Burnham 81433101R16-1-10 User Manual

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81433101R16-1/10

Price - $3.00

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 A. 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. Current 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. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations.

CANADIAN BOILERS A. 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.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility of the 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 ammable 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 re 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 ttings 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 when 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 efciency.

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, crankcase 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 ammable debris,

rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean

and free of re 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

ring 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

Improper installation, adjustment, alteration, service or 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 maintenance and service to operate safely. Follow the instructions contained

in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

All 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 ooring. Do not install boiler on carpeting.

Do not tamper with or alter the boiler or controls.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler ueways 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

I. Pre-Installation ............................................................6

II. Unpack Boiler ..............................................................7

III. Water Piping and Trim .................................................

IV. Venting/Air Intake Piping ..........................................12

V. Electrical and Sequence of Operations .......................

VI. Oil Piping ..................................................................21

VII. System Start-up ..........................................................23

VIII. Service and Cleaning ..................................................

IX. Repair Parts ...............................................................

X. Appendix

Low Water Cut Oﬀ .....................................................39

Water Content: 6.1 gallons

Figure 1: LEDV Packaged Boiler

I. Pre-Installation

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. ALL EQUIPMENT is carefully manufactured, 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 led 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 nal 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 oor is not level, or if water may be encountered on oor around boiler.

1. In unconned spaces (basement) in buildings of

conventional frame, brick, or stone construction,

inltration normally is adequate to provide air for combustion. An unconned 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. In a conned 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.

D. 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 unconned spaces (basement) in buildings of

conventional frame, brick, or stone construction,

inltration normally is adequate to provide air for

ventilation.

2. In conned 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.

4. PROVIDE SERVICE CLEARANCE of at least 24” at front of boiler for servicing.

5. For minimum clearances to combustible materials, see Figure 2.

C. PROVIDE COMBUSTION AIR SUPPLY to

accommodate proper combustion of oil. Local and national codes may apply and should be referenced.

E. Do not install boiler where gasoline or other ammable

vapors or liquids, or sources of hydrocarbons (i.e.

bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.

II. Unpack Boiler

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

A. REMOVE CRATE

1. 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 ttings.

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 backward, and set rear

legs down on oor. 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 at 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. Remove 4 hex head cap screws that attach hinges to door.

5. Attach 2 hinge brackets & 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 at 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 is 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.

E. 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 in control.

2. Secure exible conduit to Jacket Wrapper side with

conduit clamp and sheet metal screw. Conduit must be on same side of boiler as Swing Door hinges.

F. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

G. INSPECT FRONT AND REAR DOOR INSULATION

AND COMBUSTION CHAMBER LINER

1. OPEN BURNER SWING DOOR on front of boiler.

Use ashlight to inspect insulation secured to front and rear doors. Inspect ceramic ber blanket

secured to bottom of combustion chamber. Inspect inner and outer door gaskets. Replace any damaged pieces.

Figure 2: Minimum Clearances to Combustible Materials

Figure 3: Proper Hinge Bracket Installation and Assembly

III. 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

prevent oxygen contamination of boiler water.

There are many possible causes of oxygen

contamination such as:

1. Addition of excessive make-up water as a result of system leaks.

2. Absorption through open tanks and ttings.

3. Oxygen permeable materials in the distribution system.

In order to insure long product life, oxygen sources

should be eliminated. This can be accomplished by taking the following measures:

1. Repairing system leaks to eliminate the need for addition of make-up water.

2. Eliminating open tanks from the system.

3. Eliminating and/or repairing ttings 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.

B. Connect System supply and return piping to boiler. See

Figures 5 and 7. Also consult I=B=R Installation and Piping Guides. Maintain minimum ½ inch clearance from hot water piping to combustible materials.

1. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is 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.

2. If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be

equipped with ow control valves to prevent gravity

circulation of boiler water during the operation of the cooling system.

