INTREPID - Slant/Fin
Contents
1. CAUTION NEVER BURN GARBAGE OR PAPER IN THE BOILER AND NEVER LEAVE COMBUSTIBLE MATERIAL ON OR AROUND IT 4 TR Series Sufficient space shall be left clear around the boiler Do not stack items on or box in the appliance within the required clearances to combustibles 1219mm 48 Minimum Clearance above Burner door Bor 810mm 31 7 8 TR Series PITCH UP 21 mm m 1 4 per linear foot PITCH UP 21 mm m 1 4 per linear foot BAROMETRIC DRAFT REGULATOR CHIMNEY DO NOT INSTALL DRAFT REGULATOR HER Drill 6 mm 1 4 HOLE TO MEASURE DRAFT SMOKE CO and stack 18 temperature 229 mm 9 MAINTAIN 0 5 MM 0 02 W C DRAFT OVER FIRE BAROMETRIC DRAFT REGULATOR INSTALLED ON HORIZONTAL CONNECTION CHIMNEY REQUIREMENTS A The chimney must be constructed in accordance with all local applicable 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 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 Breaching should at least equal the area of the large2. 1 For steam boilers maintain a sodium chromate solution strength of 2 25 kg per 190 L 1 Ib per 50 gal of water and refill to the top of the gauge glass 2 For water boilers maintain a sodium chromate solution strength of 2 25 kg per 190 L 1 Ib per 50 gal of water and refill to normal fill pressure with system vented 3 Raise water temperature to at least 82 C 180 F for one hour to release dissolved gases 4 Shut down burner by disconnecting the main switch C To clean the fireside surfaces first shut down burner by disconnect ing all electrical power to the burner by turning OFF the OIL BURN ER EMERGENCY SWITCH See IV General Maintenance 1 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 operation ONLY THE NOZZLES SPECIFIED IN THIS MANUAL OR ON THE BURN ER LABEL SHOULD BE USED FOR REPLACEMENT 2 Protect all of the fireside surfaces by swabbing with neutral miner al oil 3 Close main cast iron burner door door on which burner is mount ed Make sure that the entire seal fiberglass rope is making good contact with the boiler casting when replacing 3 8 16 x 25 mm 1 long hex head bolt and tightening 4 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
3. Refill boiler until water level is again two inches from the top of the gauge glass 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 fre quently 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 skimmer tapping remove valve plug skimmer tapping and refill the START OF SKIMMING LEVEL 51 mm 2 BELOW TOP OF GAUGE GLASS 1 1 2 MALLEABLE IRON 150 PSI STREET ELBOW 1 1 2 SKIMMER 447 DRAIN VALVE 648 251 2 ENa y COVERED BUCKET OPERATING WATER LEVEL Figure 9 12 TR Series boiler to 622 mm 24 water level After 15 minute operation readjust level to normal operating level of 648 mm 25 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 bo
4. 645 mm 1172W 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 645 mm 293 W 1 sq in per 1000 Btu hr of TOTAL input of ALL fuel burning appliances within the enclo sure 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 openings shall communicate directly or by means of ducts with outdoors or to such spaces crawl or attic that freely communicate with outdoors See figures 3b 3c and 3d b Where directly communicating with outdoors or by means of vertical ducts each opening shall have a free area of not less than 645 mm 1172 W 1 sq per 4 000 Btu hr or 5964 mmf litre 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 645 mm 586 W 1 sq per 2 000 Btu hr or 11928 mm Litre hr 70 sq per gal per hr of total input of all a
5. AND DISCONNECT SWITCH MUST BE CUTOUT CUTOUT PROVIDED AS REQUIRED BY LOCAL CODES 43 0802D 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 L2 OTHER 43 0014 aL lt CONTROL x Lu i z 24 VOLT THERMOSTAT NOTE SWITCH AUX TERMINAL ONLY IF ON F3 OR F5 BURNER RIELLO FIELD CONNECTION JUNCTION BOX BURNER FACTORY MOUNTED IN a ALCUN QUICK DISCONNECT PLUG ELECTRONIC AQUASTAT L7248L CIRCULATOR IN 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 B1 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 TR Series 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 OVERCURRENT PROTECTION DEVICE FIELD WIRING NOTE AUX TERMINAL ONLY ON F3 am
6. GAUGE NIPPLE 6 mm 1 4 CLOSE Figure 4 STEAM SUPPLY 4 381 mm 15 min xk NORMAL WATER LEVEL 38mm N 1 1 2 REAR OF BOILER 38mm 1 1 2 CLEAN OUT PLUG Models TR 30 through TR 40 TR Series 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 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 19 mm 34 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 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 p
7. Underwriters for specific requirements Approximate Total Weight of Boiler Assembly filled with water NET OUTPUT CHIMNEY SIZE AFUE lee t SIZE TANKLESS HEATER Water Steam Water Steam Steam x kw MBH kW MBH kw MBH kW MBH Sq Ft 15 oxi Water Steam Bm USGPM mL s USGPM 34 117 30 101 39 421 X15 8 8 15 38 131 c 203x203 4g 170 146 56 40 SQQ 844 838 3 90 221 3 50 1 55 190 c ue 178x4 6m 83 3 178 7 261 415 63 223 56 191 74 796 6 3 20 6 3 40 8 12 15 i 203 8 284 440 252 4 00 203 305 g x15 4 6m 200 8 200 470 MINIMUM CLEARANCE Provide accessibility clearance of 610 mm 24 from surfaces requiring servicing top and front and 457 mm 18 on any side requiring pas sage The boiler shall be installed with the following MINIMUM clear ances from combustible materials A CHIMNEY CONNECTOR 457 mm 18 B BACK AND LEFT SIDE 152 mm 6 except as limited by 457 mm 18 clearance for chimney connector C RIGHT SIDE 152 mm 6 except for allowing for Burner door fully open which requires for Beckett Burner 191 mm 7 Riello E Series Burner 267 mm 10 2 D FLOOR the boiler is approved for installation on a combustible floor but subject to any local code requirements NOT to be installed on or over carpet NOTE As an alternate The burner door is removable so that the above service clearances are not mandatory
