UTICA BOILERS STARFIRE 3 STEAM Technical Document

INSTINST INSTINST
INSTALLAALLA
ALLAALLA
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
WW
WW
WAA
AA
ATERTER
TERTER
TER
OIL FIRED CAST IRON BOILER
Utica Boilers •P.O. Box 4729 •Utica, NY 13504

TT
TT
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 ........................................... PAGES 6-9
TANKLESS HEATER PIPING ............................................................................ PAGE 10
3/4" TAPPING OPTIONS ................................................................................... PAGE 11
VENTING SYSTEM INSPECTION & INSTALLATION ....................................... PAGE 12
OIL TANK PIPING .............................................................................................. PAGE 13
ELECTRICAL WIRING ..................................................................................... PAGES 14
THERMOSTAT INSTALLATION........................................................................ PAGE 15
NORMAL SEQUENCE OF OPERATION ........................................................... PAGE 15
OPERATING INSTRUCTIONS .................................................................. PAGES 16-19
SERVICE CHECK LIST ..................................................................................... PAGE 20
REPLACEMENT PARTS LIST.....................................................................PAGES 21-28
RATINGS, DATA AND DIMENSIONS ........................................................... PAGE 29-30
KEEP THIS MANUAL NEAR BOILER. RETAIN FOR FUTURE REFERENCE
SERIES SFH 3
CAST IRON
OIL FIRED BOILER
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS
PUBLISHED FEBRUARY 1996
PRINTED IN USA
MADE IN USA
TESTED FOR 100 LBS.
ASME WORKING PRESSURE

PAGE 1
IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANT!ANT!
ANT!ANT!
ANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.
WARNING:WARNING:
WARNING:WARNING:
WARNING:
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.
DANGERDANGER
DANGERDANGER
DANGER
DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
WARNINGWARNING
WARNINGWARNING
WARNING
WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
CAUTION - Indicates a potential hazardous situation which, if not avoided, MAY result
in minor or moderate injury. It may also be used to alert against unsafe practices.
WARNING:WARNING:
WARNING:WARNING:
WARNING: 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.

INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION PRTION PR
TION PRTION PR
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. In Canada all installations must
be in accordance with the authorities having jurisdiction and CSA B139.
LOCATE BOILER 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 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 enter, or to permit replacement of another appliance such as a water heater.
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 .............................................................. 6 IN.
SIDES ............................................................. 6 IN.
NOTE: CLEARANCE FOR ACCESS SHOULD EXCEED FIRE PROTECTION
CLEARANCE.
REMOVE CRATE and plastic protective wrapper and inspect for damage. All equipment
is carefully manufactured, inspected and packaged by experienced 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 filed immediately against the carrier by the
cosignee. Move boiler to permanent position by sliding or walking.
PAGE 2

VENTILAVENTILA
VENTILAVENTILA
VENTILATION & COMBTION & COMB
TION & COMBTION & COMB
TION & COMBUSTIONUSTION
USTIONUSTION
USTION AIRAIR
AIRAIR
AIR
WARNING:WARNING:
WARNING:WARNING:
WARNING: AIR OPENINGS TO COMBUSTION AREA MUST NOT
BE OBSTRUCTED. BY FOLLOWING THE CHART BELOW , ADEQUATE
COMBUSTION AIR CAN BE MAINTAINED.
COMBUSTION AIR REQUIREMENTS
(Minimum Opening Requirements)
*UNCONFINED AREA **CONFINED AREA
Outside Inside Outside Combustion Air
Combustion Combustion VERT. DUCTS HORZ. DUCTS
BTU/HR Air 1 IN.2Air 1 IN.21 IN.21 IN.2
INPUT /5000 BTU/HR /1000 BTU/HR /4000 BTU/HR /2000 BTU/HR
(Paragraph 4) (See Fig 1) (See Fig 2 & 3 (See Fig 4
(MIN. 100 IN2) Pages 5 & 6) Page 6)
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).
1. Ventilation of boiler room must be adequate enough to provide sufficient air to
properly support combustion.
2. When a boiler 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 boiler 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
from spaces freely communicating with the outdoors. A permanent opening or openings
PAGE 3

