Utica Boilers SFE IV Steam Operation and Installation Manual
Contents
1. 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 19 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 BOILERS SHOULD BE CLEANED BY SKIMMING OR BLOWING DOWN NOTICE Do not leave Boiler unattended during cleaning skimming process 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 Figure 7 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 oil2. BONERS STARFIRE IV STEAM Series 4 OIL FIRED MODELS CAST IRON BOILER SFE 3090S SFE 3090ST INSTALLATION OPERATION amp SFE 4125S MAINTENANCE MANUAL SFE 4125ST SFE 5185S SFE 5185ST SFE 6210S SFE 6210ST PATENT 7 823 544 Manufactured by A ECR International Inc LIN 65 E 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com An 150 9001 2008 Certified Company P N 240009806 Rev B 03 2014 DIMENSIONS Figure 1 ASME PRESSURE RELIEF VAL VE j A ka 21 7787 RB E 917327 ml C be PRESSURE E CONTROLI ELWC T CYCLE GUARD i V 35 374 II a a Ee A oan D J DIMENSIONS Front of Jacket to Center Line of Flue Outlet Diameter Flue Outlet A B C SrE3090 16 m TT SFE 5185 23 10 7 Doo o a SFE 6210 27 Length of Flush Boiler No Jacket STANDARD EQUIPMENT Crated boiler flush jacket oil burner target wall liner safety valve steam water level gauge steam pressure gauge steam pressure control low water cut off d
3. ON CLOSE NIPPLE HARTFORD LOOP CONNECTION SKIM TAPPING ON BACK OF BOILER WATER LINE RETURN MAIN CLEANOUT TEE S FROM BOTTOM OF BOILER SUPPLY AND RETURN PIPING 2 See Figure 8 for typical piping for domestic hot water heater Bee e Automatic mixing valve must be installed on tankless Water a a na cana heater outlet Install per valve manufacturer s Ever DUMNS SEAME OL CEA y scalding instructions AA DANGER e Install adjustable flow restrictor in cold water inlet due to varying water conditions 3 See Figures 9 and 10 for the suggested piping for a modular steam boiler Figure 8 PIPING FOR BUILT IN DOMESTIC HOT WATER HEATER UNTEMPERED HOT WATER TO AUTOMATIC WASHER e e a TEMPERING VALVE HOT INSTALLED BELOW CENTER LINE OF BOILER HOT CONNECTION l DOMESTIC HOT WATER FLOW CONTROL REGULATOR T amp P VALVE COLD WATER COLD WATER IN 10 SUPPLY AND RETURN PIPING Figure 9 SUGGESTED PIPING FOR MODULAR STEAM BOILERS PUMPED RETURN STOP VALVE p lt SJ F 8 T TRAP HIGH LEVEL SPILL DO NOT USE WITH gt CONDENSATE PUMP P TO SYSTEM TRAP TO RECEIVER CHECK TANK VALVE A SJ TO RECEIVER TANK BLOWOFF STOP VALVE rRon 7 SOLENOID RECEIVER Valve TANK OPTIONAL IL FROM RECEIVER TANK 7 Figure 10 SUGGESTED PIPING FOR MODULAR STEAM BOILERS GRAVITY RETURN STOP CHECK VALVE OPTIONAL VENTING SYSTEM INSPEC
4. TALLY e See Ratings Table page 3 for recommended minimum chimney or vent sizes CHIMNEY 3 92 M GAS VENT OR TYPE L VENT 2 61 M MIN Inadeguate draft causes 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 14 per foot Bolt or screw joints together to avoid sag 12 OIL TANK AND PIPING Tank Installation e Install oil tank and piping in accordance with National Board of Fire Underwriters and local regulations e Oil storage tank vent fill pipe and caps should be as prescribed by local codes e In no case should vent pipe be smaller than 114 I P S Fill pipe should not be less than 2 I P S Suction Line Installation e Suction line from tank to burner should be one continuous piece of tubing to prevent air entering line e Suction line must be 34 O D copper tubing for runs of 50 feet or less and 2 O D for longer runs Oil Line Installation e Oil return line same size as suction line must be used on any installation where bottom of tank is below fuel unit of burner e Bury oil lines or protect from mechanical injury e Flare fittings on all oil lines are recommended Compression fittings on suction line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle e Do not run overhead fuel lines from tank to oil bu
