STARFIRE IV SERIES 4 WATER OIL FIRED CAST IRON BOILER Models SFH-3085 SFH-3100 SFH-4100 SFH-4125 SFH-4145 SFH-5160 SFH-5185 SFH-6175 SFH-6210 INSTALLATION, OPERATION & MAINTENANCE MANUAL Tested For 75 psi ASME Working Pressure Manufactured by: ECR International, Inc. 2201 Dwyer Avenue, Utica NY 13501 web site: www.ecrinternational.com An ISO 9001-2008 Certified Company P/N 240009735, Rev.
TABLE OF CONTENTS Dimensions ������������������������������������������������������������������������������������������������������������������� 3 Boiler Ratings & Capacities ������������������������������������������������������������������������������������������� 4 Introduction ������������������������������������������������������������������������������������������������������������������ 5 Ventilation & Combustion Air ������������������������������������������������������������������������������������
DIMENSIONS DIMENSIONAL DATA BOILER SECTION A DEPTH OF FLUSH JACKET B FRONT OF CASING TO CENTER LINE OF FLUE OUTLET C DIA.
BOILER RATINGS & CAPACITIES BOILER RATINGS BOILER MODEL NUMBER (2) (1) (3) OIL BURNER INPUT HEATING CAPACITY NET RATINGS WATER gph *Mbh *Mbh *Mbh (3) A.F.U.E. CHIMNEY SFH-3085W SFH-3085WT 0.85 119 103 90 85.0% 8X8X15 SFH-3100W SFH-3100WT 1.00 140 119 103 84.0% 8X8X15 SFH-4100W SFH-4100WT 1.00 140 122 106 86.0% 8X8X15 SFH-4125W SFH-4125WT 1.25 175 151 131 85.0% 8X8X15 SFH-4145W SFH-4145WT 1.45 203 173 150 84.0% 8X8X15 SFH-5160W SFH-5160WT 1.
INTRODUCTION ! WARNING • Allow 24 inches in the front and top for servicing and cleaning, or removing tankless water heating coil. Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury. • 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. • Installation must conform to requirements of the authority having jurisdiction.
VENTILATION & COMBUSTION AIR ! WARNING Asphyxiation, fire hazard. Do not obstruct air openings to combustion area. Follow instructions below, to maintain adequate combustion air.
VENTILATION & COMBUSTION AIR 4. When air for combustion and room ventilation is from 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. inside buildings, 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.
VENTILATION & COMBUSTION AIR Figure #2 Figure #3 Figure #4 8
CONNECTING SUPPLY AND RETURN PIPING 1. Connect supply and return piping as suggested in 4. Hot water boilers installed above radiation level must Figure #5, below. When boiler is used in connection with refrigerated systems: be provided with low water device either as part of boiler or at time of boiler installation. 5. When boiler is connected to heating system utilizing A. Chilled medium MUST BE IN PARALLEL with boiler.
CONNECTING SUPPLY AND RETURN PIPING 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. B. These methods are used to protect systems using 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. C.
CONNECTING SUPPLY AND RETURN PIPING Figure #7 - Mixing Valve Piping Figure #8 - Primary Secondary Piping With Bypass 11
CONNECTING SUPPLY AND RETURN PIPING 8. Typical indirect water heater installation using circulators is shown in Figure #9. 9. Typical indirect water heater installation using zone valves is shown in Figure #10.
SYSTEM PIPING ! WARNING Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns, scalding, or water damage due to discharge of steam and/or hot water during operation. Discharge line shall: • Connect to safety valve outlet. Piped down to safe point of disposal. Check local codes for maximum distance from floor or allowable safe point of discharge. • Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line.
CONNECTING SUPPLY AND RETURN PIPING Figure #12 - Recommended Piping For Boilers Equipped With T3 Or T4 Tankless Heater ! DANGER Water temperatures exceeding 125°F will cause severe burns instantly or death by scalding. • Automatic mixing valve must be installed on outlet of domestic coil. Installation must comply with valve manufacturer’s recommendations, and instructions. • Do not remove bolts or limit at time of installation.
CONNECTING SUPPLY AND RETURN PIPING OPTIONS UTILIZING 3/4” TAPPING Figure #13 - Optional Location For Air Vent Figure #14 - Optional Location For Expansion Tank (Non-Diaphragm Type) 15
VENTING SYSTEM INSPECTION & INSTALLATION INSPECT CHIMNEY to verify 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 conflict, local code will prevail. Figure #15 • 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 positive pressure in combustion chamber.
OIL TANK AND PIPING • Install burner per instructions provided with burner-ina-box kit. • 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.
ELECTRICAL WIRING ! 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. Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to: • USA- National Electrical Code, ANSI/NFPA 70. Install fused disconnect switch between boiler and meter at convenient location.
ELECTRICAL WIRING Figure #18 - Wiring Diagram Beckett AFG without Tankless Heater ZR Figure #19 Wiring Diagram Beckett AFG wth Tankless Heater 19
ELECTRICAL WIRING Figure #20 Wiring Diagram Riello 40F5 without Tankless Heater Figure #21 Wiring Diagram Riello 40F5 with Tankless Heater 20
ELECTRICAL WIRING Figure #22 Wiring Diagram Riello 40F10 without Tankless Heater Figure #23 Wiring Diagram Riello 40F10 with Tankless Heater 21
ELECTRICAL WIRING Figure #24 Wiring Diagram Carlin EZ-1/2 without Tankless Heater Figure #25 Wiring Diagram Carlin EZ-1/2 with Tankless Heater 22
OPERATING INSTRUCTIONS Operating Instructions 1. Inspect venting system at start of each heating season. 2. Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints. Repair if necessary. 3. Remove vent pipe at base of chimney or flue and, using mirror, check for obstruction. Safety Relief Valve ! WARNING Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.
OPERATING INSTRUCTIONS Preventive Maintenance - of oil fired 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 flueways, improper combustion will result, causing additional sooting and scaling until flueways are completely closed.
OPERATING INSTRUCTIONS TABLE 1 - BECKETT AFG SETTINGS BOILER MODEL HEAD TYPE HEAD SETTING STATIC PLATE NOZZLE PUMP PRESSURE [PSI] AIR BAND AIR SHUTTER SFH-3085W(T) L1 -- 3⅜ 0.75-60°B 140 0 8 SFH-3100W(T) L1 -- 3⅜ 0.85-60°B 140 1 8 SFH-4100W(T) V1 0 2¾ 0.85-60°B 140 0 6 SFH-4125W(T) V1 0 2¾ 1.10-60°B 140 1 8 SFH-4145W(T) V1 2 2¾ 1.25-60°B 140 2 10 SFH-5160W(T) F12 -- 2¾ 1.35-70°B 140 1 10 SFH-5185W(T) F12 -- 2¾ 1.
OPERATING INSTRUCTIONS Figure #26 SAFETY RELIEF VALVE Instructions For Closing Burner Swing Door 1. Swing burner and door to right until insulation is slightly compressed and stud is exposed. 2. Attach nut to stud and tighten until built in stop contacts the mounting door. 3. Replace oil line to burner. 4. Replace lower jacket panel, and tighten screws. 5. Connect power cable at factory supplied burner electrical disconnect. 6. Turn on power to boiler. 7. Bleed oil line.
Date Service Performed Company Name & Tech Initials Company Address & Phone # SERVICE RECORD 27
IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.