PAGE 4
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 boiler 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.
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, on page 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
FIGURE 1 FIGURE 2

PAGE 5
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 4 for combustion air minimum opening requirements.
FIGURE 3 FIGURE 4

PAGE 6
CONNECTING SUPPLCONNECTING SUPPL
CONNECTING SUPPLCONNECTING SUPPL
CONNECTING SUPPLYY
YY
Y AND RETURN PIPINGAND RETURN PIPING
AND RETURN PIPINGAND RETURN PIPING
AND RETURN PIPING
IMPORTANT: Circulators in the following illustrations are mounted on the system supply
side, but mounting on the system return side is also acceptable practice.
1. Connect supply and return piping as suggested in figure 5, below. When the boiler is
used in connection with refrigerated systems:
A. The chilled medium MUST BE IN PARALLEL with the boiler.
B. Use appropriate valves to prevent the chilled medium from entering the heating boiler.
2. During the heating cycle open valves A and B, close valves C and D.
3. During heating cooling cycle open valves C and D, close valves A and B.
A. Maintain a minimum clearance of one inch to hot water pipes.
In air handling units where they may be exposed to refrigerated air circulation, the
boiler piping system MUST be supplied with flow control valves or other automatic means
to prevent gravity circulation of the boiler water during the cooling cycle.
4. Hot water boilers installed above radiation level must be provided with a low water
device either as part of the boiler or at the time of boiler installation.
5. When a boiler is connected to a heating system that utilizes multiple zoned circulators,
each circulator must be supplied with a flow control valve to prevent gravity circulation.
FIGURE 5

FIGURE 6
* Reduced pressure back flow preventer must be used under provisions required by the
Environmental Protection Agency, (EPA).
6. Bypass piping is an option which gives the ability to adjust the supply boiler water
temperature to fit the system or condition of the installation. Although, this method of
piping is not typically required for baseboard heating systems.
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 6 below.
B. These methods are used to protect systems using radiant panels and the material
they are encased in from high temperature supply water from the boiler and protect the boiler
from condensation. See figures 7 and 8 on page 8.
C. This method is used to protect boilers from condensate forming as well as
protecting the heating system from high water temperature. See figure 8 on page 8.
7. Note: When using bypass piping, adjust valves A and B until desired system
temperature is obtained.
8. Bypass loop piping must be the same size piping for the supply and return.
PAGE 7
BYPASS PIPING

FIGURE 8
FIGURE 7
PAGE 8
MIXING-VALVE PIPING
PRIMARY SECONDARY PIPING WITH BYPASS

FIGURE 10
PAGE 9
FIGURE 9
9. Typical installation using circulators is shown in figure 9, below.
10. Typical installation using zone valves is shown in figure 10, below.
11. For further piping information refer to the I=B=R installation and piping guide.

RECOMMENDED PIPING FOR BOILERS EQUIPPEDRECOMMENDED PIPING FOR BOILERS EQUIPPED
RECOMMENDED PIPING FOR BOILERS EQUIPPEDRECOMMENDED PIPING FOR BOILERS EQUIPPED
RECOMMENDED PIPING FOR BOILERS EQUIPPED
WITHWITH
WITHWITH
WITH AA
AA
A T3 ORT3 OR
T3 ORT3 OR
T3 OR T4T4
T4T4
T4 TT
TT
TANKLESS HEAANKLESS HEA
ANKLESS HEAANKLESS HEA
ANKLESS HEATERTER
TERTER
TER
DANGER:DANGER:
DANGER:DANGER:
DANGER: Water temperatures exceeding 125º F will cause severe
burns instantly or death by scalding.
• An automatic mixing valve must be installed on the outlet of the domestic coil.
Installation must comply with the valve manufacture’s recommendations, and
instructions.
• Do not remove the bolts or aquastat at the time of installation.
• Pipe in accordance with the installation manual.
• Due to varying water conditions, an adjustable flow restrictor must be installed in the
cold water inlet of this coil.
FIGURE 11
PAGE 10