3. If boiler is used with an Alliance™ SL IndirectFired Domestic Water Heater, install the Alliance™ SL as a separate heating zone. Refer to the Alliance™ SL Installation, Operating, and Service Instructions for additional information.

4. Use a 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

be encountered (i.e. converted gravity circulation system, etc.).

CAUTION

Do not operate boiler with return water temperatures below 120°F.

The bypass should be the same size as the supply

and return lines with valves located in the bypass and return line as illustrated in Figures 5 and 7 in

order to regulate water ow for maintenance of

higher boiler water temperature.

Set the by-pass and return valves to a half throttle

position to start. Operate boiler until the system water temperature reaches its normal operating range.

Adjust the valves to maintain 180°F to 200°F boiler

water temperature and greater than 120°F return temperature. Adjust both valves 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.

5. 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

mounted in the system piping above the boiler.

The minimum safe water level of a hot water boiler

is just above the highest water containing cavity of the boiler; that is, a hot water boiler must be full of water to operate safely.

WARNING

Safety (relief) valve discharge piping must be

piped near oor 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.

Figure 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 ushed. A qualied 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

ushed, and before relling 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.

3. Attach a hose to hose bib located just below isolation valve in boiler supply piping. (Note

- Terminate hose in ve gallon bucket at a suitable oor drain or outdoor area).

4. Starting with one circuit, open zone valve.

5. Open hose bib.

6. Open ll valve (Make-up water line should be

located directly above isolation valve in boiler supply piping).

7. Allow water to overow from bucket until discharge

from hose is bubble free for 30 seconds.

8. Open zone valve to the second zone to be purged,

then close the rst. Repeat this step until all zones

have been purged, but always have one zone open. At completion, open all zone valves.

9. Close hose bib, continue lling the system until the pressure gauge reads 12 psi. Close ll valve. (Note - If make-up water line is equipped with

pressure reducing valve, system will automatically

ll to 12 psi.

10. Open isolation valve in boiler supply piping.

11. Remove hose from hose bib.

Figure 6: Recommended Piping for Combination Heating &

Cooling (Refrigeration) Systems

Figure 7: Recommended Water Piping for Circulator Zoned Heating Systems

IV. Venting / Air Intake Piping

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 re ofcials about restrictions and installation inspection

in your area.

2. The LE®DV Series is designed as a Direct Vent

boiler. In this conguration, all air for combustion

is supplied directly to the burner from outdoors and

ue 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 conguration may be used in installations where inltration 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 and direct, and at a place on the exterior wall that

complies with the minimum distances as specied 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. Not less 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 1 foot from nearest surface of

terminal to a roof soft.

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

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 soft; at least 3 feet from an inside corner of an

L-shaped structure. See 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 Part No.

5 Ft. 8113302

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.

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 not operate boiler if 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

is required to maintain a 1 inch clearance to

combustible materials.

• Non-combustible wall: 6½ 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

(tted with gear clamp) onto the terminal pipe.

Figure 9: Intake Terminal Location

Figure 10: Vent Installation

Figure 11: Vent Connector, Un-Assembled

Figure 12: Vent Connector, Assembled

Figure 13: Air 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.

b. Avoid any sags or dips in vent pipe.

C. Air Intake Installation (Direct Vent only)

See Figure 13.

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 is 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 ½ inch from end).

b. Slip appliance adapter over boiler ue 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 ½ inch from 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. All horizontal runs must rise at least ¼ inch per

foot toward vent terminal.

WARNING

Do not reduce size of air intake pipe.

Read, understand and follow combustion air instruction restrictions contained in the PreInstallation Section of this manual.

1. General

a. Use 4 inch diameter single wall metal pipe and

ttings available at most heating distributors.

Maximum allowable air intake length is 40

equivalent feet. Each elbow is equal to 6 equivalent feet.

b. Start at Burner. Work toward air intake terminal.

c. Maintain minimum of ¼ inch per foot slope in

horizontal run to air intake terminal. Slope down toward air intake terminal.

d. 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 Figure 13.

a. Secure with at least three (3) sheet metal screws

evenly spaced around the burner inlet ring.

b. Assemble the vacuum relief valve balance

weight onto the gate. Refer to the vacuum relief valve manufacturer's instructions.

c. 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. Seal all external joints with weatherproof caulk.

