Boyertown Furnace Solaia SL375 Setup guide

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
BOYERTOWNFURNACECO.
PO Box 100
BOYERTOWN, 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 ignored, 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 injury,
death or substantial property damage.
Warnin
g
Denotes the presence of a hazard, which if ignored, could result in minor personal
injury or property damage
Caution
Intended to bring attention to information, but not related to personal injury or property
damage.
Notice
Warnin
g
This equipment must be installed, adjusted, serviced and started only by a qualified service
agency – an individual or agency, licensed and experienced with all codes and ordinances, and who
is responsible for the installation and adjustment of the equipment. The installation must comply
with all local codes and ordinances and with the latest revision of the National Fire Protection
Standard for Oil Burning Equipment, NFPA 31.
Dan
g
e
r
Read all instructions before proceeding. Follow all instructions completely. Failure to follow these
instructions could result in equipment malfunction causing severe personal injury, death or
substantial property damage.
Do not alter this boiler in any way. The manufacturer will not be liable for any damage resulting
from changes made in the field to the boiler or its components or from improper installation.
Failure to comply could result in severe personal injury, death, or substantial property damage.
Your oil fired boiler is designed to burn No. 1 and No. 2 heating oil only. Never use gasoline or a
mixture of gasoline and oil.
Do not store gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliance.
The area around the boiler should be kept free and clear of combustible materials.
Never burn garbage or refuse in your boiler.
Never try to ignite oil by tossing burning papers or other material into your boiler.
Do not attempt to start the burner when excess oil has accumulated or the boiler is full of vapors.
D
o not operate boiler if the heat exchanger is damaged.
Do not jumper, attempt to bypass or override any of the safety limit controls.
Do not use this boiler if any part has been under water. Immediately call a qualified service
technician to inspect the boiler and replace any part of the boiler, control system or burner that has
been under water.
All installations must conform to the requirements of the authority having jurisdiction. Such
applicable requirements take precedence over the general instructions of this manual.
Where required by the authority having jurisdiction, the installation must conform to the American
Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1.
Concealed Damage- If you discover damage to the burner, boiler or controls during
unpacking, notify the carrier at once and file the appropriate claim. When calling or writing about
the boiler please have the following information available: the boiler model number and serial
number which is located on the upper left front of the unit. Record the model and serial number for
future reference in the space provided in this manual.
NOTICE

3
Table of Contents
Ratings and Data………………………………………………………………………4
Clearances……………………………………………………………………..............5
Ventilation and Combustion Air………………………………………………………5
Boiler Assembly……………………………………………………………….............6
Temperature control Installation and Adjustment
BoilerTrimPiping
Jacket Installation
System Piping………………………………………………………………...……….9
Bypass Piping
LowWaterCut-Off
ReliefValves
Expansion Tanks
Venting Systems……………………………………………………………………...10
Chimney Venting
DirectVenting
Burner Installation……………………………………………………………….…...14
Oil Tank and Piping……………………………………………………………….….15
. Wiring…………………………………………………………………………..……..15
Swing Door……………………………………………………………………..……..18
Opening the Door
Closing the Door
Door Hinge Reversal
Operation………………………………………………………………………..……..18
Sequence of Operation
Start Up
Start Up Equipment
Burner Adjustments
Control Circuit Safety Checks
Maintenance……………………………………………………………………..…….21
Boiler
Oil Burner
Vent System
Domestic Water Tank……………………………………………………………..…..22
.. Trouble Shooting Guide………………………………………………………..……...23
Parts Diagrams…………………………………………………………………..……..25
Warranty …………………………………………………………………………..…..26

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 86.5 86.5 86.9 86.9 86.9 85.0
Water Capacity 3.6 3.6 4.3 4.3 5.1 5.1 5.8 6.5
Approx. Shipping Weight 300 300 350 350 390 390 430 470
Cabinet Height 28 7/8" 28 7/8" 28 7/8" 28 7/8" 28 7/8" 28 7/8" 28 7/8"
Cabinet Width 17 3/4" 17 3/4" 17 3/4" 17 3/4" 17 3/4" 17 3/4" 17 3/4"
Cabinet Length 19 1/4" 19 1/4" 22 3/4" 22 3/4" 26 1/4" 29 3/4" 33 1/4"
Supply Outlet Height C.L. 25 3/8" 25 3/8" 25 3/8" 25 3/8" 25 3/8" 25 3/8" 25 3/8"
Return Outlet Height C.L. 4 1/2" 4 1/2" 4 1/2" 4 1/2" 4 1/2" 4 1/2" 4 1/2"
Flue Outlet Diameter 6" 6" 6" 6" 6" 6" 6"
Flue Outlet Height C.L. 20 3/4" 20 3/4" 20 3/4" 20 3/4" 20 3/4" 20 3/4" 20 3/4"