OPTIONS UTILIZING 3/4"OPTIONS UTILIZING 3/4"
OPTIONS UTILIZING 3/4"OPTIONS UTILIZING 3/4"
OPTIONS UTILIZING 3/4" TT
TT
TAPPINGAPPING
APPINGAPPING
APPING
PAGE 11
OPTIONOPTION
OPTIONOPTION
OPTIONAL LAL L
AL LAL L
AL LOCAOCA
OCAOCA
OCATION FORTION FOR
TION FORTION FOR
TION FOR AIRAIR
AIRAIR
AIR VENTVENT
VENTVENT
VENT
OPTIONOPTION
OPTIONOPTION
OPTIONAL LAL L
AL LAL L
AL LOCAOCA
OCAOCA
OCATION FOR EXPTION FOR EXP
TION FOR EXPTION FOR EXP
TION FOR EXPANSIONANSION
ANSIONANSION
ANSION TT
TT
TANKANK
ANKANK
ANK
(NON-DIAPHRAM TYPE)(NON-DIAPHRAM TYPE)
(NON-DIAPHRAM TYPE)(NON-DIAPHRAM TYPE)
(NON-DIAPHRAM TYPE)
FIGURE 12
FIGURE 13

PAGE 12
VENTING SYVENTING SY
VENTING SYVENTING SY
VENTING SYSTEM INSPECTION & INSTSTEM INSPECTION & INST
STEM INSPECTION & INSTSTEM INSPECTION & INST
STEM INSPECTION & INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
WARNING:WARNING:
WARNING:WARNING:
WARNING: 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 NFPA211. Local codes may differ from this code and should be checked. Where there
is a conflict, the local code will prevail. In Canada refer to the National Building Code or
CSA-A405 as applicable.
This boiler 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 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 figure 14 below. 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 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.
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
SFH6150,6225 8 10 8x8 8x12 15 50
SFH7275 8 10 8x8 8x12 15 50
FIGURE 14

PAGE 13
OILOIL
OILOIL
OIL TT
TT
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 15 & 16, below). An optional flexible oil
line is available.
FIGURE 15 FIGURE 16
TYPICAL INSTALLATION TWO
PIPE OIL SYSTEM
TYPICAL INSTALLATION SINGLE
PIPE OIL SYSTEM

PAGE 14
ELECTRICAL WIRINGELECTRICAL WIRING
ELECTRICAL WIRINGELECTRICAL WIRING
ELECTRICAL WIRING
SEE WIRING ADDENDUM FOR WIRING DIAGRAMS
AND COMPONENT CODING.
Electrical wiring must conform with the National Electrical Code, ANSI/NFPA No. 70-1990
when installed in the United states, the CSA C22.1 Canadian Electrical Code, Part 1, when
installed in Canada, and/or the local authority having jurisdiction.
WARNING:WARNING:
WARNING:WARNING:
WARNING: 1.When an external electrical source is utilized, the boiler, when
installed MUST BEMUST BE
MUST BEMUST BE
MUST BE electrically grounded in accordance with these requirements.
2. Install a fused disconnect switch between boiler and meter at a convenient location.

PAGE 15
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 aquastat. In
turn, the circulator and ignition systems are activated and ignition will begin.
In the event the boiler water temperature exceeds the high limit setting on the boiler mounted
aquastat, power will be interrupted between the aquastat and the ignition system. The power
will remain off until the boiler water temperature drops below the high limit setting. The
circulator will continue to operate under this condition until the thermostat is satisfied.
THERMOSTTHERMOST
THERMOSTTHERMOST
THERMOSTAA
AA
AT INSTT INST
T INSTT INST
T INSTALLAALLA
ALLAALLA
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 sets
F. A fireplace or chimney
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, ect.).

PAGE 16
OPERAOPERA
OPERAOPERA
OPERATING INSTRTING INSTR
TING INSTRTING INSTR
TING INSTRUCTIONSUCTIONS
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.
The lever of the pressure relief valve, shown in Figure 19, on page 19, on the boiler
should be operated periodically 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 immediately replaced. Corrosion can build up
rapidly at the valve seat and prevent its functioning as a safety device.
WARNING:WARNING:
WARNING:WARNING:
WARNING: WATER WILL BE BOILING HOT.
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:CAUTION:
CAUTION:CAUTION:
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, CO2
indicator and draft gauge. Bacharach or Dwyer test kits include these instruments.
INSTRUCTIONS TO OBTAIN PROPER OPERATIONINSTRUCTIONS TO OBTAIN PROPER OPERATION
INSTRUCTIONS TO OBTAIN PROPER OPERATIONINSTRUCTIONS TO OBTAIN PROPER OPERATION
INSTRUCTIONS TO OBTAIN PROPER OPERATION
OF THE BOILER-BURNER UNITOF THE BOILER-BURNER UNIT
OF THE BOILER-BURNER UNITOF THE BOILER-BURNER UNIT
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 19, on page 19. 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 CO2at this point. Increase air adjustment to lower CO2approximately one (1)
percent. Check to insure minimum negative .02 W.C., (water column), “overfire” draft and

PAGE 17
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 table on page 18 is provided as a guideline for initial start-up. Final adjustments
MUST be made using combustion instruments as previously mentioned.
CHECK SAFETY CONTROL CIRCUIT after burner adjustments have been made for
satisfactory performance.
A. High limit control: remove cover and note temperature setting. See figure 19 on page
19. 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 re-start.
B. 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
19 on page 19).
PERIODIC INSPECTION and tightening of the tankless heater/cover plate bolts will
reduce the risk of leaks. See Figure 21 on page 22.
WARNING:WARNING:
WARNING:WARNING:
WARNING:
- Use only number 2 fuel oil.
- Do not use gasoline, crankcase drainings or any oil containing gasoline.
- Do not attempt to start the burner when excess oil has accumulated, when the unit is
full of vapor or when the combustion chamber is very hot.

RIELLO SETTINGS
BOILER BURNER AIR PUMP TURB. NOZZLE
NO. NO. DAMPER PRESS. FURNISHED
SFH365 F-3 4.0 150 PSI 0.0 .65 80W
SFH3100 F-5 3.6 150 PSI 1.0 .85 80W
SFH4100 F-5 3.6 150 PSI 1.0 .85 80W
SFH3125 F-5 4.0 150 PSI 3.0 1.10 60W
SFH4125 F-5 4.0 150 PSI 3.0 1.10 60W
SFH5125 F-5 4.0 150 PSI 3.0 1.10 60W
SFH4150 F-5 6.0 150 PSI 4.0 1.25 60W
SFH5175 F-10 3.6 150 PSI 0.0 1.50 80B
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
SFH365 EZ-1 .60 150 PSI 60-.65 .60 70B
SFH3100 EZ-1 .85 150 PSI .85-1.00 .85 70B
SFH4100 EZ-1 .85 150 PSI .85-1.00 1.10 70B
SFH3125 N/A N/A N/A N/A N/A
SFH4125 EZ-1 1.00-1.10 150 PSI 1.10-1.25 1.10 70B
SFH5125 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
SFH5175 EZ-2 1.65 150 PSI 1.65-1.75 1.75 70B
SFH5200 EZ-2 1.75 150 PSI 1.65-1.75 1.50 70B
BECKETT SETTINGS
BOILER BURNER AIR AIR PUMP STATIC END NOZZLE
NO. NO. BAND SHUT. PRESS. DISC CONE FURNISHED
SFH365 AFG 0 7 140 PSI 2-3/4" F0 .60 80B
SFH3100 AFG 1 5 140 PSI 3-3/8U F3 .85 80B
SFH4100 AFG 1 5 140 PSI 3-3/8U F3 .85 80B
SFH3125 AFII N/A 6 140 PSI N/A N/A 1.10 60B
SFH4125 AFG 1 8 140 PSI 2-3/4" F4 1.10 80B
SFH5125 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
SFH5175 AFG 3 5 140 PSI 3U F12 1.50 80B H
SFH5200 AFG 5 5 140 PSI 3U F12 1.75 70B H
SFH6225 CF375 3 6 140 PSI L1 N/A 2.00 45B
SFH7275 CF375 5 4 140 PSI L1 N/A 2.25 60B
*NOTE: Model SFH3125 needs pin # 5,SFH6225 needs a head setting of 0, & SFH7275
needs a head setting of 1.
Nozzle sizes with an H designation are Hago brand, all others are Delevan.
PAGE 18