FD
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ROFSNOITCURTSNIECIVRES
TFARDDECROF"DF"
STINURENRUBRELIOBLEETS
FOR OIL, GAS
OR COMBINATION
OIL-GAS FIRING
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8143401R6-7/03
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Price - $3.00
1
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.
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TABLE OF CONTENTS
INTRODUCTION TO "FD" SERIES STEEL BOILER-BURNER UNITS ...............................................................................3
DIMENSIONS AND RATING DATA.................................................................................................................................4 & 5
FURNACE FLOOR BLANKETS.........................................................................................................................................6 & 7
CERAMIC FIBER WARNING ...................................................................................................................................................8
CLEANING INSTRUCTIONS ....................................................................................................................................................9
BURNER DATA ...............................................................................................................................................................10 & 11
BECKETT BURNER SPECIFICATIONS .......................................................................................................................12 & 13
TANKLESS HEATER PERFORMANCE.................................................................................................................................14
COIL RATINGS.........................................................................................................................................................................15
INDIRECT WATER HEATER OPERATION ..........................................................................................................................16
COMBUSTION AND VENTILATION AIR REQUIREMENTS.............................................................................................16
VENTS—FAULTS AND SUGGESTIONS ..............................................................................................................................17
EXPANSION OR AIR CUSHION TANK ................................................................................................................................18
PIPING—FORCED HOT WATER HEATING ........................................................................................................................19
PIPING—DOMESTIC HOT WATER ......................................................................................................................................20
PIPING—FORCED HOT WATER HEATING AND DOMESTIC HOT WATER.................................................................20
PIPING—DOMESTIC HOT WATER WITH STORAGE TANK ...........................................................................................21
PIPING—RECIRCULATING DOMESTIC HOT WATER SYSTEM .................................................................................... 21
PIPING—MULTI-PURPOSE BOILER APPLICATION .........................................................................................................22
PIPING—MULTIPLE BOILER OPERATIONS (PARALLEL PIPING) ................................................................................22
ORDERING REPAIR PARTS ................................................................................................................................................... 23
JACKET PARTS IDENTIFICATION.......................................................................................................................................23
WARRANTY .............................................................................................................................................................. Rear Cover
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2
INTRODUCTION TO "FD" SERIES
STEEL BOILER BURNER UNITS
Due to an excellent combination of boiler and burner,
the "FD" Series boiler-burner units are capable of
developing the optimum in combustion and thermal
efficiencies. The burner provides 12½% CO
combustion efficiency in excess of 83% on #2 fuel oil.
Forced draft operation is accomplished by means of a
3450 RPM motor and blower wheel on the burner and a
factory sealed combustion chamber. The commonly
used refractory type combustion chamber is not
required.
Pressure is produced within the boiler by the "forced
draft" operation of the burner eliminating the need for a
chimney thus resulting in a substantial savings in
building costs. A vent to the outside of the building is
the only requirement. Boiler rooms can also be kept to
a minimum size since one boiler equipped with a
tankless heater can supply all of the heating
requirements for comfort heating and domestic hot
water.
For optimum performance and serviceability from these
units adhere to the following recommendations:
1) Clean boiler flueways (firetubes after removing
turbulator baffles) with a 3" OD flue brush, at least
once a year and preferably at the end of the heating
season, or as may be necessitated to remove all soot
and scale. See Page 10 for cleaning instructions.
2) Have burner and controls checked at least once a
year. See Pages 14, 15, 21 and 22 and burner
manual for burner adjustment specifications.
3) Retain your contractor or a competent service
agency to assure that the unit is properly adjusted
and maintained.
4) The interior of the venting must be inspected and
cleaned before the start of the heating season and
should be inspected periodically throughout the
heating season for any obstructions. A clean and
unobstructed vent is necessary to allow noxious
fumes that could cause injury or loss of life to vent
safely and will contribute toward maintaining the
boiler's efficiency.
for a
2
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FLUE DAMPER:
The boiler is provided with a breaching damper which
should be secured in the open position for initial start up
of the burner. The adjustable damper in the flue collar
at the boiler outlet is provided so that if the installer or
serviceman desires, he can easily introduce a flow
restriction at the boiler outlet and thereby increase the
pressure in the firebox. Normally, it is best to leave the
damper wide open and to control air flow to the burner
entirely by adjustments at the burner inlet. Flue
restrictions such as a partially closed damper tend to
make starts rougher. Boiler tests were run at 12½%
CO2 and 0.1 inches of water stack pressure to
demonstrate ample burner air capacity for good
performance up to this pressure. Boiler pressure drop
does not change measurably at different stack and
firebox pressures as long as the burner is adjusted to
maintain the same percent CO2.
