Slant/Fin INTREPID Oil-fired Boiler User's Manual
Contents
1. Q GREEN GROUND ING SCREW GREEN D Q HIGH LIMI FIELD CONNECTION JUNCTION BOX ELAME a BURNER JUNCTION BOX FACTORY MOUNTED US QUICK DISCONNECT PLUG SOLENOID VALVE L1 IF EQUIPPED E e BURNER 2 MOTOR NOZZLE LINE 2 ES x 9 5 IF EQUIPPED CONTROL m 5 IGNITION SERVICE R7184B i ITCH VIOLET EQUIPPED THERMOSTAT 1 6 BLACK WATER HI LIMIT WITHOUT WELL BLUE 4 P N 410699000 es WHITE HONEYWELL 1408081253 RED OR WHITE ROGERS 11B83 1 RED ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED BY CODES CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED VAN GROUNDING CONDUCTOR TWO GREEN GROUND WIRES ARE FACTORY CONNECTED TO THE GREEN GROUND SCREW IN THIS BOX FIELD WIRE A GROUNDED CONDUCTOR TO THIS SCREW TOGETHER WITH THE TWO GREEN FACTORY CONNECTED GREEN WIRES WIRING FOR PACKAGED STEAM BOILER EQUIPPED WITH McDONNELL NO 67 L W C O High Pressure Limit 120 VAC 60Hz Recommemded setting 0 5 PSI Differential 5 PSI Low Limit tankless model only 1 2 recommemded setting 1602F SOLENOID T VALVE IF EQUIPPED BURNER MOTOR OTHER SAFETY CONTROL N HOT 1 4006 LOW LIMIT FOR TANKLESS2. OIL PUMP PRESSURE APPROX AIR BAND SETTING HEA us d PSIG SETTINGT 115 108 BAR t 1 8 Forward 100 BAR t 1 4 Forward 107 1 4 Forward Choke 3 Wayne part no 12329 Static Disc 2 1 2 6 air tube 1 3 4 insertion for the welded flange Burner specifications marked BAR are for Intrepid boilers approved for use in N Y C by Bureau of Air Resources 4 DIA TUBE 6 LONG d A SETTING SHOWN IN FORWARD POSITION SEE TABLE ABOVE 2 CHOKE VIEW A A ELECTRODE 1 2 ABOVE CENTER NOZZLE 1 8 1 8 GAP INTREPID CARE AND MAINTENANCE EXTENDED SHUTDOWN CLEANING OR REMOVAL OF BOILER FROM SERVICE DANGER Use CAUTION when handling chemicals and draining hot water from a boiler Scalding water and or chemicals can cause per manent injury to the skin eyes and respiratory system A Shut down burner by disconnecting all electrical power to the burner by turning OFF the BURNER EMERGENCY SWITCH of this boiler After shutting down burner while the boiler is still hot 180 F to 200 F drain water from the bottom of the boiler until it runs clear B Provide corrosion protection conditioning to the boiler water in the heating system There are a number of commercial heating sys tem preparations available from your distributor Follow the prepa ration manufacturers instructions 1 For steam boilers maintain a sod
3. it gt 24 VOLTS t t NER T pui CIRCULATOR CIRCULATOR CIRCULATOR ZONE 2 4 ZONES ZONES 1 OTHER ZONES ai ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT m nas ns na ans cm MEANS AND OVERLOAD PROTECTION AS REQUIRED BY CODES CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED 81 85 PAIN AB TERMINAL gt EL GROUNDING CONDUCTOR TWO GREEN GROUND WIRES ARE FACTORY CONNECTED TO THE GREEN GROUND SCREW IN THIS BOX FIELD WIRE A GROUNDED CONDUCTOR TO THIS SCREW TOGETHER WITH THE TWO GREEN FACTORY CONNECTED GREEN GROUND WIRES ZONE WIRING DIAGRAM FIELD CONNECTION MULTIPLE ZONED ZONE VALVE METHOD CIRCULATOR METHOD _ JUNCTION BOX FACTORY MOUNTED USING HONEYWELL V8043F OR ERIE 765 L8124 Mm ELECTRICAL POWER SUPPLY 1 OVERLOAD PROTECTION t 7 AND DISCONNECT MEANS 84 WAC MUST BE PROVIDED 4 0 A8 REQUIRED BY CODES NEUTRAL 1 STEP DOWN I TRANSFORMER 18124 ar C 10 Primaty Contro OTHER SAFETY CONTROLS H 120 6 gored Zone 1 Circulator Circulator CONNECT TO T T ON 16 zone 3 it used L8148A AQUASTAT Note Total load not to exceed 8 amp full load for circuits shown 12 INTREPID BASIC MODULE WIRING less circulator
4. All safety precautions indicated on material package must be followed INTREPID Once burner and draft have been set up then smoke and stack temperature should be checked and recorded If smoke is greater than trace review the burner instructions replace the nozzle if necessary Normal smoke to be expected at approximately 13 CO is zero to a trace AND FILLING NEW WATER BOILER There are a number of commercial preparations available from your distributor for cleaning and for corrosion protection conditioning the internal waterside surfaces of boilers Follow the preparation manu facturer s instructions DANGER Use CAUTION when handling chemicals and draining hot water from a boiler Scalding water and or chemicals can cause permanent injury to the skin eyes and respiratory system Il FILLING AND VENTING THE WATER BOILER A Refill the system with fresh water B Bring water temperature to at least 180 F promptly C Circulate water through entire system D Vent the system including the radiation E F The boiler is now ready to be put into service or on standby If brand name air control devices are used venting instructions furnished with the devices should be followed SAFETY CHECK FOR CONTROL SYSTEM High limit control test Set thermostat high enough for boiler water temperature to reach high limit control setting When this tempera ture is reached the high limit switch should open
5. OPERATING INSTRUCTIONS PRECAUTIONS BEFORE STARTING OIL BURNER Make a positive check of A through F before starting burner A ommo om T Boiler and system are full of water All air is vented from system See below All wiring is completed See pages 11 13 Oil supply is connected to the burner nozzle is installed correctly oil valve is open at tank Smokepipe is connected to chimney All combustible materials are cleared away Combustion air supply is provided See page 3 Burner settings are adjusted as per pages 14 18 and as shown on boiler jacket Main cast iron door on which burner is mounted is bolted shut and fiberglass rope seal is making good contact WARNING NEVER OPERATE any natural draft boiler Intrepid boiler is a natural draft boiler with zero draft or over fire pressure early failure of the burner nozzle and chamber is inevitable if you do Use a draft gauge and make sure that overfire draft is 02 minimum during all operating conditions Draft is negative or suction pressure ME UP COMBUSTION TEST INSTRUMENTS MUST BE USED Make sure the boiler is installed and wired properly and is full of water Open the observation door on the front above the burner Start the oil burner see burner instructions for bleeding air from oil etc IMMEDIATELY set burner air bands to obtain a bright fire with out smoke or oil stain Set the DRAFT REGULATOR to obtain 02
6. water cut off operation of cut off should be checked at least twice a year as follows A While boiler is running drain down boiler water slowly through Boiler Drain Cock shown on page 4 just until light goes on Boiler should shut down 10 seconds after light goes on B Be sure that it is the low water cut off and not the room thermo stat pressure cut out or other control that has shut off the burner C Refill the boiler and repeat test D Refill the boiler and reset controls for normal operation Float type low water cut off If this boiler is factory equipped with a McDonnell amp Miller float type low water cut off the low water cut off must be blown down flushed at least once a week SUPPLY START OF SKIMMING LEVEL 2 BELOW TOP OF GAUGE GLASS 1 1 2 MALLEABLE IRON 150 PSI STREET ELBOW 11 2 SKIMMER 251 a DRAIN VALVE NORMAL yf COVERED BUCKET OPERATING WATER RETURN Figure 9 HRD 10 CAUTION When flushing float type low water cut off control hot water and steam will flow out the blow down valve Blow down valve is illus trated below A SPECIAL FLUSHING INSTRUCTIONS For new boiler installed in old system Installation of new boiler may break loose a heavy accumulation of sediment and scale from old piping and radiators It is extremely important to blow down your McDonnell cut off more frequently the first week First week 3 times Thereafter at least once a week B
