Burnham HF User Manual

Price - $3.00

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

HF SERIES OIL FIRED BOILER

BEFORE INSTALLATION: READ THIS MANUAL

SAVE THESE INSTRUCTIONS

Installing contractor and homeowner should read and be informed as to the
proper installation and operation of this unit. The manufacturer will not be
responsible for improper installation or operation. This manual and all
associated instruction material should be conspicuously posted near the
equipment.

For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial N umber as shown on Rating Label.

Boiler Model Number Boiler Serial Number Installation Date

HF ____-____

Heating C ontractor Phone Number

Address

8143709R3-12/99

6_ _ _ _ _ _ _

1

IMPORTANT INFORMATION - READ CAREFULLY

All boilers must be installed in accorda nce with National, State and Local Plumbing,
Heating and E lectrical Codes and the regu lations of the servi ng utilities. These C odes and
Regulations may diffe r from this instruction manual. Authorities having jurisdiction should
be consulted before install ations are made.
In all cases, reference sh ould be m ade to the followi ng Standards:
All wiring on boil ers installed in the U SA shall be made in accor dance with the N ational
Electrical Cod e and/or Lo cal Regulations.

USA BOILERS

C urrent Editio n of American Na t iona l Standard ANSI/NFPA 31, “Installa t ion o f Oil Burni ng

A.

Equipment”, for r ecomm en ded installation practices.
Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,

B.

Vents, and Solid Fuel Burning Appliances”, For Venting requirements.

C.

Current Edition of Amer ican Society of Mechanical Engineers ASME CSD-1, "Con trols and
Safety Devices for Automatically Fired Boilers", for assembly and operations of controls
and safety devices.

CA NAD IAN B OILERS

Current Edition of Canadian Stand ards Association CSA B139, "Installation Code of Oil

A.

Burning Equipment", for recomm en ded installation practices.

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 imm in ently hazardou s situation
w hic h, if n ot av oid ed, w ill re su lt in d eath ,
serious injury or substantial property
damage.

WA R N I NG

Indic ates a potentially hazardous situation
which, if not avoided, could re sult in death,
serious injury or substantial property
damage.

Indic ates a potentially hazardous situation
which, if not av oided, may resu lt in
modera te or minor injury or property
damage.

Indicates special instructions on
installation, operation, or m aintenance
which are importa nt but not related to
personal injury hazards.

CAU TION

NOTICE

NOTICE

Th is boiler has a limited w a rra nty, a c o py o f which is printe d on t he back of t his m a nua l.
It is the respons ibility of the in stalling cont ractor to see th at all controls are correctly in stalled
and a re oper a t ing p rop e rly when the ins tallatio n is co mplete. The war ran ty fo r t his boiler is v a lid
only if the boiler h as been installed, maintained and operated in accordance with these
instructions.

2

DA NGER

DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.

WAR NING

Impro per installation, ad justment, alteration, servic e or mainte na nce can cause p roperty
damage, personal injury or loss of life. Fai lure to follow all instructions in the proper order
can cause personal i njury or death. Read and understand all instructions, inc luding all
those con tained in compone nt manufac turers manuals w hich are p rovided with th e
appliance before installing, starting-up, operating, maintaining or servicing this applia nce.
Keep this manual and literature in legible condition and posted near appliance for reference
by owner an d service technic ian.

This boiler requires regular maintenance and service to operate safely. Fo llow 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. 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. Installation is not complete unless a
pressure relief valve is installed into the tapping located on top of app liance - See Section III of
this ma nual for details.

This boiler is not su itable for installation o n c ombusti ble flooring, unless install ed with a
comb ustible floor shield (avai lable at extra cost). Do n ot install boiler on carpeting .

Do not tam per with or alter the boiler or controls. Re tain your contractor or a compet ent
se rv ice man to assur e th at th e unit is p ro perly adjus ted an d m ain tained .
Have Firetu be s cleane d at l eas t once a ye ar - prefe rab ly at th e star t o f the he ating sea son
to remove soot and scale. The inside of combustion cha mber should also be cle aned and
ins pecte d at the same time .
Have Oil B urn er and Contro ls ch ecke d at l eas t once a ye ar or as may be n ecess itate d.
Do not operate unit with jumpered or abs ent controls or safety devices.
Do no t operate unit if any control, switch, c omponent, or device has been subject to
water.

3

WARNING

Appliance 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 d efects and other reproductive harm. Always use pro per safety clothing,
respirators and equipment when servicing or wor king nearby the appliance.

