INTREPID INSTRUCTIONS - The Energy Conscious
Contents
1. 12 INTREPID BASIC WIRING DIAGRAMS FOR imari Honeywell L7248L See page 13 for other primaries without tankless heater 15 AMP MAXIMUM OVERCURRENT PROTECTION DEVICE Honewell L7224 24 VOLT with tankless heater L2 L1 FIELD CONNECTION THERMOSTAT le NEUTRAL HOT JUNCTION BOX WIRED TO L1 ON BECKETT 3150 7505 PRIMARY IF EQUIPPED OTHER FACTORY MOUNTED BECKETT MODELL 7600A DIEI CONTROLS VALVE IF EQUIPPED HONEYWELL R7184B Service OR BECKETT GENISYS 7505P HEATER IF EQUIPPED CIRCULATOR METHOD SPACE HEATING ONLY PRIMARY IF EQUIPP BLACK FLAME 2 DETECTOR E a FACTORY lt INSTALLED JUMPER RED FOR 7505P 2 Q ur SINGLE A zx ZONE WIRING FIELD M WIRING FOR MULTIPLE ZONE CIRCULATOR CIRCULATOR MULTIPLE ZONED E G dey SEE Adjusting Settings R845 amp Error Codes for L7224C amp L7248L on page 13 R845 R845 LEGEND FOR SINGLE AND MULTIPLE ZONED DIAGRAMS NEUTRAL FACTORY WIRING FIELD WIRING LINE VOLTAGE 24 VOLTS I CIRCULATOR I CIRCULATOR l i TO ZONE 2 ZONE 3 ZUNE 4 OTHER ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECION AS REQUIRED BY CODES CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED A IS 1 4 IN TAB TERMINAL GROUNDING CONDUCTOR TWO GREEN GROUND WIRES ARE FACTORY CONNECTED TO THE2. 7 10 Cleaning and Filling New Steam Boiler 10 Low Water Cut off Check out 10 Pressure Control Check out 11 Replacement of Steam Boiler 11 Wiring Diagrams 12 16 PP UPRHSr Data uuu aes dered eo wa s pusa gu deg qud 17 22 Care and Maintenance Extended Shutdown 23 Freezing Protection 23 eil S s Ps P sa 23 General Maintenance 23 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
3. 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 operation 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 8 16 x 1 long hex head bolt and tightening 9 Checkthe flue collector seal This is the sealant on top of the heat exchanger The sealant must be in place adjacent to Slant Fin the long bosses on front and rear sections and adjacent to the short bosses on the intermediate sections The sealant should be directly under the flue collector flange when the flue collector is replaced Use the 1 4 20 Wing Nut and washer to fasten the flue collector In order to assure a proper seal be sure that the sealant is pressed tight against the flue collector and castings For the Hinge Style the flue collectors see 9A 9a For the Hinge Style flue collectors TR 30 and TR 40 only Inspect the Fiberglass rope seal to ensure its proper location and close the Hinged top using the two latches C If boiler room is damp provide ventilation CAUTION ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME PROVIDING PROTECTION FOR FREEZING Ant
4. 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 better 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 inc
5. 1 FT ABOVE FLOOR Figure 3c Appliances located in confined spaces Air from out doors through ventilated attic See Table 2 2 4 INTREPID Duct AIR Figure 3b Appliances located in confined spaces Air from out doors See Table 2 2 4 VENTILATION LOUVERS EACH END OF ATTIC 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 INTREPID 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 ta
6. CABLE HIGH AUX TERMINAL ONLY LIMIT HARNESS ON F3 OR F5 quick DISCONNECT BLACK WATER HI LIMIT WITHOUT WELL BURNER i P N 410699000 OR WHITE ROGERS 11B83 1 4X4 RIELLO BURNER INTREPID 17 BURNER DATA BECKETT AFG BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no TR 42KB OIL PUMP APPROX NOZZLES BOILER BURNER BURNER FIRING PRESSURE Nou m AIR BAND MODEL MODEL HEAD HEAD SIZE GPH amp SETTING ceric NO SETTING TR20 20 AFG SF 11 03 SF 11 03 80 B B DELAVAN BM ECCL LEE 1 00 1 00 80 A 100 80 W 1 10 1 TR 40 AFG SF 11 02 F120 TR 50 AFG SF 11 05 F164 t Air shutter and air band settings shown are approximate ONLY NOTE 1 Extended heads on all units except model TR 20 See START UP page 8 2 No static plate for TR 50 only All burner models shown are single stage 3 Insertion depth 2 5 32 for TR30 and TR 40 2 21 32 for TR 50 Insertion depth 1 23 32 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 A ee J 7 L y u I lt u w s a x 5732 d f 7 16 ABOVE 64 See tabl for approximate settings SHUTTER
7. ENSURE SAFE AND PROPER OPERATION OF THE UNIT PITCH UP 174 PER LINEAR FOOT ORILL 1 47 HOLE MEASURE DRAFT SMOKE CD AND STACK TEMPERATURE Figure 3 Barometric Draft BAROMETRIC DRAFT REGULATOR Regulator INSTALLED ON VERTICAL RISE INTREPID oufficient space shall be left clear around the boiler Do not stack items on or box in the appliance within the required clearances to combustibles 48 Minimum Clearance above Burner BOILER MODELS A in TR 20 LD 20 11 1 2 TR 30H TR DV 30 LD 30 14 7 8 TR 40H TR 40 LD 40 18 1 4 TR 50 Z LD 50 21 5 8 TR 60 LD 60 25 TR 70 LD 70 28 3 8 INTREPID 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 gre
