Brant Steel FLEETLINE AQUA-MATIC SERIES Manual

Family Owned & Operated
FLEETLINE AQUA-MATIC SERIES
HOT WATER BOILER
NATURAL GAS - OIL - PROPANE
INSTALLATION AND SERVICE MANUAL MUST
BE LEFT WITH HOME OWNER.
These instructions have been reviewed by ETL.
ITS/ETL Listed and tested to the following standards:
- CSA - B140.7.1-1976, UL-726 (Seventh Edition) - CSA - B140.0M87
- CSA-B212-93, ASHRAE 103-1993/1996
- CGA-4.9-1969, ANSI-Z21.13b-1994
- CGA-P.2-1991, ASHRAE 103-1993/99-01
49 Craig Street, Brantford, Ontario N3R 7H8
Telephone: [phone] Fax [phone]
E-mail: [email protected]
Website: www.brantsteel.com
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CONTENTS Page
CommitmenttoQualityControl ................................................1
CAnnual fuel Utilization (A.F.U.E.)
CBoiler Sizing
CChimney
CVertical Venting
CAir for Combustion
InstallationInstructions .......................................................4
CGeneral Comment
CFreight Claims
CHeat Loss Sizing
CClearances for Service and Combustible Materials
CDraft Regulator/Draft Hood
CVent System Draft
CCombustion Air Supply Sizing for a High Efficiency Boiler
CCirculation system
CPiping
CBoiler Replacement and Service Caution
CCheck for Polarity
CWiring
CGas Piping
CFuel Oil Supply System
CCheck the Ceramic Combustion Chamber
CCombustion Chamber Curing
CCO2or O2Test
CPump Pressure Oil
CommissionProcedure .......................................................11
Homeowner'sOperatingTips..................................................12
Fleetline Boiler Ratings (Oil) ..................................................13
FleetlineBoilerRatings(Gas)..................................................14
APPENDIX
Servicing the Fleetline Boiler
Trouble Shooting Guide
Piping Schematics
Wiring Schematics
Warranty for Aqua-Matic Boiler

1
To the Consumer
The new Fleetline Aqua-Matic Series Hot Water Boilers were designed to achieve the highest
efficiencies possible without condensing. Condensing heating appliances have inherent problems
that include higher maintenance and reduced product life span. The new Aqua-Matic series of
boilers can utilize fuel oil, natural gas and propane gas for producing efficient residential heating
and reduce the production of "Green House Gases." The Aqua-Matic series boilers were designed
for easy service access that contributes to longer product life and the maintenance of efficiencies in
the 85% plus range. The homeowners' satisfaction is our first concern and we thank you for
choosing an efficient Fleetline boiler.
Sincerely,
Mark Offenhammer
President
The Aqua-Matic Series Fleetline Boilers have been tested and certified to conformto the following
standards: CGA-4.9-1969, ANSI-Z21.13b-1994, CGA-P.2-1991, ASHRAE 103-1993/1996.
Fuel Oil: CSA B140.7.1 1976, CSA-B140.0M87, UL 726 (seventh edition) CSA-B212-93,
ASHRAE 103-1993/1996.
Commitment to Quality
Brant Steel is proud to be able to supply the high quality Fleetline Aqua-Matic Boiler to the North
Americanmarketplace. We are confident thatthepurchaseof the Fleetline Home ComfortPackage
will provide years of efficient, economical, trouble-free operation.
"Quality remains long after the price is forgotten." The Fleetline boiler is a high efficiency
residentialheating appliance with maximumenergy utilization efficiency, without the maintenance
and operations problems and high purchase and installation costs of condensing boilers.
Fuel cost savings can only be achieved by matching the Fleetline boiler to the true heat loss of your
residence. During the past decades, the trend towards improving wall and ceiling insulation levels
and eliminating air infiltration by caulking and weatherstripping, has made most existing heating
appliancesoversized; someas high as 200%! When you purchase a Fleetline homecomfortsystem
your new appliance will be sized on the basis of a new heat loss calculation. This will ensure that
your new Fleetline home comfort system will deliver efficient heat to match your actual heating
demand.
We want to provide you with maximum comfort levels combined with fuel cost savings.
The following are useful bits of information presented under a series of sub-headings.