7. Seal bad masonry joints Repair damaged linings C Where more than one appliance vents into a common chimney the area of the common breeching should at least equal the area of the largest appliance flue plus 50 of the additional flue areas D Breeching area must not be reduced at connection into chimney Breeching must be inserted into but not beyond inside of chimney liner E Chimney height shall extend at least 3 feet above where it passes through the roof of the building and at least 2 feet above any ridge within 10 feet of the chimney F The use of a vent cap where permitted by code gives additional protection against adverse wind conditions and precipitation G Flue Connection Connect flue pipe between top of boiler and chim ney Horizontal sections of flue pipe must be pitched upward to the chimney at least 1 4 per foot Flue must be inserted into but not extend beyond the inside wall of the chimney flue Install draft regu lator in flue pipe as shown in figure 3 AIR SUPPLY AND VENTILATION see NFPA 31 latest edition Sufficient air for combustion and ventilation in the boiler room must be provided Failure to do this will result in poor combustion heavy soot ing and health hazards PITCH UP 1 4 PER LINEAR FOOT DO NOT INSTALL DRAFT REGULATOR HERE d BAROMETRIC DRAFT CONTROL DRILL 1 4 HOLE TO MEASURE DRAFT SMOKE COZ AND STACK TEMPERATURE Figure 3 Barome
8. and the burner should shut off automatically If the high limit does not operate to shut off the burner the high limit or the wiring is faulty Repair or replace immediately WATER CONTENT OF BOILER GALLONS Water Boiler 10 7 8 Steam Borer 69 88 10 7 126 Without tankless coil VOLUME OF WATER IN STANDARD PIPE OR TUBE Nominal Pipe Gallons Inside Gallons Size per Dia Inches Lin Ft Inches Lin ft INTREPID CLEANING AND FILLING A NEW STEAM BOILER BEFORE USING STEAM BOILER A Check burner to be certain it is ready for firing DO NOT FIRE into an empty boiler B Be prepared to heat raw water to at least 180 F as soon as it is introduced into the boiler This procedure will remove dissolved corrosive gases C Provide drain line with valve from boiler Use a bottom tapping Line and drain must be suitable for handling caustic solution D Check for low water cut off operation see section below for check out Il CLEAN STEAM BOILER SYSTEM A Fill the boiler to water line indicated on the boiler B Follow start up procedure for burner and operate the boiler with steam in the entire system for 2 or 3 days to bring oil and dirt from the system to the boiler While system is in operation maintain the proper water level in the boiler by slowly adding water to the boiler C Shut down burner cool down boiler and drain system 1 FILLING AND VENTING THE STEAM BOILER
9. overfire draft Take draft reading through slot in observation door Close the observation door Allow the burner to fire for at least one hour total firing time to bake out the volatile binders in the combus tion chamber before taking final combustion readings By alternate adjustment of the barometric draft regulator the burner air regulation and head regulation devices whichever apply set for a trace of smoke and as close to 13 as you can Then open the air bands or shutter whichever apply an additional 1 8 This should result in zero smoke with NO raw oil on the smoke paper and a smooth light off DO NOT ATTEMPT TO SET FIRE BY EYE Flame retention burners may appear efficient and smoke free from an inefficient 7 up to an overly high 14 CO However a very low CO can also result in poor ignition and raw unburned oil entering the fire box At very high any slight decrease in air flow for any reason will cause incomplete combustion with high smoke and dry Soot formation in the fire box If smoke reading is satisfactory but CO can not be increased to a satisfactory level 1296 or better or overfire draft of 0 02 W C can not be obtained check for proper sealing between sections between burner mounting plate and front section around burner blast tube and around flue collector and collar If seal is not satisfactory reseal with furnace putty or silicone with a temperature rating of at least 400 F
10. ventilation If fly screen must be used over air supply openings areas calculated should be doubled the screen should be inspected and cleaned fre quently to maintain free air flow Protect air openings against closure by snow debris etc Openings such as doors or windows if used must be locked open TABLE 2 Provisions for Combustion and Ventilation Air Supply See NFPA 31 latest edition for more detailed information Boiler Location Air Supply Action Required Unconfined space Confined space Is there sufficient air for combus tion by natural infiltration see NOTE 1 Test below Unconfined space If there is NOT sufficient air for combustion by natural infiltration due to tight construction or other conditions then it REQUIRES AIR FROM OUTDOORS SEE ACTION REQUIRED column at right See Notes 1 and 2 below If there is sufficient air for combus tion from within building but it comes from outside of the confined space SEE ACTION REQUIRED column at right See Note 1 below If there is NOT sufficient air for combustion due to tight construc tion or other conditions it REQUIRES AIR FROM OUT DOORS SEE ACTION REQUIRED column at right See NOTE 2 below Confined space Provide air from outdoors directly through a permanent outside wall opening or openings with a free open area of not less than 1 sq per 4000 Btu hr of TOTAL input of ALL fuel burning ap
11. 102 CRD 60 SS HAGO ONLY TR 70C 71332 3 00 2 75 60 SS HAGO 119 7 0 8 0 80 90 102 CRD 60 W DELAVAN Head and air band settings are approximate ONLY See START UP on page 8 and burner figure below All burner models shown are single stage NOTE 1 The air shutters on the burners for models TR 20 TR 30 and TR 40 are blank closed The air shutters on the burners for models TR 50 TR 60 and TR 70 are full open Single slotted air band for TR 20 and TR 30 2 3 4 See table for approximate settings HEAD ADJUSTMENT SCREW AIR BAND ADJUSTMENT Example shown at open 50 N position Band closes when moved clockwise right esr HEAD ADJUSTMENT Example shown at no 1 84 0 Double slotted air band TR 40 TR 50 TR 60 and TR 70 THROTTLE RING RETENTION AIR TUBE FOR NTR 60 amp TR 70 RETENTION RING AIR TUBE FOR TR 50 ADJUSTING SCREW USE 5 32 HEX ALLEN KEY 20 BURNER DATA WAYNE BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no TR 42KB BOILER MODEL BURNER NO 2 OIL NOZZLES SIZE ANGLE amp GPH GPH TYPE FIRING RATE 2 35 2 25 um DELAVAN 80 P HAGO DELAVAN HAGO 80 W 60 70 DELAVAN 70 W DELAVAN 2 75 HAGO 1 8 Forward 1 1 8 SW DELAVAN 70 DELAVAN 125 70255 113
