Burnham 81433101R16-1/10 Boiler User Manual
Contents
1. Unpack Boiler a ideis roii pre bis III Water Piping and Trim 9 IV Venting Air Intake 12 V Electrical and Sequence of Operations 18 VII System Start up 23 VIII Service Cleaning 29 IX Repair Parts 32 X Appendix Low Water Cut O f 39 suo Je8 9 49140 1938M AQ31 L 4 ACIS zz 80073 XOO1M31NI 3009 5 Y3NYNE ul m FATWA 3303Y 5 fi 919 fe e n SNIddV1 INIA W3HOLOVAJQnNVW AG 3 LON S3NI1 N3QGIH NMOHS S310N AIA INON 31V ld 5 SNIdNVIS ANSV NN pi 1031409 AYYNINd M3NMhB 110 3015 Y3HLIS 009 100 g NIMS MANNE 390 9 35055354 m 1 01 is Pre Installation INSPECT SHIPMENT carefully for any signs of 1 In unconfined spaces basement in buildings of damage 1 ALL EQUIPMENT is carefully manufactured2. will stall the fuel pump Water in the fuel in smaller amounts will cause excessive wear on the pump but more importantly water doesn t burn It chills the flame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the flueways of the boiler COLD OIL If the oil temperature approaching the fuel pump is 40 F or lower poor combustion or delayed ignition may result Cold oil is harder to atomize at the nozzle Thus the spray droplets get larger and the flame shape gets longer An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil The best solution 15 to bury the tank and lines deep enough to keep the oil above 40 F HIGH ALTITUDE INSTALLATIONS Air settings must be increased at higher altitudes Use instruments and set for 11 5 to 12 5 START UP NOISE Late ignition is the cause of start up noises If it occurs recheck for electrode settings flame shape air or water in the fuel lines SHUT DOWN NOISE If the flame runs out of air before it runs out of fuel an after burn with noise may occur That may be the result of a faulty cut off valve the fuel pump or it may be air trapped in the nozzle line It may take several firing cycles for that air to be fully vented through the nozzle Water in the fuel or poor flame shape can also cause shut down noises CHECK TEST PROCEDURE A very good test for is
3. Push red reset button to reset safety switch c Simulate power failure Follow the starting procedure to turn on the burner With the burner running turn off the power to the system by tripping the circuit breaker or removing the fuse Burner should stop Restore power Burner should start d If system does not operate as described go to the TROUBLESHOOTING AND MAINTENANCE section 3 VERIFY HIGH LIMIT OPERATION a Adjust thermostat to highest setting b Observe temperature gauge When temperature 18 indicated adjust limit to setting below observed temperature Burner should stop c Adjust limit to setting above observed temperature Burner should start d Adjust thermostat to lowest setting Adjust limit to desired setting 4 CHECK LOW WATER CUTOFF if so equipped a Adjust thermostat to highest setting b With boiler operating open drain valve and slowly drain boiler c Burner should stop when water level drops below low water cutoff probe Verify limit thermostat or other controls have not shut off boiler d Adjust thermostat to lowest setting Refill boiler H Boiler is now ready to be put into service IMPORTANT IF DURING NORMAL OPERATION IS NECESSARY TO ADD WATER MORE FREQUENTLY THAN ONCE A MONTH CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS A leaky system will increase the volume of make up water supplied to the boiler which can sig
4. end c Clip connector over vent terminal until it is fully engaged Then tighten gear clamp d Slide insulation sleeve over terminal connection so that connector is completely covered e Secure each end of insulation sleeve with the gear clamps provided 6 Secure vent pipe in position with pipe straps a horizontal runs must rise at least 4 inch per foot toward vent terminal 16 b Avoid any sags or dips in vent pipe C Air Intake Installation Direct Vent only See Figure 13 WARNING Do not reduce size of air intake pipe Read understand and follow combustion air instruction restrictions contained in the Pre Installation Section of this manual 1 General a Use 4 inch diameter single wall metal pipe and fittings available at most heating distributors Maximum allowable air intake length 1s 40 equivalent feet Each elbow 15 equal to 6 equivalent feet Start at Burner Work toward air intake terminal Maintain minimum of inch per foot slope in horizontal run to air intake terminal Slope down toward air intake terminal Seal all joints gas tight using silicone caulk or self adhesive aluminum tape 2 After determining location cut a hole in the wall to accept 4 inch air intake pipe 3 Remove the black plastic inlet cover from the right side of the Beckett AFII burner 4 Mount the vacuum relief valve tee assembly or 90 elbow into the burner inlet ring See Figur
5. FUSE ET B FILL HEATING SYSTEM WITH WATER Refer to Section III G UP BUTTON C CHECK CONTROLS WIRING AND BURNER to be TERMIN B sure that all connections are tight and burner 15 rigid dose that all electrical connections been completed and RELAYS fuses installed and that oil tank is filled and lines EN have been tested TERMINALS D LUBRICATION Follow instruction on burner and SGrurr circulator label to lubricate if oil lubricated Most motors currently used on residential type burners employ permanently lubricated bearings and thus do not require any field lubrication Water lubricated circulators do not need field lubrication FIELD TERMINALS SENSOR HOLE HORIZONTAL MOUNT Figure 18 L7248 Circuit Board Layout Horizontal Mount High Limit F C Toggle Then press the UP and or DOWN buttons Do not over lubricate This can cause as much trouble as no lubrication at all ADJUST CONTROL SETTINGS with burner service switch turned ON and room thermostat set 10 below room temperature 1 Adjustment and display modes of the L7248 L7224 Oil Electronic Aquastat Controller On the L7248 L7224 the overall range of the High Limit is from 180 F to 240 F 82 C to 116 C b Set the High Limit designated HL on the L7248 L7224 Aquastat Control at 180 F This temperature setting may be va
6. Jacket amp Insulation 33 AGA 22 34 syed 3 22 4 JAWA 331134 21159118 30 38 1 70 4939 9 123 2 WNIWSSL 403 3 33 S NOILVINSNI ATHW3SSV TvNIN231 YOLISNNOID TvNIN231 43149049 3ONVI Idd 4 HONOSHL 5 NOILdDIWDSWd 1 8 r pere 2 s mem wems eme 8 ems 09 r C ALG Java NL 35 9L87 SP9 NUNA TIO 008 10 0901 26 010 9 HO LUAJA 6801 Xog Od OD MY 10 1591402 syed 1 104 Hed 19 IO 3932eg 62 4 LNO IA 30095 133 7303 A18W3SSV 3009 SS300V 131599 4000 55322 7IOJINOO WIZZON ATI8N3SSV 3lvid OWLS M30vdS M3 ldS dWVIO 300312313 MN31dvav M39vdS 300319313 J L 8355 31220 3008129313 AQIS 7 15303 18 355 300312313 31720 MN3ldvOv 31720 AT18W3SSV YOLOSNNOO 50 3 03 303 31 19 211253 LAN G3TENNy AI18W3SSV I334SV9 YOLINSI MOLINSI 90319373 5
7. NJN 100 100 100 N 100 N 83 FUEL PUMP FILTER I SHUT OFF MAXIMUM VALVE ONE PIPE INLET LIFT 8 FT 7 Figure 16 Single Pipe Installation 21 OUTSIDE TANK FUEL PUMP ABOVE OF TANK FUEL PUMP FILL AIR PIPE VENTA AUX FILTER i s RETURN LINE R Figure 17 Two Pipe Installation C Two Pipe Oil Lines Table 3 Two Stage Units 3450 RPM Two Pipe Systems 1 For two pipe systems where more lift is required the two stage fuel unit is recommended Table Maximum Length of Tubing 2 single stage and Table 3 two stage show Lift H H allowable lift and lengths of 3 8 inch and inch 3 8 OD 1 2 OD OD tubing for both suction and return lines Refer Tubing 3 GPH Tubing 3 GPH to Figure 17 100 100 76 22 System Start up WARNING boilers equipped with burner swing door have a potential hazard which can cause severe property damage personal injury or loss of life if ignored Before opening swing door turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber Be sure to tighten swing door fastener completely when service is completed A ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER BUTTON CAPACITOR DOWN BUTTON TRANSFORMER
8. Remove 4 hex head cap screws that attach hinges to door 5 Attach 2 hinge brackets amp spacers to Tubesheet and 2 hinge brackets to Door on right side of boiler 3 Holes in each Hinge Bracket must line up with 3 matching holes in Spacer Tubesheet or Door See Figure 3 Tighten hex nuts bolts and screws by hand only 6 Replace door assembly Hinge brackets attached to door must rest on top of hinge brackets attached to tubesheet See Figure 3 Slide hinge pins through hinges from top and install cotter pins Close door and install 5 16 18 x 3 long hex head cap screws through flat washers and left side of door and into tapped holes in tubesheet Tighten all hex nuts bolts and screws When door is installed properly it 15 parallel to Tubesheet when viewed from top and sides 7 Bend sides of Jacket Wrapper down and attach 2 Jacket Straps to 4 slots at bottom of Jacket Wrapper sides with sheet metal screws Install Rear Jacket Box with 4 sheet metal screws See Figure 22 8 Connect wiring harness to burner Junction Box and install Honeywell R7184P Control see Wiring Diagram Figure 15 or 15A Reconnect Swing Door Interlock INSTALL BOILER CONTROL 1 Pull bulb and capillary tube out of hole in back of control Insert bulb in immersion well on top of boiler and secure control with set screw control 2 Secure flexible conduit to Jacket Wrapper side with conduit clamp and sheet metal screw Conduit must be on same s