This boiler contains very hot water under high p ressures. Do not unscrew any pipe fittings nor
attempt to disconnect any comp onents of this boil er 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 temper ature and pressure of the b oiler. This boiler contains components
w hich become very hot when the boiler is operating. D o not touch any components unless they
are cool.
This appliance must be properly vented and connected to an approved vent system in good
condition. Do not ope rate boiler with the absence of an unapproved ve nt 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 b e 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 con tribute toward
maintaining th e boiler's efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start
withou t service. If dam age du e to frozen pipe s is a pos sibility, the he ating system should
not be left unatttend ed 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 b urn No. 2 fuel oil only. D o not use gasoline, crankcase drai nings, or
any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any
solid fuel (i. e. wood, co al) or gaseous fuel (i. e. natu ral gas, LP/propane). All flam mable debris,
rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area
clean and free of fire hazards.

Do not operate boiler on combustible floor without a factory supplied floor shield. Concrete over
wood joists is considered combustible flooring. Do not operate on masonry floors, which may
contain moisture.

T ables of Contents

I. General Information ............................. 5

II. Installation Instructions ......................... 8

III. System Start-Up ................................... 18

I V . Service and Cleaning............................ 23

V . Repair Parts .......................................... 2 4

4

I: General Information

Figure 1: HF Packaged Boiler (HF-98/HF-173)

Table 1:

Description HF-98 HF-122 HF-147 HF-173
DOE Heating Capacity (MB H) 104 132 154 184

IBR Net Water rating (MBH) 90 115 134 160
Firing Rate (gal/hr) .85 1.10 1.25 1.50
Nozzle Spec ification .75 x 45° B .90 x 45° B 1.00 x 45° B 1.25 x 45° B
Stac k D ia me te r (inc h) 6 6 7 7
Nu mber of Tub es 12 12 18 18
Boiler Water Cap. (gal.) 20 20 40 40
Supply S i ze ( F PT) 1¼ 1¼ 2 2
Return S ize (FPT) 1¼ 1¼ 2 2
Tankless Heater Size (gal/min) 4 (5 Optional) 4 (5 Optiona l) 5 5
Chimney Size (min) 8" x 8" x 15' 8" x 8" x 15' 8" x 8" x 15' 8" x 8" x 15'
Approx. Shipping Wt. ( lb.) 450 450 720 720

DIMENSIONS Max. Working Pressure: 30 PSI (Water Only)

A O verall Width (in.) 18-1/8 18-1/8 24 24
B O verall Length Boiler (in.) 24-1/2 24-1/2 31-3/4 31-3/4
C Jacket Height ( in.) 37-3/4 37-3/4 46-3/4 46-3/4
D J acket Length (in.) 18 18 21-3/4 21-3/4
E Jacket Width ( in.) 18-1/8 18-1/8 22 22
F S moke Outlet Height (in.) 25-1/4 25-1/4 30 30
G Overall Leng th w/Burner (in.) 33 33 39 39

WATER RAT INGS AND S PECIFICATIONS

Notes:

1.

Firing rates based on 140,000 BTU per gallon of oil

2.

IBR net wa t e r r at in gs ba s ed o n a pi c k -up al lo wan c e of 1. 15

3.

Manufacturer should be consulted before selecting a boiler for installations having
unusual piping and pick-up requirements.

4.

Firebox d raft setting: -.02 in ches w ater column

5.

Ratings based on 13.0% CO

2

5

A. INSPECT SHIPMENT carefully for any signs of damage.

1 . ALL EQUIPMENT is carefully manufactured,

inspected and packed. Our responsibility ceases
upon delivery of the crated boiler to the carrier in
good condition.

2. ANY CLAIMS for damage or shortage of shipment
must filed immediately against the carrier by the
consignee. No claims for variances from, or
shortage in orders, will be allowed by the manufac­turer unless presented within sixty (60) days after
receipt of goods.

B. LOCATE BOILER in front of final position before

removing crate.

1. LOCATE so that smoke pipe connection to chim­ney will be short and direct. BOILER IS NOT
SUITABLE FOR INSTALLATION ON COMBUS­TIBLE FLOOR unless combustible floor shield,
supplied by Burnham, is used. DO NOT install on
carpeting.

2. FOR BASEMENT INSTALLATION, provide a
concrete base if floor is not perfectly level, or if
water may be encountered on floor around boiler.

3. PROVIDE SERVICE CLEARANCE of at least 48”
from the front of the jacket for servicing of burner
and removal of tankless heater.

For minimum clearances to combustible materials. See
Figure 2.

Figure 2: Minimum Clearances to Combustible Materials

NOTE:

1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.

2. HF 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.

6

C. PROVIDE AIR SUPPLY AND VENTILATION to

accommodate proper combustion. If natural ventilation
is inadequate, provide a screened opening or duct from
the boiler room to the outside. The opening or duct
must be sized so the boiler input will not exceed 4,000
BTUH/Sq. In. of free area. If other air consuming
appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.