WARNING

Do not locate air intake where petroleum distillates, CFC's, detergents, volatile vapors or any other chemicals are present. Severe boiler corrosion and failure will result.

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

D. Air Intake Installation (Indoor Air for Combustion)

1. Remove the black plastic inlet cover from the right side of the Beckett AFII burner.

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.

V. Electrical and Sequence of Operations

A. 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.

B. SEQUENCE OF OPERATIONS

1. General 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 satised 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.

. A call for heat by the thermostat energizes

c. If the burner ignites within 15 seconds from the

time the oil valve opens and the CAD cell senses

a ame, the electronic ignitor is de-energized

and the burner will operate until the call for

heat is satised or the setting of the high limit is

reached.

d. A 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 ame, 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 Sulde (cad cell) Flame Detector to monitor the burner ame and shut down the burner on ignition failure or on ame

failure during the run cycle. On either failure, the manual reset button on the R7184P will be tripped.

2. L7248C Combination Limit control.

The switching action within the L7248C control has

one setting, the high limit. The switching relay is controlled by the low voltage room thermostat. On a call for heat, the relay contacts 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 if 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. A call 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 ueways, the oil

valve is opened.

Figure 14: L7248/L7224 Setpoint and Differential

Switching Action

Figure 15: Beckett Burner Schematic Wiring Diagram

Figure 15A: Riello BF Burner Schematic Wiring Diagram

Refer to the information supplied by the burner manufacturer for any additional burner information.

VI. Oil Piping

A. General

1. Use exible oil line(s) so that Swing Door can be

opened without disconnecting oil supply.

2. A supply line fuel oil lter is recommended as a minimum for all ring rates but a pleated paper fuel oil lter is recommended for the lowest (.6 GPH) ring rate application to prevent nozzle fouling.

3. Use Flared ttings only. Do not use compression ttings.

4. Use of a high efciency micron oil lter (Garber or equivalent) in addition to conventional lter is

highly recommended.

B. Single-pipe Oil Lines.

1. Standard burners are provided with single-stage 3450 rpm fuel units with the bypass plug removed for single-pipe installations.

2. The single-stage fuel unit may be installed singlepipe with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 16.

NOTICE

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 "H"

3/8" OD

Tubing (3 GPH)

0' 84' 100'

1' 78' 100'

2' 73' 100'

3' 68' 100'

4' 63' 100'

5' 57' 100'

6' 52' 100'

7' 47' 100'

8' 42' 100'

9' 36' 100'

10' 31' 100'

11' 26' 100'

12' 21' 83'

13' --- 62'

1/2" OD

Tubing (3 GPH)

14' --- 41'

Figure 16: Single-Pipe Installation

Figure 17: Two-Pipe Installation

C. Two-Pipe Oil Lines.

1. For two-pipe systems where more lift is required,

the two-stage fuel unit is recommended. Table 2 (single-stage) and Table 3 (two-stage) show allowable lift and lengths of 3/8-inch and ½-inch OD tubing for both suction and return lines. Refer to Figure 17.

Table 3: Two-Stage Units (3450 RPM) - Two Pipe Systems

Maximum Length of Tubing

Lift "H"

3/8" OD

Tubing (3 GPH)

0' 93' 100'

2' 85' 100'

4' 77' 100'

6' 69' 100'

8' 60' 100'

10' 52' 100'

12' 44' 100'

14' 36' 100'

16' 27' 100'

18' --- 76'

"H" + "R"

1/2" OD

Tubing (3 GPH)

VII. System Start-up

WARNING

All 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 ring 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.

B. FILL HEATING SYSTEM WITH WATER. Refer to

Section III, G.