5
Installation Clearances
Boilers in rooms shall be installed with the clearances from combustible materials not
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.
WARNING
The boiler must not be installed on combustible flooring. The boiler is approved for installation on
non combustible flooring only. The boiler must not be installed on carpeting or vinyl flooring
Minimum clearances to combustible construction are as follows:
TOP - 24 IN.
FRONT - 12 IN.
FLUE CONNECTOR SINGLE WALL VENT PIPING - 9 IN.
FLUE CONNECTOR DOUBLE WALL INSULATED DIRECT VENT PIPING – 2”
REAR - 2 IN.
SIDES - 2 IN.
Consult NFPA-31 for construction techniques where the above minimum clearances cannot be obtained
Minimum recommended clearances for service and access are as follows:
TOP - 24 IN.
FRONT - 24 IN. FROM BUNER
FLUE CONNECTOR - 9 IN.
REAR - 18 IN.
SIDES - 12 IN.
Note: When installed in a utility room, the door should be wide enough to allow the largest boiler part to
enter, or to permit replacement of another appliance such as a water heater.
Ventilation and Combustion Air
Warning…Air openings to combustion area MUST NOT BE OBSTRUCTED. Adequate
combustion air must be supplied at all times.
Ventilation of boiler room must be adequate enough to provide sufficient air for combustion.
When a boiler is located in an unconfined space in a building of conventional frame or masonry construction
infiltration may provide adequate air for combustion and ventilation. If there is any doubt, install air supply
provisions for combustion and ventilation in accordance with section 5.3, Air for Combustion and
Ventilation, of the NFPA54 1988 code, it is recommend that you follow, the applicable provisions of the
local building codes as well.
When a boiler is installed in a confined space, in a building of unusually tight construction, air for
combustion and room ventilation must be obtained from the outdoors or from spaces freely communicating
with the outdoors. A permanent opening or openings having a total free area of not less than 1 square inch
per 5,000 BTU per hour of total input rating of all appliances shall be provided. Ducts may be used to convey
make-up air from the outdoors and shall have the same cross-sectional area of openings to which they are
connected.
When air for combustion and room ventilation is from inside buildings, the confined space shall be provide
with two permanent openings, one starting 12 inches from the top and one 12 inches from the bottom of the
enclosed space. Each opening shall have a minimum free area of 1 square inch per one thousand (1,000)
BTU per hour of the total input rating of all appliances in the enclosed space, but must not be less than one