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 unconfined spaces (basement) in buildings of
conventional frame, brick, or stone construction,
infiltration normally is adequate to provide air for
ventilation.

2. In confined spaces, 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.

E. PROVIDE COMBUSTION AND VENTILATION AIR.

Local code provisions may apply and should be
referenced.

WARNING

Adequate combustion and ventilation air must be
provided to assure proper combustion.

1 . Determine volume of space (boiler room). Rooms

communicating directly with the space in which the
appliances are installed, through openings not
furnished with doors, are considered a part of the
space.

Volume(ft3) = Length(ft) x Width(ft) x Height(ft)

2 . Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round
the result to the nearest 1000 BTU per hour.

3 . Determine type of space. Divide Volume by total

input of all appliances in space. If the result is
greater than or equal to 50 ft3/1000 BTU per hour,

then it is considered an unconfined space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a confined space.

4 . For boiler located in an unconfined space of a

conventionally constructed building, the fresh air
infiltration through cracks around windows and
doors normally provides adequate air for combus­tion and ventilation.

5 . For boiler located in a confined space or an uncon-

fined space in a building of unusually tight con­struction, provide outdoor air with the use of two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 3
inches. Size each opening per following:

a. Direct communication with outdoors. Minimum

free area of 1 square inch per 4,000 BTU per hour
input of all equipment in space.

b. Vertical ducts. Minimum free area of 1 square

inch per 4,000 BTU per hour input of all equip­ment in space. Duct cross-sectional area shall be
same as opening free area.

c. Horizontal ducts. Minimum free area of 1 square

inch per 2,000 BTU per hour input of all equip­ment in space. Duct cross-sectional area shall be
same as opening free area.

Alternate method for boiler located within
confined space. Use indoor air if two permanent

openings communicate directly with additional
space(s) of sufficient volume such that combined
volume of all spaces meet criteria for unconfined
space. Size each opening for minimum free area of
1 square inch per 1,000 BTU per hour input of all
equipment in spaces, but not less than 100
square inches.

6 . Louvers and Grilles of Ventilation Ducts

a. All outside openings should be screened and

louvered. Screens used should not be smaller
than 1/4 inch mesh. Louvers will prevent the
entrance of rain and snow.

b. Free area requirements need to consider the

blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of the
louver or grille is not known, assume wood
louvers have 20-25 percent free area and metal
louvers and grilles have 60-75 percent free area.

c. Louvers and grilles must be fixed in the open

position, or interlocked with the equipment to
open automatically during equipment operation.

7

II. Installation Instructions

WARNING

Failure to properly pipe boiler ma y result in improper operation and d amage to boiler or
structu re .

Oxyg en c ont amin atio n of boile r wa te r will c ause c orrosio n o f iro n an d st eel bo iler
components, a nd c an lead to boiler failure. Burnham's Standard Warranty does not cover
problems caused by o xygen contam ination of boiler wa ter or scale (lime) bu ild-up caused
by frequent addition of water.

A. Design a piping system and install boiler which will

prevent oxygen contamination of boiler water and
frequent water additions.

1. There are many possible causes of oxygen contami­nation such as:

a. Addition of excessive make-up water as a result

of system leaks.
b. Absorption through open tanks and fittings.
c. Oxygen permeable materials in the distribution

system.

2. In order to insure long product life, oxygen sources
should be eliminated. This can be accomplished by
taking the following measures:

a. Repairing system leaks to eliminate the need for

addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which

allow oxygen absorption.
d. Use of non-permeable materials in the distribu-

tion system.
e. Isolating the boiler from the system water by

installing a heat exchanger.

WARN ING

System supply and return piping must
be conn ected to corr ect boiler pipe.

Burnham recommends sizing the
s ystem circulator to su pply sufficient
flow (GPM) to allow a 20°F temper ature
diff eren tial i n the s ys tem . When s izing
the system circu lator, the pressu re
drop of all radiators, baseboard and
radiant tubing and all connecting
piping must be considered.

3. Connect System supply and return piping to boiler.
See Figures 8 and 9. Also, consult I=B=R Installa­tion and Piping Guides. Maintain minimum ½ inch

clearance from hot water piping to combustible
materials.

a. If this boiler is used in connection with refrig-

eration 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 3. Also, consult I=B=R
Installation and Piping Guides.

b. 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 flow control valves to
prevent gravity circulation of boiler water
during the operation of the cooling system.

c. If boiler is used with an Alliance™ Indirect-

Fired Domestic Water Heater, install the
Alliance as a separate heating zone. Refer to
the Alliance Installation, Operating, and Service
Instructions for additional information.

d. 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.) 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 Figure 4 in order
to regulate water flow for maintenance of higher
boiler water temperature. Set the bypass 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 the 120°F return
temperature. Adjust both valves simultaneously.
Closing the boiler return valve while opening
the bypass valve will raise the boiler return
temperature. Opening the boiler return valve
while closing the by-pass valve will lower the
boiler return temperature.

e. A water boiler installed above radiation level

must be provided with a low water cutoff device
as part of the installation.

