Pure-Pro TRIO PC6230 Setup guide

PC6230 THRU PC1259
CAST IRON BOILERS
PC6230-PC12590
INSTALLATION AND OPERATOR’S MANUAL
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
10-1-15

2
Warnin
g
Be Aware of Hazard Definitions
Danger: Denotes presence of a hazard which, if ignored, will result in severe personal
injury, death or property damage
Warning: Denotes presence of a hazard which, if ignored, could result in severe personal
injury, death or substantial property damage.
Caution: Denotes the presence of a hazard which, if ignored, could result in minor personal
injury or property damage
Notice: Intended to bring attention to information, but not related to personal injury or
property damage.
Warning: 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. All aspects of the installation
must conform to the authority having jurisdiction, or in the absence of such requirements, to the National
Fuel Gas Code, ANSI Z2231.1/NFPA 54 or to the installation of Oil Burning Equipment, NFPA 31.
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 natural gas, LP gas, No. 1 or 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 vapors or gas has accumulated in the boiler.
Do 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.

3
Warning: Any Appliance that burns natural gas, propane gas or fuel oil is capable of
producing carbon monoxide (CO). Carbon monoxide (CO) is a gas which is odorless, tasteless
and colorless but is very toxic.
If your boiler is not vented properly or is not working properly, dangerous levels of CO may
accumulate. CO is lighter that air and may travel throughout the building. Brief exposure to high
levels of CO or prolonged exposure to lesser amounts of CO may result in carbon monoxide
poisoning.
Exposure can be fatal and exposure to high concentrations may result in the sudden onset of
symptoms including unconsciousness.
Symptoms of CO poisoning include the following:
Dizziness Vision Problems Shortness of Breath
Headaches Loss of Muscle Control Unclear Thinking
Nausea Weakness Unconsciousness
The symptoms of CO poisoning are often confused with influenza, and the highest incidence of
poisoning occurs at the heating season which is during flu season. A victim may not experience
all of the listed symptoms. Suspect the presence of CO if the symptoms tend to disappear when
you leave your home.
The following sign may indicate the presence of carbon monoxide:
Hot gasses from the appliance, venting system or chimney escaping into the living
area.
Flames coming out around the appliance.
Yellow colored flames in the appliance when burning gas.
Stale or smelly air.
The presence of soot or carbon in or around the boiler.
High unexplained humidity inside the building.
If any of these symptoms of CO poisoning occur, or if any of the signs of carbon monoxide are
present, leave the premises immediately and contact a qualified service company, the gas
company or the fire department.
To reduce the risk of CO poisoning have your heating system, vent system and chimney
inspected and serviced before each heating season

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Warning If You Smell Gas:
Close the Gas shut-off valve
If you hear gas leaking evacuate the affected area immediately
Open all Windows
Do not operate any electrical switches or equipment such as phones, power plugs and
doorbells
Extinguish all open flames
Do smoke
Do not use lighters
Warn all occupants of the building, but do not use door bells
Call your gas utility company and your local heating contractor from outside the building
and notify police and fire department
Notice: 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.

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Table of Contents
Ratings and Data 6
Clearances 7
Ventilation and Combustion Air 7
Boiler Block Assembly 8
Boiler Trim Piping 11
System Piping 12
Jacket Installation 12
Venting 18
Burner Installation 20
Fuel Piping 21
Wiring 21
Operation 23
Burner Settings 24
Maintenance 25
Warranty 27
Installation and Service Check List 28