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 spaces (crawl or attic) that freely communicate with the outdoors. One of the
following methods must be used to provide adequate air for ventilation and combustion.
1. When directly communicating with the outdoors, each opening shall have a minimum free area of 1
square inch per 4,000 BTU per hour of total input rating of all equipment in the enclosure.
2. When communicating with the outdoors by means of vertical ducts, each opening shall have a minimum
free area 1 square inch per 4,000 BTU per hour of total input rating of all appliances in the enclosed
space.
3. If horizontal ducts are used, each opening shall have a minimum free area 1 square inch per 2,000 BTU
per hour total input rating of all appliances in the enclosed space.
4. When ducts are used, they shall be on the same cross sectional are as the free area of the openings to
which they connect. The minimum dimensions of rectangular air ducts shall not be less than 3 inches.
In calculating free area using louvers, grills or screens for the above, consideration shall be given to their
blocking effect. Screens used shall not be smaller than ¼ inch mesh. If free area through a design of louver
of grill is known, it should be used in calculating the size opening required to provide the free area specified.
If the design and free area is knot known, it may be assumed that wood louvers will have 20-25% free area
and metal louvers and grills will have 60-75% free area. Louvers and grills shall be fixed in the open
position or interlocked with the boiler so that they are opened automatically during boiler operation.
Boiler Assembly
LOCATE BOILER…in front of final position before removing crate.
PROVIDE A LEVEL SOLID BASE as near chimney or direct vent as possible and centrally located with
respect to the heat distribution system as practical.
The boiler must be placed within distances from boiler room walls and ceilings that comply with existing
building codes and for ease of service.
THE BOILER IS SHIPPED AS A PACKAGED UNIT OR A KNOCK DOWN UNIT
THE PACKAGED BOILER IS SHIPPED IN TWO PACKAGES.
a. Boiler and Cabinet Assembled and Crated
b. Burner/Parts Box – Includes burner, aquastat and trim piping
THE KNOCK DOWN BOILER IS SHIPPED IN THREE PACKAGES
a. Casting strapped to a skid
b. Cabinet Parts Box
1. (2) Upper mounting brackets
2. (2) Lower mounting brackets
3. (4) Lower mounting spacers
4. (1) Right side panel
5. (1) Left side panel
6. (1) Rear panel
7. (1) Top panel
8. (1) Front door panel
9. (15) Sheet metal screws
10. (2) Plastic anti short bushing
c. Burner/Parts Box – Includes burner, aquastat and trim piping
LOCATE THE BOILER in the position to be assembled and piped.
Remove crate, plastic protective wrapper and INSPECT FOR DAMAGE. All equipment is carefully
manufactured, inspected and packaged by experienced workers. Our responsibility ceases upon delivery of

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) Honeywell L7248A1000 – Remove sensor wires which are fed through the 1/2” box connector.
Attach the aquastat to the 1/2” box connector. Remove jacket top panel. Loosen and remove the wire
clamp on the immersion well and remove sensor wires from the immersion well. Run the sensor lead
through the aquastat and reinstall into the immersion well. Replace the wire clamp and tighten to secure
sensor leads in the immersion well.
c) Honeywell L7248C1022 – Remove sensor wires which are fed through the 1/2” box connector.
Remove the 1/2” box connector from the jacket side panel and insert the Heyco bushing in the hole.
Run the sensor wires through the hole in the jacket panel. Attach the aquastat to the jacket side panel
using sheet metal screws and the holes provided in the jacket panel. The sensor wires should be run
through the bottom knockout in the aquastat. The rubber grommet provided with the sensor wires is to
be securely inserted into the aquastat knockout.
2. Connect the sensor leads to the appropriate temperature control terminals.
3. Connect your line voltage and thermostat wires if applicable to the control. See electrical diagrams for
proper connections.
4. Honeywell L7248 - The overall range of the High Limit is from 1300F to 2200F. Typically it would be
set in the range of 1800F to 2000F.
5. Carlin 90200A- A manually adjusted potentiometer is used to set the High Limit, typically it would be
set in the range of 180oF to 200oF. The high limit differential is preset to 250F
Boiler Trim Piping
1. Knocked down- Install the ¾” temperature control immersion well in upper right side tapping of the rear
boiler section. Install the temperature sensor all the way into the well until it hits bottom and fasten in
place with the retaining clip (Honeywell) or retaining nut (Carlin) as provided.
2. Pipe in pressure relief valve with ¾” street elbow and with the ¾” x 3” nipple in upper left side of the
rear section. Relief valve discharge must be piped to a safe place of discharge.
3. Pipe in boiler drain with ¾” x ½” reducing coupling and the ¾” x 3” nipple in the lower left side rear
section.
4. Install ¾” pipe plug in the lower portion of the front section.
5. Knocked down – Pipe in boiler gauge with ½” x ¼” reducing bushing in upper front section.

