Boyertown Furnace SL375 manual

INSTALLATION AND OPERATOR’S MANUAL SL375 T HRU SL7175 O IL F IRED C AST I RON BOILERS Keep these instructions with the boiler at all times for future reference B OYERTOWN F URNACE C O . PO Box 100 B OYERTOWN, PA 19512 1-610-369-1450 www.boyertownfurnace.com 1-10-06[...]

2 Be Aware of Hazard Definitions Denotes presence of a hazard which, if ignor ed, will result in severe personal injury, death or property damage Dan g e r Denotes presence of a hazard which, if ignored could result in severe personal inju ry, death or substantial property damage. Warnin g Denotes the presence of a hazard, which if ignored, could r[...]

3 Table of Contents Ratings and Data……………………………… … ……………………………………4 Clearances…………………………… ………………………………………..............5 Ventilation and Combustion Air………………………………………………………5 Boiler Assembly…………?[...]

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 [...]

5 Installation Clearances Boilers in rooms shall be installed with the clearances from combustible materials not less than in dicated below. Com bustible ma t e r i a l s a r e t h o s e m a d e of o r su r f a c e d w i t h wo od , com pre ssed p ape r, p lan t fibe rs, pl ast ics , or oth er material that will ignite and burn, whether flame proof[...]

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 a ll air is provided from the outdoors, the confined space shall be provided with two perman ent openings, one commencing within 12 inches from the top, and[...]

7 the crated boiler to the carrier in good cond ition. ANY CLAIMS FOR DAMAGE OR SHORTAGE IN SHIPMENT MUST BE FILED IMMEDIATELY against the carrier by the consignee. Temperature Controls Inst allation and Adjustment 1. After cabinet installation is complete install the te mperature control on the right side of the b oiler. a) Carlin Aquastat – Att[...]

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 ar e fastened in place with the 10mm nuts provided. 3. Mount top brackets o[...]

9 System Piping Important… INSTALLATION MUST BE PERFORMED BY T ECHNICALLY QUALIFIE D 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 suppor ted and placed so that th[...]

10 VENTING Failure to follow all in structions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death. All chimneys m ust meet the requirements of NFPA 211 and NFPA 31 WARNING Chimney The boiler must be connected to an adequate chimne y or an approved venting system in accordance with these instructio[...]

11 Evidence of potential or existing chimney dam age should be determined by visua l inspection of the chimney and liner. Exterior indicators such as missing or loo se mortar/bricks, white deposits on the brick or water stains on the interior building walls should be invest igated further. The operational flue temperatures for boilers range from 35[...]

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 negat ive .04” W.C. Two or more oil burni[...]

13 3. COMBINATION AIR INTAKE/VENT SYSTEM The vent system consists of 10, 15, or 20 foot leng ths 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[...]

14 The purpose of the damper is to act as a vacuum break er 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[...]

15 DIRECT VENT OIL BURNERS Riello Burners All Riello direct vent burners are shipped with th e nozzle for the SLD375 installe d. A separate nozzle is included in the burner carton for the SLD4100 and SL D 5125. See the burner set up page or the Installer Serviceman Label attached to the boiler. for the appropriate burner settings . Boilers supplied[...]

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 perm it easy opening of the burner swing door. Use continuous heavy walled copper tubing with flare fittings only. Do not use compression fitt[...]

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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-su pplied 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 gentl y lifting to p[...]

20 Carlin 90200A Temperature Control 1. The Carlin 90200A temperature control functions as a high l imit 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 h[...]

21 2. Direct vented – Take a draft reading from the inspec tion port of the boiler. This over-fire reading will be a positive pressure. Approximate over- fire draft r eadings can be found i n the burner settings table. 3. Pump pressure – Install a pump pressure gauge in the oil pump following the oil burner manufacturer’s recommendations. Adj[...]

22 1. High limit control - Remove the temperature control cover as needed and note temperature setting. With the burner running reduce the high limit setting un til the burner shuts off. Return the high limit to its original setting. 2. To check the primary control and flame sensor shut off oil supply w ith hand valve while burner is running, fifte[...]

23 2. Clean nozzle assembly and all air handling parts. 3. Check spacing and condition of ignition electrodes. Cl ean and replace as required. 4. Nozzles should be inspected every year for plugged orifices. If it is necessary to replace the nozzle, use only the specified nozzle to be sure that the replacement meets spray specifications for the boil[...]

24 Trouble Shooting Guide Burner Will Not Start T h erm o st at S et A bove R oom T em p er at u r e H i gh Lim i t S e t on A qua s ta t t o 180 D e g. M i n. 110 V ol ts be tw e e n L 1 an d L 2 at A qua s t at 110 V ol ts be tw e e n B1 an d B2 at A qua s ta t 110 V ol ts a t Bu rn e r Refe r to Oi l B ur ne r M a nua l Ad j u st T h erm o st at[...]

25 Burner Goes Off On Safety Oi l T ank Ful l B leed O il L in es Oi l Fl o w s Fr e e l y A ir in Oil L in es Pu m p Pressu re to B u rn er S p ec. Spar k Es t abl i s he d N oz z le C lea n Matc he s Bu rne r S ettin g A ir S e ttin g M atch Pre lim in ary Se t t i ngs F ill T a n k Fue l Suppl y V a l v es O p en Ope n A l l Suppl y Va l v e s O[...]

26 Item Qty. Description SL375 SL4100 SL52 15 SL6150 SL6175 1 1 Riello F-5 Oil Burner 541151 5 41147 541148 541149 N/A 1 1 Beckett NX Oil Bu rner 541160 5411 61 541162 541163 541164 1 1 Beckett AFG Oil Burner 541170 541171 N/A N/A N/A 1 1 Heatwise PK-2 O il Burner 542245 5422 45 5422 45 542245 542245 1 1 Heatwise SU2A Gas Burner 542243 5422 43 5 42[...]

27 Solaia Residential Cast Iron Boiler Warranty First Year Limited Warranty for Solaia Residentia l Ca st Iron Water Boiler s Boyertown Furnace warrants that its reside ntial cast iron water boilers are free from de fects in material and workmanship under no rmal usage for one year from the date of origin al installation. If any parts are found to [...]

28 Installation and Se rvice Check List Boiler Model: __________ _____________ Serial No.: ______________ ______ Installation Date: ______________ ________ Installer Name: _______________ _________ Phone No.: ________ ____________ Boiler Installation □ □ Boiler and burner wired per wiring diagram and National Electric Code? 120VAC wiring Type__[...]

29 -----------------Cut and Return This Form or regist er online at www.boyertownfurnace.com----------------- Warranty Registration Boyertown Furnace Co. P.O. Box 100 Boyertown, PA 19512 Date Installed: _________________ __________ Boiler Model No.______________ ___________ Serial Number: ________________ ________ Name of Purchaser: _________ _____[...]

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