2
Annual Fuel Utilization Efficiency (A.F.U.E.)
The A.F.U.E. is a measure of the heating appliance's ability to extract heat from oil or gas,
determined over a full heating season. The A.F.U.E. increases as the burner on-time increases until
it reaches "steady-state efficiency" - the efficiency of the appliance measured when the burner is
running. Any time the burner cycles on and off, the A.F.U.E. drops because of "off-cycle" losses.
The A.F.U.E. drops most sharply when the heating plant operates between 10 and 30% burner on
time. An increase in the percentage of burner on-time improves the A.F.U.E.
Boiler Sizing
Most existing heating systems are oversized. Reducing the firing rate of the new boiler results in
longer burner on-times, increased A.F.U.E. and provides significant savings for the consumer. The
improved A.F.U.E. of the Fleetline Boiler is in direct relationship to the changing positions on the
"Burner On-Time/A.F.U.E. Curve" shown. Instead of operating between pointsAandBas in older
installed systems, the new Fleetline Boiler will operate between points C and D when it is matched
to the heat loss of your home.
BURNER ON-TIME / A F U E CURVE:

3
Through wall venting
Toprovideyouwithatotallyefficient,reliableheatingsystemandeliminateoff-cyclelosses,brick,
blockor masonryfluescan be eliminated and a side wall vent system may be utilized. The Fleetline
Aqua-Matic series boiler has been certified for direct vent. Eliminating the barometric damper or
draft hood from the installation of forced draft direct vent systems. This also allows lower input
rates and lower gross stack temperature because of the flue gas dilution before the exhaust is
discharged to the outdoors.
Vertical Venting
The Fleetline Aqua-Matic Boiler may be vented up a chimney or other vertical vent as per the
installation codes.
The boiler flue connector to the chimney should not exceed a length of 10 feet. Insulated vent
connectors should be used to improve the inlet temperature at the base of the vertical vent. No
barometric damper or draft hood should be installed in the vent system.
For chimney heights up to 30 feet, a stainless steel insulated liner shall be used. The riser insulation
shall be 1" thick and chicken wire wrapped for installation inside the chimney.
A base stainless steel tee shall be installed at the base of the chimney liner and may be installed in
the basement if there is sufficient rise from the furnace. The connector pipe shall be connected to
the furnace and the tee with standard insulated vent adapters.
Air for Combustion
The Fleetline boiler must have an assured supply of combustion air. A dedicated outside supply of
air through an installed duct or pipe should be connected on or near the burner air inlet. The
combustion air duct must have direct access to the outdoors and have a rain hood and screen
installed at the outside wall. A 1/4 inch x 1/4 inch screen is the appropriate size mesh.
Where the boiler is to be installed within a home where the operation of exhaust fans, attic fans,
kitchen ventilation systems, new high efficiency clothes dryer or fireplaces may create severe
negativepressuresandunsatisfactorycombustionandventing,specialprovisionshouldbemadefor
additional make-up air to supply the other air requirements.

4
INSTALLATION INSTRUCTIONS
General Comment
The Fleetline boiler is a quality, efficient oil or gas fired heating appliance, which must be installed
and serviced by a trained service technician in accordance with all local codes and building
ordinances.
Gas Codes: Canada - CAN CGA B149 1 & 2
United States - National Fuel Gas Code ANSI Z233-1
Oil Codes: Canada - CSA B139
United States - NFPA-31
Freight Claims
All units should be inspected for damage upon arrival. Concealed damage claims should be filed
against the carrier by the consignee. The carrier is responsible for taking prompt action on all
damage claims!
Heat Loss Sizing
A complete heat loss calculation of the residence that is receiving the new boiler should be
completed. Alternatively, the "K" factor sizing method, which uses past energyconsumptionbased
on the efficiency of the old appliance and local weather data, can be undertaken. Replacement
heatingapplianceinstallationsshouldnotusetheexistingapplianceexclusively,fordetermining
the size of the new appliance. Recent research indicates that existing installed appliances are often
over-sized, resulting in excessive energy consumption. The HRAI heat loss calculation method or
the international boiler radiation IBR method should be completed on a new home installation.
The boiler should be located on a dry solid non combustible level surface preferably as close to the
vent inlet as possible. Vent connector lengths over ten feet do not reflect good installation practice.
It is good practice to raise the boiler 24" to 36" above the finished floor to facilitate ease of service
and shorten piping requirements.
Clearances for Service and Combustible Materials
Service access to the boiler must be adequate. The easier the service access, the higher the quality
of service the unit will receive. Service clearances should be a minimum of 24 in. from the front,
24 in. from the rear and one side and, 6" in. from the other side.
The minimum installation clearances to combustible materials are:
18 in. from rear; 8 in. from front and one side; 2 in. from other side; and 1 in. from vent connector
if it is insulated. Remember if you do not leave adequate room for service it is very difficult to
maintain the boiler in an efficient manner.