12. 410699000 HONEYWELL L4080B1253 T R WHITE ROGERS 11B83 1 ORO 4X4 BURNER aM sa INTREPID BURNER DATA BECKETT AFG BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no TR 42KB BOILER BURNER BURNER MODEL MODEL HEAD FO 8 20 6555 143 ro 75 FIRING RATE SIZE GPH 75 1 00 TR 30 AFG SF 11 07 FAS 1 00 1 25 1 25 TR 40 AFG SF 11 02 F120 1 50 1 75 80 SS 80 B 2 1 t Airshutter and air band settings shown are approximate ONLY See START UP page 8 All burner models shown are single stage 5 32 GAP ELECTRODE 7 16 ABOVE 4 1 18 NOZZLE ELECTRODE ADJUSTMENTS BECKETT NOZZLES TR 50 AFG SF 11 05 F164 o 2 00 25 2 1 Extended heads all units except model TR 20 APPROX AIR BAND SETTING CLOSED m OIL PUMP APPROX PRESSURE AIR SHUT SETTING TER SET PSIG TING 100 sl CLOSED 113 10 1 1 4 113 10 1 1 2 ELAVAN 2 No static plate for TR 50 only 3 Insertion depth 25 35 for TR 30 and TR 40 221 39 for TR 50 Insertion depth 123 55 for model TR 20 4 Air Band 2 slot for TR 30 4 slot for TR 40 8 slot for TR 50 5 Burner may be equipped with a prepurge control See table for approximate settin
13. A Refill the boiler to the indicated water line B Bring water to boiling temperature promptly C The boiler is now ready to be put into service or on standby BLOWING OFF A LOW PRESSURE STEAM BOILER A A 1 1 2 NPT tapping is provided in the front of the boiler tapping no 9 figure 1 for use as a surface blow down to provide rapid skimming of oil and grease which accumulate on the surface of the water The boiler should be blown down as outlined below B Turn off electrical power supply to boiler Allow boiler to cool down and steam pressure to reduce to zero before removing skimmer tapping plug Check for steam pressure by testing the pop safety valve Keep your hands and all parts of your body away from the discharge end of the safety valve Drain boiler down one to two inches below skimmer tapping The water might be hot Remove skimmer plug slowly and carefully install a 150 psi malleable iron 1 1 2 NPT street elbow a 1 1 2 NPT skimmer valve and length of pipe and place a bucket underneath the open end of the pipe Cover bucket with a piece of cloth See figure 9 C Fill boiler slowly until water level is two inches from top of gauge glass This is the starting water level for skimming only Fire boiler to produce steam If the system is heavily laden with oil it may be diffi cult to obtain much more than a pound or so of pressure Set the pressure control at about 7 psi The higher the steam pressure you can use the bet
14. As boiler water circulates through the float chamber dirt or other sediment may be deposited This chamber is extra deep But the only sure way to keep any accumulation from interfering with float action is to blow down or flush out the control once a week Do it while boiler is in operation First note water level in gauge glass Open blow off valve at bottom of control water will pour out flush ing away sediment Drain until water is clear about a pail then close valve If level in gauge glass has dropped add water to boiler to restore level C NOTE Opening blow off valve checks cut off operation too As float drops with falling water level burner will stop After burner is off and normal operating conditions restored burner will resume firing D Be sure that it is the low water cut off and not the room thermostat pressure cut out or other control that has shut off the burner STEAM CONTROL ASSEMBLY INTREPID PRESSURE CONTROL CHECK OUT A B Check burner to be certain it is ready for firing DO NOT FIRE into an empty boiler Set thermostat high enough for boiler to make steam Set the pres sure control down to its lowest setting As the boiler starts to pro duce steam the steam pressure will start to build The burner will shut off when the steam pressure exceeds the pressure setting plus differential if control has this feature Adjust the pressure control to a higher setting The higher setting should
15. OPTIONAL OR WATER FEEDER LOW WATER ALARM E OPTIONAL NEUTRAL NOZZLE LINE HEATER IF EQUIPPED 24 VOLT THERMOSTAT 1 3 CONDUCTOR BX CABLE STEAM HARNESS 5 BLUE WIRE AVAILBLE FOR OPTIONAL ALARM OR WATER FEEDER IF USED IGNITION SEWICE SWITCH o EQUIPPED PRIMARY CONTROL GREEN GROUNDING SCREW FIELD CONNECTION BURNER JUNCTION BOX JUNCTION BOX FLAME FACTORY MOUNTED DETECTOR 2 CONDUCTOR BX CABLE QUICK DISCONNECT PLUG STEAM HARNESS 2 FIELD CONNECTED ON PRESSURE PRESSURE 2 CUTOUT CUTOUT Solenoid valve if equipped Splice Terminal Overload protection and disconnect switch must be provided as 43 0804 required by local codes Nozzle line heater if equipped On burners without nozzle line heater field connect hot line to single black wire from 3 conductor box cable in 4 x 4 junction box INTREPID 13 WIRING FOR PACKAGED STEAM BOILER For alternate option PS 801 120 L W C O or Hydrolevel Cycle Gard 450 L W C O 120 VACUGUHz HYDROLEVEL CYCLE GARD CG 450 LW COO BLUE E BLACK pee 5 AN WHITE 1 LOW WATER ALARM gt gt i 5 IF EQUIPPED OR WATER FEEDER 1 OTHER 22 1404 OPTIONAL SAF
16. Slant Fin INTREPID OIL FIRED WATER AND STEAM BOILERS NO 2 OIL INSTALLATION AND OPERATING INSTRUCTIONS SAFETY WARNING KEEP BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS FAILURE TO ADHERE TO ABOVE SAFETY WARNING MAY RESULT IN PERSONAL INJURY OR DEATH AND PROPERTY DAMAGE enar PAGE Ratings and Dimensions 2 Installation Requirements Boiler Location 5 3 3 CIearances SE dues 3 Chimney Requirements 3 Air Supply and Venting 3 Controls and Accessories 6 Piping for Steam Boilers 6 Cleaning Piping System 6 Piping for Water Units 6 Piping for Tankless Heater 7 Installing Burner Set vhs 7 Oil Suppl PIPING 7 Wiring the Boiler 7 Vent Piping and Draft Regulator 8 Operating Instructions Precautions Before Starting 8 Sta FUD pec 8 Cleaning and Filling New Water Boiler 8 Blowing Off a Steam 6 9 Cleaning and Filling New Steam Boiler 9 Low Water Cut off Check out 9 Pressure Control Check out 10 R
17. TANKS are used to con trol system pressure in an AIR ELIMINATING SYSTEM an automatic air vent is used to REMOVE air from the system water See figure 6 If system pressure needs further control add an additional tank or install a larger capacity tank The automatic air vent should be installed in the top of the boiler as in figure 6 B CONVENTIONAL COMPRESSION TANKS non diaphragm type are used to control system pressure in an AIR COLLECTING SYSTEM Within the system after initial start up and venting air is collected in the tank and acts in contact with the water to con trol pressure Air is not vented from this system If system pressure needs further control add another tank in parallel with the original tank or install a large capacity tank Locate the tank at the inlet end of the pump near the boiler See figure 7 HI PRESSURE LIMIT NIPPLE 1 4 x CLOSE NIPPLE 1 4 x 2 1 2 BOILER WALL Figure 4 SUPPLY NORMAL WATER LEVEL 112 REAR OF BOILER RETURN 1 LINE 12 CLEAN OUT PLUG Models TR 30 through TR 40 INTREPID C HOT WATER RADIATION VENTING Manual air vents should be installed at the top of all drops where piping goes downward Air must be vented or purged from all zone lines to permit proper System heating D PUMP LOCATION Locating low head pump s on return to boil er is only acceptable in residences of one or two stories See figure 6 The pump location shown in figure 7 is