8. as an incorrect setting will result in an unsatisfactory installation See figures 12A and B Figure 11 Riello 40 Series Flgure 12A ELECTRODE SETTING Figure 12B 4 mm 5 32 MODEL F 10 3 2 F3 and F5 2 to 2 5mm or 5 16 to 7 16 F10 and F15 4 to 5mm or 5 32 to 5 64 20 SETTING THE AIR ADJUSTMENT PLATE See figure 13 1 The AIR SHUTTER A assures 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 13 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 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 and temperature readings may be experienced when the burner cover is put in place Therefore the burn er cover must be in place when making the final combustion instru ment readings to ensure proper test results Figure 13 Figure 14 F
9. be used for gravity fed fuel systems and for lift systems where the total lift is less than 2 5 m 8 feet Where the total lift is greater than 2 5 m 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 and two pipe fuel oil systems WIRING THE BOILER A The wiring diagrams for the burner and boiler are enclosed separately 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 E Wiring to the boiler must come through an emergency power isola tion switch with a clearly marked red switch plate This switch should be located so that it is apparent to the homeowner when entering the basement or boiler
10. 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 Volume per Pipe Size No Diameter linear unit Inside Volume per Diameter linear unit 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 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 difficult to obtain much more than a pound or so of pressure Set the pressure control at about 48 kPa 7 psi The higher the steam pres sure you can use the better and faster the cleaning 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 boiler drain valve Close the skimmer drain valve when the water level drops to about 127 mm 5 from the top of the gauge glass The water may stop before the level drops to 127 mm 5 below the top of the glass
11. enter the adjustment mode follow the instructions above In the adjustment mode pressing the l button repeatedly will cycle through the display feature if you need to change a previous entry When not using Outdoor Reset Kit NOTE When using an outdoor reset kit refer to the Honeywell Instruction Booklet 5 High Limit ECOM fault check EnviraCOM wiring ivit n Low Limit Differential L OF Local Thermostat Status L C Enviracom Thermostat Status EE E Degrees Fahrenheit F Err7 EEPROM HL LL Haf Ldf reset to default values Restore desired settings Repeated B1 fault no voltage present DISPLAY at B1 when output is turned on water In the RUN mode the Aquastat will flash bt boiler temp temperature above 260F when voltage followed by the temperature i e 220 followed by F or C present at B1 check B1 wiring voltage Degrees Celsius 7L To read boiler settings press the key to read the parameter of interest For example Press High Limit HL is displayed followed by a three digit number i e 220 followed by F or C L 4006A LOW LIMIT FOR TANKLESS OPTIONAL TR Series 15 BASIC WIRING DIAGRAMS L7248L OR L7224C WITH TANKLESS HEATER NOTES BLOCKED VENT SAFETY Recommend high limit setting is 93 C 200 F SWITCH AND OTHER SAFETY Low limit must be set at least 11 C 20 F CONTROLS below high limit setting T Overload protect
12. if two pipe Then discon nect the oil lines from the burner The flexible electric conduit con nected 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 gen tly 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 14 mm 9 16 drive socket Open the door to completely expose the combustion chamber for thor ough cleaning and for inspection of target wall blanket provided in certain models see rating plate main cast iron burner door insula tion and burner door fiberglass sealing rope If combustion 4 Low water cut off for operation see instructions furnished with unit See page 11 G STEAM SYSTEM check 1 Low water cut off for operation see instructions furnished with unit See page 11 2 Check pressure cut off for operation See page 11 3 Anyunusual water conditions Obtain water analysis and treat water H BOILER ROOM AIR SUPPLY supply air openings should be open and free of obstruction See pages 4 amp 5 T A flue brush 57 mm 2 1 4 dia is supplied with boiler Replacements are available from dealer or hardware stores APPENDIX A Prevention or Reduction of Condensation in Flue Passages It is strongly recommended to prevent or reduce condensation in the fl
13. pipes from relief valves blow down valves and low water cut offs must be piped to safe place for discharge according to local codes or the authority having jurisdiction PIPING IMPORTANT Boilers are to be used with closed system Any application that uses steam or water from system causes the introduction 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 STEAM SUPPLY Us 457mm 18 min Boiler Size TR 50 402 mm 15 27 32 TR 60 488 mm 19 7 32 TR 70 574 mm 22 19 32 gs min x NORMAL 7 WATER LEVEL _ 24 51 2 648 25 1 2 M 38 mm 1 1 2 CLOSE NIPPLE b RETURN p gt LINE REAR OF 38mm 1 1 2 CLEAN OUT PLUG BOILER Models TR 50 through TR 70 Figure 5 TR Series 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
14. room The homeowner should be made familiar with operating the switch toggle to provide or stop power to the boiler PRESSURE REDUCING VALVE ao others onsult local codes other RELIEF valves VALVE requirement COMPRESSION TANK RETURN ALTERNATE PUMP LOCATION AUTOMATIC AIR VENT SUPPLY 2 V FLOW CONTROL VALVE TO ZONES A SUGGESTED LOCATION OF OPTIONAL AIR SCOOP TANK AND AIR VENT PACKAGE COMPRESSION TANK TO COMPRESSION RELIEF VENT ALTERNATE CONNECTION HIGH TEMPERATURE WATER TO APPLIANCES TEMPERED WATER TO FIXTURE TEMPERING FLOW REGULATING VALVE Figure 8 Recommended Piping to Tankless Heater 10 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 Breaching must be pitched upward a minimum of 21 mm m 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 vertical or horizontal Breeching near chimney with hinge horizontal and face vertical See manufac turer s instructions packed in carton with barometric draft regulator and page 4 If two or more appliances are used on the same chimney see CHIMNEY page 3 and 4 G Make up all joints with minimum air l