5. TION 8 INSTALLATION If oil fired water heater is vented into same flue as boiler provide separate hole into chimney whenever possible Boiler is to be vented by natural draft and shall not be connected into any portion of mechanical draft When this isn t possible use Y connection in flue pipe operating system under positive pressure using separate draft regulator for each unit When chimney does not provide adequate draft to handle input from water heater and boiler simultaneously wire units so only one will operate at a time favoring water heater e 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 Install boiler into chimney having a masonry or metallic chimney liner Unlined chimney will have leaks that will cause poor chimney performance no draft and could result in Figure 11 positive pressure in the combustion chamber Horizontal portions of venting system should not exceed 10 feet in length Horizontal lengths over 10 ft MORE THAN 10 3 1M will have a negative effect on chimney performance Ie 103 1 M Extend chimney at least 2 ft above any portion of ildi ithi i i HEIGHT ABOVE ANY building within 10 ft Producing a 02 inch W C draft POOE SURFACE WITTIN in the combustion chamber See Figure 11 10 3 1 M a HORIZON
6. TU Hr 1 Sq In 2000 BTU Hr Combustion Air 1 Sq In 5000 BTU Hr Step 4 Figure 1 Outside Combustion Air Vertical Ducts Horizontal Ducts Figures 2 amp 3 Figure 4 A space whose volume is not less than 50 cubic feet per 1000 BTU Hour of all appliances installed in that space cubic feet of space height x width x length A space whose volume is less than 50 cubic feet per 1000 BTU Hour of all appliances installed in that space cubic feet of space height x width x length Ventilation of boiler room must be adequate enough to provide sufficient air to properly support combustion venting and maintain safe ambient temperatures under normal operating conditions When the 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 Chapter 5 Air for Combustion and Ventilation of NFPA 31 Standard for the Installation of Oil Burning Equipment The recommendations that follow or applicable provisions of the local building codes When the boiler is installed in an unconfined space in a building of unusually tight construc
7. a A el ld APPROVED FITTINGS e BAROMETRIC i DRAFT CONTROL P SWING E FILL PIPE JOINTS SHUT OFF VALVE 4 Jd gt 9 A OL FILTER o be m el b 4 SUCTION lt A LINE a OIL e Jemecr a TANK Matve sorer A o mo el a q o 0 OIL BURNER e do RETURN LINE REFER TO LOCAL CODE OIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM DAMAGE MINIMUM 1 2 IPS OR 1 2 O D COPPER TUBING 13 ELECTRICAL WIRING Thermostat Installation 1 Thermostat should be installed on inside wall about four feet above floor 2 NEVER install thermostat on outside wall 3 Do not install thermostat where it will be affected by drafts hot or cold pipes sunlight lighting fixtures Electrical wiring must conform with the latest revisions of television fireplaces or chimneys the National Electrical Code ANSI NFPA No 70 and or 4 Check thermostat operation by raising and lowering local authority having jurisdiction thermostat as reguired to start and stop burner 5 Instructions for final adjustment of thermostat 1 When an external electrical source is utilized the are packaged with thermostat adjusting heating boiler when installed MUST BE electrically grounded anticipator calibration etc in accordance with these reguirements 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 sou
8. a low water condition an automatic low water cut off device will interrupt power between the low water a LINE cut off and burner Burner remains off until low water condition is corrected i e manually restore boiler water or utilize water feeder device which automatically restores 1 4 SLOT water to its normal operating level INSPECTION Installer Before putting boiler in operation test COVER mechanical low water cut off device for proper operation While burner is on open blow off valve located in lower portion of cut off body This will drain water quickly from cut off body and break circuit to burner If it does not replace control A DANGER BURNER ELECTRICAL DISCONNECT MOUNTING SCREWS BOTH SIDES Water temperatures exceeding 125 F will cause Tse E severe burns instantly or death by scalding Refill boiler to its normal water line Operating Instructions e Start of heating season have venting system inspected 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 flue and using mirror check for obstruction and verify compliance to latest revision of the NFPA 211 Operate lever of safety valve on boiler periodically to verify it is functioning properly See Figure 14 Safety relief valve should open before steam pressure exceeds 15 psi reading on the gauge If this pressure is ex