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Ratings and Data
Ratings
Boiler Model No. PC6230 PC7290 PC8350 PC9410 PC10470 PC11530 PC12590
Firing Rate - #2 Fuel 2.30 2.90 3.504.10 4.70 5.30 5.90
Input BTU/HR 322,000 406,000 490,000 574,000 658,000 742,000 826,000
Output BTU/HR #2 Fuel 276,000 352,000 426,000 501,000 575,000 649,000 723,000
Net Output BTU/HR #2 Fuel 240,000 306,000 370,000 436,000 500,000 564,000 629,000
Output Nat Gas 268,000 342,000 413,000 486,000 558,000 630,000 701,000
Net Output Nat Gas 233,000 297,000 360,000 423,000 485,000 548,000 610,000
Net Rating Sq. Ft. 1600 2040 2465 2910 3335 3760 4195
Water Content Gals. 17 20 23 26 29 32 35
Maximum Operating Pressure 58 PSI
Approx. Shipping Weight Lbs 1170 1300 1435 1540 1660 1785 1900
Dimensions
Cabinet Height 41-1/8” 41-1/8” 41-1/8” 41-1/8” 41-1/8” 41-1/8” 41-1/8”
Cabinet Width 25-3/8” 25-3/8” 25-3/8” 25-3/8” 25-3/8” 25-3/8” 25-3/8”
Cabinet Length 37-1/2” 42-1/4” 46-7/8” 51-3/4” 56-3/8” 61-1/8” 65-7/8”
Supply Outlet Size NPT 2” 2” 2” 2” 2-1/2” 2-1/2” 2-1/2”
Supply Outlet Height C.L. 34-1/8 34-1/8 34-1/8 34-1/8 34-1/8 34-1/8 34-1/8
Return Size NPT 2” 2” 2” 2” 2-1/2” 2-1/2” 2-1/2”
Return Outlet Height C.L. 3-7/8” 3-7/8” 3-7/8” 3-7/8” 3-7/8” 3-7/8” 3-7/8”
Flue Outlet Diameter 8” 8” 8” 8” 8” 8” 8”
Flue Outlet Height C.L. 34-1/4 34-1/4” 34-1/4” 34-1/4” 34-1/4” 34-1/4” 34-1/4”

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Boiler Components
INSPECT FOR DAMAGE. All equipment is carefully manufactured, inspected, and packaged by
experienced workers. Our responsibility ceases upon delivery of the skidded boiler and component
boxes to the carrier in good condition. ANY CLAIMS FOR DAMAGE OR SHORTAGES IN
SHIPMENT MUST BE FILED IMMEDIATELY against the carrier by the consignee.
The boiler is shipped in multiple packages consisting of the following items:
1. Assembled casting or knocked down casting strapped to a skid.
2. Jacket Carton. See jacket assembly instructions for a complete listing of all items
included.
3. Burner/Parts Box – Includes burner, hydrostat, safety relief valve, drain valve and
associated trim piping.
4.
Installation Clearances
Warning: 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.
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 - 24 IN.
FLUE CONNECTOR SINGLE WALL VENT PIPING - 18 IN.
REAR -6 IN.
SIDES - 6 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 BURNER
FLUE CONNECTOR - 18 IN.
REAR - 18 IN.
SIDES - 12 IN.
Ventilation and Combustion Air
Opening sizes must comply with state or local codes. In their absence, use the following when the boiler is
installed in a confined room:
Warning: This boiler must be supplied with combustion and ventilation air in
accordance with ANSI Z223.1/NFPA54 and all applicable local codes. 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. Never use an exhaust fan in the boiler room. The boiler room must never be
under a negative pressure or improper burner operation, flue gas leakage and carbon
monoxide emissions may occur.

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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 air.
When a boiler is located in a confined space and air for combustion and room ventilation is from
inside buildings, the confined space shall be provided 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/HR of the total input
rating of all appliances in the enclosed space, but must not be less than one hundred (100) square
inches. These openings must freely communicate with the interior areas having adequate
infiltration from the outside.
When a boiler is installed in a confined space, or in a building of unusually tight construction, air for
combustion and room ventilation must be obtained from the outdoors by means of two permanent openings
one starting 12 inches from the top and one 12 inches from the bottom of the enclosed space. When air is
taken through the outside wall or vertical ducts, at least one square inch of free opening must be provided per
4000 Btu/Hr. When air is taken through horizontal ducts at least one square inch of free opening must be
provided per 2000Bth/Hr. 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 ¼inch mesh. If free area through a design of louver
or grill is known, it should be used in calculating the opening size required to provide the free area specified.
If the design and free area is not 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 Location
Locate the boiler in an area that provides good access to the unit. To provide the best possible serviceability
the boiler should be installed using the minimum recommended service and accessibility clearances as
previously listed. Under no circumstances should the unit be installed next to combustible materials with
clearances less than listed in installation clearances above.
The boiler should be installed on a level, flat concrete floor or pad that is structurally sound and will support
the combined weight of the boiler when filled with water. This boiler is designed to be installed on
noncombustible flooring only.
The boiler should be installed as close to the chimney as possible while still being located centrally to the
piping system.
Boiler Block Assembly
Unassembled blocks are provided as a complete kit. The kit contains the following items:
(1) Rear Section (12) Stud 12mm x 68mm Supply/Return Flange
(1)Cleanout Door (2) Door Hinge with Lock Nuts
(1) Front Section (2) Burner Door Studs 12mm x 118mm
Intermediate Sections as required (22) Washers 12mm
(2) Supply/Return flanges (28) Nuts 12mm
(2) Supply/Return flange gaskets (2) Cast iron Baffles
(1) Lower Front Bushing Tubes Mastic Sealant Sections
(1) Upper Front Bushing (1) Pipe dope sealant mixture for push nipples
(2) Bushing gaskets
Warning: Secure boiler sections during assembly to prevent them from tipping over.
Warning: Never install the boiler on top of combustible flooring. Never install the boiler in
an area where combustible materials, gasoline or any other products containing flammable vapors
or liquids are stored.

