UTICA BOILERS SFM CONSTELLATION Series Manual de instrucciones

P/N 27513401, Rev. B [03/2011]

SFM CONSTELLATION SERIES

MODULAR OIL FIRED CAST IRON BOILERS

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company

Utica Boilers

2210 Dwyer Avenue, Utica NY 13504-4729

Phone: (315) 797-1310 • Fax: (866) 432-7329

e-mail: info@ecrinternational.com

web site: www.ecrinternational.com

TABLE OF CONTENTS

Safety Symbols ....................................... 2

Dimensions ............................................ 3

Boiler Ratings & Capacities ....................... 4

Introduction............................................ 5

Connecting Supply & Return Piping ............ 6

Primary Secondary Piping ......................... 7

Ventilation & Combustion Air ..................... 8

Venting System Inspection & Installation ..11

Oil Tank Installation & Piping ............... 12-13

Thermostat Installation ...........................13

Operating Instructions.............................14

Control System ......................................17

Service Check List ..................................19

REPLACEMENT PARTS LISTS

Heat Exchanger.......................................20

Swing Door & Mounting Door Components . 21

Jacket ...................................................22

Hardware ..............................................23

Controls & Hardware ...............................24

SAFETY SYMBOLS

The following dened symbols are used throughout

this manual to notify the reader of potential hazards

of varying risk levels.

INSTALLATION MANUAL AND OPERATING INSTRUCTIONS

Tested for 75 PSI ASME

Working Pressure

KEEP THIS MANUAL NEAR BOILER AND

RETAIN FOR FUTURE REFERENCE.

SFM SERIES MODULAR OIL FIRED CAST IRON BOILERS

DANGER

Indicates a hazardous situation which, if

not avoided, WILL result in death or serious

injury.

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.

CAUTION

Indicates a hazardous situation which, if not

avoided, may result in minor or moderate

injury.

NOTICE

Indicates information which should be

followed to ensure proper installation and

operation.

WARNING

Indicates a hazardous situation which, if

not avoided, could result in death or serious

injury.

MODEL NO. A B C D

SFM6225W * 29 ¼” 13 ⅝” 8” ———

SFM7275W * 32 ⅞” 13 ⅝” 8” ———

SFM24150W 21 ½” 12 ⅝” 6” 53 13⁄16”

SFM25175W 25 ⅛” 14 ¼” 7” 53 13⁄16”

SFM25200W 25 ¼” 14 ¼” 7” 53 13⁄16”

SFM26225W 29 ¼” 13 ⅝” 8” 53 13⁄16”

SFM27275W 32 ⅞” 13 ⅝” 8” 53 13⁄16”

SFM36225W 29 ¼” 13 ⅝” 8” 85 7⁄16”

SFM37275W 32 ⅞” 13 ⅝” 8” 85 7⁄16”

SFM47275W 32 ⅞” 13 ⅝” 8” 87 13⁄16”

SFM57275W 32 ⅞” 13 ⅝” 8” 149 1⁄16”

SFM67275W 32 ⅞” 13 ⅝” 8” 181 13⁄16”

SFM77275W 32 ⅞” 13 ⅝” 8” 212 11⁄16”

SFM87275W 32 ⅞” 13 ⅝” 8” 245 ⅝”

* SFM6225W & SFM7275W are Single Module Units

MODEL # CODE

SF M 2 6 225 W

SERIES

MODULAR DESIGN

NO. OF PACKED BOILERS

SECTIONS PER BOILER

G.P.H. INPUT EACH FOR BOILER

TYPE OF UNIT

MULTIPLE BOILER DIMENSIONAL DATA

DIMENSIONS

NOTES:

1. Add sufx “T” to denote boiler with tankless heater.

2. I=B=R burner capacity is based on an oil heating value of 140,000 Btu/gal. and with 13% CO2.

3. For equivalent square feet of radiation, divide I=B=R output by 150.

4. Net ratings based on 170 0 F temperature in radiators and include 15% allowance for normal piping

and pick-up load. Consult manufacturers for unusual piping and pick-up requirements.

5. Nozzle listed is for use with Beckett burner. When alternate burner is used, consult burner manufac-

turer’s recommendations.