9. backward and set rear legs down on floor Tilt boiler backward pull skid forward and set front legs down on edge of skid Install close nipple tee and plug in return coupling See Section III and Figure 5 Point tee toward permanent return location 3 Tilt boiler backward and remove skid Be careful not to damage Burner or Jacket C DETERMINE PROPER HINGE LOCATION FOR BURNER SWING DOOR Boiler is shipped with hinges on left side Approximately 12 inches are required on the hinge side for burner clearance If there will be less than 12 inches from left side of boiler to wall move hinges to right side refer to Paragraph D D HINGE LOCATION CHANGE if required refer to Figure 3 1 Pull 2 halves of Burner Swing Door Interlock apart Swing Door Interlock is connected to T T terminals on R7184P Control Lift Honeywell R7184P Control off of Burner Junction Box and disconnect wiring harness from burner 2 Remove 8 sheet metal screws from Jacket Remove rear jacket box and bend both sides of Jacket Wrapper up see Figure 22 3 Remove 2 two 5 16 18 x 3 long hex head cap screws and flat washers from right side of door Remove 2 hairpin cotter pins and 2 hinge pins from hinges on left side of door and remove Door Assembly from boiler Inspect Front and Rear Door Insulation Pieces and Combustion Chamber Liner see Paragraph G 4 Remove 4 hex nuts from bolts that attach hinges and hinge spacers to left side of Tubesheet
10. cannot be considered as a guarantee of workmanship of an Lancaster Pennsylvania hereby extends the following limited warranties to the original installer connected with the installation of the U S Boiler Company Inc owner of a residential grade water or steam boiler or U S Boiler Company Inc supplied boiler or as imposing on U S Boiler Company Inc liability of any nature for parts and or accessories manufactured and shipped on or after July 1 2008 unsatisfactory performance as a result of faulty workmanship in the ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS installation which liability is expressly disclaimed AND PARTS ACCESSORIES SUPPLIED BY U S BOILER COMPANY INC e Boilers parts or accessories installed outside the 48 contiguous United U S Boiler Company Inc warrants to the original owner that its residential grade States the State of Alaska and Canada water and steam boilers and parts accessories comply at the time of manufacture with f Damage to the boiler and or property due to installation or operation of the recognized hydronic industry standards and requirements then in effect and will be boiler that is not in accordance with the boiler installation and operating free of defects in material and workmanship under normal usage for a period of one instruction manual year from the date of original installation If any part of a residential grade boiler or g Any damage or failure of the boiler resulting from hard wat
11. clamp onto the terminal pipe DIL VENT TERMINAL EN E 7 AIR INTAKE MAY LOCATED OUTSIDE OF THIS LINE BUT NOT HIGHER THAN DIL VENT I TERMINAL HORIZONTAL CENTERLINE Figure 9 Intake Terminal Location 13 SUPPORT INTERIOR STRAPS TRIM PLATE OIL VENT TERMINAL ASSEMBLY VENT CONNECTOR FLEXIBLE OIL VENT MIN CLEARANCE TO COMBUSTIBLE 12 MIN CONSTRUCTION GRADE MAX SNOW ACCUMULATION T l T l TT ll TTE T T T 1 T T T T ET T T T 1 E a 1 I ll FRONT VIEW Figure 10 Vent Installation MIRI GEAR CLAMPS STAINLESS STEEL SPOT WELDED LINER TO CONNECTOR ALUMINUM COVER CONNECTOR ASSEMBLY Figure 11 Vent Connector Un Assembled 14 HORIZONTAL RUN MUST SLOPE TOWARD TERMINAL PER FOOT MINIMUM OIL VENT PIPE CONNECTOR 4 Figure 12 Vent Connector Assembled WEATHERPROOF EXTERIOR JOINTS WITH SILICONE CAULK INTAKE TERMINAL SCREEN FACING DOWN 12 MIN GRADE 4 MAX VACUUM RELIEF VALVE VERTICAL ORIENTATION PREFERRED FOR DUSTY INSTALLATIONS Figure 13 Ai
12. hazard AIR LEAKS Any such leaks should be repaired as they may cause erratic burning of the fuel and in extreme cases may become a fire hazard There are many possible causes of air leaks in oil lines such as i Fitting leaks due to mis flared tubing or damaged fitting ii Fuelline leak due to crushed or bent tubing iii Filter connection leaks iv Tank connection leaks There are various test kits available to trace air leaks such as electronic sight glasses Follow the manufacturers instructions to find air leaks The following actions can eliminate air leaks i Bleed pump as detailed in System Start Up Section of this manual ii Replace flare fittings iii Replace oil supply line iv Repair oil filter leaks v Replace or repair tank fittings GASKET LEAKS If 11 5 to 12 5 CO with 1 smoke cannot be obtained in the breeching look for air leaks around the flue collar Such air leaks will cause a lower CO reading in the breeching The smaller the firing rate the greater effect an air leak can have on CO readings DIRT A fuel filter is a good investment Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle The smaller the firing rate the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt WATER Water in the fuel in large amounts
13. inspected and packed Our responsibility ceases upon delivery of crated boiler to the carrier in good condition 2 ANY CLAIMS for damage or shortage in shipment must be filed immediately against the carrier by the consignee No claims for variances from or shortage in orders will be allowed by the manufacturer unless presented within sixty 60 days after receipt of goods B LOCATE BOILER in front of final position before removing crate See Figure 1 Boiler s approximate shipping weight is 325 pounds 1 LOCATE so that vent pipe will be short and direct Refer to Section V A General Venting Guidelines 2 BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR Boiler cannot be installed on carpeting 3 FOR BASEMENT INSTALLATION provide a solid base such as concrete if floor is not level or if water may be encountered on floor around boiler 4 PROVIDE SERVICE CLEARANCE of at least 24 at front of boiler for servicing 5 For minimum clearances to combustible materials see Figure 2 PROVIDE COMBUSTION AIR SUPPLY to accommodate proper combustion of oil Local and national codes may apply and should be referenced conventional frame brick or stone construction infiltration normally is adequate to provide air for combustion An unconfined space is a space whose volume is greater than or equal to 50 cubic feet per 1000 BTUH of the combined input of all air consuming appliances in the space 2 Ina conf
14. the highest water containing cavity of the boiler that 15 a hot water boiler must be full of water to operate safely WARNING Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns Do not pipe in any area where freezing could occur Do not install any shut off valves plugs or caps C Install Safety Relief Valve See Figures 5 and 7 Safety Relief Valve must be installed with spindle in vertical position Installation of the relief valve must be consistent with the ANSI ASME Boiler and Pressure Vessel Code Section IV VENT FROM ADDITIONAL ZONES Ves FROM ZONE 1 II lt _ 54 FROM ALLIANCE WATER 5 5 SHUT_OF HEATER IF USED TO ALLIANCE TO RETURN SHUT OFF unre DEALS US E VALVES WATER HEATER ZONE 1 THERMOMETER L IF USED YSTEM BYPASS RETURN VALVE HX i 4 LX BALANCING VALVE PURGE 18 MIN APER BYPASS VALVE IF CONVENTIONAL AIR SCOOP VANE ZONE VALVE AIR SCOOP IS i SYSTEM CIRCULATOR 11 TO IOl 5 ADDITIONAL SUPPLY RETURN NS VALVE v vt SYSTEM LIMIT 1 PRESSURE SHUT OFF CHECK VALVE REQUIRED 12 REDUCING VALVE IF REQUIRED LOW PUN BOILER VALVE COLD WATER UT OFF RETURN SUPPLY OPTIONAL THERMOMETER EXPANSION TANK PRESSURE SYSTEM VALVE SUPPLY PIPE WITHIN 6 OF FLOOR Fig
15. the second zone to be purged then close the first Repeat this step until all zones have been purged but always have one zone open At completion open all zone valves Close hose bib continue filling the system until the pressure gauge reads 12 psi Close fill valve Note If make up water line is equipped with pressure reducing valve system will automatically fill to 12 psi 10 Open isolation valve in boiler supply piping 11 Remove hose from hose bib WATER CHILLER HEATING SHUT OFF BOILER SHUT OFF VALVES VALVES AIR CUSHION TANK CIRCULATOR SUPPLY MAIN TO RETURN MAIN FROM COMBINED HEATING COMBINED HEATING amp COOLING SYSTEM amp COOLING SYSTEM Figure 6 Recommended Piping for Combination Heating amp Cooling Refrigeration Systems VENT FROM ADD TL BYPASSES FROM ADDITIONAL ZONES FROM ZONE 1 TO ALLIANCE WATER HEATER IF USED FROM ALLIANCE WATER 5 5 HEATER IF USED BYPASS SHUT OFF RETURN SHUT OFF VALVE VALVE THERMOMETER VALVES RETURN VALVE EM d FLOW CONTROL VALVE AIR VENT c PURGE 18 MIN CIRCULATOR VALVE IF CONVENTIONAL AIR SCOOP AIR SCOOP IS USED REDUCER 1 11 ADDITIONAL E BALL VALVE 1 FULL PORT 14 SYSTEM LIMIT LOW WATER PRESSURE SHUT OFF CHECK VALVE IF REQUIRED CUT OFF BOILER REDUCING VALVE IF REQUIRED OPTIONAL R