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To assemble the boiler body you will need two clamping units, pry bar and a plastic or wooden mallet.
Assemble the blocks as follows:
1. Place the rear boiler element vertical. Clean and inspect the twin-taper nipple seats and the
connection surface. Figure 1.
2. Grease the twin-taper nipples and their seats with pipe thread sealant/linseed oil mixture provided.
3. Insert the twin-taper nipples into the upper and lower seats and hit them lightly with the mallet to
seat them in place. The first four bottom twin-taper nipples, starting from the
rear element in models with 10-11-12 sections, must be 4-1/8” (104 mm)
long with their extension facing towards the front. Figure 2.
4. Prepare the intermediate element to be added, cleaning its twin-taper seats and checking its
connection surfaces.
5. Use the caulking gun to completely fill all of the channels in the rear element with sealant to ensure
edge seal between elements. Figure 3.
6. Bring the intermediate element to the rear element and place the top twin-taper nipple into the
intermediate element. Figure 4.
7. Position the intermediate element until it perfectly centers the lower twin taper nipple, hitting the
intermediate element with the mallet.
8. Thread clamp (A) into the hole in the twin-taper nipple and stretch it slightly. Figure 5.
9. Install lower clamp (B) and then join the two parts. Keep the two faces of the components
perfectly parallel when bringing the pieces together. If the section does not remain parallel
use pry bar to return to parallel. Figure 6.
10. Repeat the above procedures until the boiler body is completed. Do not use the tie rods to pull the
sections together. The sections must be pulled together through the push nipple ports. Do not
remove the assembly tool from the unit until the tie rods are installed.
Figure 1 Figure 2 Figure 3
Figure 4 Figure 5 Figure 6

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11. Introduce tie-rods into their seats, placing them as illustrated. The short tie rods are to be installed
in the lower positions with the short threaded part towards the front of the boiler. The tie rods in the
rear of the boiler will need to be cut so as not to extend more than 2-1/2 inches past the nut so as not
to interfere with the jacket installation.
12. Install washers and nuts onto tie-rods from the rear. Clamp the boiler body together, checking and
maintaining tie-rod extensions equal. Additional nuts are to be placed on the tie rods for jacket
assembly
13. Install lower plug bushing and upper bushing with 1/2” NPT threads using the gaskets provided.
14. Install supply and return flanges using the 12mm x 68mm studs with the shorter tread length into the
threaded openings in the casting. Tighten with nuts, washers and gaskets provided.
15. Insert a light into the combustion chamber to check for proper sealant between the sections. If light
is visible force sealant with a putty knife from the exterior between the sections.
Boilers which were split or field assembled will need to be hydrostatic pressure tested in accordance with
Section IV of the ASME Boiler and Pressure Code at a pressure equal to 1-1/2 times the maximum
allowable pressure on the boiler nameplate.
Burner Door Assembly
1. Select the direction for the burner door and place the hinges on the appropriate side.
2. Lubricate the threaded stems of the hinges and tighten them into the front section to the dimension
indicated. Then lock into position with the nut provided.
3. Place a brass hinge nut on each hinge with the extension facing the door.
4. Place the door over the hinge and use an additional brass hinge nut to lock the door into position
5. Install the 12mm x 118mm studs with the shorter tread length into the threaded openings in the front
casting.
Warning: Do not leave boile
r
unattended during hydrostatic testing. Cold water fill could
expand as it warms causing excessive pressure, resulting in severe injury, death or substantial
property damage. Leaks, if found, must be repaired immediately. Failure to do so can damage
boiler, resulting in substantial property damage.
Caution: Do not hydrostatically test the boiler with any controls installed. Damage to
controls can occur due to over pressure.
Figure 7 Figure 8 Figure 9