8. and TR 30 x RETENTION RING 4 Double slotted air band TR 40 TR 50 TR 60 and TR 70 See table for approximate settings AIR TUBE FOR TR 60 amp TR 70 RETENTION HEAD ADJUSTMENT RING AIR BAND ADJUSTMENT Example shown at open 50 X AIR TUBE position Band closes when FOR TR 50 moved clockwise right A D HEAD ADJUSTMENT Example shown at no 1 ADJUSTING SCREW USE 5 32 HEX ALLEN KEY 22 INTREPID BURNER DATA CARLIN EZ 1HP PRO amp EZ 2HP PRO FOR PACKAGED BOILERS ONLY NOZZLE FIRING OIL PUMP APPROX RATE PRESSURE AIR BAND POSITION BOILER BURNER NO 2 OIL SIZE ANGLE amp BAR USED MODEL MODEL GPH GPH TYPE 1 60 1 20 60 178 40 A Note 1 TR 20 amp TR 30 must use a blanket 2 Only the electrodes and the air band can be adjusted The burner is supplied with a calibrated bar that properly position the head in the air tube See the table above for the head positioning bars used 3 The air shutters on the burners for models TR 20 amp TR 30 are blank closed 4 Tripled slotted air shutter on the the burner for model TR 40 Flush to 116 o 1 4 Nozzle adapter Clamp screw Retention ring assembly Electrode placement retention ring assembly and nozzle adapter SEE TABLE FOR APPROXIMATE SETTINGS AIR BAND ADJUSTMENT PRE CAL IBRATED BAND CLOSES WHEN MOVED HEAD POSITIONING BAR CLOCKWISE RIGHT NOZZ
9. 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 1013 Part No 43 2764 Publication No TR 40 Rev D INTREPID I Mes 3 2 TOP VIEW FRONT VIEW WATER FRONT VIEW STEAM OPENINGS 5B 11A 118 12 3 supply 2 supply on rear section second 1 4 siphon amp pressure cutout if required 3 4 steam safety valve 14 siphon pressure gauge amp pressure cut out 11 2 supply 34 air vent or expansion tank 34 water relief valve 1 2 tankless inlet 15 tankless outlet 14 pressure temp gauge 12 high limit hi lo or combination contro 3 4 alternate electronic low water cut off 115 skimmer tapping 1 2 low limit for tankless 15 tankless inlet 1 2 tankless outlet 155 steam gauge glass amp 67 115 bushed to 3 for drain cock REAR 14 Rear section TR 50 TR 60 TR 70 steam boilers only 115 return amp 34 drain cock 112 condensate return 11 alternate return 1 34 NPT zone tapping Figure 1 25 1458 PRESSURE CUT OUT A S M E SEN POP SAFETY VALVE SUPPLY RELIEF SIPHON SUPPLY GAUGE SUPPLY Combination GLASS Gauge TANKLESS HEATER High Lo qas LOW WATER Limit or CUTOFF combination control boiler OBSE
10. ADJUSTMENT Shutter opens clockwise right Example shown at no 6 position 0 is not imprinted on burner but is the first mark on the lett EMBOSSED AIR BAND NOZZLE 1 16 ELECTRODE ADJUSTMENTS BECKETT ADJUSTMENT Example shown in closed 0 position Band opens when moved clockwise right 18 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 T Air shutter and air band settings shown are approximate ONLY See START UP page 8 All burner models shown are single stage 5 32 GAP HEAD ADJUSTMENTS 7 16 ABOVE 4 NOZZLE FOR AIR KD 1 15 BAND a 25 MA CLOCKWISE TD THE RIGHT ELECTRODE ADJUSTMENTS BELKETT OIL VALVE SHUTTER ADJUSTMENTS TTER OPENS CLOCKWISE RIGHT EXAMPLE SHOWN AT No 6 ITION See table for approximate settings INTREPID BURNER DATA RIELLO BURNERS FOR PACKAGED BOILERS ONLY For knocked down amp boiler burner units see publication no L 42KB NOZZLES SIZE ANGLE amp OIL PUMP PRESSURE SETTING PSIG FIRING RATE NO 2 OIL APPROX APPROX AIR SHUTTER HEAD SET SETTING NO 4 TING BURN
11. CTION DEVICE 3 120VAC 60Hz 2 L1 SERVICE SWITCH I I I 1 P C BOARD l I 15 HYDROLEVEL CYCLE GARD CG 450 L W C O IF EQUIPPED CONNECT LOOSE WHITE LEAD TO PROBE TERMINAL amp FASTEN WITH LOCK WASHER AND WING NUT SEE HYDROLEVEL INSTRUCTIONS 4 CONDUCTOR BX CABLE STEAM HARNESS 1 BLUE WIRE AVAILABLE FOR OPTIONAL ALARM OR WATER FEEDER IF USED PS 801 120 L W C O PRINTED CIRCUIT LOOSE WHITE WIRE LEAD TO PROBE we HEX NUT A STEAM HARNESS 2 FIELD CONNECTED ON PRESSURE CUT OUT PRESSURE CUT OUT 43 0701A NEUTRAL A ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED BY CODES A CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED A IS 1 4IN TAB TERMINAL 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 PROBE 43 0802D 24 VOLT THERMOSTAT ELECTRINC AQUASTAT CIRCULATOR 16 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 15 AMP MAXIMUM LINE VOLTAGE ALTERNATE METHOD USING OVERCURRENT WALL THERMOSTAT A 24V WALL THERMOSTAT PROTECTION BY OTHERS HONEYWELL RAB9A RELAY DEVICE OT