9. ceeded and safety relief valve leaks steam when boiler is operating at normal pressures immediately replace Corrosion can build up rapidly at valve seat and prevent its functioning as a safety device 16 OPERATING INSTRUCTIONS Start Up And Adjustment Of Oil Burner See oil burner instructions for nozzle and electrode setting Do not set fire 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 the fuel oil This may then reguire excessive boiler maintenance service costs and in some instances house cleaning or redecorating Consult a gualified service mechanic to make proper adjustments with smoke tester CO indicator and draft gauge Bacharach or Dwyer test kits include these instruments 1 Check oil burner nozzle to verify it is tight in adapter Burner mounting bolts should be tight Check electrode setting they may have been jarred out of position during transportation Lubricate burner motor if necessary Set room thermostat to call for heat or jump thermostat contacts on boiler control Open all oil line valves Turn service switch on Burner should start On one pipe fuel systems only bleed pump as soon as burner starts Allow oil to run until all traces of air in suction line disappear Turn OFF burner and install pressure gauge port on pump Start burner again and chec
10. cleaning or removing tankless water Fire hazard Do not install boiler on combustible flooring or carpeting Failure to follow these instructions could result in death or serious injury FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY Boiler must not be installed on carpeting or vinyl flooring Minimum clearances to combustible construction are ATN FRONT 24 IN FLUE CONNECTOR REAR 24 IN RIGHT SIDE 24IN heating coil Recommend 24 inches be allowed in back of boiler for convenience when skimming hole is used NOTE Clearance for access should exceed fire protection clearance When installed in a utility room the door should be wide enough to allow largest boiler part to enter or to permit replacement of another appliance such as water heater Figure 2 Minimum Clearances To Combustible Construction as seen from above Install boiler such that oil ignition system components are protected from water dripping spraying rain etc during appliance operation and service BACK AN 24 LN X AC dd tet f l 2 JANA OON VENTILATION AND COMBUSTION AIR Asphyxiation fire hazard Do not obstruct air openings to combustion area Follow instructions below to maintain adeguate combustion air COMBUSTION AIR REOUIREMENTS Minimum Opening Reguirement Unconfined Area Confined Area Outside Inside Combustion Air 1 Sq In 1000 BTU Hr Min 100 Sq In 1 Sq In 4000 B
11. fined symbols are used throughout this manual to notify reader of potential hazards of varying risk levels Installer Leave all instructions with the boiler for future reference A DANGER When this product is installed in the Commonwealth Indicates a hazardous situation which if not of Massachusetts the installation must be performed avoided WILL result in death or serious injury by a Licensed Plumber or Licensed Gas Fitter Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE PATENT 7 823 544 Indicates information which should be followed to ll ensure proper installation and operation LOCATING THE BOILER e Installations shall conform to the requirements of the authority having jurisdiction Such applicable reguirements take precedence over the general instructions of this manual Where reguired 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 boiler in front of final position before removing crate Provide level solid base as near chimney as possible and centrally located with respect to heat distribution system as practical Allow 24 inches in front top and right hand side for servicing and
12. he outdoors or spaces crawl or attic that freely communicate with the outdoors One of the following methods must be used to provide adeguate air for ventilation and combustion A When directly communicating with the outdoors each opening shall have a minimum free area of 1 sguare inch per 4 000 BTU per hour of total input rating of all eguipment in the enclosure Figure 4 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 Figure 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 Figure 6 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 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