15. will heat the distribution system water In addition to the aforementioned older systems and those supplied from wells may require that a filter or strainer be incorpo rated in the circuit at some point on the return line closest to the boiler Suitable water treatment filters are commercially available for this purpose WE STRONGLY RECOMMEND THAT YOU CONVEY THIS VITAL INFORMATION TO ALL PARTIES CONCERNED APPENDIX D USE OF NON OXYGEN DIFFUSION BARRIER UNDERFLOOR TUBING The boiler warranty does not cover leaks resulting from corrosion caused by the use of underfloor plastic tubing without an oxygen diffusion barrier Systems must have the non oxygen diffusion barrier tubing separated from the boiler with a heat exchanger Slant Fin recommends the use of underfloor plastic tubing with an oxygen diffusion barrier Other system components may also require protection from oxygen permeation TR Series 23
16. ANCOck 445 mm 17 1 2 25 1 2 PRIMARY A Alternate 38 mm CONTROL T 1 1 2 Tapping 1 4 de additional pam BURNER circulator 89 mm 3 1 2 a ii T E Y Y 44 mm COMBUSTION CHAMBER 95 mm 3 3 4 1 3 4 Figure 2 LEFT END WATER amp STEAM FRONT WATER BOILER 8 9 32 10 1 32 11 23 32 13 13 32 15 3 32 16 25 32 RATINGS WITH RIELLO BURNER Boiler OIL INPUT Model USGPH KW MBH Deep e MUN m sepia se papse par pm ps pr pr poc ps 2 152 J t S55 15 TR 40 MERI RE BERE BR URE RR REN RR RE LR ief ieo la pepep mesw zio 200 s 280 53 o zs 2 zi 2 5 88 x emo pepe pre p pe pe pe p p poe p maps sweep jefe _ eo 278 250 tar 364 258 96 96 7 255 96 294 97 995 3 00 2 85 117 399 97 327 84 284 wriwe w tert TRTO ssz 15 sr so 306 75 ws yos 46 a epp Note Standard working pressure 207 kPa 30 psi water 103 kPa For forced hot water heating systems a the boiler and 15 psi steam all piping are located within the area to be heated the boiler may be selected on the basis of gross output capacity The 254 x 4 6m ADD SUFFIX net output ratings shown are based on an allowance for X Denotes no circulator and no thermostat piping and pickup of 1 15 wate
17. IPTION AND AIR GATE TURBULATOR MODEL MODEL BELT TYPE kPa Psia SETTING NO SETTING NO E OMA ise 40 0 65 pe Delevan Series 40 809A Delevan Series 40 0 90 Delevan TR so Fen m ee se 8 ere A Series 40 1 10 80 B Delevan TR40H Series 40 SBT 567 150 473 1 25 eop Delevan 4000 445 2 5 F 10 i Hago 40 1 35 60 W Delevan TR 40 SBT 1 11 965 140 2 7 1 0 mae SPO es nm me Sr fe o om ee ee few e 09 _ me SP fralo en ia Dmm _ _ IE 36 21 RR me Se ove ow ow BR mm nm emn T Airshutter and head settings shown are approximate ONLY See START UP page 9 All burner models shown are single stage NOTE For proper insertion into combustion chamber see figure 14 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 Fig 12 A B 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 MODEL F 5 of the scale all cases the first mark is Zero The air oil ratio depends on accurate setting of the turbulator disc 2 Be careful when making this adjustment
18. ONNECTED TO A VENT HAVING SUFFICIENT DRAFT AT ALL TIMES TO ENSURE SAFE AND PROPER OPERATION OF THE BOILER 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 CO2 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 consume great quantities of air if air supply is not Draft is negative or suction pressure TR Series ample such an appliance will create a downdraft in the oil fired boiler flue This can create a hazardous condition Flue gases can be sucked out of the chimney through 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 p
19. OR PROPER INSERTION INTO COMBUSTION CHAMBER For F 3 F 5 and F 10 Riello Burners use Universal Flange Part 3005855 S F Part Flush with insulation to a maximum recess 2 of no more than 2 6mm 1 4 burners use Universal Flange Part 3005843 S F Part 4001394 and Slant Fin burner collar Part 430010 3C N d OMBUSTIO CHAMBER CARE AND MAINTENANCE CAUTION DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE UNIT IS FULL OF VAPOUR OR WHEN THE COMBUSTION CHAMBER IS VERY HOT CAUTION DO NOT TAMPER WITH THE UNIT OR CONTROLS CALL YOUR SERVICE PERSONNEL EXTENDED SHUTDOWN CLEANING OR REMOVAL OF BOILER FROM SERVICE IN AREAS NOT SUBJECT TO FREEZING 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 burn er by turning OFF the BURNER EMERGENCY SWITCH of this boil er After shutting down burner while the boiler is still hot 82 C TO 93 C 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 system preparations available from your distributor Follow the preparation manufacturer s instructions TR Series
20. PHT 115 140 1 31 1 25 1 68 1 60 1 89 1 80 TR 40 50 220 2 10 247 2 35 Standard Working Pressure 207 kPa 30 PSI water 103 kPa 15 PSI steam All boilers hydrostatically tested A S M E ADD SUFFIX X Denotes no circulator and no thermostat P Packaged water boiler has tankless heater PT Packaged water boiler with tankless heater PZ steam boiler less tankless heater PZT Packaged steam boiler with tankless heater Tankless heater rating based on intermittent draw t Ratings apply to the use of light oil of 11 000 W L 140 000 Btu per gallon The Net ratings shown are based on a piping and pick up allowance of 1 15 for water and 1 333 for steam For installations having unusual piping and pick up requirements additional allowance should be made before selecting the boiler 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 B The TR Series Boiler has full wet base sections which surround fire box for maximum 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
21. R 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 Notes 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 Popsafety 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 Pressure temperature altitude gauge use tapping no 6 High temperature limit use tapping no 7 Operating control if used use tapping no 7 Water relief valve use tapping no 3 piped full size to boiler Automatic air vent or compression tank tappings install in tapping no 2 Combustion safety control mounted on burner A low water cut off may be required by local codes If the boiler is installed above the radiation level a low water cut off device must be installed in all instances Do not install an isolation valve between the boiler and the low water cut off Jop m if used Q m Escape pipes drain