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 bushings into the holes on the right hand
side in the upper brackets.
4. Install right side jacket panel to the upper and lower brackets with sheet metal screws provided.
5. Install the ½” electrical connector required for the Carlin control or the Honeywell L7248A1000
through the hole in the front part of the right side jacket panel and tighten in place with the locknut
provided. Install the Heyco bushing in the hole when using the Honeywell L7248C1022.
6. Install the left side jacket panel, to the upper and lower brackets with the sheet metal screws provided.
7. Install the Honeywell L7248A1000 aquastat onto the box connector using the clamping screw or screw
the Honeywell L7248C1022 directly to the right side jacket panel.
8. Install the sensor wires.
a) Honeywell L7248A1000 – Run the sensor wires through the hole in the aquastat and out the box
connector. Run the sensor wires through the holes in the upper brackets and insert into
immersion well. Fasten the wires into the well using the wire clamp provided. Snap sensor
wires into control.
b) Honeywell L7248C1022 – Run the sensor wires through the Heyco bushing. Run the sensor
wires through the holes in the upper brackets and insert into immersion well. Fasten the wires
into the well using the wire clamp provided. Remove one of the unused knockouts in the
bottom of the aquastat. Insert sensor wire through the knockout securing with grommet
supplied. Snap sensor wires into control.
c) Carlin Control – Install the box provided with the control onto the box connector. Run the
sensor wires through the hole in the aquastat and out the box connector. Run the sensor wires
through the holes in the upper brackets and insert into immersion well. Fasten the wires into the
well. Insert sensor wires into control.
9. Install the top panel by sliding it in from the front catching the top panel’s lower edge under the sides
upper edges. Slide back till the top drops over the back edge, fasten with the sheet metal screws
provided.
10. Install the back panel with the small notches facing up and fasten with sheet metal screws provided.
11. Install the jacket front panel by lining up the (4) mounting screws on the front of the two sides with the
keyhole slots on the front panel and lower in to place.
12. Transfer the boiler serial number located on the left front leg onto the rating label on the jacket front
panel in the upper left corner.
(
2
)
To
p
Brackets
(4) Bottom
Bracket Spacers
Immersion Well/
Sensor Leads Anti-Short
Bushin
g
s
(2) Bottom Brackets

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
RETURN WATER TEMPERATURE COULD OPERATE BELOW 130ºFFOR EXTENDED
PERIODS OF TIME.
The Solaia boiler is a highly efficient low mass boiler in which care must be taken to ensure that high
volumes of low temperature water are not introduced into the boiler. Operating at return water temperatures
below 130ºF for extended periods of time will allow for the accumulation of condensation, scale and
increased soot formation in the boiler. Corrosion and eventual heat exchanger failure will result. A
thermostatic bypass valve is highly recommended on high water volume standing cast iron systems.
A thermostatic bypass valve will consistently ensure that return temperatures to the boiler exceed 130oF at
all times. See Figure 1 for Thermostatic Bypass valve piping.
Instead of using a thermostatic bypass, bypass piping may be accomplished by placing a 3/4” bypass line
with a throttling valve for regulation between the supply piping and return piping. Boiler return water
temperatures must exceed 130ºF with the bypass properly adjusted.
Low water cut off
Hot water boilers installed above radiation level must be provided with a low water cut off device at time of
the boiler installation.
Relief Valves
Relief valves are to be properly piped in to conform to code standards. Discharge piping from the relief
valve must be piped to a drain or must terminate 6” above the floor to eliminate damage to the structure or
personal injury. It must not be piped to a point where freezing may occur.
Expansion Tanks
The expansion tank must be properly sized to the system requirements. An undersized expansion tank will
cause system water to be lost through the relief valve and make up water to be introduced through the fill
valve. Continual introduction of fresh water will cause boiler failure.