13. ions COMPLETELY before installing Ratings Datd ss assess casino sima k in irni Vini eriei 3 Safety SVMBOIS i adj ueta ena nona ana daa ciais im ajana saama 4 Locating THE BOWS eee airi E A 5 Installations of boilers and venting shall be done Ventilation And Combustion Air 6 only by qualified expert and in accordance with this E manual Installing or venting a boiler or any other POPPY And Return eee sie SERA o Ra dan ds wees Goode ented 8 gas appliance with improper methods or materials Venting System Inspection amp Installation 12 could result in serious injury or death due to fire Oil Tank And Pip ithe cs a aka alas kaitsa 13 or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible Electrical Wiring merienenn a 14 Operating Instructions siiiiissccsterteerenrraasa 16 Maintenance Procedures cccccccccceceeeueeeeeecunuuunens 19 Keep boiler area clear and free from combustible Service Checklist arara ge bind Sa 21 materials gasoline and other flammable vapors and liquids Do not obstruct air openings to boiler room Modification substitution or elimination of factory KEEP THIS MANUAL NEAR BOILER equipped supplied or specified components could RETAIN FOR FUTURE REFERENCE result in personal injury or the loss of life SAFETY SYMBOLS Owner Installation and service of this boiler must be performed by a qualified installer The following de
14. ire In Flue Electrode Setting CO or O Proper Light Off Hot amp Cold Flue Gas Temperature Measure with instruments and record results below SERVICE RECORD Draft 0 0 Motor cmoke E Amps or O 21 NOTES 22 SERVICE RECORD uoyd 8 SSolppy Auedui0 SJEHIUT 4391 9 oweN ueduio PIO JHId BIIAIBS IMPORTANT In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is eguipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is eguipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is eguipped with a tankless coil UTICA BOILERS UTICA 2201 Dwyer Avenue BOILERS o Utica NY 13501 web site www ecrinternational com
15. is filled to water line as indicated in Figure 14 Gauge valves should be normally open To remove dirt from gauge glass petcock may be opened to flush out the glass Radiator valves on 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 on the boiler Figure 14 should be operated periodically to make sure that it is functioning properly Safety valve should open before the steam pressure exceeds the 15 psi reading on the gauge Figure 14 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
16. 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 Blowing Down The 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 as many times as reguired until blow off water is clear Owner should blow down boiler at least once each month of the heating season MAINTENANCE PROCEDURES 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 materia
17. k oil pressure for 140 Ibs Adjust if necessary BECKETT AFG SETTINGS BOILER NO HEAD TYPE HEAD sre soso u 3 075608 seems vi o 2 1 10 5099 F12 F16 SFE 5185 SFE 6210 STATIC SETTING PLATE EEA MET EET ES AIR AIR BAND SHUTTER NOZZLE PRESSURE 150 140 150 145 Boiler model number on rating plate includes suffix S or ST IMPORTANT Check safety control circuit after burner adjustments have been made for satisfactory performance 17 OPERATING INSTRUCTIONS A Pressure Control Remove cover and note pressure setting With boiler operating decrease setting When setting is lower than boiler pressure control will open and turn off boiler After checking pressure control reset control to original setting Mechanical Low Water Cut off May be checked by opening blow off valve on lower portion of cut off body while boiler is running This will drain water from boiler and break circuit to burner Refill boiler to its normal water line C Primary Control and Flame Sensor Check 1 Flame Failure Simulate by shutting off oil supply with hand valve while burner is on Sixty seconds after flameout 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 Failure With burner off close oil supply valve and run through start up procedure Safety switch should