12. ER BOILER BURNER DESCRIP MODEL MODEL TION short tube TR 30HF io short tube TR 30 i with F 5 short tube TR 40 40 Eu xS short F 10 tube TR bul 40 moe id short 10 50 40 tae short 2 10 DELAVAN Fo tube DELAVAN t Air shutter and head settings shown are approximate ONLY See START UP page 8 All burner models shown are single stage gt di g m r gt lt gt Oo o NOTE For proper insertion into combustion chamber see figure 12 Figure 9A Riello 40 Series MODEL F 5 ELECTRODE SETTING 5 64 1 8 19 20 INTREPID BURNER DATA RIELLO continued 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 Figure 9B Regulation of the combustion air flow is made by adjustment of the manual AIR ADJUSTMENT PLATE D after loosening the FIXING MODEL F 10 SCREWS C and E The initial setting of the air adjustment plate ELECTRODE SETTING should be made according to page 16 2 The proper number on the manual AIR ADJUSTMENT PLATE D Important For proper insertion into chamber see should line up with the SETTING INDICATOR B on the fan housing figure 12 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 mo
13. GREEN GROUND SCREW IN THIS BOX FIELD WIRE A GROUNDED CONDUCTOR TO THIS SCREW TOGETHER WITH THE TWO GREEN FACTORY CONNECTED GREEN GROUND WIRES A OPTIONAL HYDROSTAT MODEL 3150 IS EQUIPED WITH AN INTERNAL LOW WATER CUT OFF ZONE WIRING DIAGRAM E s PI MULTIPLE ZONED ZONE VALVE METHOD HYDROSTAT 3150 CONTROLS USING HONEYWELL V8043F OR ERIE 765 FOR TANKLESS HEATER APPLICATIONS HOT ELECTRICAL POWER SUPPLY OVERLOAD PROTECTION t 24 VAC AND DISCONNECT MEANS Zone 2 __ __ MUST BE PROVIDED T822D NEUTRAL AS REQUIRED BY CODES TRANSFORMER u ERES OTHER SAFETY TO PRIMARY CONTROLS ee CONTROL al i ti20v acyeoHz me IPE SPE FIELD CONNECTION JUNCTION BOX E FACTORY MOUNTED 1 22 EN L8148A AQUASTAT 52 Total load not to exceed 8 amp full load for circuits shown TO OTHER ZONES 43 0864 INTREPID FOR L7224C OR L7248L ADJUSTING SETTINGS F or C Pressing the button again on L7224 models will display the To discourage unauthorized changing of Aquastat settings a procedure Low Limit LL followed by a three digit number and the corresponding to enter the ADJUSTMENT mode is required To enter the ADJUST degree designator MENT mode press the UP DOWN and buttons simultaneously for three seconds Press the button until the feature requiring adjustment After approximately 60 seconds
14. HER BY OTHERS SAFETY CONTROLS HYDROLEVEL CYCLE GARD CG 450 L W C O 24V WALL THERMOSTAT FIELD WIRING SERVICE SWITCH IF EQUIPPED 2 COND BX P C BOARD NOTE AUX TERMINAL ONLY CABLE LOW ON F3 amp F5 BURNERS LIMIT HARNESS CER RISE MIE EAR ET QUICK DISCONNECT 4 p L4006A SEE HYDROLEVEL INSTRUCTIONS PLUG LOW LIMIT FOR TANKLESS OPTIONAL NOTES A OVERLOAD PROTECTION AND DISCONNECT LOW WATER ALARM SWITCH MUST BE PROVIDED AS OR WATER FEEDER OPTIONAL A REQUIRED BY LOCAL CODES FOR THIS HARNESS SEE DRAWING 43 0230 BLACK WIRE IN HARNESS 3 NUMBERS THE CIRCLES ARE FOR THE TERMINALS ON A P S 801 120 L W C O 4X4 JUNCTION McDONNELL MILLER A SEE ABOVE RIGHT FOR HYDROLEVEL PS BOT E LOL ONL 4 COND BX CABLE eae STEAM HARNESS 1 FOR L W C O BLUE WIRE AVAILABLE mx B We FOR OPTIONAL ALARM OR WATER FEEDER IF USED LEAD connect A TO PROBE HEX NUT 2 COND BX CABLE STEAM HARNESS 2 FIELD CONNECT ON PRESS CUT OUT END Cees cur our WATER BOILER WIRING FOR RIELLO BURNER AND HIGH LIMIT LINE VOLTAGE WALL THERMOSTAT BY OTHERS 15 AMP A MAXIMUM LINE VOLTAGE ALTERNATE METHOD USING OVERCURRENT WALL THERMOSTAT A 24V WALL THERMOSTAT PROTECTION DEVICE BY OTHERS HONEYWELL RA89A RELAY OTHER BY OTHERS SAFETY TOME O CONTROLS LINE VOLTAGE NEUTRAL WHITE 24V WALL THERMOSTAT SERVICE SWITCH IF EQUIPPED B 2 COND BX NOTE
15. LE RANGE STAMPED MOUNTING FLANGE CONTINUOUS WELD 360 INTREPID 23 BURNER DATA CARLIN EZ LF PRO FOR PACKAGED BOILERS ONLY LIBERTY INTREPID SPECIFICATIONS CARLIN EZ LF PRO BURNER BOILER BURNER F IRING NOZZLE NOZZLE NOZZLE MANUFACTURER HEAD APPROX e EN pus ar PRESSURE OSITIONING AIR BAND PSIG on La GPH 30H TR 30H 3 LF dm LD 30 IR 30 EZ LF Oe ee oe LD 30 TR 30 EZ LF LIE 70 AS 0 at 00 s t DENOTES FACTORY SETTINGS CARLIN COMBUSTION SHALL SUPPLY THE HIGHER FIRING RATE NOZZLE DELAVAN 1 00 70 AS AND THE HIGHER FIRING RATE HEAD POSITIONING BAR 085 1 00 INSIDE OF THE CARTON USE WIRE HARNESS S F P NA4S2151000 WITH A 90 BX CONNECTOR 2 SCREW TYPE 1 2 K 0 378 TRADE S F 400312000 IN THE CENTER KNOCKOUT AIR TUBE TYPE 12D Carlin EZ LF 443 2843 BAFFLE LAYOUT CHART C BAFFLE P N 430885000 BAFFLE 930995020 ee a FRONT amp REAR SECT FRONT amp CENTER SECT CENTER SECTIONS CENTER amp REAR SECT ma map Pase NOTE THE ABOVE BAFFLE LAYOUT CHART IS FOR ALL WATER AND STEAM BOILERS CARE AND MAINTENANCE CAUTION DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE UNIT IS FULL OF VAPOR OR WHEN THE COMBUSTION CHAMBER IS VERY HOT CAUTION DO NOT TAMPER WITH THE UNIT OR CONTR