18. supply of fresh water into the boiler This will cause damage to the boiler Use of heat exchangers will prevent this damage PIPING FOR STEAM BOILERS Provide Header and Hartford Loop as suggested See figures 4 and 5 Local codes apply CLEANING PIPING SYSTEM A To clean piping system open all valves at the heating elements After getting up a good head of steam shut the boiler down and allow the condensate to return to the boiler The condensate will carry the oil film with it Again blow off the boiler On extremely fouled Systems it may require several visits over a few days to clean the system B When steam only no water is released through the hand valve the boiler will not surge or flood Boiler A Size Dim NORMAL WATER LEVEL 2 REAR OF BOILER RETURN N CLEAN OUT PLUG Models TR 50 through TR 70 Figure 5 Recommended Steam Piping at Boiler INTREPID PIPING FOR WATER UNITS NOTE On knocked down boiler only jacket may be installed after sup ply and return piping connection but must be installed prior to adding trim 1 CIRCULATING SYSTEM A FORCED CIRCULATION hot water heating system Use the top tapping as supply tapping and use the front or rear bottom tappings for the return B A FLOW CONTROL VALVE See figure 6 will prevent gravity circulation and usually is required when tankless heater is installed Il AIR CONTROL SYSTEMS A DIAPHRAGM TYPE COMPRESSION
19. 34 000 354 3 35 469 000 3814 Standard working pressure 30 psi water 15 psi steam All boilers hydrostatically tested A S M E For forced hot water heating systems where the boiler and all piping are located within the area to be heated the boiler may be selected on the basis of gross D O E capacity output The net I B R output ratings shown are based on an allowance for piping and pickup of 1 15 water or 1 33 steam D O E capacity gross output is divided by the allowance to obtain net rating The manufacturer should be consulted before selecting a boiler for unusual piping and pickup requirements such as intermittent system operation extensive piping etc Ratings apply to the use of light oil at 140 000 Btu per gallon and apply only when burner models listed on pages 14 16 of this manual are used and are properly adjusted to pro duce 13 3544 WATER BOILER Net Ratings Nom 1 0 Round x Height in x ft 8350 8x8x15 6x15 8x8x15 6x15 558 8x8x15 EACE 84 0 608 8x8x15 7x15 8x8x15 7x15 8x8x15 8 15 8406 85 8x12x15 8x15 33 8x 12x15 10x 15 8x12x15 10x15 1108 8x 12x15 10x 15 8x 12x15 10x15 PRESSURE CUT OUT CONTROL POP SAFETY VALVE SIPHON SUPPLY GAUGE SUPPLY Combination GLASS Gauge TANKLESS HEATER WATER F WATER HighvLo LINE CUTOFF Limit or combination control for P or PT boiler OBSERVATION OBSERVATION RT 25 1 2 PR
20. 8 16 x 1 long hex head bolt and tightening 21 Check the flue collector seal This is the flat rope seal on top of the heat exchanger The rope must be in place adjacent to the long boss es on front and rear sections and adjacent to the short bosses on the intermediate sections The rope should be directly under the flue col lector flanges when the flue collector is replaced Use the two 1 4 20 x 3 4 washer hex head screws to fasten the flue collector In order to assure a proper seal be sure that the flue collector is compressing the flat rope and not hanging up on the section bosses Tighten the two screws D If boiler room is damp provide ventilation PROVIDING PROTECTION FOR FREEZING Anti freeze is sometimes used in hydronic heating systems to pro tect against freeze up in the event of power failure or safety control shutdown when the building is unoccupied It should be recognized that unless the building is kept above freezing temperature by some means the plumbing system is not protected PROPYLENE GLYCOL is used in the quick freeze food industry it is practically non toxic Its use may be permitted when tankless heaters are used When anti freeze must be used inhibited propylene glycol is recommended Useful information on the characteristics mixing proportions etc of glycol in heating systems is given in Technical Topics No 2A available from the Hydronics Institute 35 Russo Place Berkeley
21. BLAN 4 50 F 5 DELAVAN TR 40H 40 Series with short 70 B DELAVAN 145 2 00 F 10 tube OIL PUMP PRESSURE FIRING APPROX APPROX AIR SHUTTER HEAD SET SETTING NO TING BURNER DESCRIP BOILER BURNER MODEL MODEL TR 30H 40 Series short tube short tube TR 40 40 Series with short 1 25 60 ES HAGO 160 2 50 1 F 10 tube 1 70 ES HAGO 180 3 00 tu u F 10 be F 10 tube TR 50 40 Series with short 60 W DELAVAN 160 4 00 0 tbe Bor W DELAVAN t Air shutter and head settings shown are approximate ONLY See START UP page 8 All burner models shown are single stage NOTE For proper insertion into combustion chamber see figure 12 Figure 9A Rlello 40 Series MODEL F 5 ELECTRODE SETTING t 5 64 1 8 17 18 BURNER DATA RIELLO continued Figure 9B MODEL F 10 ELECTRODE SETTING Important For proper insertion into chamber see figure 12 NOTE ELECTRODES ARE PRESET AT THE FACTORY REGULATION OF THE TURBULATOR AND AIR SHUTTER FOR PROPER COMBUSTION Turbulator Setting 1 Loosen nut 1 then turn the screw 2 until the index marker 3 is aligned with the correct index number 2 Retighten the retaining nut 1 TURBULATOR SETTINGS RIELLO 40 SERIES The numbers on the casting are there to denote the high and low end of the scale in all cases the first mark if Zero The air oil ratio depends
22. DISCONNECT LOW WATER ALARM SWITCH MUST BE PROVIDED AS OPTIONAL REQUIRED BY LOCAL CODES FOR THIS HARNESS SEE DRAWING 43 0230 430167 BLACK WIRE IN HARNESS 3 NUMBERS IN THE CIRCLES ARE FOR THE TERMINALS ON A P S 801 120 L W C O McDONNELL MILLER 4X4 RIELLO BURNER ION SEE ABOVE RIGHT FOR HYDROLEVEL McDONNEL MILLER PS 801 L W C O ONLY 4 COND BX PATH STEAM HARNESS 1 FOR L W C O P C BOARD BLUE WIRE AVAILABLE 5 D FOR OPTIONAL ALARM OR WATER FEEDER IF USED BLACK LEAD CONNECT TO PROBE HEX NUT 2 COND BX CABLE STEAM HARNESS 2 FIELD CONNECT PRESS CUT OUT END 3N PRESS CUT OUT WATER BOILER WIRING FOR RIELLO BURNER AND HIGH LIMIT LINE VOLTAGE WALL THERMOSTAT BY OTHERS gt ALTERNATE METHOD USING A 24V WALL THERMOSTAT BY OTHERS HONEYWELL RA89A RELAY OTHER BY OTHERS SAFETY CONTROLS NEUTRAL LINE VOLTAGE cu VOR VOLTAGE 7 3 240 SERVICE SWITCH IF EQUIPPED 24V WALL THERMOSTAT 2 COND BX NOTE CABLE HIGH AUX TERMINAL ONLY LIMIT HARNESS ON F3 OR F5 quick DISCONNECT BLACK WATER HI LIMIT WITHOUT WELL BURNER PLUG P N
