are recommended. Compression fittings on the suction line often allow
air to be drawn into the fuel pump, making it difficult 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 equipment 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 filter and shut-off valve should be installed 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 tubing. See figures 10 & 11, below. An optional flexible oil line is available.
PAGE 9
FIGURE 10 FIGURE 11
TYPICAL INSTALLATION SINGLE
PIPE OIL SYSTEM
TYPICAL INSTALLATION TWO
PIPE OIL SYSTEM

PAGE 10
ELECTRICAL WIRINGELECTRICAL WIRING
ELECTRICAL WIRINGELECTRICAL WIRING
ELECTRICAL WIRING
Electrical wiring must conform with the latest revisions of the National Electrical Code,
ANSI/NFPA No. 70, and/or local authority having jurisdiction.
1. When an external electrical source is utilized, the boiler, when installed, MUST BE
electrically grounded in accordance with these requirements.
2. Install a fused disconnect switch between boiler and meter at a convenient location.
3. When the boiler is equipped with self-energized controls, no outside source of electric
power shall be connected to the circuit of this system. See figure 12 below.
FIGURE 12
1. COMPONENT CODING
TH-1 Thermostat (millivolt)
TH-2 Thermostat (24 Volt)
TH-3 Thermostat (Line Voltage)
TR-1 Transformer (120V/24V 40VA)
TR-2 Transformer (120V/24V 50VA)
LGV 24 Volt Gas Valve
PS Pressure Switch
MR-PS Manual Reset Pressure Sw.
Control Terminal
1K Relay Coil
1K1 Relay Contacts
1K2 Relay Contacts
LS Limit Switch
MS Manual Switch
CIR Circulator
ECO Energy Cut-Off
PSC Pilot Safety Coil
Wire Connection
LWCO Low Water Cut Off
EWF Electric Water Feeder
PG Power Generator
2. 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.
SFH-STEAM WIRING W/MM #67 MECHANICAL LWCO

THERMOSTTHERMOST
THERMOSTTHERMOST
THERMOSTAA
AA
AT INSTT INST
T INSTT INST
T INSTALLAALLA
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ALLATIONTION
TIONTION
TION
1. Thermostat should be installed on an inside wall about four feet above the floor.
2. NEVER install a thermostat on an outside wall.
3. Do not install a thermostat where it will be affected by:
A. Drafts
B. Hot or cold pipes
C. Sun light
D. Lighting fixtures
E. Television
F. Fireplace or chimneys
4. Check thermostat operation by raising and lowering thermostat as required to start
and stop the burner.
5. Instructions for the final adjustment of the thermostat are packaged with the
thermostat ( adjusting heating anticipator, calibration, etc.).
PAGE 11
NORMAL SEQNORMAL SEQ
NORMAL SEQNORMAL SEQ
NORMAL SEQUENCE OF OPERAUENCE OF OPERA
UENCE OF OPERAUENCE OF OPERA
UENCE OF OPERATIONTION
TIONTION
TION
On a call for heat, the thermostat will actuate, completing the circuit to the boiler.
In turn, the ignition systems are activated and ignition will begin.
In the event of a low water condition, an automatic low water cut-off device will
interrupted power between the low water cut-off and the burner. The burner will remain off
until the low water condition is corrected, (i.e., manually restore boiler water or utilize a water
feeder device which will automatically restore water to its normal operating level).
IMPORTANT TO THE INSTALLER: Before putting the boiler in operation, test the
Mechanical low water cut-off device for proper operation. While burner is on, open the blow-
off valve located in the lower portion of the cut-off body. This will drain the water quickly from
the cut-off body and break the circuit to the burner. If it does not, replace control.
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WARNING:ARNING:
ARNING:ARNING:
ARNING: WATER WILL BE BOILING HOT.
Refill boiler to its normal water line.

PAGE 12
OPERAOPERA
OPERAOPERA
OPERATING INSTRTING INSTR
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UCTIONSUCTIONS
UCTIONS
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 flue and, using a mirror, check for
obstruction & verify compliance to the latest
revision of the NFPA 211.
The lever of the pressure relief valve,
shown in figure 13, at right, on the boiler
should be operated periodically to make
sure that it is functioning properly.
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WARNING:ARNING:
ARNING:ARNING:
ARNING: DISCHARGE
WILL BE BOILING HOT WATER AND
STEAM.
The pressure relief valve should open before the steam pressure exceeds the 15 lb.
reading on the gauge. If this pressure is exceeded and the pressure relief valve leaks steam
when the boiler is operating at normal pressures, it should be immediately 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 if necessary.
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, bleed 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
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. Bacharach or Dwyer test kits include these
instruments.
FIGURE 13

