Slant/Fin INTREPID Installation And Operating Instructions Manual

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE

Ratings and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3

Installation Requirements:

Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Chimney Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Air Supply and Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . .7

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

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Cleaning and Filling New Water Boiler . . . . . . . . . . . . . .9–10

Blowing Off a Steam Boiler . . . . . . . . . . . . . . . . . . . . . . . . .10

Cleaning and Filling New Steam Boiler . . . . . . . . . . . . . . .10

Low Water Cut-off Check-out . . . . . . . . . . . . . . . . . . . . . . .11

Pressure Control Check-out . . . . . . . . . . . . . . . . . . . . . . . .11

Replacement of Steam Boiler . . . . . . . . . . . . . . . . . . . . . . .11

Burner Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12,13,14

Care and Maintenance:

Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Freezing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Appendix

B, C & D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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.

Printed in Canada 0906 Publication No. TR-40
Part No. 43-2764 Revision E

INSTALLATION AND OPERATING INSTRUCTIONS

OIL-FIRED WATER AND STEAM BOILERS/NO. 2 OIL

INTREPID

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, CSA B139. The installation must also
conform to the additional requirements in this Slant/Fin
Instruction Manual. Where there is any difference, the more
stringent requirement shall govern.

Do not use gasoline crankcase drainings or any oil contain­ing gasoline.

Never burn garbage or paper in this unit, and never leave
combustible material around it.

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, serviced and
repaired by a trained, experienced, service technician,
licensed for the installation and servicing of oil burning hot
water heating system equipment or otherwise qualified by
the authorities having jurisdiction over the installation.

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

354
381

354

–

104

–

306
331

90
97

266

–

78

–

1108

–

103

–

251
272

298
327

255

–

298

–

75

–

87

–

223
237

259
284

65
69

76
83

191

–

224

–

56

–

66

–

796

–

933

–

74

–

87

–

TR-20
TR-30
TR-40
TR-50
TR-60
TR-70

292
378
464
549
635
721

11-1/2
14-7/8
18-1/4
21-5/8

25

28-3/8

210
255
298
341
383
426

8-9/32

10-1/32
11-23/32
13-13/32

15-3/32
16-25/32

152¶
152¶
178
203
203
229

¶6¶
¶6¶

7
8
8
9

38
38
38
38
38

–

1-1/2
1-1/2
1-1/2
1-1/2
1-1/2

–

616
702
787
873
959

1045

24-1/4
27-5/8

31
34-3/8
37-3/4
41-1/8

Boiler Model Boiler Length “A”

mm in

Front to Flue “B”

mm in

Flue Diameter “C”

mm in

Circulator Flange

mm in

Overall Length “E”

mm in

2 TR Series

Note: Standard working pressure 207 kPa (30 psi) water,
103 kPa (15 psi) steam.

* ADD SUFFIX
X —Denotes no circulator and no thermostat
P —Packaged water boiler
PT —Packaged water boiler with tankless heater
PZ —Packaged steam boiler less tankless heater
PZT —Packaged steam boiler with tankless heater

§ Tankless heater rating based on intermittent draw.

§§ Nominal clay tile liner dimensions.

** For forced hot water heating systems where the

boiler and all piping are located within the area to
be heated, the boiler may be selected on the
basis of gross output capacity. The net output rat­ings shown are based on an allowance for piping
and pickup of 1.15 (water) or 1.33 (steam). Gross
output is divided by the allowance to obtain net
rating. The manufacturer should be consulted
before selecting a boiler for unusual piping and
pickup requirements such as intermittent system
operation, extensive piping, etc.
Note: m

2

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)

† 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

2

.

¶ TR-20 Collar is oblong, will fit 152 mm (6") diame-

ter nominal connector.

Tapping
Location Steam Boiler Water Boiler

1 76 mm (3”) supply 38 mm (1-1/2”) supply

1A 51 mm (2”) supply on rear section —

2 second 6 mm (1/4”) siphon & pressure 19 mm (3/4”) air vent or expansion tank

cut-out if required
3 19 mm (3/4”) steam safety valve 19 mm (3/4”) water relief valve
4 6 mm (1/4”) siphon, pressure gauge & —

pressure cut-out

5A — 13 mm (1/2”) tankless inlet
5B — 13 mm (1/2”) tankless inlet

6 — 6 mm (1/4”) pressure temp. gauge
7 — 13 mm (1/2”) high limit, hi/lo or

combination control

8 19 mm (3/4”) alternate electronic low

water cut-off
9 38 mm (1-1/2”) skimmer tapping —

10 13 mm (1/2”) low limit for tankless —
11A 13 mm (1/2”) tankless inlet —
11B 13 mm (1/2”) tankless outlet —