23. ETY LOW LIMIT 24 VOLT 4 CONTROL PROBE FOR TANKLESS THERMOSTAT TA OPTIONAL MOTOR NOZZLE LINE Nd WHITE Pun HEATER F C BOARD IF EQUIPPED SERVICE SWITCH IF EQUIPPED CONNECT LOOSE WHITE LEAD TO PROBE TERMINAL amp FASTEN WITH _ d 1 IGNITION LOCK WASHER AND WING NUT SEE HYDROLEVEL INSTRUCTIONS z 1 Yar 4 CONDUCTOR BX CABLE STEAM HARNESS 1 9 9 BLUE WIRE AVAILABLE FOR OPTIONAL ALARM OR WATER T VIOLET FEEDER IF USED PS 801 120 L W C O i ORANGE PRIMARY BLUE CONTROL R71848 PRINTED CIRCUIT BOARD E BLACK RED TO PROBE gt GREEN GROUNDING H SCREW HEX NUT 4 PROBE BURNER JUNCTION BOX FLAME DETECTOR 2 CONDUCTOR BX CABLE QUICK DISCONNECT PLUG STEAM HARNESS 2 FIELD CONNECTED ON PRESSURE PRESSURE OVERLOAD PROTECTION AND DISCONNECT SWITCH MUST BE CUTOUT PROVIDED AS REQUIRED BY LOCAL CODES 43 08020 AN ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED BY CODES GROUNDING CONDUCTOR GREEN GROUND WIRES ARE FACTORY CONNECTED TO THE GREEN GROUND SCREW IN THIS BOX FIELD WIRE A GROUNDED CONDUCTOR TO THIS SCREW TOGETHER WITH THE GREEN FACTORY CONNECTED GREEN WIRES L1 L2 5 OTHER z 43 0701 SAFETY 5 CONTROL X 2 24 VOLT THERMOSTAT SERVICE NOTE SWITCH 18148 AUX TERMINAL ONLY i ar AQUASTAT ON F3 OR F5 E
24. EY VENTILATION LOUVERS EACH END OF ATTIC BOILER INLET AIR VENTILATION LOUVERS FOR UNHEATED CRAWL SPACE Figure 3d Appliances located in confined spaces All air from outdoors through ventilated crawl space and outlet air to ventilated attic See Table 2 2 4 INSTALLING CONTROLS AND ACCESSORIES ON BOILER UNITS Note Jacket must be installed on boiler units prior to installation of trim l STEAM BOILER TRIM see page 2 for tapping locations and figure 4 for illustration of steam boiler A Steam pressure gauge and pressure cut out install in tapping no 4 figure 4 B Gauge glass set use tapping no 12 C Pop safety valve use tapping no 3 piped full size to boiler or pipe full size into a valveless steam header D Combustion safety control mounted on burner Il WATER BOILER TRIM see page 2 for tapping locations and fig ures 1 and 2 for illustration of water boiler A Pressure temperature altitude gauge use tapping no 6 B High temperature limit use tapping no 7 C Operating control if used use tapping no 7 D Water relief valve use tapping no 3 piped full size to boiler E Automatic air vent or compression tank tappings if used install in tapping no 2 F Combustion safety control mounted on burner PIPING IMPORTANT Boilers are to be used with closed system Any application that uses steam or water from system causes the intro duction of a frequent
25. H ENDS DRAIN PIPE mulation of sediment and scale from old piping and radia tors Itis extremely important to blow down your McDonnell amp Miller Cut off more frequently the first week First week 3 times Thereafter at least once a week See CARE amp MAINTENANCE section for instructions LOW WATER CUT OFF POSITION lt BLOW DOWN VALVE INTREPID 11 i2 BASIC WIRING DIAGRAMS OONN L8124C or A DISCONNECT JUNCTION with tankless heater Bigs 1 FACTORY MOUNTED L8148A OTHER t without tankless heater SOLEO NOZZLE LINE SAFETY LETABA 24V LV HEATER TBF SONUS AQUASTAT dae BURNER Service K MOTOR r pcs Switch 871648 u PRIMARY CONTROL I If equipped VIOLET 1 ORANGE FLAME DETECTOR FACTORY INSTALLED JUMPER See detail A p 13 for primary other than 87164 GROUND SINGLE SCREW ZONE WIRING FIELD BURNER ST ene ene WIRING FOR J BOX c ee M MULTIPLE ZONE CIRCULATOR CIRCULATOR ZONE MULTIPLE ZONED 281 CIRCULATOR METHOD TS7F SPACE HEATING ONLY 29 6545 LEGEND D FOR SINGLE AND MULTIPLE ZONED DIAGRAMS FIELD JUMPER NEUTRAL oA c o FACTORY WIBING FE LO WIRING LNE VOLTAGE 5 amem mim ppm
26. Heights N J 07922 Consult glycol manufacturers for sources of propylene glycol DO NOT use ethylene glycol because it is toxic OIL BURNER Inspect and clean annually and following any period of improper operation Recheck and adjust settings as specified for burner model and nozzle size Set burner air and draft regulator using test instru ments to obtain recommended CO and draft without smoke Refer to page 8 GENERAL MAINTENANCE These operations are recommended to be performed at regular intervals A BOILER HEATING SURFACES clean off all coatings found Reseal covers B BOILER CONTROLS check contacts settings correct functioning C PIPING check piping and accessories for leaks D CHIMNEY or STUB VENT and BREECHING check for obstruc tions and leaks E COMBUSTION AIR TO BURNER check for continued POSITIVE supply of air as required Air needs are greatest in coldest weather Refer to AIR SUPPLY page 3 F WATER SYSTEM check 1 System to be full of water and pressure to remain stable between 12 psi and 25 psi 2 Air control system noise and air binding in radiation should not occur 3 Water lines slightest leaks should be corrected 4 Low water cut off for operation see instructions furnished with unit See page 9 G STEAM SYSTEM check 1 Low water cut off for operation see instructions furnished with unit See page 9 2 Check pressure cut off for operation See page 10 3 Any unusual
27. IMARY CONTROL BURNER PRIMARY CONTROL EEZ Tankless Heater apa ps 174 2758 14 3 1 4 3 174 31 co gt 2 1 32 1 32 co o tn Co d oo co A 3 EIE 4 5 7 8 Nominal clay tile liner dimensions Tankless heater rating based on intermittent draw Water boiler models TR 30 and larger have two firing rates The boiler is factory shipped at the lower firing rate To obtain the higher firing rate refer to the INTREPID boiler installa tion instructions for the appropriate field adjustments t gross output 3 Collar is oblong will fit 6 diameter nominal connector This dimension is from the boiler jacket to the center of the flue outlet NOTE All boilers under 300 000 Btuh input are tested and rated for capacity under the U S Department of Energy D O E test procedures for boilers INTREPID INSTALLATION REQUIREMENTS BOILER LOCATION Provide a level solid foundation for the boiler Location should be near the chimney so that the Flue Pipe Connector or Breeching to the chim ney is short and direct A The foundation must be capable of supporting the weight of the boiler when filled with water Boiler Approximate Total Weight of Boiler Size Assembly filled with water B The Intrepid Boiler has full wet base sections which surround fire box for m
28. QUIPPED BURNER i 96 BLUE HIGH 7 LIMIT L RIELLO FIELD CONNECTION A 11 BURNER JUNCTION BOX FACTORY MOUNTED QUICK DISCONNECT PLUG CIRCULATOR AN ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED BY CODES VAN CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED A 81 IS 1 41 TAB TERMINAL A GROUNDING CONDUCTOR TWO GREEN GROUND WIRES ARE FACTORY CONNECTED TO THE GREEN GROUND SCREW IN THIS BOX FIELD WIRE A GROUNDED CONDUCTOR TO THIS SCREW TOGETHER WITH THE TWO GREEN FACTORY CONNECTED GREEN GROUND WIRES 14 INTREPID STEAM BOILER WIRING FOR RIELLO BURNER AND McDONELL MILLER P S 801 L W C O FOR CONNECTION TO LINE VOLTAGE WALL THERMOSTAT BY OTHERS LINE VOLTAGE ALTERNATE METHOD USING WALL THERMOSTAT A 24V WALL THERMOSTAT BY OTHERS HONEYWELL RAB9A RELAY OTHER BY OTHERS SAFETY CONTROLS NEUTRAL HYDROLEVEL CYCLE GARD 66 450 L W C 0 3 34 EZ 24V WALL THERMOSTAT ELD FI WIRI SERVICE SWITCH IF EQUIPPED 2 COND P C BOARD 9 NOTE AUX TERMINAL ONLY CABLE LOW WHITE ON F3 amp F5 BURNERS LIMIT HARNESS CONNECT LOOSE WHITE LEAD TO PROBE TERMINAL BLACK QUICK 80 L4006 a LOW LIMIT FOR TANKLESS OPTIONAL NOTES OVERLOAD PROTECTION AND