18. lock out as in flame failure 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 Preventative 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 To remove soot and scale from flueways remove top jacket panel top clean out plate open burner swing door See Figure 14 18 Opening Burner Swing Door 1 Turn off power to boiler and allow boiler to cool down 2 Disconnect power cable at factory supplied burner electrical disconnect See Figure 14 3 Loosen screws on sides of lower front jacket panel See Figure 6 Pull bottom part of lower front panel forward and lift lower front panel up and off boiler See Figure 14 4 Close oil valve and disconnect oil line from burner See Figures 12 13 IMPORTANT Do not open swing door with oil line attached 5 Remove nut from swing door stud on right hand side of door 6 Swing open burner and door to left Using flue brush brush soot and scale into combustion space where it can be removed through s
19. ls 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 inspection and tightening of the tankless heater cover plate bolts will reduce the risk of leaks See parts 3 and 5 under Coil and Cover Plate Replacement Parts 20 Electronic Low Water Cut Off Operation of the probe and control should be checked with the burner on by draining the water via the drain on the bottom of the boiler This will drain the water quickly from the boiler and break the circuit to the burner If it does not inspect the probe for scaling If scaling is present clean off the probe refill the boiler until the ELWCO is satisfied and perform the check again 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 SERVICE CHECKLIST Inspect Chimney and Flue Pipe Inspect and Clean Appliance Inspect Oil Line Size Leaks Inspect Electrical Connections Controls and Safety Devices Nozzle Size Angle Type Pump Pressure Vacuum Line Voltage Motor Amps lt x KK KK KK x par ja ery ey ee aanli ee i jm an kommt md a tn ja Install New Filter Smoke Test Room Make up Air Draft Overf
20. 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 Figure 4 CHIMNEY R L TYPE VEN PIPE VENTILATION LOUVERS CEACH AND F ATTIC VENTILATIO LOUVERS FOR UNHEATED CRAWL SPACE Figure 5 CHIMNEY VE lt ENTILATION LOUVERS CEACH AND F ATTIC TYPE PIPE UTLET AIR VENT PIPE Figure 6 P CHIMNEY OR L TYPE VENT PIPE VENT PIPE OUTLET AIR DUCT INLET AIR DUCT SUPPLY AND RETURN PIPING Burn or Scald Hazard Discharge line shall be installed to safety valve outlet connection to avoid burns scalding or water damage due to discharge of steam and or hot water during operation Discharge line shall e 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 e Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line e Have no intervening shutoff valve between safety valve and discharge to atmo
21. rain valve wiring harness burner electric disconnect plastic cover 2 supply tapping 172 return tapping skim port and primary control NOTE For tankless heater units add tankless hot water coil and low limit control RATINGS DATA As DA CERTIFIED RATINGS www ahridirectory org Oil Burner Input Net AHRI Ratings A ale niej Chimney Size Heating NRE Capacit ss Rating MBHO Round Square WITHOUT WITH TANK TANKLESS LESS SFE 30905 SFE 3090ST os G P H SFE 4125S SFE 4125ST 1 25 85 10 SFE 51855 SFE 5185ST Burner input is based on an oil heating value of 140 000 Btu gal 2 MBH 1000 Btu per hour Btu British Thermal Unit 3 Net AHRI Steam Ratings based on piping and pick up allowance of 1 333 Consult manufacturer before selecting boiler for installations having unusual piping and pick up requirements such as intermittent system operation extensive piping etc Heating Capacity and AFUE based on 13 0 CO with 0 02 W C draft over fire and 1 smoke or less Tested in accordance with U S Department of Energy test procedures TANKLESS WATER HEATER CAPACITIES Boiler Water Tankless Content Tankless eater Capacity Gallons Heater 4 Intermittent Draw Number G P M To Water Line Boiler Model Number To LWCO Line TABLE OF CONTENTS DIMENSIONS a ces near aitavad aliase sad endciadi s 2 IMPORTANT Read and understand the following A instruct
22. rce of electric power shall be connected to the circuit of this system See Steam Wiring on next page 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 14 ELECTRICAL WIRING STEAM WIRING W BECKETT BURNER FIELD INSTALLED VXT 120 WATER FEEDER CG450 ELWCO males es r k O N r p k p O FEED Li I 1 k H Va o TANKLESS i E EEE COIL FIELD I I i MODELS Vil ODEL INSTALLED 1 See eee eee eee eee FE Va TH 2 ot L4006A I 1 l l I poi eE 1 ben n fee a4 ee eee eee AO YELLOW Doo dl doll nn d FACTORY PRIMARY INSTALLED CONTROL SERVICE SWITCH JUNCTION BOX BURNER DISCONNECT BURNER JUNCTION L1 L2 G 120V 60 HZ SUPPLY OIL BURNER TRANSFORMER COMPONENT CODING Transformer 120V 24V 50VA WIRING CODE m Line Voltage By Factory gt Low Voltage By Factory NOTE Not all components listed are used in all control systems mm mmm Line Voltage By Installer Low Voltage By Installer 15 OPERATING INSTRUCTIONS Seguence Of Operation Figure 14 On call for heat thermostat will actuate completing the ELECTRONIC LOW circuit to the boiler In turn the ignition systems are WATER CUTOFF activated and ignition will begin PRESSURE RELIEF VALVE TOP JACKET N za EL In event of