8

Figure 3: Recommended Piping for Combination

Heating and Cooling (Refrigeration) System

9

THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED
WHEN PIPING THE TANKLESS HEATER:

1 . FLOW REGULATION — If flow through the heater

is greater than its rating, the supply of adequate hot
water may not be able to keep up with the demand.
For this reason a flow regulator matching the heater
rating should be installed in the cold water line to
the heater. The flow regulator should preferably be
located below the inlet to the heater and a minimum
of 3’ away from the inlet so that the regulator is not
subjected to excess temperatures that may occur
during “off” periods when it is possible for heat to
be conducted back through the supply line. The
flow regulator also limits the flow of supply water
regardless of inlet pressure variations in the range of
20 to 125 psi.

2 . TEMPERING OF HOT WATER — Installation of an

automatic mixing valve will lengthen the delivery of
the available hot water by mixing some cold water
with the hot. This prevents the possibility of
scalding hot water at the fixtures. In addition,
savings of hot water will be achieved since the user
will not waste as much hot water while seeking a
water temperature. Higher temperature hot water
required by dishwashers and automatic washers is
possible by piping the hot water from the heater
prior to entering the mixing valve. The mixing valve
should be “trapped” by installing it below the cold
water inlet to heater to prevent lime formation in the
valve. Refer to Figure 5.

3 . FLUSHING OF HEATER — All water contains some

sediment which settles on the inside of the coil.
Consequently, the heater should be periodically
backwashed. This is accomplished by installing
hose bibs as illustrated and allowing water at city
pressure to run into hose bib A, through the heater,
and out hose bib B until the discharge is clear. The
tees in which the hose bibs are located should be
the same size as heater connections to minimize
pressure drop.

4 . HARD WATER — A water analysis is necessary to

determine the hardness of your potable water. This
is applicable to some city water and particularly to
well water. An appropriate water softener should be
installed based on the analysis and dealer’s recom­mendation. This is not only beneficial to the tankless

heater but to piping and fixtures plus the many other
benefits derived from soft water.

G. INSTALL SMOKEPIPE — The HF should be vented

into a fireclay tile-lined masonry chimney or chimney
constructed from type L vent or a factory built chimney
that complies with the type HT requirements of UL103.
The chimney and vent pipe shall have a sufficient draft
at all times, to assure safe proper operation of the boiler.
See Figure 6 for recommended installation.

1 . Install a draft regulator following the instructions

furnished with the regulator. See Figure 7 for
alternate draft regulator locations.

2 . Consider the chimney overall. Chimneys that have a

high heat loss may become less suitable as the heat
loss of the home goes down and the efficiency of
the boiler installed goes up. Most homes have a
chimney appropriate for the fuel and the era in which
the home was built. That may have been a coal fired
or an inefficient oil fired boiler built into a home
without insulation or storm windows. With increas­ing fuel prices that home probably has been insu­lated and fitted with storm windows so that the heat
loss of the home has been reduced. This requires
less fuel to be burned and sends less heat up the
chimney.

A new boiler probably has a higher efficiency than
the boiler being replaced. That probably means that
the stack temperature from the new boiler will be
lower than that from the old boiler and with less
room air being drawn up the chimney to dilute the
stack gases. The combination of a large uninsulated
chimney, reduced firing rate, reduced firing time,
lower stack temperature and less dilution air can, in
some cases, contribute to the condensing of small
amounts of water vapor in the chimney. Such
condensation, when it occurs, can cause chimney
deterioration. In extreme cases, condensed water
may be visible on the outside of the breeching or
chimney. In those extreme cases, the chimney may
have to be lined to insulate the chimney and thus
prevent the condensation. The addition of dilution
air into the chimney may assist in drying the
chimney interior surfaces.

A massive chimney on a cold, or exposed outside
wall may have produced adequate draft when it was
fired with a higher input and greater volumes of
heated gases. With reduced input and volume, the
draft may be severely affected. In one instance our
research showed a new chimney of adequate sizing
produced only -.035" W.C. after 30 minutes of
continuous firing at 13.0% CO2. Outside wall
chimneys take longer to heat up and can have .00"
W.C. draft at burner startup. You may have to
consider a special alloy chimney flue liner with
insulation around it and a stabilizing draft cap or
even a draft inducing fan in severe cases.

3 . For the same reasons as in (2.) above, heat extractors

10

mounted into the breeching are not recommended.