C. CHECK CONTROLS, WIRING AND BURNER to be

sure that all connections are tight and burner is rigid, that all electrical connections have been completed and

fuses installed, and that oil tank is lled and oil lines

have been tested.

D. LUBRICATION — Follow instruction on burner and

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 eld lubrication. Water lubricated circulators do not need eld lubrication.

Do not over-lubricate. This can cause as much trouble

as no lubrication at all.

E. ADJUST CONTROL SETTINGS with burner

service switch turned “ON” and room thermostat set 10° below room temperature.

Adjustment and display modes of the L7248/

L7224 Oil Electronic Aquastat Controller.

a. 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 varied to suit

requirements of installation. Differential is xed

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 ‘I’ button

until the feature requiring adjustment is

displayed (press the “I” button again and will display LL (Low Limit on L7224):

Figure 18: L7248 Circuit Board Layout -

Horizontal Mount

· High Limit

· °F -- °C (Toggle)

Then press the UP and/or DOWN buttons

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

ash “bt” (boiler temp.) followed by the

temperature (i.e., 220), followed by °F or °C.

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, i.e., 220, followed by °F or °C.

See Figure 19 for Display Readout

Denitions.

Display

Text Description Shows

bt Boiler Temperature HL High Limit err Error Code f Degrees Fahrenheit c Degrees Celsius LL Low Limit

Figure 19: Display Readout Denitions

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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 any three (3)

operational states: Normal, High-Limit and Error. The controller moves back and forth from HighLimit to Normal state as part of normal operation.

The controller will enter the Error state when there

is 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 if the error condition clears. See Table 4.

Table 4: LED Error Codes

Error Code Cause/Action

Err1 Sensor fault; check sensor.

Err2 ECOM fault; check EnviraCom™ wiring.

Err3 Hardware fault’ replace control.

Table 5: L7248/L7224 Controller

Operating Sequence

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 is 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

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 is controlled by the low voltage room thermostat. On a call for heat, the relay contacts make to complete the line voltage

Table 6: Beckett AFII Burner

Boiler

Model

LEDV1 0.60 AFII 85 HLX50HD 0.50 x 70°B 2.5 #2 140

LEDV2 1.00 AFII 150 HLX50HE 0.85 x 60°B 3.5 #3 140

LEDV3 1.25 AFII 150 HLX50HE 1.00 x 60°B 4.0 #5 140

circulator circuit and also the burner circuit if the boiler water temperature is below the high limit

Firing Rate

(GPH)

Burner

Model

Air Tube

Combination

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. Refer 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 nished.

Settings

Delavan

Nozzle

Air

Head

(stop screw)

Pump Pressure

(PSIG)

Table 6A: Riello BF Burner Settings

Boiler Model

LEDV1 0.60 BF3 0.50 - 60° A 4.0 145 0

LEDV2 1.00 BF5 0.85 - 60° A 5.0 145 1.0

LEDV3 1.25 BF5 1.00 - 60° A 6.5 145 3.0

c. Upon reinstallation of the nozzle line assembly,

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.

2. Open all shut-off valves in the oil supply line to the burner.

3. Attach a plastic hose to fuel pump vent tting 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 equipped, and

the safety switch of the burner primary control.

Firing Rate

(GPH)

Burner

Model

Figure 20A: Electrode Tip Gap & Spacing

Delavan Oil

Nozzle

Air Gate

8. INSTALL PRESSURE GAUGE

a. Either, remove plastic hose and oil pump vent

Pump Pressure

tting, then, install a reliable pressure gauge into vent tting port, or install the gauge into the

nozzle port. See Figure 20B.

(PSIG)

Settings

Turbulator

WARNING

Very hot ue 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 tting (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 tting when

all the air is purged. NOTE: Bleeding might not be

necessary with a two pipe system. When vent tting is closed, burner ame should start immediately.