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6. Tighten the door using the remaining brass hinge nuts provided. Final adjustment of the door on the
hinge side is to be made using the brass hinge nuts.
7. Inspect for proper seal between boiler and door.
HingePin
BrassHingeNuts
Cleanout Door Assembly
1. Install baffles into the center two flue passages.
2. Install the 12mm x 68mm studs with the shorter thread length into the threaded openings in the
casting. Place the cleanout door over the studs and tighten with washers and 12mm nuts provided.
Boiler Trim Piping
1. Install the ¾” Hydrolevel 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 rubber
well cap as provided.
2. Pipe in pressure relief valve with ¾” street elbow and with the ¾” x 6” 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” coupling and the ¾” x 6” nipple in the lower left side rear section.
4. Pipe in boiler gauge with ½” x ¼” reducing bushing in upper front section.
5. Install auxiliary high limit aquastat as shown using the provided piping.

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System Piping
Important… INSTALLATION MUST BE PERFORMED BY A TECHNICALLY
QUALIFIED SERVICEMEN.
TRIO COMMERCIAL 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.
The Trio boiler is a highly efficient 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.
Low water cut off
A low water cutoff integral to the Hydrolevel 3250 fuel smart hydrostat has been provided with the boiler
package. See boiler trim piping for the recommended location. Always follow the manufacturer’s
recommendations for installation.
Relief Valves
Relief valves are to be properly piped in to conform to code standards. Discharge piping from the relief
valve must be sufficiently supported so as to avoid strain on the safety valve body.
Discharge piping should terminate 6” above the floor to eliminate damage to the structure or personal injury.
It should be piped to a location where it can be inspected for any visible signs of leakage. It must not be
piped to a point where freezing may occur.
Jacket Installation
The boiler jacket is designed so that all piping connections can be made before the Jacket is installed.
Jacket Components
2) Mounting Brackets A
(2) Mounting Brackets B
(1) Front Panel
(1) Upper Rear Panel
(1) Lower Rear Panel
(1) Left Front Panel
(1) Left Rear Panel
(1) Rear Jacket Top Stiffener
Trim Bag Components
(1) Right Front Panel
(1) Right Rear Panel
(1) Top Front Panel
(1) Top Rear Panel
(1) Insulation Strip 3” x 48” x 87”
(1) Insulation Strip 3” x 12” x 87”
(1) Insulation Rear Panel
(1) Trim Bag
(10) #8 x 1/2” Hex Washer Head Self Drilling
Screws
(60) #10 x 3/4” Hex Washer Sheet Metal
Screws
(6) #10 x 5/8” Phillips Flat Head Screws
(3) Lengths Plastic Strapping – 11 Ft.
(3) Strapping Clips
(6) Feet Foil Tape
(4) SB875-11 Anti Short Bushings
Warning: The discharge of the pressure relief or safety valve must be piped close to the
floor to prevent scalding in the event of a discharge. The discharge piping must be sized the
same as the valve outlet. Never install any valve between the boiler and the safety valve or in the
discharge piping. Failure to comply with this warning can result in an explosion causing property
damage, severe personal injury, or death.

13

14
Mounting Bracket Installation
Attach four jacket mounting brackets to the boiler. Note there are two different jacket brackets which end
up on opposite corners facing outward. Slide the slots in the mounting brackets over the boiler tie rods
between the two 12 x 1.75 mm nuts located on each end of the tire rods. Tighten the outer nuts to secure the
brackets into position. Place two of the SB875-11 anti short bushings into holes in jacket brackets on the
same side of the boiler as the aquastat immersion well.
Figure 1
Insulation Installation
Cut the 3” x 48” x 87” insulation to the appropriate widths as listed below.
6-Section…………25- /4” x 87”
7-Section ………...30” x 87”
8-Section…………34-1/4” x 87”
9-Section………….39-1/2” x 87”
10-Section………...44-1/4” x 87”
11-Section………...36-7/8” x 87”
12-Section…...……41-5/8” x 87”
Tape the 3” x 12” x 87” insulation strip to the 3” x 36 7/8” x87” piece to make the wrapper for the 11
section boiler or to the 3” x 41 5/8” x 87” piece to make the wrapper for the 12 section boiler using the foil
tape.
Drape the insulation over the boiler with the foil side facing out.
Fasten the insulation to the boiler using the three supplied plastic straps and buckles.