10
VENTING
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
WARNING
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" W.C. flue draft and having the capacity to handle the amount of flue gas that is
introduced. A chimney with an internal construction of corrosion resistant tile, stainless steel, or some other
material that will withstand flue gas temperatures up to 10000F is required.
Masonry and metal chimneys shall be constructed in accordance with applicable building code
requirements. Masonry chimneys shall be lined with an approved clay tile liner or a listed chimney lining
system installed in accordance with manufacturers’ instructions and also meeting the requirements of
NFPA-211 Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances. Metal chimneys
also shall meet the requirements of NFPA-211. Factory built chimneys shall be listed and shall be installed
in accordance with their listing and NFPA-211.
Prior to installation of the boiler, the chimney or venting system shall be examined by the installer and
determined to be in good condition. All joints of the chimney must be tightly sealed. The inside of the
chimney should be free of all obstruction, such as loose brick, broken pieces of tile, or corroded metal. If
chimney flues are divided or there are multiple flues within one chimney, make sure there are no openings
in the partition separating the divided or individual flues. When a new appliance is connected to an existing
chimney, that chimney shall be brought up to current requirements. Chimneys which are relined shall be
done so with an approved liner that will resist corrosion, softening, or cracking from the flue gasses.
All chimney clean-out doors and flue connections must fit tightly so they will seal to avoid air
leakage.
The inside area of the chimney liner should equal, at a minimum, the area of the vent pipe exiting the
furnace. If more than one appliance is installed, the area of both appliances shall be used in determining the
required inside area of the chimney.
The flue gas exit of a chimney shall be at least 3 feet above the highest point where it passes through the
roof of a building and at least 2 feet higher than any portion of a building within 10 feet of such chimney.
The chimney height will also be determined by the height of the surrounding trees, buildings and terrain.
When chimney downdraft conditions cause faulty operation that creates a hazard, corrective steps must be
taken.
When altering the surrounding obstructions is not possible, a chimney cap can be constructed on the top of
the chimney to avoid downdrafts. The chimney cap should be pyramid shaped on the top with a perfectly
flat surface immediately above the chimney outlet. The hood should be attached by four (4) iron supports.
The four iron supports should be equal in height to the width of the chimney opening. Four plates, flaring
down, can be added to help insure that the wind will pass straight over the chimney outlet.
Chimney Relining
A tile lined masonry chimney serving an oil fired boiler should comply with applicable building codes such
as NFPA-211. An additional listed lining may be required to reduce transient low draft during startup and
acid water condensation during cyclic operation. This is particularly true for high mass masonry chimneys
serving oil fired furnaces of higher efficiency. For masonry chimneys, local experience can indicate how
well construction has withstood the lower temperatures produced by higher efficiency furnaces.

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
boilers range from 350ºF to 450ºF at the outlet of the boiler. These temperatures are further reduced before
reaching the chimney due to heat loss through the vent connector and dilution from the draft regulator. The
resulting flue gas temperatures may become low enough to form condensation on the chimney liner walls.
To prevent condensation, it is necessary that the internal chimney wall temperature always be kept above the
dew point of the flue gasses. If the chimney is a masonry type, it may have to be lined with a flue liner, if
the temperature loss is too great for the boiler. A liner will act as an insulator and reduce the flue gas
temperature loss. Insulation may be added around the liner for further temperature stability. Refer to NFPA-
31 for recommended liner sizing tables as developed by the Oil Heat Vent Analysis Program.
Chimney Connector
The chimney connector pipe between the boiler and chimney shall be of equal diameter as the flue outlet of
the boiler. Refer to boiler specifications in this manual for proper size flue pipe for your model boiler. Any
reduction in size required for the chimney must be made at the chimney connector. The vent connector pipe
must be made of 24 gauge (or thicker) corrosion-resistant steel. The vent connector pipe should be as short
as possible and installed so that it has a continuous rise from the boiler to the chimney. Long horizontal vent
runs can result in the possibility of condensation in the flue pipe or the chimney. All horizontal runs of vent
connector pipe should be pitched upward a minimum of 1/4 inch per foot of run. The horizontal length of
the vent pipe connector shall not exceed 10 feet. The chimney connector shall be installed so as to minimize
the number of elbows and to avoid sharp turns or other construction features that would create excessive
resistance to the flow of flue gasses. Tees may be used in a straight section in conjunction with a barometric
draft regulator; however, they must not be used for a 90° turn. No device that will obstruct the free flow of
flue gasses shall be installed in the chimney connector. This does not exclude the use of devices specifically
designed for the use in chimney connectors such as automatic dampers. The vent pipe should be joined
with metal screws and supported by straps. A thimble should be used to connect the vent connector pipe to
the chimney so the pipe may be readily removed in case of inspection or replacement.
No chimney connector shall pass through any floor or ceiling. The vent connector pipe must not pass
through a combustible wall or partition unless they are guarded at the point of passage by a ventilated metal
thimble not less than 12 inches larger in diameter than the connector, on metal or fireclay thimbles adequate
protection is provided at the passageway. An acceptable passageway could be either an approved, ventilated
metal thimble which is at least 12 inches larger in diameter than the vent connector pipe, or brick work
which is at least 8 inches thick constructed into the wall and surrounding the vent connector
Clearances from combustible materials or materials shall be in accordance with the clearances given. The
vent connector pipe should extend only to (and not beyond) the inside wall of the chimney. A thimble
should be used to connect the vent connector pipe to the chimney so that the vent connector pipe may be
readily removed in case of inspection or replacement.
Connection to the chimney must be made above the bottom of the chimney to avoid blockage. Vent piping
should extend just into the chimney far enough to expel flue gasses. Inserting the vent piping too far into
the chimney will cause undue obstruction. Use a thimble or a slip joint where vent pipe enters the chimney
to allow easy removal for cleaning.
If a draft regulator is required in the vent piping; it should be located at least 24 inches from the boiler if
possible in either a horizontal or vertical section of the vent pipe. The draft regulator must be installed in the
same room as the boiler and in such a manner that there is no difference in pressure between the air in the
vicinity to the regulator and the combustion air supply. Ensure that the barometric damper is accessible for
adjustment.