Figure 6: Recommended Smokepipe Arrangement and Chimney Requirements

Figure 7: Proper and Improper Locations of Draft Regulator

11

12

Figure 8: Recommended Boiler Piping for Circulator Zoned Heating Systems

13

Figure 9: Boiler Piping for Zone Valve Zoned Heating Systems

DA NGE R

Positively assu re all el ectrical connectio ns are unpow ered befo re attempting installation or
service of electrical components or connections of the boiler or building. Lock out all electrical
boxes wi th padlock o nce power is turn ed off.

WARN ING

Failure to prop erly wire electrical connections to the boiler m ay result in serious physical
harm.

Electrical power may be from mo re than one source. Make sure all power is off before
attempting any electrical work.

Each boiler must be protected with a properly sized fused disconnect.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Refer to the

wiring diagram of any controls used with the boiler. Read, understand and follow all wiring
inst ructions su pplied with th e controls.

H. Electrical

1. Install wiring and electrically ground boiler in
accordance with requirements of the 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 should be run from the

main electrical service with a fused disconnect
switch in the circuit.

3 . Wiring should conform to Figure 10 and/or 11.

I. System Controls and Wiring

1. Refer to National Electric Code or Local Electric
Codes for proper size and type of wire required.
Follow Code.

2. Use anti-short bushings on all wiring passing
through boiler jacket, junction boxes and/or control
boxes.

3. Use armored cable (BX) over all exposed line
voltage wiring.

4. If an Alliance™ indirect water heater is used, use
priority zoning. Do not use priority zoning for
Hydro-Air Systems.

5. Single Zone System – Connect the system circula­tor wire leads to the proper locations on the
Aquastat control, L8124C/L8148A. See Figure 10 or

11. Connect the thermostat to the ‘T-T’ terminals on
the L8124C/L8148A control. Set thermostat heat
anticipator settings to 0.60 amps.

6. Conventional Circulator Zoned System – Read,
understand and follow all of the instructions
provided with the Honeywell R8888 control.

7. Conventional Zone Valve Zoned System – Locate
C1 and C2 inside the L8124C Honeywell control.
Connect the two (2) terminals to the system
circulator wire leads, supplied with boiler.

Connect the H1 and H2 terminals inside the R8889
to the ‘T-T’ terminals in the L8124C Honeywell
Control.

Connect the thermostat of each zone and the
circulator for that zone to R8889 panel. If an
Alliance™ indirect water heater is used, connect
the Alliance thermostat and circulator to the Zone 1
terminals of the R8889. Set thermostat anticipator
settings to 0.12 amps.

14

Figure 10: Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls, without Tankless Heater

Figure 11: Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls, with Tankless Heater

15

J. Oil Piping

K. Single-pipe Oil Lines

1. Use flexible oil line(s) so that burner can be
removed without disconnecting the oil supply.

2 . A supply line fuel oil filter is recommended as a

minimum for all firing rates but a pleated paper
fuel oil filter is recommended for the lowest firing
rate application to prevent nozzle fouling.

3. Use Flared fittings only. Do not use compression
fittings.

4. Use of a high efficiency micron filter (Garber or
equivalent) in addition to conventional filter is
highly recommended.

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 12.

NO TIC E

Oil piping m ust be ab solu t e ly a irtight or
leaks or loss of prime may result. Bleed line
and fuel unit completely.

Figure 12: Single-Pipe Installation

16

TAB LE 2: SINGLE STAGE U NITS (3450 RPM)
TWO PIPE SYSTEMS

TABLE 3: TWO-STAGE UNITS (3450 R PM)

TWO-PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

(See Figure)

"H" +"R" (See Figure)

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'
14' -- - 41'

1/2" OD

Tubing (3 GPH)

Lift "H"

"H" + "R" (Se e Figu re)

(See Figure)

Maximum Length of Tubing

3/8" OD

Tubing

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'

---

1/2" OD

Tubing

L. Two-Pipe Oil Lines

1 . For two-piped 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 1/2 inch
OD tubing for both suction and return lines. Refer
to Figure 13.

76'

Figure 13: Two-Pipe Installation

17

III. System Start-Up

A. Verify that the venting, water piping, oil piping, and

electrical system are installed properly. Refer to
installation instructions contained in this manual.

B. Confirm all electrical, water and oil supplies are turned

off at the source and that the vent is clear from
obstructions.

C. Fill entire heating system with water and vent air from

system. Use the following procedure on a Series Loop
or multi-zoned system installed as per Figure 8 or 9.

1. Close isolation valve in boiler supply piping.

2. Isolate all circuits by closing zone valves or
balancing valves.

3. Attach a hose to bib cock located just below
isolation valve in boiler supply piping. (Note ­Terminate hose at a suitable floor drain or outdoor
area).

