Burnham LE1, LE2, LE3 Operation And Service Instructions Manual
As an ENERGY STAR® Partner, U.S. Boiler Co., Inc. has determined that the LE1 red at the
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81433010R18-1/08
Price - $3.00
IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY
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1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS
MANUAL.
2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CAN NOT BE INSTALLED
ON CARPETING.
3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING, HEATING
AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY DIFFER FROM THIS
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 clearances between boiler, vent connector and
combustible material.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Chimney require-
ments, type of venting material and clearances between vent connector pipe and combustible materials.
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.
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment”, for recommended Installation Practices.
4. 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.
5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROPERTY
DAMAGE COULD RESULT IF THE BOILER IS CONNECTED TO A DIRTY OR INADEQUATE CHIMNEY. THE INTERIOR
OF THE CHIMNEY FLUE 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 CHIMNEY FLUE 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.
6. READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESSORY DEVICES. THESE
ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS OF THE
MANUFACTURER.
7. 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.
8. FOR OPTIMUM PERFORMANCE AND SERVICEABILITY FROM THIS UNIT ADHERE TO THE FOLLOWING
RECOMMENDATIONS:
A. DO NOT TAMPER WITH THE UNIT OR CONTROLS. Retain your contractor or a competent serviceman to assure that the unit is properly adjusted and
maintained.
B. Clean Firetubes at least once a year - preferably at the end of the heating season to remove soot and scale. Inside of Combustion Chamber should also be
cleaned at the same time.
C. Have Oil Burner and Controls checked at least once a year or as may be necessitated.
CANADA BOILERS
2
TAbLE OF CONTENTS
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I. General Information .................................. 3
II. Installation Instructions ............................
III. Operating and Service Instructions ..........
12
I. General Information
IV. Boiler Cleaning ........................................ 20
5
V. Repair Parts .............................................
21
VI. Appendix
Low Water Cut Off ................................... 27
1. INSPECT SHIPMENT carefully for any signs of
damage.
A. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated Boiler to the carrier in good
condition.
B. 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.
Approximate shipping weight: 325 pounds
Water content: 6.1 gallons
Water Content: 6.1 Gallons
Figure 1: LE™ Packaged Boiler
2. LOCATE BOILER in front of nal position before
removing crate. See Figure 1.
A. LOCATE so that smoke pipe connection to chimney
will be short and direct. BOILER IS SUITABLE
FOR INSTALLATION ON COMBUSTIBLE
FLOOR. Boiler can not be installed on carpeting.
B. 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.
C. PROVIDE SERVICE CLEARANCE of at least 24”
clearance in front for servicing.
D. For minimum clearances to combustible materials
See Figure 2.
3
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Combustible Materials
3. PROVIDE COMBUSTION AND VENTILATION
AIR. Local code provisions may apply and should be
referenced.
A. 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)
B. 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.
C. 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 unconned space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a conned space.
D. For boiler located in an unconned space of a
conventionally constructed building, the fresh air
inltration through cracks around windows and
doors normally provides adequate air for combustion and ventilation.
E. For boiler located in a conned space or an uncon-
ned space in a building of unusually tight con-
struction, 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:
Direct communication with outdoors.
(1)
Minimum free area of 1 square inch per 4,000
BTU per hour input of all equipment in space.
(2) 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.
(3) 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
conned space. Use indoor air if two permanent openings communicate directly with
additional space(s) of sufcient volume such
that combined volume of all spaces meet
criteria for unconned 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.
F. Louvers and Grilles of Ventilation Ducts
(1) 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.
(2) 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.
4
II. Installation Instructions
1. REMOVE CRATE
A. Remove all fasteners at crate skid.
B. Lift outside container and remove all other inside
protective spacers and bracing. Remove container
containing Safety Relief Valve, Boiler Drain Valve
and Pipe Fittings.
2. REMOVAL OF BOILER FROM SKID
A. 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 coupling, tee, and plug in return
coupling, see Step 7 and Figure 1. Point tee toward
permanent return location.
B. Tilt boiler backward and remove skid. Be careful not
to damage Burner and Jacket.
3. CHANGE HINGE POSITION if necessary.
A. Look at the area where boiler will be installed. If
left side of boiler will be less than 12 inches from a
wall, move hinges to right side of boiler. See B
through I below.
B. Pull 2 halves of Burner Swing Door Interlock apart.
Swing Door Interlock is connected to T-T terminals
on R7184A Control. Lift Honeywell R7184A
Control off of Burner Junction Box, open Burner
Ignition Transformer and disconnect wiring harness
from left side of burner. Find round plastic cover
inside Junction Box and install in hole in left side
of burner.
