Slant/Fin Intrepid Steam User Manual

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

Ratings and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Installation Requirements:

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

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

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

Air Supply and Venting . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

Blowing Off a Steam Boiler . . . . . . . . . . . . . . . . . . . .7, 10

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

Low Water Cut-off Check-out . . . . . . . . . . . . . . . . . . . .10

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

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

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-16

Burner Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-22

Care and Maintenance:

Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Freezing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .23

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.

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
Devices for Automatically Fired Boilers, No. CSD-1, latest
edition.

THIS MANUAL MUST BE LEFT WITH OWNER AND

SHOULD BE HUNG ON OR ADJACENT TO THE

BOILER FOR REFERENCE.

IMPORTANT: This boiler must be installed by a trained,
experienced, service technician, licensed for the installation
and servicing of oil burning equipment or otherwise qualified by
the authorities having jurisdiction over the installation.

Printed in U.S.A. 1113 Publication No. TR-40 Rev.E
Part No. 43-2764

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

INTREPID

SERVICE COMPANY

Name __________________________________________
Address__________________________________________
Telephone ________________________________________
Model # __________________________________________
Serial # __________________________________________

INSTALLATION AND OPERATING INSTRUCTIONS

READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE.

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 AHRI output ratings shown are based on an allowance for piping and

pickup of 1.15 (water) or 1.33 (steam). D.O.E. capacity gross output is divided by the

allowance to obtain net rating. The manufacturer should be consulted before selecting a

boiler for unusual piping and pickup requirements such as intermittent system operation,

extensive piping, etc.

† Ratings apply to the use of light oil at 140,000 Btu per gallon, and apply only when burner

models listed on pages 17-19 of this manual are used, and are properly adjusted to pro-

duce 13% CO

2

.

§ Nominal clay tile liner dimensions.
** Tankless heater rating based on intermittent draw.
¶ Water boiler models TR-30 and larger may have two firing rates. The boiler is factory shipped

at the lower firing rate. To obtain the higher firing rate, refer to the INTREPID boiler installa-

tion instructions for the appropriate field adjustments.
‡ AHRI gross output (Btuh) and thermal efficiency.
❑ 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.

Boiler
Model

No.*

AHRI Burner
Capacity Oil

Input

D.O.E.

Heating

Capacity MBH

AHRI Net Ratings AHRI Chimney Size

A.F.U.E.

%

Dimensions (inches)

Boiler

Sect.

Tankless

Heater

GPM **

Water

MBH *

Steam
MBH *

Steam
Sq. Ft.

Nom. Rect.

x Height

§

(in x in x ft)

I.D. Round

x Height

(in x ft)

Boiler

Length

“A”

Front

to

Flue

¢

“B”

Flue
Dia.

“C”

Return

Circulator

Flange

“D”

Overall
Length

“E”

GPH †BTUH Water Steam Water Steam Water Steam

TR-20
TR-30H
TR-30-1.10

¶

TR-30-1.25

¶

TR-40H
TR-40-1.60

¶

TR-40-1.80

¶

TR-50H
TR-50-2.10

¶

TR-50-2.35

¶

TR-60
TR-70-3.00

¶

TR-70-3.10

¶

0.75

1.00

1.10

1.25

1.50

1.60

1.80

2.00

2.10

2.35

2.60

3.00

3.10

105,000
140,000
154,000
175,000
210,000
224,000
252,000
280,000
294,000
329,000
364,000
420,000
434,000

89
120
131
149
181
189
212
241
247

272

‡

301

‡

355

‡

358

‡

–
–

130

–
176
188

–
235
245

–

311

‡

349

‡

362

‡

77
104
114
129
157
164
184
210
215
237
262
309
311

–
–

98

–
132
146

–
177
184

–
233
262
272

–
–

408

–
550
588

–
736
767

–
971

1092
1129

8 x 8 x 15
8 x 8 x 15
8 x 8 x 15
8 x 8 x 15
8 x 8 x 15
8 x 8 x 15
8 x 8 x 15
8 x 8 x 15

8 x 8 x 15
8 x 12 x 15
8 x 12 x 15
8 x 12 x 15
8 x 12 x 15

5 x 15
6 x 15
6 x 15
6 x 15
7 x 15
7 x 15
7 x 15
8 x 15
8 x 15

8 x 15
10 x 15
10 x 15
10 x 15

85.1

86.0

84.8

85.0

86.0

84.4

84.2

86.0

84.0

82.7

‡

82.7

‡

84.6

‡

82.4

‡

–
–

84.1
–

84.0

83.8
–

84.0

83.4
–

85.5

‡

83.2

‡

83.3

‡

111⁄2
147⁄8
147⁄8
147⁄8
181⁄4
181⁄4
181⁄4
215⁄8
215⁄8
215⁄8

25

28

3

⁄8

283⁄8

89⁄32
101⁄32
101⁄32
101⁄32

1123⁄32
1123⁄32
1123⁄32
1313⁄32
1313⁄32
1313⁄32

153⁄32

1625⁄32
1625⁄32

6

❑

6
6
6
7
7
7
8
8
8
8
9
9

11⁄4
11⁄4
11⁄4
11⁄4
11⁄4
11⁄4
11⁄4
11⁄2
11⁄2
11⁄2
11⁄2

–
–

241⁄4
275⁄8
275⁄8
275⁄8

31
31
31

34

3

⁄8
343⁄8
343⁄8
373⁄4
411⁄8
411⁄8

2
3
3
3
4
4
4
5
5
5
6
7
7

2.20

3.10

3.20

3.40

3.80

3.90

4.15

4.30

4.40

4.70

4.90

5.40

5.45

–
–

3.00
–

3.40

3.50
–

3.90

4.00
–

4.50

5.00

5.00

RATINGS

INTREPID

3

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:

B. The boiler can be installed on both combustible and non-combustible

floors, but must NOT be installed on or above carpeting.

C. The Intrepid Boiler has full wet base sections which surround fire-

box for maximum heat absorption of burning fuel, and low floor
temperature.

D. If boiler is to be located over buried conduit containing electric wires

or telephone cables, consult local codes or the National Board of Fire
Underwriters for specific requirements.

CAUTION: NEVER BURN GARBAGE OR PAPER IN THE UNIT AND
NEVER LEAVE COMBUSTIBLE MATERIAL AROUND IT.

MINIMUM CLEARANCE

Provide accessibility clearance of 24" from surfaces requiring servicing
(top and front) and 18" on any side requiring passage. The boiler shall
be installed with the following MINIMUM clearances from combustible
materials:
A. CHIMNEY CONNECTOR-18"
B. BACK AND SIDES- 6" EXCEPT as limited by 18" clearance

from chimney connector
NOTE: Except in closets and alcoves, clearances above in (A) and
(B) may be reduced by providing forms of protection as specified in
NFPA 31, latest edition.

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 must be inserted into, but not beyond, inside of chimney
liner.

E. Chimney height shall extend at least 3 feet above where it passes

through the roof of the building, and at least 2 feet above any ridge
within 10 feet of the chimney.

F. The use of a vent cap, where permitted by code, gives additional

protection against adverse wind conditions and precipitation.

G. Flue Connection: Connect flue pipe between top of boiler and chim-

ney. Horizontal sections of flue pipe must be pitched upward to the
chimney at least 1/4" per foot. Flue must be inserted into, but not
extend beyond, the inside wall of the chimney flue. Install draft regu­lator in flue pipe, as shown in figure 3.

AIR SUPPLY AND VENTILATION (see NFPA 31, latest edition)
Sufficient air for combustion and ventilation in the boiler room must be
provided. Failure to do this will result in poor combustion, heavy soot­ing and health hazards.

CAUTION

: AN OIL-FIRED UNIT SHALL BE CONNECTED TO A
VENT HAVING A SUFFICIENT DRAFT AT ALL TIMES TO ENSURE
SAFE AND PROPER OPERATION OF THE UNIT.

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

INSTALLATION REQUIREMENTS

4

INTREPID

INTREPID

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, 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

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 NFPA 31, latest edition for more detailed information.

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 is NOT sufficient air for
combustion by natural infiltration
due to tight construction or other
conditions, then it REQUIRES AIR
FROM OUTDOORS. SEE
“ACTION REQUIRED” column at
right. See Notes (1) and (2) below.