PAGE 13
INSTRUCTIONS TO OBTAIN PROPER OPERATION
OF THE BOILER-BURNER UNIT
A 1/4" diameter slot is provided in the inspection cover plate to take draft readings in the
combustion chamber. See figure 13, on page 12. A 1/4" diameter hole will be required in
the flue 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 CO2 at this point. Increase air adjustment to lower CO2 approximately one (1)
percent. Check to insure minimum negative .02 w.c., (water column), “overfire” draft and
zero (0) smoke. If - .02 w.c. “overfire” draft can not be maintained, changes and/or
modifications may be required in the venting or the chimney.
The following tables are provided as a guideline for initial start-up. Final adjustments
MUST be made using combustion instruments as previously mentioned.
RIELLO SETTINGS
BOILER BURNER AIR PUMP TURB. NOZZLE
NO. NO. DAMPER PRESS. FURNISHED
SFH3100 F-5 3.6 150 PSI 1.0 .85 80W
SFH4125 F-5 4.0 150 PSI 3.0 1.10 60W
SFH4150 F-5 6.0 150 PSI 4.0 1.25 60W
SFH5200 F-10 5.0 150 PSI 0.0 1.75 80B
CARLIN SETTINGS
BOILER BURNER AIR PUMP HEAD NOZZLE
NO. NO. DAMPER PRESS. BAR FURNISHED
SFH3100 EZ-1 .85 150 PSI .85-1.00 .85 70B
SFH4125 EZ-1 1.00-1.10 150 PSI 1.10-1.25 1.10 70B
SFH4150 EZ-1 1.25-1.35 150 PSI 1.10-1.25 1.25 70B
SFH5200 EZ-2 1.75 150 PSI 1.65-1.75 1.75 70B
BECKETT SETTINGS
BOILER BURNER AIR AIR PUMP STATIC END NOZZLE
NO. NO. DAMP. SHUT. PRESS. DISC CONE FURNISHED
SFH3100 AFG 1 5 140 PSI 3-3/8U F3 .85 80B
SFH4125 AFG 1 8 140 PSI 2-3/4" F4 1.10 80B
SFH4150 AFG 2 6 140 PSI 2-3/4" F6 1.25 80B
SFH5200 AFG 5 5 140 PSI 3U F12 1.75 70B H
SFH6225 CF375 4 6 140 PSI L1 N/A 2.00 45B
SFH7275 CF375 4 6 140 PSI L1 N/A 2.25 45B
* NOTE: model SFH3125 needs pin # 5,SFH6225 needs a head setting of 1, &
SFH7275 needs a head setting of 2.
Nozzle sizes with an H designation are Hago brand, all others are Delevan.
Information in above table uses Beckett model AFG burner for model numbers
SFH365-5200 and Beckett model CF375 for model numbers 6225 and 7275.
CHECK SAFETY CONTROL CIRCUIT after burner adjustments have been made for
satisfactory performance.

A. Pressure control - on steam boilers - remove cover and note pressure setting. With boiler
operating, decrease the setting. When the setting is lower than boiler pressure, the
control will open, and turn off the boiler. After checking pressure control, reset control
to original setting.
B. Mechanical low water cut-off: Operation may be checked by opening the blow-off valve
on the lower portion of the cut-off body, while the boiler is running. This will drain the
water from the boiler and break the circuit to the burner.
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WARNING:ARNING:
ARNING:ARNING:
ARNING: WATER WILL BE BOILING HOT.
Refill boiler to its normal water line.
C. Primary control and flame sensor: To Check:
1. Flame failure - simulate by shutting off oil supply with hand valve while burner is on.
Sixty seconds after flameout, 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 supply valve and run through start-up
procedure, The safety switch should lock out as in flame 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.
PREVENTIVE MAINTENANCE of an oil fired boiler reduces operating costs. The boiler
and vent pipe should be inspected for accumulation of soot or scale deposits periodically
but at least once every year before the start of each heating season. When soot is present
on the section walls and flueways, improper combustion will result, causing additional
sooting and scaling until flueways are completely closed. To remove soot and scale from
the flueways, remove top jacket panel, top clean-out plate, open burner swing door. (figure
13 on page 12).
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
13 on page 12.
4. Loosen screws on the sides of the lower front jacket panel. See figure 6 on page 6.
Pull the bottom part of the lower front panel forward and lift the lower front panel up and off
the boiler. See figure 13 on page 12.
5. Close oil valve. See figures 10 and 11, on page 9.
6. Disconnect oil line from burner.
7. Do not try to open swing door with oil line attached.
8. Remove nut from swing door stud on right hand side of door.
9. Swing open burner and door to the left.
Using a flue brush, brush the soot and scale into the combustion space where it can be
removed through the swing door opening.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: USE CAUTION WHEN VACUUMING IN THE CHAMBER
AREA. DAMAGE TO CHAMBER COULD RESULT.
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
PAGE 14