5
Draft Regulator/Draft Hood
The Fleetline boiler is installed without a barometric draft regulator or draft hood as the boiler is
equipped with a burner capable of operating against a positive over-fire pressure.
Vent System Draft
The installation of a Shirvent MVP 100 will ensure that you will have sufficient draft for safe and
proper operation of the Fleetline Boiler.
Combustion Air Supply Sizing for High Efficiency Boiler with No Barometric
Damper or Draft Hood
10.16 cm 80,000 BTUH to 100,000 BTUH 4" diameter
12.7 cm 100,000 BTUH to 150,000 BTUH 5" diameter
15.2 cm 150,000 BTUH to 190,000 BTUH 6" diameter
The air intake pipe must be capable of withstanding damage and kinking. Double wall aluminum
flex supported and with long radius bends is recommended. The maximum length of pipe should be
25 ft (7.6) meters where outdoor air temperatures may be severe below 00F (-17.7°C) then it may
be necessary to insulate the combustion air supply duct to retard the condensation on the outside of
the pipe that may drip on to the floor or the boiler.
SPECIAL NOTE:This boiler is approved for use with propane, No. 2 fuel oil, and
natural gas. Never us gasoline or crankcase oil, which may contain
gasoline, as fuel for the heating appliance.
Never attempt to burn garbage or paper in the heating unit and remove
paper and rags from around the unit. For your safety, do not store or
use gasoline or other flammable vapour or liquids in the vicinity of
this or any other heating appliance.
Circulation System
Before connecting the new boiler to an existing steel piping system that is over 40 years old, the
system should be flushed to prevent scale/sludge from returning to the boiler. If the present system
is being converted from a gravity open system, this is a must item. If a high pressure test of the
existing hydronic system is necessary, the boiler itself must not be exposed to the pressure test.
Isolate the boiler during the test.
Piping
The Fleetline Aqua-Matic Series is a low mass boiler and care should be taken to ensure that a high
volume of water shall not be allowed to flood the boiler from a high volume standing cast iron
system. The high volumetric flow will cause combustion problems from cool surface flame
impingement.

6
Boiler Replacement and Service Caution to Ensure Performance
The replacement of old large cast iron boilers and large steel boilers with new modern compact
efficient boilers (sometimes called low mass) can cause problems from excessive corrosion being
produced with low operating water temperatures. Combustion by-products in fuels produce acidic
sulphur oxides which corrode cast iron and steel surfaces, when the oxides condense in a water
solution on the boiler surfaces. The water dew point on the inside surfaces of a boiler is 120°F
(49°C) for fuel oil burning and 140°F (60°C) for natural gas. The amount of acid compound in the
combustion process is dictated by the fuel. However, the presence of chlorides in the combustion
air greatly increases the rate for the production of mild acid compounds that are very active on cast
iron and steel surfaces.
The safest operating temperature range for modern boilers, proven conclusively by tests, is 160°F
(71°C) to 210°F (99°C). Allowing the boiler water temperature to drop below 160°F (71°C) is
asking for increased rates of corrosion due to the acid becoming more corrosive due to dilution with
watercondensate. Theproductionof corrosionfromcoldflametemperaturescanleadtorapidwater
condensate. The rapid production of corrosion from cold flame temperatures can lead to severe
boiler plugging and then to premature boiler failure.
The following step-by-step procedure should be followed for connecting your new Fleetline boiler
to an existing circulation system:
1. Connect the boiler return and supply pipes to the main circulating system as selected. Install
a manual shut-off valve on both the return line and supply line and on the boiler by-pass
loop. Theby-pass loop is a must on all standingcastiron radiation systems. This eliminates
flooding (cold return) on a low mass boiler and gravity flow during off cycles.
2. A.S.M.E. Boiler Code requires feed or make-up water to be introduced to the piping system
and not directly to the boiler. Pressure reducing valves should be installed and adjusted to
15 psi cold water.
3. Maximum operating water temperature 210°F (99°C).
Maximum operating water pressure 15 psi.
4. Pressure relief valve must be piped from the boiler and downward to within 6 in. of the floor
to avoid the potential for accidental face and body injuries.
5. An expansion tank, circulating pump and automatic bleeds must be part of the system.
6. See typical piping diagrams in the appendix.
7. If the expansion tank is an extrol or bladder tank the pressure should be set between 10 psi
to 15 psi in accordance with the height of the system above the boiler (ie.) two storey cast
iron standing system is normally 15 feet. Two storey baseboard fin convector is normally
12 feet above the boiler.