Figure 20B: Checking / Adjusting Fuel

Pump Pressure

9. CHECK / ADJUST OIL PRESSURE

a. Check oil pressure to correspond to a specied

value for a particular LEDV boiler model. Refer to Table 6.

b. For adjustment, locate oil pressure adjusting

screw and turn screw to obtain oil pressure

specied.

10. ADJUST AIR SETTING on burner for alight orange

colored ame. 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 nal check using suitable instrumentation

to obtain CO2 of 11.5% to 12%. These settings

will assure a safe and efcient operating condition. If ame appears stringy instead of solid re, try

another nozzle of the same type.

11. TURN "OFF" BURNER BY OPENING SERVICE SWITCH. Remove pressure gauge. Install gauge port plug and tighten. Re-start burner.

12. 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 ame shape and efcient combustion.

Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO2 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.

b. FLAME SHAPE — Looking into the

combustion chamber through the ame plug hole, the ame should appear straight with

no sparklers rolling up toward the top of the

chamber. If the ame 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.

c. 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 re hazard.

d. AIR LEAKS — Any such leaks should be

repaired, as they may cause erratic burning of

the fuel and in extreme cases may become a re

hazard.

There are many possible causes of air leaks in oil lines such as:

i. Fitting leaks due to mis-ared tubing or

damaged tting.

ii. Fuel line 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

nd air leaks.

The following actions can eliminate air leaks:

i. Bleed pump as detailed in System Start-Up

Section of this manual.

ii. Replace are ttings.

iii. Replace oil supply line.

iv. Repair oil lter leaks.

v. Replace or repair tank ttings.

e. GASKET LEAKS — If 11.5 to 12.5% CO2 with

a #1 smoke cannot be obtained in the breeching,

look for air leaks around the ue collar. Such

air leaks will cause a lower CO2 reading in the

breeching. The smaller the ring rate the greater

effect an air leak can have on CO2 readings.

f. DIRT — A fuel lter 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 ring rate, the smaller the slots

become in the nozzle and the more prone to plugging it becomes with the same amount of dirt.

g. WATER — Water in the fuel in large amounts

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 ame and causes smoke and

unburned fuel to pass out of the combustion

chamber and clog the ueways of the boiler.

h. 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 ame 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 is to bury the tank and lines deep enough to keep the oil above 40°F.

i. HIGH ALTITUDE INSTALLATIONS — Air

settings must be increased at higher altitudes. Use instruments and set for 11.5 to 12.5% CO2.

j. START-UP NOISE — Late ignition is the

cause of start-up noises. If it occurs recheck for

electrode settings, ame shape, air or water in

the fuel lines.

k. SHUT DOWN NOISE — If the ame 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 in the fuel pump, or it may be air trapped in the nozzle line. It may take

several ring cycles for that air to be fully vented

through the nozzle. Water in the fuel or poor

ame shape can also cause shut down noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the

fuel system and with a 2 foot length of tubing, re out of an auxiliary ve 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:

WARNING

ONLY

a. Simulate ame failure:

• Follow the starting procedure to turn on the

• Close the hand valve in the oil supply line.

• Safety switch should lock out in

• Push red reset button to reset safety switch.

b. Simulate ignition failure:

• Follow the starting procedure to turn on the

• Safety switch should lock out in

• Push red reset button to reset safety switch.

FOR HEATING SERVICEMAN

burner.

approximately 15 seconds. Ignition should stop and oil valve should close. Blower will stop after postpurge period.

burner, but do not open the oil supply hand valve.

approximately 15 seconds. Ignition and motor should stop and oil valve should close.

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

is 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. Rell boiler.

H. Boiler is now ready to be put into service.

IMPORTANT

IF, DURING NORMAL OPERATION, IT 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 signicantly

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

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 ring of

burner outside the combustion chamber. Be sure to tighten swing door fasteners completely when service is completed.

NOTICE

BURNER SHUTDOWN: Open Service Switch to turn off burner.

Manual Oil Supply Valve should be closed and Electric Service to boiler turned off if boiler will not be operated for an extended period of time.