22. Slant Fin w H 3131567 CONFORMS TO UL STD 726 CERTIFIED TO CAN CSA STD B140 7 05 OIL FIRED WATER AND STEAM BOILERS NO 2 OIL INSTALLATION AND OPERATING INSTRUCTIONS READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE SAFETY WARNING KEEP BOILER AREA CLEAR AND FREE FROM COM BUSTIBLE MATERIALS GASOLINE AND OTHER FLAM MABLE VAPORS AND LIQUIDS FAILURE TO ADHERE TO ABOVE SAFETY WARNING MAY RESULT IN PERSONAL INJURY OR DEATH AND PROPERTY DAMAGE CONTENTS Ratings and Dimensions 23 Installation Requirements DONCEPOCGUONM Sd UIT EE dS ae 3 i rcps Mr erm 34 Chimney Requirements 5 Blocked Vent Safety Switch 5 Air Supply and Venting 5 7 Controls and Accessories 8 Piping Tor Steam Boilers 8 Cleaning Piping System 8 Piping tor Water wx Rn dare p ox et 8 9 Piping for Tankless Heater 9 installing BUC 27253 xc dre kd chan eee eines ee ews 9 Oil SUDDIV PIDING 9 Wiring ine BOGT sisi aea angie Sapiens eee mee eee 9 AR E 10 IMPORTANT The installation of this appliance must conform Precautions Before Starting bb Gee Chea oka eee de ed 4s 10 to the requirements of the auth
23. THER WITH THE TWO GREEN FACTORY CONNECTED GREEN GROUND WIRES A OPTIONAL HYDROSTAT MODEL 3150 IS EQUIPED WITH AN INTERNAL LOW WATER CUT OFF CIRCULATOR METHOD FOR MULTIPLE ZONED ZONE VALVE METHOD L8124 L7224C OR OPTIONAL HYDROSTAT 3150 CONTROLS VEINS I FOR TANKLESS HEATER APPLICATIONS HOT t ELECTRICAL POWER SUPPLY OVERLOAD PROTECTION Zone 1 7 2 MUST BE PROVIDED WHITE m T822D REQUIRED BY CODES BLACK p 4 e NEN EE m TO OTHER SAFETY PRIMARY CONTROLS L8148A AQUASTAT CONTROL TO x __ _ o Eo nnam _ 457 NS CT TO dii ZONES 43 0864 CONNECT T T ON Note Total load not to exceed B amp full load for circuits shown Uf Mi 14 TR Series FOR L7248L Enter adjustment Mode by pressing Up Down and l buttons simultaneously for seconds I button changes display feature Up and Down buttons change settings Freeze Protection Turn on or off On fires boiler at 40 F External Low Limit Off if not using Anti Short Cycle Timeout seconds set OFF or up to 5 Min Thermal Purging Limit Temperature F or C OFF to disable Thermal Purging Time Delay minutes shown only if tPL is enabled 2 2 lt 0 0 ___ ____ After 60 seconds without any button inputs the control will automatically return to the RUN mode re
24. d around flue collector and collar If seal is not satisfactory reseal with furnace putty or silicone with a temperature rating of at least 204 C 400 F All safety precautions indicated on material package must be followed G Once burner and draft have been set up then smoke CO 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 BEFORE FILLING WATER 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 82 C 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 Il CLEANING WATER BOILER SYSTEM A Prepare a boil out solution of sodium hydroxide caustic soda or tri sodium phosphate NOTE Use caution in handling chemicals Caustic soda is harmful to skin eyes and clothing 1 Proportions 2 25 kg per 190 L 1 Ib per 50 gal of system water 2 Stir chemical in water until dissolved and pour into the boiler through a top tapping Replace plug Fill the entire system with water Start the burner using the start up procedure Circulate t
25. d with all Intrepid TR Series boilers must be installed on the barometric damper Refer to the manufacturers instructions provided with the Blocked Vent Safety Switch for installation location instructions CAUTION DISCONNECT ELECTRICAL POWER WHEN WIRING The Blocked Vent Safety Switch is to be FIELD wired see wiring diagrams into the line voltage connection being wired into the junction box so the Blocked Vent Safety Switch breaks power supply to the boiler shutting it down in the event of a spillage IMPORTANT The Blocked Vent Safety Switch must be wired in accordance with The National Electrical Code the Installation of Oil Burning Equipment CSA B139 The installation must also conform to any applicable local codes the manufacturer s instructions the requirements of this Slant Fin manual and any authority having jurisdiction Where there is any difference the more stringent requirement shall govern Check the operation of the Blocked Vent Safety Switch A Block chimney or vent pipe B Adjust thermostat to call for heat C Allow approximately two minutes for the system to back up and the burner to shut down D Perform steps B and C again AIR SUPPLY AND VENTILATION see CSA B1389 latest edition Section 7 Sufficient air for combustion and ventilation in the boiler room must be provided Failure to do this will result in poor combus tion heavy sooting and health hazards CAUTION AN OIL FIRED BOILER MUST BE C
26. eaks secure with sheet metal screws OPERATING INSTRUCTIONS PRECAUTIONS BEFORE STARTING OIL BURNER Make a positive check of A through H before starting burner A Boiler and system are full of water All air is vented from system See below All wiring is completed 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 4 Burner settings are adjusted as per pages 12 14 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 Draft is negative or suction pressure CAUTION DO NOT START THE BOILER UNLESS ALL CLEAN OUT DOORS ARE SECURED IN PLACE UJ WARNING NEVER OPERATE any natural draft boiler TR Series boiler is a natural draft boiler with zero draft or overfire 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 0 5 mm 02 minimum during all operating conditions 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 bur
27. he water through the entire system Vent the system including the radiation Allow boiler water to reach operating temperature if possible Continue to circulate the water for a few hours Shut off the burner With CAUTION drain the boiler solution to a safe location DO NOT LEAVE SOLUTION SITTING IN SYSTEM OVER 2 HOURS J Wash the water side of the boiler thoroughly using a high pres sure water stream Fill and drain the boiler several times Ill TREATING WATER FOR CORROSION CONTROL This is not scale control A Prepare a solution of sodium chromate Proportions 94cc 100L 6 oz per 50 gallons of system water B Stir chemical into water until dissolved and pour into the boiler through a top tapping Replace plug IV FILLING AND VENTING THE WATER BOILER Refill the system with fresh water Bring water temperature to at least 82 C 180 F promptly Circulate water through entire system Vent the system including the radiation 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 V 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 bu