6. Electrical service to be 120 Volts, 15 Amps, 60 Hz. (Each Boiler).

7. The MEA number for the SFM series is 182-86E.

8. The MEA number for the AFG burner is 213-83-E.

STANDARD EQUIPMENT: Crated Boiler, Flush Jacket, Oil Burner, Target Wall/Liner, ASME Relief

Valve, Theralitimeter Gauge, Drain Cock, Wiring Harness, Burner Electrical Disconnect, Plastic Cover,

Supply Tapping - 2”, Return Tapping - 1 ¼”, High Limit and Circulator Control, Primary Control. For

Tankless Heater Units-add Tankless Hot Water Coil.

MODEL NO.

FIRING

RATE

G.P.H.

INPUT

M.B.H.

DOE

OUTPUT

M.B.H.

IBR

OUTPUT

M.B.H.

MODEL NO.

OF MODULES

NO. OF

MODULES

TOTAL

BOILER

WATER

VOLUME

GAL

BOILER

WEIGHT

LBS.

PUMP

PRESSURE

P.S.I

NOZZLE

FURNISHED

SFH6225W 2.25 315 254 221 SFM6225W 1 19.5 915 140 2.00 45B

SFH7275W 2.75 385 307 267.1 SFM7275W 1 22.5 1058 140 2.25 45B

SFM24150W 3.00 420 350 304 SFM4150W 2 27.0 1251 140 1.25 80B

SFM25175W 3.50 490 412 358 SFM5175W 2 33.0 1546 140 1.50 80B

SFM25200W 4.00 560 462 402 SFM5200W 2 33.0 1546 140 1.75 80B

SFM26225W 4.50 630 508 442 SFM6225W 2 39.0 1831 140 2.00 45B

SFM27275W 5.50 770 614 534.2 SFM7275W 2 45.0 2116 140 2.25 45B

SFM36225W 6.75 945 762 663 SFM6225W 358.5 2745 140 2.25 45B

SFM37275W 8.25 1155 921 801.3 SFM7275W 367.5 3174 140 2.25 45B

SFM47275W 11.00 1540 1228 1068.4 SFM7275W 4 90.0 4232 140 2.25 45B

SFM57275W 13.75 1925 1535 1335.5 SFM7275W 5 112.5 5290 140 2.25 45B

SFM67275W 16.50 2310 1842 1602.6 SFM7275W 6 135.0 6347 140 2.25 45B

SFM77275W 19.25 2695 2149 1869.7 SFM7275W 7 157.5 7905 140 2.25 45B

SFM87275W 22.00 3080 2456 2136.8 SFM7275W 8 180.0 8464 140 2.25 45B

BOILER RATINGS, CAPACITIES & DIMENSIONS

All installations must conform to the requirements

of the authority having jurisdiction. Such applicable

requirements take precedence over the general

instructions of this manual.

Where required by the authority having jurisdiction,

the installation must conform to the American Society

of Mechanical Engineers Safety Code for Controls and

Safety Devices for Automatically Fired Boilers, ANSI/

ASME No. CSD-1.

LOCATE BOILERS in front of nal position before remov-

ing crate. Provide a level solid base as near the chimney

as possible, and centrally located with respect to the heat

distribution system as practical.

WARNING

Boiler may not be installed on combustible

ooring.

Allow 24 inches in the front and top for servicing and

cleaning, or removing tankless water heating coil.

When installed in a utility room, door should be wide

enough to allow 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 ooring. Minimum clearances to

combustible construction are:

TOP .......................................... 24 IN.

FRONT ...................................... 24 IN.

FLUE CONNECTOR ........................ 9 IN.

REAR .......................................... 6 IN.

SIDES....................................... 12 IN.

NOTICE

Clearance for access should exceed fore

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 led immediately against the

carrier by the cosigner. Move boiler to permanent

position by sliding or walking.

INTRODUCTION

The recommended method of connecting the supply and return piping can be seen in Figure #1 below.

