Slant-Fin INTREPID Oil-fired Boiler User Manual
INTREPID
OIL-FIRED WATER AND STEAM BOILERS/NO. 2 OIL
INSTALLATION AND OPERATING INSTRUCTIONS
SAFETY WARNING:
KEEP BOILER AREA CLEAR AND FREE FROM
COMBUSTIBLE MATERIALS, GASOLINE AND
OTHER FLAMMABLE VAPORS AND LIQUIDS.
FAILURE TO ADHERE TO ABOVE SAFETY
WARNING, MAY RESULT IN PERSONAL INJURY
OR DEATH AND PROPERTY DAMAGE.
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE
Ratings and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation Requirements:
Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Chimney Requirements . . . . . . . . . . . . . . . . . . . . . . . . .3
Air Supply and Venting . . . . . . . . . . . . . . . . . . . . . . . . . .3
Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . .6
Piping for Steam Boilers . . . . . . . . . . . . . . . . . . . . . . . . .6
Cleaning Piping System . . . . . . . . . . . . . . . . . . . . . . . . .6
Piping for Water Units . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Piping for Tankless Heater . . . . . . . . . . . . . . . . . . . . . . .7
Installing Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Oil Supply Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Wiring the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Vent Piping and Draft Regulator . . . . . . . . . . . . . . . . . . .8
Operating Instructions:
Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . .8
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cleaning and Filling New Water Boiler . . . . . . . . . . . . . .8
Blowing Off a Steam Boiler . . . . . . . . . . . . . . . . . . . . .6, 9
Cleaning and Filling New Steam Boiler . . . . . . . . . . . . .9
Low Water Cut-off Check-out . . . . . . . . . . . . . . . . . . . . .9
Pressure Control Check-out . . . . . . . . . . . . . . . . . . . . .10
Replacement of Steam Boiler . . . . . . . . . . . . . . . . . . . .10
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-14
Burner Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-20
Care and Maintenance:
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Freezing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .21
IMPORTANT: The installation of this equipment must conform
to the requirements of the authority having jurisdiction or, in
the absence of such requirements, to the Installation of Oil
Burning Equipment, ANSI/NFPA 31, latest edition, and to the
National Electrical Code ANSI/NFPA 70, latest edition. The
installation must also conform to the additional requirements in
this Slant/Fin Instruction Manual. Where there is any difference, 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
De
vices for Automatically Fired Boilers, No. CSD-1, latest
edition.
THIS MANUAL MUST BE LEFT WITH OWNER AND
SHOULD BE HUNG ON OR ADJACENT TO THE
BOILER FOR REFERENCE.
IMPORTANT: This boiler must be installed by a trained,
experienced, service technician, licensed for the installation
and servicing of oil burning equipment or otherwise qualified by
the authorities having jurisdiction over the installation.
Printed in U.S.A. 207 Publication No. TR-40
Part No. 43-2764
2
INTREPID
Standard working pressure 30 psi water, 15 psi steam.
All boilers hydrostatically tested — A.S.M.E.
* For forced hot water heating systems where the boiler and all piping are located within
the area to be heated, the boiler may be selected on the basis of gross D.O.E. capacity
output. The net I=B=R output ratings shown are based on an allowance for piping and
pickup of 1.15 (water) or 1.33 (steam). D.O.E. capacity gross output is divided by the
allowance to obtain net rating. The manufacturer should be consulted before selecting a
boiler for unusual piping and pic
extensive piping, etc.
† Ratings apply to the use of light oil at 140,000 Btu per gallon, and apply only when burner
models listed on pages 14-16 of this manual are used, and are properly adjusted to pro-
duce 13% CO
.
2
kup requirements such as intermittent system operation,
§ Nominal clay tile liner dimensions.
**
Tankless heater rating based on intermittent draw.
¶ Water boiler models TR-30 and larger have two firing rates. The boiler is factory shipped
at the lower firing rate. To obtain the higher firing rate, refer to the INTREPID boiler installation instructions for the appropriate field adjustments.
‡
I.B
.R.
gross output
q Collar is oblong, will fit 6" diameter nominal connector.
¢ This dimension is from the boiler jacket to the center of the flue outlet.
NOTE: All boilers under 300,000 Btuh input are tested and rated for capacity under the U.S.
Department of Energy (D.O.E.) test procedures for boilers.
NTREPID
I
3
I
NSTALLATION 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 chimney 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
TR-20 440
TR-30 550
TR-40 660
TR-50 785
TR-60 895
TR-70 1000
B. The Intrepid 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 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.
CHIMNEY REQUIREMENTS
A. The chimney must be constructed in accordance with all local appli-
cable codes and the National Board of Fire Underwriters. See boiler
models and rating table shown on page 2 for chimney sizes.
B. Check chimney condition.
Existing chimneys and stacks may have deteriorated; without repairs
their use would be hazardous. Before connecting to an old chimney
or stack:
1. Clean it.
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 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 m
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
e
xtend beyond, the inside wall of the chimney flue. Install draft regu-
lator in flue pipe, as shown in figure 3.
AIR SUPPLY AND VENTILATION (see NFPA 31, latest edition)
Sufficient air f
pro
vided.
ing and health hazards.
ust be inserted into, but not beyond, inside of chimney
or combustion and ventilation in the boiler room must be
F
ailure to do this will result in poor comb
ustion, heavy soot-
4
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, CO2and 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
* 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-
uently to maintain free air flow.
q
Protect air openings against closure by snow, debris, etc. Openings such
as doors or windows, if used, must be locked open.
TABLE 2: Provisions for Combustion and Ventilation Air Supply. See NFPA 31, latest edition for more detailed information.