10. Open isolation valve in boiler supply piping.

11. Remove hose from bib cock.

D. CONFIRM that the boiler and system have no water

leaks.

E. CHECK CONTROLS, WIRING AND BURNER to be

sure that all connections are tight and burner is rigid.
Verify that all electrical connections have been
completed, fuses installed, that the oil tank is filled and
oil lines have been tested.

F. 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 field lubrication. Water lubricated
circulators do not need field lubrication.

G. SET CONTROLS with burner service switch turned

“OFF”.

1. SET ROOM THERMOSTAT about 10° above
room temperature.

2. PRESS RED RESET BUTTON on R4184D Oil
Primary Control and release.

4. Starting with one circuit at a time, open zone valve
or valve.

5. Open bib cock.

6. Open fill valve (Make-up water line should be
located directly after isolation valve in boiler supply
piping between air scoop and expansion tank).

7. Allow water to flow into drain until discharge from
hose is bubble free for 30 seconds.

8. When zone is completely purged of air, close zone
valve or balancing valve. Open the zone valve for
the next zone to be purged. Repeat this step until
all zones have been purged. At completion, open
all zone valves or valves.

9. Close bib cock, continue filling the system until the
pressure gauge reads 12 psig. Close fill valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
fill to 12 psig.

3. SET HIGH LIMIT dial on L8124C/L8148A at
temperature to suit requirements of installation.

H. REMOVE GUN ASSEMBLY

1. Check nozzle size, head size, gun setting, and

18

Table 4: Beckett AFG

Boiler

Model

No.

HF 9 8 .8 5 A FG HAGO .75 45 ° B 3 -3/8" U 8 0 L 1 0
HF122 1.10 A FG HAGO .90 45° B 3-3/8"U 10 2 L1 0
HF147 1.25 A FG HAGO 1.0 45° B 2-3/4"U 10 0 V1 0
HF173 1.50 A FG HAGO 1.25 45° B 2-3/4"U 10 2 V1 2

3 . Close vent fitting and burner flame should start

4. If the burner does not start immediately, check the

K. ADJUST OIL PRESSURE

Firi ng

Rate

(GPH)

Burner

Manufacturer Size Angle Type Shutter Band

Nozzle Specifications

SOLID stream without air bubbles for approxi­mately 10 seconds.

immediately.

manual overload switch on the motor, if so
equipped, and the safety switch on the burner
primary control.

Static

Plate

Air Setti ngs

Head

4. TURN “OFF” BURNER and remove pressure
gauge. Install gauge port plug and tighten. Start
burner again.

M. FLAME FAILURE

The HF boiler controls operate the burner automati­cally. If for unknown reasons the burner ceases to fire
and the rest button on the primary control has tripped,
the burner has experienced ignition failure. Before
pressing the rest button, call your serviceman immedi­ately.

1. Locate oil pressure adjusting screw and turn
screw until Pressure Gauge reads the correct
pump pressure required for the specific boiler.
Refer to Table 4 .

Head

Setti ng

2. DO NOT REMOVE PRESSURE GAUGE until
later.

L. OTHER ADJUSTMENTS

1. ADJUST THE AIR BAND AND/OR AIR SHUT­TER.

Beckett Burners:
a. Adjust air supply by loosening lock screws and

moving the air shutter and if necessary the air
band. Refer to Table 4 preliminary settings.

2. ADJUST DRAFT REGULATOR for a draft of

-.02” (water gauge) over the fire after chimney has
reached operating temperature and while burner is
running.

3. READJUST AIR BANDS on burner for a light
orange colored flame while draft over the fire is

-.02” w.c. Use a smoke test and adjust air for
minimum smoke (not to exceed #1) with a mini­mum of excess air. Make final check using suitable
instrumentation to obtain a CO2 of 11.5 to 12.5%
with draft of -.02” w.c. in fire box. These settings
will assure a safe and efficient operating condition.
If the flame appears stringy instead of a solid flame,
try another nozzle of the same type. Flame should
be solid and compact. After all adjustments have
been made, recheck for a draft of -.02” w.c. over the
fire.

N. CHECK FOR CLEAN CUT OFF OF BURNER

1. AIR IN THE OIL LINE between fuel unit and
nozzle will compress when burner is on and will
expand when burner stops, causing oil to squirt
from nozzle at low pressure as burner slows down
and causing nozzle to drip after burner stops.
Usually cycling the burner operation about 5 to 10
times will rid oil line of this air.

2. IF NOZZLE CONTINUES TO DRIP, repeat step
N.1. If this does not stop the dripping, remove cut
off valve and seat, and wipe both with a clean cloth
until clean. Then replace and readjust oil pressure.
If dripping or after burn persist replace fuel pump.