23. rner Figure 12 Typical Installation Single Pipe Oil System APPROVED FITTINGS i ra o q ef I I Tt ft Tf i I LI DL kd j SWING JOINTS REFER T NATIONAL j BOARD F FIRE UNDERWRITERS BAROMETRIC VENT PIPE DRAFT CONTROL ki FILLER PIPE DIL GAUGE j TM SHUT OIL FILTER OIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM DAMAGE MINIMUM 378 IPS R 3 8 0 D COPPER TUBING Fuel Pump Connections e Fuel pump connections and by pass should be made according to instructions attached to fuel pump e If tank is more than 20 from boiler install two stage fuel unit in place of single stage pump supplied as standard eguipment with burner e Verify rotation and speed are the same and pump is suitable for burner horsepower rating Install oil line filter and shut off valve in the suction line Install shut off valves in both 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 An optional flexible oil line is available See Figures 12 13 Figure 13 Typical Installation Two Pipe Oil System Re q PM o 9
24. sphere Do not plug or place any obstruction in discharge line e Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing e Allow complete drainage of valve and discharge line e Install safety valve with spindle in vertical position e Do not install shutoff valve between boiler and safety valve e Support safety valve discharge piping e Be short and straight as possible e Terminate with plain end not threaded e Constructed of material suitable for exposure to temperatures of 375 F 191 C or greater Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements Figure 4 Safety Valve SAFETY VALVE DISCHARGE PIPING BOILER Check local codes for maximum distance from floor or other allowable safe point of discharge it 6 Above Floor SUPPLY AND RETURN PIPING 1 Suggested piping for steam heating system can be seen in Figure 7 Actual piping may vary based on system design and local conditions Figure 7 NOTE BOTH 2 SUPPLY TAPPINGS MUST BE USED ALL NEAR BOILER SUPPLY HEADER PIPING MUST BE A MINIMUM OF 2 DO NOT REDUCE OPTIONAL ONE OR TWO TAKE OFFS TO SYSTEM 12 MIN 1 1 2 MINIMUM IF RETURN PIPING IS LARGER INCORPORATE SIZE TO EQUAL THE RETURN PIPE SIZE HEADER RECOMMENDED SIZING 3 SECTION 2 4 SECTION 2 1 2 5 6 7 SECTION 3 SUPPLY CONNECTI
25. tion 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 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 1 000 BTU per hour of the total input rating of all appliances in the enclosed space but must not be less than 100 square inches These openings must freely communicate with the interior areas having adequate infiltration from the outside See Figure 3 Figure 3 CHIMNEY OR LTYPE VENT PIPE BASEBOARD VENT PIPE VENTILATION AND COMBUSTION AIR 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 t
26. wing door opening NOTICE Use caution when vacuuming in chamber area Damage to chamber could result Recommend replacing nozzle at start of each heating season Lubricate burner motor and circulator motor if required with few drops of good grade of light motor oil Do not over oil Have qualified 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 Startup and Adjustment of Oil Burner Closing The 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 it until built in stop contacts mounting door 3 Reconnect 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 and bleed oil line MAINTENANCE PROCEDURES Burn and scald hazard Verify Boiler is off and cooled before performing maintenance Have a gualified service agent perform maintenance Failure to follow these instructions could result in death or serious injury Before seasonal start up it is advisable to have a gualified service agency check boiler for soot and scale in flues change oil filter and nozzle clean burner and re adjust burner input rate to maintain proper operation and high operating efficiency On steam boilers verify boiler
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