12 13 mm (1/2”) steam gauge glass & 67 LWCO —

13 38 mm (1-1/2”) bushed to 19 mm (3/4”) for drain cock 38 mm (1-1/2”) return &

19 mm (3/4”) drain cock
14 38 mm (1-1/2”) condensate return 38 mm (1-1/2”) alternate return
15 3/4” NPT zone tapping —

102mm

(14”)

810 mm (31-7/8")

445 mm (17-1/2")

32 mm (1-1/4")

95 mm (3-3/4")

635 mm

(25")

372 mm
(14-5/8")

648 mm
(25-1/2")

44 mm
(1-3/4")

DRAIN COCK
(Alternate 38 mm
(1-1/2") Tapping
for additional
circulator.)

TR-70

In.

TR-30

3.10

3.35

3.26

3.52

434
469

127
137

104
112

229
229

–
–

–
–

5.45

5.70

343
259

5.00
–

315

–

GROSS OUTPUTBoiler

Model

Number

*

OIL INPUT

mL/s USGPH† kW MBH MBH MBH MBH

MBH Sq. Ft.

Nom. Rect

×Height§§

in.×in.×ft.

mm×mm×m

mmWater Steam

mL/s mL/sUSGPM USGPM

Round I.D.×

Height

in.×ft.

mm.×m

kW kW

kW

m

2

kW

NET OUTPUT** CHIMNEY SIZE TANKLESS HEATER§

Water

Water*

Water Steam

Steam

Steam

Steam

FLUE SIZEAFUE %

.79

.75

1.15

1.31

1.68

1.89

1.60

1.80

2.10

2.35

2.60

2.85

2.20

2.47

2.73

3.00

1.10

1.25

TR-20

TR-40

TR-50

TR-60

31

105

45
51

66
74

224
252

294
329

364
399

86
96

107
117

154
175

26

90

39
44

57
64

195
218

75
80

87
96

134
151

–

–

39

–

57

–

195

–

134

–

23 79

34
38

50
56

170
190

117
131

30

–

–

–

43

–

146

–

101

–

–

–

39

–

55

–

608

–

421

–

152

–

83.50

5"×15'

127×4.6m

152
152

84.15
–

84.85

83.50

178
178

83.80
–

84.45

83.33

203
203

83.45
–

84.06
–

203
203

–
–

–
–

¶6¶

6
6

7
7

8
8

8
8

9
9

139

2.20

202
214

246
261

3.90

4.15

4.40

4.70

4.90

5.20

277
296

309
328

3.20

3.40

–

–

189

–

221

–

3.50
–

4.00
–

4.50
–

252

–

284

–

3.00
–

RATINGS

89 mm (3-1/2")

LEFT END – WATER & STEAM

Water

Figure 1

Figure 2

Steam

6"×15'

152×4.6m

7"×15'

178×4.6m

10"×15'

254×4.6m

8"×15'

203×4.6m

8" × 12"

× 15'

203 × 305

× 4.6m

8" × 8"

× 15'

203 × 203

× 4.6m

1 1

TR Series

3

BOILER LOCATION

Provide a level, solid foundation for the boiler. Location should be near
the chimney so that the Flue Pipe Connector or Breaching to the chim­ney 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 Underwriters for specific requirements.

MINIMUM CLEARANCE

Provide accessibility clearance of 610 mm ( 24") from surfaces requiring
servicing (top and front) and 457 mm (18") on any side requiring pas­sage. The boiler shall be installed with the following MINIMUM clear­ances 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

1

/2")

Riello E Series Burner–267 mm (10

1

/2")

D. FLOOR - the boiler is approved for installation on a combustible

floor, but subject to any local code requirements.

NOTE: As an alternate:
The burner door is removable so that the above service clearances are
not mandatory.

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.

INSTALLATION REQUIREMENTS

Boiler

Size

TR- 20

TR-30
TR-40
TR-50
TR-60
TR-70

kg

200
250
300
355
405
455

lbs

440
550
660
785
895

1000

Approximate Total Weight of Boiler

Assembly, filled with water

84.1

–

83.8

–

83.4

–

In.