A. General. Inspection, service and cleaning should

be conducted annually. Turn off electric power and close oil supply valve while conducting service or maintenance.

B. Firetubes and Combustion Chamber.

1. CLEAN THE FIRETUBES

a. For access to reside of boiler, pull two halves

of Burner Swing Door Interlock wiring harness apart, remove fasteners holding door closed and open swing door.

b. Prior to cleaning boiler, lay a protective cloth or

plastic over combustion chamber liner.

c. Using a 1 1/2" diameter wire brush (30" handle),

clean retubes. Measure 15" from end of brush

opposite handle, and mark handle. DO NOT

allow this mark to go past front end of retube

during cleaning, or brush will hit rear door insulation piece.

2. CLEAN THE COMBUSTION CHAMBER

Using wire or ber bristle brush, clean inside of

combustion chamber. DO NOT let brush hit rear door insulation piece or combustion chamber liner.

3. AFTER CLEANING

a. Vacuum debris inside bottom of rear door,

remove protective cloth, and vacuum remaining

reside of boiler as necessary. BE CAREFUL

not to damage liner or rear door insulation piece. Inspect front and rear door insulation pieces, front door gaskets and combustion chamber liner for damage. Replace any damaged pieces.

4. CLOSE BOILER

CAUTION: Do not start burner unless burner swing

door is securely closed. Close door, install fasteners, and tighten securely. Door should be parallel to tubesheet when viewed from top and sides. Reconnect two halves of Swing Door Interlock.

C. Vent/Air Intake System. Inspect for obstructions, soot

accumulation, proper support, and deterioration of pipe,

ttings, and joints.

1. Inspect inside of vent pipe.

a. Disconnect appliance adapter from boiler ue

collar.

b. Remove any obstructions and clean with a wire

brush as required.

c. Reconnect appliance adapter to boiler ue collar

as detailed in Section IV: Venting/Air Intake Piping.

2. Clean terminal screens. Terminals must be free of obstruction, undamaged, with screens securely in place.

3. Terminal and wall thimbles (if used) must be weather-tight.

4. Pipe must be full round shape, and show no damage from impact or excessive temperature.

5. Pipe must be supported at minimum 5 foot intervals and must not sag.

6. All vent joints must be secure and watertight.

7. All air intake joints must be secure and airtight.

D. Burner.

1. Replace the oil supply line lter.

2. Remove and clean the pump strainer (if applicable).

3. Replace the nozzle with an equivalent nozzle. Refer

to Table 6 for Beckett Burner Settings. Refer to Table 6a for Riello BF Burner Settings.

4. Clean and inspect the electrodes for damage, replacing any that are cracked or chipped.

5. Clean the combustion head of all lint and soot.

6. Inspect the transformer cables and connectors.

7. Remove and clean the cad cell.

8. Clean the blower wheel and the air control of any lint.

9. Check all wiring for secure connections or insulation breaks.

10. Re-adjust the burner as detailed in Section VII: System Start-up, Paragraph F.

E. Controls. Test Controls for proper operation as

detailed in Section VII: System Start-up, Paragraph G.

F. Low water cutoff (if so equipped).

1. Float Type

a. Monthly Blowoff. During the heating season, if

an external oat 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 ush 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 qualied

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 oat when this type of control is used. Check oat

for evidence of collapse and check mercury bulb (where applicable) for mercury separation or discoloration.

2. Probe Type (Annual Service). Probe type LWCO should be removed once a year, examined and cleaned of any dirt accumulations to assure proper operations. Do not attempt to repair mechanisms

in the eld. 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:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. 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 crystalline 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.

IX. Repair Parts

All 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.