28. hut 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 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 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 a heavy accumulation of sediment and scale from old piping and radiators It s extremely imp
29. iler is running drain down boiler water slowly through Boiler Drain Cock shown on page 2 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 Il 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 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 Fig 10 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 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 O
30. ion and disconnect 15 AMP switch must be provided as required by M local codes OVERCURRENT PROTECTION DEVICE R8184G OR 688 415 PRIMARY CONTROL 24V THERMOSTAT CIRCULATOR BLACK YELLOW AS a NOZZLE LINE HEATER IF EQUIPPED PENES WIRING FOR PACKAGED STEAM BOILER EQUIPPED WITH McDONNELL NO 67 L W C O WIRING FOR PACKAGED STEAM BOILER EQUIPPED WITH Mc DONNELL NO 67 L W C O High Pressure Limit 120 VAC 60Hz Recommemded setting 0 5 PSI 15 AMP MAXIMUM OVERCURRENT Z PROTECTION DEVICE Low Limit tankless model only L1 L2 recommemded setting 160e9F SOLENOID IR 1 DN Uo T VALVE IF EQUIPPED OTHER Q E 1 LOW WATER ALARM SAFETY 5 OR WATER FEEDER CONTROL OPTIONAL Il i I BURNER Le ee NOZZLE LINE 3 CONDUCTOR BX CABLE 24 VOLT HEATER STEAM HARNESS 5 BLUE WIRE THERMOSTAT IF EQUIPPED Fog AVAILBLE FOR OPTIONAL ALARM OR WATER FEEDER IF USED GNITION SERVICE 17 A SWITCH IF m m VV MM EQUIPPED ro BLACK as ORANGE PRIMARY a CONTROL R8184G w See GREEN o OO GREEN GROUNDING SCREW 67 MMLW CO RED FIELD CONNECTION BURNER JUNCTION BOX JUNCTION BOX FLAME FACTORY MOUNTED DETECTOR O O 2 CONDUCTOR BX CABLE QUICK DISCONNECT PLUG STEAM HARNESS 2 FIELD CONNECTED ON PRESSURE PRESSURE CUT OUT CUT OUT Solenoid valve if equipped Splice Terminal Overload protection and disconnect swi
31. long bosses on front and rear sections and adjacent to the short bosses on the intermediate sections The rope should be directly under the flue collector flanges when the flue collector is replaced Use the two 1 4 20 x 19 mm 37 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 CAUTION ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE BURNER IS TO BE SHUT DOWN FOR AN EXTENDED PERIOD OR TIME ll Water Treatment Treatment for boiler feed water should be considered in areas of known problems such as where a high mineral content and hard ness exist Antifreeze may be added to the system water to protect the system Please adhere to the specifications given by the antifreeze manufacturer Do not use automotive ethylene glycol undiluted or petroleum based antifreeze Personal injury death or property damage can result Inhibited propylene glycol especially made for hydronic systems is recommended An antifreeze water mixture may require a backflow preventer within the automatic water feed piping Check that components such as diaphragm expansion tanks radiation pumps etc are suitable for and sized for use with glycol A 40 antifreeze content normally will provide freeze up protection to 10 F 23 C A 50 solution will nor
32. mally provide freeze up protection to about 30 F 34 C Note Do not use antifreeze other than specifically made for hot water heating systems e System may contain components which might be negatively affect ed by antifreeze Check total system frequently when filled with antifreeze e Advise system operator and or owner that system is filled with a glycol mix Follow antifreeze manufacturer s instructions Il OIL BURNER ALL SERVICE TO THE OIL BURNER OIL FILTER OIL STRAINER ETC SHOULD BE PERFORMED BY A PROFESSIONALLY TRAINED SERVICE PERSON Inspect and clean annually and following any period of improper oper ation Recheck and adjust settings as specified for burner model and nozzle size Set burner air and draft regulator using test instruments to obtain recommended CO and draft without smoke TR Series 21 Refer to page 9 All service to the oil burner oil filter oil strainer etc should be performed by a professionally trained service person IV GENERAL MAINTENANCE 7 Use the flue brush to clean the pinned flueways between the sec These operations are recommended to be performed at regular inter tions t A wire brush may be used to remove any carbon accumu vals lation that may have developed in the combustion chamber A CLEAN BOILER HEATING SURFACES THOROUGHLY DOWN TO Vacuum the loose soot and debris from the boiler CLEAN METAL B BOILER CONTROLS check contacts settings correct functioning 1 T
33. ner air bands to obtain a bright fire without smoke or oil stain Set the DRAFT REGULATOR to obtain 0 5 mm 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 to 1396 as you can Then open the air bands or shutter whichever apply an additional 3 mm 4 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 1496 However a very low CO 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 If smoke reading is satisfactory but can not be increased to a satisfactory level 12 or better or overfire draft of 0 5 mm 0 02 W C can not be obtained check for proper sealing between sec tions between burner mounting plate and front section around TR Series burner blast tube an