7
Wiring
All external wiring must conform to existing electrical codes laid down by the authorities having
jurisdiction. In the United States these are the B.O.C.A. Codes 2001.3 and 2001.2.3. In Canada,
they are the C.S.A. standard C22-1 and the Canadian Electrical Code.
1. Field connections should be protected with a 15 amp rated fusetron.
2. Install a separate fused disconnect switch as required so power can be shut off for servicing.
3. Ground the boiler to the water piping, unless the water supply is plastic.
4. Install the room thermostat or relocate the room thermostat away from cold drafts, air
currents, lamps, televisions or sunlight. Set the heat anticipator on the thermostat at 0.2
amps, if applicable, or to match the operating control. Connect the thermostat leads to the
circulation pump operating control or aquastat as applicable. See wiring diagrams.
Checking for Polarity
The burners used on the Fleetline boilers have solid state control systems. This means that they are
sensitive to the proper connection of the hot and neutral power lines. The controls will be damaged
if the two lines are reversed.
Do Not Depend on the wiring at the boiler being properly colour coded.
1. Set your volt meter to line voltage.
2. Place one prong on your grounded
electric entry box and one prong on
the black wire.
3. Read the voltage.
4. If the voltage is zero, check the white. If
line voltage shows, reverse the 115 volt
leads entering the boiler junction box
If a meter is not available, a tattle light can be used.

8
Gas Piping
1. Connect gas piping according to ANSI Z223.1 or CAN GGA-B149 and all local codes that
are in place.
2. The burner and its individual shut off valves must be disconnected from the gas supply
piping system during any pressure testing of that system in excess of 1/2 inch PSIG (3.45
KPA).
3. A gas boiler for installation in a residential garage must be installed so the burner and the
ignition source are located not less than 18 inches (45.7 cm) above the finished floor. The
boiler must be located or protected to avoid physical damage from vehicles (ie) raise boiler
48 inches (122 cm) above floor when the potential for damage is severe.
4. The gas supply pressure as shown on the rating plate should be between 5 IN WC. and 9 IN
WC. for natural gas and 11 IN WC. for propane gas.
5. A1/8"N.P.Tpluggedtappingaccessibleforatestgaugeconnectionislocatedonthemanual
gas shut off valve.
The supply pressure should not be allowed to vary as this will effect the input to the boiler
burner.
For installations above 2000 feet (610M) pressure adjustment or orifice change may be
required. Check with gas supplier as to BTU content of gas supplied at altitude.
Fuel Oil Supply System
ObtainingoptimumperformancefromyournewFleetlineboilerrequiresthatthefuelsupplysystem
is in good working order.
1. An old (i.e. in excess of 15 years) fuel supply line should be replaced with new copper
tubing. This will ensure a clean fuel supply.
2. Fuel supply lines must be absolutely airtight. Use only flared fittings and oil resistant pipe
dope on all threaded tank connections. Check all joints and threaded fittings for leaks. Use
a vacuum gauge to proof the installation.
3. Leave the existing felt filter, normally found at the tank, in place. Double filtrations is an
added benefit. Fit the fuel suction line with a high quality paper throwaway cartridge type
strainer; 5 micron to 10 micron maximum rating. The paper filter cartridge should be
mounted on the casing of the boiler. This allows a flexible fuel line to be connected with
adequate slack for easy removal of the oil burner without disconnecting the fuel lines.
4. Install disc type valve in the suction line of a two pipe fuel system.

