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
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.
2
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 efciency.
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.
3
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 ...............................................................
9
18
29
32
X. Appendix
Low Water Cut Off .....................................................39
4
Water Content: 6.1 gallons
Figure 1: LEDV Packaged Boiler
5
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 unconned spaces (basement) in buildings of
conventional frame, brick, or stone construction,
inltration normally is adequate to provide air for
combustion. An unconned 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 conned 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 unconned spaces (basement) in buildings of
conventional frame, brick, or stone construction,
inltration normally is adequate to provide air for
ventilation.
2. In conned 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.
6
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.
7
Figure 2: Minimum Clearances to Combustible Materials
Figure 3: Proper Hinge Bracket Installation and Assembly
8
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.
9
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 qualied 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 relling 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 overow 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.
10
Figure 6: Recommended Piping for Combination Heating &
Cooling (Refrigeration) Systems
Figure 7: Recommended Water Piping for Circulator Zoned Heating Systems
11
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
ofcials about restrictions and installation inspection
in your area.
2. The LE®DV Series is designed as a Direct Vent
boiler. In this conguration, 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 conguration may be used in
installations where inltration 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 specied 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 soft.
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.
12
Figure 8: Vent Terminal Location
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