O. 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 HF
boiler is the result of extensive testing to obtain
the best flame shape and efficient combustion.
Other brands of the same spray angle and spray
pattern may be used but may not perform at the
expected level of CO2 and smoke. Nozzles are

19

See Manila folder in file titled “HF”

Figure 14: Electrode / Head Setting

delicate and should 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 carry.

b. FLAME SHAPE — Looking into the combus-

tion chamber through the flame plug hole, the
flame should appear straight with no sparklers
rolling up toward the top of the chamber. If the
flame drags to the right or left, sends sparklers
upward or makes wet spots on the combustion
chamber, 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 ignitor, and around the air
inlet. Any such leaks should be repaired as they
may cause erratic burning of the fuel and in the
extreme case may become a fire 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 fire
hazard.

There may be many possible causes of leaks in
oil lines such as:

20

i . Fitting leaks due to misflared tubing or

damaged fitting.
i i. Fuel line leak due to crushed or bent tubing.
iii. Filter connection leaks.
iv. Tank connection leaks.

The following actions can eliminate air leaks:

i . Bleed pump as detailed in System Start-Up

Section of this manual.
i i. Replace flare fittings.
iii. Replace oil supply line.
iv. Repair oil filter leaks
v. Replace or repair tank fittings.

e. GASKET LEAKS— If 11.5% to 12.5% CO

with a #1 smoke cannot be obtained in stack,
look for air leaks around the canopy seal. Such
air leaks will cause a lower CO2 reading in the
stack. The smaller the firing rate the greater
effect an air leak can have on CO2 readings.

f. DIRT— A fuel filter is a good investment.

Accidental accumulation of dirt in the fuel
system can clog the nozzle strainer and produce
a poor spray pattern from the nozzle.

g. WATER— Water in the fuel, in large amounts,

will stall the fuel pump. Water in the fuel
pump, in smaller amounts, will cause excessive
wear on the pump, but more importantly water
does not burn. It chills the flame, causes smoke,
and allows unburned fuel to pass through the
combustion chamber and clog the flueways of
the boiler.

2

i . HIGH ALTITUDE INSTALLATIONS

Typically, the rule to use for high altitudes is to
increase the air supply by 4% per each 1000 ft.
above 2000 ft. altitude from sea level. This
means that the air setting will have to be higher
than the calibration marks in proportion to the
altitude. 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, flame shape, air or water in the
fuel lines.

k . SHUT DOWN NOISE — If the flame runs out of

air before it runs out of fuel, an after burn with
noise may occur. That may be the result of a
faulty cut-off valve in the fuel pump, or it may be
air trapped in the nozzle line. It may take several
firing cycles for that air to be fully vented
through the nozzle. Water in the fuel or poor
flame shape can also cause shut down noises.

P. TEST CONTROLS

1. CHECK THERMOSTAT OPERATION. Raise and
lower thermostat setting as required to start and
stop burner.

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 flame shape gets longer. An
outside fuel tank that is above grade or has fuel
lines buried in the ground above the frost line is a
good candidate for cold oil. The best solution is
to place the tank and oil lines in the ground
below the frost line.

2. VERIFY PRIMARY CONTROL SAFETY FEA­TURES using procedures outlined in Instructions
furnished with control (See back of Control Cover)
or Instructions as follows:

a. Simulate flame failure:

• Follow the starting procedure to turn on the

burner.

• Close the hand valve in the oil supply line.

• Safety switch should lock out in approxi-

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

21

• Push red reset button to reset safety switch.

b. Simulate ignition failure:

• Follow the starting procedure to turn on the

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

• Safety switch should lock out in approxi-

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

• Push red reset button to reset safety switch.

c. Simulate power failure:

• Follow the starting procedure to turn on the

burner.

• With the burner running, turn off the power

to the system by tripping the circuit breaker
or removing the fuse.

• Burner should stop.

• Restore power. Burner should start.

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 tempera-

ture. Burner should start.

d. Adjust thermostat to lowest setting. Adjust limit

to desired setting.

4 . CHECK LOW WATER CUTOFF (if so equipped).

a. Adjust thermostat to highest setting.
b. With boiler operating, open drain valve and

slowly drain boiler.

c. Burner should stop when water level drops below

low water cutoff probe. Verify limit, thermostat or
other controls have not shut off boiler.

d. Adjust thermostat to lowest setting. Refill boiler.

Q. FREQUENT WATER ADDITION

A leaky system will increase the volume of make-up
water supplied to the boiler which can significantly
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.

22

IV. Service and Cleaning

NOTICE

BURNER SHUTDOWN: Open Service
Switch to turn off burner.

Manual Oil Supply Valve should be closed
and E lectric Service to b oiler turned off if
bo ile r will not be operated for an ext e nded
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 fireside of boiler, remove fasteners

holding flue box panel closed.

