Slant-Fin XL-2000 User Manual
™
XXLL--22000000
OIL-FIRED WATER 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 . . . . . . . . . . . . . . . . . . . . . . . . . .3,4
Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . .5
Piping for Water Units . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installing Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Oil Supply Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Wiring the Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Vent Piping and Draft Regulator . . . . . . . . . . . . . . . . . . . .5
Operating Instructions:
Precautions Before Starting . . . . . . . . . . . . . . . . . . . . . . .7
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cleaning and Filling New Water Boiler . . . . . . . . . . . . . . .8
Care and Maintenance:
Extended Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Freezing Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Oil Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Burner Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11,12
IIMMPPOORRTTAANNTT:
form 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.
:
The installation of this equipment must con-
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
author
ities having jurisdiction over the installation.
Printed in U.S.A.305 Publication No. XL-40
Part No. 48-0090 Revision C
2
3
/4" RELIEF
VALVE TAPPING
1
1/2 SUPPLY
T
APPING
1
/2" AIR VENT
O
R EXPANSION TANK
T
APPING
T
OP VIEW
1/4 NPT PRESSURE
& TEMPERATURE TAPPING
F
RONT VIEW
3/4 REAR DRAIN
1 1/2 ALTERNATE
REAR RETURN
1 1/2 RETURN
TAPPING
1/2 NPT
CONTROL TAPPING
Figure 2.
XL-2000
Figure 1.
TABLE 1: Ratings and Dimensions
BOILER
MODEL
NO.
I=B=R
BURNER
CAPACITY
OIL INPUT † §
GPH BTUH
D
.O.E.
HEATING
CAPACITY
MBH *
W
ATER
I=B=R
WATER
NET
RATING
MBH *
NOM.
X HEIGHT‡
(in x in x ft)
I=B=R
CHIMNEY SIZE
I.D
RECT
. ROUND
X HEIGHT
(in x ft)
XL-20 0.65 91,000 78 68 8 x8x15 6 x 15 83.56 8
XL-30H 0.85 119,000 104 90 8 x8x15 6 x 15 86.00 12
XL-30 1.00 140,000 121 105 8 x8x15 6 x 15 85.04 12
1.15 161,000 138 120 8 x8x15 6 x 15 84.12 12
XL-40H 1.25 175,000 152 132 8 x8x15 7 x 15 86.00 15
XL-40 1.35 189,000 162 141 8 x8x15 7 x 15 85.05 15
1.55 217,000 186 162 8 x8x15 7 x 15 84.38 15
XL-50 1.80 252,000 217 189 8 x8x15 8 x 15 85.00 19
2.00 280,000 239 206 8 x8x15 8 x 15 84.19 19
Standard working pressure 30 psi.
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 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 output is divided b
Technical Service department 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 11 and 12 of this manual are used, and
y the allowance to obtain net rating. The Slant/Fin
are properly adjusted to produce 13% CO2.
‡
Nominal clay tile liner dimensions.
§ Water boiler models XL-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 XL-2000 boiler installation instructions for the appropriate field adjustments
¶
Oblong flue collar. Fits 6” dia. vent connectors.
#
All dimensions subject to nor
NOTE: All boilers under 300,000 Btuh (87.9 kw) input are tested and rated for
capacity under the U.S. Depar tment of Energy (D.O.E.) Test Procedures for
Boilers.
DIMENSIONS (inches) #
BOILER
LENGTH
AFUE %
. “H” models have only one firing rate.
“A”
11
FRONT TO
FLUE
“B”
/
16
3
/
16
3
/
16
3
/
16
11
/
16
11
/
16
11
/
16
3
/
16
3
/
16
9
4
/
5
6
/
5
6
/
5
6
/
1
8
/
1
8
/
1
8
/
13
9
13
9
mal manufacturing tolerance.
FLUE
DIA.
“C”
6¶ 1
16
61
16
6 1
16
61
16
71
16
7 1
16
71
16
/
81
16
/
81
16
CIRCULA
SUPPLY
FLANGE
NPT
1
1
1
1
1
1
1
1
1
/
/
/
/
/
/
/
/
/
TOR
4
4
4
4
4
4
4
2
2
“D”
APPROX.
OVERALL
LENGTH
“E”
3
25
/
8
7
28
/
8
7
28
/
8
7
28
/
8
3
32
/
8
3
32
/
8
3
32
/
8
7
35
/
8
7
35
/
8
XL-2000
3
T
HE INSTALLATION INSTRUCTIONS IN THIS MANUAL
ARE ABBREVIATED. SEE THE FRONT COVER OF THIS
MANUAL FOR REFERENCES TO CODES AND STANDARDS.
BOILER LOCATION
Provide a level, solid foundation for the boiler. Location should
be near the chimney so that the Flue Pipe Connector or
B
reeching 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
XL-20 317
XL-30 405
XL-40 493
XL-50 581
* Includes burner, circulator and controls
B. The XL-2000 Boiler has full wet base sections which sur-
round 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" clear-
ance 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.
C
HIMNEY REQUIREMENTS (see NFPA 31, latest edition)
A. The chimney must be constructed in accordance with all
l
ocal 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 connecti
ng 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 lining.
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 chimney. 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 combus-
Figure 3.
Barometric Draft
Regulator
Location
4
XL-2000
tion, heavy sooting and health hazards. 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
D
O NOT vent this boiler to the same chimney flue used by a
and overfire draft* will change unpredictably.
2
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 infiltrat
ion 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
* Draft is negative or suction pressure
will create a downdraft in the oil-fired boiler flue. This can create a hazardous condition. Flue gases can be sucked out of
t
he 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
i
ts 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 combus-
Action Required
NONE
tion 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
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, smok
.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.
e and draft readings must be normal. (CO
betw
een 11% and 13%, smoke between ZERO and a TRACE, draft between .02” W.C. and
2
XL-2000
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).
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