16. 3405 3801 SNILNNOW 5 4015 36 BECKETT AFII BURNER REPLACEMENT PARTS LEDV2 Beckett Part Number Complete Burner without Primary Control BCB5408 Air Tube Combination 5 Air Tube Screws 4352 Blower Wheel 21438 Coupling Motor to Pump 21437 51484U 31623 5394 21757 21941 31658 Head Assembly AFII 51671 6 Slot 51672 9 Slot 2139 51485 3666 Part Description Electrodes Replacement Kit Escutcheon Plate Fuel Pump Single Stage with Solenoid Valve Fuel Pump Two Stage with Solenoid Valve Gasket Flange Inlet Air Scoop Main Housing Assembly 51584 Nozzle Adapter 21444 213 51621 51424GY 7440 31613BK 21821BK Nozzle Line Heater Rear Access Door Electronic Ignitor 4 x 4 Electrical Box Electrical Box Extension Stop Screw Hole Plug Splined Nut 37 SERVICE RECORD DATE SERVICE PERFORMED 38 X Low Water Cut Off LWCO on Hot Water Boilers WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off LWCO Only use connections specifically identified for Low Water Cut Off In all cases follow the Low Water Cut Off manufacturer s instructions When A low water cutoff is required to protect a hot water boiler when any connected heat distributor radiation is installed below the top of t
17. Do not locate air intake termination into a crawl space or under a deck that also includes the vent termination regardless of distance between terminations 17 V Electrical and Sequence of Operations A B 18 ELECTRICAL 1 Install wiring and ground boiler in accordance with requirements of authority having jurisdiction or in absence of such requirements the National Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electric Code 2 A separate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions 3 Wiring should conform to Figures 15 and 15A 4 Thermostat heat anticipator setting 0 3 amp SEQUENCE OF OPERATIONS 1 General A call for heat by the thermostat energizes the L7248C limit control which in turn energizes the R7184P primary control to turn on the burner The circulator will operate as long as there is a call for heat If the call for heat is not satisfied and the high limit setting is reached the circulator will continue to operate and the burner will stop until the high limit circuit is closed by a drop in boiler water temperature 2 L7248C Combination Limit control The switching action within the L7248C control has one setting the high limit The switching relay 18 controlled by the low voltage room thermostat On a call for heat the relay c
18. ETURN VALVE THERMOMETER COLD WATER SUPPLY RETURN EXPANSION SUPPLY PRESSURE RELIEF SYSTEM VALVE SUPPLY PIPE WITHIN 6 OF FLOOR Figure 7 Recommended Water Piping for Circulator Zoned Heating Systems 11 IV Venting Air Intake A General Guidelines 1 Vent system installation must be in accordance with these instructions and applicable provisions of local building codes Contact local building or fire officials about restrictions and installation inspection in your area 2 The LE DV Series is designed as a Direct Vent boiler In this configuration all air for combustion 18 supplied directly to the burner from outdoors and flue gases are vented directly outdoors through wall See Figures 10 and 11 The LEDV may be side wall vented with combustion air supplied from indoors This configuration may be used in installations where infiltration provides adequate air for combustion and ventilation Flue gases are still vented directly outdoors through wall 3 For minimum clearances to combustible materials refer to Figure 2 4 Maximum wall thickness that vent terminal may be installed through is 10 inches WARNING DO NOT locate vent terminal where exposed to prevailing wind Moisture and ice may form on surfaces around vent termination To prevent deterioration surfaces should be in good repair sealed painted etc 5 Locate the vent terminal so vent pipe is short a
19. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR LE9DV SERIES DIRECT VENT OIL FIRED BOILER NTERTE W lt As an ENERGY STAR Partner Burnham Hydronics has determined that LEDV1 fired at the 0 60 rate meets the ENERGY STAR guidelines for Energy efficiency established by the United States Environmental Pro tection Agency EPA For service or repairs to boiler call your heating contractor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number Boiler Serial Number Installation Date LEDV Heating Contractor Phone Number Address Burnham by U S Boiler Company 81433101 16 1 10 53 00 IMPORTANT INFORMATION READ CAREFULLY All boilers must be installed in accordance with National State and Local Plumbing Heating and Electrical Codes and the regulations of the serving utilities These Codes and Regulations may differ from this instruction manual Authorities having jurisdiction should be consulted before installations are made In all cases reference should be made to the following Standards USA BOILERS Current Edition of American National Standard ANSI NFPA 31 Installation of Oil Burning Equipment for recommended installation practices B Current Edition of American National Standard ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances For Venting requirements C Cu
20. O JHL 30 dl S310N 8 1 LYVLS 134 JOMINOO 1 15 08 0 1 69 NOILOSLONd HOLIMS 30435 11 16 8 4 5 38 OL SW3ll 353 1 301911949 S3TIVISNI Ag 8 8 4 5 19 5 5 SUPPLIED BY INSTALLER SERVICE OVERCURRENT 1 SWITCH PROTECTION DISCONNEC ia oo 0 120 ut suPPLY 2 GND fo wecken 2 DOOR CAD INTERLOCK CELL RIELLO PRIMARY i L CONTROL 2 i HONEYWELL 72482 2 AQUASTAT CONTROL 9222 i RELAY LC 1 boeg pestes Ger e RIS RD HONEYWELL R8239A CONTROL CENTER WIRING BY INSTALLER AET UD peng AL1009 POSTPURGE TIMER CIRCULATOR SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C WIRE CODE LOW VOLTAGE SIZE 18 2 AWG POWER LIMITED CIRCUIT CABLE 75 105 C BK BLACK LINE VOLTAGE SIZE 18 TYPE TW OR TEW AWM WIRE ES LINE VOLTAGE SIZE 14 TYPE TW OR TEW AWM WIRE GR GREEN GY GRAY WIRENUT OR ORANGE RD RED WH WHITE NOTES 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN ABO
21. VE OR ITS EQUIVALENT Figure 15A Riello BF Burner Schematic Wiring Diagram Refer to the information supplied by the burner manufacturer for any additional burner information 20 VI Oil A General l Use flexible oil line s so that Swing Door can be opened without disconnecting oil supply supply line fuel oil filter is recommended as minimum for all firing rates but a pleated paper fuel oil filter is recommended for the lowest 6 GPH firing rate application to prevent nozzle fouling Use Flared fittings only Do not use compression fittings Use of a high efficiency micron oil filter Garber or equivalent in addition to conventional filter is highly recommended B Single pipe Oil Lines l Standard burners are provided with single stage 3450 rpm fuel units with the bypass plug removed for single pipe installations The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet See Figure 16 Single pipe installations must be absolutely airtight or leaks or loss of prime may result Bleed line and fuel unit completely Table 2 Single Stage Units 3450 RPM Two Pipe Systems Maximum Length of Tubing H R Lift 3 8 OD 1 2 OD Tubing 3 GPH Tubing 3 GPH 84 100 100 100 100 o e 100 Ad o N 100 100 100
22. ailure the manual reset button on the R7184P will be tripped 17224 10 F 6 C DIFFERENCE 17248 15 F EC DIFFERENCE OW LIMIT 10 F DIFFERENCE Figure 14 L7248 L7224 Setpoint and Differential Switching Action STARTS 34 2 6 N 1132 Qvo al WE DN L OO TN3INI ONIMS u3Nun8 STVNINYSL nNOOVYIANS 37199193933 193NNOO lt lt AMV MGL YO ML OMY L 3715 AMV M3L YO ML 3dAL OMY 81 3215 JOVLIOA INN 2 501 56 318vO NONIO G3LINT s3MOd OMY 2 81 3215 MOT 2 801 5 OMY 81 3715 39 OINSOWI J3Nsina HU 2 H 390L SLIHM M 3018 HM 18 108109 degLZ 1332038 11 MOTIBA 7 m E Z MIYOS di l 5 69 39NvNO NO 4 6 N3349 59 ama 78 yovia 18 Alddns hj 400 HIA M3MOd 1 09 02 mm SLI 3AO8V NMOHS SV 3MIM Q30v1d3M 5 Q3ov1d3M 38 LSNW JHL 5 Sv TWNISIY