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

clean firetubes.

c. Remove fasteners holding burner door. Carefully

remove door with burner still attached.

2 . CLEAN THE COMBUSTION CHAMBER

Using wire or fiber bristle brush, clean inside of
combustion chamber.

3. AFTER CLEANING
a. Vacuum debris inside combustion chamber and

vacuum remaining fireside of boiler as necessary.

23

V. Repair Parts

NOTE: When ordering parts always give the serial number and model number shown on the boiler. Also provide the name of

the part(s) shown below:

Figure 15: HF Series Bare Boiler

24

ITEM N O. DES CRIPTIO N PART NU MBER

1

2

3

4

5

6

7 Flue Box Do or w/ Insulation

8

9

10

11

12

Rear Smoke box

Ja cke t - Lowe r Rear

Shell

Jacket - Right Side P anel

Front Flue B ox

Flue Box Frame Insulation

Com bustion C h amber F loor Insulat ion

Jacket - Lower F ront Panel

Burner Door
Burner Door Insulat ion
Jacket - Le ft S ide P anel

61137004 61147005

70 437033 70 437042

8 103701 8 103702

70 437031 70 437040

61137009 61137010

61137009 61137010

D16850 D16800

21350

I

21325

I

70 437038 70 437047

D15700 D15800

21300

I

70 437032 70 437041

21400

I

21400

I

21375

I

13

14 Bu rner Spacer Plate 70 237001

NOT SHOWN Jacket - Upper F ront 70 437034 704370432

Jacket - Top Left Side Panel 604370361 604370451
Jacket - To p Right Side Panel 704370371 704 370461

25

26

Figure 16: Beckett AFG Oil Burner Repair Part

For replacement oil burner parts, contact your wholesaler or the burner manufacturer: R.W . Beckett Co., P .O. Box 1289, Elyria, OH 44036
[phone] or (800) OIL BURN(645-2876)

BECKETT BURNER PARTS LIST FOR RSA SERIES STEEL BOILERS

FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER
MANUFACTURER:

R. W. BECKETT CORP.
38251 CENTER RIDGE RD.
P . O. BOX 1289
EL YRIA, OHIO 44036
1-800-645-2876

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also, provide the

name of the part(s) and part(s) number as listed below.

Boiler Model HF-96 HF-122 HF-147 HF-173
Burner Model AFG AFG AFG AFG
Air Tube Combination
Spec. No.

1) Air Band
Air Ban d Nu t
Air Ban d Sc rew

2) A ir Sh utter
Air Shu tter Screw

6) Blower

7) Bulkhead F itting

8 ) Bulk head Fit t i ng Loc k nut
9 ) Connec t or Tu be Ass em bly

10) Coupling

11) E l ec tro de C lamp
Elect r ode Clamp S c rew

12) Electrode In su lator Assembly

15 ) S pid er Spac er Ass embly
16 ) Es c ut cheon P l ate
18 ) Fla nge and A ir Tube A ssem bly

Ga sket

19 ) Hea d

He ad Scr ews
Hole Plug

20) Housing A ssem b ly w/Inlet B ell

21) Motor

22 ) Noz zle Adap ter
23 ) Nozzle Line E lectrode

Assembly

25 ) Pu m p

27) Static Plate

28)

Ignitor

29)

30 )
31 ) Ign i to r Gasket Kit
32 ) Wire Guard
33 ) Baffle

Hing e Sc rew

Ignitor

Holding Screw

Ignitor

AFG 5 0M B AFG5 0M B I AFG7 0 MD I AFG7 0 MD I

N Y 11 01 N Y1101 NY 1108 NY 1108

3492BKA 3492BKA 3492BKA 3492BKA

4150 4150 4150 4150
4198 4198 4198 4198

3709BK 3709BK 3709BK 3709BK

4198 4198 4198 4198
2999 2999 2999 2999
3488 3488 3488 3488
3666 36 66 366 6 3666
5636 56 36 563 6 5636
2454 24 54 245 4 2454

14 9 14 9 14 9 14 9
4219 42 19 421 9 4219
5780 5780 5780 5780
550 3 550 3 550 3 550 3
3493 34 93 349 3 3493

3146806 3146806 3146 806 3146 806

31498 31498 31498 31498

5912 59 12 591 3 5913
422 1 422 1 422 1 4221
2139 21 39 213 9 2139
5624 56 24 5624 56 24
2456 24 56 2456 24 56

21 3 21 3 21 3 21 3

NL50MB NL50MB NL50MD NL50MD

2460 24 60 246 0 2460
3384 3384 3383P 3383P
7440 7440 7440 7440
421 7 421 7 4217 421 7
4198 4198 4198 4198

51304 51304 51304 51304

3345 33 45 3345 3345

N/A N/A N/A N/A

27

28