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 safe simultaneous removal of all products of
combustion.
If two or more openings are provided into one chimney, they shall be at different levels on the same story of
the building, with the smaller appliance entering at the highest possible level consistent with clearances to
combustible materials.
Two or more connectors shall not be joined together unless the common connector, manifold and chimney
are properly sized. Adequate draft must be available to safely remove all products of combustion
simultaneously without leakage, or back flow.
Direct Venting
Failure to follow all instructions can result in flue gas spillage and carbon monoxide
emissions, causing severe personal injury or death. All installations must meet the requirements of
NFPA31. Use only the ETL listed venting system components supplied with the packaged boiler. All vent
connections must be securely fastened and sealed with high temperature sealant.
WARNING
External vent surfaces are hot. Surface discoloration of the building may occur due to improper
burner or boiler adjustment. We will not accept any liability for such discoloration.
Caution
Follow all instructions which are included with your specific direct vent kit.
1. Choose the vent location. The preferred location of venting system is on the opposite wall of the known
prevailing winds.
2. The exit terminal of the system must conform to the following guidelines. See figure on following
page.
a. The vent terminal shall not be less than 3 feet above any forced air inlet to the house.
b. The vent terminal shall not be less than 4 feet below, 4 feet horizontally, or 1 foot above any
door window or gravity inlet into the building.
c. The vent terminal shall be installed at least 1 foot above ground. The vent must be
maintained to keep the location 1 foot above any solid surface including snow, ice and
landscape materials. The vent shall not be installed in a window well or any other
fabricated depression.
d. The vent terminal shall not be less than 2 feet from an adjacent building.
e. The vent terminal shall not be less than 7 feet above grade when located adjacent to public
walkways.
f. The vent terminal shall not be located so that flue gasses are directed to jeopardize people or
overheat combustible structures, materials or enter buildings.
g. All joints in the vent system are to be sealed with Permatex high temperature sealer or
equivalent to prevent the leakage of products of combustion into the building

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 thru the wall for the vent termination end should be ¼” larger than the vent termination end
itself or approximately 7 ¼” square.
Install the vent termination thru the opening in the wall centering it in opening. Apply a bead of silicone
caulking around the perimeter of the vent termination end. Attach the termination to the house by
screwing it fast thru the holes in the termination end.
Install the flexible vent piping with the provided connector between the boiler and the termination end.
The joints at the boiler, vent connectors, and termination end should be securely fastened and must be
sealed with high temperature silicone to prevent leakage of flue gasses.
THE MINIMUM DISTANCE TO COMBUSTIBLE MATERIALS FROM THE 5” SINGLE
WALL VENT PIPING IS 9”. THE MINIMUM DISTANCE TO COMBUSTIBLE MATERIALS
FROM THE 5” DOUBLE WALL INSULATED VENT PIPING IS 2”. CONSULT NFPA-31
FOR REDUCED CLEARANCES.
The air intake must be installed to the air inlet collar on the combination vent hood and to the burner.
The air intake kit consists of one 4” galvanized elbow, one 4” galvanized tee, one vacuum relief valve
(barometric damper), and one length of 4” flexible piping.
The vacuum relief valve (barometric damper) is to be assembled and then installed in the 4” tee with the
hardware provided. Install the fresh air intake duct tee and damper as close as possible to the burner.

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 THAT RESULTS FROM THE 4” TEE AND 4”
ELBOW SUPPLIED.