29. RTION INTO COMBUSTION CHAMBER COMBUSTION CHAMBER FOR BOILER MODELS TR 40 amp TR 50 USE 7 RIELLO EXTENSION FLANGE RG 9019C FOR MECTRON 10 BURNER INTREPID 19 BURNER DATA CARLIN BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no TR 42KB FIRING NOZZLES OIL PUMP APPROX RATE PRESSURE approx AIR BAND BOILER BURNER NO20IL ANGLE amp SETTING HEAD SET OPENING MODEL MODEL GPH TYPE PSIG TING t TR 20 71357 75 DELAVAN 100 1 0 2 0 45 50 ee DEG 99 FRD TR 30H 71357 1 00 DELAVAN 100 20 30 70 80 Ab 99 FRD DELAVAN 100 80 90 DELAVAN 100 90 AIR TUBE 100 50 FORTR 20 DELAVAN TR 30 amp TR 40 HAGO 113 60 j DELAVAN 1 75 105 90 60 W DELAVAN 2 00 45 P HAGO 100 3 0 40 60 B DELAVAN 2 00 70 W DELAVAN 110 3 0 50 70 SS HAGO 71399 2 35 2 25 70 W DELAVAN 109 5 0 60 99 FRD TR 60 71316 2 60 2 50 70 P HAGO 108 5 0 50 102 CRD 3 70 DELAVAN 71316 2 85 2 75 70 P HAGO 107 6 0 80 102 CRD 3 DRIP HOLE TR 60 87189 2 60 2 50 4555 HAGO 107 5 0 50 BAR N Y C 102 CRD 3 ONLY TR 70 71332 3 10 2 75 125 8 0 90 102 CRD DELAVAN 71332 3 35 3 00 60 SS HAGO 125 10 0 90 102 CRD 60 W DELAVAN TR 70 78790 3 10 3 00 60 B DELAVAN 107 8 0 90 BAR N Y C
30. TURE WATER TO APPLIANCES WIRING THE BOILER A The wiring diagrams for the burner and boiler may be found on pages 11 13 B 24 volt control wiring should be approved Safety Circuit wire protected as needed C Power supply wiring to the burner must be 14 gauge or heavier as required and should have a properly fused disconnect switch 120 volt wiring to pumps and safety controls must also be 14 gauge or heavier Wire must be enclosed in approved conduit D All wiring must be installed in compliance with the National Electric Code or any local or insurance codes having jurisdiction TEMPERING COLD WATER SUPPLY FLOW REGULATING VALVE Figure 8 Recommended Piping to Tankless Heater VENT PIPING AND DRAFT REGULATOR A B C Horizontal vent connector into the chimney should not be inserted Vent pipes must be installed having the same diameter as the boiler outlet See page 2 Vent pipes and breeching must be pitched upward a minimum of 1 4 per foot Connect vent pipe to the chimney using as few elbows as possible beyond the inside wall of the chimney Install barometric draft regulator on horizontal breeching near chim ney with hinge horizontal and face vertical See manufacturer s instructions packed in carton with barometric draft regulator If two or more appliances are used on the same chimney see CHIMNEY page 3 Make up all joints with minimum air leaks secure with sheet metal Screws
31. aximum heat absorption of burning fuel and low floor temperature C If boiler is to be located over buried conduit containing electric wires or telephone cables consult local codes or the National Board of Fire Underwriters for specific requirements MINIMUM CLEARANCE Provide accessibility clearance of 24 from surfaces requiring servicing top and front and 18 on any side requiring passage The boiler shall be installed with the following MINIMUM clearances from combustible materials A CHIMNEY CONNECTOR 18 B BACK AND SIDES 6 EXCEPT as limited by 18 clearance from chimney connector NOTE Except in closets and alcoves clearances above in A and B may be reduced by providing forms of protection as specified in NFPA 31 latest edition PITCH UP 1 4 PER LINEAR FOOT BAROMETRIC DRAFT CONTROL DO NOT INSTALL DRAFT REGULATOR HERE ORILL 1 4 TEMPERATURE BAROMETRIC DRAFT REGULATOR INSTALLED ON HORIZONTAL CONNECTOR CHIMNEY REQUIREMENTS A The chimney must be constructed in accordance with all local appli cable codes and the National Board of Fire Underwriters See boiler models and rating table shown on page 2 for chimney sizes B Check chimney condition Existing chimneys and stacks may have deteriorated without repairs their use would be hazardous Before connecting to an old chimney or stack 1 Clean it Inspect it thoroughly Remove obstructions Replace worn sections of metal stacks
32. be above the steam pressure in the boiler This should turn the burner back on Reset the pressure control as needed for the system The pressure control should be checked at least twice a year REPLACEMENT OF STEAM BOILERS Anytime an older steam boiler is removed from the heating system and replaced with a new boiler there are certain conditions that have to be examined on the heating system A Steam systems have a tendency to develop scale inside the wet return lines and the boiler The older the system the greater the accumulation of scale that can exist inside the piping Therefore it is necessary when replacing a steam boiler to check the piping for blockage or restrictions Clean or replace the piping as required See special flushing instructions on this page Replace all buried wet return lines All equipment air vents radiation equipment etc in the steam heating system should be checked for proper operation All piping should be checked for proper pitch It is good engineering practice to repack or tighten the packing nuts on all valves in the heating system SPECIAL FLUSHING INSTRUCTIONS Installed McDonnell amp Miller 67 low water cut off and water level gauge installation bollenmay breakeisabed hederae NIPPLE ix 5 THD AT BOTH ENDS S coMP ADAPT TEE FITTING 2 2 O D TUBE WATER LEVEL 254 OFF FLOOR WATER LEVEL GAUGE amp MALE PIPE TO 3 COMP ADAPT NIPPLE 5x5 THD AT BOT
33. ctor must be disconnected from the burner by grasping the plastic half of the connector closest to the flexible conduit and gently pulling it in the direc tion of the conduit until it is disconnected Remove the single 3 8 16 hex head screw on the LEFT side of the swinging door You will need a 9 16 drive socket Open the door to complete ly expose the combustion chamber for thorough cleaning and for inspection of target wall blanket provided in certain mod els see rating plate main cast iron burner door insulation and burner door fiberglass sealing rope If combustion cham ber parts above are badly deteriorated then replace with origi nal factory parts available at your distributor 6 Usethe flue brush to clean the pinned flueways between the A wire brush may be used to remove any carbon accumulation that may have developed in the combustion chamber Vacuum the loose soot and debris from the boiler 7 Inspect the burner combustion head Clean if necessary and make sure all the adjustments are correct See burner data pages for the burner installed Replace oil nozzle with new one and readjust electrodes To insure proper burner opera tion ONLY THE NOZZLES SPECIFIED IN THIS MANUAL OR ON THE BURNER LABEL SHOULD BE USED FOR REPLACEMENT 8 Close main cast iron burner door door on which burner is mounted Make sure that the entire seal fiberglass rope is making good contact with the boiler casting when replacing 3
34. eplacement of Steam 10 Wiring Diagrams Red em Re 669 11 14 Burner Data 2 isses RR 15 20 Care and Maintenance Extended Shutdown 21 Freezing Protection 21 Oil B triet 5o isle LER bit bane ee 21 General Maintenance 21 IMPORTANT The installation of this equipment must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the Installation of Oil Burning Equipment ANSI NFPA 31 latest edition and to the National Electrical Code ANSI NFPA 70 latest edition The installation must also conform to the additional requirements in this Slant Fin Instruction Manual Where there is any differ ence the more stringent requirement shall govern In addition where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers No CSD 1 latest edition THIS MANUAL MUST BE LEFT WITH OWNER AND SHOULD BE HUNG ON OR ADJACENT TO THE BOILER FOR REFERENCE IMPORTANT This boiler must be installed by a trained experienced service technician licensed for the installation and servicing of oil burning equipment or otherwise qualified by the authorities having jurisdiction over the installation Printed in U S A 207 Publicatio
