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INSTALLATION AND OPERATOR’S MANUAL
SL375 THRU SL7175
OIL FIRED CAST IRON BOILERS
Keep these instructions with the boiler at all times for
future reference
BOYERTOWN FURNACE CO.
PO Box 100
BOYERTOWN, PA 19512
1-610-369-1450
www.boyertownfurnace.com
1-10-06
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2 Be Aware of Hazard Definitions Denotes presence of a hazard which, if ignored, will result in severe personal injury, Danger death or property damage Denotes presence of a hazard which, if ignored could result in severe personal injury, Warning death or substantial property damage. Denotes the presence of a hazard, which if ignored, could result in minor personal Caution injury or property damage Intended to bring attention to information, but not related to personal injury or
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3 Table of Contents Ratings and Data………………………………………………………………………4 Clearances……………………………………………………………………..............5 Ventilation and Combustion Air………………………………………………………5 Boiler Assembly……………………………………………………………….............6 Temperature control Installation and Adjustment Boiler Trim Piping Jacket Installation System Piping………………………………………………………………...……….9 Bypass Piping Low Water Cut-Off Relief Valves Expansion Tanks V
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4 Ratings and Data Boiler Model No. SL375 SLD375 SL4100 SLD4100 SL5125 SLD5125 SL6150 SL7175 Firing Rate - #2 Fuel 0.75 0.75 1.00 1.00 1.25 1.25 1.50 1.75 Input BTU/HR 105,000 105,000 140,000 140,000 175,000 175,000 210,000 245,000 DOE Capacity BTU/HR 91,000 91,000 122,000 122,000 153,000 153,000 184,000 208,250 Net IBR Rating BTU/HR 79,000 79,000 106,000 106,000 133,000 133,000 160,000 181,100 Net Rating Sq. Ft. 526 526 707 707 887 887 1,067 1,207 AFUE Rating 85.5 85.5 8
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5 Installation Clearances Boilers in rooms shall be installed with the clearances from combustible materials not WARNING less than indicated below. Combustible materials are those made of or surfaced with wood, compressed paper, plant fibers, plastics, or other material that will ignite and burn, whether flame proofed or not, or whether plastered or not. The boiler must not be installed on combustible flooring. The boiler is approved for installation on non comb
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6 hundred (100) square inches. These openings must freely communicate with the interior areas having adequate infiltration from the outside. When the boiler is installed in a confined space and all air is provided from the outdoors, the confined space shall be provided with two permanent openings, one commencing within 12 inches from the top, and one commencing 12 inches from the bottom of the enclosure. The openings shall communicate directly, or by ducts, with the outdoors or space
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7 the crated boiler to the carrier in good condition. ANY CLAIMS FOR DAMAGE OR SHORTAGE IN SHIPMENT MUST BE FILED IMMEDIATELY against the carrier by the consignee. Temperature Controls Installation and Adjustment 1. After cabinet installation is complete install the temperature control on the right side of the boiler. a) Carlin Aquastat – Attach the 4 x 4 Junction box supplied with the Carlin control using the 1/2” electrical box connector attached to the side of the jacket. b) Hon
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8 Jacket installation 1. Open Cabinet Parts Box Check for damages. Damage claims must be filed immediately with carrier. 2. Install the (4) 3/4” OD x 1-9/16” bottom bracket spacers onto the tie rods, followed by the bottom brackets, with the tabs pointing outward, which are fastened in place with the 10mm nuts provided. 3. Mount top brackets on the boiler tie rods with the tabs pointing outward. Fasten in place between the 10mm nuts provided on the casting. Insert the two anti-short bu
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9 System Piping Important… INSTALLATION MUST BE PERFORMED BY TECHNICALLY QUALIFIED SERVICEMEN SOLAIA BOILERS HAVE A MAXIMUM OPERATING PRESSURE OF 58PSI NOTE: If normal operating pressures are greater than 30psi please contact the manufacturer for required trim. Pipes that are connected to boiler fittings must be supported and placed so that they do not create stresses on the boiler fittings themselves. BY PASS PIPING IS REQUIRED ON ALL LOW MASS BOILERS WHERE THE BOILER RET