23. ance and service to operate safely Follow the instructions contained in this manual Installation maintenance and service must be performed only by anexperienced skilled and knowledgeable installer or service agency heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler Installation is not complete unless a pressure relief valve is installed into the tapping located on top of appliance See Water Piping and Trim Section of this manual for details It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed This boiler is suitable for installation on combustible flooring Do not install boiler on carpeting Do not tamper with or alter the boiler or controls Inspect flueways at least once a year preferably at the start of the heating season The inside of the combustion chamber the vent system and boiler flueways should be cleaned if soot or scale has accumulated Oil Burner and Controls must be checked at least once a year or as may be necessitated Do not operate unit with jumpered or absent controls or safety devices Do not operate unit if any control switch component or device has been subject to water Table of Contents A 1 Pre Installation a
24. arge NOTE If the heat exchanger involved is no longer available due to product obsolescence U S Boiler Company Inc liability under these warranties shall under no or redesign the value used to establish the retail price will be the published price as circumstances exceed the purchase price paid by the owner for the residential shown in the Burnham Repair Parts Pricing where the heat exchanger last grade boiler involved Some states do not allow the exclusion or limitation of appeared or the current retail price of the then nearest equivalent heat exchanger incidental or consequential damages so the above limitation or exclusion may not MegaSteam Waterside Corrosion Warranty U S Boiler Company Inc warrants the apply to you cast iron sections of the MegaSteam boiler to resist Temperature Induced Chloride 8 Limitation of Warranties These warranties set forth the entire obligation of U S Activated Graphitic Corrosion for a period of five years from the date of original Boiler Company Inc with respect to any defect in a residential grade boiler parts installation In the event that any cast iron section of a Mega Steam boiler fails due to or accessories and U S Boiler Company Inc shall have no express obligations this corrosion mechanism during this period U S Boiler Company Inc will repair or responsibilities or liabilities of any kind whatsoever other than those set f
25. case drainings or any oil containing gasoline Never burn garbage or paper in this boiler Do not convert to any solid fuel i e wood coal Do not convert to any gaseous fuel i e natural gas LP propane All flammable debris rags paper wood scraps etc should be kept clear of the boiler at all times Keep the boiler area clean and free of fire hazards All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe property damage personal injury or loss of life Before opening swing door turn off service switch to boiler and disconnect two halves of Burner Swing Door Interlock wiring harness to prevent accidental firing of burner outside the combustion chamber Be sure to tighten swing door fastener completely and reconnect two halves of Burner Swing Door Interlock when service is completed WARNING Improperinstallation adjustment alteration serviceor maintenance can cause property damage personal injury or loss of life Failure to follow all instructions in the proper order can cause personal injury or death Read and understand all instructions including all those contained in component manufacturers manuals which are provided with the appliance before installing starting up operating maintaining or servicing this appliance Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician This boiler requires regular mainten
26. ce Switch door is securely closed Close door install fasteners to turn off burner and tighten securely Door should be parallel Manual Oil Supply Valve should be closed to tubesheet when viewed from top and sides and Electric Service to boiler turned off if Reconnect two halves of Swing Door Interlock boiler will not be operated for an extended C period of time Vent Air Intake System Inspect for obstructions soot accumulation proper support and deterioration of pipe fittings and joints A General Inspection service and cleaning should be conducted annually Turn off electric power and close oil supply valve while conducting service or maintenance 1 Inspect inside of vent pipe a Disconnect appliance adapter from boiler flue collar B Firetubes and Combustion Chamber b Remove any obstructions and clean with a wire brush as required 1 CLEAN THE FIRETUBES c Reconnect appliance adapter to boiler flue collar For access to fireside of boiler pull two halves as detailed in Section IV Venting Air Intake of Burner Swing Door Interlock wiring harness Piping apart remove fasteners holding door closed and 2 Clean terminal screens Terminals must be free of open swing door obstruction undamaged with screens securely in b Prior to cleaning boiler lay a protective cloth or place plastic over combustion chamber liner Usinga 1 2 diameter wire brush 30 handle clean firetub
27. e boiler water temperature is below the high limit Table 6 Beckett Burner Boiler Firing Rate Burner Air Tube Model GPH Model Combination Delavan Nozzle Air Head Pump Pressure stop screw PSIG Table 5 L7248 L7224 Controller Operating Sequence System Response Thermostat Circulator starts calls for Boiler temperature is checked Burner heat restarts when the water temperature is below high limit setting Burner is turned off Burner restarts when exceeds the the water temperature drops below the high limit setting minus the differential Thermostat f Circulator and burner turn off is satisfied Error If an error condition is detected all outputs condition are shut down Burner is off Control continues to function and restarts when error is corrected During the error check sequence the system checks for drift in the sensor and corrosion in the connections setting The high limit switch shuts off the burner If boiler water temperature exceeds the high limit setting The circulator will continue to operate as long as the thermostat 1s calling for heat The high limit automatically resets after the water temperature drops past the setpoint and through the differential F BURNER START UP WARNING Do not attempt to start the burner when excess oil has accumulated in the chamber when boiler is full of vapor or when combustion chamber is very hot 1 VERIFY burner settings a R
28. e 13 a Secure with at least three 3 sheet metal screws evenly spaced around the burner inlet ring Assemble the vacuum relief valve balance weight onto the gate Refer to the vacuum relief valve manufacturer s instructions Mount the vacuum relief valve into the tee and fasten with a screw and nut in collar tabs To ensure proper operation the gate must be level across the pivot point and plumb Refer to vacuum relief valve manufacturer s instructions 5 Install remainder of air intake securing each joint with at least three 3 sheet metal screws evenly spaced WARNING Do not locate air intake termination where natural convention or wind conditions may cause the boiler exhaust gases to be drawn into the air intake 6 Install air intake terminal See Figure 13 7 Sealall external joints with weatherproof caulk WARNING Donotlocate air intake where petroleum distillates CFC s detergents volatile vapors or any other chemicals are present Severe boiler corrosion and failure will result D Air Intake Installation Indoor Air for Combustion 1 Remove the black plastic inlet cover from the right side of the Beckett AFII burner 2 Attach the Air Intake Terminal directly to the burner intake collar 3 Discard the Vacuum Relief Valve Alternate to 1 2 and 3 Keep the black plastic inlet cover in place and discard the Air Intake Terminal and the Vacuum Relief Valve WARNING
29. ed and the safety switch of the burner primary control WARNING Very hot flue gases come out of sight hole when boiler is operated without sight plug installed Always wear proper eye protection 7 Bleed the fuel unit when the burner motor starts rotating To bleed loosen the vent fitting with plastic hose attached and catch the oil in an empty container Continue to bleed for 15 seconds after oil is free of air bubbles Tighten the vent fitting when all the air is purged NOTE Bleeding might not be 9 CHECK ADJUST OIL PRESSURE necessary with a two pipe system When vent fitting is closed burner flame should start immediately Figure 20B Checking Adjusting Fuel Pump Pressure a Check oil pressure to correspond to a specified value for a particular LEDV boiler model Refer to Table 6 25 26 b For adjustment locate oil pressure adjusting screw and turn screw to obtain oil pressure specified 10 ADJUST AIR SETTING on burner for alight orange colored flame Flame should be solid and compact Use smoke tester and adjust air for a minimum smoke not to exceed 1 with a minimum excess air Make final check using suitable instrumentation to obtain CO2 of 11 5 to 12 These settings will assure a safe and efficient operating condition If flame appears stringy instead of solid fire try another nozzle of the same type TURN OFF BURNER BY OPENING SERVICE 11 12 SWITCH Remove pressure gauge In