16. LER 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 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 T A flue brush 2 1 4 dia is supplied with boiler Replacements are available from dealer or hardware stores Copyright 2013 SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 FAX 516 484 5921 Canada Slant Fin LTD LTEE Mississauga Ontario www slantfin com BOILERS amp BASEBOARD Only Home ame You Want Heating YOU
17. OLS CALL YOUR SERVICE PERSONNEL 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 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 thor oughly 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 a 1 4 20 Wing Nut Remove the Wing Nut and carefully remove the flue collector Try not to disturb the sealant under the flue collector For the Hinge Style the flue collectors see 4A 4a For the Hinge Style flue collector TR 30 and TR 40 only Open the two latches a
18. ROUND 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 15 AMP MAXIMUM OVERCURRENT Differential 5 PSI Z PROTECTION DEVICE Low Limit tankless model only 11 12 recommemded setting 160 SOLENOID p a VALVE m IF EQUIPPED OTHER Q 1 Low WaTER ALARM L 4006 FATETI OR WATER FEEDER LOW LIMIT CONTROL OPTIONAL FOR TANKLESS I lI I OPTIONAL BURNER C C 7 U C 24 VOLT HEATER STEAM HARNESS 5 BLUE WIRE THERMOSTAT IF EQUIPPED AVAILBLE FOR OPTIONAL ALARM OR WATER FEEDER IF USED IGNITION Eo ORANGE PRIMARY CONTROL SERVICE SWITCH IF EQUIPPED BLACK N uL 3 7 WHITE J GREEN GROUNDING SCREW Z 67 MM L W C O FIELD CONNECTION BURNER JUNCTION BOX JUNCTION BOX Y E FACTORY MOUNTED QUICK DISCONNECT PLUG o OO DETECTOR 2 CONDUCTOR BX CABLE STEAM HARNESS 2 FIELD CONNECTED ON PRESSURE PRESSURE T 252 CUT OUT CUT OUT Solenoid valve if equipped e 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
19. RVATION PORT OBSERVATION OIL BURNER it Ta PORT 25 1 2 PRIMARY CONTROL DRAIN COCK I i BURNER Alternate 112 tapping for additional circulator PRIMARY CONTROL b 134 Figure 2 COMBUSTION CHAMBER LEFT END WATER amp STEAM RATINGS AHRI Burner OE AHRI Net Ratings AHRI Chimney Size Tankless lu n Nom Rect 1 D Round 1 0 Rou Hed MES SER x Heights x Height in x in x ft in x ft 77 105 000 8x8x15 2 140 000 8x8x15 3 TR 30 1 10 1 1 10 154 000 8x8x15 6 3 TR 30 1 25 1 1 25 175 000 8x8x15 6 3 210 000 8x8x15 7 4 TR 40 1 60 1 1 60 224 000 8x8x15 7 4 TR 40 1 80 1 1 80 252 000 8x8x15 7 4 280 000 8x8x15 8 5 TR 50 2 10 1 2 10 294 000 8x8x15 8 5 TR 50 2 35 1 2 35 329 000 8x12x15 8 5 364 000 8x12x15 8 6 TR 70 3 00 1 3 00 420 000 8 x 12x15 9 7 TR 70 3 10 1 3 10 434 000 8x 12x15 9 7 Standard working pressure 30 psi water 15 psi steam S Nominal clay tile liner dimensions All boilers hydrostatically tested A S M E Tankless heater rating based on intermittent draw For forced hot water heating systems where the boiler and all piping are located within Water boiler models TR 30 and larger may have two firing rates The boiler is factory shipped the area to be heated the boiler may be selected on the basis of gross D O E capacity at the lower firing rate To obtain the higher firing rate refer to the INTREPID boiler installa output The net AHRI output rat
20. T HIGH TEMPERATURE WATEH TO APPLIANCES 7 TEMPERED WATER TO FIXTURE TEMPERING COLD WATER SUPPLY FLOW REGULATING VALVE Figure 8 Recommended Piping to Tankless Heater INTREPID VENT PIPING AND DRAFT REGULATOR A Vent pipes must be installed having the same diameter as the boiler outlet See page 2 B Vent pipes and breeching must be pitched upward a minimum of 1 4 per foot C Connect vent pipe to the chimney using as few elbows as possible D Horizontal vent connector into the chimney should not be inserted beyond the inside wall of the chimney E 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 F If two or more appliances are used on the same chimney see CHIMNEY page 3 G Make up all joints with minimum air leaks secure with sheet metal SCrews OPERATING INSTRUCTIONS PRECAUTIONS BEFORE STARTING OIL BURNER Make a positive check of A through F before starting burner A 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 pe
21. at 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 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 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 m Boiler Location Air Supply Action Required Unconfined space Unconfined space Confined space Is there sufficient air for combus tion by natural infiltration see NOTE 1 Test below 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 suff