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 opening on the burner cover using three sheet metal
screws.
The Riello BF5 burners for use with direct vent systems are shipped with the controls, which provide
pre and post purge. Pre purge is provided to ensure clean starts under all conditions. Post purge is
provided to ensure that the boiler fires at maximum efficiency and dependability throughout the heating
season. Post purge timing is variable. The factory set post purge timing should be set at
approximately 45 seconds. Post purge times in excess of 60 seconds when using the Riello burner
will cause the Honeywell Aquastat to lock out on an error code Err4 B1 fault.
Beckett Burners
Boilers supplied with the Beckett NX burner are supplied with an inlet air adapter which must be
installed in place of the inlet air louvers. Refer to the Beckett NX burner manual.
Beckett NX burners for use with direct vent systems are shipped with the controls, which provide pre
and post purge. Pre purge is provided to ensure clean starts under all conditions. Post purge is provided
to ensure that the boiler fires at maximum efficiency and dependability throughout the heating season.
Post purge of the oil burner is controlled through the electronic circuitry supplied on the oil burner
primary control. The factory set post purge timing is set at approximately one minute.
Burner Installation
The burner is mounted to the door with (4) 8mm studs, nuts and washers (located in the burner trim bag).
Thread the (4) studs in to the (4) M8 holes threaded to permit connection to the burner. Thread the shorter
length of stud into cast door.
Check that the correct nozzle is properly installed in the burner as shown in the preliminary burner settings
and that the burner electrode are adjusted as per the oil burner manual.
When using the Beckett AFG oil burner on the three or four section boiler, the opening in the
refractory on the door must be enlarged to insert the oil burner without damaging the door
refractory. Use a sharp utility knife to carefully trim the opening to size.
The oil burner when properly installed will extend beyond the refractory liner of the burner door.
Riello - will extend approximately 2” beyond the refractory on the swing door.
HeatWise - will extend approximately 3” beyond the refractory on the swing door.
Beckett AFG - will extend approximately 4-1/8” beyond the refractory on the swing door.
Beckett NX - will extend approximately 2-3/4” beyond the refractory on the swing door.
Check that there is a complete seal between the door and the burner flange after installing ceramic fiber seal
furnished with the burner.
Place burner Installer/Serviceman label on boiler jacket front panel as required.

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 instructions attached to the fuel
pump.
An oil line filter and shut-off valve should be installed in the suction line.
On a two- pipe system you will need to supply a second approved flexible oil line in order to be able to
swing the burner door open without disconnecting oil lines. An optional flexible oil line is available through
your distributor.
Electrical Wiring
ELECTRICAL WIRING MUST CONFORM TO THE NATIONAL ELECTRICAL CODE,
ANSI/NFPA No. 70-1990 AND LOCAL CODES.
THE BOILER MUST BE ELECTRICALLY GROUNDED AND ON A SEPARATE FUSSED
DISCONNECT SWITCH.
ELECTRICAL SHOCK IS HAZARDOUS. TURN OFF ALL POWER SUPPLIES AT SERVICE
ENTRANCE BEFORE STARTING TO MAKE WIRING CONNECTIONS OR REPAIRS.
Refer to wiring diagrams in rear of manual for electrical connections. The boiler should be connected by a
separate, permanently live electrical supply line with a 15 amp fused rating. Use No. 14 AWG wires rated
for at least 90o C. Install a separate fused disconnect switch near the boiler so power can be shut off for
servicing.
Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after servicing.
Install the room thermostat on an inside wall away from fireplaces, appliances or sunlight. Set the heat
anticipator according to the instructions from the aquastat manufacturer. Connect the thermostat leads to the
“TT” connections on the aquastat control or system control.
The indirect water heater, if used, should be wired in such a fashion that the heat to the building is
temporarily interrupted when there is a demand for domestic water. Commercially available circulator
prioritizing packages are available. Consult factory for their application.