30. ee Figure 9 7 The LEDV must be vented with 4 Z Flex Direct Oil Vent 20 feet is the maximum vent length allowed The vent pipe is available in 5 10 15 and 20 foot lengths Table 1 lists vent part numbers Table 1 Vent Pipe Part Numbers 4 Direct Oil Vent Pipe Pipe Length 10 Ft 8113303 15 Ft 8113304 20 Ft 8113305 8 The vent system must be completed with the Direct Oil Vent Kit which is shipped with the boiler 12 MIN r AIR INTAKE TERMINAL SCREEN FACING DOWN Components of this kit are listed in the Repair Parts Section of this manual DANGER Vent pipe may not be spliced Do not drill through vent pipe Do not operate boiler if vent pipe has been crushed Vent pipe must be completely sealed Do notoperate boilerif vent pipe insulation sleeve is damaged frayed or missing B Vent Installation Direct Vent and Side Wall Vent 1 Install Vent Terminal See Figure 10 a After determining the location from previous Section cut an opening in the wall for the vent terminal Combustible wall 8 inches diameter hole 18 required to maintain a 1 inch clearance to combustible materials Non combustible wall 6 inches diameter hole is required b Secure 10 square trim plate to outside wall c Insert the vent terminal through the opening until the stop bead rest against the trim plate d Slide the 10 square inside trim plate assembly fitted with gear
31. efer to Table 6 for Beckett Burner Settings Refer to Table 6A for Riello BF Burner Settings b Check electrodes to comply with dimensions shown in Figure 20A For adjustment loosen the electrode clamp screw and slide rotate electrodes as needed Securely re tighten the clamp screw when finished Settings 24 Table 6A Riello BF Burner Settings Pt Settings ______ Boiler Firing Rate Burner Delavan Oil Model GPH Model Nozzle AirGate Pump Pressure PSIG NOZZLE TO TIP 3 3 a j SPACING 5 32 1 4 1 NOZZLE CENTER Figure 20A Electrode Tip Gap amp Spacing c Upon reinstallation of the nozzle line assembly 8 INSTALL PRESSURE GAUGE check that head air plate setting number pointer lines up with a number on the scale which matches a value shown in Table 6 for a particular boiler burner model a Either remove plastic hose and oil pump vent fitting then install a reliable pressure gauge into vent fitting port or install the gauge into the nozzle port See Figure 20B 2 Open all shut off valves in the oil supply line to the burner 3 Attach a plastic hose to fuel pump vent fitting and provide a container to catch the oil 4 REMOVE GAUGE PORT PLUG from fuel pump and install pressure gauge 5 REMOVE TEST PLUG IN FLUE COLLAR 6 Close the service switch to start the burner If the burner does not start immediately check the manual overload switch on the motor if so equipp
32. er or scale any part or accessory provided by U S Boiler Company Inc is found to be defective buildup in the heat exchanger in material or workmanship during this one year period U S Boiler Company Inc h Any damage caused by improper fuels fuel additives or contaminated will at its option repair or replace the defective part combustion air that may cause fireside corrosion and or clogging of the HEAT EXCHANGER WARRANTIES burner or heat exchanger U S Boiler Company Inc warrants to the original owner that the heat exchanger of its i Any damage resulting from combustion air contaminated with particulate residential grade boilers will remain free from defects in material and workmanship which cause clogging of the burner or combustion chamber including but under normal usage for time period specified in the chart below of the original owner at not limited to sheetrock or plasterboard particles dirt and dust particulate the original place of installation If a claim is made under this warranty during the No Any damage defects or malfunctions resulting from improper operation Charge period from the date of original installation U S Boiler Company Inc will at its maintenance misuse abuse accident negligence including but not limited to option repair or replace the heat exchanger If a claim is made under this warranty after operation with insufficient water flow improper water level improper water the expiration of the No Char
33. erate boiler with return water system leaks temperatures below 120 F 2 Absorption through open tanks and fittings The bypass should be the same size as the supply and return lines with valves located in the bypass 3 Oxygen permeable materials in the distribution system and return line as illustrated in Figures 5 and 7 in In order to insure long product life oxygen sources order to regulate water flow for maintenance of should be eliminated This can be accomplished by higher boiler water temperature taking the following measures Set the by pass and return valves to a half throttle 1 Repairing system leaks to eliminate the need for position to start Operate boiler until the system addition of make up water water temperature reaches its normal operating 2 Eliminating open tanks from the system 3 Eliminating and or repairing fittings which allow oxygen absorption 4 Use of non permeable materials in the distribution system 5 Isolating the boiler from the system water by installing a heat exchanger Connect System supply and return piping to boiler See Figures 5 and 7 Also consult I B R Installation and Guides Maintain minimum inch clearance from hot water piping to combustible materials 1 Ifthis boiler is used in connection with refrigeration range Adjust the valves to maintain 180 F to 200 F boiler water temperature and greater than 120 F return temperature Adjust both valv
34. es Measure 15 from end of brush 4 Pi t be full dsh dsh d opposite handle and mark handle DO NOT PRU DA from impact or excessive temperature 3 Terminal and wall thimbles 1f used must be weather tight allow this mark to go past front end of firetube during cleaning or brush will hit rear door 5 Pipe must be supported at minimum 5 foot intervals insulation piece and must not sag 2 CLEAN THE COMBUSTION CHAMBER 6 All vent joints must be secure and watertight Using wire or fiber bristle brush clean inside of 7 Allair intake joints must be secure and airtight combustion chamber DO NOT let brush hit rear door insulation piece combustion chamber liner n 3 AFTER CLEANING 1 Replace the oil supply line filter a Vacuum debris inside bottom of rear door 2 Remove and clean the pump strainer 1f applicable remove protective cloth and vacuum remaining 3 Replace the nozzle with an equivalent nozzle Refer fireside of boiler as necessary BE CAREFUL to Table 6 for Beckett Burner Settings Refer to not to damage liner or rear door insulation piece Table 6a for Riello BF Burner Settings Inspect front and rear door insulation pieces 4 Clean and inspect the electrodes for damage front door gaskets and combustion chamber liner replacing any that are cracked or chipped for damage Replace any damaged pieces 5 Clean the combustion head of all lint and soot 29 6 Ins
35. es simultaneously Closing the boiler return valve while opening the by pass valve will raise the boiler return temperature Opening the boiler return valve while closing the by pass valve will lower the boiler return temperature A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation If a low water cut off is required it must be systems the boiler must be installed so that the chilled medium 18 piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler see Figure 6 Also consult I B R Installation and Piping Guides Ifthis boiler 15 connected to heating coils located in air handling units where they may be exposed to refrigerated air the boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during the operation of the cooling system If boiler is used with an Alliance SL Indirect Fired Domestic Water Heater install the AllianceTM SL as a separate heating zone Refer to the Alliance SL Installation Operating and Service Instructions for additional information Use system bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may mounted in the system piping above the boiler The minimum safe water level of a hot water boiler 18 just above
36. ge period from the date of original installation U S Boiler chemistry or damage from freezing Company Inc will at its option and upon payment of the pro rated service charge set k Any damage caused by water side clogging due to dirty systems or forth below repair or replace the heat exchanger The service charge applicable to a corrosion products from the system heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of heat ni Damade or malfunction dde o4he lack of required maintenanae outlined ih exchanger model involved at the time the warranty claim is made as follows the and Operating Manual hited with the unit 6 Exclusive Remedy U S Boiler Company Inc obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall U S Boiler Company Inc be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time Any damage resulting from natural disaster Years in Service Cast Water No Cl Cast Iron Steam No CI Carbon Steel No CI Cast Aluminum No CI Stainless Steel No Ch
37. he hot water boiler baseboard on the same floor level as the boiler In addition some jurisdictions require the use of a LWCO with a hot water boiler Where The universal location for a LWCO on both gas and oil hot water boilers is above the boiler in either the supply or return piping The minimum safe water level of a water boiler is at the uppermost top of the boiler that is it must be full of water to operate safely What Kind Typically in residential applications a probe type LWCO is used instead of a float type due to their relative costs and the simplicity of piping for a probe LWCO How to Pipe A tee is commonly used to connect the probe LWCO to the supply or return piping as shown below SY RETURN SS ee g amp amp E ABLE S MINIMUM SAFE E WATER LINE N x gt LWCO Location Select the appropriate size tee using the LWCO manufacturer s instructions Often the branch connection must have a minimum diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee Ideally manual shutoff valves should be located above the LWCO and the boiler to allow for servicing This will allow probe removal for inspection without draining the heating system Many probe manufac
38. hen installing starting up or servicing this boiler to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when the boiler is operating Do not touch any components unless they are cool This boiler must be properly vented and connected to an approved vent system in good condition Do not operate boiler with the absence of an approved vent system This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting and air intake systems must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency This boiler is supplied with controls which may cause the boiler to shut down and not re start without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative This boiler is designed to burn No 2 fuel oil only Do not use gasoline crank
39. ide of boiler as Swing Door hinges MOVE BOILER TO PERMANENT POSITION by sliding or walking INSPECT FRONT AND REAR DOOR INSULATION AND COMBUSTION CHAMBER LINER 1 OPEN BURNER SWING DOOR on front of boiler Use flashlight to inspect insulation secured to front and rear doors Inspect ceramic fiber blanket secured to bottom of combustion chamber Inspect inner and outer door gaskets Replace any damaged pieces Z 3 MIN TO VENT PIPE 1 MIN TO VENT TERMINAL 1 FRONT VIEW RIGHT SIDE VIEW Figure 2 Minimum Clearances to Combustible Materials 5 VIEW 5 HINGES AS INSTALLED AT FACTORY CLEVIS TUBESHEET SWING DOOR HINGE SET ASSEMBLY VIEW Figure 3 Proper Hinge Bracket Installation and Assembly Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or building Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure U S Boiler s Standard Warranty does not cover problems caused by oxygen contamination of boiler water A Design and install boiler and system piping to be encountered 1 e converted gravity circulation prevent oxygen contamination of boiler water system etc There are many possible causes of oxygen contamination such as CAUTION 1 Addition of excessive make up water as a result of Do not op
40. ined space combustion air may be ducted directly from the outdoors to the burner Refer to Section IV for installation of air intake duct to the burner VENTILATION AIR must be provided to maintain the ambient temperature at safe limits Local and national codes may apply and should be referenced 1 In unconfined spaces basement in buildings of conventional frame brick or stone construction infiltration normally is adequate to provide air for ventilation 2 In confined spaces closet etc two permanent openings one near the top of the enclosure and one near the bottom shall be provided Each opening shall have a free area of not less than 1 sq inch per 1000 BTUH of the total input of all appliances in the space Do not install boiler where gasoline or other flammable vapors or liquids or sources of hydrocarbons bleaches cleaners chemicals sprays paint removers fabric softeners etc are used or stored Unpack Boiler CAUTION Do not drop boiler Do not bump boiler jacket against floor A REMOVE CRATE Remove all fasteners at crate skid 2 Lift outside container and remove all other inside protective spacers and bracing Remove vacuum relief valve and miscellaneous trim bag containing safety relief valve and pipe fittings B REMOVAL OF BOILER FROM SKID 1 Boiler is secured to base with 2 bolts 1 at left front and 1 at right rear Remove both bolts 2 Tilt boiler walk boiler
41. line silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 31 IX Repair Parts LE DV Series Repair Parts may be obtained through your local U S Boiler Wholesale Distributor Should you require assistance in locating a U S Boiler Distributor in your area or have questions regarding the availability of U S Boiler products or repair parts please contact U S Boiler Customer Service at 717 481 8400 or Fax 717 481 8408 i X 3 NIPPLE SUPPLIED N 7 Figure 21 LEDV Boiler amp Controls 6 Beckett R7184 O1 Primary Conr 1 80160847 5 Strain Retief Bushing Not Show 8139028 32 REAR BOX W INSULATION P N 6043302 WRAPPER PANEL P N 6043301 SHELL WRAPPER INSULATION P N 7203303 8 4 PHILLIPS HEAD SHEET METAL SCREW P N 80860000 REAR STRAP P N 7043303 FRONT STRAP ASSEMBLY P N 6043303 Figure 22 LEDV Boiler
42. nd direct and at a place on the exterior wall that complies with the minimum distances as specified in Figure 8 and listed below The vent terminal must be located a Not less than 12 inches above grade plus snow accumulation as measured to the nearest edge of terminal b Not less than 3 feet to center of terminal above any forced air inlet located within 10 feet c Notless than 1 foot to center of terminal horizontally from any door window or gravity air inlet d Not less than 7 feet to center of terminal above a public walkway e Not less than 3 feet to center of terminal from an inside corner of an L shaped structure f Not less than foot from nearest surface of terminal to a roof soffit g Not directly above or not less than 6 feet horizontally from an oil tank vent or gas meter h Not less than 2 feet from nearest surface of terminal to an adjacent building Figure 8 Vent Terminal Location 12 CAUTION Operation of boiler with improperly adjusted burner may result in soot damage to side of house 6 Intake Terminal Location Direct Vent only Locate Air Intake Terminal not less than 12 inches to the left right or bottom of the vent terminal Do not locate air intake terminal above vent terminal Intake terminal must be at least 12 inches above grade plus snow accumulation at least 1 foot from a roof soffit at least 3 feet from an inside corner of an L shaped structure S
43. ng kind caused by or relating to improper installation full particulars in support of the claim The owner is required to make available for inspection by U S Boiler Company Inc or its representative the parts claimed to be defective and if requested by U S Boiler Company Inc to ship these parts prepaid to U S Boiler Company Inc at the above address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts 4 Proper Use and Maintenance The warranties extended by U S Boiler Company Inc conditioned upon the use of the residential grade boiler parts and accessories for its intended purposes and its maintenance accordance with U S Boiler Company Inc recommendations and hydronics industry standards For proper installation use and maintenance see all applicable sections of the Installation and Operating and Service Instructions Manual furnished with the unit 5 This warranty does not cover the following THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY a Expenses for removal or reinstallation The homeowner will be responsible ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from U S Boiler Company Inc C
44. nificantly shorten the life of the boiler Entrained in make up water are dissolved minerals and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas Both can result in reduced boiler life The accumulation of sediment can eventually isolate the water from contacting the steel When this happens the steel in that area gets extremely hot and eventually cracks The presence of free oxygen in the boiler creates a corrosive atmosphere which if the concentration becomes high enough can corrode the 27 28 steel through from the inside Since neither of these failure types are the result of a manufacturing defect the warranty does not apply Clearly it is in everyone s best interest to prevent this type of failure The maintenance of system integrity is the best method to achieve this Section VIII Service and Cleaning WARNING All boiler cleaning must be completed with burner service switch turned off Boilers equipped with burner swing door have a potential hazard which can cause severe property damage personal injury or loss of life if ignored Before opening swing door turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber Be sure to tighten swing door fasteners completely when service is completed 4 CLOSE BOILER NOTICE CAUTION Do not start burner unless burner swing BURNER SHUTDOWN Open Servi