22. connect hot line to single black wire from 3 conductor box cable in 4 x 4 junction box gt gt INTREPID WIRING FOR PACKAGED STEAM BOILER For alternate option PS 801 120 L W C O or Hydrolevel Cycle Gard 450 L W C O p SOLENOID I VALVE LOW WATER ALARM IF EQUIPPED OR WATER FEEDER L 4006A i OPTIONAL LOW LIMIT 24 VOLT FOR TANKLESS OPTIONAL UE TAT BURNER MOTOR NOZZLE LINE HEATER IGNITION s ele UNI 1 IF EQUIPPED T T VIOLET zm T PRIMARY controL R7184B AE O GREEN GROUNDING SCREW BLACK A BURNER JUNCTION BOX FLAME DETECTOR 2 CONDUCTOR BX CABLE QUICK DISCONNECT PLUG OVERLOAD PROTECTION AND DISCONNECT SWITCH MUST BE PROVIDED AS REQUIRED BY LOCAL CODES 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 BOILER WIRING DIAGRAM FOR RIELLO OTHER SAFETY CONTROL NOTE SWITCH AUX TERMINAL ONLY CIF ON F3 OR F5 EOUTPPED BURNER RIELLO FIELD CONNECTION JUNCTION BOX BURNER FACTORY MOUNTED A QUICK DISCONNECT PLUG I I I I I w 2 A 1 I 23 4 NEUTRAL HOT e on 989 238 S lt HOT 15 AMP MAXIMUM OVERCURRENT PROTE
23. eparations 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 The boiler is now ready to be put into service or on standby F If brand name air control devices are used venting instructions furnished with the devices should be followed Ill 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 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 a OF BOILER GALLONS Water Boiler Steam Boiler Without tankless coil VOLUME OF WATER IN STANDARD PIPE OR TUBE Standard Steel Pipe Type L Copper Tube Norninal Pipe Inside Gallons Inside Gallons Size Schedule Diamete
24. g 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 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 ELBOW 14 x 90 BOILER WALL Figure 4 RG CLOSE J REAR OF NIPPLE BOILER DE as CLEAN OUT PLUG Models LD 30 through LD 40 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
25. 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 START OF SKIMMING LEVEL 27 BELOW TOP OF GAUGE GLASS 1 3 27 MALLEABLE IRON 150 PSI STREET ELBOW 1 1 2 SKIMMER 7 DRAIN VALVE COVERED BUCKET 25 12 NORMAL OPERATING Figure 9 INTREPID 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 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 sedi
26. he Intrepid Boiler has full wet base sections which surround fire box for maximum heat absorption of burning fuel and low floor temperature D 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 CAUTION NEVER BURN GARBAGE OR PAPER IN THE UNIT AND NEVER LEAVE COMBUSTIBLE MATERIAL AROUND IT 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 BAROMETRIC DRAFT CONTROL DO INSTALL OR AFT REGULATOR HERE 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 stac
27. hes from the top of the gauge glass INTREPID 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 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 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
28. i 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 Heights N J 07922 Consult glycol manufacturers for sources of propylene glycol DO NOT use ethylene glycol because it is toxic OIL BURNER All service to the oil burner oil filter oil strainers etc should be performed by a professionally trained service person 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 COo 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 BOI
29. icating 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 conditions 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 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 Figure 3a Appliances located in confined spaces Air from inside the building See Table 2 2 3 VENTILATION LOUVERS EACH END OF ATTIC INLET AIR DUCT ENDS
30. icient 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 NONE Provide air from outdoors directly through a permanent outside wall opening or openings with a free open area of not less than 1 sq in per 4000 Btu hr of TOTAL input of ALL fuel burning appliances 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 3d Where directly commun