9
5. A shut-off gate valve must be installed in the fuel supply line located at or near the oil
storage tank in compliance with local codes. The shut-off valve, spindle packing should be
checked for tightness to eliminate potential air leaks into the fuel delivery system. Always
keep the valve shut off if the burner is shut down for an extended period of time. Tag
burnertoindicatefuelsupplyisclosedandremovefusefromelectricalcircuittoeliminate
improper operation due to lack of fuel.
6. A return fuel line must be used on an installation where the fuel level of the tank is always
below the level of a burner. The return line must be equal to the suction line. The minimum
size oil line should be 3/8 in. copper tubing. For runs up to 25 feet (7.6M) 1/2" for runs over
this length.
7. Use fuel storage tanks bearing the label of Underwriters Laboratories and Accessories
prescribed by local codes.
The preceding covers the basic installation of the new Fleetline Aqua-Matic series oil and gas
boilers. Basic wiring and piping arrangements are in the Appendix for your individual installation
requirements. Burner installation and set up instructions are in burner manuals for the set up of the
burner of your choice.
The Appendix also includes the basic rating charts for the boiler both oil and gas and the
commission procedure.
Check the Ceramic Combustion Chamber
Thecombustionchamberhasbeenfactoryinstalled. Beforeinstallingtheburner,checkthechamber
for damage. The position is 2 3/4" from the mounting plate to the front edge of the combustion
chamber. This measurement is important. It allows the combustion head of the burner to be
protected from high temperatures. (Refer to burner manual for insertion length)
WARNING: DO NOT TURN ON THE BURNER UNTIL YOU HAVE CHECKED THE
POLARITY.
Combustion Chamber Curing
Some moisture and binders remain in the ceramic combustion chambers after fabrication. It is
important to clear the chamber of these residues before testing. If you smoke test before curing -the
instrument will fill with condensate and require complete servicing. To cure the chamber run the
unit for 3 consecutive 3 minute cycles using the post purge as the "off-time". The exhaust will have
a pungent odour and produce a white cloud of steam.
Testing the Unit
To provide a high level of customer comfort and unit operating efficiency, each unit must be tested
after the installation has been completed.

10
Required Test Equipment
- C02analyser or 02analyser with Co capability
- Draft Gauge (Manometer)
- Fuel Pressure Gauge (oil)
- Smoke Tester (oil)
- Stack Thermometer
- Thermometer for domestic water test
- Volt Meter or Tattlelite
Carbon Dioxide or 02Test
During every new start-up and after every burner service call, a C02or 02test should be taken. All
of our testing including the approval testing yielded C02levels between 13% and 14.5% for oil and
9.5% - 11% for gas.
A Smoke Test is also necessary. For oil the acceptable reading is zero to a slight trace.
All tests should be performed after the burner has been operating for 10 minutes or the boiler water
and the piping system is up to temperature.
The C02or 02level can be adjusted upward by closing the air shutter, to obtain the higher levels of
C02recommended. The position of the turbulators on the assembly is very important and should be
checked to ensure accuracy of set-up. See charts in Appendix for all set up guidelines on the
Fleetline Boilers.
Pump Pressure (Oil)
All burners will be shipped with the pump pressure set at 160 p.s.i.g. It is good practice to check
this setting at the time of installation.
WARNING: TheRiello oil pumpdoes nothavestandardpipe threadsontheoil gauge port. Use
the adapter supplied with the unit. Using standard fittings will result in oil leaks that cannot be
repaired. Riello have an excellent pressure gauge available, compatible with their burner.

11
FLEETLINE AQUA-MATIC BOILER
COMMISSION PROCEDURE
Before the contractor installing the boiler leaves the installation location the contractor should
complete this commission check list to verify the work is completed and the necessity for call backs
will be eliminated.
1. Is the system filled with water?
2. Is the air purged from the system?
3. Are the automatic air vent caps open?
4. Have the oil burner supply lines been checked for leaks?
5. Has the gas line been pressure tested and tagged?
6. Has the burner (oil or gas) been tested with final tests using combustion test
instruments.
7. Have all safety and operating controls been cycled to verify operation and then set
at normal operating temperatures?
8. Has the anti scald valve been temperature tested to confirm maximum supply water
temperature at 1300F.
9. Verify no system leaks when unit is operating at selected temperature.
10. When the boiler is connected to free standing cast iron radiation, finned base board
convectors or in floor multi-zone systems, ensure boiler is bypassed and a system
circulating pump, plus expansion tank is installed.
11. Proof operating controls, return all settings to normal after proofing controls.
12. Open feed water valve to set operating system pressure at 12 psi, drain if above,
when unit is at full operating temperatures.
Customer: Name
Address (Street)
Town or City Postal Code
Installation Date Completed
Commission Test Completed
Heating Contractor Name
Address
Telephone
Technician's Signature
License Number
Leave with customer including installation manual. Verify commission steps with home
owner before leaving job site.