Figure 21: LEDV Boiler Trim & Controls

Item Description Qty. Part Number

1 Honeywell L7248C1014 High Limit & Circulator Relay 1 100059-01

2 Honeywell 123871A, 3/4 NPT x 3 1 80160452

3 Conbraco 10-408-05, 3/4 FPT, 30 PSI Relief Valve 1 81660319

4 Temperature/Pressure Gauge 1-1/2 DIA (Long Shank) 1 100282-02

5 Conbraco 35-302-03, 3/4 FPT Drain Valve 1 806603061

6 Beckett R7184 Oil Primary Control 1 80160847

7 Burner Disconnect Harness 1 8133302

8 Strain Relief Bushing (Not Shown) 1 8136029

Figure 22: LEDV Boiler Jacket & Insulation

Figure 23: LEDV Bare Boiler Assembly

Figure 24: Vent Kit Repair Parts

Figure 25: Beckett AFII Oil Burner Repair Part

P.O. Box 1289, Elyria, OH 44036 (216) 327-1060 or (800) OIL BURN(645-2876)

For replacement oil burner parts, contact your wholesaler or the burner manufacturer: R.W. Beckett Co.,

BECKETT AFII BURNER REPLACEMENT PARTS

LEDV1 LEDV2 LEDV3

Part Description

Beckett Part Number

Complete Burner (without Primary Control) BCB5406 BCB5407 BCB5408

Air Tube Combination HLX50HD HLX50HE

Air Tube Screws 4352

Blower Wheel 21439 21438

Coupling (Motor to Pump) 21437

Electrodes (Replacement Kit) 51484U

Escutcheon Plate 31623

Stop Screw 3166502 3166503 3166505

Fuel Line 5394

Fuel Pump (Single Stage, with Solenoid Valve) 21757

Fuel Pump (Two Stage, with Solenoid Valve) 21941

Gasket, Flange 31658

Head Assembly (AFII) 51671 (6 Slot) 51672 (9 Slot)

Hole Plug 2139

Inlet Air Scoop 51485

Splined Nut 3666

Main Housing Assembly 51584 51476

Motor 21444

Nozzle Adapter 213

Nozzle Line Heater 51621

Rear Access Door 51424GY

Electronic Ignitor 7440

4 x 4 Electrical Box 31613BK

Electrical Box Extension 21821BK

SERVICE RECORD

DATE SERVICE PERFORMED

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 specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) 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 the hot water boiler (i.e.

baseboard on the same oor 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 oat 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.

draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration 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, if 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.

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

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas red

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 lling the system.

The boiler should attempt to operate once the water level is above the LWCO.

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Using Cast Iron, Carbon Steel, Cast Aluminum,

or Stainless Steel Heat Exchangers

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Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied parts and/or accessories manufactured and shipped on or after July 1, 2008:

ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY U.S. BOILER COMPANY, INC.

U.S. Boiler Company, Inc. warrants to the original owner that its residential grade water and steam boilers and parts/accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a residential grade boiler or any part or accessory provided by U.S. Boiler Company, Inc. is found to be defective in material or workmanship during this one year period, U.S. Boiler Company, Inc. will, at its option, repair or replace the defective part.

HEAT EXCHANGER WARRANTIES

U.S. Boiler Company, Inc. warrants to the original owner that the heat exchanger of its residential grade boilers will remain free from defects in material and workmanship under normal usage for time period specified in the chart below of the original owner at the original place of installation. If a claim is made under this warranty during the “No

Charge” period from the date of original installation, U.S. Boiler Company, Inc. will, at its

option, repair or replace the heat exchanger. If a claim is made under this warranty after the expiration of the “No Charge” period from the date of original installation, U.S. Boiler Company, Inc. will, at its option and upon payment of the pro-rated service charge set forth below, repair or replace the heat exchanger. The service charge applicable to a 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 the heat exchanger model involved at the time the warranty claim is made as follows:

NOTE: If the heat exchanger involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the Burnham

Repair Parts Pricing where the heat exchanger last

appeared or the current retail price of the then nearest equivalent heat exchanger.