C. Remove 8 sheet metal screws from jacket. Remove
rear jacket box and bend both sides of Jacket
Wrapper up, see Figure 19.
D. Remove 2 (two) 5/16" - 18 x 3" long hex head cap
screws and atwashers 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 Step 6.
E. 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.
F. 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.
G. 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 atwashers 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.
H. 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 19.
I. Connect wiring harness to a knockout on right side
of Junction Box and install Honeywell R7184A
Control, see Wiring Diagram, Figures 11A and 11B.
Reconnect Swing Door Interlock.
Figure 3: Hinge Installation & Assembly, LE Boiler
5
Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems
Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems
6
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4. INSTALL BOILER CONTROL.
A. 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.
B. 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.
5. MOVE BOILER TO PERMANENT POSITION by
sliding or walking.
6. INSPECT FRONT AND REAR DOOR INSULATION
PIECES AND COMBUSTION CHAMBER LINER
A. OPEN SWING DOOR on front of boiler. Use
ashlight to inspect insulation pieces secured to
front and rear doors. Inspect Ceramic Fiber Blanket
secured to bottom of combustion chamber with
water glass adhesive. Replace any damaged pieces.
7. CONNECT SUPPLY AND RETURN PIPING TO
HEATING SYSTEM
A. Hot water pipes shall have clearances of at least ½”
from all combustible construction.
B. Use a system by-pass 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.).
Valves should be located in the by-pass and return
line as illustrated in Figures 4 and 5 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 tempera-
ture. Opening the boiler return valve while closing
the by-pass valve will lower the boiler return
temperature.
C. 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.
D. 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 circula-
tion of boiler water during the operation of the
cooling system.
Figure 6: Recommended Piping for
Combination Heating & Cooling
(Refrigeration) Systems
E. 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 mount-
ed 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.
F. There are many possible causes of oxygen contami-
nation 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 distribu-
tion system.
(5) Isolating the boiler from the system water by
installing a heat exchanger.
7
8. INSTALL SMOKEPIPE — The LE should be vented
into a reclay tile-lined masonry chimney or a chimney
constructed from Type L Vent or a factory built
chimney that complies with the Type HT requirement,
of UL103. The chimney and vent pipe shall have a
sufcient draft at all times, to assure safe proper
operation of the boiler. See Figure 7 for recommended
installation.
a home without insulation or storm windows. With
increasing fuel prices that home probably has been
insulated and tted 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 efciency 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 ring rate, reduced ring 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.
C. Heat extractors mounted into the breeching are not
recommended.
Figure 7
A. Install the draft regulator following the instructions
furnished with the regulator. See Figure 8 for
alternate draft regulator locations.
Figure 8
B. 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 efciency 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 red or an inefcient oil red boiler built into
9. INSTALL ELECTRIC WIRING
A. Follow the National Electrical Code and local
regulations. A separate electrical circuit must be run
from the main electrical service with an overcurrent device/disconnect in the circuit. A service
switch is recommended and may be required by
some local jurisdictions. Wiring should conform to
Figures 11A, 11B and 11C.
B. CANADA — Refer to CSA standard C22.2 Part 1,
1990, Electrical Features of Fuel Burning Equipment (Gas and Oil).
C. If boiler is installed in Canada, a blocked vent safety
switch must be installed. Refer to Blocked Vent
Safety Switch Instruction Supplement provided
with boiler (Canada only).
10. FUEL UNITS AND OIL LINES
Use exible oil line(s) so that Swing Door can be
opened without disconnecting oil supply.
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.
SINGLE-PIPE OIL LINES — Standard burners are
provided with single-stage 3450 rpm fuel units with the
by-pass plug removed for single-pipe installations.
The single-stage fuel unit may be installed single-pipe
with gravity feed or lift. Maximum allowable lift is 8
feet. See Figure 9.
8
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Figure 9
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TWO-PIPE OIL LINES - For two-pipe systems where
more lift is required, the two-stage fuel unit is
recommended. Tables 2 (single-stage) and 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 10.
Be sure that all oil line connections are absolutely
airtight.
Check all connections and joints. Flared ttings are
recommended. Do not use compression ttings.
Open the air-bleed valve and start the burner. For clean
bleed, slip a 3/16” ID hose over the end of the bleed
valve and bleed into a container. Continue to bleed for
15 seconds after oil is free of air bubbles. Stop burner
and close valve.
Figure 10
9
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