35. gs SHUTTER ADJUSTMENT Shutter opens clockwise right Example shown at no 6 position 0 is not imprinted on burner but is the first mark on left EMBOSSED AIR BAND ADJUSTMENT Example shown in closed 0 position Band opens when moved clockwise right 15 16 INTREPID BURNER DATA BECKETT CF 375 BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no TR 42KB Boiler Burner Firing Rate Size Angle amp Oil Pump Pressure Air Shutter Air Band Head Model Model GPH GPH Type MFG Setting PSIG Setting t Setting Setting 10 3 10 10 T Air shutter and air band settings shown are approximate ONLY See START UP page 8 All burner models shown are single stage HEAD ADJUSTMENTS 9 IS IMPRINTED ON BURNER IS THE FIRST MARK ON THE LEFT MARKER FOR AIR 8 ADJUSTMENT IN CLOSED 0 POSITION MOVED CLOCKWISE T0 Te RIGHT OIL VALVE SHUTTER ADJUSTMENTS TER OPENS CLOCKWISE E SHOWN AT No 6 ITION 5 32 GAP ELECTRODE 7 16 ABOVE 1 16 See table for approximate settings NOZZLE ELECTRODE ADJUSTMENTS BECKETT INTREPID BURNER DATA RIELLO BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no L 42KB SIZE ANGLE amp SETTING GPH TYPE MFR PSIG F 5 F 5 short tube TR 30 40 Series with puse poe 709 ES HAGO
36. ium chromate solution strength of 16 oz per 50 gallons of water and refill to the top of the gauge glass 2 For water boilers maintain a sodium chromate solution strength of 6 oz per 50 gallons of water and refill to normal fill pressure with system vented 3 Raise water temperature to at least 180 F for one hour to release dissolved gases 4 Shut down burner by disconnecting the main switch C To clean the fireside boiler surfaces first shut down burner by dis connecting all electrical power to the burner by turning OFF the OIL BURNER EMERGENCY SWITCH of this boiler in order to perform the following work in 1 through 10 below 1 Remove the flue pipe from the boiler flue collar and clean thoroughly 2 Inspect the entire vent connector back to the chimney and clean if necessary 3 Inspect the chimney for soot debris and other unsafe condi tions of the chimney and take the necessary action 4 Remove the flue collector by first removing the top jacket panel The flue collector is held in place by two hex 1 4 20 screws Remove the screws and carefully remove the flue col lector Try not to disturb the flat fiberglass rope under the flue collector 5 When necessary to clean the combustion chamber you must first CLOSE the suction valve and return valve if two pipe Then disconnect the oil lines from the burner The flexible electric conduit connected from the junction box on the boiler to the burner via a plastic conne
37. n No TR 40 Part No 43 2764 TAPPINGS AND OPENINGS FLUE COLLECTOR 3 2 TOP VIEW 3 supply 2 supply on rear section second 14 siphon amp pressure cutout if required 34 steam safety valve 1 4 siphon pressure gauge amp pressure cut out 1155 supply 3 4 air vent or expansion tank 34 water relief valve 1 2 tankless inlet 12 tankless outlet 14 pressure temp gauge yg high limit hi lo or combination control 4 alternate electronic low water cut off 11 skimmer tapping 1 2 low limit for tankless 1 5 tankless inlet 1 5 tankless outlet 12 steam gauge glass amp 67 11 bushed to 34 for drain cock 112 condensate return 34 NPT zone tapping 11 2 return amp 34 drain cock 117 alternate return INTREPID FRONT VIEW STEAM 12 1 9 FRONT VIEW WATER 6 5A 58 REAR 14 REAR 14 Rear section TR 50 TR 60 TR 70 steam boilers only Figure 1 A S M E SUPPLY RELIEF OBSERVATION PORT OIL BURNER 17 1 DRAIN COCK Alternate 112 tapping 11 for additional circulator Y Figure 2 COMBUSTION CHAMBER LEFT END WATER amp STEAM FRONT RATINGS D O E B R Burner Heating Capacity Capacity 0 T en MBH Water Steam Steam anos ML x Height 5 in x in x ft 294 000 d 329 000 29 364 000 298 EE 399 000 327 701 3 10 4
38. nditions and at the same time a all doors win dows and other like openings must be closed b all fuel burning appliances should be FIRING c all exhaust fans and clothes dryers turned ON At the above conditions the CO smoke and draft readings must be normal CO2 between 11 and 13 smoke between ZERO and a TRACE draft between 02 W C and 04 W C negative pressure 2 Aside from tight construction some of the conditions that steal air for combustion from a boiler are other fuel burning appliances exhaust fans and clothes dryers 3 Generally louvers made of wood have a free open area of 20 and those made of metal have a 60 to 70 free open area Screens also reduce the open area of the louvers INTREPID pe niuis i I I I I DIN a TE E E E Figure 3a Appliances located in confined spaces Air from inside the building See Table 2 2 3 HIMNEY VENTILATION LOUVERS EACH END OF ATTIC INLET AIR DUCT ENDS 1 FT BOILER ABOVE FLOOR Figure 3c Appliances located in confined spaces Air from out doors through ventilated attic See Table 2 2 4 OUTLET AIR DUCT pi BOILER INLET AIR DUCT Figure 3b Appliances located in confined spaces Air from out doors See Table 2 2 4 HIMN
39. nter mittent draw in the ratings table on page 2 COMPRESSION TANK INSTALLING THE BURNER See Burner Data pages 14 18 and Burner Manual supplied with burn TO COMPRESSION er If burner is not mounted as received mount to boiler placing flange TANK over mounting studs Use gasket between flange and boiler Distance RELIEF VENT between flange and nose of burner must be as shown on pages 14 18 Check to see that nozzle and settings are as given in burner data tables pages 14 18 OIL SUPPLY PIPING Install the oil tank or tanks and piping from tank to burner Follow local e e codes and practices NFPA No 31 INSTALLATION OF OIL BURNING ALTERNATE EQUIPMENT and the instruction sheet attached to the oil burner pump CONNECTION A one pipe system should be used for gravity fed fuel systems and for lift systems where the total lift is less than 8 feet Where the total lift is greater than 8 feet a two pipe system must be used In some instances local codes may require a two pipe system for below grade fuel oil tanks Be sure to set up the fuel oil pump for the piping system used follow the instructions attached to the pump Be sure to include a good quality low pressure drop fuel oil filter in the supply line from the tank This is necessary especially at low fuel oil flow rates small nozzle Sizes to prevent nozzle plugging See Slant Fin publication on one pipe TEMPERED and two pipe fuel oil systems TO FIXTURE HIGH TEMPERA