MAINTENANCE PROCEDURESMAINTENANCE PROCEDURES
MAINTENANCE PROCEDURESMAINTENANCE PROCEDURES
MAINTENANCE PROCEDURES
Before seasonal start up it is advisable to have a competent service agency check the
boiler for soot and scale in the flues, change oil filter and nozzle, clean the burner and
readjust burner input rate to maintain high operating efficiency.
On steam boilers make certain the boiler is filled to the water line as indicated in figure
13 on page 12. The gauge cocks should be normally open. To remove dirt from the gauge
glass the petcock may be opened to flush out the glass.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: DISCHARGE MAY BE BOILING HOT WATER.
The radiator valves on a one-pipe steam system must be either wide open or tightly shut.
Do not attempt to regulate room temperature by partially closing the radiator valve.
Air vents on steam radiators and the supply main release air from the system. If radiators
do not heat satisfactorily, make sure the air vents are clean and operational.
The lever of the pressure relief valve, shown in figure 13 on page 12, on the boiler should
be operated periodically to make sure that it is functioning properly.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: DISCHARGE WILL BE BOILING HOT WATER AND STEAM.
The safety valve should open before the steam pressure exceeds the 15 lb. reading on the
gauge, (figure 13 on page 12). If this pressure is exceeded and the safety valve does not
open, it must be replaced. If the safety valve leaks steam when the boiler is operating at
normal pressures, it should be immediately replaced. Corrosion can build up rapidly at the
valve seat and prevent its functioning as a safety device.
If the water in a steam boiler appears to be dirty or oily, or the water level in the gauge
glass fluctuates considerably, the boiler should be cleaned. A competent service person will
use approved cleaning compounds and properly clean and flush out the boiler. He/she
should also clean or replace air vents and traps, clean flue passages and check for proper
operation of all controls and safety devices.
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.
IMPURITIES IN BOILER WATER of a steam boiler may cause foaming and an
unsteady water line, or prevent steam generation. They may result in objectionable odors
escaping from the vents on water boilers. This condition is caused by oil, grease, and
sediment from pipe fittings collecting within the boiler and can be remedied only by giving
the boiler a thorough cleaning.
PAGE 15
be adjusted to produce the conditions shown in Start-up and Adjustment of Oil Burner
procedure.
INSTRUCTIONS FOR CLOSING BURNER SWING DOOR.
1. Swing burner and door to the right until insulation 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. Reconnect 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.

PAGE 16
BOILERS SHOULD BE CLEANBOILERS SHOULD BE CLEAN
BOILERS SHOULD BE CLEANBOILERS SHOULD BE CLEAN
BOILERS SHOULD BE CLEANEDED
EDED
ED by skimming or blowing down.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: The boiler should not be left unattended during the cleaning
process.
1. SKIMMING OFF IMPURITIES
Some of the impurities in the boiler water will float on the water and must be skimmed
off.
With the boiler empty and cool, slowly begin to add water. After water has entered boiler
- never before - turn “on” oil burner and adjust water flow so that the water being added is
kept just below boiling point. Avoid boiling and turbulence.
Gradually raise hot water level to skimming hole, see figure 6 on page 6, installed on
the rear section of the boiler being careful not to raise it above the opening of the hole. Skim
until there are no impurities. Repeat the process if necessary.
Water may be checked to make sure it is free from oil by drawing off a sample at the
skimming hole. If the sample is reasonably free from oil, it will not froth when boiled on stove.
This test does not indicate the amount of sediment which may lay in the bottom of the boiler.
It is therefore necessary that the boiler be further cleaned by “blowing down.”
2. BLOWING DOWN BOILER
Before blowing down the boiler, fill it to the water line. Turn on burner and allow five
pounds of steam pressure to build up. Run a temporary connection from one of the drain
valves to a nearby sewer. Connect to a drain valve on the opposite end of the boiler from
feed water inlet, if possible. Shut off the oil burner, open drain valve and blow down the entire
contents of boiler.
Allow boiler to thoroughly cool and slowly refill to water line. Repeat step 2 as many times
as required until blow off water is clear. Owner should blow down boiler at least once each
month of the heating season.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: WATER WILL BE BOILING HOT.
3. USING CLEANING COMPOUND
If an exceptional amount of dirt or sludge seems to be present in the boiler, a boiler
cleaning compound made by a reputable manufacturer may be used according to the
instructions of the manufacturer of the compound. When any type of cleaning compound
is used, care must be taken to thoroughly flush all traces of the compound out of the boiler.
Following blow down allow the boiler to cool. Add fresh water slowly. Be certain to blow
enough times as required to remove compounds from system.
The area around the boiler must be kept clear and free of combustible materials,
gasoline and other flammable vapors and liquids.
The free flow of combustion and ventilation air to the boiler and boiler room must not be
restricted or blocked.
PERIODIC INSPECTIONPERIODIC INSPECTION
PERIODIC INSPECTIONPERIODIC INSPECTION
PERIODIC INSPECTION and tightening of the tankless heater/cover plate bolts will
reduce the risk of leaks. See part numbers 3 & 5, figure 15 on page 19.
MECHANICAL LOW WATER CUT-OFF:
Operation should be checked, with burner on, by opening the blow-off valve located in
the lower portion of the low water cut-off body. This will drain the water quickly from the cut-
off body and break the circuit to the burner. If it does not, replace the control.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: WATER WILL BE BOILING HOT.