34. nstallation FOR REFERENCE Heating Contractor Boiler Model Number Address Boiler Serial Number Phone Number Installation Date Printed in Canada 1014 Publication No TR 40 Part No 43 2764 Revision L 2 TR Series Tapping A G FLUE COLLECTOR 3 2 TOP VIEW Location Steam Boiler Water Boiler AND 76 mm 3 supply 38 mm 1 1 2 supply OPENINGS 51 mm 2 supply on rear section second 6 mm 1 4 siphon amp pressure 19 mm 3 4 air vent or expansion tank cut out if required 1 19 mm 3 4 steam safety valve 19 mm 3 4 water relief valve 6 1 4 siphon auge amp FRONTVIEW Water 6 13 mm 1 2 tankless inlet 13 mm 1 2 tankless inlet 6 mm 1 4 pressure temp gauge 13 mm 1 2 high limit hi lo or combination control 19 mm 3 4 alternate electronic low water cut off 38 mm 1 1 2 skimmer tapping 13 mm 1 2 low limit for tankless 13 mm 1 2 tankless inlet 13 mm 1 2 tankless outlet 13 mm 1 2 steam gauge glass amp 67 LWCO 38 mm 1 1 2 bushed to 19 mm 3 4 for drain cock 38 mm 1 1 2 return amp 19 mm 3 4 drain cock 38 mm 1 1 2 condensate return 38 mm 1 1 2 alternate return Figure 1 3 4 NPT zone tapping 25 PRESSURE CUT OUT A S M E CONTROL POP SAFETY VALVE RELIEF SIPHON VALVE GAUGE SUPPLY GLASS WATERS LOW WATER OBSERVATION 810 mm 31 7 8 PORT OBSERVATION 648 mm E DR
35. o clean the fireside boiler surfaces first shut down burner by dis C PIPING check piping and accessories for leaks connecting all electrical power to the burner by turning OFF the OIL D CHIMNEY or STUB VENT and Breeching check for obstructions chamber parts above are badly deteriorated then replace with original factory parts available at your distributor BURNER EMERGENCY SWITCH corrosion and leaks 2 Remove the flue pipe from the boiler flue collar and clean thorough E COMBUSTION AIR TO BURNER check for continued POSITIVE ly supply of air as required Air needs are greatest in coldest weather 3 Inspect the entire vent connector back to the chimney and clean if Refer to AIR SUPPLY pages 4 amp 5 necessary F WATER SYSTEM check 4 Inspect the chimney for soot debris and other unsafe conditions of 1 System to be full of water and pressure to remain stable the chimney and take the necessary action between 83 kPa and 173 kPa 12 psi and 25 psi 5 Remove the flue collector by first removing the top jacket panel The 2 Air control system noise and air binding in radiation should flue collector is held in place by two hex 1 4 20 screws Remove the not occur screws and carefully remove the flue collector Try not to disturb the 3 Water lines slightest leaks should be corrected flat fiberglass rope under the flue collector 6 When necessary to clean the combustion chamber you must first CLOSE the suction valve and return valve
36. o operate at its maximum effectiveness APPENDIX C WATER QUALITY Recent investigations of boilers which were installed in hard water areas revealed that mineral deposits had accumulated at the bottom of the heat exchanger In addition sludge scale and other solid contaminants were present in boilers installed in older systems or where the water was supplied from a well This accumulation observed to be 64 mm 2 1 2 or more creates an insulating layer that drastically affects boiler efficiency by reducing the transmission of heat through this primary transfer surface and causes extreme metal temperatures that eventually crack the heat exchanger Note DOMESTIC TANKLESS HOT WATER COILS ARE HIGHLY SUSCEPTIBLE TO THIS CONTAMINATION THE TERMS OF THE BOILER WARRANTY WILL NOT APPLY TO FAILURES ENCOUNTERED UNDER THESE CIRCUMSTANCES RECOMMENDATIONS On all installations in hard water areas 1 The system should be thoroughly inspected for leaks which must be repaired however minor they may be 2 The initial water charge of the system must be treated to reduce its hardness to an acceptable level 3 Where a continuous fresh supply of hard water is fed to the system as with process or steam boilers it is essential that a The feed water is treated to reduce the level of hardness to a point where no significant deposition occurs in the boiler OR b The treated boiler water circulates through a closed circuit heat exchanger which in turn
37. or flood C See page 10 for complete blowing off instructions PIPING FOR WATER UNITS NOTE On knocked down boiler only jacket may be installed after supply and return piping connection but must be installed prior to adding trim I CIRCULATING SYSTEM A FORCED CIRCULATION hot water heating system Use the top tapping as supply tapping and use the front and or rear bottom tappings for the return B AFLOW 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 PRESSURE
38. ority having Jurisdiction Ok 1n Start Up 10 the absence of such requirements to the Installation of Oil Cleaning and Filling New Water Boiler 10 Burning Equipment CSA B139 The installation must also Cleaning Filling New Steam Boiler 10 11 conform to the additional requirements in this Slant Fin sui es i Instruction Manual Where there is any difference the more Pressure Control Check out 12 stringent requirement shall govern Replacement of Steam Boiler 12 Wiring DIAQIAMS x cut acie teet cbe en 13 17 Do not use gasoline crankcase drainings or any oil contain can 18 20 ing gasoline Care and Maintenance Extended Shutdown 20 Freezing Protection 20 Never burn garbage or paper in this unit and never leave Ol BUM serres PLU 20 combustible material around it General Maintenance 21 Appendix A 21 AppendixB GAD O O OD 25 IMPORTANT This boiler must be installed serviced and repaired by a trained experienced service technician licensed for the installation and servicing of oil burning hot THIS MANUAL MUST BE LEFT WITH OWNER AND SHOULD BE HUNG ON OR ADJACENT TO THE BOILER water heating or steam system equipment or otherwise quali fied by the authorities having jurisdiction over the i
39. ortant to blow down your McDonnell 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 RS OPEN POSITION BLOW DOWN X VALVE a m gt ra TR Series 13 BASIC WIRING DIAGRAMS FOR Honeywell L7248L See pages 14 17 for other primaries 15 AMP MAXIMUM OVERCURRENT without tankless heater PROTECTION DEVICE Honewell L7224C 24 VOLT with tankless heater HOT FIELD CONNECTION THERMOSTAT HYDROSTAT MODEL 3150 HIRED PRIHARY IE ERDIPPED FACTORY MOUNTED BECKETT MODELL 7600A IF EQUIPPED ps WG 1f equipped HONEYWELL R7184B BECKETT GENISYS 7505 ELECTRONIC AQUASTAT SINGLE ZONE WIRING BURNER J BOX MULTIPLE ZONED SEE Adjusting l CIRCULATOR METHOD Auli SPACE HEATING ONLY l Settings amp Error Codes for L7224C amp L7248L on page 14 LEGEND FOR SINGLE AND MULTIPLE ZONED DIAGRAMS FACTORY WIRING FIELD WIRING LINE VOLTAGE m TO OTHER ELECTRICAL POWER SUPPLY PROVIDE DISCONNECT EE MEANS AND OVERLOAD PROTECION AS REQUIRED BY CODES CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED IS 1 4 IN 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 TOGE