TR-30

TR-40

TR-50

GROSS OUTPUT

Boiler
Model

Number

*

OIL INPUT

mL/s† USGPH† kW MBH MBH MBH MBH MBH Sq. Ft. mmWater Steam

mL/s mL/sUSGPM USGPM

Round I.D. ×

Height

in × ft.

mm × m

kW

kW

kW m

2

kW

NET OUTPUT CHIMNEY SIZE TANKLESS HEATER

Water

Water**

Water Steam

Steam

Steam**

Steam

FLUE SIZEAFUE %

RATINGS WITH BECKETT BURNERS

1.15

1.31

1.68

1.89

2.20

2.47

1.10

1.25

1.60

1.80

2.10

2.35

45

51

66

74

86

96

154

175

224

252

294

329

39

44

55

63

72

80

132

149

188

214

246

272

39

–

55

–

72

–

132

–

188

–

246

–

34

38

48

55

63

69

117

131

170

190

223

237

30

–

43

–

56

–

101

–

146

–

191

–

39

–

56

–

74

–

421

–

606

–

796

–

152

152

178

178

203

203

84.8

83.5

84.4

83.3

84.0

–

6

6

7

7

8

8

202

214

246

261

284

296

3.20

3.40

3.90

4.15

4.40

4.70

189

–

221

–

252

–

3.00

–

3.50

–

4.00

–

6"×15'

152×4.6m

8"×15'

203×4.6m

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 —Packaged steam boiler less tankless heater
PZT —Packaged steam boiler with tankless heater

§§ Tankless heater rating based on intermittent draw.

† 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 stream. For installations having unusual piping and pick-up
requirements, additional allowance should be made before selecting the boiler.

Model

TR-30

TR-40

TR-50

kg

217

257

305

lbs.

479

566

673

kg

221

261

309

lbs.

488

575

682

kg

215

254

295

lbs.

473

559

651

kg

224

263

304

lbs.

483

579

671

P PT PZ PZT

Rectangular

I.D. × Height

in. × in × ft.

mm × mm × m

8"×12"×15'
203×305×

4.6m

8"×8"×15'

203×203

×4.6m

7"×15'

178×4.6m

4 TR Series

Figure 3.

Barometric Draft
Regulator
Location

PITCH UP

21 mm/m (1/4" per linear foot)

Drill 6 mm (1/4")

HOLE TO

MEASURE

DRAFT, SMOKE,

CO

2

and stack

temperature

PITCH UP
21 mm/m (1/4" per linear foot)

457 mm

(18")

MINIMUM

229 mm (9")

DRILL 6 MM (1/4")

HOLE TO
MEASURE DRAFT,
SMOKE, CO

2

AND

STACK

TEMPERATURE

MAINTAIN 0.5

MM (0.02")

W.C. DRAFT

(OVER-FIRE)

MAINTAIN 0.5

MM (0.02")

W.C. DRAFT

(OVER-FIRE)

BAROMETRIC DRAFT REGULATOR

INSTALLED ON HORIZONTAL CONNECTION

BAROMETRIC DRAFT REGULATOR

INSTALLED ON VERTICAL RISE

229 mm (9")

457 mm

(18")

MINIMUM

B. Check chimney condition.

Existing chimneys and stacks may have deteriorated; without
repairs their use would be hazardous. Before connecting to an
old chimney or stack:

1. Clean it.

2. Inspect it thoroughly.

3. Remove obstructions.

4. Replace worn sections of metal stacks.

5. Seal bad masonry joints.

6. 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 largest 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 (

1

/4" 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.

AIR SUPPLY AND VENTILATION

(see CSA B139, 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 combus­tion, heavy sooting and health hazards.

BAROMETRIC DRAFT

REGULATOR

BAROMETRIC DRAFT

REGULATOR

TR Series

5

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, CO

2

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

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 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 fre­quently 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.

* Draft is negative or suction pressure

Boiler Location Air Supply

2.1 Unconfined space Is there sufficient air for combus­tion by natural infiltration (see
NOTE (1), “Test...” below)?

2.2 Unconfined space 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.

2.3 Confined space If there is sufficient air for combus­tion from within building but it
comes from outside of the
confined space, see “ACTION
REQUIRED” column at right.
See Note (1) below.

2.4 Confined space If there is NOT sufficient air for
combustion due to tight construc­tion or other conditions it
REQUIRES AIR FROM OUT­DOORS. SEE “ACTION
REQUIRED” column at right.
See NOTE (2) below.

Action Required

NONE

Provide air from outdoors directly through a permanent out­side wall opening or openings with a free open area of not
less than 645 mm

2

/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

2

/293 W (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 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

2

/1172 W (1 sq. in. per 4,000 Btu/hr.)

or 5964 mm

2

/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

2

/586 W (1 sq. in. per 2,000 Btu/hr.) or

11928 mm

2

/Litre/hr ((70 sq. in. per gal. per hr.) of total
input of all appliances 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 CO

2

, smoke and draft readings must be normal. (CO2between 11% and 13%, 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.