31. ings shown are based on an allowance for piping and tion instructions for the appropriate field adjustments pickup of 1 15 water or 1 33 steam D O E capacity gross output is divided by the t AHRI gross output Btuh and thermal efficiency allowance to obtain net rating The manufacturer should be consulted before selecting a Collar is oblong will fit 6 diameter nominal connector boiler for unusual piping and pickup requirements such as intermittent system operation This dimension is from the boiler jacket to the center of the flue outlet extensive piping etc NOTE All boilers under 300 000 Btuh input are tested and rated for capacity under the U S T Ratings apply to the use of light oil at 140 000 Btu per gallon and apply only when burner Department of Energy D O E test procedures for boilers models listed on pages 17 19 of this manual are used and are properly adjusted to pro duce 13 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 boiler can be installed on both combustible and non combustible floors but must NOT be installed on or above carpeting C T
32. k Clean it Inspect it thoroughly Remove obstructions Replace worn sections of metal stacks 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 O O1 OQ N 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 CAUTION AN OIL FIRED UNIT SHALL BE CONNECTED TO A VENT HAVING A SUFFICIENT DRAFT AT ALL TIMES TO
33. lant Fin INTREPID OIL FIRED WATER AND STEAM BOILERS NO 2 OIL INSTALLATION AND OPERATING INSTRUCTIONS SERVICE COMPANY READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE 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 CONTENTS 2s saa og ee eee RE ERR PAGE Ratings and Dimensions 2 Installation Requirements Boiler Location 323 ard das uu ee Gare ah es aa 3 Clearances 3 Chimney Requirements 3 Air Supply and Venting 3 Controls and Accessories Piping for Steam Boilers 7 Cleaning Piping System 7 Piping for Water Units 7 Piping for Tankless Heater 8 Installing Burner 8 Oil Supply Piping 8 Wiring the Boiler 8 Vent Piping and Draft Regulator 9 Operating Instructions Precautions Before Starting 9 ctl PPcr m 9 Cleaning and Filling New Water Boiler 9 Blowing Off a Steam Boiler
34. 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 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 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 Il 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 inter mittent draw in the
35. ment 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 Installed McDonnell amp Miller 67 low water cut off and water level gauge NIPPLE Lx E THD AT BOTH ENDS m COMP ADAPT FITTING i WATER LEVEL GAUGE 4 8 MALE OD COMP ADAPT DRAIN PIPE D eS 0 0 TUBE A 3 x Deh gd WATER LEVEL 25l oFF FLOOR x 11 PRESSURE CONTROL CHECK OUT A Check burner to be certain it is ready for firing DO NOT FIRE into an empty boiler B 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 C Adjust the pressure control to a higher setting The higher setting should be above the steam pressure in the boiler This should turn the burner back on D Reset the pressure control as needed fo
36. nd swing open the flue collector top on its hinge 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 elec tric conduit connected from the junction box on the boiler to the burner via a plastic connector 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 direction 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 completely expose the combustion chamber for thorough cleaning and for inspec tion of target wall blanket provided in certain models see rat ing plate main cast iron burner door insulation and burner door fiberglass sealing rope If combustion chamber parts above are badly deteriorated then replace with original factory parts available at your distributor 6 Remove the Baffles from between the casting sections Use the flue brush to clean the pinned flueways between the sections T 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 Reinstall all flue Baffles between the casting sections see pg 23 for Baffle Layout Chart 7 Inspect the burner combustion head Clean if necessary and
37. nk 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 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 NORMAL Boiler A Size Dim WATER LD 70 2219 LEVEL x 1 REAR OF BOILER E x 2 m d RETUAN LINE Det Models LD 50 through LD 70 CLEAN CUR PLUG Figure 5 Hecommended Steam Piping at Boiler 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 CIRCULATING SYSTEM A FORCED CIRCULATION hot water heating system Use the top tappin