(For detailed piping recommendations refer to the engineering manual)

RETURN

SUPPLY

CIRCULATOR

REAR OF BOILER

FRONT OF BOILER BRANCH

BRANCH

MAIN

CONNECTING SUPPLY AND RETURN PIPING

Figure 1 - MODULAR BOILER HOOK-UP RECOMMENDED PARALLEL PIPING

ZONE 1 ZONE2

ZONE 3

REAR OF

BOILER

BRANCH

12"

MAX

FRONT OF

BOILER

AIR ELIMINATOR &

EXPANSION

TANK

PRIMARY

PUMP

PRIMARY

LOOP

SECONDARY

PUMP

LOAD

PUMPS

EXPANSION

TANK & SYSTEM

FILL

An alternate method of connecting the supply and return piping can be seen in Figure #2 below.

(Refer to the engineering manual for detailed piping recommendations.)

Note: The tapping sizes for the supply and return piping are 2” and 1 ½” respectively.

It is recommended that the main piping be 3” and the branches 1 ½”.

PRIMARY SECONDARY PIPING

Figure 2 - PRIMARY SECONDARY PIPING

1. When a boiler is located in an unconned

space in a 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. 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

latest revision of the NFPA 54 code, the

recommendations that follow, or applicable

provisions of the local building codes.

COMBUSTION AIR REQUIREMENTS

(MINIMUM OPENING IN SQUARE INCHES)

*UNCONFINED AREA **CONFINED AREA

OUTSIDE

COMBUSTION AIR

INSIDE

COMBUSTION AIR

OUTSIDE

COMBUSTION AIR

1 IN2/5000BTU

(PARAGRAPH 2)(SQ IN)

1 IN2/1000 BTU

(MIN 100IN2) (FIG 4)

(SQ IN)

1 IN2/4000

BTU

(FIG 3)(SQ IN)

1 IN2/2000

BTU

(FIG 3)(SQ IN)

BTU/HR INPUT

315,000 63 315 78.75 158

385,000 77 385 96.25 193

420,000 84 420 105 210

490,000 98 490 123 245

560,000 112 560 140 280

630,000 126 630 158 315

770,000 154 770 193 385

945,000 189 945 237 473

1,155,000 231 1155 289 578

1,540,000 308 1540 385 770

1,925,000 385 1925 482 963

2,310,000 462 2310 578 1155

2,695,000 539 2695 675 1348

3,080,000 616 3080 770 1540

* Unconned area: A space whose volume is not less than 50 cubic feet per 1000 BTU per hour of all appli-

ances 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 in-

stalled in that space (cubic feet of space = height x width x length).

2. When a boiler is installed in an unconned

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 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.

VENTILATION & COMBUSTION AIR

WARNING

Air openings to combustion area must not be

obstructed. Follow the chart below to obtain

and maintain adequate combustion air.

3. When air for combustion and room ventilation is

from inside buildings, the 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 #4.

4. When the boiler is installed in a conned space

and 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.

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 #3.

VENTILATION & COMBUSTION AIR

Figure 3 - COMBUSTION AIR SUPPLIED FROM OUTSIDE THE BUILDING

OIL LINE MUST BE BURIED OR OTHERWISE

PROTECTED FROM DAMAGE. MINIMUM

OIL FILTER

SHUT OFF VALVE

SWING JOINTS

APPROVED FITTINGS

OIL GAUGE

FILLER PIPE

VENT PIPE

.5" IPS OR 1/2" O.D. COPPER TUBING

REFER TO NATIONAL BOARD OF

FIRE UNDERWRITERS

MINIMUM

OIL TANK

TYPICAL INSTALLATION SINGLE PIPE OIL SYSTEM WITH 2 OR MORE UNITS

TEES

NIPPLES

INSPECT CHIMNEY to make certain it is constructed

according to the latest revision of NFPA211. Local codes

may differ from this code and should be checked. Where

there is a conict, the local code will prevail.

This boiler must be installed into a chimney which has

a masonry or metallic chimney liner.

VENTILATION & COMBUSTION AIR

VENTING SYSTEM INSPECTION & INSTALLATION

Figure 4 - COMBUSTION AIR SUPPLIEDFROM INSIDE THE BUILDING

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.

Figure 5

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