40. p F5 BURNERS QUICK DISCONNECT PLUG 4 COND BX CABLE STEAM HARNESS 1 FOR L W C O BLUE WIRE AVAILABLE OR OPTIONAL ALARM OR WATER FEEDER IF USED ALTERNATE METHOD USING A 24V WALL THERMOSTAT HONEYWELL RA89A RELAY BY OTHERS LINE VOLTAGE WALL THERMOSTAT BY OTHERS OTHER SAFETY CONTROLS 24V WALL THERMOSTAT SERVICE SWITCH IF EQUIPPED 2 COND BX CABLE LOW LIMIT HARNESS L4006A LOW LIMIT FOR TANKLESS OPTIONAL LOW WATER ALARM OR WATER FEEDER OPTIONAL 430167E BLACK SEE ABOVE RIGHT FOR HIT HYDROLEVEL McDONNEL MILLER PS 801 L W C O ONLY P C BOARD g LOOSE WHITE LEAD CONNECT TO PROBE 2 COND BX CABLE STEAM HARNESS 2 FIELD CONNECT ON PRESS CUT OUT END 17 HYDROLEVEL CYCLE GARD CG 450 L W C O P C BOARD WHITE CONNECT LOOSE WHITE LEAD TO PROBE TERMINAL amp FASTEN WITH LOCK WASHER AND WING NUT SEE HYDROLEVEL INSTRUCTIONS NOTES N OVERLOAD PROTECTION AND DISCONNECT SWITCH MUST BE PROVIDED AS REQUIRED BY LOCAL CODES A FOR THIS HARNESS SEE DRAWING 43 0230 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 18 TR Series BURNER DATA BECKETT BURNERS FOR PACKAGED BOILERS ONLY FIRING RATE BOILER BURNER BURNER NO 2 OIL MODEL MODEL HEAD TR30 AFG SF 1801 TR 40 AFG SF 1802 TR 50 AFG SF 1803 F120 6 06 6 82 T Air shutter and air band settings are app
41. pen blow off valve at bottom of control water will pour out STEAM CONTROL ASSEMBLY Installed McDonnell amp Miller 67 low water cut off and water level gauge NIPPLE 13 x 127 1 2 x 5 THD AT BOTH ENDS 16 mm 5 8 COMP ADAPT ADAPTER FITTING 13x 16 mm S 1 2 x 5 8 13 mm 1 2 S O D TUBE N N WATER LEVEL 648 mm 25 1 2 OFF FLOOR TEE 13 x 13 x 13 mm 12 x 1 2 x 1 2 WATER LEVEL GAUGE 10 mm 3 8 MALE PIPE TO 13 mm 1 2 OD COMP ADAPT NIPPLE 13 x 51 mm 1 2 x 2 c NIPPLE 13 x 127 mm 1 2 x 5 THD AT BOTH ENDS DRAIN PIPE Fig 10 flushing 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 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 s
42. ppliances in the confined space See Figures 3b 3c and 3d 1 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 windows 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 CO2 smoke and draft readings must be normal CO2 between 1196 and 1396 smoke between ZERO and a TRACE draft between 0 5 mm 02 W C and 1 0 mm 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 dry ers 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 TR Series 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 305 mm 1 FT ABOVE FLOOR Figure 3c Appliances located in confined spaces Air from out doors through ventilated attic See Table 2 2 4 CHIMNEY Figure 3b Appliances located in confined spaces Air from out doors See Table 2 2 4 CHIMNEY VENTILATION LOUVERS EACH END OF ATTIC INLET AIR VENTILATION LOUVERS FO
43. r or 1 33 steam Gross P Packaged water boiler output is divided by the allowance to obtain net rating The PT Packaged water boiler with tankless heater manufacturer should be consulted before selecting a boiler PZ Packaged steam boiler less tankless heater for unusual piping and pickup requirements such as inter PZT Packaged steam boiler with tankless heater mittent system operation extensive piping etc Note m of steam is equal to net output W divided by 757 W square feet of steam is equal to net output BTU divided by 240 BTUs 8 heater rating based on intermittent draw Nominal clay tile liner dimensions BURNER NET RATINGS CHIMNEY SIZE AFUE Boiler Sections 6 x15 5500 8 00 386 215 340 811518150 330 2T 357_ 4 6m ss pojas 8406 83 451 5 277 440 252 4 00 p 6 309 490 264 450 wx EC Sp T I p p 7 545 315 5 00 Lp p 99 570 y Sm RR UE I EA X gx 15 t Ratings apply to the use of light oil at 11 000 W L 140 000 Btu per gallon and apply only when burner models listed on pages 15 17 of this manual are used and are properly adjusted to produce 13 CO TR 20 Collar is oblong will fit 152 mm 6 diameter nomi nal connector Rip Em m EP99006531 VERIFI TR Series RATINGS WITH BECKETT BURNER Boiler OIL INPUT GROSSOUTPUT OUTPUT Model Number mL st USG
44. rner the high limit or the wiring is faulty Repair or replace immediately gt 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 82 C 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 TR Series WATER CONTENT OF BOILER TR 20 TR 30 1 L USG L USG L US 11 Water Boiler 405 107 496 131 587 155 674 178 8 8 40 5 10 7 47 7 12 6 VOLUME OF WATER IN STANDARD PIPE OR TUBE Standard Steel Pipe Nominal Schedule Inside 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 D Procedure to dissolve oil and grease in boiler 1 Fill boiler to proper water line 2 Prepare a boil out
45. rovide 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 ratings table on page 2 RADIANT FLOOR LOW WATER TEMPERATURE AND LARGE WATER VOLUME SYSTEMS A boiler by pass loop three way valve arrangement primary secondary pumping with a boiler loop or other acceptable method must be used to provide a minimum 130 return water temperature to the boiler This will prevent condensation on the cast iron sections that can result in poor combustion and damage to the boiler INSTALLING THE BURNER See Burner Data pages 12 to 14 and Burner Manual supplied with burner 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 insertion depth must be as indicated on page 14 fig 14 CAUTION DO NOT USE GASOLINE CRANKASE 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 CSA B139 and the instruction sheet attached to the oil burner pump A one pipe system should
46. roviding 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 CSA B139 latest edition section 7 for more detailed information m Is there sufficient air for combus tion by natural infiltration see NOTE 1 Test below If there in 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 2 2 Unconfined space 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 2 3 Confined space 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 2 4 Confined space Boiler Location Air Supply Action Required Unconfined space NONE Provide air from outdoors directly through a permanent out side wall opening or openings with a free open area of not less than