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10 VENTING WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. All chimneys must meet the requirements of NFPA 211 and NFPA 31 Chimney The boiler must be connected to an adequate chimney or an approved venting system in accordance with these instructions. An adequate chimney or venting system is one that is sealed and lined with the capability of producing a -.04"
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11 Evidence of potential or existing chimney damage should be determined by visual inspection of the chimney and liner. Exterior indicators such as missing or loose mortar/bricks, white deposits on the brick or water stains on the interior building walls should be investigated further. The operational flue temperatures for º º boilers range from 350 F to 450 F at the outlet of the boiler. These temperatures are further reduced before reaching the chimney due to heat loss through the v
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12 With the burner operating, use a draft gauge to adjust the regulator to the proper setting (see instructions enclosed with draft gauge to adjust the regulator to the proper setting). When the burner air supply and draft are properly adjusted, the draft in the flue should be a negative .02" W.C. to negative .04” W.C. Two or more oil burning appliances each equipped with a safety control may be permitted to be connected to one common chimney if sufficient draft is available for the sa
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13 3. COMBINATION AIR INTAKE/VENT SYSTEM The vent system consists of 10, 15, or 20 foot lengths of 5” single wall flexible stainless vent piping, or 10 or 15 foot lengths of double wall insulated flexible stainless vent piping and an equal length of 4” air intake piping and a stainless steel intake/vent termination end. Consult the Direct Vent manual included with the direct vent kit for more detailed installation instructions. The hole t
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14 The purpose of the damper is to act as a vacuum breaker in the event of a blockage in the air intake. NOTE: The balance weight of the vacuum relief valve must be installed in a level position and adjusted to lightly close while burner is operating. Be sure to lock the balancing weight after adjustment. ALL JOINTS IN THE AIR INTAKE ASSEMBLY MUST BE SECURELY FASTENED. THE MAXIMUM LENGTH OF FLEXIBLE AIR INTAKE DUCT, WHICH CAN BE RUN TO THE BURNER, IS TWENTY FEET PLUS THE LENGTH T
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15 DIRECT VENT OIL BURNERS Riello Burners All Riello direct vent burners are shipped with the nozzle for the SLD375 installed. A separate nozzle is included in the burner carton for the SLD4100 and SLD5125. See the burner set up page or the Installer Serviceman Label attached to the boiler. for the appropriate burner settings. Boilers supplied with Riello burners will also be supplied with a 3” to 4” galvanized adapter. The adapter is to be fastened directly to the flange open
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16 Oil Tank and Piping Oil tanks and piping should be installed in accordance with the National Board of Fire Underwriters and local codes. Connection of the flexible oil line to burner must be positioned to permit easy opening of the burner swing door. Use continuous heavy walled copper tubing with flare fittings only. Do not use compression fittings. Do not run overhead fuel lines from tank to oil burner. Fuel pump supply and return connections should be made according to
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19 Swing Door Opening the Door 1. Turn off power to boiler. 2. Allow boiler to cool down. 3. Unplug the burner power cable at factory-supplied burner Molex plug electrical disconnect. 4. Lift the front jacket panel up and off the boiler. 5. Remove the four nuts from swing door studs. 6. Swing open burner door to the left while gently lifting to prevent rubbing of door studs. Closing the Door 1. Swing burner door to right while lifting at the burner to prevent the door from rubbing o
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20 Carlin 90200A Temperature Control 1. The Carlin 90200A temperature control functions as a high limit only. Start-Up Warning…Use only … No. 2 fuel oils. Note: Do not attempt to start the burner if excess oil has accumulated. Note: Do not use gasoline, crankcase draining or any oil containing gasoline. 1. Make sure that normal water level has been obtained in the boiler and system. 2. Check that all safety devices are in place. 3. Check that thermostats are correctly c