MINIMUM INSTALLATION CLEARANCES TO
COMBUSTIBLE MATERIAL:
FRONT - 48 Inches ABOVE OR TOP - 18 Inches
SIDES - 18 Inches VENT CONNECTOR PIPE - 18 Inches
REAR - 18 Inches
NOTE:
1. Listed clearances comply with American National
Standard ANSI/NFPA 31, Installation of oil burning
equipment.
2. FD Series boilers can be installed in rooms with
clearances from combustible material as listed
above. Listed clearances can not be reduced for
alcove or closet installations.
3. For reduced clearances to combustible material,
protection must be provided as described in the
above ANSI/NFPA 31 standard.
4. Check dimensional data for boiler service
recommended clearances.
For additional information consult the service department.
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456
FURNACE FLOOR BLANKETS
The furnace floor and the furnace wall below the mud
ring are not water backed. These surfaces must be
insulated from the intense heat in the furnace. The FD
Series boiler now employs precut, refractory ceramic
fiber (RCF) blankets to provide this insulation. They
are light weight, easy to handle and do not crack like the
poured refractory used heretofore.
The blankets must be replaced if they become water
logged or lose their thickness or shape for any other
reason, such as abuse during firetube cleaning.
BLANKET INSTALLATION
1. Confirm that the blankets are the appropriate size for
your FD boiler model using the chart opposite.
2. Unbolt the Burner Mounting Plate from the boiler
and set it aside.
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3. Remove the Burner Mounting Plate Insulation. It
may be poured-in-place refractory or precast,
lightweight RCF. In either case, it may be reused if
removed intact. Replacement, precast, lightweight
RCF Burner Mounting Door Insulation is available
from Burnham as Part No. 8203401 for Models FD7
through FD30 and as Part No. 8203402 for Models
FD38 and FD45.
4. Thoroughly clean any refractory or other insulation
out of the furnace.
5. On a flat surface, place the larger diameter 1" thick
Bottom Blanket.
6. Lay the smaller diameter 2" thick Top Blanket in the
center of the Bottom Blanket. Keep repositioning
the Top Blanket until you have equal Bottom
Blanket exposure all around the outside edge. See
dimension 'C' in the chart opposite and refer to the
illustration of blanket placement.
7. Fold the two (2) blankets in half, keeping the Top
Blanket centrally positioned on the Bottom Blanket.
8. Slide the folded blankets through the Burner
Mounting Plate opening and onto the furnace floor.
9. Unfold the blankets and position the blankets such
that the larger diameter 1" thick Bottom Blanket
curls up the wall of the furnace by at least 1½" all
around the furnace.
It is important that this curled edge of the Bottom
Blanket makes contact with the furnace wall all
around to protect the furnace wall from overheating
below the mudring. Refer to the illustration of
correctly installed blankets.
10. Reinsert the Burner Mounting Plate Insulation and
seal all gaps and cracks with ceramic caulking.
Ceramic caulking is available from Burnham in 10
ounce tubes (Part No. 9056081) and in gallon pails
(Part No. 9056982).
11. Reinstall the Burner Mounting Plate. Since neither
the blankets nor the ceramic caulk require cure
time, the boiler may be returned to service
immediately.
7
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Warning:
This product contains refractory ceramic fibers (RCF). RCF has been classified as
a possible human carcinogen. After this product is fired, RCF may, when exposed
to extremely high temperature (>1800F), change into a known human carcinogen.
When disturbed as a result of servicing or repair, RCF becomes airborne and, if
inhaled, may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace previously fired RCF (combustion chamber insulation,
target walls, canopy gasket, flue cover gasket, etc.) 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 air tight plastic bag.
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.
8
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