17

18

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 on the lower (2)
8mm studs until the insulation is slightly compressed and the studs are exposed.
2. Install the nuts onto the upper studs.
3. Attach nuts to the lower studs and hand tightening only.
4. Tighten the upper nuts first followed by the lower nuts until a complete seal is made.
Door Hinge Reversal
WARNING:
IN ORDER TO MOVE THE DOOR HINGES SAFELY TO THE RIGHT SIDE YOU MUST MOVE
THE TEMPERATURE CONTROL TO THE LEFT SIDE CABINET PANEL. THIS IS TO INSURE
POWER IS SAFELY REMOVED FROM THE BURNER WHEN OPENING THE BURNER SWING
DOOR. FAILURE TO DO SO MAY RESULT IN PROPERTY DAMAGE OR SERIOUS INJURY.
1. The knock out on the upper left side panel of the cabinet must be removed and a snap plug will have to
be installed to close up the hole for normal aquastat position on the right side jacket panel.
2. Install the box connector into the left side jacket panel.
3. The plastic anti short bushings in the upper brackets must be removed from the holes in the right side
and placed in the holes on the left side of the upper brackets.
4. The ¾” aquastat immersion well must be moved to the upper left rear ¾” tapping and the relief valve
must be installed in the upper right rear ¾” boiler tapping.
5. The 48” sensor wires must be run through the upper left side brackets and through the ½” electrical
fitting in the left side panel.
6. Install the temperature control on the boiler left side jacket panel.
7. Remove the hinges from the left side of the boiler.
8. Remove the 8mm stud from the left lower position and install in the right lower position.
9. Reinstall the hinge brackets using the 8mm bolt for upper hinge and nut and washer on lower hinge.
10. Riello Burner - Remove the burner Molex wiring harness from the right side of the burner and
install on the left side of the burner.
Beckett Burner – Remove the Molex wiring harness from it’s existing position in the burner
junction box and place it in the knock out marked number 2.
Operation
Sequence of Operation
Honeywell L7248 Aquastat Control.
1. If the room temperature or indirect water heater falls below the thermostat setting and calls for heat
starting the burner and circulating pump. The burner and pump will continue to operate until the room
heating or domestic water requirements are met. In the event the boiler water temperature reaches the
High Limit setting the burner will shut off with the circulator continuing to operate. If the thermostat
continues to call for heat and the boiler temperature falls below the High Limit setting the burner will
restart.

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 connected and set.
4. Check that the inside of the boiler is free of any fuel residue or foreign materials and that the ceramic
fiber insulation on the burner door has not been damaged.
5. Check oil burner nozzle to ensure that the right size and type is installed and tight in the adapter. See
preliminary settings for proper nozzle size and type.
6. Check electrode settings, as they may have been jarred out of position during transportation. See oil
burner instructions for nozzle and electrode setting
7. Check that the Burner mounting bolts are tight.
8. Lubricate burner motor and circulator motor if required.
9. Open all oil lines valves.
10. Set room thermostat to call for heat.
11. Set aquastat high limit between 180oF and 200oF
12. Turn service switch on. Burner should start. On one pipe fuel system only you may have to bleed the oil
system. To bleed attach a clear plastic tube to the oil pump bleed port and allow oil to run until all the
air is out of the oil suction line feeding the oil burner. See burner and fuel pump manufacturers
recommendations for proper bleeding of the fuel system.
13. Turn “OFF” burner and install pressure gauge into the gauge port on the pump. See the burner
manufacture’s manual for location of ports.
14. Start burner again and check oil pressure for conformance to preliminary oil burner settings. Adjust if
necessary. See oil burner manufacturer’s instructions for pump adjustment.
Start-up Equipment
THE FOLLOWING PROPER COMBUSTION INSTRUMENTS ARE REQUIRED TO DETERMINE
PROPER AIR ADJUSTMENTS AND DRAFT WHEN SETTING UP OR SERVICING THE OIL
BURNER.
1. CO2Analyzer
2. Draft gauge
3. Fuel pressure gauge
4. Stack thermometer
5. Smoke tester
Do not attempt to make any adjustments or start the boiler without the proper equipment.
Burner Adjustments
Allow the burner to operate for at least 15 minutes and then make the following adjustments.
1. Chimney vented– A 5/16” diameter hole will be required in the flue pipe between the boiler and the
barometric damper as close to the boiler as possible. Set the draft regulator (barometric damper) using a
draft gauge to obtain a negative draft in the flue pipe of -.02 to -.04 in. W.C. Take a draft reading from
the inspection port of the boiler. This over-fire reading will be a positive pressure. Approximate over-
fire draft readings can be found in the burner settings table.