Date Nozzle Pump Pressure Smoke Draft CO2or O2Flue Temperature
Size Angle Type PSI # O.F. INF oF
SERVICE CHECK LIST
*
x
x
x
x
Inspect Chimney and Flue pipe
Inspect and Clean Appliance
Inspect Oil Line - Size/Leaks
Inspect Electrical Connections
Install New Filter
Room Make-up Air
Electrode setting
Nozzle-Size, Angle, Type
Measure with Instruments and Record results on
chart provided below
*
*
*
*
x
x
*
Pump Pressure/Vacuum
Line Voltage/Motor Amps
Smoke Test
Draft-Overfire/In Flue
CO2or O2
Flue Gas Temperature
Proper Light-Off (Hot & Cold)
Controls and Safety Devices
x
x
x
*
*
PAGE 17
During the heating season, the blow-off valve on the low water cut-off should be opened
once a week to flush out the sediment chamber so the device will be free to function properly.
See figure 13 on page 12. Use a pail to catch the discharge.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: WATER WILL BE BOILING HOT.
It is suggested that a qualified service agency be employed to make an annual
inspection of the boiler and heating system. They are experienced in making the inspections
outlined above and, in the event repairs or corrections are necessary, can make the proper
changes for safe operation of the boiler.

PAGE 18
SFH-S REPLASFH-S REPLA
SFH-S REPLASFH-S REPLA
SFH-S REPLACEMENT PCEMENT P
CEMENT PCEMENT P
CEMENT PARAR
ARAR
ARTS - HEATS - HEA
TS - HEATS - HEA
TS - HEAT EXT EX
T EXT EX
T EXCHANGERCHANGER
CHANGERCHANGER
CHANGER
FIGURE 14
ITEM PART ITEM PART
NO. NO. DISCRIPTION QTY NO. NO. DISCRIPTION QTY
1 100-5-10.01 REAR SECTION 1
2 100-1-8.01 #60 PUSH NIPPLE
3 SEC. (2) 4 SEC. (3) 5 SEC. (4)
6 SEC. (5) 7 SEC. (6)
3 10051101 CENTER SECTION
3 SEC. (1) 4 SEC. (2) 5 SEC. (3)
6 SEC. (4) 7 SEC. (5)
4 10051202 FRONT SECT. CASTOVER 1
5 5611508 KIT - TARGET WALL & 1
INSULATION BLANKET
6 25511005 INSUL BLANKET 16X24 1
(6 & 7 SECTION)
7 HW-025.01 TIE ROD 1/2X12.1/2 (4 SEC) 3
HW-025.02 TIE ROD 1/2X16.1/2 (5 SEC)
HW-025.03 TIE ROD 1/2X20.1/2 (6 SEC)
HW-025.05 TIE ROD 1/2X9 (3 SEC)
HW-025.09 TIE ROD 1/2X23.1/2 (7 SEC)
8 100-1-5.01 #22 PUSH NIPPLE
3 SEC. (2) 4 SEC. (3) 5 SEC. (4)
6 SEC. (5) 7 SEC. (6)
9 MS-006.00 ROPE MED DENSITY
3 SECT (13") 4 SECT (19.5’)
5 SECT (26’) 6 SECT (32.5’)
7 SECT (39’)
10 HW-008.03 WASHER 1/2 ID FLAT 3
11 HW-003.05 NUT 1/2-13 HEX HEAD 3
FULLY ASSEMBLED HEAT EXCHANGERS
10022201 3 SECTION WITHOUT COIL
10022202 4 SECTION WITHOUT COIL
10022203 5 SECTION WITHOUT COIL
10022207 6 SECTION WITHOUT COIL
10022208 7 SECTION WITHOUT COIL
10022204 3 SECTION WITH TANKLESS COIL
10022205 4 SECTION WITH TANKLESS COIL
10022206 5 SECTION WITH TANKLESS COIL
10022209 6 SECTION WITH TANKLESS COIL
10022210 7 SECTION WITH TANKLESS COIL