*MegaSteam Waterside Corrosion Warranty: U.S. Boiler Company, Inc. warrants the cast iron sections of the MegaSteam boiler to resist Temperature Induced Chloride Activated Graphitic Corrosion for a period of five years from the date of original installation. In the event that any cast iron section of a Mega Steam boiler fails due to this corrosion mechanism during this period, U.S. Boiler Company, Inc. will repair or replace, at its option, the cast iron section assembly.

LIFETIME NIPPLE LEAKAGE WARRANTY

U.S. Boiler Company, Inc. warrants the cast iron and steel nipples that join the cast iron boiler sections to be free of defects in material and workmanship for the lifetime of the original owner at the original place of installation. In the event that such nipples are found to be defective in material and workmanship during this period, U.S. Boiler Company, Inc. will repair or replace at its option, the cast iron section assembly.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These warranties are applicable only to boilers, parts, or accessories designated as residential grade by U.S. Boiler Company, Inc. and installed in a single or two-family residence and do not apply to commercial grade products.

2. Components Manufactured by Others: Upon expiration of the one year limited warranty on residential grade boilers, all boiler components manufactured by others but furnished by U.S. Boiler Company, Inc. (such as oil burner, circulator and controls) will be subject only to the manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by U.S. Boiler Company, Inc. are conditioned upon the installation of the residential grade boiler, parts, and accessories in strict compliance with U.S. Boiler Co., Inc. installation instructions. U.S. Boiler Company, Inc. specifically disclaims liability of any kind caused by or relating to improper installation.

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: a. Expenses for removal or reinstallation. The homeowner will be responsible

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.

b. Components that are part of the heating system but were not furnished by

U.S. Boiler Company, Inc. as part of the residential boiler.

c. Improper burner adjustment, control settings, care or maintenance.

d. This warranty cannot be considered as a guarantee of workmanship of an

installer connected with the installation of the U.S. Boiler Company, Inc. boiler, or as imposing on U.S. Boiler Company, Inc. liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation, which liability is expressly disclaimed.

e. Boilers, parts, or accessories installed outside the 48 contiguous United

States, the State of Alaska and Canada.

f. Damage to the boiler and/or property due to installation or operation of the

boiler that is not in accordance with the boiler installation and operating instruction manual.

g. Any damage or failure of the boiler resulting from hard water or scale

buildup in the heat exchanger.

h. Any damage caused by improper fuels, fuel additives or contaminated

combustion air that may cause fireside corrosion and/or clogging of the burner or heat exchanger.

i. Any damage resulting from combustion air contaminated with particulate

which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles, dirt, and dust particulate.

j. Any damage, defects or malfunctions resulting from improper operation,

maintenance, misuse, abuse, accident, negligence including but not limited to operation with insufficient water flow, improper water level, improper water chemistry, or damage from freezing.

k. Any damage caused by water side clogging due to dirty systems or

corrosion products from the system. l. Any damage resulting from natural disaster. m. Damage or malfunction due to the lack of required maintenance outlined in

the Installation and Operating Manual furnished 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. U.S. Boiler Company, Inc. liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade boiler involved. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entire obligation of U.S. Boiler Company, Inc. with respect to any defect in a residential grade boiler, parts, or accessories and U.S. Boiler Company, Inc. shall have no express obligations, responsibilities or liabilities of any kind whatsoever other than those set forth herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to complete and mail the Warranty Card provided with the product or register product online at www.burnham.com within ten days after the installation of the boiler, although

failure to comply with this request will not void the owner’s rights under these

warranties. Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the owner should write to U.S. Boiler Company, Inc.,

C/O Burnham, P.O. Box 3079, Lancaster, PA 17604, giving

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.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Years in Service 1-5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25+

Cast Iron Water 5 15 20 25 30 40 45 50 55 60 65 70 75

Cast Iron Steam*

Carbon Steel 5 15 20 25 30 40 45 50 55 60 65 70 75

Cast Aluminum 30 40 50 60 70 Stainless Steel 30 40 50 60 70

Service Charge as a % of Retail Price

No Charge 10

No Charge 100

Burnham 81433101R16-1-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual