UTICA BOILERS STARFIRE 3 WATER Instruction manual

P/N 27512801, Rev. B [02/2011]
STARFIRE 3 WATER
OIL FIRED CAST IRON BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
Utica Boilers
2210 Dwyer Avenue, Utica NY 13504-4729
Phone: [phone] • Fax: [phone]
e-mail: [e-mail]
web site: www.ecrinternational.com

2
Tested for 75 PSI ASME
Working Pressure
H
Safety Symbols........................................................................................................................... 2
Dimensions................................................................................................................................. 3
Boiler Ratings, Capacities ............................................................................................................. 4
Introduction................................................................................................................................ 5
Ventilation & Combustion Air......................................................................................................... 6
Connecting Supply & Return Piping ................................................................................................ 9
Tank-less Heating Piping..............................................................................................................13
3/4” Tapping Options ..................................................................................................................14
Venting System Inspection & Installation.......................................................................................15
Oil Tank Installation & Piping........................................................................................................16
Electrical Wiring .........................................................................................................................17
Thermostat Installation ...............................................................................................................17
Operating Instructions.................................................................................................................18
Service Check List ......................................................................................................................22
Replacement Parts......................................................................................................................23
SAFETY SYMBOLS
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
IMPORTANT: Read the following instructions COMPLETELY
before installing!
!
WARNING
Keep boiler area clear and free from
combustible materials, gasoline and other
ammable vapors and liquids.
DO NOT obstruct air openings to the boiler
room.
Modication, substitution or elimination
of factory equipped, supplied or specied
components may result in property damage,
personal injury or the loss of life.
To the owner: Installation and service of
this boiler must be performed by a qualied
installer.
To the installer: Leave all instructions with
the boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts the
installation must be performed by a Licensed
Plumber or Licensed Gas Fitter.
TABLE OF CONTENTS
!
DANGER
Indicates a hazardous situation which, if
not avoided, WILL result in death or serious
injury.
!
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or serious
injury.
NOTICE
Indicates information which should be
followed to ensure proper installation and
operation.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, may result in minor or moderate
injury.
Keep this manual near boiler and
Retain for future reference

3
NOTES:
Add sufx “T” to denote boiler with tankless heater.•
I=B=R burner capacity is based on an oil heating value• of 140,000 Btu/gal. and with 13% CO2.
Net ratings based on 170° F temperature in radiators • and include 15% allowance for normal piping and pickup
load. Consult manufacturers for unusual piping and pick-
up requirements.
 *Allratingssubjecttoverication.
For equivalent square feet of radiation, divide I=B=R • output by 150.
120 Volts, 15 Amps, & 60 Hz required to operate this • boiler.
For altitudes above 2,000 ft. ratings may be reduced at • rate of 4% for every 1,000 ft. above sea level.
BOILER
SEC-
TION
A
LENGTH
OF
FLUSH
JACKET
B
FRONT OF
CASTING
TO CENTER LINE
OF
FLUE OUTLET
C
DIA.
OF
FLUE
OUTLET
317 ⅞" 11 ¼" 6"
421 ½" 12 ⅝" 6"
525 ⅛" 14 ¼" 7"
6 29 ¼" 15 15⁄16" 8"
732 ⅞" 17 15⁄16" 8"
DIMENSIONAL DATA
!
WARNING
All installations of boilers and venting
should be done only by qualied expert
and in accordance with the appropriate
Manufacturer’s Installation, Operation and
Maintenance Manual. Installing or venting
boiler or any other gas appliance with
improper methods or materials may result
in serious injury or death due to re or to
asphyxiation from poisonous gases such
as carbon monoxide which is odorless and
invisible.
DIMENSIONS

4
Net I=B=R water ratings shown are based on a piping and pickup allowance of 1.15.
1Consult manufacturer before selecting a boiler for installation having unusual piping and pickup requirements,
such as intermittent system operation, extensive piping systems, etc.
2 For forced hot water heating systems where boiler and all piping are within the area to be heated, boiler may be
selected on basis of heating capacity.
STANDARD EQUIPMENT: Crated Boiler, Flush Jacket, Oil Burner, Target Wall/Liner, Circulator- 1¼”, ASME
Relief Valve, Theralitimeter Gauge, Drain Cock, Wiring Harness, Burner Electrical Disconnect, Plastic Cover, Supply
Tapping-2”, Return Tapping-1 1/2”, High Limit and Circulator Control, Primary Control. For Tank-less Heater Units-
add Tank-less Hot Water Coil, Flow Restrictor and Triple Aquastat Relay.
BOILER RATINGS
(1)
BOILER
MODEL
NUMBER
(2)*
I=B=R
OIL BURNER
INPUT
D.O.E.
HEATING
CAPACITY
(3)(4)*
I=B=R
NET
RATINGS
WATER
A.F.U.E. MINIMUM NATURAL DRAFT
CHIMNEY SIZE
PUMP
PRES-
SURE
G.P.H. MBH MBH* MBH RATING ROUND SQUARE PSI
365 .65 91 79 68.7 86.0 6 8X8X15 140
3100 1.00 140 117 102 81.0 6 8X8X15 140
3125 1.25 175 144 125 80.0 78X8X15 140
4100 1.00 140 120 104 86.0 6 8X8X15 140
4125 1.25 175 149 130 82.5 78X8X15 140
5125 1.25 175 151 131 86.0 78X8X15 140
4150 1.50 210 175 152 81.0 78X8X15 140
5175 1.75 245 206 179 81.5 8 8X8X15 140
5200 2.00 280 231 210 81.0 8 8X8X15 140
6150 1.50 210 181 157 86.0 8 8X8X15 140
6225 2.25 315 254 221.0 ——— 8 8X12X15 140
7275 2.75 385 307 267.1 ——— 8 8X12X15 140
TANKLESS WATER HEATER CAPACITIES
BOILER
MODEL
NUMBER
FIRING
RATE
G.P.H.
TANKLESS
HEATER
NUMBER
TANKLESS
HEATER CAPACITY
INTERMITTENT DRAW
G.P.M.
BOILER
WATER CONTENT
GALS.
365 .65 T3 available on request 10.5
3100 1.00 T3 3.25 10.5
4100 1.00 T4 3.25 13.5
3125 1.25 T3 3.75 10.5
4125 1.25 T4 3.75 13.5
5125 1.25 T4 3.75 16.5
4150 1.50 T4 4.00 13.5
6150 1.50 T4 4.00 19.5
5175 1.75 T4 4.25 16.5
5200 2.00 T4 5.50 16.5
6225 2.25 T4 5.75 19 5
7275 2.75 T4 6.00 22 5
BOILER RATINGS & CAPACITIES

5
Installations must conform to 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 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.
Allow 24 inches in the front and top for servicing
and cleaning, or removing tank-less water
heating coil.
When installed in utility room, door should be
wide enough to allow largest boiler part to enter,
or to permit replacement of another appliance
such as water heater.
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.........................................6 IN.
NOTICE
Clearance for access should exceed re
protection clearance.
REMOVE CRATE and plastic protective wrapper,
inspect for damage. All equipment is carefully
manufactured, inspected and packaged. Our
responsibility ceases upon delivery of crated boiler
to carrier in good condition. Any claims for damage
or shortage in shipment must be led immediately
against the carrier by cosigner. Move boiler to
permanent position by sliding or walking.
!
WARNING
Improperinstallation,adjustment,alteration,
service or maintenance can cause personal
injury or loss of life.
!
WARNING
Boiler may not be installed on combustible
ooring.
INTRODUCTION

6
Ventilation of boiler room must be adequate enough to 1.
provide sufcient air to properly support combustion.
When boiler is located in an unconned space in a 2.
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. Provide combustion
air and ventilation air in accordance with the section
“Air for Combustion and Ventilation,” of the National
Fuel Gas Code, ANSI Z223.1 / NFPA 54, or applicable
provisions of local building codes.
When a boiler is installed in an unconned space, 3.
in a building of unusually tight construction, air for
combustion and room ventilation must be obtained
from outdoors or from spaces freely communicating
with the outdoors. A permanent opening or openings
having a total free area of not less than 1 square inch
per 5,000 BTU per hour of total input rating of all
appliances shall be provided. Ducts may be used to
convey make-up air from the outdoors and shall have
the same cross-sectional area of the openings to which
they are connected.
COMBUSTION AIR REQUIREMENTS
(MINIMUM OPENING IN SQUARE INCHES)
BTU/HR
INPUT
*UNCONFINED AREA **CONFINED AREA
OUTSIDE
COMBUSTION AIR INSIDE COMBUSTION AIR OUTSIDE COMBUSTION AIR
1 IN2/5000BTU/HR
(PARAGRAPH 4)
1 IN2/1000 BTU/HR
(MIN 100IN2)
(Figure 1)
1 IN2/4000 BTU/
HR
(Figures 2&3)
1 IN2/2000 BTU/
HR
(Figure 4)
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
*Unconned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).
**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).
When air for combustion and room ventilation is from 4.
inside buildings, 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 #1.
When the boiler is installed in a conned space and 5.
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 outdoors. One of the
following methods must be used to provide adequate
air for ventilation and combustion.
!
WARNING
Air openings to combustion area must not be obstructed. Follow chart below to obtain and maintain
adequate combustion air.
VENTILATION & COMBUSTION AIR

7
When directly communicating with the outdoors,A. 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.
When communicating with the outdoors by meansB. 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.
If horizontal ducts are used, each opening shallC. 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.
When ducts are used, they shall be of the sameD. 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.
VENTILATION & COMBUSTION AIR
In calculating free area using louvers, grills or screens 6.
for the above, consideration shall be given to their
blocking effect. Screens used shall not be smaller than
¼ inch mesh. If the free area through a design of
louver or grill is known, it should be used in calculating
the size opening required to provide the free area
specied. 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 xed in
the open position or interlocked with the boiler so that
they are opened automatically during boiler operation.
Refer to the CombustionAir Requirementschart on
previous page for combustion air minimum opening
requirements.
Figure #1

8
Figure #5
VENTILATION & COMBUSTION AIR
Figure #2
Figure #3 Figure #4

9
Connect supply and return piping as suggested in 1.
Figure #5, below. When boiler is used in connection
with refrigerated systems:
Chilled medium MUST BE IN PARALLEL with boiler.A.
Use appropriate valves to prevent chilled mediumB. from entering heating boiler.
During heating cycle open valves A and B, close valves 2.
C and D.
During heating cooling cycle open valves C and D, close 3.
valves A and B.
Maintain minimum clearance of one inch to hotA. water pipes.
In air handling units where they may be exposed to
refrigerated air circulation, boiler piping system MUST be
supplied with ow control valves or other automatic means
to prevent gravity circulation of boiler water during cooling
cycle.
Hot water boilers installed above radiation level must 4.
be provided with low water device either as part of
boiler or at time of boiler installation.
When boiler is connected to heating system utilizing 5.
multiple zoned circulators, each circulator must be
supplied with ow control valve to prevent gravity
circulation.
*Reducedpressurebackowpreventermustbeused
under provisions required by the Environmental
ProtectionAgency,(EPA).
Bypass piping is an option which gives ability to 6.
adjust supply boiler water temperature to t system
or condition of installation. Although, this method of
piping is not typically required for baseboard heating
systems.
Figure #5
CONNECTING SUPPLY AND RETURN PIPING
Figure #5

10
This method is used to protect boilers fromA. condensate forming due to low temperature return
water. Generally noticed in large converted gravity
systems or other large water volume systems. See
Figure #6.
These methods are used to protect systems usingB. radiant panels and material they are encased in
from high temperature supply water from boiler
and protect boiler from condensation. See Figures
#7 and #8 following page.
This method is used to protect boilers fromC. condensate forming as well as protecting heating
system from high water temperature. See Figure
#8 following page.
Note: When using bypass piping, adjust valves A and B
until desired system temperature is obtained.
Bypass loop piping must be same size piping for supply 7.
and return.
CONNECTING SUPPLY AND RETURN PIPING
Figure #6 Bypass Piping

11
CONNECTING SUPPLY AND RETURN PIPING
Figure #7 - Mixing Valve Piping
Figure #8 - Primary Secondary Piping With Bypass

12
CONNECTING SUPPLY AND RETURN PIPING
Typical installation using circulators is shown in 8. Figure
#9.
Typical installation using zone valves is shown in 9.
Figure #10.
For further piping information refer to I=B=R 10.
installation and piping guide.
Figure #9 - Primary Secondary Piping With Bypass
Figure #10 - Primary Secondary Piping With Bypass

13
Automatic mixing valve must be installed on outlet • of domestic coil. Installation must comply with valve
manufacture’s recommendations, and instructions.
Do not remove bolts or aquastat at time of installation.•
Pipe in accordance with boiler’s Installation, Operation• and Maintenance Manual.
Due to varying water conditions, adjustable ow • restrictor must be installed in cold water inlet of this
coil.
!
DANGER
Water temperatures exceeding 125°F will
cause severe burns instantly or death by
scalding.
CONNECTING SUPPLY AND RETURN PIPING
Figure #11 - Recommended Piping For Boilers Equipped With T3 Or T4 Tank-Less Heater

14
CONNECTING SUPPLY AND RETURN PIPING
Figure #12 - Optional Location For Air Vent
OPTIONS UTILIZING 3/4” TAPPING
Figure #13 - Optional Location For Expansion Tank (Non-Diaphragm Type)

15
INSPECT CHIMNEY to make certain it is
constructed according to latest revision of the NFPA
211. Local codes may differ from this code and
should be checked. Where there is a conict, local
code will prevail. In Canada refer to National Building
Code or CSA-A405 as applicable.
Boiler must be installed into chimney which has
masonry or metallic chimney liner.
Unlined chimney will have leaks that will cause poor
chimney performance (NO DRAFT), and could result
in poor positive pressure in combustion chamber.
Horizontal portions of venting system should
not exceed 10 feet in length. Horizontal lengths
over 10 feet will have negative effect on chimney
performance.
Chimney should extend at least 2 feet above any
portion of building within 10 feet. See Figure #14.
It should produce negative draft of .06 to .08 inches
of water column, (W.C.), as measured with draft
gauge between boiler and barometric draft control
while maintaining .02 inch W.C. negative draft in
combustion chamber. See chart “Chimney or Vent
Sizes” for recommended chimney or vent sizes.
Inadequate draft will cause improper combustion,
resulting in dirty ue ways and high fuel bills.
CONNECT FLUE PIPE same size as boiler outlet
to chimney, sloping upward continuously toward
chimney approximately ¼” per foot. Bolt or screw
joints together to avoid sag.
If oil red water heater is vented into same ue as
boiler, provide separate hole into chimney whenever
possible. When not possible, use “Y” connection in
ue pipe, using separate draft regulator for each
unit. When chimney will not provide adequate
draft to handle input from water heater and boiler
simultaneously, wire units so that only one will
operate at a time, favoring water heater.
CHIMNEY OR VENT SIZES
MODEL NO. ROUND
INCHES SQUARE INCHES HEIGHT FEET
MIN MAX MIN MAX MIN MAX
365,3100
4100 6 8 8X8 8X8 15 40
4125,3125
4150, 5125 78 8X8 8X10 15 40
5175,5200 810 8X8 8X12 15 50
6150,6225 8 10 8x8 8x12 15 50
7275 810 8x8 8x12 15 50
VENTING SYSTEM INSPECTION & INSTALLATION
Figure #14

16
Install oil tank and piping in accordance 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 vent pipe be smaller than 1¼” I.P.S. Fill pipe
should not be less than 2” I.P.S.
Suction line from tank to burner should be one
continuous piece of tubing to prevent air entering
line. Suction line, must be ⅜” O.D. copper tubing
for runs of 50 feet or less, and ½” O.D. for longer
runs. Oil return line, same size as suction line,
must be used on any installation where bottom of
tank is below fuel unit of burner. Oil lines should
be buried or otherwise protected from mechanical
injury. Flare ttings on all oil lines are recommended.
Compression ttings on suction line often allow air
to be drawn into fuel pump, making it difcult to
maintain oil pressure at 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 fuel pump. If
tank is more than 20’ from boiler, a two stage fuel
unit should be installed in place of single stage pump
supplied as standard equipment with burner. Make
certain rotation and speed are same and pump is
suitable for burner horsepower rating.
Oil line lter and shut-off valve should be installed
in suction line. Shut-off valves should be installed
in both suction and return lines at burner for
convenience in servicing burner. Allow extra tubing
at burner so burner may be removed from boiler for
cleaning without disconnecting tubing. (See Figures
#15 & #16, below). An optional exible oil line is
available.
OIL TANK AND PIPING
Figure #15 - Typical Installation Single Pipe Oil System Figure #16 - Typical Installation Two Pipe Oil System

17
Thermostat should be installed on inside wall about 1.
four feet above the oor.
NEVER 2. install thermostat on outside wall.
Do not install thermostat where it will be affected by: 3.
Drafts• Hot or cold pipes• Sun light•
Lighting xtures• Television sets•
Fireplace or chimney•
Check thermostat operation by raising and lowering 4.
thermostat as required to start and stop burner.
Instructions for nal adjustment of thermostat 5.
are packaged with thermostat ( adjusting heating
anticipator, calibration, ect.).
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to:
USA- National Electrical Code, ANSI/NFPA 70.• Canada - Canadian Electrical Code, Part I, CSA C22.1:• Safety Standard for Electrical Installations.
SEE WIRING ADDENDUM FOR WIRING DIAGRAMS AND COMPONENT CODING.
Install fused disconnect switch between boiler and meter at
convenient location.
On call for heat, thermostat will actuate, completing
circuit to aquastat. In turn, circulator and ignition
systems are activated and ignition will begin.
In event boiler water temperature exceeds high limit
setting on boiler mounted aquastat, power will be
interrupted between aquastat and ignition system.
Power will remain off until boiler water temperature
drops below high limit setting. Circulator will continue
to operate under this condition until thermostat is
satised.
ELECTRICAL WIRING
THERMOSTAT INSTALLATION
SEQUENCE OF OPERATIONS
!
WARNING
Electrical shock hazard. Turn OFF electrical
power supply at service panel before making
electrical connections. Failure to do so could
result in death or serious injury.

18
Venting system should be inspected at start of each
heating season. Check vent pipe from boiler to
chimney for signs of deterioration by rust or sagging
joints. Repair if necessary.
Remove vent pipe at base of chimney or ue and,
using mirror, check for obstruction.
!
WARNING
Water will be boiling hot.
Lever of pressure relief valve, shown in Figure #9,
page 12 of this manual, on boiler should be operated
periodically to make sure it is functioning properly.
Pressure relief valve should open before water
pressure exceeds 30 lb. reading on gauge. If this
pressure is exceeded and pressure relief valve leaks
water when boiler is operating at normal pressures, it
should be immediately replaced. Corrosion can build
up rapidly at valve seat and prevent its functioning as
safety device.
Start-Up And Adjustment Of Oil Burner
(See oil burner instructions for nozzle and electrode
setting)Check oil burner nozzle to make certain it is tight in
A. adapter. Burner mounting bolts should be tight.
Check electrode setting, they may have been jarredB. out of position during transportation.
Lubricate burner motor and circulator motor ifC. required. Some circulators are water lubricated and
do not require oiling.
Set room thermostat to call for heat, or jump
D. thermostat contacts on the boiler control.
Open all oil line valves.E. Turn service switch on. Burner should start.F.
On one pipe fuel systems only, vent pump as soonG. as burner starts. Allow oil to run until all traces of
air in the suction line disappear.
Turn “OFF” burner and install pressure gauge port H. on pump.
Start burner again and check oil pressure for 140I. lbs. Adjust if necessary.
!
CAUTION
Do not set re visually.
Instruments are only reliable method to determine
proper air adjustments. Improperly adjusted burner
causes soot and high fuel bills because of incomplete
combustion of 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 proper adjustments with smoke tester, CO2
indicator and draft gauge. Bacharach or Dwyer test
kits include these instruments.
Instructions For Proper Operation Of Boiler-
Burner Unit
A ¼” diameter slot is provided in inspection cover
plate to take draft readings in combustion chamber.
See Figure #19. A ¼” diameter hole will be
required in ue pipe between boiler and barometric
damper (if used) to take draft, CO2, smoke and
temperature readings. Adjust air shutter on oil burner
to obtain “trace” of smoke. Measure CO2at this point.
Increase air adjustment to lower CO2 approximately
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 venting or chimney.
Following table (page 20) is provided as 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.
High limit control: remove cover and note temperature 1.
setting. See Figure #19. With burner operating,
decrease setting to minimum point. When boiler water
temperature exceeds this set point, high limit switch
will open, shutting off power to oil burner. Return
setting to desired high limit point. Burner should
restart.
OPERATING INSTRUCTIONS

19
Primary control and ame sensor check following: 2.
Flame failureA. - simulate by shutting off oil supply
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.
Ignition failureB. - with burner off, close oil supply
valve and run through start-up procedure, The
safety switch should lock out as in ame failure.
Power failureC. - 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 oil red boiler reduces
operating costs. Boiler and vent pipe should be
inspected for accumulation of soot or scale deposits
periodically but at least once every year before start
of each heating season. When soot is present on
section walls and ueways, improper combustion will
result, causing additional sooting and scaling until
ueways are completely closed. To remove soot and
scale from ueways, remove top jacket panel, top
clean-out plate, open burner swing door. (See figure
#19)
Periodic Inspection - and tightening of tankless
heater/cover plate bolts will reduce risk of leaks. See
ReplacementParts“HeatExchanger” section.
Instructions For Opening Burner Swing Door
Turn off power to boiler. 1.
Allow boiler to cool down. 2.
Disconnect power cable at factory supplied burner 3.
electrical disconnect. See Figure #19
Loosen screws on the sides of lower front jacket panel. 4.
See Figure #19.
Pull bottom part of lower front panel forward.
5.
Lift lower front panel up and off boiler. See 6. Figure
#19.
Close oil valve. See 7. Figures #15 & #16.
Disconnect oil line from burner.
8.
Do not try to swing door with oil line attached. 9.
Remove nut from swing door stud on right hand side of 10.
door.
Swing open burner and door to the left. 11.
Using ue brush, brush soot and scale into
combustion space where it can be removed through
swing door opening.
It is recommended to replace nozzle at start of each
heating season. Lubricate burner motor and circulator
motor - if required - with few drops of good grade
light motor oil. Do not over oil. Have competent
service person service burner and check controls and
check electrodes for carbon or cracks in insulators.
Burners should be adjusted to produce conditions
shown in Start-upandAdjustmentofOilBurner
procedure covered earlier in this section.
!
WARNING
• Use only number 2 fuel oil.
• Do not use gasoline, crankcase drainings or
any oil containing gasoline.
• Do not attempt to start burner when excess
oil has accumulated, when unit is full of vapor
or when combustion chamber is very hot.
OPERATING INSTRUCTIONS
NOTICE
Use caution when vacuuming in the chamber
area. Damage to chamber could result.

20
RIELLO SETTINGS
BOILER NO. BURNER NO. AIR DAMPER PUMP
PRESS. TURB. NOZZLE FURNISHED
365 F-3 4.0 150 PSI 0.0 .65 80W
3100 F-5 3.6 150 PSI 1.0 .85 80W
4100 F-5 3.6 150 PSI 1.0 .85 80W
3125 F-5 4.0 150 PSI 3.0 1.10 60W
4125 F-5 4.0 150 PSI 3.0 1.10 60W
5125 F-5 4.0 150 PSI 3.0 1.10 60W
4150 F-5 6.0 150 PSI 4.0 1.25 60W
5175 F-10 3.6 150 PSI 0.0 1.50 80B
5200 F-10 5.0 150 PSI 0.0 1.75 80B
CARLIN SETTINGS
BOILER NO. BURNER NO. AIR DAMPER PUMP
PRESS. HEAD BAR NOZZLE FURNISHED
365 EZ-1 .60 150 PSI 60-.65 .60 70B
3100 EZ-1 .85 150 PSI .85-1.00 .85 70B
4100 EZ-1 .85 150 PSI .85-1.00 1.10 70B
3125 N/A N/A N/A N/A N/A
4125 EZ-1 1.00-1.10 150 PSI 1.10-1.25 1.10 70B
5125 EZ-1 1.00-1.10 150 PSI 1.10-1.25 1.10 70B
4150 EZ-1 1.25-1.35 150 PSI 1.10-1.25 1.25 70B
5175 EZ-2 1.65 150 PSI 1.65-1.75 1.75 70B
5200 EZ-2 1.75 150 PSI 1.65-1.75 1.50 70B
BECKETT SETTINGS
BOILER
NO. BURNER NO. AIR BAND AIR SHUT. PUMP PRESS. STATIC DISC END CONE NOZZLE FURNISHED
365 AFG 0 7 140 PSI 2-3/4" F0 .60 80B
3100 AFG 1 5 140 PSI 3-3/8U F3 .85 80B
4100 AFG 1 5 140 PSI 3-3/8U F3 .85 80B
3125 AFII N/A 6140 PSI N/A N/A 1.10 60B
4125 AFG 18140 PSI 2-3/4" F4 1.10 80B
5125 AFG 18140 PSI 2-3/4" F4 1.10 80B
4150 AFG 26140 PSI 2-3/4" F6 1.25 80B
6150 AFG 26140 PSI 3-3/4” F6 1.25 80B
5175 AFG 3 5 140 PSI 3U F12 1.50 80B H
5200 AFG 5 5 140 PSI 3U F12 1.75 70B H
6225 CF375 36140 PSI L1 N/A 2.00 45B
7275 CF375 5 4 140 PSI L1 N/A 2.25 60B
*NOTE:Model3125needspin#5,6225needsaheadsettingof1.NozzlesizeswithanHdesignationare
Hagobrand,allothersareDelevan.
OPERATING INSTRUCTIONS