38. ozzle plugging See Slant Fin publication on one pipe and two pipe fuel oil systems 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 INTREPID Wiring to the boiler must come through an emergency power isolation switch with a clearly marked red switch plate This switch should be located so that it is apparent to the homeowner when entering the base ment or other boiler area The homeowner should be made familiar with operating the toggle to provide or stop the power to the boiler FLOW CONTROL VALVE TO ZONES PRESSURE REDUCING RELIEF AUTOMATIC VALVE VALVE AIR VENT by althers SSS DIAPHRAGM COMPRESSION 5 ES LOCATION OF s OPTIONAL AIR ALTERNATE SCOOP TANK PUMP AND AIR VENT LOCATION PACKAGE COMPRESSION TANK RELIEF VALVE CIRCULATING Pd PUMP TO COMPRESSION TANK RELIEF RETLIRH ur S ALTERNATE CONNECTION FOR COMPRESSION TANK WATER INLE
39. r knocked down amp boiler burner units see publication no TR 42KB HEAD SET OPENING FIRING NOZZLES OIL PUMP RATE PRESSURE BOILER BURNER NO20IL SIZE ANGLE amp SETTING MODEL MODEL GPH GPH TYPE MFR PSIG TING t TR 20 41857 45 70 A DELAVAN 100 1 0 2 0 45 50 99 FRD 0 APPROX APPROX AIR BAND 2 1 2 DEG WRAPPED DELAVAN eed 1 00 60 A 75 TR 30H 71357 1 00 99 FRD 0 1 10 1 10 60 A DELAVAN 100 TR 30 2 0 3 0 80 90 DELAVAN 100 2 0 3 0 TR 60 87189 2 60 2 50 45 SS HAGO 107 BARN Y C 102 CRD 3 ONLY AIR TUBE TR 40H 71373 1 50 1 50 45 ES 100 3 0 50 FORTR 20 1 80 1 75 Iw 99 FRD 99 FRD 70 SS 99 FRD 102 CRD 3 70 W 71316 2 85 2 75 107 102 CRD 3 DELAVAN DRIP HOLE e e 3 10 2 75 60 SS HAGO 125 TR 70 71332 e 102 CRD 60 W DELAVAN 102 CRD TR 70 78790 3 10 300 60 B 107 BAR N Y C 102 CRD 60 SS ONLY TR 70C 71332 3 00 275 60 SS HAGO 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 THROTTLE RING NOTE 1 The air shutters on the burners for models TR 20 TR 30 and TR 40 are blank closed 2 The air shutters on the burners for models TR 50 TR 60 and TR 70 are full open 3 Single slotted air band for TR 20
40. r pages 14 18 and as shown on boiler jacket H Main cast iron door on which burner is mounted is bolted shut and fiberglass rope seal is making good contact CAUTION DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS ARE SECURED IN PLACE Ow GQ TI TI O 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 START UP COMBUSTION TEST INSTRUMENTS MUST BE USED A Make sure the boiler is installed and wired properly and is full of water B Open the observation door on the front above the burner C 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 overfire draft Take draft reading through slot in observation door D 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 E 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
41. r per Dia per Inches No Inches Lin Ft Inches Lin ft 10 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 III FILLING AND VENTING THE STEAM BOILER 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
42. r 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 B Replace all buried wet return lines C 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 D Itis good engineering practice to repack or tighten the packing nuts on all valves in the heating system SPECIAL FLUSHING INSTRUCTIONS Installation of new boiler may break loose heavy accu mulation of sediment and scale from old piping and radia tors Iis extremely importanttoblow down your McDonnell amp Miller Cut off more frequently the first week First week 3 times Therealter al least once a week See CARE amp MAINTENANCE section for instructions LOW WATER CUT OFF t OPEN POSITION VALVE i L DT lt s BLOW DOWN
43. ratings table on page 2 IMPORTANT Escape pipes or drain pipes from relief valves safety valves blow down valves and low water cut off must be piped off to a safe place INSTALLING THE BURNER See Burner Data pages 14 18 and Burner Manual supplied with burn er If burner is not mounted as received mount to boiler placing flange over mounting studs Use gasket between flange and boiler Distance 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 CAUTION DO NOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE OIL SUPPLY PIPING Install the oil tank or tanks and piping from tank to burner Follow local codes and practices NFPA No 31 INSTALLATION OF OIL BURNING EQUIPMENT and the instruction sheet attached to the oil burner pump 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 n