12
FLEETLINE
AQUA-MATIC BOILER
Thank you for selecting a Fleetline Aqua-Matic Boiler for heating and domestic hot water
requirements. We are proud to introduce this new state of the art product to the market place. We
have combined existing proven components with a control package that will produce for you
efficiency and total heating comfort. This match will provide many years of trouble free
performance.
HOMEOWNER'S OPERATING TIPS
Have your Fleetline boiler serviced and checked by a licensed and trained heating professional
annually to maintain efficiency.
Your Fleetline Aqua-Matic Boiler is supplied with either a power gas burner or a power oil burner.
For your safety do not store combustibles, or flammable materials near your Fleetline Aqua-
Matic Boiler.
Do you have sufficient combustion air?
An assured supply of combustion air is required for safe efficient combustion. A direct combustion
air connection to your burner is the best solution.
IF THE BURNER FAILS TO OPERATE
First check the following:
1. Check your thermostat; turn it up well above your normal room temperature settings.
2. Check your master on/off switch, is it on?
3. Check your electrical service panel for blown fuses or tripped breakers.
4. If you have fuel oil check your supply of fuel.
If the burner has shut down on safety the burner reset button will flash red on your burner. Press
the reset button once only. If you do not obtain a restart call for service.
If your gas burner has locked out turn the power off on the control box, allow 30 seconds to elapse,
and then turn on. If the burner fails to start call for service.
For Service, Call:
Phone:

FLEETLINE AQUA-MATIC SERIES
BOILER RATINGS
FUEL OIL
Burner
Model Nozzle *
Pump
Pressure
PSI
(F)
Input
(BTUH)
(G)
Air
Setting End Cone Turbulator Setting Co2
(H)
Gross
Stack
0°F 0°C
(K)
EFF.
SS.
Beckett .65 60° 160 100,028 33 F0 - 12.7 300 148.0 88
AFG .75 60° 160 120,034 37 F0 - 13.6 333 167.2 88
.85 60° 160 140,890 45 F3 - 13.6 352 177.0 87
1.10 60° 160 183,386 85 F6 - 13.6 400 204.4 85
Carlin .65 60° 160 105,169 .70 - .75 13.1 305 151.6 89
EZ1 .75 60° 160 121,134 .75 - .75 13.2 333 167.2 87
.85 60° 160 141,874 1.00 - 1.00 13.5 378 192.2 86
1.10 60° 160 182,830 1.25 - 1.10 13.7 372 188.8 86
Riello .65 60° 160 101,280 2.5 - 0 14.1 286 141.1 89
BF5 .75 60° 160 120,264 3.1 - 0 13.7 299 148.3 88
.85 60° 160 132,816 3.5 - 2. 13.3 335 168.3 86
1.10 60° 160 177,829 7 - 3.5 12.8 373 189.4 86
NOTES:
* Brass nozzles lowest temperature during long firing tests. Nozzles - Delevan W - Danfoss B - Hago B - Monarch R
F. Test fuel 34.70 API gravity
Input varies due to nozzle and end cone temperatures during tests
G. All air gate settings with outdoor air intake connection in place
H. All tests conducted with boiler supply water at 180°F (82.20°C)
K. For field set up maximum Co213.5% 022.6% 0 smoke

FLEETLINE AQUA-MATIC SERIES
BOILER RATINGS
NATURAL GAS PROPANE
Burner Type of Gas Manifold IN.WC. Orifice Turbulator Air Gate Input BTUH
Carlin N 3.5 20 - 3/4 70,000
G3B N 3.5 14 - 1 1/2 100,000
N 3.5 7 - 2 1/4 120,000
N 3.5 3 - 3 150,000
P 3.5 30 - 3/4 70,000
P 3.5 25 - 1 1/2 100,000
P 3.5 20 - 2 1/4 120,000
P 3.5 16 - 3 150,000
Riello 40 N 0.70 - 0 1.40 70,000
N 0.85 - 1 1.75 100,000
N 0.91 - 2 1.80 120,000
N 1.20 - 2 2.25 150,000
P 0.90 - 0 1.60 70,000
P 1.16 - 0 1.75 100,000
P 1.38 - 2 2.30 125,000
P 1.85 - 2 2.50 150,000
Test Set Up Natural Co210.8% Co Ø
Propane Co213.8% Co Ø
All tests completed at 180°F (82.2°C) water temp.