40. on accurate setting of the turbulator disc Be careful when making this adjustment as an incorrect setting will result in an unsatisfactory installation See figures 10A and 10B Figure 10A MODEL F 5 2 Figure 10B Sino MODEL F 10 3 2 INTREPID SETTING THE AIR ADJUSTMENT PLATE See figure 11 1 The hydraulic AIR SHUTTER A is operated by the HYDRAULIC JACK F assuring complete opening of the combustion air intake Regulation of the combustion air flow is made by adjustment of the manual AIR ADJUSTMENT PLATE D after loosening the FIXING SCREWS C and E The initial setting of the air adjustment plate should be made according to page 16 2 The proper number on the manual AIR ADJUSTMENT PLATE D should line up with the SETTING INDICATOR B on the fan housing cover Once set the air adjustment plate should be secured in place by tightening SCREWS C and E Manually open and release the hydraulic air shutter to ensure it has free movement 3 The final position of the air adjustment plate will vary on each instal lation Use instruments to establish the proper settings for maximum and a smoke reading of zero NOTE Variations in flue gas smoke CO and temperature readings may be experienced when the burner cover is put in place Therefore the burner cover must be in place when making the final combustion instrument readings to ensure proper test results Flgure 11 Figure 12 FOR PROPER INSE
41. pliances in the building See Note 1 and 3 The confined space shall be provided with two permanent air openings one near the top of the enclosure and one near the bottom EACH opening shall have a free air opening of not less than 1 sq in per 1000 Btu hr of TOTAL input of ALL fuel burning appliances within the enclosure The two openings shall freely communicate with the interior areas of the building which in turn would have to have adequate infiltration of air from outdoors See Notes 1 3 and Figure 3a a Air from the outdoors shall be provided to the confined space by two permanent openings one in or near the top of the enclosure space and one in or near the bottom The open ings shall communicate directly or by means of ducts with outdoors or to such spaces crawl or attic that freely com municate with outdoors See figures 3b 3c and Where directly communicating with outdoors or by means of vertical ducts each opening shall have a free area of not less than 1 sq in per 4 000 Btu hr 35 sq in per gal per hr of TOTAL input rating of ALL appliances in the enclosure If horizontal ducts are used each opening shall have a free area of not less than 1 sq in per 2 000 Btu hr 70 sq in per gal per hr of TOTAL input of ALL appliances in the confined space See Figures 3b 3c and 3d Test for sufficient air for combustion by infiltration by running this boiler for 30 minutes under all of the following co
42. required in large multi story building installations especially when high head pumps are used and is also recommended for all applications E A conventional compression tank may be connected to the 3 4 tapping as shown in figure 7 IMPORTANT Hot water heating systems containing high water volume such as would occur with cast iron radiation require special care with air elimination The circulator pump should be located on the boiler supply PRESSURE REDUCING RELIEF VALVE VALVE by others 7 COMPRESSION TANK RETURN ALTERNATE PUMP LOCATION FLOW CONTROL SUPPLY SUGGESTED LOCATION OF OPTIONAL AIR SCOOP TANK AND AIR VENT PACKAGE pipe and the expansion tank and air scoop should be located near the pump suction See Figure 6 Alternate Pump Location PIPING TANKLESS HEATER if used l Heater capacities are listed on Page 2 Pipe the built in tankless heater using the inlet and outlet tappings indicated on the heater figure 8 A Tempering valve illustrated but not furnished is suggested to provide more volume of temperate water to kitchen and bath B High temperature water for dishwasher and laundry may be piped direct C A flow control valve should be used to control the rate of flow of water through the coil otherwise the heating capacity of the coil will be exceeded To insure sufficient hot water the flow rate through the coil should be limited to a maximum shown for i
43. ter and faster the cleaning D As steam develops open the SKIMMER drain valve with caution to Skim the oil and film from the top of the water DO NOT open the boil er drain valve Close the skimmer drain valve when the water level drops to about 5 from the top of the gauge glass The water may stop before the level drops to 5 below the top of the glass Refill boil er until water level is again two inches from the top of the gauge glass E Repeat D above until all film is skimmed off and the water settles to a normal movement Add make up fresh water to the boiler as described in D above during the blow off operation to maintain the proper skimming water level in the vessel Empty bucket frequently in order to see the difference in water cleanliness F When surging has stopped and water is clean and no film can be seen floating in the bucket shut off boiler drain down to level of skim mer tapping remove valve plug skimmer tapping and refill the boiler to 24 1 2 water level After 15 minute operation readjust level to normal operating level of 25 1 2 from bottom of boiler see figure 9 Check the pop safety valve for proper operation Check the low water cut off operation see below G The entire process may have to be repeated over a period of a few days on extremely fouled systems LOW WATER CUT OFF CHECK OUT Electronic probe type low water cut off If this boiler is factory equipped with an electronic probe type low
44. tric Draft BAROMETRIC DRAFT REGULATOR Regulator INSTALLED ON VERTICAL RISE Any oil fired boiler must have a steady draft and an ample supply of combustion air at all times during firing If air supply or chimney draft is unreliable and overfire draft will change unpredictably DO NOT vent this boiler to the same chimney flue used by a fireplace or coal or wood burning furnace or boiler The draft produced by solid fueled devices varies tremendously between high fire and low fire In modern weather stripped energy saving buildings or older buildings which have been modified similarly natural infiltration may not supply enough air for combustion particularly if other fuel burning appliances exhaust fans or draft inducers are competing for the same air supply Fireplaces other solid fuel burning appliances and exhaust fans con sume great quantities of air if air supply is not ample such an appliance will create a downdraft in the oil fired boiler flue This can create a haz ardous condition Flue gases can be sucked out of the chimney through Draft is negative or suction pressure INTREPID the vent regulator into the living space DO NOT operate this boiler and a solid fuel burning appliance at the same time unless the solid fuel burner is provided with its own outside air supply See Table 2 Provisions for Combustion and Ventilation Air Supply for determining need and method of providing air for combustion and
45. water conditions Obtain water analysis and treat water H BOILER ROOM AIR SUPPLY air vents should be open and free of obstruction See page 3 flue brush 2 1 4 dia is supplied with boiler Replacements are available from dealer or hardware stores SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 Sf f i nt Fin FAX 516 484 5921 Canada Slant Fin LTD LTEE Mississauga Ontario www slantfin com
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