Boiler Location Air Supply
2.1 Unconfined space Is there sufficient air for combus-
Action Required
NONE
tion by natural infiltration (see
NOTE (1), “Test...” below)?
2.2 Unconfined space If there is NOT sufficient air for
combustion by natural infiltration
due to tight construction or other
conditions, then it REQUIRES AIR
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).
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.
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.
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.
(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 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.
(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, 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 CO2, smoke and draft readings must be normal. (CO2between 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.
NTREPID
I
5
Figure 3a.
Appliances located in confined spaces. Air from
inside the building. See Table 2 (2.3).
Figure 3b.
Appliances located in confined spaces. Air from outdoors. See Table 2 (2.4).
Figure 3c.
Appliances located in confined spaces. Air from outdoors through ventilated attic. See Table 2 (2.4).
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).
6
INTREPID
INSTALLING CONTROLS AND
ACCESSORIES ON BOILER UNITS
: Jacket must be installed on boiler units prior to installation
Note
of trim.
I. 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
o. 4, figure 4.
n
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.
II. WATER BOILER TRIM, see page 2 for tapping locations, and fig-
ures 1 and 2 for illustration of water boiler.
A. Pressure- temperature - altitude gauge — use tapping no. 6.
B. High temperature limit — use tapping no. 7.
C. Operating control (if used) — use tapping no. 7.
D. Water relief valve — use tapping no. 3, piped full size to boiler.
E.
Automatic air vent or compression tank tappings — if used,
install in tapping no. 2.
F. Combustion safety control — mounted on burner.
PIPING
IMPORTANT:
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.
Boilers are to be used with closed system. Any
Local codes apply.
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 or rear bottom
tappings for the return.
. A FLOW CONTROL VALVE (See figure 6) will prevent gravity
B
circulation and usually is required when tankless heater is
installed.
II. 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 control 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)
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.
NTREPID
I
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 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.
PIPING TANKLESS HEATER (if used)
I. Heater capacities are listed on Page 2.
II. 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
B. High temperature water, for dishwasher and laundry, may be
C. A flow control valve should be used to control the rate of flow of
(See Figure 6, Alternate Pump Location.)
provide more volume of temperate water to kitchen and bath.
piped direct.
w
ater 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 maxim
mittent draw in the ratings table on page 2.
um shown for inter-
7
INST
ALLING THE BURNER
See Burner Data, pages 14-18, and Burner Manual supplied with burner. If burner is not mounted as received, mount to boiler, placing flange
o
ver 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.
OIL SUPPLY PIPING
Install the oil tank or tanks and piping from tank to b
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
g
reater than 8 f
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 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 ha
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.
eet, a tw
o-pipe system m
ve a properly fused disconnect switch. 120
ust be used.
ur
ner. Follow local
In some
8
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.
. Install barometric draft regulator on horizontal breeching, near chim-
E
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.
B. All wiring is completed. See pages 11-13.
C. Oil supply is connected to the burner; nozzle is installed correctly; oil
valve is open at tank.
D. Smokepipe is connected to chimney.
E. All combustible materials are cleared away.
F. Combustion air supply is provided. See page 3.
G. Burner settings are adjusted as per 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.
Once burner and draft have been set up, then smoke, CO
G.
temperature should be checked and recorded. If smoke is greater than
trace, review the burner instructions; replace the nozzle if necessary.
Normal smoke to be expected at approximately 13% CO
a trace.
CLEANING AND FILLING A NEW WATER BOILER
I. There are a number of commercial preparations available from your
istributor for cleaning and for corrosion protection conditioning the
d
internal (waterside) surfaces of boilers. Follow the preparation manufacturer’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.
II. 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.
III. 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 temperature 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.
2
is zero to
2
and stac
k
WARNING: NEVER OPERATE any natural draft* boiler
(Intrepid 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 .02", minimum, during all operating conditions.
* Draft is negative or suction pressure.
ST
AR
A. Make sure the boiler is installed and wired properly and is full of
B. Open the observation door (on the front, above the burner).
C. Start the oil burner (see burner instructions for bleeding air from oil,
D
.
E. By alternate adjustment of the barometric draft regulator, the burner
F. If smoke reading is satisfactory, but CO2can not be increased to a
(COMB
T
-UP
water.
etc.).
IMMEDIATELY, set burner air bands to obtain a bright fire without smoke or oil stain. Set the DRAFT REGULATOR to obtain .02"
o
verfire draft*. Take draft reading through slot in observation door.
Close the observation door. Allow the burner to fire for at least one
hour total firing time, to bake out the volatile binders in the combustion chamber bef
air regulation and head regulation devices (whichever apply), set for
a trace of smoke and as close to 13% CO
the air bands or shutter (whichever apply) an additional 1/8". This
should result in zero smoke with NO raw oil on the smoke paper and
a smooth light-off. DO NOT ATTEMPT TO SET FIRE BY EYE.
Flame retention burners may appear efficient and smoke free from
an inefficient 7% up to an overly high 14% CO
CO2can also result in poor ignition and r
the fire box. At very high CO
reason will cause incomplete combustion, with high smoke and dry
soot formation in the fire box.
satisfactory level (12% or better) or overfire draft of 0.02" W.C. can
not be obtained, chec
burner mounting plate and front section, around burner blast tube
and around flue collector and collar
with furnace putty or silicone with a temperature rating of at least
400° F. (All safety precautions indicated on material package must
be followed.)
USTION
TEST INSTR
ore taking final combustion readings.
2
k f
or proper sealing betw
UMENTS MUST BE USED)
as you can. Then open
2
. However, a very low
2
a
, any slight decrease in air flow for any
w (unburned) oil entering
een sections, between
. If seal is not satisfactory, reseal
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