15
APPENDIX
SERVICING THE FLEETLINE AQUA-MATIC BOILER
To only be done by licensed, trained & experienced heating contractors.
The Fleetline boiler should be cleaned and serviced on an annual basis, by a licensed & trained heating
professional, with special care taken to ensure the vent system is air tight and not allowing combustion
products to enter the residence.
Boiler Heat Exchanger
Clean and vacuum all heating surfaces and flue collector box. Check boiler surfaces for corrosion to
ensure the surface temperatures are above condensation temperatures. If surface corrosion is noted
balance boiler water flow to maintain temperatures above 160°F (71°C) minimum.
Burner
Check and clean the entire assembly. The electrode settings should be confirmed as on specification.
Check gas valve confirm pressure 3.5" wc.
Check pump pressure 160 psi minimum sitting on the oil burner.
Check limit control for boiler safety.
Complete combustion efficiency tests with accurate test equipment. For oil the smoke test should be
completed twice-one minute after start up (cold surface smoke) and after 10 minutes minimum run or
boiler water temperature is above 160°F (71°C).
Circulator
Oil motor if required. Test circulator for adequate flow. Allow boiler to operate till limit is achieved
with circulator off. Start circulator and the supply pipe above the flow control valve should change
temperature instantaneously. When the impeller is not providing adequate flow, the flow control valve
cannot be forced open to a maximum flow position. If the system has zone controls open one zone to
confirm pump capacity.
The pipe valves and circulation system should be inspected for leaks. The expansion tank should be
tested and the terminal units should be bled and tested for air.
TROUBLESHOOTING GUIDE
When burner is locked out on safety - trouble light on, press the reset button once only. Then call your
authorized service source. See burner manual for more troubleshooting guides.
TROUBLE: BURNER DOES NOT START
SOURCE PROCEDURE CAUSES REMEDY
Thermostat Check thermostat settings.
Jump TT terminal on operating
control. If burner starts, fault is
thermostat circuit.
Thermostat set too low.
Open thermostat wires.
Loose thermostat
connectors.
Turn thermostat up.
Repair or replace wires.
Tighten connection.

TROUBLE: BURNER DOES NOT START, CONT'D...
SOURCE PROCEDURE CAUSES REMEDY
Thermostat Faulty thermostat.
Thermostat not level.
Dirty thermostat contacts.
Replace thermostat.
Level thermostat.
Clean contacts.
Power Check boiler disconnect switch
and main disconnect switch Switch open.
Tripped breaker or blown fuse.
Close switch.
Reset breaker or replace fuse.
Operating
Control Check for line voltage between the black and white leads. No
voltage indicates no power to
the control.
Limit control switch open.
Open circuit between limit
control and disconnect switch.
Limit line voltage or power
failure.
Check limit setting (210).
Jump terminals - if burner
starts replace control. Repair
circuit. Call utility company.
Burner See burner service manual.
OIL TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME
SOURCE PROCEDURE CAUSES REMEDY
Oil Supply Check tank for oil.
Check for water in oil tank
using a dip stick coated with
litmus paste.
Listen for pump whine.
Empty tank.
Water in oil tank.
Fuel supply valve closed.
Fill tank.
Strip tank of water exceeding
2 in. in depth.
Open valve.
Oil Line and
Filter Open pump bleed port and start burner. Milky oil or no oil
indicates loss of prime. Listen
for pump whine.
Air leak in fuel system.
Oil filter plugged.
Plugged pump strainer.
Restriction in oil line.
Repair leak-use only flared
fittings. Do not use Teflon
tape on oil fittings. Replace
filter cartridge. Clean strainer.
Repair oil line.
Oil Pump Install pressure gauge in port of
fuel pump. Pressure should be
160 psi minimum.
Pump discharge pressure set
too low. Set pressure at 160 psi minimum.
TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME
SOURCE PROCEDURE CAUSES REMEDY
Nozzle Inspect nozzle for plugged
orifice and distributor slots and
specifications.
Plugged orifice or distributor.
Plugged nozzle strainer.
Poor spray pattern.
Replace nozzle with nozzle
specified.

TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME, CONT'D...
SOURCE PROCEDURE CAUSES REMEDY
Nozzle
Combustion
Air
Adjustments
Inspect nozzle for correct size
and specifications.
Check air gate.
Check turbulator setting.
Incorrect nozzle installed.
Air gate open too far.
Turbulator open too far.
Install correct nozzle.
Decrease air gate setting.
Decrease turbulator opening.
TROUBLE: BURNER FIRES BUT FAILS ON SAFETY
SOURCE PROCEDURE CAUSES REMEDY
Poor Fire
Heat
Exchanger
Inspect flame for shape,
uniformity of color and
stability.
Read draft over the fire with a
long probe inserted through
the inspection port. Should
not exceed +0.03 in. W.C.
Unbalanced fire.
Excessive draft.
Insufficient draft.
Too little combustion air.
Plugged heat exchanger or
plugged chimney.
Replace nozzle with specified
nozzle.
Reduce draft setting.
Increase draft.
Increase combustion air.
Clean out heat exchanger.
Repair and have chimney
relined.
TROUBLE: BURNER FIRES, BUT THEN LOSES FLAME
SOURCE PROCEDURE CAUSES REMEDY
Poor Fire
Oil Supply
Combustion
Air
Inspect flame for stability and
color.
If burner loses flame prior to
the burner locking out, fault is
in fuel system.
Cold oil. Outside storage
Reduce combustion air
supply. Install pressure gauge
in gauge port of fuel pump.
Pressure should be 160 psi
minimum.
Unbalanced fire.
Excessive draft over 0.15 in.
W.C.
Too little combustion air.
Air leak in fuel system.
Water in oil tank.
Fuel supply valve closed.
Restriction in oil line.
Plugged fuel filter.
Plugged pump strainer.
Unheated boiler area.
Too much combustion air.
Pump discharge pressure
incorrectly set.
Replace nozzle with specified
nozzle.
Reduce draft setting.
Increase combustion air.
Repair leak-use only flared
fittings.
Strip tank of water exceeding
2 in. in depth.
Open valve.
Clear oil line restriction.
Replace filter cartridge.
Clean strainer.
Discuss with oil supplier.
Close air gate and turbulator
to raise CO2.
Set pressure at 160 psi
minimum.

TROUBLE: BURNER FIRES, BUT THEN LOSES FLAME, CONT'D...
SOURCE PROCEDURE CAUSES REMEDY
Excessive
Draft
Poor Flue
Gas
Nozzle
Take a draft reading. Draft
should be 0.15 in. W.C. max.
Insert test probe into heat
exchanger tube. If reading is
greater by 1/2% or more,
sample was being diluted near
flue box.
Inspect nozzle for plugged
orifice and distributor slots.
Incorrect draft setting.
Leak in flue system.
Plugged orifice or distributor.
Plugged nozzle strainer.
Poor spray pattern.
Reduce draft setting.
Install draft regulator if
necessary.
Sample gas in boiler shell.
Seal flue system leak.
Replace nozzle with specified
nozzle.
Install 5 micron paper filter to
protect burner.
TROUBLE: BURNER FIRES BUT PULSATES
SOURCE PROCEDURE CAUSES REMEDY
Draft
Combustion
Air
Oil Supply
Pump
Nozzle
Heat
Exchanger
Restriction
Take a draft reading. Draft
should be 0 or -0.01 in. W.C.
minimum.
Inspect installation for
combustion air provisions.
Bleed pump; inspect for air
leaks or water contamination.
Install pressure gauge in
gauge port of fuel pump.
Pressure should be 160 psi
minimum.
Inspect nozzle for plugged
orifice and distributor slots.
Read draft over the fire with a
long probe inserted through
the sight door. Should not
exceed +0.03 in. W.C.
Down drafts.
Insufficient draft.
Excessive draft
-0.15 in. W.C.
Improper installation.
Air leak in fuel system.
Water in oil tank.
Pump discharge pressure
incorrectly set.
Plugged orifice or distributor.
Plugged nozzle strainer.
Poor spray pattern.
Plugged heat exchanger.
Install aerocowl vent cap.
Increase draft setting or resize
vent system.
Reduce draft, install draft
regulator if necessary.
Provide opening that freely
communicate with outside.
Repair leak-use only flared
fittings.
Strip tank of water exceed 2
in. in depth.
Set pressure at 160 psi.
Replace nozzle with nozzle
specified on burner housing.
Install 5 micron paper filter to
protect burner.
Clean out heat exchanger.