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
1 sq. in. per 4000 Btu/hr of TOTAL input of ALL fuel burning
appliances in the building. See Note (1) and (3).

The confined space shall be provided with two permanent air
openings, one near the top of the enclosure and one near the
bottom. EACH opening shall have a free air opening of not less
than 1 sq. in. per 1000 Btu/hr. of TOTAL input of ALL fuel burning
appliances within the enclosure. The two openings shall freely
communicate with the interior areas of the building which in turn
would have to have adequate infiltration of air from outdoors.
See Notes (1, 3) and Figure 3a.

(a) Air from the outdoors shall be provided to the confined space

by two permanent openings, one in or near the top of the
enclosure space and one in or near the bottom. The 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.

* Draft is negative or suction pressure

6

INTREPID

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).

INTREPID

7

INSTALLING CONTROLS AND
ACCESSORIES ON BOILER UNITS
Note: Jacket must be installed on boiler units prior to installation

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

no. 4, figure 4.
B. Gauge glass set — use tapping no. 12.
C. Pop safety valve — use tapping no. 3, piped full size to boiler; or

pipe full size into a valveless steam header.
D. Combustion safety control — mounted on burner.

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: 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
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.

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.

B. A FLOW CONTROL VALVE (See figure 6) will prevent gravity

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)

8

INTREPID

C. HOT WATER RADIATION VENTING - Manual air vents should be
installed at the top of all "drops"(where piping goes downward).

Air must be vented or purged from all zone lines to permit proper
system heating.

D. PUMP LOCATION-Locating low-head pump(s) on return to boil-

er is only acceptable in residences of one or two stories. (See
figure 6) The pump location shown in figure 7 is required in large,
multi-story building installations, especially when high-head
pumps are used and is also recommended for all applications.

E. A conventional compression tank may be connected to the 3/4"

tapping as shown in figure 7.

IMPORTANT: Hot water heating systems containing high water volume,
such as would occur with cast-iron radiation, require special care with air
elimination. The circulator pump should be located on the boiler supply
pipe and the expansion tank and air scoop should be located near the
pump suction. (See Figure 6, Alternate Pump Location.)

PIPING TANKLESS HEATER (if used)

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

provide more volume of temperate water to kitchen and bath.

B. High temperature water, for dishwasher and laundry, may be

piped direct.

C. A flow control valve should be used to control the rate of flow of

water through the coil, otherwise the heating capacity of the coil
will be exceeded. To insure sufficient hot water, the flow rate
through the coil should be limited to a maximum shown for inter­mittent draw in the ratings table on page 2.

IMPORTANT: Escape pipes or drain pipes from relief valves, safety
valves, blow-down valves, and low-water cut-off must be piped off to a
safe place.

INSTALLING THE BURNER

See Burner Data, pages 14-18, and Burner Manual supplied with 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 must be as shown on pages 14-18.
Check to see that nozzle and settings are as given in burner data tables,
pages 14-18.
CAUTION

: DO NOT USE GASOLINE, CRANKCASE DRAININGS, OR

ANY OIL CONTAINING GASOLINE.

OIL SUPPLY PIPING

Install the oil tank or tanks and piping from tank to burner. Follow local
codes and practices, NFPA No. 31, INSTALLATION OF OIL BURNING
EQUIPMENT and the instruction sheet attached to the oil burner pump.
A one-pipe system should be used for gravity-fed fuel systems and for lift
systems, where the total lift is less than 8 feet. Where the total lift is
greater than 8 feet, a two-pipe system must be used. In some
instances, local codes may require a two-pipe system for below grade
fuel oil tanks. Be sure to set-up the fuel oil pump for the piping system
used; follow the instructions attached to the pump. Be sure to include a
good quality, low pressure drop fuel oil filter in the supply line from the
tank. This is necessary, especially at low fuel oil flow rates (small nozzle
sizes), to prevent 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 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.

Wiring to the boiler must come through an emergency power isolation
switch with a clearly marked red switch plate. This switch should be
located so that it is apparent to the homeowner when entering the base­ment or other boiler area. The homeowner should be made familiar with
operating the toggle to provide or stop the power to the boiler.