45. ny Inc and installed in a PROCEDURE FOR OBTAINING WARRANTY SERVICE single or two family residence and do not apply to commercial grade products In order to assure prompt warranty service the owner is requested to complete 2 Components Manufactured by Others Upon expiration of the one year limited and mail the Warranty Card provided with the product or register product online warranty on residential grade boilers all boiler components manufactured by at www burnham com within ten days after the installation of the boiler although others but furnished by U S Boiler Company Inc such as oil burner circulator failure to comply with this request will not void the owner s rights under these and controls will be subject only to the manufacturer s warranty if any warranties Upon discovery of a condition believed to be related to a defect in 3 Proper Installation The warranties extended by U S Boiler Company Inc material or workmanship covered by these warranties the owner should notify are conditioned upon the installation of the residential grade boiler parts and the installer who will in turn notify the distributor If this action is not possible or accessories in strict compliance with U S Boiler Co Inc installation does not produce a prompt response the owner should write to U S Boiler instructions U S Boiler Company Inc specifically disclaims liability of any Company Inc Box 3079 Lancaster PA 17604 givi
46. ny three 3 operational states Normal High Limit and Error The controller moves back and forth from High Limit to Normal state as part of normal operation The controller will enter the Error state when there 15 an abnormal condition The operating states are a Normal Boiler temperature has gone below the high limit setting minus the differential and has not exceeded the high limit setting b High Limit Boiler temperature has gone above the high limit setting and has not dropped below the high limit setting minus the differential c Error The controller has detected an error condition e g open sensor and has shut down the burner output The controller continues to monitor the system and automatically restarts 1f the error condition clears See Table 4 Table 4 LED Error Codes Cause Action Sensor fault check sensor ECOM fault check EnviraCom wiring Hardware fault replace control d Low Limit Boiler temperature has gone below the low limit setting minus the low limit differential and has not gone above the low limit setting e The operating sequence for L7248 L7224 is described below and shown in Table 5 The switching action in the L7248 L7224 control has one setting the high limit see Figure 14 The switching relay 18 controlled by the low voltage room thermostat On a call for heat the relay contacts make to complete the line voltage circulator circuit and also the burner circuit if th
47. olating fuel side problems is to disconnect the fuel system and with a 2 foot length of tubing fire out of an auxiliary five gallon pail of clean fresh warm 2 oil from another source If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite G TEST CONTROLS WARNING Before installation of the boiler is considered complete the operation of all boiler controls must be checked particularly the primary control and high limit control 1 CHECK THERMOSTAT OPERATION Raise and lower thermostat setting as required to start and stop burner 2 VERIFY PRIMARY CONTROL SAFETY FEATURES using procedures outlined in Instructions furnished with control See back of Control Cover or Instructions as follows ron HEATING SERVICEMAN ONLY a Simulate flame failure Follow the starting procedure to turn on the burner Close the hand valve in the oil supply line Safety switch should lock out in approximately 15 seconds Ignition should stop and oil valve should close Blower will stop after postpurge period Push red reset button to reset safety switch b Simulate ignition failure Follow the starting procedure to turn on the burner but do not open the oil supply hand valve Safety switch should lock out in approximately 15 seconds Ignition and motor should stop and oil valve should close
48. omponents that are part of the heating system but were not furnished Eu rr ih c U S Boiler Company Inc as part of residential boiler c Improper burner adjustment control settings care or maintenance by U 5 Boiler Company
49. ontacts close to complete the line voltage circulator circuit and also the burner circuit if the boiler water temperature is below the high limit setting The high limit switch shuts off the burner 1f boiler water temperature exceeds the high limit setting See Figure 14 3 R7184P Oil Primary Control The R7184P operates the oil burner motor solenoid oil valve and the electronic ignitor in response to a call for heat from the L7248C limit control a Acall for heat will energize the burner motor and electronic ignitor b After a 15 second pre purge period in which time a draft is established in the flueways the oil valve is opened SETTING c Ifthe burner ignites within 15 seconds from the time the oil valve opens and the CAD cell senses a flame the electronic ignitor is de energized and the burner will operate until the call for heat is satisfied or the setting of the high limit is reached d manual reset button is provided to reset the safety switch after lockout e When the call for heat ends or the CAD cell fails to sense a flame the oil valve will close The combustion blower will continue to operate for a postpurge period of approximately two 2 minutes 4 CAD Cell The Beckett AFII burners used on the LEDV Series are supplied with a C554A Cadmium Sulfide cad cell Flame Detector to monitor the burner flame and shut down the burner on ignition failure or on flame failure during the run cycle On either f
50. orth replace at its option the cast iron section assembly herein These warranties are given in lieu of all other express warranties LIFETIME NIPPLE LEAKAGE WARRANTY ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY U S Boiler Company Inc warrants the cast iron and steel nipples that join the cast iron WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR boiler sections to be free of defects in material and workmanship for the lifetime of the PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE original owner at the original place of installation In the event that such nipples are YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO found to be defective in material and workmanship during this period U S Boiler THE HEAT EXCHANGER IN A RESIDENTIAL GRADE BOILER SHALL Company Inc will repair or replace at its option the cast iron section assembly EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE ADDITIONAL TERMS AND CONDITIONS HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NOT ALLOW LIMITATION ON HOW 1 Applicability The limited warranties set forth above are extended only to the LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY original owner at the original place of installation within the United States and Canada These warranties are applicable only to boilers parts or accessories NOT APPLY TO YOU designated as residential grade by U S Boiler Compa
51. ould be removed once a year examined and cleaned of any dirt accumulations to assure proper operations Do not attempt to repair mechanisms in the field Complete replacement mechanisms including necessary gaskets and installation instructions are available from the manufacturer Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repair Parts list designates parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystal
52. pect the transformer cables and connectors 7 Remove and clean the cad cell Clean the blower wheel and the air control of any lint Check all wiring for secure connections or insulation breaks 10 Re adjust the burner as detailed in Section VII System Start up Paragraph F Controls Test Controls for proper operation as detailed in Section VII System Start up Paragraph G Low water cutoff if so equipped 30 1 Float Type a Monthly Blowoff During the heating season 1 an external float type low water cutoff is on the boiler the blow off valve should be opened once a month use greater frequency where conditions warrant to flush out the sediment chamber so the device will be free to function properly b Annual Service Float type low water cutoffs should be dismantled annually by qualified personnel to the extent necessary to insure freedom from obstructions and proper functioning of the working parts Inspect connecting lines to boiler for accumulation of mud scale etc and clean as required Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly Give special attention to solder joints on bellows and float when this type of control is used Check float for evidence of collapse and check mercury bulb where applicable for mercury separation or discoloration 2 Probe Type Annual Service Probe type LWCO sh
53. r Intake Installation e Secure the inside trim plate to inside wall f Tighten the gear clamp to the terminal pipe g Seal all external joints with a weatherproof caulk 2 Cut vent pipe to length with a hack saw 3 Install Vent Connector Appliance Adaptor See Figures 11 and 12 a Apply a continuous bead of high temperature adhesive sealant supplied with boiler around outside of corrugated pipe of vent connector b Twist vent connector into end of vent pipe Turn the connector counter clockwise until it 1s engaged approximately 4 inches into the inner vent pipe and the outer collar of the connector overlaps the outside of the vent pipe c Tighten the gear clamp on the outer collar of the connector d Repeat steps a through c with the appliance adapter 4 Connect vent pipe to boiler a Apply a continuous bead of high temperature adhesive sealant supplied with boiler to inside of appliance adapter approximately inch from end b Slip appliance adapter over boiler flue collar and tighten gear clamp 5 Connect vent pipe to terminal a Carefully slide insulation sleeve over vent connector and vent pipe until gear clamp on small end of connector can be accessed WARNING Do not operate LEDV with barometric damper in vent Do not connect venting to chimney b Apply a continuous bead of high temperature adhesive sealant supplied with boiler on inside of cent connector approximately inch from
54. ried to suit requirements of installation Differential is fixed at 15 F i Adjusting Settings To discourage unauthorized changing of Aquastat settings a procedure to enter the adjustment mode is required To enter the adjustment mode press the UP DOWN and I buttons see Figure 18 simultaneously for three 3 seconds Press the button until the feature requiring adjustment is displayed press the button again and will display LL Low Limit on L7224 to move the set point to the desired value After 60 seconds without any button inputs the control will automatically return to the READ mode ii Display In the RUN mode the Aquastat will flash bt boiler temp followed by the temperature 1 e 220 followed by or To read boiler settings press the I key to read the parameter of interest For example press I HL High Limit is displayed followed by a three digit number 1 220 followed by F or C See Figure 19 for Display Readout Definitions Display Text Description Shows bt Boiler Temperature HL High Limit HL err Error Code Err f Degrees Fahrenheit Degrees Celsius LL Low Limit LL Figure 19 Display Readout Definitions 23 After approximately 60 seconds without any key pressed the display will enter a dim display mode To return to the bright display mode simply press any key 2 Control Operating Characteristics The L7248 L7224 can be in a
55. rrent Edition of American Society of Mechanical Engineers ASME CSD 1 Controls and Safety Devices for Automatically Fired Boilers for assembly and operations of controls and safety devices D wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and or Local Regulations CANADIAN BOILERS Current Edition of Canadian Standards Association CSA B139 Installation Code for Oil Burning Equipment for recommended Installation Practices B All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and or Local Regulations The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage NOTICE Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards NOTICE This boiler has a limited warranty a copy of which is printed on
56. stall gauge port plug and tighten Re start burner HINTS ON COMBUSTION a NOZZLES Although the nozzle is a relatively inexpensive device its function is critical to the successful operation of the oil burner The selection of the nozzle supplied with the LEDV boiler is the result of extensive testing to obtain the best flame shape and efficient combustion Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO and smoke Nozzles are delicate and should be protected from dirt and abuse Nozzles are mass produced and can vary from sample to sample For all of those reasons a spare nozzle is a desirable item for a serviceman to have FLAME SHAPE Looking into the combustion chamber through the flame plug hole the flame should appear straight with no sparklers rolling up toward the top of the chamber If the flame drags to the right or left sends sparklers upward or makes wet spots on the rear door insulation piece the nozzle should be replaced If the condition persists look for fuel leaks air leaks water or dirt in the fuel as described below FUEL LEAKS Any fuel leak between the pump and the nozzle will be detrimental to good combustion results Look for wet surfaces in the air tube under the transformer and around the air inlet Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a fire
57. the back of this manual 15 the responsibility ofthe installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete The warranty for this boiler is valid only if the boiler has been installed maintained and operated in accordance with these instructions DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance If you smell gas vapors DO NOT try to operate any appliance DO NOT touch any electrical switch or use any phone in the building Immediately call the gas supplier from a remotely located phone Follow the gas supplier s instructions or if the supplier is unavailable contact the fire department WARNING Boiler materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the boiler This boiler contains very hot water under high pressures Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment w
58. turers recommend an annual inspection of the probe How to Wire LWCO s are available in either 120 VAC or 24 VAC configurations The 120 VAC configuration can be universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler after the service switch 1f so equipped The presence of water in a properly installed LWCO will cause the normally open contact of the LWCO to close thus providing continuity of the 120 VAC service to the boiler It is recommended to supply power to the probe LWCO with the same line voltage boiler service as shown below Wiring of Typical LWCO A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler However a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application How to Test Shut off fuel supply Lower water level until water level is BELOW the LWCO Generate a boiler demand by turning up thermostat Boiler should not attempt to operate Increase the water level by filling the system The boiler should attempt to operate once the water level 18 above the 39 For Residential Grade Water and Steam Boilers L Im nt 22 Stainless Steel Heat Exchangers and Parts Accessories Subject to the terms and conditions set forth below U S Boiler Company Inc d This warranty
59. ure 5 Recommended Water Piping for Zone Valve Zoned Heating Systems D Install Drain Valve in return piping See Figure 5 E Oil grease and other foreign materials which accumulate in new hot water boilers and a new or reworked system should be boiled out and then thoroughly flushed A qualified water treatment chemical specialist should be consulted for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations F After the boiler and system have been cleaned and flushed and before refilling the entire system add appropriate water treatment chemicals if necessary to bring the pH between 7 and 11 G Fill entire heating system with water and vent air from system Use the following procedure on a Series Loop System equipped with zone valves See Figure 5 1 Close isolation valve in boiler supply piping 2 Isolate all circuits by closing zone valves or balancing valves 10 Attach a hose to hose bib located just below isolation valve in boiler supply piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area Starting with one circuit open zone valve 5 Open hose bib 6 Open fill valve Make up water line should be located directly above isolation valve in boiler supply piping Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds Open zone valve to
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