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Assemble Side Panels
The boiler side panels are designed to telescope to the appropriate length in order to fit any size boiler. See
Figure 2 below for front side and Figure 3 for rear side jacket panels.
Figure 2
Figure 3

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On a flat surface place the rear side upside down with the bottom channel facing up. Place the bottom
channel of the front panel over the channel of the rear panel and adjust the overall length of the side panel as
shown in Figure 4 below.
Place two #10 x 3/4” hex washer sheet metal screws into the bottom channel to lock the overall length of the
assembled side to the proper length as shown in the figure below.
Install two #10 x 3/4” hex washer sheet metal screws along the top to hold the two halves together
temporarily.
Figure 4
Repeat the above procedure for the left side jacket assembly.
Assemble Side Jacket Assemblies to Boiler
Align the six holes as indicated in Figure 4 with those located in the boiler mounting brackets. Fasten the
sides to the brackets using six #10 x 3/4” hex washer sheet metal screws.
Install three #8 x 1/2” hex washer head self drilling screws in the holes as indicated in Figure 4 to further
attach the sides together.
Remove the two #10 x 3/4” hex washer sheet metal screws which were installed temporarily along the top
of the jacket side assemblies.
Install two #10 x 5/8” Phillips flat head screws into the 1/8” holes on the front edge of both the left and right
side panel as shown in Figure 2
Rear Jacket Panels
Place rear panel insulation on back section of boiler with the foil facing outward.
Install the lower rear jacket panel to the side panels using four #10 x 3/4” hex washer sheet metal screws.
See Figures 3 and 5.
Install the upper rear jacket panel to the side panels using four #10 x 3/4” hex washer sheet metal screws.
See Figures 3 and 5.

17
Figure 5
Temperature Sensor Installation
1. Install (2) SB875-11 black anti short bushings into the upper holes in the mounting brackets along
the right hand side of the boiler.
2. Install (1) SB875-11 black anti short bushing into the 7/8” hole in the right front jacket panel.
3. Run the sensor through the mounting brackets and the jacket side panel.
Install Top Panels
Install stiffener onto bottom side of rear top panel using double faced tape as per figure 7. Place rear top
panel over the side and rear panels. Place the front top panel over the sides. Fasten the top panels using #10
x 3/4” hex washer sheet metal screws starting from the front and rear side and working into the middle. See
Figure 6 and Figure 7 for top panel drawings.
Figure 6

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Figure 7
Name Plate Installation
Install nameplate provided in the upper left jacket corner. Install Commercial label on upper right corner of
the jacket covering slots. Transfer the boiler serial number which is rivited to the front leg of the boiler to
the nameplate.
Aquastat Installation and Adjustment
1. After cabinet installation is complete install the temperature control on the right side of the boiler.
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. HydroLevel 3250 Plus - The overall range of the High Limit is from 1300F to 2200F. Typically it would
be set in the range of 1800F to 2000F.
VENTING
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
Warning: The vent installation must be in accordance with the National Fuel Gas Code
ANSI Z223.1/NFPA 54, the ASHRAE Equipment Handbook on Venting or the applicable
provisions of local building codes. Failure to follow all instructions can result in flue gas spillage
and carbon monoxide emissions, causing severe personal injury or death.

19
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.
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.
Chimney downdraft conditions cause faulty operation that creates a hazard, corrective steps must be taken.
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 cyclical 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 the construction has withstood the lower temperatures produced by higher efficiency furnaces.
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 equal in diameter to 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

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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 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 the 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.
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.
Burner Installation
Follow the burner manufacturer’s installation instructions for proper installation, fuel piping, wiring, burner
adjustment and servicing.
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.
The refractory opening in on the door may need to be trimmed for proper burner insertion. Do not force the
burner through the door.
Check that there is a complete seal between the door and the burner flange after installing ceramic fiber seal
furnished with the burner.
Note: A high temperature stainless floor liner is provided with Riello oil burners. This should be
installed on the floor of the combustion chamber tight to the front section.
Warning: The burner must be installed and adjusted in accordance with the burner
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