44. s not draw ing excessive current Err 8 condition will keep repeating if B1 fault is not cleared OTHER SAFETY CONTROLS BASIC WIRING DIAGRAMS L7224C OR LB124C OR 15 WITH TANKLESS HEATER MAXIMUM OVERCURRENT PROTECTION DEVICE SIEMENS M NDTES 1 RECOMMENDED HIGH LIMIT SETTING IS 200 F LOW LIMIT MUST BE SET AT LEAST 20 F BELOW HIGH LIMIT SETTING PUMP ZONING TERMIMALS ZR AND ZC FURNISHED ON LB8124 AND L7224C CONTROLS SEE PUMP ZONING DIAGRAM BELOW THERMOSTAT T QVERLOAD PROTECTION OTSCONMECT SWITCH MUST BE PROVIDED AS REQUIRED HY LOCAL CODES YELLOW FLAME NOZZLE LINE HEATER ELUUIPPED DETECTOR 43 DB8124 14 INTREPID BASIC MODULE WIRING less circulator a 2 uuo eee BRE SOLENOID i5 VALVE L1 IF EQUIPPED BURNER B NOZZLE LINE z OTHER IF EQUIPPED CONTROL BLACK I GNI TION SERVICE SWITCH IF EQUIPPED WATER HI LIMIT WITHOUT WELL P N 410699000 HONEYWELL L4080B1253 OR WHITE ROGERS 11B83 1 R7184B mani E BLUE 24 VOLT THERMOSTAT BLACK RED GREEN GROUND SCREW FLAME BURNER JUNCTION BOX DETECTOR FIELD CONNECT ION JUNCTION BOX FACTORY MOUNTED 43 0801C di QUICK DISCONNECT PLUG ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED BY CODES CONTROL CASE MUST CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED A GROUND ING CONDUCTOR TWO GREEN G
45. stem failure communication to Outdoor Reset Module lost Outdoor Reset Module failure multiple outdoor temperature sensors detected on the bus or outdoor temperature sensor failure Check EnviraCOM wiring 1 2 3 check sensor wiring Warning Boost Failure Boost Mode active at least once per cycle for the last 60 consecutive cycles Check Outdoor Reset curve settings IDHW Module Sensor failure communication to DHW Module lost DHW Module failure or temperature sensor failure Check EnviraCOM wiring 1 2 3 check sensor wiring Warnings are generated to enunciate the system is not operating optimally but the Aquastat is still operating and maintaining boiler temperature In the instance where an Outdoor Reset Module is used the warnings may indicate a reset curve setting error one or more features is not running optimally and the Aquastat is reverting to default settings or has stopped running the Outdoor Reset algorithms The warnings are cleared when the issue s is resolved b To clear Err 8 condition depress and hold all three user keys simultaneously for 60 seconds Err 8 condition clears and display returns to normal Err 8 condition is designed to catch welded relays on the Aquastat and will normally only occur near end of life for the control If Err 8 condition has occurred early in the controls life be sure to check for voltage feedback to B1 when B1 should be off and check current draw on b terminal to be sure oil burner i
46. to 13 CO 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 COs However a very low can also result in poor ignition and raw unburned oil entering the fire box At very high COs any slight decrease in air flow for any reason will cause incomplete combustion with high smoke and dry soot formation in the fire box F If smoke reading is satisfactory but 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 All safety precautions indicated on material package must be followed G 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 is zero to a trace CLEANING AND FILLING A NEW WATER BOILER l There are a number of commercial pr
47. vement 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 Figure 11 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 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 Figure 12 FOR PROPER INSERTION INTO COMBUSTION CHAMBER MODEL F 5 2 COMBUSTION FOR BOILER MODELS LO 40 amp LD 50 USE CHAMBER RIELLO EXTENSION FLANGE NO RG 9019C FOR MECTRON 10 BURNER Figure 10B MODEL F 10 3 2 INTREPID tl BURNER DATA CARLIN BURNERS FOR PACKAGED BOILERS ONLY Fo
48. without any key presses the display will is displayed enter a dim display mode To return to the bright display mode simply press any key HL High Limit LL_ Low Limit L7224 only DESCRIPTION Ldf Low Limit Differential L7224 only Boiler Temperature bt ELL_ External Low Limit L7248L only High Limit H L Then press the UP and or DOWN buttons to move the set point to the desired value to change between F and C or to enable On or dis Low Limit LL able Off the External Low Limit After 60 seconds without any button Low Limit Differential L d inputs the control will automatically return to the RUN mode Local Thermostat Status l l DISPLAY In the RUN mode the Aquastat will flash bt boiler temp followed by Enviracom Thermostat Status the temperature i e 220 followed by F or C l d Error Code rr To read boiler settings press the key to read the parameter of interest Degrees Fahrenheit For example press High Limit HL is displayed followed by a three digit number i e 220 followed by Degrees Celsius Dr Aquastat EnviraC OM Error Code Cause Action Alarm Eri fault check water sensor 2 ECOM fault check EnviraCOM wiring B1 fault check B1 wiring voltage Low Line check L1 L2 110 Vac Warning Fuse check EC OM wires replace fuse Warning Outdoor Reset Sy
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