47. roximate ONLY See START UP page 9 A All burner models shown are single stage See table for approximate settings SHUTTER ADJUSTMENT Shutter opens clockwise right Example shown at no 6 position 0 is not imprinted on burner but is the first mark on the left EMBOSSED AIR BAND ADJUSTMENT Example shown in closed 0 position Band opens when moved clockwise right 4 mm 5 32 GAP ELECTRODE 8 mm 5 16 ABOVE NOZZLE 2 mm 1 16 ELECTRODE ADJUSTMENTS BECKETT L hr GPH 417 1 10 CLOSED FAS 447 4 74 1 25 1 25 80 ES HAGO 80 W NOZZLES OIL PUMP PRESSURE APPROXIMATE SETTING AIR SHUTTER kPa psig SETTING NO f APPROXIMATE AIR BAND SETTING NO f EHE 1 50 80 ES HAGO 779 113 mE 1 1 4 80 B DELAVAN 1138 10 1 112 zape ee e 80 B DELAVAN n UU 80 W 80 W DELAVAN NOTE 1 Extended heads on all units 2 No static plate for TR 50 only 3 Insertion depth 55 mm 2 5 32 for TR 30 and TR 40 67 mm 2 21 82 for TR 50 4 Air Band 2 slot for TR 30 4 slot for TR 40 8 slot for TR 50 29 mm 1 1 8 ome meee PET 21 L a ew o s 2 15 16 TR Series 19 BURNER DATA RIELLO BURNERS FOR PACKAGED BOILERS ONLY FIRING OIL PUMP BURNER RATE PRESSURE NO 2 OIL SETTING BOILER BURNER DESCR
48. solution of sodium hydroxide caustic soda and tri sodium phosphate NOTE Use caution in handling chemicals Caustic soda is harmful to skin eyes and clothing a Proportions 2 25 kg per 190 L 1 Ib per 50 gal of system water b Stir chemicals into water until dissolved and pour into the boiler through a top tapping Replace plug 3 Start the burner boil the water for at least 5 hours shut off the burner E With CAUTION drain the boiler solution to a safe location DO NOT LEAVE SOLUTION SITTING IN SYSTEM OVER 2 HOURS Wash the water side of the boiler thoroughly using a high pres sure water stream Fill and drain the boiler several times Ill TREATING WATER FOR CORROSION CONTROL This is not scale control A Prepare a solution of sodium chromate Proportions 2 25 kg per 190 L 1 Ib per 50 gal of boiler water B Stir chemical in water until dissolved and pour into boiler through a top tapping Replace plug IV 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 water The boiler should be blown down as outlined below B Turn off
49. st appliance flue plus 50 of the additional flue areas D Breaching area must not be reduced at connection into chim ney Breaching must be inserted into but not beyond inside of chimney liner E Chimney height shall extend at least 1 m 3 feet above where it passes through the roof of the building and at least 0 5 m 2 feet above any ridge within 3 m 10 feet of the chimney F The use of a vent cap where permitted by code gives addition al protection against adverse wind conditions and precipitation G Flue Connection Connect flue pipe between top of boiler and chimney Horizontal sections of flue pipe must be pitched upward to the chimney at least 21 mm m per foot Flue must be inserted into but not extend beyond the inside wall of the chimney flue Install draft regulator in flue pipe as shown in figure 3 MINIMUM DO NOT INSTALL DRAFT REGULATOR HERE BAROMETRIC DRAFT REGULATOR DRILL 6 MM 1 4 HOLE TO MEASURE DRAFT SMOKE CO2 AND STACK TEMPERATURE 229 mm 9 MAINTAIN 0 5 MM 0 02 W C DRAFT OVER FIRE Figure 3 Barometric Draft Regulator Location BAROMETRIC DRAFT REGULATOR INSTALLED ON VERTICAL RISE BLOCKED VENT SAFETY SWITCH All Intrepid TR Series boilers must be installed with a Blocked Vent Safety Switch The Blocked Vent Safety Switch will detect spillage of flue gases due to a blocked vent or inadequate draft The Blocked Vent Safety Switch supplie
50. tch must be provided as 43 0804 required by local codes Nozzle line heater if equipped gt gt 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 16 TR Series WIRING FOR PACKAGED STEAM BOILER 15 MAXIMUM OVERCURRENT For alternate option PS 801 120 L W C O or Hydrolevel Cycle Gard 450 L W C O 120 VAC 60H2 X _ HYDROLEVEL CYCLE GARD CG 450 LW CO 2 L1 rc SOLENOID VALVE LOW WATER ALARM IF EQUIPPED 1 OR WATER FEEDER OPTIONAL r L 4006A LOW LIMIT 24 VOLT FOR TANKLESS OPTIONAL THERMOSTAT BURNER MOTOR NOZZLE LINE I I I I HEATER l I I ar IGNITION ____ I N I D o 4 CONDUCTOR BX CABLE STEAM HARNESS 1 IF EQUIPPED M r BLUE WIRE AVAILABLE FOR OPTIONAL ALARM OR WATER T T FEEDER IF USED PS 801 120 L W C O E l PRIMARY E control E PRINTED R71848 CIRCUIT Q Q LOOSE WHITE WIRE LEAD l q I l l 1 L 1 NEUTRAL HOT n wn 325 P C BOARD SERVICE SWITCH IF EQUIPPED CONNECT LOOSE WHITE LEAD TO PROBE TERMINAL amp FASTEN WITH LOCK WASHER AND WING NUT SEE HYDROLEVEL INSTRUCTIONS BLACK 7 TO PROBE I GREEN GROUNDING Te SCREW A PROBE BURNER JUNCTION BOX FLAME DETECTOR 2 CONDUCTOR BX CABLE QUICK DISCONNECT PLUG STEAM HARNESS 2 FIELD CONNECTED ON PRESSURE PRESSURE OVERLOAD PROTECTION
51. ue passages for fossil fuel cast iron boilers This can be accomplished by the use of a manual bypass between the boilers the use of Primary Secondary piping e the use of other effective arrangments or devices TR Series APPENDIX B THERMOSTAT HEAT ANTICIPATOR SETTINGS Fixed anticipator thermostats are not adjustable Adjustable anticipator thermostats depending on thermostat model may be adjustable from a 18 to a 9 setting by moving a pointer on the anticipator The higher the anticipator setting towards 9 the longer it will take for the thermostat to respond to a change in room tempera ture Too high a setting and the boiler will be slow to respond to a temperature change in the room This can cause the room temperature to drop to an uncomfortable level before the boiler starts This may generate homeowner complaints The lower the anticipator setting toward 18 the faster the thermostat will respond to a change in room temperature Too low a setting and the boiler will short cycle Boiler short cycling will cause unnecessary wear on the equipment and in the case of oil boilers it can lead to poor combustion and more frequent cleaning of the combustion area It is important to understand what the thermostat is controlling and then determine the amp rating of that relay gas valve zone valve or control This information is usually stamped somewhere on the component A properly set anticipator will allow the system t
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